F3hfe613 Industrial

CURSOR SERIES
TIER 4B
STAGE IV
Industrial application
F3HFE613B*B010
F3HFE613D*B010
F3HFE613B*B011
F3HFE613D*B011
Technical repair manual

This document provides data, specifications, instructions and
methods to perform repair interventions on the assembly and
its components.
Anyhow, this document is addressed to qualified and special-

ised personnel.
Before performing any intervention, check that the document

relating to the vehicle model on which the intervention is being
performed is available and also make sure that all accident pre-
vention devices, including but not limited to, goggles, helmet,
gloves, shoes, as well as work equipment, lifting and transport
equipment, etc., are available and efficient, and also make sure
that the vehicle is in safety conditions for intervention.
Making interventions strictly observing the indications given

here, as well as using specific equipment indicated, assures a
correct repair intervention, execution timing observance and
operators safety.
Each repair intervention must be finalised to the recovery of

functionality, efficiency and safety conditions that are provided
by Iveco.
Each intervention on the vehicle that is finalised to a modifica-

tion, alteration or anything else which has not been authorised
by FPT relieves FPT of any liability, and, in particular, where the
assembly is covered by a warranty, each intervention will
immediately invalidate the warranty.
FPT declines any liability for repair work.
FPT is available to provide any information necessary for the

implementation of the interventions and to provide instruc-
tions for any cases and situations not covered in this publica-
tion.
The data contained in this issue may not be up-to-date due to

possible modifications made by the Manufacturer for technical
or commercial reasons, or to adaptations required by laws in
force in different countries.
In the event of discordance between the information in this

publication and the actual assembly, please contact the FPT
network before performing any interventions.
The complete or partial reproduction of the text or illustra-
tions herein is forbidden.
Publication edited by:

FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print P2D32C011 E - 1st Ed. 10.2014
CURSOR SERIES 1
Introduction
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
REGARDING THE ELECTRICAL SYSTEM . . 7
- Grounding and screening . . . . . . . . . . . . . . . . . 8
CONVERSIONS BETWEEN THE MAIN UNITS OF

MEASUREMENT OF THE INTERNATIONAL SYSTEM
AND THE MOST COMMONLY
USED DERIVED SIZES . . . . . . . . . . . . . . . . . . 9
PAGE HEADER
AND FOOTER INTERPRETATION . . . . . . . 10
Print P2D32C011 E Base - 10/2014

2 CURSOR SERIES
Base - 10/2014 Print P2D32C011 E

CURSOR SERIES 3
GENERAL INFORMATION
Manuals for repairs are split into Parts and Sections, each one of which is marked by a number; the contents of these sections are
indicated in the general table of contents.
Sections with mechanical contents include technical data, tightening torque collections, tool lists, assembly connections - disconnec-
tions, overhauls at the bench, troubleshooting and scheduled maintenance.
On sections or parts of the electric/electronic system section there are the descriptions of the electric network and the electronic
systems of the assembly, wiring diagrams, electric characteristics of components, component codes and troubleshooting relative
to the control units specific to the electric system.
Section 1 describes the engine operation and its general features.
Section 2 describes the type of fuel supply and the engine operating diagrams.
Section 3 refers specifically to the electrical equipment and regards wiring, electrical and electronic appliances which differ depen-
ding on use.
Section 4 describes scheduled maintenance and specific overhauling.
Section 5 deals with removal-refitting operations of the main components of the engine.
Section 6 describes the general mechanical overhaul of the engine fitted on the rotating stand.
Section 7 provides the technical specifications of the engine such as data, fitting clearance and tightening torques.
Section 8 deals with the equipment required for carrying out the operations.
The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians,
must comply with to prevent any serious injury.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of
symbols has been defined to classify warnings, while another set has been specified for service operations.
SYMBOLS - Warnings
Danger for persons

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

The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify
the warranty.
General danger
! Includes the dangers of both above described signals.
Environmental protection
Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.
NOTE Indicates an additional explanation for a piece of information.
Service operations
Example:
1 1 = Housing for connecting rod

small end bush. Tighten to torque
Tighten to torque + angle value

2 2 = Housing for connecting rod bea-
rings

4 CURSOR SERIES
Removal
Intake
Disconnect
Refitting
Exhaust
Connect
Disassembly
Operation
Dismantling
Assembly
Assemble Compression ratio
Tolerance
Tighten to the specified torque
Weight difference
Tighten to the specified torque + angle

Rolling torque
value
Press or caulk Rotation
Registration Angle
Adjustment Angle value
Visual check
Preload
Fitting position check
Measuring
Value to be found Revolutions per time unit
Check
Tools Temperature
Surface for machining

Pressure
Finished workpiece bar
Oversized
Interference
Oversized by no more than .....
Forced assembly
Max.
Undersized
Clearance
Undersized by no more than.....
Shim
Min.
Lubricate Selection
Moisten of oversizing
Grease class
Temperature < 0o C
Coolant
Cold
Sealant
Winter
Temperature > 0o C
Bleeding air Hot
Summer

CURSOR SERIES 5
GENERAL WARNINGS
The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors
! should be contacted whenever a dangerous situation that has not been described occurs.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and mainte-
nance handbooks. Check the working condition and suitability of tools not subject to periodic review.
The manual handling of loads must be assessed in advance since it also depends not only on weight but also on its size
and on the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such
tools is strictly permitted by authorised personnel only. Stay at a safe distance from the load and never below it.
In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out
from accidentally striking workshop personnel.
Shop activities performed by two technicians must always been executed with caution; avoid operations that may be
dangerous for any collaborators due to lack of field of vision or incorrect position.
Keep any personnel not assigned to the operations clear of working area.
Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it. Scrupulously observe
all safety warnings on the assembly.
Do not leave the assembly in motion unattended during repair work.
When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands
and that the manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp.
When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe
all the specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point
cards of harmful materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks, in order to prevent sudden fires/explosions. Adequately store inflammable, corrosive and polluting fluids and
liquids according to what provided by regulations in force. Strictly avoid using containers for food to store harmful liquids.
Avoid drilling or burning pressurised containers and discard cloths impregnated with inflammable substances into suita-
ble containers.
Worn out, damaged or consumable parts must be replaced with original spare parts.
During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and
stains of liquids and oils. Electric sockets and electrical equipment necessary to perform repair operations must meet
safety rules.

6 CURSOR SERIES
Wear all required P.P.E and garments when called for by the operation at issue. Contact with moving parts may cause
serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc.
Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside.
Do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas.
Wear an appropriate respirator in the presence of paint dust.
Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid
direct contact with liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact
occurs.
Before overhauling, clean the assemblies and make sure they are integral and complete. Tidy up detached or disassem-
bled parts with their securing elements (screws, nuts, etc.) into special containers.
Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking nuts
with nylon inserts must always be replaced.
Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.
Before pressure washing mechanical parts, protect electrical connectors and any control units.
The tightening of screws and nuts should always be carried out according to directions. FPTs sales and assistance net-
work is available to provide any clarifications necessary to carry out any repair work not covered by this document.
Before welding:
- Disconnect all electronic control units and unplug the power cable from the batterys positive terminal (connecting
it to the chassis ground) and connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
- Wait approximately 15 minutes before proceeding with welding.
- Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable
materials flow when welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), remove the electronic control units.
The disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.

CURSOR SERIES 7
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the
! chassis earth cable first of all from the negative terminal of the battery.
Before connecting the batteries to the system, make sure that the system is suitably insulated.
Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from
the battery terminals.
Do not cause sparks to verify the presence of voltage in a circuit.
Do not use a test lamp to verify circuit continuity, but proper control equipment only.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding,
grounding, etc.) conform with the FPT system and that they are carefully restored after repair or maintenance work.
Measurements on the ECUs, jack connections and electrical connections of components must be done only on regular
test lines, with special jacks and jack bushings. Never use improvised equipment like metal wires, screwdrivers, pins or
similar. This may not only cause short circuits, but also damage the jack connectors, resulting in poor contact.
Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or special
truck.
Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries)
may lead to their destruction.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening
torque.
Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
Do not directly supply current to components served by electronic control units with nominal vehicle voltage.
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.
NOTE The connectors are shown from cable side. Connector views contained in the manual are representative of cable side.

8 CURSOR SERIES
Grounding and screening

The negative conductors connected to circuit ground point must be as short as possible and connected in star form, ensuring
that their tightening is done neatly and sufficiently (Figure 1 ref. M).
The following precautions must be observed regarding the electronic components:
electronic control units must be connected to the system ground when equipped with metal housings.
The negative cables of the electronic control units must be connected at a circuit ground point, such as dashboard compartment
ground (avoiding serial or chain connections), as well as to the negative terminal of the battery or batteries.
Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal insulation.
Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
The metal braid of shielded circuits must be in contact only at the ECU side to which the signal is to be sent (Figure 2).
In the case of junction connectors, the unshielded section (d) near to the latter must be as short as possible (Figure 2).
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Figure 1
1. STAR CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT GROUND M
Figure 2
88039
2. SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR

d. DISTANCE ! 0

CURSOR SERIES 9
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND THE MOST COMMONLY USED DERIVED SIZES
Power
1 kW = 1.36 HP
1 kW = 1.34 hp
1 HP = 0.735 kW
1 HP = 0.986 hp
1 hp = 0.746 kW
1 hp = 1,014 HP
NOTE The unit HP is converted into hp for simplicity according to a 1:1 ratio
1 hp = 1 CV.
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rpm = 0.1047 rad/s
1 rad/s = 9.55 rpm
Pressure
1 bar = 1.02 kg/cm2
2
1 kg/cm = 0.981 bar
1 bar = 105 Pa
NOTE Where accuracy is not particularly required:

- the unit Nm is converted into kgm for simplicity according to a ratio of 10:1
1 kgm = 10 Nm;
- the unit bar is converted into kg/cm2 for simplicity according to a ratio of 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 273.15 K
0 F = 255.37 K
0 C = 32 F (the conversion factor between Celsius and Fahrenheit is 1:1.8)

10 CURSOR SERIES
PAGE HEADER AND FOOTER INTERPRETATION
Type Section Page

of engine title number
Basic edition referring to When present, a

Number of Language closing phase of drafting
printed copies of Publication month-year update
month-year (Revi) to the basic edition

CURSOR SERIES 1
CURSOR SERIES STAGE IV

CURSOR SERIES TIER 4B
Page
General information 1
Operating diagrams 2
Electrical equipment 3
Scheduled Maintenance 4
Removal-refitting of the main engine components 5
General mechanical overhaul 6
Technical specifications 7
Tools 8
Standard safety precautions Appendix

2 CURSOR SERIES

CURSOR SERIES 3
UPDATE DATA
Section Description Page Revision date

4 CURSOR SERIES

CURSOR SERIES SECTION 1 - GENERAL INFORMATION 1
SECTION 1
General information
Page
IDENTIFICATION DATA . . . . . . . . . . . . . . . . . . 3
CORRESPONDENCE BETWEEN TECHNICAL CODES
AND COMMERCIAL CODES . . . . . . . . . . . . 4
PRODUCT TECHNICAL CODE . . . . . . . . . . . . 5
PRODUCT COMMERCIAL CODE . . . . . . . . . . 6
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER - TORQUE CURVES . . . . . . . . . . . . . . 10
ENGINE CHARACTERISTICS . . . . . . . . . . . . . . 11

2 SECTION 1 - GENERAL INFORMATION CURSOR SERIES

IDENTIFICATION DATA
F3HFE613B*B010 - F3HFE613D*B010
Figure 1
221052
1. Engine technical code - 2. Engine serial number - 3. Manufacturing date (DD/MM/YY)

Ref. F3HFE613B*B010 F3HFE613D*B010
A 407 (545) 384 (515)
B F3HFE613B*B F3HFE613B*D
F3HFE613B*B011 - F3HFE613D*B011
Figure 2
221051
1. Engine technical code - 2. Engine serial number - 3. Manufacturing date (DD/MM/YY)
Ref. F3HFE613B*B011 F3HFE613D*B011

A 5801904778 XZ 5801904779 XZ
B 120R-011220*00 120R-011227*00
C 24R-031589*00 24R-031588*00
D *2000/25E*2010/22*1043*00 *2000/25E*2010/22*1043*00
E e3*97/68QA*2010/26*1047*00 e3*97/68QA*2010/26*1074*00

CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES
Technical codes Commercial Codes

F3HFE613B*B010
C13 ENT Z W
F3HFE613D*B010
F3HFE613B*B011
C13 ENT L W
F3HFE613D*B011

PRODUCT TECHNICAL CODE

The technical code is assigned during production; it is used to identify the main characteristics, characterise the application and
the corresponding level of power output. It is stamped on one side of the crankcase near the oil filter.
F 3 H F E 6 1 3 B * B 0 1 0
F 3 H F E 6 1 3 D * B 0 1 0
F 3 H F E 6 1 3 B * B 0 1 1
F 3 H F E 6 1 3 D * B 0 1 1
VARIANTS OF
THE BASIC
ENGINE
TYPE-APPROVAL FOR STANDARDS
TYPE-APPROVAL FOR PERFORMANCE
APPLICATION
MAIN ENGINE SPECIFICATIONS
NUMBER OF CYLINDERS
CYLINDER CONFIGURATION
THE ENGINE
PROJECT EVOLUTION
ENGINE FAMILY IDENTIFICATION

PRODUCT COMMERCIAL CODE

The commercial name has the aim of making the information on the engine characteristics more easily identifiable, bringing toge-
ther engines of different families, origin and applications for which they are to be used.
The commercial acronym is not used for any technical purpose to recognise the parts which make up the engine.
C 13 E N T Z W
C 13 E N T L W
CONTROL UNIT TYPE: W = EDC17 hp 41
EMISSIONS: L = STAGE IV, Z = Tier 4B
INTAKE: T = TURBOCHARGED WITH INTERCOOLER
CRANKCASE: N = NON-STRUCTURAL (standard distribution)
INJECTION: E= ELECTRONIC
DISPLACEMENT: 13 = 13,000 c.c. NOMINAL
ENGINE FAMILY IDENTIFICATION: C= CURSOR

ENGINE VIEWS
Figure 3
221031
1. Heat exchanger lubricant oil - 2. Oil sump - 3. Oil sump drain plug - 4. Lubrication oil filter - 5. Coupling of engine
coolant return fitting - 6. Turbocharger - 7. Turbocharger outlet pipe - 8. Electrically controlled engine brake valve
LEFT SIDE VIEW
Figure 4
221032
1. Lifting eyelet - 2. Electronic control unit ECU - 3. Lubricant oil level dipstick - 4. Alternator -
5. Fuel filter - 6. Electric starter motor - 7. Engine air inlet pipe - 8. High and low pressure pump for common rail system -
9. Engine oil filler cap
RIGHT SIDE VIEW

Figure 5
221033
1. Turbocharger - 2. Thermostat unit and cylinder head water outlet pipe - 3. Water pump - 4. Fan control coupling -
5. Engine flywheel pulley - 6. Automatic tensioner - 7. Alternator - 8. Lubricant oil level dipstick - 9. Intake manifold inlet
SIDE VIEW FROM THE FRONT
Figure 6
221034
1. Blow-by breather housing - 2. Engine flywheel - 3. Oil sump - 4. Oil sump drain plug - 5. Lubrication oil filter -
6. Electrically controlled exhaust brake valve - 7. Turbocharger - 8. Lifting eyelet - 9. Engine oil filler cap
SIDE VIEW FROM THE REAR

Figure 7
221049
TOP SIDE VIEW

Figure 8
221050
ISOMETRIC VIEW

POWER - TORQUE CURVES

F3HFE613D*B010 - F3HFE613D*B011
Figure 1
Torque
221053
Power
F3HFE613B*B010 - F3HFE613B*B011
Figure 2
Torque
221054
Power

ENGINE CHARACTERISTICS
Type F3HFE613B*B010 F3HFE613D*B010

F3HFE613B*B011 F3HFE613D*B011
Cycle Diesel 4-stroke
Power supply Turbocharged
Injection Direct
Number of cylinders 6 in line

Bore mm 135
Stroke mm 150
+ + +.. = Total displacement cm3 12882
Compression
ratio
16.5: 1
Max. power kW 407 384

(HP) (553) (522)
rpm 2100 2100
Maximum torque Nm 2407 2258
(kgm) (245) (230)
rpm 1400 1400
Low
idle
speed rpm 850 100
High
idle
speed rpm 2350 50
Intercooler
TURBOCHARGING Waste Gate
Turbocharger type
HONEYWELL
LUBRICATION
Oil pressure with engine warmed
up: Forced by gear pump, pressure relief valve, oil filter
bar (oil temperature 120 C) 0.6
- at idle speed bar 3.5
- at max speed bar
COOLING Fluid
Water pump drive: By means of belt
Thermostat:
- opening start C 80
- max. opening C 90
NOTE The data, specifications and performance figures are only valid if the fitter complies with all the installation instructions
provided by FPT.
Furthermore, the fitted appliances must always be in compliance with the torque, power and engine speed for which
the engine was designed.

Type
Cooling
REFILLING circuit (1)
Total capacity 19.5
Lubrication circuit (2)
total capacity (3) 32 (28.8)
Periodic replacement:
sump at minimum level 20 (18)
sump at maximum level 28 (25)
Fuel tank (4) -
Urea tank (5) -
(1) The quantities indicated only refer to the engine in its standard configuration. Use a mix of 50% water and Actifull OT even
in summer. As an alternative to Actifull OT, use another product that complies with the specifications FPI9.COOL002 and/or
standard ASTM D-6210.
(2) Only use lubricants which comply with the international specifications API CJ-4 / ACEA E9. The recommended oil is SAE
10W-40 which complies with the specifications FPT FPI9.LUBR001. FPT recommends only the use of original lubricants AkcelA
or AmbrA which comply with standard SAE 10W40. Oil consumption is considered acceptable up to quantities of 0.5% of
fuel consumption.
(3) The quantities indicated refer to the first refuel only and are relative to the engine, oil sump and filter.
(4) Use STANDARD fuel which complies with standards ASTM D975 or EN 590. The indications connected to the fuel tank
capacity are the responsibility of the vehicle/equipment manufacturer since these are subject to changes depending on the
various vehicle/outfitting configurations.
(5) Only use AdBlue/DEF which complies with specification ISO 22241.
Filling from drums or tanks can cause contamination of the diesel, with the consequent risk of damaging the injection
! system; if necessary, perform suitable filtration or sedimentation of the impurities before refuelling.
The data, specifications and performance figures are only valid if the fitter complies with all the installation instructions
! provided by FPT.

CURSOR SERIES SECTION 2 - OPERATING DIAGRAMS 1
SECTION 2
Operating diagrams
Page
POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . 3
- CPN 5.2 high pressure pump . . . . . . . . . . . . . 4
- Pressure limiter valve . . . . . . . . . . . . . . . . . . . . 9
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Oil filter tightening torques . . . . . . . . . . . . . . . 10

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Oil pressure regulator valve . . . . . . . . . . . . . . . 13

HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . 13
- Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . . 14

ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . 14
- Valve integrated in piston cooling nozzle . . . . . 15
- Oil vapour recirculation (Blow-by) . . . . . . . . . . 16

PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . 20
EXHAUST GAS POST-
TREATMENT SYSTEM (ATS) . . . . . . . . . . . . 22
- Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- AdBlue specifications . . . . . . . . . . . . . . . . . . . . 26
- ATS system
heating/cooling system . . . . . . . . . . . . . . . . . . . 27

2 SECTION 2 - OPERATING DIAGRAMS CURSOR SERIES
Page
MAIN COMPONENTS OF ATS SYSTEM . . . . . 29

- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- AdBlue fluid level gauge control . . . . . . . . . . . 30
- DeNOx 2.2 supply module
(SM - Supply Module) . . . . . . . . . . . . . . . . . . . 31
- Filter removal . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . 34
- DeNOx 2.5
dosing module (DM - Dosing Module) . . . . . . 35
- Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . 35
- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Nitrogen oxide detecting sensor . . . . . . . . . . . 37
- Exhaust gas temperature sensor . . . . . . . . . . . 38
- Temperature and humidity sensor . . . . . . . . . 39
SCHEDULED MAINTENANCE FOR ATS SYSTEM 40

POWER SUPPLY
The Common Rail fuel system has a special pump that continuously keeps fuel at high pressure, independently from the stroke
and the cylinder which is to receive the injection and accumulates fuel in a common duct for all injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the ECU.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from the rail takes
place in the corresponding cylinder.
Figure 1
Low pressure
High pressure
Fuel Return
221056
1. Electro-injector - 2. Electronic control unit cooling - 3. ECU (EDC 17 hp41) - 4. Fuel filter - 5. High pressure fuel pump -
6. fuel return

Figure 2
210171
A High pressure - B Low pressure

1 High pressure pump - 2 Fuel filter - 3 Tank - 4 Fuel prefilter - 5 Engine control unit -
6 Electric injectors - 7 Overpressure valve - 8 Pressure accumulator valve - 9 Pressure sensor
CPN 5.2 high pressure pump

It is a pump, equipped with two plungers, that takes drive from the distribution gear. The gear supply pump is installed on the
same control shaft.

Figure 3
180252
1 Fuel delivery to rail - 2 Fuel supply from filter - 3 Fuel supply from tank -
4 Fuel delivery to filter - 5 Plug - 6 Fuel return to tank
Technical data
Pump characteristics
Transmission ratio 1:1
Number of cam plungers / lobes 2/3
Incoming fuel temperature (gear pump) - 40 80C (90 max 100h)
Maximum 280 Nm at maximum flow
Max torque at nominal speed
Average 80 Nm at maximum flow
Average power required 18 kW
Weight 15.3 kg
Maximum speed in overspeed (250 h) 2625 rpm
Nominal speed 2100 rpm
Overspeed (1h) 3150 rpm
Maximum pressure at gear pump output 13 bar abs
Pressure at gear pump intake 0.35 1 bar abs

Figure 4
180253
1 Plunger (2x) - 2 CP5 gear plungers - 3 Flow regulator
Figure 5
180254
1 Pressure sensor - 2 Rail - 3 Pipes to injectors - 4 Fuel return - 5 Overpressure valve -

6 Fuel inlets from high pressure pump
The rail volume is of reduced sizes to allow a quick pressurisation at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise pulsations caused by injectors openings and closings and by the high-pressure pump
operation.
This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.
Some calibrated holes have been made in the retaining fittings of the high pressure pipes, with the function of damping the oscilla-
tions in pressure generated by the opening of the injectors and the plungers of the high pressure pump.
A fuel pressure sensor (1) is screwed to the rail.
The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value
is checked and, if necessary, corrected.
Specifications
Technical data
Nominal rail volume 28.6 cm3
Inner diameter 9 mm
Nominal pressure 2.200 bar
operating temperature -40 to 140 C

Figure 6
180255
1 Electrical connection - 2 Coil - 3 High pressure fuel intake fitting - 4 Injector closing force -
5 Spray nozzle - 6 Injector nozzle - 7 Fuel return hole - 8 IQA codes - 9 Production code
The electro-injectors are mounted on the cylinder head and operated by the engine control unit. They are supplied by a HP fuel
line and connected to a return line at atmospheric pressure required for operation of the pilot valve.

Figure 7
190508
1 Coil - 2 High pressure fuel intake fitting - 3 Filter - 4 Pressure rod - 5 Needle - 6 Nozzle -
7 Pressure chamber - 8 Fuel return - 9 Control volume - 10 Pilot valve shutter
The electro-injector may be considered as mainly made up of two parts:
- actuator/spray nozzle consisting of pressure rod (4), needle (5) and nozzle (6).
- control solenoid valve, consisting of a coil (1) and pilot valve.
Electro-injector operation is divided into three phases:
1st Phase - Resting position
The coil (1) is not energised and the shutter (10) of the pilot valve is closed.
Under this condition, opening and closing forces are balanced as fuel pressure in the control volume (9) equals that of the pressure
chamber (7).
2nd Phase- Injection start
The coil (1) is energised and causes the shutter (10) to rise.
The fuel of the control volume (9) flows off towards the return manifold (8) causing a drop in pressure.
Simultaneously, the line pressure exerts an opening pressure in the pressure chamber (7) that lifts the needle (5) thus causing
fuel to be injected into the cylinders.
3rd Phase - End of injection
The coil (1) is de-energised and makes the shutter (10) return to its closed position. This creates a balance in the forces acting
upon the needle (5), causing it to return to its closed position and consequently halt the injection of fuel.

Pressure limiter valve
Figure 8
158450
It is a safety valve mounted on the hydraulic accumulator which prevents the pressure of the fuel in the rail from exceeding the
threshold 2400 bar.
It consists of a shutter and a spring, calibrated so that when the pressure in the rail reaches too high a value, the valve regulates
it by releasing part of the fuel to the tank.
Furthermore, in case of failure of the injection pressure control system, it allows the engine to function with limited performance.
Fuel filter
Figure 9
221058
1. Bleed fitting - 2 . Fuel filter - 3. Drain valve - 4. Clogged filter sensor - 5. Fuel temperature sensor - 6. Fuel filter inlet -
7. Fuel filter outlet
Technical data
Maximum load 750 l/h
Nominal pressure < 13 bar
operating temperature -40 to 120 C
Pressure drop with new filter <0.5 bar @ 750 l/h
Pressure drop with filter at end of life >2 bar
Capacity 1.7 l

Oil filter tightening torques
TORQUE
DETAIL
Nm kgm
1 Fitting for bleeding 18 2 1.8 0.2
2 Fuel filter 32.5 2.5 3.25 0.25
3 Drain valve 1.5 0.5 0.15 0.05
4 Clogged filter sensor 30 2 3 0.2
5 Fuel temperature sensor 30 2 3 0.2

LUBRICATION
Engine lubrication is obtained with a gear pump driven by the crankshaft via gears.
A heat exchanger governs the temperature of the lubricating oil.
It houses the oil filter, indicator sensors and safety valves.
Figure 10
221059
A Descending oil - B Oil at pressure

Oil pump Safety valve

Figure 11 Figure 12
73540
60560
MAIN DATA TO CHECK THE SAFETY
The oil pump (1) shall not be overhauled. If you find any
VALVE SPRING
damage, replace the entire oil pump.
To change the gearing (2) of the crankshaft, see the relevant
section.
Figure 13
108846
OIL PUMP SECTION

Overpressure safety valve - Initial opening pressure 10 1 bar.

Oil pressure regulator valve

Figure 15
Figure 14
161269
161256
A: Opening Start - B: Opening End

The oil pressure relief valve is located on the left-hand side
of the crankcase. MAIN DATA TO CHECK THE PRESSURE RELIEF VALVE
SPRING
Start of opening pressure 5 bar.
HEAT EXCHANGER
Figure 16
180296
1 By-pass valve - 2 Heat exchanger - 3 Oil filter support seat

Technical data
By-pass valve opening pressure 2.5 0.3 bar

Filter by-pass valve

Figure 17
73545
The valve quickly opens at a pressure of: 3.4 0.3 bar.
ENGINE OIL FILTER

Figure 18
180257
1 Oil filter support - 2 Cap O-Ring - 3 Cartridge O-Ring - 4 Filter element- 5 Closing cap -
6 Drain plug
Technical data
Maximum operating pressure 13 bar
Operating temperature -30 to 120 C
By-pass valve opening pressure 3.4 0.3 bar

tightening torque
Oil filter retainer at the support base 60 5 Nm
Drain plug on the engine oil filter 6.5 1.5 Nm
Valve integrated in piston cooling nozzle

The valve allows oil to enter and thus lubrication of pistons only above the pressure value shown below.
Figure 19
109080
Technical data
Valve opening pressure 1.7 0.2 bar
This permits filling the circuit and therefore lubricating the most stressed parts even when working at lower pressures.

Oil vapour recirculation (Blow-by)

Part of the gas produced by combustion leaks out of the piston gaskets through the openings of the piston rings, into the sump
and mixes with the oil vapour it contains.
This mixture is conveyed upwards and is partially separated from the oil by a device located at the top of the timing system cover
and sent into the air intake circuit.
The device is essentially composed of a rotary filter fitted to the high pressure pump/camshaft control shaft and a rear cover hou-
sing the normally closed valves that manage the flow of the mixture.
A pressure sensor that detects the clogging of the Blow-by filter is located on the rocker arm cover.
By measuring the pressure under the rocker arm cover, it is also able to detect the presence of fuel in oil.
Figure 20
221061
1. Blow-by box cover - 2. O-Ring - 3. Blow-by filtering element - 4. Cover - 5. Gasket

PIPE
Figure 21
Water coming into pump

Water circulating in the engine
Water leaving the thermostat (to the radiator) 221060
COOLING SYSTEM DIAGRAM

1. Electrically controlled exhaust brake valve - 2. Oil heat exchanger - 3. Water pump intake pipe-
4. Water pump - 5. Thermostat case
Description Operation
The engine cooling system is a closed circuit forced circula- The water pump driven by a poly-V belt by the crankshaft
tion system and can be connected to an additional heater (if sends coolant into the crankcase and with a greater head into
any) and to the Intarder heat exchanger. the cylinder head.
It consists mainly of the following components: When the coolant temperature reaches and exceeds the
- an expansion tank and plug with two built-in valves: an working temperature, it causes the thermostat to open and
outlet and an inlet, which regulate the pressure of the the fluid is channelled from here to the radiator and cooled
system; by the fan.
- a coolant level sensor The pressure inside the system depending on the tempera-
ture variation is controlled by the discharge and charge valves
- an engine cooling unit to dissipate the heat taken by the incorporated in the expansion reservoir filling plug.
coolant from the engine through the intercooler. The discharge valve has a double function:
- a heat exchanger to cool the lubricant oil; - keep the system under light pressure in order to raise the
- a centrifugal water pump incorporated in the crankcase; coolant boiling point;
- an electric fan; - discharge into the atmosphere the pressure surplus pro-
- thermostat to control coolant circulation. duced in case of high coolant temperatures.
The function of the inlet valve is to permit the transfer of coo-
lant from the expansion tank to the radiator when a low pres-
sure is generated inside the system due to coolant volume
reduction as a result of lowering of temperature.

Water pump Water leaving the thermostat

Figure 22 Figure 24
221063
Check that the thermostat works properly, replace it if there

60631
is any doubt.
SECTION ON WATER PUMP
Technical data
The water pump is composed of: rotor, bearing, gasket and Start of stroke temperature 84C 2C
drive pulley. Minimum stroke temperature
(15 mm) 94C 2C
Check that the pump casing shows no sign of

! cracking or water leakage; replace the water pump
assembly if it does.
Technical data
Maximum operating pressure 3.5 bar
Operating temperature -40 to 115 C
Thermostat
Water circulating in the engine
Figure 23
221062

SENSOR
Figure 25
Engine exhaust gas
Intake air
Compressed air (hot)
221057
TURBOCHARGING DIAGRAM
Description
The turbocharging system is composed of: an air filter, a tur-
bocharger and an intercooler.
The air cleaner is a dry type composed of a filtering cartridge
that is periodically changeable.
The function of the turbocharger is to use the energy of the
engines exhaust gas to deliver pressurized air to the cylin-
ders.
The intercooler is composed of a radiator applied on the
engine coolant radiator, and it is used for lowering the tempe-
rature of the air coming out from the turbocharger to send
it to the cylinders.

Turbocharger
Figure 26
75532
A. CLOSED THROTTLE VALVE B. THROTTLE VALVE OPEN
Figure 27
1. Pneumatic actuator pipe - 2. Oil inlet - 3. Compressed air outlet- 4. Compressor inlet - 5. Oil outlet - 6. Turbine intake
flange (from engine) - 7. Exhaust gas outlet (to outside) - 8. Control pin - 9. Pneumatic actuator
221065
Essentially this consists of: - an pressure limiter valve fitted on the turbine casing. Its
- a central body in which a shaft is housed, supported by function is to choke the exhaust gas outlet (detail B),
bushings, the ends of which are connected to: the sending a portion of the exhaust gas directly into the
turbine rotor and the compressor rotor; exhaust pipe when the turbo charging pressure down
from the turbocharger reaches a calibrated value;
- a turbine casing and a compressor casing mounted on
the end of the central body;

Figure 28
221064
1 Throttle valve (flap) - 2 Electric actuator - 3 Coolant outlet/inlet fittings
The throttle valve (1) is fitted on the exhaust pipe downstream from the turbine, it is operated by an electric actuator (2).
The main function is that of an engine brake: when the throttle valve closes, it blocks the exhaust gas outlet; this causes an increase
in pressure upstream of the engine break, which exerts a resistance on the up stroke of the pistons.
This resistance extends throughout the entire kinematic chain, applying a braking effect on the driving wheels.
The main novelty of this type of engine brake, compared to the previous ones, is the electric actuator that makes it possible to
choke the exhaust gas outlet to increase its output temperature.
This possibility is used to:
- rapidly bring the SCRT catalytic converter to its thermal operating condition (reduction of cold engine emissions);
- regenerate the DPF filter inside the SCRT catalytic converter (avoid post-injection with a positive effect on consumption
and problems connected to the dilution of oil that afflict DPF-equipped engines).
The electric actuator (2) is connected to the engine cooling circuit by means of pipes (3).

EXHAUST GAS POST-TREATMENT SYSTEM (ATS)

Schematic
Figure 29
Exhaust gas
Compressed air
Intake air
Engine coolant
Electrical cable
AdBlue path
CAN
CAN
CAN
C
U SCR DOC
C
185019
1. Intake manifold - 2. Exhaust manifold - 3. Intercooler - 4. Air filter - 5. Inlet air humidity and temperature detection
sensor - 6. Compressor - 7. Turbine - 8. Engine brake - 9. NOx sensor - 10. Exhaust gas temperature sensor - 11. Dosing
module - 12. Temperature sensor - 13. Exhaust gas temperature sensor - 14. Exhaust gas temperature sensor - 15. NOx
sensor - 16. NH3 sensor - 17. NH3 sensor control unit - 18. Denox 2.5 supply module - 19. AdBlue tank - 20. AdBlue level
sensor - 21. AdBlue quality sensor - 22. Diverter valve - 23. Engine control unit (EDC17CV41).
To restrict the emissions in the exhaust to within the limits prescribed by legal regulations, an exhaust gas post-treatment system
(ATS) has been adopted combining two devices:
- two catalytic converters for the treatment of HC (unburnt hydrocarbons) and CO (carbon monoxide);
- The DeNOx 2.2 device for the treatment of NOx (nitrogen oxide).
The ATS system is controlled electronically by the EDC17CV41 control unit which on the basis of the engine rpm, torque delive-
red, the exhaust temperature, the quantity of nitrogen oxides and the intake air humidity, adjusts the flow rate of the AdBlue
solution to be introduced into the system.
The pump module picks up the reagent solution from the tank and sends it under pressure to the mixing and injection module
to be injected into the exhaust pipe.

Figure 30
AdBlue path
Electrical cable
Engine coolant
185020
1. CAN line - 2. AdBlue tank - 3. AdBlue level sensor - 4. AdBlue quality sensor - 5. AdBlue temperature sensor - 6. Engine
control unit (EDC17CV41- 7). Inlet air humidity and temperature sensor detection - 8. NOx sensor control unit -
9. NH3 sensor control unit - 10. Denox 2.5 supply module - 11. UREA pressure sensor - 12. NH3 sensor -
13. NOx sensor - 14. Temperature sensor - 15. CUC - 16. SCR catalytic converter - 17. Temperature sensor -
18. Mixer - 19. Dosing module - 20. Exhaust gas temperature sensor - 21. DOC catalytic converter - 22. Exhaust gas
temperature sensor - 23. NOx sensor - 24. Diverter valve - 25. NOx sensor control unit
The ATS system consists essentially of:

- a DOC (Diesel Oxidation Catalyst) ;
- an SCR catalytic converter (Selective Catalyst Reduction);
- a CUC filter (Clean Up Catalyst)
- reactive solution tank (water + urea: AdBlue) with level indicator, temperature sensor and Urea quality detection sensor;
- one H2O diverter valve;
- one feeder module;
- one dosing module;
- three exhaust gas temperature sensors;
- one humidity detection sensor fitted on the engine air inlet pipe downstream of the air filter.
- two nitrogen oxide (NOx) detection sensors;
- a sensor that detects NH3 (ammonia) at exhaust gas outlet.

Figure 31
185021
The catalytic converters have two functions:

- The first consists of a DOC (Diesel Oxidation Catalyst) in which the exhaust gas is cleaned of any HC (unburnt hydrocar-
bons) and CO (carbon monoxide);
- the second consists of the SCR (Selective catalyst reduction) and CUC (Clean Up Catalyst) upstream of which there is
the AdBlue metering module and mixer; the reactions to reduce the NOx (nitrogen oxide) takes place in these catalytic
converters.
In the first stage the exhaust gases leaving the turbine encounter the DOC oxidation catalytic converter in which the hydrocar-
bons (HC) and carbon monoxide (CO) with oxygen O2 present are transformed, through reactions of oxidation, into carbon
dioxide (CO2) and water (H2O).
In the second phase the metering module introduces in the exhaust gases, through an injector prearranged for metering, placed
in the exhaust pipe upstream of the SCR catalytic converter, a solution of water and urea (AdBlue).
The final phase takes place in the SCR catalytic converter: due to the effect of the exhaust gas temperature, the reagent solution
evaporates instantly and, by hydrolysis, converts into ammonia (NH3) and carbon dioxide (CO2) at the same time; evaporation
of the solution causes lowering of the exhaust gas temperature, bringing it closer to the optimum temperature required by the
process.
By reacting with the oxygen in the exhaust gas the ammonia is converted into free nitrogen (N2) and water vapour (H2O).
The engine ECU as a function of the number of engine revolutions, torque, exhaust gas temperature, intake air humidity, amount
of nitrogen oxides and the amount of urea present in the exhaust gases, detected by the respective sensors, regulates the flow
rate of the solution AdBlue to be injected into the system.
The NH3 sensor downstream from the SCR controls the amount of AdBlue injected.
It detects the presence of ammonia in the exhaust gas and sends a signal to the engine management control unit providing a
feedback signal.

Figure 32
223415
1. NOx sensor upstream from the DOC -2. Engine coolant 3-way valve - 3. DeNOx 2.5 dosing module -
4. Intake air humidity and temperature sensor - 5. DeNOx 2.2 supply module - 6. AdBlue tank -
7. AdBlue tank level sensor - 8. Urea (UQS) quality sensor - 9. Selective catalytic reduction (SCR) - 10. Exhaust gas tempe-
rature sensor upstream from the SCR - 11. Exhaust valve module - 12. Diesel oxidizing catalytic converter (DOC) -
13. Exhaust gas temperature sensor upstream from the DOC -14. Exhaust gas temperature sensor downstream from the
SCR - 15. NH3 sensor - 16. NH3 sensor control unit - 17. NOx sensor downstream from the SCR

AdBlue specifications
ISO 22241 / AUS32 / DIN V 70070
Solution of 32.5% urea in water
Min. Max.
Urea content 31.8 33.2 % of weight
Density at 20C 1.087 1.093 g/cm3
Refractive index at 20C 1.3814 1.3843
Alkali as NH3 0.2 %
Biuret 0.3 %
Aldehyde 5 mg/kg
Insolubles 20 mg/kg
Phosphate (PO4) 0.5 mg/kg
Calcium 0.5 mg/kg
Iron 0.5 mg/kg
Copper 0.2 mg/kg
Zinc 0.2 mg/kg
Chrome 0.2 mg/kg
Nickel 0.2 mg/kg
Aluminium 0.5 mg/kg
Magnesium 0.5 mg/kg
Sodium 0.5 mg/kg
Potassium 0.5 mg/kg

ATS system heating/cooling system

The system has two functions:
- continuous cooling of the dosing module;
- heating the AdBlue tank, the supply module and the AdBlue pipes and, at the same time, cooling the dosing module.
Figure 33
Engine coolant
AdBlue path
185019
COOLING CONDITIONS
1. Dosing module - 2. Engine - 3. Diverter valve - 4. AdBlue tank - 5. Feeder module.
Given the unfavourable assembly position from the point of view of cooling and given the high temperatures that the exhaust
gas reach downstream of the catalytic converter, the dosing module is connected to the engine cooling circuit and continuously
cooled.

Figure 34
Engine coolant
AdBlue path
185023
SIMULTANEOUS HEATING AND COOLING CONDITIONS

1. Dosing module - 2. Engine - 3. Diverter valve - 4. AdBlue tank - 5. Feeder module.
The AdBlue runs the risk of freezing at temperatures below -11C.

When the temperature of AdBlue in the tank falls below the limit value, the diverter valve (3) switches allowing the passage
of the engine coolant into the coil inside the tank (4) and then into the supply module (5).
In this stage, the engine cooling temperature is such that it acts as a heater for the components mentioned above.
After this, the engine coolant is conveyed towards the dosing module to lower the temperature.

MAIN COMPONENTS OF ATS SYSTEM

Tank
Figure 35
215387
The tank with the level indicator command (1) contains the reducing substance comprising a solution of 33% urea and water,
known as AdBlue. There is a gauze filter (3) on the filler (4). A urea quality sensor (2) and a temperature sensor are built into
the tank.
NOTE FPT recommends that the AdBlue is kept at a temperature of less than 50 C in the tank during operation.
Tank ventilation: The circuit must be protected from dust.

AdBlue fluid level gauge control

Figure 36
215388
1. AdBlue intake - 2. AdBlue return - 3. Coolant outlet - 4. Coolant outlet pipe -

5. AdBlue heating coil - 6. Engine coolant inlet pipe - 7. Connector -
8. Engine coolant intake - 9. Ad Blue intake pipe - 10. Filter -
11. Lower plate (AdBlue NTC temperature sensor) - 12. Float (AdBlue level sensor) -
13. Comb pipe - 14. AdBlue return pipe
The indicator control for the AdBlue liquid level is a device consisting of:
- a float (level sensor);
- an NTC temperature sensor;
- a coil for heating the liquid in low temperatures.
It informs the ECU of changes in the current due to the resistance, caused by the position of the float in relation to the level
of the AdBlue liquid.
Frozen AdBlue can be warmed using a coolant heating cool (5).
A solenoid operated by the control unit regulates the flow of fuel in the AdBlue tank heater/circuit.
The Urea quality sensor is integrated in the tank to meet the antitampering prescriptions.
NOTE Seal the connectors with a water tight seal before checking the AdBlue tank for leaks.
Temperature sensor: NTC;

1 kOhm +/-5% at 25C
Recommended level sensor specifications: 70 at low level;
20 Kat high level

Electrical connections:
Figure 37
215389
Ref. Description
1 Level
2 Common ground
3 NTC signal (temperature)
DeNOx 2.2 supply module (SM - Supply Module)

Figure 38
185025
1. Main filter - 2. Electric connector - 3. Pressure compensation diaphragm - 4. Feed pipe from tank - 5. Pump module
heating liquid inlet pipe - 6. AdBlue return pipe to tank - 7. Pump module heating liquid outlet pipe - 8. Delivery line to
dosing module
The AdBlue supply module consists mainly of a diaphragm pump which takes up the AdBlue from the tank and sends it to the
dosing module.
It is equipped with a circuit connected to the engine cooling system which, in low temperatures, stops the AdBlue from freezing.
Inside there is a pressure sensor.
The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and are
dependent on the operating conditions of the engine and from the signals sent by the sensors.
Electrical supply requirements for the DeNOx 2.2 (SM) supply module for 7.2 kg/h:
24 V system: 2750 mA max. with battery voltage 28 V

Figure 39
185029
1. Engine coolant connector - 2. AdBlue inlet from tank - 3. AdBlue return to tank -
4. AdBlue outlet to dosing module - 5. Pressure sensor - 6. Filter - 7. Diaphragm pump - 8. Valve 4/2.
To prevent any damage to the pump and the dosing module, the supply module contains a filter which cleans the AdBlue of
any impurities.
Refer to the procedure described below to replace the filter.

Filter removal Figure 43
Figure 40
185430
185435 - On the basis of the colour of the filter, insert the correct
part of the tool (1) into the filter
NOTE During installation of the supply module, bear in
mind the minimum clearance for replacing the filter.
The minimum measurement is approximately 155 Figure 44
mm.
Figure 41
185431
- Insert the specific tool (1) until a click is heard indicating

that the filter (2) has been completely engaged.
185428
- Unscrew and remove the filter cover (1).

Figure 45
Figure 42
185432
185429
- Remove the compensation element (1). - Remove the filter (1).

Filter assembly Figure 49

Figure 46
185428
185433 - Thoroughly clean the filter cover (1).

- Thoroughly clean the contact surface (1) with water. - Screw on the filter cover and tighten to a torque of 20
5 Nm.
Figure 47
Figure 50
185434
- Moisten the gaskets and insert the new filter (1).
185435
Figure 48
NOTE During installation of the supply module, bear in

mind the minimum clearance for replacing the filter.
The minimum measurement is approximately 155
mm.
185429
- Insert the new compensation element (1).
NOTE Make sure that the filter cover and the contact sur-
face of the supply module show no signs of being
cracked or damaged. If they do, replace the dama-
ged components.

DeNOx 2.5 dosing module (DM - Dosing Module)

Figure 51
193974
1. Power connection - 2. AdBlue inlet - 3. Coolant inlet/outlet.
The dosing module is controlled by the engine control unit. Its function is to dose the AdBlue to be injected into the exhaust
pipe upstream of the SCR catalytic converter.
It is fitted on the catalytic converter and while in operation it is subject to high temperatures. For this reason it is connected
to the engine cooling circuit by means of the pipes (3).
Maximum AdBlue injection pressure: 9 bar.
Hydraulic capacity of the DeNOx 2.5 dosing module (DM):
Normal circulation with no injection: ~ 8 kg/h
Maximum with small urea injection: ~ 15 kg/h (8 kg/h + 7 kg/h)
Maximum with large urea injection: ~ 20 kg/h (8 kg/h + 12 kg/h)
Diverter valve
Figure 52
180580
1. Power connection - 2. AdBlue tank heating liquid pipe - 3. Dosing module coolant pipe - 4. Coolant pipe from engine.
The diverter valve is a 2 position/3 way type solenoid valve. On the basis of the temperature detected by the NTC sensor, the
diverter valve closes or opens the passage for the engine coolant into the AdBlue tank heating coil. The dosing module cooling
circuit always stays open.
The first position, in fact, allows the cooling of the dosing module (DM - Dosing Module) while the second position allows the
cooling of the AdBlue tank, the supply module (SM - Supply Module) and related pipes as well as the heating of the DM.

NH3 sensor
Figure 53
185027
The NH3 sensor is connected to the engine management control unit and by detecting the amount of ammonia (NH3) present
in the exhaust gas leaving the catalytic converter it allows an exact adjustment of the amount of AdBlue to be injected.
Figure 54
185028
A. Vehicle side connector - B. Sensor side connector.

101. Power supply - 102. CAN LINE H - 103. CAN LINE L - 104. Ground.
NH3 SENSOR CHARACTERISTICS NOMINAL
Operating voltage 10 - 32 V
Average current 1.2 A
Peak current 4.0 A
Operating limit values -40 - 105 C

Nitrogen oxide detecting sensor
Figure 55
102302
1. Positive - 2. Ground connection - 3. CAN LINE L - 4. CAN LINE H - 5. Spare

The NOx sensor detects the amount of nitrogen oxide present in the exhaust gas entering and leaving the catalytic converter.
On the basis of this information the engine control unit adjusts the amount of AdBlue to be injected and also measures the effi-
ciency of the catalytic converters.
NOx SENSOR CHARACTERISTICS NOMINAL

Ambient temperature: - 40 - +105 C
(+105 - +115 C allowed for 10 min)
Cable temperature: 230 C allowed for 100 h

Exhaust gas temperature sensor
Figure 56
102303
Figure 57
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable power voltage at output - 3. Connector - 4. Grey signal cable - 5. White ground cable -
6. Sensor
It has the function of sending information to the control unit regarding the temperature of the exhaust gas entering and exiting
the catalyst that is necessary for calculating the amount of urea to inject in the system.
EXHAUST GAS TEMPERATURE SENSOR CHARACTERISTICS NOMINAL

Power supply 5.00 V 0.1%
Voltage at a temperature -40 - 1,000 C 0.727 - 2.297 V
Pull-up resistance 1,000 0.1%
Cable resistance 1

Temperature and humidity sensor

Figure 58
125531
1. Power supply - 2. Percentage of humidity - 3. Ground - 4. Temperature

This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to
the ECU. These data are used by the ECU to determine the level of nitrogen oxide emissions.
Figure 59
223113
ELECTRIC BLOCK DIAGRAM

1. Power supply unit - 2. Percentage of humidity - 3. Ground - 4. Temperature (NTC)
A. Reference oscillator - B. Oscillator - C. Sample frequency generator - D. Amplifier Low-Step Filter
HUMIDITY SENSOR SPECIFICATIONS NOMINAL

Supply voltage 5.00 0.25 VDC
Current absorption 10 mA
Operating range 0% RH - 100% RH
Output impedance 70
Insulating resistance 1 M @ 500 V
TEMPERATURE SENSOR SPECIFICATIONS NOMINAL

Operating range -40 - 125 C
Resistance at 25 C NTC 2.186 k 1%
Maximum power at 25 C 100 mW

SCHEDULED MAINTENANCE FOR ATS SYSTEM

Below are indicated the checks, tests and adjustments which are to be carried out on the components of the ATS system at
the established time interval.
The frequency of the operations are indicative since the engine use and its characteristics are essential in evaluating replacements
and checks.
Not only it is permitted, but it is also recommended that the staff in charge of maintenance also perform those checking and
maintenance operations which may not be included in the list below but which are recommended by good-practices and particu-
lar conditions of use of the engine.
Furthermore, in case of clear malfunctioning of the system, prompt measures must be taken to verify the causes of the defect.
Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with acci-
dent-prevention laws for the safety of the staff in charge of maintenance.
Component Function Maintenance

Tank pre-filter Protects the tank during refilling phases No maintenance anticipated
(300 m or 100 m (1)) (clean if necessary)
Supply module pre-filter Protects the supply module from impurities coming 600 hours (2)
(100 m or 70 m (1)) from the tank
AdBlue inlet filter to supply Protects the supply module during first start-up No maintenance anticipated
module (100m) (clean if necessary)
Supply module filter Protects the supply module 3,600 hours (3)
AdBlue return filter from Protects from impurities introduced while changing No maintenance anticipated
supply module to tank the main filter (clean if necessary)
(100m)
Dosing module filter Protects the dosing module during first start-up No maintenance anticipated
(36 m)
1) For applications operating in dusty environments.

2) To be performed every year even if the specified operating hours interval has not been reached.
3) To be performed every two years even if the specified operating hours interval has not been reached.
Figure 60
185427
FILTER LOCATION
1. Dosing module filter - 2. Dosing module - 3. AdBlue return filter from supply module to tank -
4. Supply module pre-filter - 5. Tank pre-filter - 6. AdBlue tank - 7. AdBlue inlet filter to supply module - 8. Supply module -
9. Supply module filter.
CURSOR SERIES SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
VEHICLE SIDE WIRING . . . . . . . . . . . . . . . . . . . 3
- Wire by wire vehicle side wiring diagram 1 of 2 3
- Wire by wire vehicle side wiring diagram 2 of 2 4
PIN OUT CONNECTOR 1B (96 PIN) -

CONTROL UNIT EDC 17 HP 41 . . . . . . . . . 5
ENGINE SIDE WIRING . . . . . . . . . . . . . . . . . . . 8
- Wire by wire engine side wiring diagram 1 of 2 8
- Wire by wire engine side wiring diagram 2 of 2 9
- Engine side wiring diagram 1 of 2 . . . . . . . . . . 10
- Engine side wiring diagram 2 of 2 . . . . . . . . . . 11
PIN OUT CONNECTOR 1A (96 PIN) -

CONTROL UNIT EDC 17 HP 41 . . . . . . . . . 12
CRIN INJECTOR 3.3 . . . . . . . . . . . . . . . . . . . . . . 15
- Pressure sensor on rail (RSD 4) . . . . . . . . . . . . 15
- Crankshaft pressure sensor . . . . . . . . . . . . . . . 16
- Exhaust gas pressure sensor (P 3) . . . . . . . . . . 16
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . 17
- Camshaft sensor . . . . . . . . . . . . . . . . . . . . . . . 18
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 19
- Coolant temperature sensor . . . . . . . . . . . . . . 19
- Oil pressure and temperature sensor . . . . . . . 20
- Turbocharging air pressure

and temperature sensor . . . . . . . . . . . . . . . . . 20
- Fuel pre-filter clogged sensor . . . . . . . . . . . . . . 21
- Fuel filter clogged sensor . . . . . . . . . . . . . . . . . 21
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . 23
ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . 24

2 SECTION 3 - ELECTRICAL EQUIPMENT CURSOR SERIES

Print P2D32C011 E
Figure 1
CURSOR SERIES
VEHICLE SIDE WIRING

Wire by wire vehicle side wiring diagram 1 of 2
1. 96 pin vehicle EDC connector - 2. CAN BUS to Customer s application computer - 3. Diagnostic connector - 4. Area Network C Controller - 5. NOx
control unit downstream from the SCR - 6. NOx sensor downstream from the SCR - 7. NOx sensor upstream from the DOC - 8. NOx sensor upstream
from the DOC - 9. NH3 control unit - 10. NH3 sensor - 11. Urea Quality sensor - 12. Quick-fit connector - 13. Battery disconnect switch (BDS) -
14. Alternator - 15. Alternator connector kit (J1) - 16. Electric starter motor - 17. Battery - 18. Battery charge warning light - 19. SCR suction line hose heater
- 20. Fuel pre-filter heater relay - 21. Fuel pre-filter heater- 22. SCR electric heater - 23 SCR heater relay - 24. Fuel pre-filter/prefilter heater relay - 25. Fuel
filter heater - 26. Grid Heater relay - 27. Water in fuel indicator - 28. ATS intelligent sensors auxiliary relay - 29. Grid Heater - 30. Starter motor control relay -
SECTION 3 - ELECTRICAL EQUIPMENT
31. Starter motor relay - 32. Stare motor/body controller interlock (vehicle safety) - 33. Starter motor/body controller interblock relay -
34. Key switch - 35. Alternative connections (A. Control unit under timed relay - B. Control unit under BDS - C. Control unit not under BDS)
3
218026
Base - 10/2014
4
Base - 10/2014
Figure 2
Wire by wire vehicle side wiring diagram 2 of 2
1. 96 pin vehicle EDC connector - 2. Area Network B Controller - 3. SCR tank temperature and level sensor - 4. Diagnostic LED -
5. DEF dosing module - 6. Exhaust gas temperature sensor downstream of the SCR - 7. Exhaust gas temperature sensor upstream from the SCR -
8. Exhaust gas temperature sensor upstream from the DOC - 9. Humidity and ambient temperature sensor - 10. SCR tank heating valve -
11. SCR pump module (A. SCR pressure sensor - B. SCR Reverting valve - C. SCR pump motor)
CURSOR SERIES
218027
Print P2D32C011 E
PIN OUT CONNECTOR 1B (96 PIN) - CONTROL UNIT EDC 17 HP 41

Figure 3
190542
Pin Signal
1 Battery positive 4
2 SCR Heater
3 Battery negative 1
4 SCR suction line hose heater
6 -
7 SCR pressure sensor
8 SCR temperature sensor
9 Temperature sensor downstream from the catalytic converter
10 Common ground
11 -
12 -
13 Water in filter sensor
14 -
15 Humidity sensor
16 Upstream exhaust gas temperature
17 -
18 -
19 Starter relay
20 ATS intelligent sensors auxiliary relay (H)
21 -
22 -
23 DEF dosing module
24 -
27 Common battery positive
29 Ground for low side power stage 11
30 -
31 SCR level sensor
32 Temperature sensor upstream from the catalytic converter
33 -
34 Engine output speed
35 -
36 -

Pin Signal
37 -
38 -
39 Common ground
40 Air temperature sensor
41 -
42 -
43 Common ground
44 OBD warning light
45 ATS intelligent sensors auxiliary relay (L)
46 CAN-H
47 CAN-L
48 -
51 Diagnostic LED ground
53 -
54 -
55 -
56 -
57 -
58 -
59 -
60 -
61 Prefilter / Fuel filter heater relay
62 -
63 Thermostat input signal. 50 ignition switch
64 -
65 -
66 -
67 -
68 Common power supply
69 KL15
70 Interface ISO-K
71 Controller Area Network 1 (high)
72 SCR tank heating valve
76 Ground for low side power stage 14
77 Diagnostic LED positive
78 -
79 -
80 -
81 -
82 -
83 Grid Heater relay
84 SCR pump motor
85 SCR Reverting valve

Pin Signal
86 -
87 -
88 Outlet to ground 21
89 SCR pump motor
90 Common power supply
91 -
92 -
93 Auxiliary relay / SCR heater relay
94 -
95 Controller Area Network
96 DEF dosing module

8
Base - 10/2014
Figure 4
ENGINE SIDE WIRING
Wire by wire engine side wiring diagram 1 of 2
1. EDC connector (96-way) - 2. Fuel temperature sensor - 3. Coolant temperature sensor - 4. Oil pressure and temperature sensor - 5. Turbocharging air
pressure and temperature sensor - 6. Fuel pre-filter clogged sensor - 7. Fuel filter clogged sensor - 8. Pressure on rail sensor (RSD 4) - 9. CRIN injectors 3.3
CURSOR SERIES
221047
Print P2D32C011 E
Print P2D32C011 E
Figure 5
CURSOR SERIES
Wire by wire engine side wiring diagram 2 of 2
1. EDC connector (96-way) - 2. Throttle valve - 3. Crankshaft pressure sensor - 4. Crankshaft sensor -
5. Camshaft sensor - 6. ZME Fuel metering unit - 7. Exhaust gas pressure sensor (P3)
9
221048
Base - 10/2014
10
Base - 10/2014
Figure 6
Engine side wiring diagram 1 of 2
1. Control unit - 2. Engine connector - 3. Speed sensor- 4. Oil pressure temperature sensor -
5. Water temperature sensor - 6. Pressure sensor on rail (RDS) - 7. Injectors (Cylinders 1,2 ) -
8. Engine brake solenoid valve - 9. Injectors (Cylinders 3,4 ) - 10. Air pressure temperature sensor
CURSOR SERIES
223410
Print P2D32C011 E
Engine side wiring diagram 2 of 2

Figure 7
1. Control unit - 2. Engine connector - 3. Timing sensor - 4. Diesel temperature sensor - 5. Pump sensor
223411

PIN OUT CONNECTOR 1A (96 PIN) - CONTROL UNIT EDC 17 HP 41

Figure 8
190542
Pin Signal
A01 Injector 1, Bank 2 cylinder 4
A04 -
A05 -
A06 Oil pressure and temperature sensor ground
A07 Turbocharger temperature pressure sensor signal power supply
A08 Fuel pre-filter clogged power supply (5V)
A09 -
A10 -
A11 Pressure on rail sensor power supply
A12 Fuel temperature sensor signal
A13 Oil pressure and temperature sensor temperature signal
A14 -
A15 -
A16 Exhaust gas pressure sensor signal (P 3)
A17 CAN-H
A18 CAN-L
A19 Common ground (exhaust gas pressure sensor (P 3), Fuel per-filter clogged sensor)
A20 -
A21 -
A22 -
A23 -
A24 -
A28 -
A29 -
A30 -
A31 Oil pressure and temperature sensor power supply (5V)
A32 Crankshaft pressure sensor power supply
A33 Exhaust gas pressure sensor power supply (P 3)
A34 -
A35 Oil pressure and temperature sensor pressure signal
A36 Rail pressure sensor signal

Pin Signal
A37 Turbocharger temperature pressure sensor signal
A38 -
A39 Coolant temperature sensor signal
A40 -
A41 -
A42 Crankshaft pressure sensor signal
A43 -
A44 -
A45 -
A46 -
A47 -
A48 -
A52 -
A53 -
A54 -
A55 -
A56 -
A57 -
A58 ZME Fuel metering unit power supply
A59 Common ground (fuel temperature sensor, coolant temperature sensor)
A60 Rail pressure sensor ground
A61 Crankshaft pressure sensor signal
A62 Fuel pre-filter clogged sensor signal
A63 -
A64 -
A65 Crankshaft sensor signal (-)
A66 Crankshaft sensor signal (+)
A67 Camshaft sensor signal (+)
A68 Camshaft sensor signal (-)
A69 Common ground (input 7)
A70 -
A71 -
A72 -
A76 -
A77 -
A78 Fuel filter clogged sensor ground
A79 Fuel filter clogged sensor signal
A80 -
A81 -
A82 -
A83 ZME Fuel metering unit

Pin Signal
A84 -
A85 -
A86 Turbocharger temperature pressure sensor signal
A87 -
A88 -
A89 -
A90 Ground (input 5)
A91 -
A92 -
A93 -
A94 -
A95 -
A96 -

CRIN INJECTOR 3.3 Rail pressure sensor (RSD 4)

Figure 9 Figure 10
178241
1. Electrical connections - 2. Electromagnet assembly
This is an N.O. solenoid valve.

They are connected to the EDC ECU on connector 2.
The resistance of the coil of each individual injector is 0.56
- 0.57 .
The electro-injector essentially consists of two parts: 190509
- actuator - spray nozzle consisting of a pressure rod, a The value of injection pressure is used to keep the pressure
needle and a jet level under control and to determine the time duration of the
injection electronic command.
- control solenoid valve made up of coil and pilot valve
The solenoid valve checks the lift of the nozzle needle.
START OF INJECTION Pin Description ECU pin
Upon being supplied with power, the coil moves up the shut- 1 Ground (-) EDC17, pin A/60
ter. The fuel in the control volume flows back towards the 2 Signal (Output) EDC17, pin A/36
return duct resulting in a pressure drop in control volume. 3 Power supply (+) EDC17, pin A/11
At the same time, the fuel pressure in the pressure chamber
moves up the needle resulting into the fuel being injected into
the cylinder.
Specifications Measurement Conditions
END OF INJECTION Pressure range 0 - 2400 bar
When power to the coil is cut off, the shutter closes again Power supply 5V
so as to re-create an equilibrium which moves the needle Output voltage 0.5 - 4.5V
back into its closed position and stops the injection process.
Closing torque 140 Nm
Maximum working pressure 1.800 bar

Minimum working pressure 250 bar
Electrical connection M4 nut 1.5 0.25 Nm

Crankshaft pressure sensor Figure 13

The crankshaft pressure sensor is used to measure the pres-
sure inside the engine.
Figure 11
221069

Pressure range 60 - 750 kPa
Power supply 5V
Operating temperature -30 - +130 C
Output voltage 0.2 V
190512
tightening torque 140 Nm
Pin Description ECU pin

Figure 14
1 Power supply EDC17, pin A/32
2 Earth EDC17, pin A/42
3 Signal EDC17, pin A/61
Exhaust gas pressure sensor (P 3)

Figure 12
221068
221070
Semiconductor sensor used to measure the exhaust gas

pressure

1 Power supply (+) EDC17, pin A/33
2 Ground (-) EDC17, pin A/19*
3 Signal (Output) EDC17, pin A/16
* Common ground

Crankshaft sensor Figure 16

This sensor is an inductive one and is located on the flywheel.
NOTE If this signal fails the rev counter will not work.
S
NOTE The sensor gap is not adjustable.
Figure 15
190511
The flywheel has 60 sections, on 58 of which there is a hole.

The sensor reads the signal generated by these holes.
The EDC 17 uses this signal to:
- recognise the position of the pistons during normal run-
ning;
- determine the engine speed.
Figure 17
190510

1 Signal (+) EDC17, pin A/66
2 Signal (-) EDC17, pin A/65
Specifications Measurement Conditions 221071

resistance 850 - 870
tightening torque 6 - 10 Nm

Camshaft sensor Figure 19

This inductive sensor is located on the camshaft.
The signal generated by this sensor is used by the EDC17
control unit as the injection timing signal.
NOTE The sensor gap is not adjustable. S
Figure 18
190511
The sensor generates signals obtained from the magnetic

flow lines which come towards the teeth of the phonic wheel
fitted on the shaft (number of teeth: 7).
Figure 20
190510

2 Signal (-) EDC17, pin A/68 210300

resistance 850 - 870
tightening torque 6 - 10 Nm

Fuel temperature sensor Coolant temperature sensor

It is an N.T.C type sensor and is located on the fuel filter. It is an N.T.C type sensor and is located on the fuel filter.
It detects the fuel temperature thus enabling the electronic It detects the fuel temperature thus enabling the electronic
control unit to determine the fuel density and volume and control unit to determine the fuel density and volume and
adjust the delivery. adjust the delivery.
Figure 21
Figure 23
113561
113561
2 Ground (-) EDC17, pin A/59*
* Common ground 2 Ground (-) EDC17, pin A/59*
* Common ground
Figure 22 Figure 24
190515 190515

Oil pressure and temperature sensor Turbocharging air pressure and temperature
It is mounted on the crankcase. sensor
This is fitted on the intake manifold.
The signals measured are transmitted to the EDC17 control
unit which in turns sends the information to the instrument Figure 27
panel (indicator / pressure warning light).
NOTE The engine oil temperature is only used by the

EDC 17 control unit and is not sent to the instru-
ment panel.
Figure 25
1
2
3
4
190519

190517 1 Ground (-) EDC17, pin A/90
Pin Description ECU pin 2 Temperature signal EDC17, pin A/37
1 Ground (-) EDC17, pin A/6 3 Power supply (5V) EDC17, pin A/07
2 Temperature signal EDC17, pin A/13 4 Pressure signal EDC17, pin A/86
3 Power supply (5V) EDC17, pin A/31
4 Pressure signal EDC17, pin A/35
Figure 26
190518

Fuel pre-filter clogged sensor Fuel filter clogged sensor

This is fitted on the intake manifold; the sensor described ser- It is a normally closed electric sensor which identifies the
ves to measure the absolute pressure on the intake manifold clogged fuel filter by calculating the pressure between its two
and the supply air flow temperature doors.
Figure 28 Figure 30
190523
190519
Pin Description ECU pin 1 Ground (-) EDC17, pin A/78
1 Ground (-) EDC17, pin A/19 2 Signal EDC17, pin A/79
2 N.T.C. N.T.C.
3 Power supply (5V) EDC17, pin A/08
Specifications Measurement Condi-
4 Output signal EDC17, pin A/62 tions
Rated voltage 12 / 24 V
Maximum switched voltage 200 mA
Differential opening pressure 210 10 kPa
Maximum working pressure 500 kPa
Operating temperature - 40C/+120C
tightening torque 30 2 Nm
Figure 29 Figure 31
190518 190524

<
ALTERNATOR
Figure 32
106283
B+: Positive +30V - B-: Negative - S: battery voltage sensor - IG: alternator activation - L: to recharging indicator
Specifications
Supplier 28 V 90A
Rated voltage 28.3 0.5 V
Nominal supply current 90A
Speed 5000 rpm
Belt tension 730 N
Direction of rotation clockwise, viewed from pulley
Weight 6.9 kg
Tightening torque on terminal B+ 12.5 2 Nm
Figure 33 Figure 34
L. to the recharge warning light, IG, alternator start-up,
S. battery voltage sensor 106281 106282
Alternator wiring diagram Alternator current delivery curve

<
ELECTRIC STARTER MOTOR

Figure 35
221067
Voltage 24 V
Nominal power 7.8 KW (SAE J544B 24V Heavy Duty)
Rotation direction control side clockwise
Pinion number of teeth 10
Supplier DENSO
Weight ~ 10.5 kg
Tightening torque on terminal 30 26 4 Nm
Tightening torque on terminal 50 3.6 1 Nm

ELECTRIC STARTER MOTOR

Figure 36
221066
Electric starter motor characteristics
Ref. Description Unit of measurement

T Torque Nm
C Current strength A
O Power KW
V Voltage V
S Speed Rpm

<
Figure 37
Electric starter motor characteristics
215787
WIRING DIAGRAM
1. Main current contactor - 2. Control solenoid - 3. Electric engine - 4. Battery/ies


CURSOR SERIES SECTION 4 - SCHEDULED MAINTENANCE 1
SECTION 4
Scheduled maintenance
Page
SCHEDULED MAINTENANCE . . . . . . . . . . . . . 3
- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHECKS TO BE MADE DURING PERIODS OF USE -
HOW TO PROCEED . . . . . . . . . . . . . . . . . . 5
- Check the engine lubricant oil level . . . . . . . . . 5
- Engine coolant level check (example) . . . . . . . 5
- Visual inspection of the engine . . . . . . . . . . . . . 6
- Draining the water from the fuel prefilter . . . . 6
- Check tension and condition of ancillary

belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Inspection of the exhaust duct/s . . . . . . . . . . . 7

PERIODIC MAINTENANCE - HOW
TO PROCEED . . . . . . . . . . . . . . . . . . . . . . . . 7
- Engine lubricant oil change . . . . . . . . . . . . . . . . 7
- Replacing the engine oil filter . . . . . . . . . . . . . . 8
- Replacement of fuel prefilter

(example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Fuel filter change . . . . . . . . . . . . . . . . . . . . . . . 10
- Ancillary belt replacement . . . . . . . . . . . . . . . . 11
- Check turbocharger connection pipes

and wastegate linkage . . . . . . . . . . . . . . . . . . . 11
- Turbocharger lubricant pipe tightness check . . 11
- Turbocharger gasket seal check . . . . . . . . . . . . 12
- Replacing blow-by filter element . . . . . . . . . . . 12

UNSCHEDULED MAINTENANCE -
HOW TO PROCEED . . . . . . . . . . . . . . . . . . 13
- Check tappet clearances and adjust

if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Changing the engine coolant

(example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2 SECTION 4 - SCHEDULED MAINTENANCE CURSOR SERIES

SCHEDULED MAINTENANCE
Introduction
To ensure best operating conditions, on the following pages are indicated the checks, tests and adjustments which shall be carried
out on the different parts at the established time.
The frequencies of the maintenance operations are indicative since the engine use and its characteristics are essential to evaluate
replacements and checks.
Not only it is permitted, but we also suggest that the staff in charge of maintenance should also perform those checking and main-
tenance operations which do not fall among those listed below, but are recommended by good-practices and particular conditions
of use of the engine.
Furthermore, in case of clear malfunctioning of the engine, for example excessive grade of smoke of exhaust gases, high tempera-
ture of the coolant or low oil pressure, prompt measures must be taken to verify the causes of the defect.
Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with acci-
dent-prevention laws for the safety of the staff in charge of maintenance.
Checks and scheduled maintenance procedures
Checks to be made during periods of use Frequency
Check the engine lubricant oil level every start-up
Check engine coolant level every start-up
Visual inspection of the engine 50 hours
Draining the water from the fuel prefilter 150 hours (1)
Check tension and condition of ancillary belt 300 hours
Inspection of the exhaust duct/s Six-months
Periodical maintenance Frequency
Change engine lubricant oil (*) 600 hours (2) (3)
Change engine oil filter (*) 600 hours (2) (3) (4)
Fuel prefilter change 600 hours (1) (5)
Fuel filter change 600 hours (1) (2) (4)
Change ancillary belt 1,200 hours
Check turbocharger connection pipes and wastegate linkage 1,200 hours
Replacing blow-by filter element 1,800 hours (2)
Unscheduled maintenance: Frequency
Check tappet clearances and adjust if necessary 2,400 hours
Change the engine coolant 3,000 hours (5)
(*) Interval for the application in earth moving machinery: 100 hours less than standard applications
1) Maximum period relating to the use of high quality fuel, (specification ASTM D975 or EN 590); which is reduced in the event
of fuel contamination and alarm signals caused by filter clogging and/or the presence of water in the prefilter. The filter clogging
signal indicates that the filter must be replaced. If the warning light of water present in the prefilter does not go off after drai-
nage, then the prefilter must be replaced.
3) Frequencies are valid for lubricant oils which comply with the international specifications as indicated in Section 1 - General
table General Characteristics.
4) Only use filters with the following specifications:
- degree of filtering < 12 m
- filtering efficiency 99.5% ( > 200).

NOTE The scheduled maintenance operations are only valid if the fitter observes all installation regulations provided by
FPT.
Scheduled maintenance of ATS system Frequency

No maintenance anticipated
Tank prefilter (300 m or 100* m (1))
(clean if necessary)
Prefilter supply module (100 m or 70 m (1)) 600 hours (2)
AdBlue inlet filter to supply module (100 m)
Supply module filter 3,600 hours (3)
AdBlue return filter from supply module to tank (100 m)
Dosing module filter (36 m) -
1) For applications operating in dusty environments.

REQUIREMENTS
- Do not disconnect the battery supply while the engine is running.
- Do not perform arc welding near the engine without first removing its electrical wiring.
- After all maintenance operations that require disconnecting the batteries, make sure that the terminals have been well secu-
red on the poles.
- Do not use a battery charger to start the engine.
- Disconnect the battery/batteries from the on-board system while recharging.
- Do not paint the devices, components and electrical connectors of the engine equipment.
- Electrically disconnect the battery/batteries before performing any electrical work.
- Contact the Manufacturer before installing any electronic equipment.
Do not perform any operation that would change the calibration of the injection pump.
It was adjusted during the engine test phase and based on its destination.

CHECKS TO BE MADE DURING PERIODS Engine coolant level check (example)

OF USE HOW TO PROCEED
Only proceed when the engine is not turning and is at low
Check the engine lubricant oil level temperature in order not to run the risk of burns.
- Remove the pressurization cap from the expansion tank.
Figure 1 - Visually check that the coolant in the expansion tank is
above the minimum level.
- If necessary, top up the expansion tank with a mixture of
50% water and Actifull OT, as indicated in Section 1 -
General table General Characteristics.
- Top up the expansion tank until the MAX limit is rea-
ched; if there is no level indicator on the expansion tank,
make sure that the coolant in the expansion tank is a few
centimetres below the filling hole in order to allow an
increase in the coolant volume following a rise in tempe-
rature.
When the engine is hot, pressure builds up in the

221035 ! cooling circuits which may eject hot liquid violen-
tly, resulting in a risk of burns.
Only proceed when the engine is not turning and is at low Open the filler cap of the coolant tank only if
temperature in order not to run the risk of burns; make sure necessary and only when the engine is cold.
the engine is level or in its normal operating position in order
to obtain an accurate oil level reading.
- Use the oil level dipstick (2) to check that the lubricant
oil level is between the Min and Max limits. Clean the pressurization cap of the expansion
- If the level is insufficient, it is necessary to top up the oil tank before performing the operation so as to
by removing the cap and pouring lubricant oil through minimize the risk of contaminating the system.
the hole (1).
For the top-up only use lubricant oil that complies

with the international standards as indicated in
Section 1 - General table General Characteri-
stics.
Clean the oil cap before performing the operation

so as to minimize the risk of contaminating the
system.
- Use the oil level dipstick (2) to check that the lubricant
oil level does not exceed the Max limit on the dipstick.
Make sure that the dipstick is fully inserted and

that the filler plug is tightened fully in the clockwise
direction.

Visual inspection of the engine

Clean the cock tap (1) before performing the
Perform a thorough check before start-up in order to obtain operation so as to minimize the risk of contamina-
maximum engine duration. ting the system.
Check for any leaks (oil, coolant and fuel), broken or weake-
ned pipes, loose clips and bolts, worn belt, wiring (loose con-
nections, worn or frayed cables) and a build-up of dirt; in the Check tension and condition of ancillary belt
event of any problems, perform the operations necessary to
restore the engine.
Figure 3
Any spilt fluid must be removed for all types of

leak (coolant, oil or fuel).
If a leak is discovered then find its source and carry
out the necessary repair.
A build-up of oil or grease on the engine repre-

! sents a fire risk.
Draining the water from the fuel prefilter 221036
Figure 2 Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
- Check that the belt is not worn, soiled with oil or fuel, or
showing signs of tears. Otherwise replace the belt if
necessary .
- Use a inch square wrench to check the efficiency of
the automatic belt tensioner.
When the engine is off, but still hot, the belt may
! start to move without warning. Wait for the
engine temperature to decrease to prevent
serious danger of an accident.
221037
In the case of a high risk of refuelling with fuel polluted with

foreign agents and water, the following check should be per-
formed at each refuelling.
Proceed when the engine is not rotating.
- Place a container for collecting liquids under the prefilter
(2).
- Unscrew the valve plug (1) located at the bottom of the
filter; in some versions, the plug includes the water in die-
sel sensor.
- Drain the liquid until only diesel is released.
- Fully retighten the plug manually.
- Dispose of the drained liquids according to the applicable
regulations in force.

Inspection of the exhaust duct/s Ref. No. Description Torque

Visually check that the exhaust gas system is not blocked, cor- 3 1 Oil drain plug 95 10 Nm
roded or damaged.
in the event of any problems, perform the operations neces- Clean the plugs before performing the operations
sary to restore the exhaust duct. so as to minimize the risk of contaminating the
system.
PERIODIC MAINTENANCE - HOW TO
PROCEED
Engine lubricant oil change After changing the engine lubricant oil make sure
that the level does not exceed the Max limit on
Figure 4 the oil level dipstick.

direction.
Dispose of consumable materials and the parts in

! contact with them (for example filters) in accor-
dance with the law.
221038

- Place a suitable container for collecting the spent oil
under the oil sump next to the lubricant oil drain plug (3).
- Unscrew the lubricant oil drain plug (3); afterwards
extract the oil level dipstick (2) and remove the lubricant
oil cap (1) to assist the flow of the engine lubricant oil.
- Wait until the oil sump has completely emptied, then
retighten the lubricant oil drain plug (3) to the torque
indicated in the table
Proceed with the refilling operation through the hole (1)
situated on the tappet cover, using lubricant oil that complies
with the international standards as indicated in Section 1 -
General table General Characteristics.
- Use the oil dipstick (2) to check that the lubricant oil level
does not exceed the Max limit.
- Retighten the lubricant oil cap (1).
When changing the replacement of the engine lubricant oil
it is necessary to replace the oil filter (see paragraph ENGINE
OIL FILTER REPLACEMENT).

Replacement of the engine oil filter Ref. No. Description Torque

4 1 Engine oil filter 60 5 Nm
Figure 5 Drain plug on engine
3 1 oil filter 6.5 1.5 Nm
After changing the engine lubricant oil make sure

that the level does not exceed the Max limit on
the oil level dipstick.

direction.
221039

Only use filters with the following specifications: ! contact with them (for example filters) in accor-
- degree of filtering < 12m dance with the law.
- filtering efficiency > 200 (99.5%)
- Proceed with draining the spent lubricant oil (see para-
graph ENGINE LUBRICANT OIL REPLACEMENT).
- Place a suitable container for collecting the spent oil
under the oil filter next to the drain plug (3).
- Remove the filter (4) by unscrewing it.
- Replace the filter element (2) and the O-ring seal (1) con-
tained inside the filter (4).
- Carefully clean the surfaces
- Moisten the O-ring seal (1) of the new filter with oil.
- Tighten the drain plug (3) and the filter body (4) to the
torque indicated in the table.
- Proceed with the refilling operation of the lubricant oil
(see paragraph ENGINE LUBRICANT OIL
REPLACEMENT).
Operate the engine for a few minutes and then check the
level using the dipstick.
If necessary, top up to compensate for the quantity of oil used
to fill up the filtering cartridge.

Replacement of fuel prefilter (example)

Figure 7
Figure 6
221041
221044
- Loosen the following bleed connectors connecting them
to the designated pipes to allow the residue to flow into
suitable containers and prevent any soiling:
Screw (1) located on the prefilter support.
- Close the tank cock. Bleeder connection (3) located on the filter support.
- Place a suitable container for collecting the fuel under the - Act on the pump (2) located on the fuel prefilter (provi-
fuel prefilter next to the bleeder plug or, if present, the ded by the bodybuilder) until fuel flows out without air
water presence sensor (2) from the bleeder screw (1); upon completion of the ope-
ration tighten the screw.
- Remove the filter cartridge (1)
- Continue to act on the pump until fuel flows out without
- Moisten the O-ring seal (3) of the new filter with oil. air from the bleeder connection (3) located on the fuel
- Screw the cartridge by hand until it comes into contact filter; upon completion of the operation tighten the
with the support and then tighten it to the torque indica- screw.
ted in the table.
- Reconnect the lower electric connection of the water Take utmost care to prevent any fuel from soiling
presence sensor, if present. the control belt
Ref. No. Description Torque
1 1 Fuel pre-filter cartridge 19.5 1 Nm
- Tighten the bleed screws to the prescribed torque.
Do not fill the new prefilter until it has been posi- Ref. No. Description Torque
tioned on the support: this prevents allowing 1 1 Prefilter bleeder screw 18 2 Nm
impurities to enter and damage the circuit and
injection system. 3 1 Fitting for bleeding 18 2 Nm
- Start the engine and let it run idle for a few minutes to
expel any residual air in the circuit.

contact with them (for example filters) in accor For the engine to function correctly the fuel cir-
dance with the law. cuit must be free from air.

Fuel filter change

Figure 9
Figure 8
221041
221040
- Loosen the following bleed connectors connecting them
to the designated pipes to allow the residue to flow into
suitable containers and prevent any soiling:
Screw (1) located on the prefilter support.
- Close the tank cock. Bleeder connection (3) located on the filter support.
- Place a suitable container below the fuel filter in line with - Act on the pump (2) located on the fuel prefilter (provi-
the drain plug (4) to collect the fuel. ded by the bodybuilder) until fuel flows out without air
from the bleeder screw (1); upon completion of the ope-
- Open the drain plug (4) and the bleeder connection (5) ration tighten the screw.
and drain any residual fuel.
- Continue to act on the pump until fuel flows out without
- Remove the filter element (2) by unscrewing the relative air from the bleeder connection (3) located on the fuel
bell-shaped support (3).
filter; upon completion of the operation tighten the
- Replace the filtering element (2) and the O-ring seal (1) screw.
inside the bell housing support (3).
- Grease the O-ring seal (1) of the filter. Take utmost care to prevent any fuel from soiling
- Insert the filter element (2) and tighten the relative bell-- the control belt
shaped support (3) to the torque indicated in the table.
Tighten the drain plug (4) to the torque indicated in the table
- Tighten the bleed screws to the prescribed torque.
Do not fill the new filter until it has been positio- Ref. No. Description Torque
ned on the support: this prevents allowing impuri- 1 1 Prefilter bleeder screw 18 2 Nm
ties to enter and damage the circuit and injection 3 1 Fitting for bleeding 18 2 Nm
system.
- Start the engine and let it run idle for a few minutes to
expel any residual air in the circuit.
3 1 Fuel filter 32.5 2.5 Nm
For the engine to function correctly the fuel cir-
4 1 Threaded plug 1.5 0.5 Nm cuit must be free from air.
5 1 Fitting for bleeding 18 2 Nm

contact with them (for example filters) in accor
dance with the law.

Change ancillary belt

Check turbocharger connection pipes and
wastegate linkage
Figure 10
- Only proceed when the engine is not turning and is at
low temperature so as not to run the risk of burns.
Turbocharger lubricant pipe tightness check
Figure 11
221042

- Using a 1/2 inch square wrench, operate on the belt ten-
sioner (1) and pull off the control belt of the crankshaft
/ electromagnetic coupling / water pump / alternator (A) 221045
pulley.
- Replace the worn belt with a new one and fit it on the - Check the tightening torque of the connections (1,2) and
pulleys and guide rollers. perform a visual inspection to check for any oil leaks.
- Using the aforesaid tools, operate on the automatic belt - Replace the gaskets (3,4) of the connectors (1,2) if there
tensioner in order to key the new belts in their operating are any leaks.
position.
The exhaust pipes must not have sharp bends and

Replace the belt if it shows signs of abrasion, angles of less than 30
cracks or tears or if it is soiled with oil or fuel.
The flange replacement gaskets and fixtures must

When the engine is off, but still hot, the belt may be fitted without sealant: this may contaminate
! start to move without warning. Wait for the the oil.
engine temperature to decrease to prevent
serious danger of an accident.

Turbocharger gasket seal check

Replacing blow-by filter element
Figure 12
Figure 13
221046
221043
- Check for any soot between the intake manifold and the
turbocharger, replace the gasket if soot is found. - Unscrew the screws (3) and remove the cover (4)
- Check the conditions of the turbocharger gasket (e.g. - Unscrew the screws (2) and remove the blow-by filter
breakages, deformation, ...), replace if necessary. element (1)
Turbocharger blade check
- Check for any cracks along the entire surface of the tur- Carefully clean the seating of the filter and the
bocharger cover.
- Make sure that the turbocharger impeller contains no
bent or damaged blades.
Wastegate linkage check - Position the new blow-by filter element (1) in its seat.
- Check that the wastegate linkage control is well tighte-
- Apply some Loctite 243 on the screws (3) and tighten
ned, lubricated and not misshapen.
them to the torque indicated in the table.
- Position the cover (4) and tighten the screws (3) to the
torque indicated in the table.
Tightening
Ref. No. Description torques
Fastening screws for
blow-by filter element
2 4
Phase 1 5 Nm
Phase 2 15 Nm
3 6 blow-by cover 7 1 Nm

contact with them (for example filters) in accor-
dance with the law.

UNSCHEDULED MAINTENANCE - HOW TO PROCEED

Check tappet clearances and adjust if necessary
Figure 14
167109
Adjustment of clearance between rockers and crosspieces FIRING ORDER 1-4-2-6-3-5

governing the intake and exhaust valves and adjustment of
the preloading of the pump injector rocker arms should be
carried out with extreme care. Take the cylinder whose clea- Clockwise Balancing Adjust clea- Adjust
rance has to be adjusted into the combustion phase; the val- start-up and cylinder rance injector
ves of this cylinder are closed while they balance the symme- rotation valves no. of cylinder pre-loading
tric cylinder valves. Symmetric cylinders are 1-6, 2-5 and 3-4. valve no. cylinder no.
In order to properly operate, follow these instructions and 1 and 6 at 6 1 5
data specified on the table. T.D.C.
Adjusting clearance between rocker arms and crosspieces 120 3 4 1
governing the intake and exhaust valves;
120 5 2 4
- Use a polygonal wrench to slacken the locking nut (1) 120 1 6 2
of the rocker arm adjusting screw (2);
120 4 3 6
- insert the feeler gauge blade (3);
120 2 5 3
- Screw or unscrew the adjustment screw of the rocker
arm with an appropriate wrench (2);
- Make sure that the gauge blade (3) can slide with a slight
friction;
- Lock the nut (1), by blocking the adjustment screw;
Pre-loading of rockers controlling pump injectors: NOTE To perform adjustments correctly, the order indi-
- Using a polygonal wrench, loosen the nut locking the cated in the table must be followed; check the
rocker adjustment screw (5) controlling the pump injec- accuracy of position during each rotation phase
tor (6); using the pin 99360612, to be inserted into the
- Using an appropriate wrench (4), loosen the adjustment 11th hole of each of the three sections with 18
screw until the pumping element is at the end-of-stroke; holes each.
- Tighten the adjustment screw, with a dynamometric
wrench, to 5 Nm tightening torque (0.5 kgm);
- Unscrew the adjustment screw by 1/2 - 3/4 of a turn;
- tighten the locking nut. Finish the refitting procedure by fitting the head cover toge-
ther with seal.

Changing the engine coolant (example)

- Only proceed when the engine is not turning, and is at
low temperature, so as not to run the risk of burns.
- Place a container for collecting coolant under the heat
exchanger (radiator).
- Remove the pressurization cap from the expansion tank.
- Loosen the retaining elements and remove the sleeves
connecting the engine cooling circuit to the heat exchan-
ger.
- Drain the coolant from the heat exchanger (radiator)
and wait until it is completely empty.
- Once emptied, restore the integrity of the cooling circuit,
by ensuring the perfect seal of the sleeves.
- Refill the engine and the heat exchanger until the cooling
circuit is completely full using a mixture of 50% water and
Actifull OT, as indicated in Section 1 - General table
General Characteristics.
Do not fill the expansion tank to the brim.
- With the coolant cap open, start the engine and let it idle
for approx. one minute. This helps to completely bleed
the air contained in the cooling circuit.
- Stop the engine and top up with more coolant, if neces-
sary.
- When the engine is cold, make sure that the coolant in
the expansion tank is a few centimetres below the filling
hole.
- In the event of an externally located level indicator as
regards the heat exchangers, proceed with the top up
operation by making sure that the coolant does not over-
fill the internal volume of the exchanger in order to allow
the expansion of coolant volume during increases in tem-
perature.
Failure to observe the procedure described above

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

cooling circuits which may eject hot liquid violen-
tly, resulting in a risk of burns. Open the filler cap
of the coolant tank only if necessary and only
when the engine is cold.

CURSOR SERIES SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS 1
SECTION 5
Removal-refitting of the main engine
components
Page
REMOVAL-REFITTING OF THE MAIN

ENGINE COMPONENTS . . . . . . . . . . . . . . . 3
REMOVAL-REFITTING OF ANCILLIARY
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Alternator removal-refitting . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Water pump removal-refitting . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Thermostat case removal-refitting . . . . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Electric starter motor removal-refitting 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Engine cable removal-refitting . . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Turbocharger removal-refitting . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Oil filter removal-refitting . . . . . . . . . . . . . . . . . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Heat exchanger removal-refitting . . . . . . . . . . . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS CURSOR SERIES
Page
- Oil sump removal-refitting . . . . . . . . . . . . . . . 7

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Fuel filter removal-refitting . . . . . . . . . . . . . . . 8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Fuel system bleeding . . . . . . . . . . . . . . . . . . . . 9
- Common rail removal-refitting . . . . . . . . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Control unit removal-refitting . . . . . . . . . . . . . 10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Blow-by removal-refitting . . . . . . . . . . . . . . . . 10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Head cover removal-refitting . . . . . . . . . . . . . 11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Electro-injector wiring removal-refitting . . . . . . 11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Electro-injector removal-refitting . . . . . . . . . . . 12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Intake manifold removal-refitting . . . . . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Exhaust manifold removal-refitting . . . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Cylinder head removal-refitting . . . . . . . . . . . . 15
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Alternator removal-refitting
REMOVAL-REFITTING OF THE MAIN
ENGINE COMPONENTS Removal
REMOVAL-REFITTING OF ANCILLARY
BELT
Figure 17
Removal
Figure 15
221083
Unscrew the screws (1,2) and remove the alternator (3).

221042
Refitting
Using a 1/2 inch square wrench, operate on the belt tensioner Fit the alternator (3) and tighten the screws (1, 2) to the
(1) and remove the control belt of the crankshaft / electroma- required torque.
gnetic coupling / water pump / alternator (A) pulley.
Refitting 1.2 2 Screw M10x1.5 44 4 Nm
Using a 1/2 inch square wrench, operate on the belt tensioner Water pump removal-refitting
(1) and position the control belt of the crankshaft / electro-
magnetic coupling / water pump / alternator (A) pulley.
Removal
Figure 16
Figure 18
223412
Unscrew the screws (1) and remove the water pump (2).
150675
INSTALLATION DIAGRAM OF WATER PUMP

- ALTERNATOR - DRIVE BELT PULLEY
1. Alternator - 2. Electromagnetic coupling -
3. Water pump - 4. Crankshaft

Refitting Electric starter motor removal-refitting

Screw in the screws (1) and secure the water pump (2).
Removal
1 4 M8x1.25 24.5 2.5 Nm Figure 21
Thermostat case removal-refitting
Removal
Figure 19
221094
Remove the nuts (1) from the studs.

Remove the electric starter motor (2).
Refitting
221086
Fit the starter motor (2) and tighten the nuts (1) on the studs
Unscrew the screws (2,3) and remove the thermostat assem- to the prescribed torque.
bly (1). Ref. No. Description Torque
1 3 M12x1.75 74 8 Nm
Refitting
Fit the thermostat case (1) with a new gasket and tighten the
fastening screws (2, 3) to the specified torque.
2.3 4 M8x1.25 30 3 Nm
Figure 20
155929
Tighten the screws securing the thermostat case following

the sequence indicated in the figure.

Engine cable removal-refitting Turbocharger removal-refitting
Removal Removal
Figure 22 Figure 23
223414 221087
Free the clips fixing the engine cable. Remove the oil delivery pipe (1) and the oil return pipe (2)
from the turbocharger.
Disconnect the electrical connections from the sensor
Lift the safety lever (A). Figure 24
Move the connector, disconnecting it from the control unit
(B).
Lift the connector, releasing the pawl (C).
Disconnect the engine cable ($) from the engine.
Refitting
Make al the electrical connections and secure the engine
cable with clamps to the clips.
221091
Unscrew the screws and the nuts (2, 4) and remove the tur-
bocharger (1) from the exhaust manifold (3).

Refitting
Figure 27
Figure 25
221087
221091
Connect the oil delivery pipe (1) and the sump oil return pipe
(2) to the turbocharger.
Fit the turbocharger (1) with a new gasket on the exhaust
manifold (3). Tighten the couplings to the recommended torque.
Tighten the screws (4) and the nuts (2) to the prescribed tor- Ref. No. Description Torque
que. 4 M8x1 24.5 2.5 Nm
2.5 4 M12x1.75 75 Nm
Figure 26
160652
Tighten the screws securing the turbocharger following the

sequence indicated in the figure.

Oil filter removal-refitting Refitting
Removal Fit the heat exchanger (1) and tighten the fastening screws
(2, 3) to the specified torque.
Figure 28 Ref. No. Description Torque
Screw M8x1.25
2.3 22 Phase 1 11.5 3.5 Nm
Phase 2 24.5 2.5 Nm
Figure 30
221092 180274
Unscrew and remove the oil filter (3). Tighten the screws securing the heat exchanger following the
Unscrew the screws (1) and remove the oil filter support (2). sequence indicated in the figure.
Refitting Oil sump removal-refitting
Fit the oil filter support (2) and tighten the screws (1). Removal
Oil and fit new seals.
Screw the filter (3) until the gaskets come in contact with the Figure 31
resting bases.
Tighten the filter to the specified torque.
1 4 Screw M8x1.25 23.5 2.5 Nm
3 1 Oil filter 60 5 Nm
Heat exchanger removal-refitting
Removal
Figure 29
60516
Unscrew the screws (2) and remove the engine oil sump (1)
together with the spacer (3) and the gasket.
221093
Unscrew the screws (2, 3) and remove the complete heat

exchanger (1).

Refitting Fuel filter removal-refitting
Figure 32 Removal
Figure 34
60665
Arrange the gasket (4) on the oil sump (1), position the spa-
cer (3) and fit the sump on crankcase screwing in the screws 221040
(2) to the prescribed torque.

Ref. No. Description Torque temperature so as not to run the risk of burns.
2 16 Screw M10x1.5 45 4.5 Nm Close the tank cock.
Figure 33 Place a suitable container below the fuel filter in line with the
drain plug (4) to collect the fuel.
Open the drain plug (4) and the bleeder connection (5) and
drain any residual fuel.
Remove the filter element (2) by unscrewing the relative bell--
shaped support (3).
Refitting
Replace the filtering element (2) and the O-ring seal (1) inside
155922
the bell housing support (3).
Tighten the screws securing the toil sump following the Grease the O-ring seal (1) of the filter.
sequence indicated in the figure. Insert the filter element (2) and tighten the relative bell-sha-
ped support (3) to the torque indicated in the table.
Tighten the drain plug (4) to the torque indicated in the table.
Do not fill the new filter until it has been positio-

ned on the support: this prevents allowing impuri-
ties to enter and damage the circuit and injection
system.
Ref. No Description Torque

3 1 Fuel filter 32.5 2.5 Nm
4 1 Threaded plug 1.5 0.5 Nm

Fuel system bleeding Common rail removal-refitting
Figure 35 Removal
Figure 36
221118
221041
Unscrew the fittings and remove the high pressure fuel supply
pipes (8).
Loosen the following bleed connectors connecting them to
the designated pipes to allow the residue to flow into suitable Unscrew the fittings from the rail and the injectors and detach
containers and prevent any soiling: the high pressure fuel pipes (1, 2, 3, 4, 5 ) e (6) and the fuel
return pipe (7) from the head.
- Screw (1) located on the prefilter support.
- Bleeder connection (3) located on the filter support. NOTE The high pressure fuel pipes must be replaced
Act on the pump (2) located on the fuel prefilter (provided at each disassembly.
by the bodybuilder) until fuel flows out without air from the
bleeder screw (1); upon completion of the operation tighten
the screw. Disconnect the electric connection from pressure sensor
(11).
Continue to act on the pump until fuel flows out without air
from the bleeder connection (3) located on the fuel filter; Unscrew the fastening screws (9) and remove the rail (10).
upon completion of the operation tighten the screw.
Refitting
Fit the rail (10) onto the head and tighten the fastening screws
Take utmost care to prevent any fuel from soiling (9) to the specified torque.
the control belt Connect the high pressure fuel pipes and tighten the fittings
by hand in the sequence (1, 2, 3, 6, 5, 4) to the rail and the
injectors.
Tighten the bleed screws to the prescribed torque.
NOTE Before tightening the fittings to torque make
sure that the pipes (1) are not touching each
1 1 Prefilter bleeder screw 18 2 Nm other.
Start the engine and let it run idle for a few minutes to expel
any residual air in the circuit. Complete assembly of the high pressure fuel pipes (1, 2, 3, 6,
5, 4) by first tightening the injector side fittings and then those
on the rail side.
For the engine to function correctly the fuel cir- Connect the high pressure fuel supply pipes (8) and tighten
cuit must be free from air. them to the prescribed torque.
Connect the fuel return pipe (7) from the rail and tighten to
the prescribed torque.
Dispose of consumable materials and the parts in 9 4 Screw M8x1.25 23.5 2.5 Nm
dance with the law. (1, 2,
3, 6, 6 Screw M16x1.5 42 2.5 Nm
5, 4)
8 Connector M16x1.5 42 2.5 Nm
7 M14x1.5 50 Nm

Control unit removal-refitting Blow-by removal-refitting
Removal Removal
Figure 37 Figure 38
221096 221043
Unscrew the screws (5) and remove the bracket (4). Remove Unscrew the screws (3) and remove the cover (4)
the fuel pipes (3, 6), unscrew the screws (2) ad remove the
Unscrew the screws (2) and remove the blow-by filter ele-
engine control unit (1).
ment (1)
Refitting
Refitting
Position the engine control unit (1) and tighten the screws
(2).
Carefully clean the seating of the filter and the
Position the bracket (4) and tighten the screws (5). Connect
cover.
the fuel pipes (3) and (6).
ECU mount retaining Position the new blow-by filter element (1) in its seat.
2 3 screws 19 3 Nm
3,6 2 Fittings M18x1.5 37 3 Nm Apply some Loctite 243 on the screws (2) and tighten them
to the torque indicated in the table.
Position the cover (4) and tighten the screws (3) to the tor-
que indicated in the table.
blow-by filter element
2 4
Phase 1 5 Nm
Phase 2 15 Nm
3 6 blow-by cover 7 1 Nm

dance with the law.

Figure 39 Refitting
Position the head cover (1) and insert all the screws (2).
2 24 Screw M6x1 8.5 1.5 Nm
Figure 41
221126
Tighten the screws securing the blow-by cover following the

221122
Head cover removal-refitting
Tighten the screws securing the head cover following the
Removal sequence indicated in the figure.
Figure 40 Electro-injector wiring removal-refitting
Removal
Figure 42
221100
Unscrew the fastening screws (2) and remove the head cover
(1).
223413
Remove the wiring clamps.

Disconnect the connector from the rail pressure sensor (1).
Disconnect the electrical connections (2) from the injectors.
Remove the screws (3) securing the connector and remove
all the wiring.

Refitting
Figure 44
Position the wiring and secure it appropriately with clamps.
Connect the electrical connections (2) to the injectors.
Connect the connector from the rail pressure sensor (1).
Secure the connector with the screws (3).
2 12 Cable clamps 1.5 0.25 Nm
Head wiring connec-
3 4 tor fixing screw 8 2 Nm
Electro-injector removal-refitting
Removal
Figure 43
169827
Remove the screws (1) from the brackets (2) supporting the
injectors.
Figure 45
183457
Disconnect the electrical connections (1) from the electro--

injectors.
169826
Position the specified tool 99342157 (1) and extract the

injectors (2) from the head.

Refitting
Figure 47
Figure 46
221117
Fit the retaining brackets (3) on the injectors (4) and position
them in the relevant seats in the cylinder head.
Position the screws (2)
Secure the fuel pipes, lock the screws (4) securing the injector
brackets to the specified torque.
Ref. No Description Torque
4 6 Screw M8x1.25 32.5 3.5 Nm
Fit the crosspieces (1) on the valve stem all with the largest
hole on the same side.
Figure 48
169828
Fit the sealing gasket (2) on the injectors (1).
183457
Connect the electrical connections (1) of the injectors.

1 12 Cable clamps 1.5 0.25 Nm

Intake manifold removal-refitting Exhaust manifold removal-refitting
Removal Removal
Figure 49 Figure 51
221095 221090
Unscrew the screws (1) and remove the intake manifold (2) Unscrew the fastening screws (1) and remove the exhaust
together with the engine preheating resistor (3). manifold (3) together with the turbocharger (2).
Refitting Refitting
Fit the intake manifold (2) together with the engine prehea- Fit the exhaust manifold (3) with new gaskets together with
ting resistor (3) and tighten the screws (1) to the prescribed the turbocharger (2).
torque.
Ref. No. Description Torque Figure 52
1 6 Screw M10x1.5 50 5 Nm
Figure 50
180272
Tighten the screws securing the exhaust manifold following

the sequence indicated in the figure.
Tightening
Screw M10x1.5
12 Phase 1 40 5 Nm
Phase 2 60 5 Nm
NOTE Lubricate the screws with graphite oil.
221127
Tighten the screws securing the intake manifold following the


Cylinder head removal-refitting

NOTE New screws must be used at each assembly of
Removal the head.
Lubricate the thread of the screws with engine
Figure 53 oil before assembly.
Figure 55
60515
60565
Unscrew the cylinder head screws .
Pre-tighten using the torque wrench (1) :
NOTE The cylinder head fastening screws are to be Ref. No. Description Torque
replaced each time you remove them. Cylinder head fixing
screws
26
Phase 1 75 Nm
By means of metal ropes, lift the cylinder head (1). Phase 2 150 Nm
Replace the sealing gasket (2).
Figure 56
Refitting
Check that the pistons: 1 and 6 are exactly at the T.D.C.
Put the gasket (2) on the crankcase.
Place the cylinder head (1) on the crankcase.
Figure 54
60566
Use tool 99395216 (1) for angle tightening:

Cylinder head fixing
screws
221076
26
Phase 1 90
Phase 2 90
Tighten the fastening screws in the sequence shown in the
figure.


CURSOR SERIES SECTION 6 - GENERAL MECHANICAL OVERHAUL 1
SECTION 6
General mechanical overhaul
Page
ENGINE DISASSEMBLING . . . . . . . . . . . . . . . . . 5
- Removing the front suspension mounts . . . . . . 5
- Damper flywheel removal . . . . . . . . . . . . . . . . 7
- Alternator water pump

drive belt removal . . . . . . . . . . . . . . . . . . . . . 7
- Alternator removal . . . . . . . . . . . . . . . . . . . . . 7
- Pulley removal . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Water pump removal . . . . . . . . . . . . . . . . . . . 8
- Thermostat case removal . . . . . . . . . . . . . . . . 8
- Crankshaft front
gasket removal . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Turbocharger removal . . . . . . . . . . . . . . . . . . . 9
- Oil filter removal . . . . . . . . . . . . . . . . . . . . . . . 10
- Heat exchanger removal . . . . . . . . . . . . . . . . . 10
- Starter motor disassembly . . . . . . . . . . . . . . . . 10
- Intake manifold removal . . . . . . . . . . . . . . . . . . 10
- Blow-by case removal . . . . . . . . . . . . . . . . . . . 11
- Blow-by filter removal . . . . . . . . . . . . . . . . . . . 11
- Timing gear cover

removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Removal of head cover . . . . . . . . . . . . . . . . . . 11
- Fuel filter removal . . . . . . . . . . . . . . . . . . . . . . 12
- High pressure pump removal . . . . . . . . . . . . . 12
- Engine flywheel removal . . . . . . . . . . . . . . . . . 13
- Crankshaft rear gasket

removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE MOUNTS REMOVAL . . . . . . . . . . . . . 14
- Flywheel case removal . . . . . . . . . . . . . . . . . . . 14
- Double gear removal . . . . . . . . . . . . . . . . . . . . 14

2 SECTION 6 - GENERAL MECHANICAL OVERHAUL CURSOR SERIES
Page Page
- Connecting rod removal . . . . . . . . . . . . . . . . . 14 SELECTION OF MAIN HALF-BEARINGS . . . . . . 29
- Disassembling the oil pump . . . . . . . . . . . . . . . 14 - Thickness of the main bearing shells . . . . . . . . 29
- Rocker arm shaft removal . . . . . . . . . . . . . . . . 15 - Main half-bearings selection

(nominal diameter) . . . . . . . . . . . . . . . . . . . . 31
- Rail removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Main half-bearings selection
- Injector removal . . . . . . . . . . . . . . . . . . . . . . . 15 (rectified pins) . . . . . . . . . . . . . . . . . . . . . . . . 32
- Camshaft removal . . . . . . . . . . . . . . . . . . . . . . 16 - Main half-bearings selection

(nominal diameter pins) . . . . . . . . . . . . . . . . . 34
- Cylinder head removal . . . . . . . . . . . . . . . . . . 16
(nominal diameter pins) . . . . . . . . . . . . . . . . . 35
- Oil sump removal . . . . . . . . . . . . . . . . . . . . . . 17
- Suction strainer removal . . . . . . . . . . . . . . . . . 17 (pins with rectified diameter) . . . . . . . . . . . . . 36
- Connecting rod removal . . . . . . . . . . . . . . . . . 17 - Checking the oil pump
and timing control gear . . . . . . . . . . . . . . . . . 38
- Axis alignment check . . . . . . . . . . . . . . . . . . . . 18
- Checking crankshaft end float . . . . . . . . . . . . . 38
- Lower crankcase removal . . . . . . . . . . . . . . . . 18
- Crank pin fitting clearance check . . . . . . . . . . . 38
- Crankshaft removal . . . . . . . . . . . . . . . . . . . . . 18
OVERHAUL OF CONNECTING
- Main bearings removal . . . . . . . . . . . . . . . . . . 18 ROD-PISTON ASSEMBLY . . . . . . . . . . . . . . . 39
- Oil sprayer removal . . . . . . . . . . . . . . . . . . . . . 18 - Piston rings removal . . . . . . . . . . . . . . . . . . . . 40
COMPREHENSIVE CRANKCASE CHECKS . . . . . 19 - Piston removal . . . . . . . . . . . . . . . . . . . . . . . . 40
- Crankcase checks . . . . . . . . . . . . . . . . . . . . . . 19 - Measuring the piston diameter . . . . . . . . . . . . 40
- Cylinder liners Removal . . . . . . . . . . . . . . . . . . 21 - Measuring the piston pin diameter . . . . . . . . . 40
- Cylinder liner refitting and protrusion check . . 21 - Conditions for correct pin-piston coupling . . . 41
- Crankshaft measurements . . . . . . . . . . . . . . . . 22 - Measuring seal rings . . . . . . . . . . . . . . . . . . . . . 41
- Main half-bearings shim . . . . . . . . . . . . . . . . . . 23 - Connecting rod checks . . . . . . . . . . . . . . . . . . 42
- Measuring main journals . . . . . . . . . . . . . . . . . 23 - Axis alignment check . . . . . . . . . . . . . . . . . . . . 44
- Measuring crankpins . . . . . . . . . . . . . . . . . . . . 24 - Torsion check . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Defining the diameter class of the seats - Bending check . . . . . . . . . . . . . . . . . . . . . . . . . 45

for half-bearings on the crankcase . . . . . . . . . 25
- Small end bushing check . . . . . . . . . . . . . . . . . 45
- Defining the diameter class of the main journal
and crankpin . . . . . . . . . . . . . . . . . . . . . . . . . 26 - Piston assembly . . . . . . . . . . . . . . . . . . . . . . . . 45
- Defining the diameter class of the seats for - Fitting piston rings . . . . . . . . . . . . . . . . . . . . . . 46
half-bearings on the crankcase
CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . . 46
- Defining the diameter class of the seats for
half-bearings on the crankcase - Main operation . . . . . . . . . . . . . . . . . . . . . . . . 46

Page Page
- Valve removal . . . . . . . . . . . . . . . . . . . . . . . . . 46 - Rod half-bearing fitting . . . . . . . . . . . . . . . . . . 61
- Checking the planarity of the head - Assembling connecting rod - piston assemblies
on the cylinder assembly . . . . . . . . . . . . . . . . 47 in the cylinder liners . . . . . . . . . . . . . . . . . . . . 61
- Valve descale and check . . . . . . . . . . . . . . . . . 47 - Fitting crankshaft

front gasket . . . . . . . . . . . . . . . . . . . . . . . . . . 62
- Regrinding - replacing the valve seats . . . . . . . 48
- Cylinder head assembly . . . . . . . . . . . . . . . . . . 63
- Replacing the valve guides . . . . . . . . . . . . . . . . 49
- Installing the oil pump . . . . . . . . . . . . . . . . . . . 64
- Checking protrusion of injectors . . . . . . . . . . . 49
- Fitting flywheel box . . . . . . . . . . . . . . . . . . . . . 65
- Valve spring check . . . . . . . . . . . . . . . . . . . . . . 49
- Fitting crankshaft
- Valve assembly . . . . . . . . . . . . . . . . . . . . . . . . 49 rear gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
- Mounting the oil seal ring . . . . . . . . . . . . . . . . 50 - Engine flywheel assembly . . . . . . . . . . . . . . . . 66
TIMING SYSTEM ASSEMBLY - Fitting camshaft . . . . . . . . . . . . . . . . . . . . . . . . 66

OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . 50
- Injector assembly . . . . . . . . . . . . . . . . . . . . . . . 69
- Main operation . . . . . . . . . . . . . . . . . . . . . . . . 50
- Rail installation . . . . . . . . . . . . . . . . . . . . . . . . . 70
- Replacement gear bush idle gear . . . . . . . . . . . 50
- Fitting rocker shaft assembly . . . . . . . . . . . . . . 70
- Replacement of the dual idle gear bushes 51
- Camshaft timing . . . . . . . . . . . . . . . . . . . . . . . 71
- Tolerance characteristics . . . . . . . . . . . . . . . . . 53
- Pulser ring timing . . . . . . . . . . . . . . . . . . . . . . . 75
- Class of importance of
product characteristics . . . . . . . . . . . . . . . . . . 53 - High pressure pump assembly . . . . . . . . . . . . . 76
- Camshaft bushes check . . . . . . . . . . . . . . . . . . 54 - Intake and exhaust rocker arm clearance adjustment
77
- Replacing camshaft
bushes using drift . . . . . . . . . . . . . . . . . . . . . . 55 - Tappet cover assembly . . . . . . . . . . . . . . . . . . 78
- Rocker shaft check . . . . . . . . . . . . . . . . . . . . . 56 - Fuel filter assembly . . . . . . . . . . . . . . . . . . . . . 78
- Exhaust valve rocker arm check . . . . . . . . . . . 57 - Timing gear assembly cover mounting . . . . . . . 79
- Intake valve rocker arms check . . . . . . . . . . . . 57 - Blow-by filter fitting . . . . . . . . . . . . . . . . . . . . . 79
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 57 - Blow-by case fitting . . . . . . . . . . . . . . . . . . . . . 80
- Main operation . . . . . . . . . . . . . . . . . . . . . . . . 57 - Suction strainer installation . . . . . . . . . . . . . . . 80
- Oil sprayer assembly . . . . . . . . . . . . . . . . . . . . 57 - Oil sump assembly . . . . . . . . . . . . . . . . . . . . . 80
- Main bearings assembly . . . . . . . . . . . . . . . . . . 57 - Inlet manifold assembly . . . . . . . . . . . . . . . . . . 81
- Crankshaft assembly . . . . . . . . . . . . . . . . . . . . 58 - Starter motor assembly . . . . . . . . . . . . . . . . . . 81
- lower crankcase assembly . . . . . . . . . . . . . . . . 58 - Heat exchanger assembly . . . . . . . . . . . . . . . . 81
- Diagram of tightening sequence of lower crankcase - Oil filter assembly . . . . . . . . . . . . . . . . . . . . . . 82

fixing screws . . . . . . . . . . . . . . . . . . . . . . . . . . 60
- Turbocharger assembly . . . . . . . . . . . . . . . . . . 82

Page
- Exhaust manifold assembly . . . . . . . . . . . . . . . 82
- Thermostat case assembly . . . . . . . . . . . . . . . 84
- Water pump assembly . . . . . . . . . . . . . . . . . . 84
- Pulley assembly . . . . . . . . . . . . . . . . . . . . . . . . 85
- Alternator assembly . . . . . . . . . . . . . . . . . . . . 85
- Fitting water pump/alternator

drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
- Damper flywheel installation . . . . . . . . . . . . . . 86
- Removing the engine from the stand . . . . . . . 86
- Oil pressure adjustment valve assembly . . . . . 86
- Fitting the front suspension mounts . . . . . . . . 86

ENGINE DISASSEMBLING Figure 2

Protect the electrical parts before washing wish pressurised
water spray. Before securing the engine onto the rotating stand
99322230, remove the engine cable disconnecting it from the
control unit and from all sensors/senders to which it is connec-
ted.
Remove all components that may interfere with assembly of
the brackets as shown below.
Removing the front suspension mounts
Figure 1
221080
Unscrew the screws (2) and remove the water inlet pipe to
the pump (1).
Figure 3
221079
Unscrew the fastening screws (2) and remove the front mount
(1).
221081
Unscrew the fastening screws (2) and remove the front mount
(1) (turbocharger side).

Figure 4
223409
Secure the engine to the rotating stand 99322230 with the brackets 99361036 (1).

Damper flywheel removal Coolant pump alternator drive belt

disassembly
Figure 5 Figure 7
71702 166728
Lock the flywheel using the tool 99360351 (1). Using a 1/2 inch square wrench (1), act in the direction of the
arrow, remove the ancillary drive belt (2).
Figure 6
NOTE The flexible belt must be replaced with a new

one every time it is removed from the vehicle.
Alternator removal
Figure 8
221082
Remove the damper flywheel (2) by acting on the screws (1).
221083
Unscrew the screws (1,2) and remove the alternator (3).

Pulley removal Thermostat case removal
Figure 9 Figure 11
221084 221086
Unscrew the screws (1) and remove the pulley (2). Unscrew the screws (2, 3) and remove the thermostat assem-
bly (1).
Water pump removal
Crankshaft front gasket removal
Figure 10 Figure 12
60490
221085
Fit puller 99340053 (2) and take off the crankshaft seal (1).
Unscrew the screw (7) and remove the automatic belt tensio- Extract the flange (3).
ner (8).
Unscrew the screws (5) and remove the pulley (6).
Unscrew the screw (3) and remove the pulley (4).
Unscrew the screws (1) and remove the water pump (2).

Turbocharger removal Figure 15
Figure 13
221089
Remove the collar (3), remove the fitting (4) with the relative
221087
seal.
Remove the oil delivery pipe (1) and the oil return pipe (2) Remove the P3 sensor connecting pipe (5).
from the turbocharger. Unscrew the screws (1) and remove the flange (2).
Figure 14 Figure 16
221088 221090
Disconnect the coolant pipes (2, 3) from the engine brake Unscrew the fastening screws (1) and remove the exhaust
device actuator (1). manifold (3) together with the turbocharger (2).
Open the collar (4) and remove the engine brake device (1). Figure 17
221091
Unscrew the screws and nuts (2, 4) and remove the turbo-
charger (4) from the exhaust manifold (3).

Oil filter removal Starter motor disassembly
Figure 18 Figure 20
221092 221094
Unscrew and remove the oil filter (3). Remove the nuts (1) from the studs.
Unscrew the screws (1) and remove the oil filter housing (2). Remove the starter motor (2).
Heat exchanger removal Intake manifold removal
Figure 19 Figure 21
221093 221095
Unscrew the screws (2,3) and remove the complete heat Unscrew the screws (1) and remove the intake manifold (2)
exchanger (1). together with the engine preheating resistor (3).

Figure 22 Timing gear cover

removal
Figure 25
221096
Unscrew the screws (5) and remove the bracket (4).

Remove the fuel pipes (3, 6), unscrew the screws (2) ad 221099
remove the engine control unit (1).
Unscrew the screws (2) and remove the distribution cover (1).
Blow-by case removal
Removal of head cover
Figure 23
Figure 26
221097
Unscrew the screws (1) and remove the blow-by case (2). 221100
Blow-by filter removal Unscrew the fastening screws (2) and remove the head cover
(1).
Figure 24
221098
Unscrew the screws (1) and remove the blow-by filter (2).

Fuel filter removal Figure 29
Figure 27
221103
221101 Remove the blocks (1) and disconnect the pipes (2,3).
Remove the collars (5) and remove the pipe (4)
Unlock the cable ties (6).
Remove tube (6)
Disconnect the fuel outlet (1) and inlet (4) pipes from the high
pressure pump (5) and the fuel filter (3). Figure 30
Unscrew the screws (2) and remove the oil filter housing toge-
ther with the support (3).
High pressure pump removal
Figure 28
221104
Unscrew the screws (1,2,4) and remove the bracket (3).

Unscrew the screws (5) and remove the high pressure pump.
Figure 31
221102
Undo the nut (1).

Apply thetool to extract the high pressure pump gear
99366198 (3) and remove the high pressure pump control
gear (2).
160624
Unscrew the retaining screws (1) and remove the flange (2)
supporting the high pressure pump.

Figure 32 Engine flywheel removal
Figure 35
221105
Unscrew the screws (2) and remove the gear (1) fitted with
221108
impulse wheel.
Figure 33 Using the tool 99360351 to lock the mounted engine flywheel
(1) unscrew the retaining screws (2); then remove the tool (1)
and remove the engine flywheel (3).
Crankshaft rear gasket removal
Figure 36
221106
Unscrew the screws (2) and remove the thrust plate (1) and
the sheet gasket.
Figure 34
60500
Fit puller 99340054 (2) and take off the seal (1).
221107
Unscrew the screws (2) and remove the idle gear (1).

ENGINE MOUNTS REMOVAL Double gear removal

Figure 37 Figure 39
221109 221111
Remove screws (1) and disassembly the double gear (2).

Unscrew the screws (4) and remove the engine suspension
(3).
Connecting rod removal
Undo the screws (1) and remove the cover (2).
Figure 40
Flywheel case removal
Figure 38
221112
Unscrew the screw (1) and remove the connecting rod (2).
221110 Disassembling the oil pump

Unscrew the screws (1) and remove the flywheel case (2). Figure 41
221113
Unscrew the fastening screws (1) and remove the oil pump
(2).
Rocker arm shaft removal Rail removal
Figure 42 Figure 44
221118
Unscrew the fittings and remove the high pressure fuel supply
pipes (8).
221129 Unscrew the fittings from the rail and the injectors and detach
the high pressure fuel pipes (1, 2, 3, 4, 5 ) e (6) and the fuel
Unscrew the screws (1) fixing the rocker arm shaft. return pipe (7) from the head.
Figure 43
NOTE The high pressure fuel pipes must be replaced
at each disassembly.
Disconnect the electric connection from pressure sensor (11).

Unscrew the fastening screws (9) and remove the rail (10).
Injector removal
Figure 45
114025
Use the specified tool 99360553 (1) on the rocker arm shaft
(2) and remove the shaft (2) from the cylinder head. Remove
the crosspieces (3) from the cylinder head.
183457
Disconnect the electrical connections (1) from the

electro-injectors.

Figure 46 Camshaft removal
Figure 48
60514
Fit the appropriate plugs (1) in the place of the injectors.

Remove the camshaft (2).
169827 Cylinder head removal
Remove the screws (1) from the brackets (2) supporting the Figure 49
injectors.
Figure 47
60515
Unscrew the fixing screws on the cylinder head (3).
NOTE The cylinder head fastening screws are to be

replaced each time you remove them.
By means of metal ropes, lift the cylinder head (1).

169826
Remove the seal (2)
Position the tool for extraction the injectors (1) and remove
the injectors (2) from the head.

Oil sump removal Connecting rod removal
Figure 50 Figure 52
60516
47574
Slacken the screws (2) and remove the engine oil sump (1)
with the frame (3) and the gasket. Turn the crankcase (1) into vertical position.
Suction strainer removal Figure 53
Figure 51
60518
Undo the screws (2) fixing the connecting rod cap (3) and
221114 remove it.
Unscrew the screws (2, 3) and remove the suction strainer (1).
NOTE Keep the connecting rod half-bearings in their
respective housings and/or note down their
assembly position since, if reusing them, they will
need to be fitted in the position found upon remo-
val.

Axis alignment check Crankshaft removal
Figure 54 Figure 56
47570
Using the tool for lifting the crankshaft 99360500 (1), remove
the crankshaft (2).
Main bearings removal

61696
Figure 57
Check the connecting rods axes for parallelism (1) using a sui-
table device (5) and proceeding as follows.
Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
Set the spindle on the on the V prisms resting the connecting
rod (1) on the stop bar (2).
Lower crankcase removal
Figure 55
47571
Remove the main half-bearings (1).
Oil sprayer removal

Unscrew the screws and remove the oil sprayers (2).
Remove the cylinder sleeves as described in the related para-
graph.
60519
Using an appropriate wrench and the hex wrench unscrew the NOTE once the engine disassembly is complete, clean
screws (1) and (2) and take off the lower crankcase. accurately the removed parts and check their
integrity.
NOTE Note down the assembly position of the top The following pages give instructions for checks
and bottom main half-bearings since, if reusing and main measurements to do as to determine
them, they will need to be fitted in the position whether the parts can be reused.
found upon removal.

CRANKCASE ASSEMBLY CHECKS Figure 60

Crankcase checks
Figure 58
60595
A. = Selection class 135.000 - 135.013

34994
B = Selection class 135.011 - 135.024
After disassembling the engine, thoroughly clean the cylinder-- Y = Marking area
crankcase assembly.
Carefully inspect the crankcase for cracks. When wear is over 0.150 mm or maximum ovalization is 0.100
mm compared to the values shown in the figure, replace the
Check the condition of casting hole plugs. cylinder barrel because it is not possible to adjust, lap or dress
If the caps are rusted, or if there is any doubt about the effi- it.
ciency of the seal, replace them.
During fitting operations, apply LOCTITE 270 to the caps. NOTE Cylinder liners are equipped with spare parts
The internal diameter of the cylinder liners is checked to ascer- belonging to selection class A.
tain the extent of ovalization, taper and wear, using the bore
meter (2) fitted with a dial gauge (1) previously reset on the
ring gauge (3) of the diameter 135 mm.
Figure 61
NOTE If the 135 mm ring gauge is not available, use a

micrometer.
Figure 59
60597
A = 153.500 - 153.525
B = 152.000 - 152.025
60596 C = 153.461 - 153.486
1 = 1st measurement D = 151.890 - 151.915
2 = 2nd measurement
3 = 3rd measurement The illustrated diagram refers to the outer diameters of cylin-
der liners (C) and (D) and the inner diameters of their seats
Measurements should be carried out for every single cylinder
(A) and (B).
liner at three different heights and on two (A-B) perpendicular
plane levels as shown in the figure.

Figure 62
60598
Cylinder liners can be removed and fitted several times into different housings, if needed.
Figure 63
221075
During checks, make sure that the main data for the cylinder liners is the same as in the figure.

Cylinder liners Removal Figure 66
Figure 64
47577
60520A
Position the extraction tool 99360706 (2) and the plate

99360728 (4), as shown in the figure, making sure that the Check the protrusion of the cylinder liners using the tool
plate (4) rests correctly on the cylinder liner. 99360334 (2) together with spacers 99360336 and tightening
the screw (1) to a torque of 225 Nm
Fasten the screw nut (1) and take off the cylinder liner (3) from
the crankcase. Figure 67
Cylinder liner refitting and protrusion check
Figure 65
60520B
Using the dial gauge (0-5mm) 99395603 supplied with a base

with dial gauge carrier 99370415 (3), check that the protrusion
of the cylinder liners in relation to the contact surface of the
cylinder heads is 0.045 - 0.075, if this is not the case, replace
the adjustment ring (1, Figure 65), supplied as a spare part in
different thicknesses.
16798 Figure 68
Always replace the watertight rings (3, 4 and 5).

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

parts in the following thicknesses: 0.08 mm -
0.10 mm - 0.12 mm - 0.14 mm.
60521
Once assembly is complete, block the cylinder liners (1) at the

crankcase (2) with stud bolts 99360703 (3).
Crankshaft measurements
Figure 69
38.700
39.000
47.785
47.800
3.380
A 3.430
99.970
100.000 131.122
131.147
X Y 95.970 47.95
96.000 48.00
38.700
39.000
47.785
47.800
3.380
A 3.430
60521
A = 3.115 - 3.146

Main half-bearings shim Figure 71

Check the condition of the crankshaft main journals; there
must no be signs of scoring, ovalisation or excessive wear . The
values shown refer to rated pin diameter.
Measuring main journals
Figure 70
181691
X = Main journals fitting detail

During the grinding operation, pay attention to the values of
the main journal couplings shown in the details X.
NOTE All main journals and crankpins must also be

47535
ground to the same undersizing class, in order
to avoid any alteration to shaft balance .
Before grinding the pins using a micrometer (1), measure the
main journals and the crank pins (2) and decide, on the basis
of the undersizing of the half-bearings, the final diameter to
which the pins are to be ground.
NOTE It is advisable to enter readings in a table.
NOTE For a more accurate reading, take different mea-

surements on more than one point of the shaft
and calculate the average value.

Measuring crankpins
Figure 73
Figure 72
181692
47536
Y=Crankpin fitting detail
Before grinding the pins, using a micrometer (1), measure the
During the grinding operation, pay attention to the values of
main journals of the shaft (2) and decide, on the basis of the
the crankpins shown in Y.
undersizing of the half-bearings, the final diameter to which the
pins are to be ground.
NOTE All main journals and crankpins must also be
NOTE For a more accurate reading, take different mea- ground to the same undersizing class, in order
surements on more than one point of the shaft to avoid any alteration to shaft balance.
and calculate the average value.
Figure 74
114045
Write down the measurements of the main journals and crankpins of the crankshaft in the table.

Defining the diameter class of the seats for half-bearings on the crankcase
Figure 75
190208
To identify the diameter class of the seats for the main half-bearings, look at the front part of the crankcase in the position as indicated
in the figure.

Defining the diameter class of the main journals and crankpins

In order to identify the diameter class of the crankpins and main journals, identify the three sets of figures marked on the front of
the crankshaft.
Figure 76
210301
A: The set of seven digits refers to the crankpin, more specifically:

- The isolated digit indicates the state of the pins (1 = STD, 2 = - 0.127)
- The six digits, taken individually, represent the diameter class of each crankpin to which they refer.
B: The set of eight digits refers to the crankpin, more specifically:
- The isolated digit indicates the state of the pins (1 = STD, 2 = - 0.127)
- The seven digits, taken individually, represent the diameter class of each crankpin to which they refer.
C: The first number, of five digits, is the part number of the shaft.

(nominal diameter)
To identify the diameter class of the seats for the main half-bearings, look at the front part of the crankcase in the position as indicated
in the figure.
Figure 77
STATUS OF MAIN CRANKPIN NOMINAL

CLASS CLASS
JOURNAL DIAMETER
1 99.970 - 99.977
1 STD 2 99.978 - 99.985
2 -0.127 3 99.986 - 99.989
4 99.990 - 100.00
221130
Example:
Figure 78
210315

(nominal diameter)
The diameter class of each connecting rod bearing must be selected before identifying the diameter of each crankpin.
In order to identify the diameter class of the crankpins, identify the three sets of figures marked on the front of the crankshaft.
Figure 79
STATUS OF MAIN CRANKPIN NOMINAL

CLASS CLASS
JOURNAL DIAMETER
1 95.970 - 95.979
1 STD
2 95.980 - 95.989
2 -0.127
3 95.990 - 96.000
223408
Example:
Figure 80
210316

SELECTION OF MAIN HALF-BEARINGS

Depending on the thickness of the half-bearings, the tolerance classes are selected, distinguished by a coloured mark.
The tables give the specifications of the main bearings available as spare parts in the standard sizes (STD) and in the permissible
oversizes (+0.127, +0.254, +0.508).
Thickness of the main bearing shells
Figure 81
210304
1. Coloured marking area
STD +0.127 +0.254 +0.508
210308
Red 3.115 - 3.122 - 3.242 - 3.294 3.369 - 3.376

Red/Black - 3.179 - 3.186 - -
Green 3.123 - 3.130 - - -
Green\Black - 3.187 - 3.194 - -
Yellow* 3.131 - 3.138 - - -
Yellow/Black * - 3.195 - 3.202 - -
Black* 3.139 - 3.146 - - -
Black/Black - 3.203 - 3.210 - -
* Not supplied as a spare part.

Figure 82
210305
1. Coloured marking area
STD +0.127 +0.254 +0.508
210311
Red 1.960 - 1.970 - 2.087 - 2.097 2.214 - 2.224

Red/Black - 2.023 - 2.033 - -
Green 1.970 - 1.980 - 2.097 - 2.107 2.224 - 2.234
Green\Black - 2.033 - 2.043 - -
Yellow* 1.980 - 1.990 - - -
Yellow/Black ** - 2.043 - 2.053 - -
* Not supplied as a spare part. If necessary, replace with Green half-bearing
** Not supplied as a spare part. If necessary, replace with Green\Black half-bearing

Main half-bearings selection (nominal diameter)

After detecting, for each main journal, the necessary data on crankcase and crankshaft, select the type of half-bearings to be used,
in compliance with the following table:.
210306
1 2 3 4
STD CLASS 106.300 106.308 160.316 106.324
106.307 106.315 106.323 106.330
1 Red Red Green Green
99.970
99,977 Red Green Green Yellow*
2 Red Green Green Yellow*

99,978
99,985 Green Green Yellow* Yellow*
3 Green Green Yellow* Yellow*

99,986
99,993 Green Yellow* Yellow* Black
4 Green Yellow* Yellow* Black

99,994
100.000 Yellow* Yellow* Black Black
210307
* Not supplied as a spare part. If necessary, replace with Green\Black half-bearing
NOTE If using big end half-bearings of a different thickness, fit the thicker bearing at the bottom.

Main half-bearings selection (rectified pins)

If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameters of the pins is as indicated in the table and fit the only type of half-bearing indicated
for the undersizing in question.
210306
1 2 3 4
-0.127 CLASS 106.300 106.308 160.316 106.324
106.307 106.315 106.323 106.330
1 Red / Black Red / Black Green/Black Green/Black
99,843
99,850 Red / Black Green/Black Green/Black Yellow/Black*
2 Red / Black Green/Black Green/Black Yellow/Black*

99,851
99,858 Green/Black Green/Black Yellow/Black* Yellow/Black*
3 Green/Black Green/Black Yellow/Black* Yellow/Black*

99,859
99,866 Green/Black Yellow/Black* Yellow/Black* Black / Black
4 Green/Black Yellow/Black Yellow/Black Black / Black

99,867
99,873 Yellow/Black* Yellow/Black* Black / Black Black / Black
210307
NOTE If using main half-bearings of a different thickness, fit the thicker bearings at the bottom (plate side).

210306
1 2 3 4
-0.254 CLASS 100.000 100.011 100.021 100.021
100.010 100.020 100.030 100.030
3
Red Red Red Red
99.726
4
Red Red Red Red
99.746
210307
210306
1 2 3 4
-0.508 CLASS 106.300 106.308 160.316 106.324
106.307 106.315 106.323 106.330
3
Red Red Red Red
99.472
4
Red Red Red Red
99.492
210307

Main half-bearings selection (nominal diameter pins)

Select the main half-bearings by referring to the markings on the connecting-rod body, in the indicated position
.
NOTE The number indicating the diameter class of the seat for half-bearings can be: 1, 2 or 3
1) Serial No.
2) Letter indicating the weight class
A = 5537- 5570 g.
B = 5571 -5604 g.
C = 5605 -5637 g.
3) Number indicating the selection of the diameter of the big end bearing seat
1 = 100.000- 100.010mm
2 = 100.011- 100.020mm
3 = 100.021- 100.030mm
4) Engine type
5) Connecting rod identification plate
Figure 83
155939

Main half-bearings selection (nominal diameter pins)
210309
210312
1 2 3
STD CLASS 100.000 100.011 100.021
100.010 100.020 100.030
1 Red Red Green
95.990
96.000 Red Green Green
2 Red Green Green

95.980
95.989 Green Green Yellow*
3 Green Green Yellow*

95.970
95.979 Green Yellow* Yellow*
210310

Main half-bearings selection (pins with rectified diameter)

If the journals have been rectified, the procedure described cannot be applied.
In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of the crankpins
and to mount the bearing shells identified with the relevant table.
210309
210312
1 2 3
-0.127 CLASS 100.000 100.011 100.021
100.010 100.020 100.030
1 Red/Black Red/Black Green\Black
95.863
95.873 Red/Black Green\Black Green\Black
2 Red/Black Red/Black Green\Black
95.853
95.862 Green\Black Green\Black Yellow/Black *
3 Green\Black Green\Black Yellow/Black *
95.843
95.852 Green\Black Yellow/Black * Yellow/Black *
210310
* Not supplied as a spare part. If necessary, replace with Green\Black half-bearing

210309 210312
1 2 3
-0.254 CLASS 100.000 100.011 100.021
100.010 100.020 100.030
1 Red Red Green
95.736
95.746 Red Red Green
2 Red Green Green
95.726
210310
210309 210312
1 2 3
-0.508 CLASS 100.000 100.011 100.021
100.010 100.020 100.030
1 Red Red Green
95.482
95.492 Red Red Green
2 Red Green Green

95.472
210310

Checking the timing and oil pump gear control Crank pin fitting clearance check
Figure 84
Figure 86
47594
Connect the connecting rods to the relevant journals of the

crankshaft, placing a length of calibrated wire on the journals.
108836 mount the connecting rod caps (1) together with half-bearings;
Check that the toothing of the gear is neither damaged nor tighten the screws (2) securing the connecting rod caps to the
worn; if it is, take it out with an appropriate extractor and prescribed torque.
replace it. Use tool 99395216 (3) to additionally tighten the screws to
When fitting the gear (1) on the crankshaft (2), heat it for no the prescribed angle.
longer than 2 hours in an oven at the temperature indicated Tightening
below . Ref. No. Description
torques
Technical data Screws fixing connec-
ting rod cap
Heating temperature for gear fit- (2) 12
180C Step 1 70 Nm
ting
Let it cool down after pressing Step 2 60
If changing the pin (3), after fitting it on, check it protrudes from
the crankshaft as shown in the figure. NOTE The thread of the screws (2), before assembly
Checking crankshaft end float , has to be lubricated with engine oil.
Figure 85
Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
envelope containing the wire.
Upon final assembly: check the diameter of the threading of the
screws (2) which must not be less than 13.4 mm, otherwise
replace the screw;
lubricate the crankpins and big end bearings;
tighten the screws (2) as described above.
47588
The thrust clearance is checked by placing a specific dial gauge

(0 5mm) 99395603 (1) on the crankshaft (2) as shown in
the figure.
If the value obtained is higher than specified, replace the rear
thrust half-bearings and repeat the clearance check.

OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

Figure 87
155940
1. Connecting rod body - 2. Half-bearings - 3. Connecting rod cap - 4. Cap fastening screw - 5 Circlip -
6. Slotted oil scraper ring with spiral spring - 7. Claw seal ring - 8. Trapezoidal seal ring -
9. Piston pin - 10. Piston
Make sure the pistons do not show any sign of seizing, scoring, cracking or excessive wear; otherwise, replace as necessary.

Piston rings removal Figure 90
Figure 88
155941
155943
Remove the piston circlips (2) using the caliper 99360184 (1).
Remove the gudgeon pin (1).
If removal is difficult use the appropriate drift.
NOTE Pistons are equipped with three circlips: the first
is a sealing ring, with trapezoidal section; the
Measuring the piston diameter
second is a claw seal ring; the third oil scraper.
Figure 91
NOTE Pistons are grouped into classes A and B depen-

ding on diameter.
Piston removal
Figure 89
155944
Using a micrometer (2), measure the piston diameter (1) to

determine the assembly clearance; The diameter has to be
detected at the value indicated.
Measuring the piston pin diameter

Figure 92
155942
Remove the piston pin circlips (2) using the round tipped cali-
pers (1). 155945
Measuring the pin diameter (2) with a micrometer (1).

Figure 93
181694
* = The distance is measured on a of 130 mm

X = 0.8 0.1 mm
Conditions for correct piston pin-piston Measuring seal rings
coupling
Figure 95
Figure 94
16552A
155946 Check the thickness of the circlip using a micrometer 2(1).

During the coupling phase, make sure that the main data for Figure 96
the pin and piston is the same as that indicated in Figure 93.
Lubricate the pin (1) and the relevant housings on the internal
piston hubs with engine oil; the pin must be inserted in the
piston with a light finger pressure and it should not come out
by gravity.
181693
Check the clearance between the sealing ring (2) and the rela-
ted housings on the piston (1) using a feeler gauge (3).

Connecting rod checks

Figure 97
Figure 99
3513
The sealing ring (2) of the 1 seat is trapezoidal.

155939
The clearance measurement X between the sealing ring and
the housing is done by placing the piston (1) with the related 1 Standard numbers
ring in the cylinder sleeve (3) so the half of the sealing ring pro-
trudes from the cylinder sleeve. 2 Letter indicating the weight class
A = 5537 -5570 g.
Figure 98 B = 5571 -5604 g.
C = 5605 -5637 g.
3 Number indicating the selection of the diameter of the

big end bearing seat:
1 = 100.000 100.010 mm
2 = 100.011 100.020 mm
3 = 100.021 100.030 mm
4 Engine type
5 Connecting rod identification plate
Connecting rods weight class

warning during assembly
36134 When installing connecting rods, make sure they all
Check the end gap of the sealing rings (1), using a feeler gauge belong to the same weight class.
(2), entered in the cylinder liner (3).
If the distance between ends is lower or higher than the value Data concerning the class section of connecting rod housing
required, replace the circlips. and weight are stamped on the connecting rod.

Figure 100
181695
* =Values to be obtained after fitting the bush

During checks make sure that the main data of the bushing, connecting rod, pin and half bearings is that shown in the diagram.

Axis alignment check Torsion check

Figure 102
Figure 101
61694
Check the torsion of the connecting rod (5) by comparing two

points (A and B) of the pin (3) on the horizontal plane of the
61696 axis of the connecting rod.
Position the mount (1) of the dial gauge (2) so that this pre--
Check the connecting rods axes for parallelism (1) using a sui- loads by approx. 0.5 mm on the pin (3) at point A and zero
table device (5) and proceeding as follows. the dial gauge (2). Move the spindle (4) with the connecting
Fit the connecting rod (1) on the spindle of the tool (5) and rod (5) and compare any deviation on the opposite side B of
lock it with the screw (4). the pin (3): the difference between A and B must be no grea-
ter than 0.08 mm.
Set the spindle on the on the V prisms resting the connecting
rod 1 on the stop bar (2).

Bending check Small end bushing check
Figure 103 Figure 104
073535
Check that the bushing in the small end has not come loose
and shows no sign of seizure or scoring. Otherwise replace it.
61695 The bushing (2) is removed and fitted with a suitable drift (1).
Check the bending of the connecting rod (5) by comparing When driving it in, make absolutely sure that the holes for the
two points C and D of the pin (3) on the vertical plane of the oil to pass through in the bushing and small end coincide.
axis of the connecting rod. Using a reamer, rebore the bushing so as to obtain a diameter
Position the vertical mount (1) of the dial gauge (2) so that this of 59.060 to 59.076 mm.
rests on the pin (3) at point C.
Piston assembly
Swing the connecting rod to and fro, establishing the highest
position of the pin and reset the dial gauge (2) in this condi- Figure 105
tion.
Shift the spindle (4) with the connecting rod (5) and repeat the
check on the highest point on the opposite side D of the pin
(3).
The difference between points C and D must not exceed 0.08
mm. 1
2
4 5
3
181833
The piston (1) must be mounted on the connecting rod (2) so

that the ideogram (4), that indicates the fitting direction of the
cylinder liner and the punching (3) of the connecting rod are
seen as in the figure.
NOTE The arrow (5) must face the engine flywheel.

Figure 106 CYLINDER HEAD OVERHAUL
Main operation
Before removing cylinder head, check hydraulic tightness using
specific tool; in case of leaks not caused by core plugs or threa-
ded plugs, replace cylinder head.
NOTE When replacing the cylinder head, it is supplied

as a spare part with a threaded plug, which must
be removed during assembly.
NOTE In case of plugs removal/replacement, when

assembling apply sealant Loctite 121078 on the
plugs.
181830
Fit the pin (2) and fasten it on the piston (1) with the circlips Valve removal
(3).
NOTE Before removing cylinder head valves, number
Fitting piston rings them so that when they are refitted, if not ove-
rhauled or replaced, they are refitted in the
Figure 107 same positions as when they where removed.
Intake valves are different form exhaust valves
in that they have a notch placed at valve head
centre.
Figure 108
155950
To fit the circlips (1) on the piston (2) use the pliers 99360184
(3).
Position the rings so that the word TOP (4) is facing
upwards, direct the ring openings so they are staggered 180
apart. 47583
Fit and secure tool 99360263 (2) with the bracket (4); screw
down with the device 99360259 (1) so the cotters (3) can be
removed; take out the tool (2) and extract the top plate (5),
spring (6) and bottom plate (7).
NOTE Repeat this operation for all the valves.
Turn the cylinder head upside down and remove the valves
(8).

Checking the planarity of the head on the Valve descale and check
cylinder block
Figure 110
Figure 109
48625
198344
Check the supporting surface (1) of the head on the cylinder Remove all carbon deposits from the valves using a wire brush.
assembly with a rule (2) and a feeler gauge (3).
If you find any deformation, level the head on a surface grinder;
maximum amount of material that can be removed 0.2 mm.
NOTE After this operation, check valve recessing and

injector protrusion.
Figure 111
A B
155953
* = Value to be obtained after driving in the valve guides

A = intake - B = exhaust
Check that the valves show no signs of seizure or cracking and also check with a micrometer that the valve stem diameter is within
the required values: replace the valves if it is not.
Regrind the valve seats, if required, using a grinding machine and removing as less material as possible.
Use a bore gauge to check that the diameter inside the valve guide corresponds to the value indicated, after fitting.

Regrinding - replacing the valve seats
NOTE The valve seats are reground whenever the valves or the valve guides are ground and replaced.
Figure 112
181831
1 Intake valve seat 2 Exhaust valve seat

When replacing/checking the valve seats, refer to the main data provided in the figure.
Figure 113 If they need to be replaced, using the same tool and taking care
not to accidentally damage the cylinder head, remove as much
material as possible from the valve seats until it is possible to
extract them from the cylinder head using a punch .
Heat the cylinder head to 80 - 100 C and, using a drift, fit in
the new valve seats (2), chilled beforehand in liquid nitrogen.
Using the tool (1), regrind the valve seats according to the
angles shown in the previous figure .
After regrinding the valve seats and using a dial gauge (0-5mm)
99395603 with base 99370415, check that the position of the
valves in relation to the cylinder head surface respects the
values shown below:
Technical data
Intake valves recessing -0.54 - -0.86 mm
41032 Exhaust valves recessing -1.65 - -1.95 mm
Check the valve seats (2). If there are light scorings or burnings,
regrind them with a suitable tool (1) according to angles
shown in the previous figure.

Replacing the valve guides Valve spring check
70000
163815
Before fitting, the flexibility of the valve springs has to be chec-
* = Measurement to be obtained after driving in the valve ked using a suitable device.
guides
The valve guides are removed with the drift 99360143. Figure 117
Assembly is carried out with the drift 99360296 equipped with
tool 99360143.
It determines the exact position of the valve guides fitted in
the cylinder head; if they are not available, you need to drive
the valve guides into the cylinder head so they protrude by a
value equal to the one given below .
Technical data
Valve guide standout 30.08 - 31.2 mm
After driving in the valve guides, smooth their holes with slee- 108842
ker 99390330.
Compare the load and elastic deformation data with that of
Checking protrusion of injectors the new springs indicated in the figure.
Figure 115 Valve assembly

Figure 118
47585
Check injector protrusion (2) using a dial gauge (1).
193982
Lubricate the valve stem and insert the valves in the respective
valve guides; fit the lower plates (1).

Mounting the oil seal ring TIMING SYSTEM

ASSEMBLY
Figure 119 Technical data
Intake valve control cam lift 9.231 mm
Exhaust valve control cam lift 9.5607 mm
rated assembling clearance bet-
0.045 to 0.085 mm
ween gear bushings and pins
Main operation
Change transmission gear bushing.
Figure 121
155958
Using the specific keying device 99360329, fit the oil seal ring
(2) on the valve guides (3) and then fit the valves as follows.
NOTE If the valves not have been overhauled or repla-

86925
ced, refit them according to the numbering
noted during removal.
1. Camshaft - 2. Bushing - 3. Pin - 4. Connecting rod -
Intake valves are different from exhaust valves 5. Camshaft control gear -
in that they have a notch placed at the centre of 6. Transmission gear - 7. Double transmission - gear -
the poppet valve. 8. Crankshaft driving gear
Replace the bushings (2) when worn.
Figure 120
86290
Fit the springs (6), the upper plate (5).

Fit tool 99360263 (2) and secure it with the bracket (4). screw
down with device 99360259 (1) so the cotters (3) can be fit-
ted; remove the tool (2).

181832
After driving the bushing, bore it to obtain the diameter shown 101601
in the figure.
After driving the bushing, bore it to obtain the diameter shown
NOTE The bushing must be driven into the gear in the in the figure.
direction of the arrow setting the latter to the
dimension shown.
NOTE The bushing must be driven into the gear in the
direction of the arrow setting the latter to the
At the end of the boring operation, check that the gear dimension shown.
bushing/journal assembly clearance is equal to the indicated
value.
Check that the nominal assembly clearance between gear
Technical data
bushings and pins is equal to the value stated below.
0.045 - 0.085 mm Technical data
ween gear bushings and pins
0.045 - 0.085 mm
Replacement of the dual idle gear bushes ween gear bushings and pins
Checking cam lift and camshaft journals alignment
Figure 123
86925
1. Camshaft - 2. Bushing - 3. Pin - 4. Connecting rod -

5. Camshaft l control gear -
6. Transmission gear - 7. Double transmission gear -
8. Crankshaft driving gear
Replace the bushings (2) when worn.

Figure 125
47506
Place the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) using a dial gauge (2), comparing the values with those
specified below.
Technical data
Intake valve control cam lift 9.231 mm
Exhaust valve control cam lift 9.5607 mm
Figure 126
47507
Still with the camshaft (4) set on tailstocks (1), check the alignment of the supporting pins (3) with the dial gauge (2); it must not
exceed 0.030 mm.
If the disalignment exceeds this value, replace the shaft:

Figure 127
47505
To check the assembly clearance, measure the internal diameter of the bush and the diameter of the camshaft pins (1), the difference
represents the existing clearance.
If you find any clearances exceeding 0.135 mm replace the bushings and , if necessary, the camshaft.
Figure 128
187402
The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth; whereas, if they show any signs
of seizing or scoring, the shaft and the relevant bushings should be replaced.
Tolerance characteristics
TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation
Class of importance product characteristics
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL E
IMPORTANT
SECONDARY

Camshaft bushes check
Figure 129
155956
* = Bush inner diameter after installation

The surface of the bushings must show no sign of seizing or scoring; replace them if they do.
Measure the bush inner diameters with a bore meter and replace them if the value measured exceeds the tolerance value.
Figure 130
107217
A. Drift with seat for bushings to insert/extract - B. Dowel pin for positioning bushings. -
C. Reference mark to insert seventh bushing correctly - D. Reference mark to correctly insert bushings 1, 2, 3, 4, 5, 6. -
E. Guide bushing - F. Guide line - G. Guide bushing to secure to the seventh bushing mount -
H. Plate fixing bushing G to cylinder head - I. Grip - L. Extension coupling.
To remove and refit the bushes, use the drift 99360499.

Replacing camshaft bushes using beater NOTE The bushings are extracted from the front of
Disassembly each seat.
NOTE Position the drift 99360499 accurately during

the removal phase.
NOTE Removal does not require the drift extension
for bushes 5, 6 and 7 and it is not necessary to
use the guide bushing. For bushes 1, 2, 3 and 4
Figure 131 it is necessary however to use the extension and
the guide bushings.
71725
Remove the bushes in the following order (7, 6, 5, 4, 3, 2, 1).
assembly
To insert the bushes (1, 2, 3, 4 , 5 ), proceed as follows.
Figure 132
107217
Assemble the drift 99360499 together with the extension.

Position the bush to insert on the drift (A) making the dowel pin (B) on it coincide with the seat on the bush.
Position the guide bush (E) and secure the guide bush (G) on the seat of the 7th bush with the plate (H) .
While driving in the bush, make the reference mark (F) match the notch (M). In this way, when it is driven home, the lubrication
hole on the bush will coincide with the oil pipe in its seat.
NOTE Bushing fitting is finished when the 1st reference notch (D) is flush with the guide bushing (G).

71724
71723
To insert the bush (7), proceed as follows.
To insert the bushing (6), proceed as follows:
Unscrew the grip (l) and the extension (N).
Unscrew the grip (l) and the extension (N).
Refit the guide (G) from the inside as shown in the figure.
Position the extension (N) and the guide bush (E) as shown
in the figure. Position the bush on the drift (A) and bring it close to the seat
, making the bush hole coincide with the lubrication hole in the
Position the bush to insert on the drift (A) making the dowel head.
pin (B) on it coincide with the seat on the bush.
Drive it.
Position the guide bush (E) and secure the guide bush (G) on
the seat of the 7th bush with the plate (H) . The 7th bush is fully driven in when the reference mark (C) is
flush with the bush seat.
While driving in the bushing, make the reference mark (F)
match the notch (M). In this way, when it is driven home, the
lubrication hole on the bush will coincide with the oil pipe in
its seat.
NOTE Bush fitting is finished when the 1st reference

notch (D) is flush with the guide bush (G).
Rocker shaft check
Figure 135
073557
NOTE The camshaft cams directly control the 12 rocker arms for the valves.
The intake valve control rocker arms are keyed directly onto the rocker arms shaft.
Exhaust valves control rocker arms are keyed onto the rocker arms shaft interposing the levers with engine brake
control eccentric pin. The rockers slide on the cam profiles via rollers.
The other end acts on a bar supported by the stem of the two valves.
There is a pad between the rocker arm adjustment screw and the crosspiece.
There are two lubrication pipes inside the rocker arms.
Check the shaft surfaces for signs of seizure, scoring or wear. Otherwise replace the shaft.

Exhaust valve rocker arm check ENGINE ASSEMBLY
Figure 136 Main operation

Use the specific brackets to secure the engine crankcase to the
rotating stand 99322230 with brackets 99361036
Oil sprayer assembly
Figure 138
181688
Check that the bush surfaces do not show any sign of scoring
of excessive wear; otherwise, replace the whole rocker arm .
Intake valve rocker arms check

Figure 137
47586
Fit the oil nozzles (2), making the dowel pin coincide with the
hole (3) on the crankcase.
Main bearings assembly
Figure 139
155960
Check that the bush surfaces do not show any sign of scoring
of excessive wear; otherwise , replace the whole rocker arm
.
49021
Arrange the half-bearings (1) on the main bearings in the cran-

kcase (2).
NOTE If it is found that the main bearings do not need

to be replaced, fit them back in exactly the same
sequence and position as in removal.
If they need to be replaced, select the bearings as described

in the chapter Defining the diameter class of the seats for half--
bearings on the crankcase.

Crankshaft assembly Figure 142
Figure 140
47595
Apply LOCTITE 5970 onto the crankcase using the designated

47570 tool (1)
Lubricate the half-bearings. 60632
Using the tool for lifting the crankshaft 99360500 (1), fit the Apply the sealant (LOCTITE 5970) following the indications
crankshaft (2). the figure.
lower crankcase assembly NOTE Fit the lower crankcase within 10 minutes of
applying the sealant.
Figure 141
Figure 143
49021
Arrange the half-bearings (1) on the main bearing supports in

the lower crankcase (2). 60559
Fit the lower crankcase by means of a suitable hoist and hooks

(1).

47579 47581
Using a torque wrench (3), tighten the internal screws (1) to Using a torque wrench 99395216 (2), tighten the outer hex--
the prescribed torque, i.e. using tool 99395216 (4) socket screws (1) to the prescribed torque, then use the speci-
fic tool (3) tighten to a specific angle.
Tightening
Ref. No. Description Tightening
torques Ref. No. Description
torques
Lower crankcase inner
tightening screws Outer screws fixing
lower crankcase
(1) 14 Step 1 160 Nm (1) 26
Step 1 30 Nm
Step 2 60
Step 2 60
Step 3 60
NOTE Always use new screws each time you fit the
lower part of the crankcase.

DIAGRAM OF TIGHTENING SEQUENCE OF LOWER CRANKCASE FIXING SCREWS
First step:
inner screws
FRONT
preliminary
SIDE
tightening
160 Nm
60593
Second step:
FRONT internal bolt
SIDE angle tightening
60
60593
Third step:
FRONT internal bolt
SIDE angle tightening
60
60593
Fourth step:
outer screws
FRONT
preliminary
SIDE
tightening
30 Nm
60592
Fifth step:
FRONT
SIDE external bolt
angle tightening
60
60594

Rod half-bearing fitting

NOTE If it is found that the big-end bearings do not
need to be replaced, fit them back in exactly the
Figure 146
same sequence and position as in removal.
If they need to be replaced, select the big-end
bearings as described in the chapter: Defining
the diameter class of the main journals and cran-
kpins.
NOTE Do not try to adapt the half-bearings.
155951
Lubricate the half-bearings (1) and fit them onto the connec-
ting rod and the cap.
Assembling connecting rod - piston assemblies in the cylinder liners
Figure 147
187915
1. Rod-piston assembly - 2. Marking area on the piston crown of ideogram specifying the assembly position and the selection
class - 3. Area of connecting rod marking- 4. Arrow indicating the assembly orientation of the connecting rod - piston assembly
(turned towards the flywheel)
Rotate the crankcase placing it vertically.
Lubricate the pistons, piston rings and inside the cylinder liners.

60616 47594
Using the clamp to introduce the piston into the cylinder liner Connect the connecting rods to the relevant pins of the crank-
99360603 (1), fit the piston-connecting rod assembly (2) into shaft, fit the connecting rod caps (1) together with half-bea-
the cylinder liners following the diagram in the previous Figure. rings; tighten the screws securing the connecting rod caps (2)
to the prescribed torque.
Check that the number of each connecting rod corresponds
to the cap coupling number . Use goniometer 99395216 (3) to additionally tighten the
screws to the prescribed angle.
Tightening
During assembly, make absolutely sure that the Ref. No. Description
torques
connecting rod does not hit against the cylinder
liner walls. Screws fixing connec-
ting rod cap
(2) 12
Step 1 70 Nm
Check that the ideogram stamped on the piston crown faces Step 2 60
the engine flywheel; or the recess in the piston skirt matches
the position of oil nozzles . Crankshaft front gasket installation
NOTE The pistons are supplied as class A spare parts Figure 150
and can also be fitted in class B cylinder liners.
NOTE Before reusing the screws, measure the diame-

ter of the thread; this must be less than 13.4 mm
; otherwise replace the screw. Before fitting,
lubricate the screw thread with engine oil.
60563
Using the centring ring 99396035 (2), check the exact position
of the cover (1), otherwise act as necessary and tighten the
screws (3).

Figure 151
NOTE New screws must be used at each assembly of
the head.
Lubricate the thread of the screws with engine
oil before assembly.
Figure 154
60564
Position the sealing gasket (1) on the crankshaft; fit the keying
device 99346250 (2) and, while tightening the nut of the tool
(3) drive the sealing gasket (1) into place.
Cylinder head assembly

60565
Figure 152 Pre-tighten using the torque wrench (1):

Tightening
Ref. No. Description
torques
screws
(-) 26
Step 1 75 Nm
Step 2 150 Nm
Figure 155
60515
Check that the pistons: 1 and 6 are exactly at the T.D.C.

Put the sealing gasket (2) on the crankcase.
Place the cylinder head (1) on the crankcase.
Figure 153
60566
Use tool 99395216 (1) for angle tightening:

Tightening
torques
screws
(-) 26
Step 1 90
Step 2 90
221076
Tighten the fastening screws in the sequence shown in the

figure.

Installing the oil pump Figure 158
Figure 156
221111
221113
Fit the double gear (1) and tighten the screws (2) to the pre-
scribed torque.
Fit the oil pump (2) and tighten the fastening screw (1).
Tightening NOTE Lubricate the screws ( 2) with engine oil before
torques assembly.
(1) 4 M8 X 1.25 screws 24. 5 2.5 Nm
Figure 157 Tightening

torques
Screws M12 X 1.75
(1) 3 Step 1 30 3Nm
Step 2 90
221112
Fit the connecting rod (2) and tighten the screw (1) to the pre-
scribed torque .
Tightening
torques
(1) 1 M8 x 1.25 screws 24. 5 2.5 Nm

Fitting flywheel box Figure 161
Figure 159
221078
47592
Tighten the screws securing the flywheel housing to the crank-
Apply LOCTITE 5970 onto the housing using the designated case following the sequence indicated in the figure.
tool (1) as indicated in the figure.
Crankshaft rear gasket assembly
NOTE Fit the flywheel housing within 10 minutes of
applying the sealant . Figure 162
Figure 160
60568
Key the sealing gasket (1) onto the crankshaft, fit the keying
device 99346260 (2) and while tightening the nut (3) drive in
221077 the sealing gasket.
Use a torque wrench to tighten the screws to the specific
tightening torque in the sequence shown in the figure.
Tightening
torques
Screws M12 X 1.75 X 70
(A) 2 Step 1 20 Nm
Step 2 63 7Nm
Screws M12 X 1.75 X 35
(B) 6 Step 1 20 Nm
Step 2 63 7Nm
Screws M12 X 1.75 X 100
(C) 10 Step 1 20 Nm
Step 2 63 7Nm
2 Screws M12 X 1.75 X 193
(D) Step 1 20 Nm
Step 2 63 7Nm
Screws M12 X 1.75 X 120
(E) 1 Step 1 20 Nm
Step 2 63 7Nm

Engine flywheel assembly Fitting camshaft
160624
49037 Fit the high pressure pump support flange (2) and tighten the
fastening screws (1).
Position the flywheel (1) on the crankshaft, lubricate the thread
of the screws (2) with engine oil and screw them down. Figure 166
Block rotation using the tool used to fasten the engine flywheel
housing 99360351 (3); tighten the screws (2) in two steps.
Tighten using a torque wrench (4).
Tightening
torques
Engine flywheel bolts
(2) 8 Step 1 120 Nm
Step 2 90
NOTE Lubricate the screws with engine oil.
Figure 164
160655
Apply the gauge 99395226 (1) to correctly position the high

pressure pump support flange (2).
Figure 167

49036
Tighten to angle with wrench 99395216 (1).
160624
Tighten the screws to the required torque.

Tightening
torques
(1) 6 M8 x 1.25 screws 24.5 2.5 Nm

221115
Fit the camshaft (4), positioning it with the reference marks

(!) as shown in the figure.
182251
Lubricate the seal ring (3) and fit it onto the shoulder plate (2).
Position the crankshaft with the pistons 1 - 6 at the T.D.C. Fit the shoulder plate (2) with the sheet metal gasket (1) and
This situation occurs when: tighten the screws (5) to the specific torque and in the order
indicated in Figure 170.
the hole of the engine flywheel (4) with a reference mark (5)
can be seen through the inspection window. Tightening
torques
The tool 99360612 (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the engine flywheel (4). M8 x 1.25 screws
(-) 5 Step 1 20 2 Nm
If this condition does not occur, turn the flywheel (4) appro-
priately. Step 2 20 2 Nm
Remove tool 99360612 (1). Figure 170
151833
Tightening sequence
Step 1 1 - 2 - 3 -4 - 5
Step 2 6 - 7 - 8 - 9 - 10


torques
M8 x 1.25 screws
(2) 3 Step 1 30 Nm
Step 2 90
NOTE Lubricate the screws (2) with engine oil before

assembly.
Figure 174
221107
Unscrew the screws (2) and remove the idle gear (1).
Figure 172
221116
Position the gear (2) on the camshaft so that the 4 slots are
centred with the holes for fixing the camshaft, without fully loc-
king the screws (5).
NOTE Lubricate the screws (5) with engine oil before

160654
assembly.
Apply the gauge 99395225 (1).

With a magnetic dial gauge (1) check clearance between the
Check and adjust the position of the connecting rod (3) for the gears (2, 3), which must be between 0.074 - 0.195 mm, other-
transmission gear; tighten the screw (2) to the specified tor- wise adjust the clearance as indicated below:
que.
Loosen the screws (4) securing the transmission gear (3).
Figure 173
Loosen the screw (2) securing the connecting rod, move the
connecting rod (3) in order to obtain the required clearance.
Lock the screw (2) securing the connecting rod and the screws
(4) securing the transmission gear to the prescribed torque.
221107
Refit the transmission gear (1) and lock the screws (2) to the
required torque.

Injector assembly Figure 176
Figure 175
221117
Fit the retaining brackets (3) on the injectors (4) and position
them in the relevant seats in the cylinder head.
Position the screws (2)
NOTE After having fitted the fuel pipes, lock the screws
(4) securing the injector brackets to the prescri-
bed torque.
Tightening
torques
(4) 6 M8 x 1.25 screws 30 35Nm
169828
Fit the crosspieces (1) on the valve stem all with the largest
hole on the same side.
Fit the sealing gasket (2) on the injectors (1).

Rail installation Tightening

torques
(1 -
2 Fittings M14 X 1.5 23.5 2.5 Nm
NOTE The high pressure fuel pipes cannot be re-used 6)
but must be replaced each time they are remo-
ved Connect the fuel return pipe (7) from the rail and tighten to
the prescribed torque.

torques
(7) 2 Fittings M14 X 1.5 50 Nm
Fitting rocker shaft assembly
NOTE before refitting the rocker-arm shaft assembly,

make sure that all the adjustment screws have
been fully unscrewed.
221118
Fit the rail (10) onto the head and tighten the fastening screws
(9) to the specified torque. Figure 178
Tightening
torques
(9) 4 M8 x 1.25 screws 23.5 2.5 Nm
Connect the high pressure fuel pipes and tighten the fittings by
hand in the sequence (1, 2, 3, 6, 5, 4) to the rail and the injec-
tors.
NOTE Before tightening the fittings to torque make

sure that the pipes (1) are not touching each
other.
Complete injector assembly operations by tightening the faste-

116190
ning screws to the specified torque.
Tightening Apply the tool 99360553 (1) to the rocker arm shaft (2) and
Ref. No. Description fit the shaft on the cylinder head.
torques
(9) 4 M8 x 1.25 screws 33 37 Nm
Complete assembly of the high pressure fuel pipes (1, 2, 3, 6,
5, 4) by first tightening the injector side fittings and then those
on the rail side.
Tightening
torques
(1- 6) 12 Fittings M16 X 1.5 42 Nm
Connect the high pressure fuel supply pipes (8) and tighten
them to the prescribed torque.
Tightening
torques
(8) 2 Fittings M16 X 1.5 60 2.5 Nm
Fix the fuel supply pipe support brackets, tightening the screws
to the required torque.

Figure 179 Camshaft timing
Figure 181
221119
Screw the screws in four steps as follows:

Tightening
torques
rocker arm shaft
Step 1 25 Nm
(1- 7) 7
Step 2 60 Nm
Step 3 80 Nm
Step 4 60
185252
Tightening sequence
Step 1 - 4 1-7 Apply the tool for engine flywheel rotation 99360321 (7) and
the specific spacer 99360325 (8) to the gear housing (3).
Figure 180
NOTE The arrow shows the direction of rotation of

the engine when running .
With the aforementioned tool, turn the flywheel (1) in the

direction of the engine rotation so as to bring cylinder piston
1 to 54 before the T.D.S. during compression (cylinder 6 in
discharge phase).
NOTE This condition occurs when the hole with two

notches (5) on the engine flywheel (1), can be
183457 seen through the small inspection window (2).
Connect the electrical connections (1) to the injectors and

block the cables using cable clamps.
Tightening
torques
(1) 12 Cable clamps 1.5 0.25 Nm

Figure 182
During the CHECK phase, not during the engine
overhaul phase, the allowed tolerance of the mea-
surement is between -0.05 - +0.12 mm.
During OVERHAUL, the allowed tolerance is
0.05 mm.
Figure 184
71774
Check that the tool for positioning the T.D.C 99360612 (1),
through the seat (2) of the engine speed sensor , enters the
hole (3) in the engine flywheel (4). in this condition, the fly-
wheel is in the reference position (piston no. 1 to 54 before
T.D.C.).
If this is not the case, turn and adjust the engine flywheel(4) 177714
appropriately.
Using the specific tool to turn the engine flywheel 99360321,
Remove tool 99360612 (1). turn the crankshaft in the opposite direction to that of opera-
tion until the pointer of the dial gauge reaches the minimum
Figure 183 value beyond which it can no longer fall.
NOTE The measurement must be taken holding the

rocker roller in contact with the profile of the
exhaust cam of the camshaft.
185253
Carefully clean the surface of the head on which the rocker

arm cover rests.
Using the magnetic support 99370400 (2), as shown in the
figure, arrange the dial gauge (0-30mm) 99395606 (1) with
theflat based rod (3) positioned on the rocker arm roller (4)
which controls the exhaust valves of cylinder no. 3 and preload
to at least 8 mm.
Position the flat based dial gauge so that its axis pas-
ses through the centre of the roller on which it is
resting.

185524
Camshaft rotation angle

Y Cam lift based on the rotation angle of the camshaft
185523
D Cam lift in correspondence of the 54 before the top
dead centre , 1st cylinder end of compression Turn the engine flywheel in the engine operating direction until
reset the dial gauge. the dial gauge indicates the required camshaft lift value.
Technical data
NOTE The dial gauge is to be zeroed with the rocker Cam timing dial gauge value 5.95 0.05 mm
arm roller in contact with the base radius of the
cam profile . Check that the required cam lift values are displayed under the
For this, turn the flywheel until it exceeds pro- following conditions:
trusions (A-B) and (B-C) on the cam profile - The hole with two notches (5) is visible through the small
connected to the engine brake operation. inspection window.
This condition occurs when the flywheel is tur- - The tool 99360612 (1), through the seat (2) of the engine
ned in the opposite direction of the operating speed sensor , enters the hole (3) in the engine flywheel
direction by approx. 1 and 1/4 rotations. (4).

221105
Perform the following if the conditions stated have not been

obtained:
Turn the engine flywheel until the required cam lift value 185523
appears on the dial gauge.
Turn the flywheel (4) again until it reaches the following condi-
Loosen the screws (2) that fasten the gear (1) to the camshaft tions:
and use the slots on the gear (1).
- The hole with two notches (5) is visible through the small
Act on the engine flywheel to obtain the conditions indicated inspection window.
while keeping the cam lift value unchanged.
- The tool 99360612 (1), through the seat (2) of the engine
Lock the screws (2) and repeat timing check as described speed sensor , enters the hole (3) in the engine flywheel
above. (4).
NOTE While performing this operation recover the

clearance between the camshaft gears.
Tighten the screws (2) to the prescribed torque.

Tightening
torques
Camshaft (2) gear
fastening screws
(2) 4
Step 1 60 Nm
Step 2 60
When adjustment via the slots is not sufficient for recovering

the offset, proceed as follows:
Lock the screws (2) and turn the engine flywheel a 1/2 turn in
the opposite direction of the operating direction.
Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
Cam timing dial gauge value 5.95 0.05 mm
Remove the screws (2) and disassemble the camshaft gear (1).

Figure 189 Pulser ring timing
Figure 190
221120
Fit the gear (2) with the four slotted holes (1) centred in rela-
tion to the holes securing the camshaft and tighten the screws
to the prescribed tightening torque.
Tightening
torques
Screws M14x2
(1) 4 Step 1 60 Nm
Step 2 60
Recover the clearance between the timing system gears by tur-

ning the flywheel in the opposite direction of the engine rota-
tion direction and subsequently turning it in the engine rotation
direction until the dial gauge shows the specific value. Check
the previously described conditions.
Technical data 185254
Cam timing dial gauge value 5.95 0.05 mm

Turn the crankshaft bringing cylinder piston no. 1 in compres-
sion stage to TDC; turn the flywheel by approximately 1/4 turn
in the opposite direction to the normal direction of rotation.
Turn the flywheel again according to normal direction of rota-
tion (anti-clockwise) until the hole marked with the three not-
ches can be seen through the inspection hole under the fly-
wheel housing (4).
NOTE If the engine flywheel does not have 3 notches,

to identify the reference hole simply: turn the
flywheel in the opposite direction to the opera-
ting direction until you reach the position mar-
ked with 2 notches (54 before cyl. 1 T.D.C.);
continue rotating in the engine operating direc-
tion for 4 holes (remember that each hole cor-
responds to a flywheel rotation of 6).

Fit tool 99360612 (5) into the flywheel sensor seat (6). Tightening
torques
Through the timing sensor, insert the tool for phonic disc
timing on the camshaft 99360613 (2) on the tooth (") recove- (1 - 3) 5 M12x1.5 37.5 2.5Nm
red from the phonic wheel. (4) 2 M12x1.75 32.5 2.5 Nm
If the tool (2) is difficult to fit, loosen the screws (3) and direct (5) 2 M8x1.25 24.5 2.5 Nm
the phonic wheel (1) properly so as to position the tool (2)
on the tooth correctly. Figure 192
Tighten the screws (3).
Tightening
torques
(3) 4 M8X1.25 screws 24.5 2.5 Nm
High pressure pump assembly

Bring the flywheel to 36 before TDC of the first cylinder.
NOTE This position can be obtained by turning the

engine flywheel in the opposite direction to the
operating direction in the 30 position marked
by THREE notches (4) and continuing to turn
the flywheel in the same direction until reaching
the next hole (by 6).
If the engine flywheel does not have 3 notches,
to identify the reference hole simply: turn the
flywheel in the opposite direction to the opera-
ting direction until reaching the position marked
with 2 notches (54 before cyl. 1 T.D.C.); conti-
187918
nue rotating in the engine operating direction
for 3 holes (remember that each hole corre-
sponds to a flywheel rotation of 6).
Fit the high pressure pump and make sure that
! the seat of the key (1) on the pump shaft is facing
Insert the specific tool 99360612 through the seat of the fly- the pump intakes (2) .
wheel sensor into the corresponding hole on the flywheel.
Figure 191
221104
Position the bracket (3) and tighten the screws (1,2).

Position the high pressure pump (6) and tighten the screws (4,
5)


torques
(2) 1 Nut M24x1.5 250 15 Nm
Intake and exhaust rocker arm clearance

adjustment
NOTE The adjustment of clearance between the roc-

ker arms and crosspieces controlling the intake
and exhaust valves must be done very carefully.
Figure 195
221103
Position the blocks (1)

Position the pipes (2,3)
Position the pipe (4) and tighten the collars (5)
Position the pipe (6)
Tightening
torques
(2,3) 2 Fittings M16x1.5 42 4.2 Nm
(4,6) 2 Fittings M18x1.5 37 3 Nm
221128
A Hole on flywheel with reference mark, corresponding to

NOTE Make sure that the pipe is not damaged after the TDC of pistons 1-6
mounting and that there are no fuel leaks while
engine is running. B Hole on flywheel with reference mark, corresponding to
the TDC of pistons 2-5
The high pressure pipes which have been remo-
ved cannot be used again and must be replaced. C Hole on flywheel with reference mark, corresponding to
the TDC of pistons 3-4
D Flywheel hole with two notches corresponding to posi-
tion 54 before TDC of pistons 1-6 (camshaft timing refe-
Figure 194
rence );
E Flywheel hole with three notches corresponding to posi-
tion 30 before TDC of pistons 1-6 (reference to high
pressure fuel pump timing system and phonic wheel
timing).
In order to perform adjustments correctly, during each rota-
tion phase, check the positioning accuracy using the tool for
TDC Engine 99360612, inserting it into the hole marked with
a notch on the flywheel corresponding to the position of the
pistons.
221121
Fit thegear (2) and tighten the nut (1) to the prescribed torque.
Remove tool 9936061.

Figure 196 Tappet cover assembly
Figure 197
114287
221122
Take the cylinder whose clearance has to be adjusted into the
combustion phase; the valves of this cylinder are closed while Position the cover and insert all the screws.
they balance the symmetric cylinder valves. Replace the screws in the sequence 1-10-20-21-9 and then in
the sequence shown in the figure until contact.
NOTE The correspondence of the symmetrical cylin- Tighten the screws 1-24 in the sequence shown to the prescri-
ders is 1 - 6, 2 - 5 and 3 - 4. bed torque.
In order to carry out these operations correctly, follow the Tightening

indications below in accordance with the indications in the Ref. No. Description
torques
table. (1 - 24) 24 Screws M6x1 8.5 1.5 Nm
Using a box wrench, loosen the nut (1) locking the adjustment
screw. Fuel filter assembly
Insert the feeler gauge blade (3) corresponding to the opera-
ting clearance indicated in the table Data and assembly clea- Figure 198
rance in SECTION 7 - Technical specifications.
Use a suitable wrench to screw or unscrew rocker arm (2)
adjusting screw.
Check that the blade of the feeler gauge (3) can slide with a
light amount of friction.
Lock the nut (1) holding the adjustment screw still.
To carry out the adjustments stated above, the sequence
shown in the table is mandatory.
FIRING ORDER 1-4-2-6-3-5
Start and rotation in Balancing Adjust valve
the engine direction cylinder clearance for
valves no. cylinder no.
221123
1 and 6 at T.D.C. 6 1
120 degree of angle [] 3 4 Position the fuel filter together with the support (3), tighten the
120 degree of angle [] 5 2 screws (2) to the prescribed torque, connect the fuel inlet (4)
120 degree of angle [] 1 6 and outlet (1) pipes onto the filter support
120 degree of angle [] 4 3
Tightening
120 degree of angle [] 2 5 Ref. No. Description
torques
(2) 4 M8x1.25 24.5 2.5Nm
NOTE Check during each rotation phase, the accuracy (1,4) 2 Fittings M18x1.5 37 3Nm
of the position by using the specific pin and
inserting it into the hole marked with a notch on
the flywheel corresponding to the position of
the pistons.

Timing gear assembly cover mounting Blow-by filter fitting
221124
221098
Fit the blow-by case (2) together with the gasket (3). Fit the blow-by case (2) and tighten the screws (1) to the speci-
Tighten the screws (1) to the prescribed torque. fied torque.
Tightening
torques NOTE During assembly, apply LOCTITE 243 to the
(1) 21 Screws M6x1 10 Nm screws (1).
Tightening sequence
torques
Screws securing the
blow-by filter
(1) 3
Step 1 5 Nm
Step 2 15 Nm
221125

Blow-by case fitting Tightening

torques
Figure 202 Screws fixing suction
(1,2) 5 strainer to lower cran- 24 5 Nm
kcase
Oil sump assembly
Figure 205
221097
Position the blow-by case (2)and tighten the screws (1).

Tightening
torques
(1) 7 Blow-by case screws 7 1 Nm
60665
Tightening sequence
Figure 203 Arrange the gasket (4) on the oil sump (1), position the spacer
(3) and fit the sump onto the engine crankcase screwing in the
screws (2) to the prescribed torque.
Tightening
torques
(2) 16 M10X1.5 screws 45 4.5 Nm
Tightening sequence
Figure 206
221126
Suction strainer installation

Figure 204
155922
221114
Turn the engine and position the oil suction strainer (1).
Tighten the screws (3) and secure the flange.
Tighten the screws (2) and secure the supports.
Inlet manifold assembly Tightening

torques
Figure 207 (1) 3 M12X1.75 screws 74 8 Nm
Heat exchanger assembly
Figure 210
221095
Fit the intake manifold (2) together with the engine preheating
resistor (3) and tighten the screws (1) to the prescribed tor-
que.
221093
Tightening
torques
Fit the heat exchanger (1) and tighten the fastening screws (2,
(1) 6 M10X1.5 screws 50 5 Nm 3) to the prescribed torque.
Tightening sequence Tightening
Figure 208 torques
M82X1.25 screws
(1,2) 22 Step 1 11.5 3.5 Nm
Step 2 24.5 2.5 Nm
Tightening sequence
Figure 211
221127
Starter motor assembly

180274
Figure 209
221094
Fit the starter motor (2) and tighten the nuts (1) on the studs
to the prescribed torque.

Oil filter assembly Figure 214

Figure 212
160652
Tighten the screws securing the turbocharger to the prescri-

221092
bed torque following the sequence indicated in the figure.
Fit the oil filter support (2) and tighten the screws (1).
Tightening
Oil and fit new seals. Ref. No. Description
torques
Screw the filter (3) until the gaskets come in contact with the Screws and nuts
resting bases . (1- 6) 4 securing the turbo- 75 Nm
charger
Tighten the filter to the specified torque.
Tightening
Ref. No. Description NOTE Lubricate the screws with graphite oil.
torques
(1) 4 M8X1.25 screws 23.5 2.5 Nm
(3) 1 Oil filter 60 5 Nm
Exhaust manifold assembly
Turbocharger assembly
Figure 215
Figure 213
221090
Fit the exhaust manifold (1) with new gaskets together with the
221091 turbocharger (2).
Fit the turbocharger (1) with a new gasket on the exhaust Tighten the screws securing the exhaust manifold to the pre-
manifold (3), tightening the screws (4) and the nuts (5) to the scribed torque.
prescribed torque.
Tightening
torques
M10X1.5 screws
(1) 24 Step 1 40 5 Nm
Step 2 60 5 Nm
NOTE Lubricate the screws with graphite oil.

Tightening sequence
Figure 216
180272
Figure 217
Figure 219
221089
221087
Position the P3 sensor connecting pipe (5).

Connect the oil delivery pipe (1) and the sump oil return pipe
Position the flange (2) and tighten the screws (1). (2) to the turbocharger.
Screw in the fitting (4) with the relative gasket on the connec- Tighten the fittings to the prescribed torque.
tor
Tighten the collar (3). Tightening
torques
Figure 218 Oil drain and inlet
(1,2) 4 22 27 Nm
pipe fittings
221088
Open the collar (4) and insert the engine brake device (1).
Connect the coolant pipes (2, 3) from the engine brake device
actuator (1).

Thermostat case assembly Water pump assembly
221086 221085
Fit the thermostat case (1) with a new gasket and tighten the Tighten the screw (7) and secure the automatic belt tensioner
fastening screws (2,3) to the prescribed torque according to (8).
the sequence indicated in the next figure. Screw in the screws (5) and secure the pulley (6).
Figure 221 Screw in the screw (3) and secure the pulley (4).
Screw in the screws (1) and secure the water pump (2).
Tightening
torques
(1) 4 M8x1.25 24.5 2.5 Nm
(3) 1 Screw M12x1.75 105 5 Nm
(5) 6 Screw M12x1.75 105 5 Nm
(7) 1 Screw M10x1.5 50 5 Nm
155929
Tighten the fastening screws following the order indicated in

the table.
Tightening
torques
Thermostat case
fixing screws
(1 - 12) 7
Step 1 27 to 33 Nm
Step 2 27 to 33 Nm
Tightening sequence
Step 1 1-2-3-4-5-6-7
Step 2 8 - 9 - 10 - 11 - 12 - 13 - 14

Pulley assembly Alternator/water pump

drive belt assembly
221084
166728
Block rotation of the flywheel with the tool 9936035. To fit the belt (2) use suitable equipment to adjust the belt ten-
Fit the electro-magnetic connector (2) and tighten the screws sioner (1) in the direction indicated by the arrow in the figure.
(1) to the prescribed torque.
Fit the pulley (2) and tighten the nut (1) to the prescribed tor- NOTE Belt tensioner is of automatic type; therefore,
que. further adjusting is not provided after mounting.
Tightening
torques
Electromagnetic Figure 226
(1) 1 67.5 7.5 Nm
connector screw
Alternator assembly
Figure 224
108844
1 Alternator - 2 Electromagnetic connector -

221083
3 Water pump - 4 Crankshaft
Fit the alternator (2) and tighten the screws (1) to the prescri- Upon assembly, check the correct installation as shown in the
bed torque. figure.
Tightening
torques
(1) 2 Screw M10x1.5 44 4 Nm

Damper flywheel installation Oil pressure adjustment valve assembly
221082 60486
Fit the damper flywheel (2) by acting on the 6 fastening screws Fit the oil pressure adjustment valve (1) and tighten the faste-
(1). ning screws to the prescribed torque.
Tightening
Tightening Ref. No. Description
torques
Oil pressure regulator
Screws M14X2 (1) 2 23.5 2.5 Nm
valve
(1) 6 Step 1 70 Nm
Step 2 50 Fitting the front suspension mounts
Figure 229
NOTE Before fitting, lubricate the screw thread (1)
with engine oil.
Removing the engine from the stand

Refill the engine with required oil quantity.
Remove the engine from the rotating stand 99361036 and
remove the brackets securing the engine.
221081
Fit the front engine mount (1) (turbocharger side) and tighten
the screws (2) to the prescribed torque.
Tightening
torques
Screws M16X2
(2) 4 Step 1 120 Nm
Step 2 45

221080 221079
Fit the water inlet pipe to the pump (1) and tighten the screws Position the front mount (1) and tighten the screws (2) to the
(2). prescribed torque.
Tightening Tightening
Ref. No. Description Ref. No. Description
torques torques
(1) 4 M8X1.25 screws 34.5 3.5 Nm Screw M16x2
(2) 4 Step 1 120 Nm
Step 2 45


CURSOR SERIES SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . 3
DATA - INSTALLATION CLEARANCES . . . . . 5
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 11

2 SECTION 7 - TECHNICAL SPECIFICATIONS CURSOR SERIES

GENERAL CHARACTERISTICS
F3HFE613D*B010 F3HFE613B*B010
Type
Cycle Diesel 4-stroke

Power supply Turbocharged with aftercooler
Injection Direct
Number of cylinders 6 in line

Bore mm 135
Stroke mm 150
+ + +.. = Total displacement cm3 12882
Compression ratio 16.5 : 1
kW 407 384
(HP) (553) (522)
Max. power
rpm 2100 2100
Nm 2407 2258
(kgm) (245) (230)
maximum torque
rpm 1400
Idle speed with no load rpm 850 100
Maximum engine idle speed rpm 2350 50
DISTRIBUTION
A
Start before T.D.C. A = 19
End after B.D.C. B = 31

B
C
Start before B.D.C. D = 50
D End after T.D.C. C= 9

Type
Of operation
mm 0.40 0.05
X
mm 0.60 0.05
The high pressure fuel supply system

is managed by the BOSCH EDC 17. It consists
of the CPN 5.2 high-pressure pump, electro--
POWER SUPPLY
injectors, hydraulic accumulator (rail), EDC 17
control unit and pressure and temperature sen-
sors.
Injection Bosch CRSN3-22
High pressure supply pump Bosch CCPN5 22/2
Electro-injectors type Bosch CRIN3-22
Firing order 1-4-2-6-3-5
bar
Varying injection pressure bar bar 2000

DATA - INSTALLATION CLEARANCES
Type F3HFE613D*B011 F3HFE613B*B011
mm
CRANK GEAR AND CYLINDER ASSEMBLY DATA
1 Cylinder liner housings
upper 153.500 - 153.525

1
lower 152.000 - 152.025
Cylinder liners:
outer diameter
L upper 153.461 - 153.486
2
lower 151.890 - 151.915
2 length L 252.2
Cylinder liners - crankcase seat
upper 0.014 - 0.039
lower 0.085 - 0.135
Outer diameter 2 -
3 Cylinder liners:
X
Inner diameter 3 135.000 - 135.020
Protrusion X** 0.045 - 0.075

** With a load of 8,000 kg
Pistons:
1
X measuring point X 50
Outer diameter1 1A 134.903 - 134.933
2 pin housing 2 59.063 - 59.093
A* 0.067 - 0.117
Piston - cylinder liners
B* -
Piston diameter 1 -
X
Piston protrusion X -
3 Piston pin 3 58.994 - 59.000
Piston pin - pin seat 0.063 - 0.099

mm
X1 2.480 - 2.510
X1
Piston ring slots X2 2.580 - 2.610
X2
X3 4.050 - 4.080
X3
* measured on of 121 mm
** measured on of 120 + 0.15 mm
S 1 Piston rings:
S2 trapezoidal sealing S1* 2.296 - 2.340
S3 bevelled S2 2.470 - 2.500
milled scraper ring with slots and
S3 3.970 - 3.990
internal spring
* measured at 2 mm from outer 0.063 - 0.099
1 0.140 - 0.214
Piston rings - slots 2 0.065 - 0.140
3 0.060 - 0.110
Piston rings -
X1 Piston ring end gap in cylinder liner:
X2 X1 0.35 - 0.45
X3 X2 0.65 - 0.80
X3 0.40 - 0.75
Connecting rod small end bush seat 1 63.000 - 63.030
1
Connecting rod bearing seat 2 100.000 - 100.030
1 100.000 - 100.010
2 Classes 2 100.011 - 100.020
3 100.021 - 100.030
4 Bushing diameter at connecting rod small end
external 4 63.120 - 63.160
3 internal 3 59.060 - 59.076
Connecting rod half-bearings (S)
thickness
S
Red colour 1.960 - 1.970
Green colour 1.971 - 1.980
Yellow colour* 1.981 - 1.990
* Fitted in production only and not supplied as spare part.
Bush at connecting rod small end -
0.090 - 0.160
housing
Piston pin - bushing 0.060 - 0.082
Connecting rod half-bearings -

Connecting rod weight
A g. 5537 - 5570
Class B g. 5571 - 5604
C g. 5605 - 5637

mm
Measuring point x -
Maximum error in parallelism of

/ -
connecting rod axes
1 2 Main journals 1 nominal value 99.970 - 100.000

1 99.970 - 99.979
Selection class 2 99.980 - 99.989
3 99.990 - 100.000
1 99.970 - 99.977
S1 S 2
2 99.978 - 99.985
Selection class
3 99.986 - 99.993
4 99.994 - 100.000
Crankpins 2 nominal value 95.970 - 96.000
1 95.970 - 95.979
Selection class 2 95.980 - 95.989
3 95.990 - 96.000
Main half-bearings YES
Red colour 3.115 - 3.122
Green colour 3.123 - 3.130
Yellow colour* 3.131 -3.138
Black colour* 3.139 -3.146
Connecting rod half-bearings S2
Red colour 1.960 - 1.970
Green colour 1.970 -1.980
Yellow colour* 1.980 -1.990
* Half-bearings only fitted in production
Main bearings 3 106.300 - 106.330
3 A 106.300 - 106.307
B 106.308 - 106.315
Selection class
C 106.316 - 106.323
D 106.324 - 106.330
Main journals half-bearings 0.008 - 0.130
Half-bearings crankpins 0.060 - 0.100
Main half-bearings -
Connecting rod half-bearings -
Thrust main journal X1 47.95 - 48.00

X1
Thrust main bearing X2 40.94 - 40.99

X2

mm
X3
Half thrust washers (thickness) X3 3.38 - 3.43
Crankshaft end play 0.10 - 0.30
Alignment 1-2 -
Centring 1-2 -
CYLINDER HEAD - TIMING SYSTEM

1
Valve guide housing on cylinder head 1 15.980 - 15.997
2
2 10.015 - 10.030
Valve guides
3 3 16.012 - 16.025
Valve guides and seats on the head 0.015 - 0.045
Valve guides -
4 4 9.960 - 9.975
60 30 7 30
Valves:
4 9.960 - 9.975
60 +30 7 30

Valve stem and related guide 0.040 - 0.070
Housing on head for valve seat:
1 49.185 - 49.220
1 46.985 - 47.020
1
2 Outside diameter of valve seats: valve housing inclination on cylinder head:
2 49.260 - 49.275
2 47.060 - 47.075
Valve seat 0.2

mm
X 0.54- 0.86
Recessing
X X 1.65- 1.95
X
Between valve seat and cylinder head 0.040 - 0.090
X
Valve spring height:

free spring H 76
H under a load of:
H1
H 2 660 33 N H1 59
1140 57 N H2 46
Camshaft bush housing fitted in the

88.000- 88.030
cylinder head: 1 7

2
Camshaft journals: 1 7 82.950 - 82.968
1 3
Camshaft bushing outer diameter: 88.153 - 88.183
Bushing inner diameter 83.018 - 83.085
Bushings and seats in cylinder head 0.123 - 0.183

Bushings and supporting pins 0.050 - 0.135
H 9.231
Useful cam height:
9.5607
1
Rocker-arm shaft 1 41.984 - 42.000
mm
Internal rocker arm diameter:
42.045 - 42.061
59.000 - 59.019

mm
Rocker arm bush outer diameter:
-
59.070 - 59.110
Rocker arm bush inner diameter:
-
56.045 - 56.064
Bushes and housing:
-
0.051 - 0.110
Rocker arm bushes and shaft: 0.045 - 0.077

TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
Screws securing the crankcase to the lower crankcaseL
Inner screws First step: pre-tightening 160 16
Inner screws Second step: Angle tightening M18x2 60
Inner screws Third step: Angle tightening 60
Outer screws Fourth step: 30 3
M12x1.75
Outer screws Fifth step: 60
Union for piston cooling nozzle 50 5 5 0.5
Screws securing heat exchanger pre-tightening 11.5 3.5 1.15 0.35
M8x1.25
to crankcase L tightening 24.5 2.5 2.4 0.25
Screws fixing suction strainer to lower crankcase 24.5 2.5 2.4 0.25
Screws securing spacer and oil First step 45 4.5 4.5 0.45
M10x1.5
sumpL Second step 45 4.5 4.5 0.45
Oil sump drain plug 95 10 9.5 1
Oil level dipstick retainer 39 6 3.9 0.6
Screws securing flywheel case to pre-tightening 20 2
M12x1.75
crankcaseL tightening 63 7 6.3 0.7
Screws securing flywheel case to
M10x1.5 44 4 4.4 0.4
headL
First step: pre-tightening 78 7.5
M18x2 screw fixing cylinder Second step: pre-tightening 150 15
head: (*) Third step: Angle tightening 90
Fourth step: Angle tightening 90
First step: pre-tightening 25 2.5
M16x1.5 Screw securing rocker Second step: pre-tightening 60 6
arm shaftL Third step: pre-tightening 80 8
Fourth step: Angle tightening 60
Screws fastening oil pressure
23.5 2.5 2.3 0.2
regulating valve
Rocker arm cover M6x1
8.5 1.5 0.8 0.1
fastening screws
Lock nut for rocker arm
M10x1.25 39 5 3.9 0.5
adjustment screw
M8x1.25 screws for injector
35 3.5
brackets
M8x1.25 Screws securing First step 20 2 2 0,2
camshaft shoulder plate to
headL Second step 20 2 2 0,2
Screws securing bracket on
M12x1.75 100 10 10 1
cylinder head to lift engine

TORQUE
DETAIL
Nm kgm
Screws fixing engine mount First step: pre-tightening 120 12
bracket to flywheel casing Second step: Angle tightening 55
M16x2 screws securing engine First step: pre-tightening 120 12
suspension to crankcase Second step: Angle tightening 45
M14X2 screws fastening the First step: pre-tightening 60 6
camshaft gear (*) Second step: Angle tightening 60
Screw fixing pulser ring to timing
M8x1.25 24.5 2.5 2.5 0.2
gear
M10x1.5 screws securing exhaust pre-tightening 40 5 4 0.5
manifold (**)L tightening 60 5 6 0.5
Screws fastening collars on
M6x1 12 0.5 1.2
exhaust manifold
Screws fastening collars on
82 0.8 0.2
exhaust pipe
Screws fixing the exhaust brake
19 3 1.9 0.3
hydraulic actuator cylinder
M14x2 screws fixing the First step: pre-tightening 70 7
connecting rod cap Second step: Angle tightening 60
M18x1.5 screws fixing the engine First step: pre-tightening 120 12
flywheel (*) Second step: Angle tightening 90
M14x2 screws fixing the damper First step: pre-tightening 70 7
flywheel to the drive pulley (*) Second step: Angle tightening 50
M14x2 screws fixing the drive First step: pre-tightening 70 7
pulley to the crankshaft (*) Second step: Angle tightening 50
M12x1.75 screw fixing the First step: pre-tightening 30 3
intermediate gear pins (*) Second step: Angle tightening 90
Screw fixing rod to adjust
24.5 2.5 2.4 0.2
transmission gear M8x1.25
M8x1.25 screws fixing the oil
24.5 2.5 2.4 0.2
pump
M8x1.25 screw fixing crankshaft
24.5 2.5 2.4 0.2
gasket front cover
Diesel filter breather 18 2 (1.8 0.2)
M8x1.25 screw fastening fuel
24.5 2.5 2.4 0.2
filter support
Fuel filter cap 32.5 2.5 3.2 0.2
Fuel filter drain 1.5 0.5 0.2 0.1

TORQUE
DETAIL
Nm kgm
Screw fastening oil filter support M8x1.25 23.5 2.5 2.4 0.2
Oil filter cap 60 5 6 0.5
Oil filter drain plug 6.5 1.5 0.7 0.1
Screw fastening control unit
19 3 1.9 0.3
mount
Screws and nuts securing
M12x1.75 75 7.5
turbocharger
Electrical actuator to
31.8 1.75 3.2 0.2
turbocharger retainer nut
Screws fastening actuator bracket
22.6 1.7 2.3 0.2
mount to turbocharger
Screws fastening oil return pipe
M8x1 24.5 2.5 2.4 0.2
to turbocharger
Screws securing thermostat
M8x1.25 30 3 3 0.3
assemblyL
Screws securing water pump M8x1.25 24.5 2.5 2.45 0.25
Screws fixing water inlet pipe to
M8x1.25 34.5 3.5 3.4 0.3
crankcase
Screws fastening fan to
M8x1.25 34.5 3.5 3.4 0.4
electromagnetic coupling
M12x1.75 screws fixing the
electromagnetic coupling to the 100 5 10 0.5
crankcase
Screw fixing the automatic belt
M10x1.5 50 5 5 0.5
tensioner
Screws securing steady tensioner M12x1.75 105 5 10.5 0.5
Starter motor fastening screws M12x1.75 74 8 7.4 0.8
Screws securing the air heater
and intake manifold to the M10x1.5 50 5 5 0.5
cylinder headL
Screws fixing air compressor M12x1.75 74 8 7.4 0.8
Nut fixing air compressor drive
170 10 17 1
gear
M12x1.5 screws fastening HP
37.5 2.5 3.7 0.2
pump to the support plate
M8x1.25 screws fastening HP
pump mounting plate to the 24.5 2.5 2.4 0.2
timing system casing
M24x1.5 nut for fixing the high
250 15 25 1.5
pressure pump gear
M16x1.5 fuel filler on head 55 5 5.5 0.5

TORQUE
DETAIL
Nm kgm
M12x1.75 screws securing the oil
32.5 2.5 3.3 0.2
pump to the bracket
M16x1.5 couplings fixing the high
pressure fuel pipe to the HP 42 4.2
pump
M18x1.5 couplings securing the
37 3 3.7 0.3
LP fuel pipe to the HP pump
M6x1 screws securing Blow-by screws marked with numbers 10 1 1 0.1
to timing caseL screws marked with letters 71 0.7 0.1
42 2.5 4,2 0,25
fuel pipe to rail
42 2.5 4,2 0,25
fuel pipe to rail
42 2.5 4,2 0,25
fuel pipe to rail
M14x1.5 coupling securing the
50 5
fuel return pipe to rail
M8x1.25 screws securing the rail
24.5 2.5 2.5 0.3
to the head
Rail safety valve M20x1.5 110 5 11 0,5
M8x1.25 nut fixing the heater
16 1 1.6 0.1
electrical connections
M12x1.75 74 8 7.4 0.8
PTO fixing screws
M10x1.5 44 4 4.4 0.4
pre-tightening 5 0.5
Screws securing Blow-by filterkL
tightening 15 1.5
M10x1.5x35
44 4 4.4 0.4
(lower retainer)
Screws fastening alternator sup- M10x1.5x60
44 4 4.4 0.4
port (lower retainer)
M8x1.25x30
24.5 2.5 2.45 0.25
(upper retainer)
M10x1.5 44 4 4.4 0.4
Alternator fixing screws
M8x1.25 24.5 2.5 2.45 0.25
Alternator pulley securing 75 7.5
Power steering retainer collar 6 2.5 0.6 0.25
Screws fixing power steering
M10x1.5 46.5 4.5 4.6 0.4
pump to the compressor
Screws fixing air-conditioner
M8x1.25 24.5 2.5 2.4 0.25
compressor to mount

TORQUE
DETAIL
Nm kgm
Screws fixing the air-conditioner
M8x1.25 24.5 2.5 2.4 0.25
compressor mount
Fixing screw for guard 24.5 2.5 2.5 0.25
Flywheel rev sensor support
23.5 2.5 2.3 0.2
fastening
Securing rail pressure sensor M18x1.5 70 5 7 0,5
filter clogged sensor fastening 55 5 5.5 0.5
Water/fuel temperature sensor
35 3.5
fastener
Thermometric switch/transmitter
25 2.5
fastener
Air temperature transmitter
35 3.5
fastener
Pulse transmitter fastener 82 0.8 0.2
Pressure sensor retainer on the
27.25 2.75 2.7 0.28
rocker cover
Exhaust brake solenoid valve
M24x1.5 32 3 3.2 0.3
fastener
PWM solenoid valve fastener 82 0.8 0.2
Nuts for injector electrical con-
1.5 0.25 0.15
nection
Head wiring connector fixing
82 0.8 0.2
screw
Power Unit
Screws securing front and rear
M14x70.80 192,5 19,5 19,2 1,9
rubber blocks to chassis
Screws securing front and rear
M16x130 278 28 27,8 2,8
rubber blocks to engine
Flanged HEX screw for front First step: pre-tightening 120 12
M18x62
engine block Second step: Angle tightening 45
Cylindrical hex socket head First step: pre-tightening 60 6
M14x60
screw for front engine block Second step: Angle tightening 45
Flanged HEX screw for rear First step: pre-tightening 100 10
engine block Second step: Angle tightening 60
* Lubricate with engine oil before assembly
** Lubricate with graphitised oil before assembly
k Apply LOCTITE 243 before assembly
L See tightening sequence


CURSOR SERIES SECTION - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION - TOOLS CURSOR SERIES

TOOLS
TOOL No. NAME
99322230 Rotary telescopic stand (range 2000 daN, torque 375 daNm)
99340053 Extraction tool for crankshaft front ring seal
99342157 Extraction tool for injectors
99346250 Key to fit crankshaft front gasket
99346260 Key to fit crankshaft rear gasket
99350072 Box wrench for block junction bolts to the lower crankcase

TOOLS
TOOL No. NAME
99360143 Punch for valve guide removal
99360184 Pliers for removing/refitting piston rings (105 -160 mm)
99360259 Tool to remove and refit engine valves

(to be used with special plates)
99360263 Plate to remove and refit engine valves

(to be used with 99360259)
99360296 Tool for valve guide refitting (to be used with 99360143)
99360321 Tool for rotating the flywheel

TOOLS
TOOL No. NAME
99360325 Spacer (to be used with 99360321)
99360329 Adjuster for gasket assembly on valve guide
99360334 Cylinder liner protrusion gauge

(to be used with 99370415-99395603 and special plates)
99360336 Spacer (to be used with 99360334)
99360338 Plate for cylinder liners compression

(to be used with 99360334 -99360336)
99360351 Tool to retain engine flywheel

TOOLS
TOOL No. NAME
99360499 Drift to take down and fit back camshaft bushes
99360500 Tool for lifting the crankshaft
99360553 Tool for assembling and installing rocker arm shaft
99360585 Arm for removing and installing engine
99360603 Clamp for fitting piston into cylinder liner (90 - 175 mm)
99360612 Tool for engine T.D.C. positioning

TOOLS
TOOL No. NAME
99360613 Tool for timing of phonic wheel on camshaft
99360703 Check tool for cylinder liners
99360706 Tool to extract cylinder liners (use with specific rings)
99360728 Ring (135 mm - 141mm) (to be used with 99360706)
99361036 Brackets for fastening engine to 99322230 rotary stand
99366198 Tool for removing the high pressure pump gear

TOOLS
TOOL No. NAME
99370400 Tool for checking engine timing (use with 99395606)
99370415 Stand for dial gauge for checking cylinder liner protrusion
(to be used with 99395603)
99389813 Torque wrench (20-120 Nm) with 1/2 square head
99389829 9X12 coupling torque wrench (5-60 Nm)
99389833 14X18 coupling torque wrench (20-120 Nm)
99389834 Torque screwdriver (1-6 Nm) for adjusting injector solenoid

valve connector retainer nut

TOOLS
TOOL No. NAME
99390330 Sleeker for valve guide
99395216 Pair of gauges for angular tightening with 1/2 and 3/4 square
heads
99395225 Gauge for defining the distance between the centres of cam-
shaft and transfer case gear
99395226 Gauge to determine centre distance between camshaft and high

pressure pump
99395603 Dial gauge (0-5 mm)
99395606 Dial gauge (0 -30 mm)

TOOLS
TOOL No. NAME
99396035 Centering ring of crankshaft front gasket cover

CURSOR SERIES APPENDIX 1
Appendix
Page
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . 3
- Standard safety precautions . . . . . . . . . . . . . . . 3
- Accident prevention . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Protection of the environment . . . . . . . . . . . . 4

2 APPENDIX CURSOR SERIES

CURSOR SERIES APPENDIX 3
SAFETY REGULATIONS - Do not perform operations without the necessary

Standard safety precautions instructions.
We direct your attention on some precautions that must be - Do not use equipment to perform works other than
necessarily followed in a regular work environment and, in those for which they have been designed, you may sustain
case of non-compliance, any other precaution will not be suffi- accidents, even of serious type.
cient to protect the safety of the staff in charge of maintenance. - In case of checks or calibrations that require the engine
- Please obtain information and inform the staff on applica- to be on, make sure that the room is properly ventilated
ble laws on safety, making the informative material availa- and use proper fans to remove exhaust gases: intoxication
ble for consultation. and death hazard.
- Please keep the rooms as clean as possible and properly
ventilated. During maintenance
- Equip the rooms with specific, well-visible first-aid boxes, - Never open the filling cap of the cooling circuit when the
always stocked up with suitable medical aids. engine is hot. The operating pressure will spill the high
- Be equipped with suitable fire extinguishing devices, pro- temperature liquid with serious risk of burns. Wait until
perly signalled and never obstructed. Check their opera- the temperature drops below 50 C.
tion on a regular basis and train the staff on the interven- - Never add coolant to an overheated engine and only use
tion priorities and methods. appropriate fluids.
- Arrange gathering points for the evacuation of the rooms, - Always operate with engine off: in case particular circum-
properly signalling the exit routes. stances require maintenance interventions with the
- Absolutely prohibit smoking in the areas where the works engine on, consider all the risks involved in these opera-
subject to fire hazard are carried out. tions.
- Draw the attention on prohibitions and indications with - Use adequate and safe containers for draining the engine
suitable signs, which are immediately comprehensible fluids and exhaust oil.
always in case of emergency. - Keep the engine clean from oil, diesel and/or chemical sol-
vents.
- The use of solvents or detergents during maintenance
Accident prevention may develop toxic vapours. Always ventilate the work
rooms. Use safety masks when required.
- Do not wear cloths with loose edges, rings and chains,
while working near engines and moving organs. - Do not leave cloths soaked with flammable substances
near the engine.
- Use protective gloves and glasses when:
- filling up inhibitors or antifreeze; - When starting up the engine after a repair operation,
- replacing or filling up lubricant; arrange for suitable measures to stop air suction in case
- using air or liquids under pressure (allowed pressure of over-revving.
2 bar) - Do not use quick screwers.
- Wear a protective helmet if working in an area with - Do not disconnect the batteries whilst the engine is run-
suspended loads or overhead systems. ning.
- Always wear safety shoes and cloths fitted to the body, - Before any interventions involving the electrical circuits,
better if equipped with rubber bands at the edges. disconnect the batteries.
- Use protective creams for hands. - Disconnect the batteries from the on-board network
- Change wet clothes as soon as possible. while charging.
- In the presence of voltage higher than 48-60V, check the - After each intervention, make sure the polarity of the bat-
effectiveness of the ground electric connections. Make terys terminals is respected and the latter are well tighte-
sure your hands and feet are dry and perform the work ned and protected against accidental short circuits and
standing on insulating platforms. oxidation phenomena.
Do not proceed if not qualified! - Do not disconnect and connect the electric connections
- Do not smoke or spark free flames near batteries and any when power is on.
combustible material. - Before carrying out removal operations on pipes (pneu-
- Return oily rags or solvents to fire-proof containers. matic, hydraulic or fuel pipes) check the possible presence
of fluid or air under pressure. Adopt the necessary pre-
cautions, exhausting the residual pressures or closing the
shut-off valves. Always wear suitable masks or protective
glasses. Failure to follow these rules may cause serious
accidents and intoxication.

4 APPENDIX CURSOR SERIES
- Avoid improper tightening operations or out of torque. Protection of the environment

The engines components may be damaged also seriously,
thus prejudicing their life cycle. - Allows prioritise protection of the environment imple-
menting all necessary precautions to protect the safety
- Avoid draughts from fuel tanks in copper alloy and/or and health of staff.
pipes without filters.
- Make sure you and all staff are fully aware of current stan-
- Do not apply changes to the cabling, their length must not dards for the treatment and disposal of fluids and engine
be modified. oils. Set up adequate signage and specific courses to
- Do not connect any utility to the engines electric equip- ensure a full understanding of the rules and the basic pre-
ment, if not specifically approved by FPT. vention measures.
- Do not modify the fuel or hydraulic systems without - Collect used oil in suitable containers with water tight
authorisation from FPT. Any unforeseen change will void seals also providing storage in areas which are adequately
the warranty and may prejudice the engines duration and marked,ventilated, away from sources of heat and present
life cycle. no fire hazard.
For engines equipped with electronic units: - Handle batteries with care in well ventilated areas and in
antacid containers. Beware of fumes coming from the bat-
- Do not carry out any arch welding without previously teries: they may pose a serious risk of poisoning and con-
removing the electronic units. tamination of the environment.
- Remove the electronic control units in case of interven-
tions in which the temperatures will exceed 80 C.
- Do not paint the electronic components and connec-
tions.
- Do not modify or alter the data contained in the engine
management electronic control unit. Any manipulation or
alteration of the electronic components will invalidate the
service warranty of the engine and may also affect its ope-
ration and duration.

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CURSOR SERIES

Technical repair manual

Anyhow, this document is addressed to qualified and special-

Before performing any intervention, check that the document

Making interventions strictly observing the indications given

Each repair intervention must be finalised to the recovery of

Each intervention on the vehicle that is finalised to a modifica-

FPT declines any liability for repair work.

FPT is available to provide any information necessary for the

The data contained in this issue may not be up-to-date due to

In the event of discordance between the information in this

Publication edited by:

- Grounding and screening . . . . . . . . . . . . . . . . . 8

CONVERSIONS BETWEEN THE MAIN UNITS OF

Print P2D32C011 E Base - 10/2014

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Danger for persons

Risk of serious damage to the assembly

NOTE Indicates an additional explanation for a piece of information.

1 1 = Housing for connecting rod

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Tighten to the specified torque + angle

Press or caulk Rotation

Surface for machining

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GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

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Grounding and screening

The following precautions must be observed regarding the electronic components:

1. STAR CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT GROUND M

2. SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR

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CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

NOTE Where accuracy is not particularly required:

Print P2D32C011 E Base - 10/2014

PAGE HEADER AND FOOTER INTERPRETATION

Type Section Page

Basic edition referring to When present, a

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CURSOR SERIES STAGE IV

Removal-refitting of the main engine components 5

General mechanical overhaul 6

Standard safety precautions Appendix

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Section Description Page Revision date

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1. Engine technical code - 2. Engine serial number - 3. Manufacturing date (DD/MM/YY)

1. Engine technical code - 2. Engine serial number - 3. Manufacturing date (DD/MM/YY)

Ref. F3HFE613B*B011 F3HFE613D*B011

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CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES

Technical codes Commercial Codes

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PRODUCT TECHNICAL CODE

TYPE-APPROVAL FOR STANDARDS

TYPE-APPROVAL FOR PERFORMANCE

MAIN ENGINE SPECIFICATIONS

Ref. F3HFE613BB011 F3HFE613DB011

Type F3HFE613BB010 F3HFE613DB010