F5A F5C CIH малые до 100

ENGINES
F5A, F5C
Service Manual
84208945 7/09
Replaces 84208195
Printed in U.S.A. CNH America LLC, Racine, WI 53404 U.S.A.

286 -- 7/09 © 2009 CNH America LLC. All Rights Reserved.
Case IH is a registered trademark of CNH America LLC.
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS............................................................. A
ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A
POWER PRODUCTION ................................................................. B

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A
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INTRODUCTION
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Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5C
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5A
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5C
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5A
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INTRODUCTION
Foreword
This publication contains data, features instructions and methods for performing repair operations on the assembly
and its components and is addressed to qualified, specialized personnel.
Check to make sure you have the right publication related to the component you are about to work on before you start.
Make sure that you have all the necessary safety equipment: safety glasses, helmet, gloves, footwear, etc. Check
that the working lifting and transport equipment is available and in working order. Make sure that vehicle is secured.
Proceed by carefully observing the instructions contained in this publication and use the indicated specific tools to
ensure correct repair procedures and safety of operators.
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INTRODUCTION
Safety rules
Standard safety precautions
Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for
consultation.
• Keep working areas as clean as possible.
• Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain
adequate sanitary equipment.
• Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked
on a regular basis and personnel must be trained on proper interventions and priorities.
• Keep all emergency exits free of obstructions and clearly marked.
• Smoking in working areas subject to fire danger must be strictly prohibited.
Prevention of injury
• Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to
engines and equipment in motion.
• Wear safety gloves and goggles when performing the following operations:
• Topping off or changing lubrication oils.
• Using compressed air or liquids at a pressure greater than 2 bar (29 psi).
• Wear a safety helmet when working close to hanging loads or equipment working at head level.
• Always wear safety shoes and fitting clothes.
• Use protection cream for hands.
• Change wet clothes as soon as possible.
• In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connections.
Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with
electricity.
• Do not smoke or start an open flame close to batteries and any fuel material.
• Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers.
• Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may
occur.
• If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes.
During maintenance
• Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating
pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122
°F).
• Never add coolant to an overheated engine and use only appropriate liquids.
• Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be
aware of all the risks involved with such an operation.
• Always use adequate and safe containers for engine fluids and used oil.
• Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents.
• Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated.
Wear a safety mask if necessary.
• Do not leave soiled rags that may contain any flammable substances close to the engine.
• Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air
in case of engine runaway.
• Never disconnect the batteries while the engine is running.
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INTRODUCTION
• Disconnect the batteries prior to performing any work on the equipment.

• Disconnect the batteries to place a load on them with a load tester.
• After any work is performed, verify that the battery clamp polarity is correct and that the clamps are tight and safe
from accidental short circuit and oxidation.
• Before disconnecting any pipelines (pneumatic, hydraulic, fuel pipes, etc.), verify that all pressure has been re-
leased. Take all necessary precautions bleeding and draining residual pressure. Always wear the proper safety
equipment.
• Do not alter the lengths of any wires.
• Do not connect any electronic service tool to the engine electrical equipment unless specifically approved by Iveco.
• Do not modify the fuel system or hydraulic system unless approved by Iveco, Any unauthorized modification will
compromise warranty assistance and may affect engine operation and life span.
For engine equipped with an electronic control unit

• Do not weld on any part of the equipment without removing the control unit.
• Remove the in case of work requiring heating over 80 °C (176 °F).
• Do not paint the components and the electronic connections.
• Do not alter any data filed in the electronic control unit driving the engine. Any manipulation or alteration of elec-
tronic components will void engine warranty assistance and may affect the correct working order and life span of
the engine.
Respect of the Environment

• Respect of the environment should be of primary importance. Take all necessary precautions to ensure person-
nel’s safety and health.
• Inform the personnel of the laws regarding the dispensing of used engine fluids.
• Handle batteries with care, storing them in a well ventilated environment and within anti-acid container.
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INTRODUCTION
Torque
F5C
DESCRIPTION SIZE TORQUE
Oil Pan
Threaded cap with O-ring 45 - 55 N·m (33 - 41 lb ft)
Oil pan spacer M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
- Angle torque 85 - 95 °
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Conical thread cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
Cylinder head M15x1.5
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Exhaust Manifold
Exhaust manifold 10 - 20 N·m (7 - 15 lb ft)
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INTRODUCTION
Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)

EGR Unit
Heat exchanger fastening to valve 20 - 30 N·m (15 - 22 lb ft)
unit
Heat exchanger fastening to throw 20 - 30 N·m (15 - 22 lb ft)
EGR fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Valve 5 - 15 N·m (4 - 11 lb ft)
Manifold fastening nuts 20 - 30 N·m (15 - 22 lb ft)
Manifold fastening rings 5 - 15 N·m (4 - 11 lb ft)
Pulley
Engine crankshaft pulley 335 - 365 N·m (247 - 269 lb ft)
Connecting Rod
Connecting rod cap
- Pre-torque 45 - 55 N·m (33 - 41 lb ft)
Flywheel
Flywheel
Timing
Phonic wheel 12 - 18 N·m (9 - 13 lb ft)
Thrust block 20 - 30 N·m (15 - 22 lb ft)
Gear 31 - 41 N·m (23 - 30 lb ft)
Injector
Injector stud screw 21 - 29 N·m (15 - 21 lb ft)
Injector fastening nut
- Angle torque 25 - 35 N·m (18 - 26 lb ft)
LDA
Manifold side 15 - 25 N·m (11 - 18 lb ft)
Pump side 15 - 25 N·m (11 - 18 lb ft)
Sensors
Crankshaft speed sensor 5 - 15 N·m (4 - 11 lb ft)
Camshaft speed sesnor 5 - 15 N·m (4 - 11 lb ft)
Water temperature sensor 31 - 41 N·m (23 - 30 lb ft)
Oil temperature sensor 20 - 30 N·m (15 - 22 lb ft)
Air pressure sensor 5 - 15 N·m (4 - 11 lb ft)
Fuel filter
Union fixing to support 20 - 30 N·m (15 - 22 lb ft)
Fuel filter 20 - 30 N·m (15 - 22 lb ft)
Supply Pump
Supply pump 20 - 30 N·m (15 - 22 lb ft)
Inlet 20 - 30 N·m (15 - 22 lb ft)
Fast clutch 20 - 30 N·m (15 - 22 lb ft)
Turbocharger
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INTRODUCTION
Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)

Oil delivery inlet 20 - 30 N·m (15 - 22 lb ft)
Delivery pipe fastening screw 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to turbo 10 - 20 N·m (7 - 15 lb ft)
Cooling pipe
Water pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Water pipe to the support 20 - 30 N·m (15 - 22 lb ft)
Conical threaded cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Oil
Oil pressure control valve 40 - 50 N·m (30 - 37 lb ft)
Oil dipstick 20 - 30 N·m (15 - 22 lb ft)
Oil inlet pipe 10 - 20 N·m (7 - 15 lb ft)
Pickup tube to block 8 - 12 N·m (6 - 9 lb ft)
Pickup tube support 30 - 40 N·m (22 - 30 lb ft)
Oil filter cartridge union 40 - 50 N·m (30 - 37 lb ft)
Oil filter 20 - 30 N·m (15 - 22 lb ft)
Oil filter cartridge 16 - 20 N·m (12 - 15 lb ft)
Oil pump
- Stage 1 10 - 20 N·m (7 - 15 lb ft)
- Stage 2 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger
Threaded caps 40 - 50 N·m (30 - 37 lb ft)
Exchanger unit 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Thermostat
Thermostat unit 20 - 30 N·m (15 - 22 lb ft)
Bleed vent 35 - 45 N·m (26 - 33 lb ft)
Fan support
Water pump 20 - 30 N·m (15 - 22 lb ft)
Bearing 35 - 45 N·m (26 - 33 lb ft)
Fan support 20 - 30 N·m (15 - 22 lb ft)
Pulley 35 - 45 N·m (26 - 33 lb ft)
Alternator
Alternator support 45 - 55 N·m (33 - 41 lb ft)
Alternator 45 - 55 N·m (33 - 41 lb ft)
Lifting
Front hook 45 - 55 N·m (33 - 41 lb ft)
Rear hook 65 - 75 N·m (48 - 55 lb ft)
Injection Pump
Pump gear
- Torque 85 - 95 N·m (63 - 70 lb ft)
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INTRODUCTION
Torque
F5A
DESCRIPTION SIZE TORQUE
Oil Pan
Side cap M6 35 - 45 N·m (26 - 33 lb ft)
Side caps M22 45 - 55 N·m (33 - 41 lb ft)
Front cap M35 35 - 45 N·m (26 - 33 lb ft)
Fixing of sump 65 - 75 N·m (48 - 55 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
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INTRODUCTION
Exhaust Manifold
Exhaust manifold 30 - 40 N·m (22 - 30 lb ft)
Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)
Pulley
Engine crankshaft pulley 335 - 365 N·m (247 - 269 lb ft)
Connecting Rod
Connecting rod cap
Flywheel
Flywheel
Timing
Phonic wheel 12 - 18 N·m (9 - 13 lb ft)
Thrust block 20 - 30 N·m (15 - 22 lb ft)
Gear 31 - 41 N·m (23 - 30 lb ft)
Injector
Injector stud screw 21 - 29 N·m (15 - 21 lb ft)
Injector fastening nut
- Angle torque 25 - 35 N·m (18 - 26 lb ft)
LDA
Manifold side 15 - 25 N·m (11 - 18 lb ft)
Pump side 15 - 25 N·m (11 - 18 lb ft)
Sensors
Crankshaft speed sensor 5 - 15 N·m (4 - 11 lb ft)
Camshaft speed sesnor 5 - 15 N·m (4 - 11 lb ft)
Water temperature sensor 31 - 41 N·m (23 - 30 lb ft)
Oil temperature sensor 20 - 30 N·m (15 - 22 lb ft)
Air pressure sensor 5 - 15 N·m (4 - 11 lb ft)
Fuel filter
Union fixing to support 20 - 30 N·m (15 - 22 lb ft)
Fuel filter 20 - 30 N·m (15 - 22 lb ft)
Supply Pump
Supply pump 20 - 30 N·m (15 - 22 lb ft)
Inlet 20 - 30 N·m (15 - 22 lb ft)
Fast clutch 20 - 30 N·m (15 - 22 lb ft)
Turbocharger
Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)
Oil delivery inlet 20 - 30 N·m (15 - 22 lb ft)
Delivery pipe fastening screw 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to turbo 10 - 20 N·m (7 - 15 lb ft)
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INTRODUCTION
Cooling pipe
Water pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Water pipe to the support 20 - 30 N·m (15 - 22 lb ft)
Conical threaded cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Oil
Oil pressure control valve 40 - 50 N·m (30 - 37 lb ft)
Oil dipstick 20 - 30 N·m (15 - 22 lb ft)
Oil inlet pipe 10 - 20 N·m (7 - 15 lb ft)
Pickup tube to block 8 - 12 N·m (6 - 9 lb ft)
Pickup tube support 30 - 40 N·m (22 - 30 lb ft)
Oil filter cartridge union 40 - 50 N·m (30 - 37 lb ft)
Oil filter 20 - 30 N·m (15 - 22 lb ft)
Oil filter cartridge 16 - 20 N·m (12 - 15 lb ft)
Oil pump
- Stage 1 10 - 20 N·m (7 - 15 lb ft)
- Stage 2 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger
Threaded caps 40 - 50 N·m (30 - 37 lb ft)
Exchanger unit 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Thermostat
Thermostat unit 20 - 30 N·m (15 - 22 lb ft)
Bleed vent 35 - 45 N·m (26 - 33 lb ft)
Fan support
Water pump 20 - 30 N·m (15 - 22 lb ft)
Bearing 35 - 45 N·m (26 - 33 lb ft)
Fan support 20 - 30 N·m (15 - 22 lb ft)
Pulley 35 - 45 N·m (26 - 33 lb ft)
Alternator
Alternator support 45 - 55 N·m (33 - 41 lb ft)
Alternator 45 - 55 N·m (33 - 41 lb ft)
Lifting
Front hook 45 - 55 N·m (33 - 41 lb ft)
Rear hook 65 - 75 N·m (48 - 55 lb ft)
Injection Pump
Pump gear
- Torque 85 - 95 N·m (63 - 70 lb ft)
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INTRODUCTION
Special tools
F5C
380000134 Valve guide gasket assembly tool
380000134 1
380000150 Tool for engine T.D.C. positioning
380000150 2
380000219 Beater for valve guide disassembly and

reassembly
380000219 3
380000220 Ring for plunger introduction into the cylinder

barrel - 60 - 125 mm
380000220 4
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INTRODUCTION
380000221 Pliers for plunger snap ring disassembly and

reassembly - 60 - 125 mm
380000221 5
380000222 Sleeker for valve guide
380000222 6
380000228 Dial gauge - 0 - 5 mm
380000228 7
380000229 Dial gauge holding tool for rotatory injection

pump phasing (use with 380000228)
380000229 8
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INTRODUCTION
380000302 Tool for engine valve disassembly and

reassembly
380000302_3A 9
380000304 Measuring device for angular torque
380000304 10
380000364 Dial gauge holding base for miscellaneous

measures (use with 380000228)
380000364_3A 11
380000667 Beater for removing/refitting camshaft bushes

(to be used with 380000999)
380000667 12
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INTRODUCTION
380000670 Tool for cartridge filter disassembly
380000670 13
380000978 Rotary stand for overhauling units
380000301 14
380000999 Handle for interchangeable beaters
380000999_3-2 15
380001006 Diesel engine cylinder compression control

device
380001006_3 16
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INTRODUCTION
380002385 Tool for rotating the engine flywheel
380002385_3A 17
380100072 Puller for the gear coupling the injection pump

to the engine
380100072_3A 18
380100073 Tool for lifting the crankshaft
380100073_3-2 19
380100074 Adapter for counterpressure checking in

cylinders (use with 380001006)
380100074_3-2 20
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INTRODUCTION
380100075 Front main seal installation tool
380100075_3-2 21
380100076 Rear main seal installation tool
380100076_3-2 22
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INTRODUCTION
Special tools
F5A
380000134 Valve guide gasket assembly tool
380000134 1
380000150 Tool for engine T.D.C. positioning
380000150 2
380000219 Beater for valve guide disassembly and

reassembly
380000219 3
380000220 Ring for plunger introduction into the cylinder

barrel - 60 - 125 mm
380000220 4
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INTRODUCTION
380000221 Pliers for plunger snap ring disassembly and

reassembly - 60 - 125 mm
380000221 5
380000222 Sleeker for valve guide
380000222 6
380000228 Dial gauge - 0 - 5 mm
380000228 7
380000229 Dial gauge holding tool for rotatory injection

pump phasing (use with 380000228)
380000229 8
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INTRODUCTION
380000302 Tool for engine valve disassembly and

reassembly
380000302_3A 9
380000304 Measuring device for angular torque
380000304 10
380000364 Dial gauge holding base for miscellaneous

measures (use with 380000228)
380000364_3A 11
380000667 Beater for removing/refitting camshaft bushes

(to be used with 380000999)
380000667 12
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INTRODUCTION
380000670 Tool for cartridge filter disassembly
380000670 13
380000978 Rotary stand for overhauling units
380000301 14
380000988 Tool for stopping the engine flywheel
380000988_3 15
380000999 Handle for interchangeable beaters
380000999_3-2 16
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INTRODUCTION
380001006 Diesel engine cylinder compression control

device
380001006_3 17
380100072 Puller for the gear coupling the injection pump

to the engine
380100072_3A 18
380100073 Tool for lifting the crankshaft
380100073_3-2 19
380100074 Adapter for counterpressure checking in

cylinders (use with 380001006)
380100074_3-2 20
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INTRODUCTION
380100075 Front main seal installation tool
380100075_3-2 21
380100076 Rear main seal installation tool
380100076_3-2 22
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INTRODUCTION
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DISTRIBUTION SYSTEMS - A
ELECTRICAL POWER SYSTEM - 30.A
F5A
F5C
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Contents
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
Alternator - Remove
Prior operation:
Fan and drive Belt - Remove (B.50.A)
1. Hold the alternator (1) and detach it from its sup-

port loosening the screw (2). Recover the nut and
washer.
73092768 1
Next operation:
Alternator - Install (A.30.A)
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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM
Alternator - Install
Prior operation:
Alternator - Remove (A.30.A)
1. Install the alternator (1).

2. Tighten the bolts by hand until the belt is in place.
3. Once the belt is on the pulleys and tight, the alterna-
tor bolts can be tightened.
73092768 1
Next operation:
Fan and drive Belt - Install (B.50.A)
84208945 01/06/2009
A.30.A / 4
Index

Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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POWER PRODUCTION - B
ENGINE - 10.A
F5A
F5C
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Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454C
F5CE9454G
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE9454E
F5CE9484E
F5CE5454B
F5CE9484C
F5AE9454A
F5AE9484A
F5AE9454D
F5AE9484B
F5AE9484G
FUNCTIONAL DATA
ENGINE
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F5C
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F5A
Connecting rod and piston

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Balancer
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
F5A
Wiring harness
Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F5C
Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electronic control
Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
F5C
Sensing system
Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
SERVICE
ENGINE
Service instruction Finding T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Service instruction Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Valve drive
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
F5C
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

F5C
Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

F5C
Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

F5C
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

F5C
Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

F5C
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

F5C
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
F5C
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
F5C
Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

F5C
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

F5C
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
F5C
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

F5C
Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

F5C
Crankshaft
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F5C
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

F5C
Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
F5C
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
F5C
Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
F5A
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

F5A
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
F5A
Timing gear
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
F5A
Timing gear housing

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
F5A
Connecting rod and piston

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
F5C
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

F5C
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
F5A
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
F5A
Cylinder block
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Valve cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Front cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
F5A
Rear cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
F5A
Wiring harness
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
F5C
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POWER PRODUCTION - ENGINE
ENGINE - General specification

F5CE9454C
Cycle Diesel 4 strokes

Feeding Turbocharged with intercooler
Injection Direct
N. of cylinders 4 In-line
Bore 99 mm (3.898 in)
Stroke 104 mm (4.094 in)
Total displacement 3202 cm³
Compression ratio 17 : 1
Max. power 40 kW (54 Hp) @ 2300 RPM
Max. torque 220 N·m (162 lb ft) @ 1400 RPM
Loadless engine idling 1100 - 1200 RPM
Loadless engine peak 2700 - 2800 RPM
Timing
Intake
- Start before T.D.C. 19 °
- End after B.D.C. 37 °
Exhaust
- Start before B.D.C. 61 °
- End after T.D.C. 21 °
Valve Clearance (hot)
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
Valve Clearance (cold)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Injection Type Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2
Cylinder and Crankshaft Unit
Cylinder bore 99.000 - 99.020 mm (3.8976 - 3.8984 in)
Pistons
- Outside diameter 98.908 - 98.918 mm (3.8940 - 3.8944 in)
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Clearance between cylinder bore and piston 0.082 - 0.112 mm (0.0032 - 0.0044 in)
Piston protrusion -0.22 - 0.07 mm (-0.0087 - 0.0028 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
Clearance between piston pin and housing 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Piston ring landings
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
Clearance between Rings and Landings
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
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- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)

Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Small end bearing housing 39.460 - 39.490 mm (1.5535 - 1.5547 in)
- Big end bearing housing 67.833 - 67.841 mm (2.6706 - 2.6709 in)
- Small end bearing inside diameter 39.570 - 39.595 mm (1.5579 - 1.5589 in)
- Small end bearing inside diameter (installed) 36.010 - 36.020 mm (1.4177 - 1.4181 in)
Connecting rod big end bearing thickness
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Clearance between Piston pin and small end bearing 0.011 - 0.024 mm (0.0004 - 0.0009 in)
Maximum allowable twist for connecting rod 0.09 mm (0.0035 in) @ 125 mm (4.9213 in)
Crankshaft
- Main journal diameter (1-2-3-4) 76.182 - 76.208 mm (2.9993 - 3.0003 in)
- Main journal diameter (5) 83.182 - 83.208 mm (3.2749 - 3.2759 in)
- Rod journals 64.015 - 64.038 mm (2.5203 - 2.5212 in)
Main bearing thickness 2.165 - 2.174 mm (0.0852 - 0.0856 in)
Main bore diameter (1-2-3-4) 80.588 - 80.514 mm (3.1728 - 3.1698 in)
Main bore diameter (5) 87.588 - 87.614 mm (3.4483 - 3.4494 in)
Clearance between main bearings and journals (1-2-3-4) 0.064 - 0.095 mm (0.0025 - 0.0037 in)
Clearance between main bearings and journals (5) 0.059 - 0.100 mm (0.0023 - 0.0039 in)
Clearance between rod bearing and journals 0.033 - 0.041 mm (0.0013 - 0.0016 in)
Main journal width for thrust bearing on crankshaft 31.85 - 32.150 mm (1.2539 - 1.2657 in)
Main journal width for thrust bearing in cylinder block 32.50 - 32.55 mm (1.2795 - 1.2815 in)
Thrust bearing thickness 2.51 - 2.56 mm (0.0988 - 0.1008 in)
Clearance between the crankshaft and thrust bearing 0.095 - 0.270 mm (0.0037 - 0.0106 in)
Cylinder Head
Valve guide seats in cylinder head 12.960 - 12.995 mm (0.5102 - 0.5116 in)
Valve Guides
- Inside diameter 8.023 - 8.038 mm (0.3159 - 0.3165 in)
Valves (Intake)
- Valve stem diameter 7.985 - 8.000 mm (0.3144 - 0.3150 in)
- Valve face angle 60 °
Valves (Exhaust)
Clearance between Valve stem and Guide 0.040 - 0.053 mm (0.0016 - 0.0021 in)
Valve seat in the cylinder head
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
Valve seat (Exhaust)
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
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Valve spring height

- Free spring 44.6 mm (1.756 in)
- Under a load of 256 - 284 N (58 - 64 lb) 34 mm (1.339 in)
Under a load of 500 - 556 N (112 - 125 lb) 23.8 mm (0.937 in)
Injector protrusion 1.7 - 2.35 mm (0.0669 - 0.0925 in)
Camshaft bore inside diameter
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Clearance between cam bearings and journals 0.038 - 0.162 mm (0.0015 - 0.0064 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
- Tappet (Upper and Lower) 15.924 - 15.954 mm (0.6269 - 0.6281 in)
- Tappet (Middle) 15.960 - 15.975 mm (0.6283 - 0.6289 in)
Clearance between tappets and housing 0.03 - 0.068 mm (0.0012 - 0.0027 in)
Rocker Assembly
- Rocker Shaft Outside diameter 18.979 - 19.000 mm (0.7472 - 0.7480 in)
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
Clearance between rockers and shaft 0.020 - 0.054 mm (0.0008 - 0.0021 in)

F5CE9454G

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
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- Intake 0.20 mm (0.008 in)

- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
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Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
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F5CE9454E

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
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- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)

Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
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Valve spring height

-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)

F5CE9484E

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
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- Intake 0.20 mm (0.008 in)

- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
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Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
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F5CE5454B

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
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- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)

Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
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Valve spring height

-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)

F5CE9484C

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
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- Intake 0.20 mm (0.008 in)

- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
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Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
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F5AE9454A

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
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- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)

Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
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Valve spring height

-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)

F5AE9484A

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
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- Intake 0.20 mm (0.008 in)

- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
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Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
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F5AE9454D

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
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- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)

Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
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Valve spring height

-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)

F5AE9484B

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
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- Intake 0.20 mm (0.008 in)

- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
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Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
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F5AE9484G

Injection Direct
Bore 99 mm (3.898 in)
Timing
Intake
Exhaust
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
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- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)

Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Crankshaft
Cylinder Head
Valve Guides
Valves (Intake)
Valves (Exhaust)
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
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Valve spring height

-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
Rocker Assembly
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
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ENGINE - Overview
F5C
73092733 1
ENGINE FRONT VIEW
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73092734 2
ENGINE RIGHT SIDE VIEW
73092735 3
ENGINE LEFT SIDE VIEW
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73092736 4
ENGINE LEFT SIDE VIEW
73092737 5
ENGINE TOP VIEW
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ENGINE - Overview
F5A
73092883 1
FRONT VIEW OF ENGINE
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73092884 2
LEFT SIDE VIEW OF ENGINE
73092885 3
RIGHT SIDE VIEW OF ENGINE
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73092886 4
REAR VIEW OF ENGINE
73092887 5
TOP VIEW OF ENGINE
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Connecting rod and piston - Exploded view
73092848A 1
CONNECTING ROD AND PISTON UNIT COMPONENTS
(1) Snap ring (5) Screws

(2) Pin (6) Half bearings
(3) Piston (7) Connecting rod
(4) Piston rings (8) Bushing
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Balancer - Overview
F5A
73092889 1
Dynamic Balancer
(1) Reference notches for alignment and timing (4) Balancing masses
(2) Thrust washers (5) Shaft
(3) Bushings (6) Case
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Wiring harness - Overview EGR System

F5C
73092804 1
(1) Water temperature sensor (4) Crankshaft speed sensor

(2) Air temperature pressure sensor (5) Sectioning
(3) EGR Valve
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Wiring harness - Overview KSB
73092807 1
ELECTRIC CABLE TO CONNECT KSB WITH CERA
(1) Interface (3) Air sensor

(2) KSB signal (4) STOP
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Electronic control Control module - Electrical schema EGR System
73092805 1
Electrical Layout
20000 - Starter battery 58105 - Engine high water temperature warning light
25201 - Remote control for pre-heating switch 58484 - Diagnosis warning light
48035 - Engine rev. no. sensor 47034 - Engine water temperature sensor for EGR
52502 - Key commutator for services with start 78029 - EGR solenoid valve
61121 - Resistor for engine pre-heating 86020 - EGR E.C.U.
58101 - Pre--heating (on) warning light 85156 - Air pressure temperature sensor
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Electronic control Control module - Overview EGR System

F5C
73092806 1
Technical specifications
Manufacturer Bitron
Rated Voltage 13.5 V
Actual Voltage 10 - 16 V
Working temperature -30 - 100 °C (-22 - 212 °F)
Maximum current input Less than 5 A
EGR valve control signal PWM 133 - 147 Hz
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Ref. Description
1 PWM output signal for EGR solenoid valve
2 -
3 ECU Mass
4 Mass for pre--heating (on) warning light
5 ECU supply (+ 15)
6 K line signal
7 Intake manifold temperature and pressure sensor supply
8 EGR solenoid valve feed (potentiometer)
9 K line mass
10 EGR solenoid valve mass (potentiometer)
11 Cooling liquid temperature sensor mass, on thermostat unit
12 Air pressure and temperature sensor mass
13 Engine RPM Signal
14 E.C.U. supply (+30)
15 Pre--heating remote control switch
16 Engine high temperature warning light
17 Diagnosis warning light
18 Start
19 EGR solenoid valve position signal
20 Cooling liquid temperature sensor, on thermostat unit
21 Air temperature sensor signal
22 Pressure sensor signal, on intake manifold
23 Negative from engine drive shaft impulse transmitter
24 Engine drive shaft transmitter mass
25 Positive from engine drive shaft impulse transmitter
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Sensing system Crankshaft sensor - Overview

It is an inductive type sensor placed on the front left side of the engine. It generates signals obtained by the magnetic
flow lines closing up through the openings of a tone wheel splined on the engine crankshaft. The same signal is used
to pilot the tachometer fitted on the vehicle instrument panel. It is connected to the Electronic Control Unit pins 25C
(signal) and 24C (signal). The third pin is for shielding. The Sensor’s resistance value is nearly 900 Ω.
73092812 1
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ENGINE - Service instruction Finding T.D.C.

1. Position the engine drive shaft at T.D.C. of cylinder
1 rotating the flywheel until achieving the following
conditions:
• The notch (2) is visible from the inspection
hole.
• Tool 380000150 (1) should be fitted through
the case into the port on the flywheel.
73092764 1
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ENGINE - Service instruction Maintenance schedule

Checks and regular servicing Frequency (hours)
Engine visual inspection Daily
Check for presence of water in the fuel filter or pre-filter Daily
Check engine oil level Daily
Check air filter Daily
Check battery Every six months
Check cooling liquid level Daily
Check the wear conditions of the fan belt 300
Check for presence of water in the pre-filter 150
Check for presence of water in the filter Every six months
Check the compressor belt wear conditions 300
Injection pump overhaul 3000
Check turbo-compressor and clean it if necessary 1200
Tappet check and adjustment 1000
Change engine oil 500
Replace engine oil filter 500
Replace fuel pre-filter 1000
Replace fuel filter 600
Replace the fan belt 1200
Replace air filter 1200
Replace the compressor belt 1500
Change the cooling liquid Every 2 years or 1200 hours
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Rocker assembly Housing - Remove

F5C
Prior operation:
Valve cover - Remove (B.10.A)
1. Loosen the fastening screws (1), remove the over-

head holding the whole rocker arm unit (2) and re-
cover the two gaskets (3).
73092771 1
Next operation:
Rocker assembly Housing - Install (B.10.A)
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Camshaft Push rod - Remove

F5C
Prior operation:
Rocker assembly Housing - Remove (B.10.A)
1. Remove the push rods (1).
73092775 1
Next operation:
Camshaft Push rod - Inspect (B.10.A)
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Rocker assembly Rocker arm - Remove

F5C
Prior operation:
1. Loosen the rocker arm fastening screw (1) from the

disassembled rocker arm holding unit and then re-
move the rocker arm.
73092779 1
2. Withdraw the rocker arm (1) from one side recovering

the equalizers (2) from the other.
73092780 2
Next operation:
Rocker assembly Rocker arm - Install (B.10.A)
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Camshaft Push rod - Inspect

F5C
Prior operation:
Camshaft Push rod - Remove (B.10.A)
1. Check that the rocker arm rods are not deformed;

there must be no trace of wear or seizure on the
spherical housings of the rocker arm adjusting
screws as well as on the tappets (pointers); oth-
erwise these parts must be replaced. The suction
valve rods are identical and therefore interchange-
able.
73092794 1
Next operation:
Camshaft Push rod - Install (B.10.A)
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Camshaft Push rod - Install

F5C
Prior operation:
Camshaft Push rod - Inspect (B.10.A)
1. Fit the push rods in their housing.
Next operation:
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Rocker assembly Rocker arm - Install

F5C
Prior operation:
Rocker assembly Rocker arm - Remove (B.10.A)
1. Fit the rocker arms onto the shaft.

2. The intake arms (short) (2) goes on first, and then
the exhaust arms (long) (1).
73092780 1
Next operation:
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Rocker assembly Housing - Install

F5C
Prior operation:
1. Replace the gaskets (3), reassemble the rocker arm

holding case (2) and tighten the fastening screws (1)
to the prescribed torque setting.
2. After having completed the assembly, check that the
rocker arms are correctly positioned on the valves
and the tappet push rods.
73092771 1
Next operation:
Valve cover - Install (B.10.A)
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Valve drive Camshaft - Remove

Prior operation:
Timing gear housing - Remove (B.10.A)
1. Loosen the fastening screws (1) and disassemble

the camshaft (3) holding plate (2).
73092822A 1
2. Carefully withdraw the camshaft (1) from the engine

bock.
73092823A 2
Next operation:
Valve drive Camshaft - Install (B.10.A)
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Camshaft Tappet - Remove

F5C
Prior operation:
Valve drive Camshaft - Remove (B.10.A)
1. Withdraw the tappets (1) from the engine block.
73092824A 1
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Valve drive Camshaft - Measure

Prior operation:
1. Place the camshaft on footstocks and, using a dial

gauge placed on the central support, check that the
radial oscillation does not exceed 0.015 mm (0.0006
in) otherwise, replace the shaft.
IMPORTANT: The surface of the camshaft pins and of
cams must be extremely smooth. In case any trace of
meshing or scratches are detected, replace the shaft and 73092828 1
the relevant bushings.
2. Using a micrometer (1), check the diameter of the
camshaft (2) supporting pins on the two perpendicu-
lar axles.
73092829 2
Next operation:
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Camshaft Bushing - Measure

F5C
1. The front camshaft bush (2) must be driven into the

respective seat.
2. There must be no trace of meshing or wear in the
inner surface.
3. Using a bore meter (1) measure the front diameter of
the camshaft bush (2).
4. Measurements must be made on two perpendicular
axles.
73092830 1
73092831 2
MAIN DATA OF THE CAMSHAFT BUSH AND RELEVANT SEAT
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Camshaft Bushing - Replace

F5C
1. Use the beater 380000667 (2) and hand grip

380000999 (3) to disassemble and replace the
bushings (1).
IMPORTANT: In phase of assembly, the bush (1) must be
oriented making the lubrication ports coincide with those
on the crankcase.
73092832 1
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Camshaft Tappet - Install

F5C
Prior operation:
Camshaft Tappet - Remove (B.10.A)
1. Lubricate the tappets (1) and fit them into the relevant
seats within the crankcase.
73092834 1
Next operation:
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Valve drive Camshaft - Install

Prior operation:
1. Lubricate the camshaft supporting bush and assem-

ble the camshaft (1) paying attention not to damage
the bushing or the shaft’s seats.
73092823A 1
2. Position the camshaft (3) holding plate (1) with the

slot towards the upper side of the crankcase and the
marking towards the operator; tighten the fastening
screws (2) to the prescribed torque setting.
73092835 2
Next operation:
Valve drive Camshaft - End play (B.10.A)
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Valve drive Camshaft - End play

Prior operation:
1. Check the end play of the camshaft. The measure-

ment should be 0.10 - 0.36 mm (0.004 - 0.014 in).
73092836 1
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Valve assembly Valve - Cleaning

F5C
Prior operation:
Cylinder head - Disassemble (B.10.A)
1. Remove carbon deposits from the valves using a

wire wheel.
2. Check that the valves show no signs of seizure or
cracking. Replace if any defects are found.
73092876 1
Next operation:
Valve assembly Valve - Measure (B.10.A)
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Valve assembly Valve - Measure

F5C
Prior operation:
Valve assembly Valve - Cleaning (B.10.A)
1. Using a micrometer (2) measure the valve stem (1).

The prescribed value is 7.985 - 8.000 mm (0.314 -
0.315 in).
73092877 1
Next operation:
Cylinder head - Assemble (B.10.A)
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Valve assembly Spring - Measure

F5C
Prior operation:
Cylinder head - Disassemble (B.10.A)
1. Before assembly, test the valve spring flexibility using

specific tool. Compare the load and elastic strain test
results with the technical specifications of the new
springs, reported in the table below.
73092880 1
Height Load
(H) 44.6 mm (1.756 in) 0 N (0 lb)
(H1) 34 mm (1.339 in) 256 - 284 N (58 - 64 lb)
(H2) 23.8 mm (0.937 in) 502 - 554 N (113 - 125 lb)
Next operation:
Cylinder head - Assemble (B.10.A)
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Crankshaft Rear seal - Install

F5C
1. Fit the specific tool 380100076 (5) to the rear shank

(6) of the engine drive shaft, fix it with the screws (4)
and install the new seal (3).
2. Position part (1) on part (5), tighten the screw nut
(2) until the seal has been fitted (3) into the flywheel
casing (7).
73092782 1
Next operation:
Flywheel - Install (B.10.A)
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Crankshaft Front seal - Install

F5C
1. Fit the inner part of tool to the front crankshaft. Make

sure that the engine crankshaft pin is correctly fitted
into the tool spline in order to avoid damaging it. Fix
it with the screw and install the new seal.
2. Place the outer section of the tool on the previously
fitted one, tighten the screw nut until completely fit-
ting the seal into the casing.
73092788A 1
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Crankshaft Main bearing - Remove

Prior operation:
Oil pan - Remove (B.60.A)
1. Loosen the screws (1) and disassemble the crank-

shaft bearing caps (2).
73092818 1
2. The third (central) main bearing cap (1) and associ-

ated support have a bearing-half (2) equipped with
thrust bearing.
NOTE: Note down the assembly position of the upper
and lower half bearings since, in case of reuse after the
overhaul, they will have to be reassembled in the same
position.
73092819 2
3. Remove the crankshaft. Refer to Crankshaft - Re-

move (B.10.A) for the proper procedure.
4. Remove the crankshaft upper half bearings (1).
73092821 3
Next operation:
Crankshaft Main bearing - Install (B.10.A)
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Crankshaft - Remove
F5C
Prior operation:
1. Using tool 380000362 (1) and a hoist, remove the

engine crankshaft (2) from the crankcase.
73092820 1
Next operation:
Crankshaft - Install (B.10.A)
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Crankshaft - Measure
Prior operation:
Crankshaft - Remove (B.10.A)
1. In case meshing, scratches or excessive oval shap-

ing is detected on the main journals and crankshaft
bearing pins, it is necessary to grind the pins. Before
proceeding with pin (2) grinding, measure the shaft
pins by means of a micrometer (1) in order to estab-
lish to which diameter the pins must be reduced.
73092838 1
73092839 2
PROSPECT REPORTING MEASUREMENT VALUES OF THE ENGINE DRIVE SHAFT MAIN JOURNALS AND
CRANKSHAFT BEARING PINS
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73092840 3
ENGINE DRIVE SHAFT MAIN TOLERANCES
73092841 4
Next operation:
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Crankshaft Main bearing - Install

1. Carefully clean the crankshaft half bearings (1) hav-
ing lubrication port and fit them in their respective
seats.
IMPORTANT: If using the old bearings, be sure to place
them back into their original position.
2. Install the bearing with the thrust shoulders in the
correct position.
73092842 1
Next operation:
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Crankshaft - Install
F5C
Prior operation:
Crankshaft Main bearing - Install (B.10.A)
1. Install the engine crankshaft (2) using a suitable hoist

(1).
73092820 1
Next operation:
Crankshaft - End play (B.10.A)
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Crankshaft Journal - Measure

Prior operation:
1. Check the clearance between the engine crankshaft

main journals and the respective crankshaft bearings
proceeding as follows:
• Carefully clean the parts and eliminate any oil
residue.
• Place a calibrated wire (3) onto the journal (4),
lengthwise, as shown in the figure.
• Fit the caps (1) and the half bearings (2) on the
relevant supports.
NOTE: Always use new screws in the assembly phase.
73092843 1
2. Tighten the pre-lubricated screws (1) and tighten

them in three subsequent phases:
• Stage 1 - 45 - 55 N·m (33 - 41 lb ft).
• Stage 2 - 74 - 86 N·m (55 - 63 lb ft).
73092844A 2
3. • Stage 3 - Using tool 380000304 (1) fitted as

shown in the figure and further tighten the
screws (2) by 85 - 95 °.
73092845A 3
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B.10.A / 76
4. Remove the caps from their support. The clearance

between the crankshaft bearings and the relevant
pins should be detected comparing the width mea-
sured by the gauge wire (2) at the point of maximum
width with the scale graduation reported on the pack-
age (1) of the gauge wire.
5. The numbers reported on the scale indicate the
clearance in millimeters. If the clearance detected
differs from the prescribed value, replace the half
bearings and repeat the measurement; once achiev-
ing the slack prescribed, lubricate the crankshaft
bearings and finally assemble the supports tighten-
ing the fastening screws as described previously.
73092846A 4
Next operation:
84208945 01/06/2009
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Crankshaft - End play

Prior operation:
1. The check of the shoulder clearance is performed

with a magnetic based dial gauge (2) placed on the
engine shaft (3) as indicated in the figure.
2. If the clearance is out of spec, remove the cap (1)
and replace the thrust bearing.
73092847A 1
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Crankshaft Rear seal - Install

F5A
1. Fit the specific tool (5) to the rear shank (6) of the
engine drive shaft, fix it with the screws (4) and install
the new seal (3).
2. Position part (1) on part (5), tighten the screw nut
(2) until the seal has been fitted (3) into the flywheel
casing (7).
73092904 1
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Crankshaft Front seal - Install

F5A
1. Fit the inner part of tool to the front crankshaft. Make

sure that the engine crankshaft pin is correctly fitted
into the tool spline in order to avoid damaging it. Fix
it with the screw and install the new seal.
2. Place the outer section of the tool on the previously
fitted one, tighten the screw nut until completely fit-
ting the seal into the casing.
73092909 1
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Crankshaft - Remove
F5A
1. Using tool 380000362 (1) and a hoist, remove the

engine crankshaft (2) from the crankcase.
73092920 1
Next operation:
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Crankshaft - Install
F5A
Prior operation:
1. Install the engine crankshaft (2) using a suitable hoist

(1).
73092920 1
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Timing gear - Install

F5C
1. Align the tooth on the crankshaft gear (1) that has

the 45 ° bevel, with the timing gear (2) that has two
reference marks as shown in the figure.
2. Rotate the camshaft keeping the timing gear in place
until the camshaft’s pin fits into the relevant housing
within the timing gear.
3. Install the screws of the transmission gear without
fully tightening them.
4. With a magnetic base dial gauge, check the clear-
ance among the engine crankshaft gear and the
camshaft gear: it must be 0.068 - 0.168 mm (0.003
- 0.007 in).
5. Tighten the fastening screws of the transmission
gear.
73092786 1
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Timing gear - Install

F5A
1. Align the tooth on the crankshaft gear (1) that has

the 45 ° bevel, with the timing gear (2) that has two
reference marks as shown in the figure.
2. Rotate the camshaft keeping the timing gear in place
until the camshaft’s pin fits into the relevant housing
within the timing gear.
3. Install the screws of the transmission gear without
fully tightening them.
4. With a magnetic base dial gauge, check the clear-
ance among the engine crankshaft gear and the
camshaft gear: it must be 0.068 - 0.168 mm (0.003
- 0.007 in).
5. Tighten the fastening screws of the transmission
gear.
73092907 1
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Timing gear housing - Remove

F5C
1. Remove the rear part (1), of the timing gearcase

cover.
73092774 1
Next operation:
Timing gear housing - Install (B.10.A)
84208945 01/06/2009
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Timing gear housing - Install

F5C
Prior operation:
1. Assemble the front case (1) and tighten the fastening

screws to the prescribed torque.
NOTE: It is absolutely necessary to clean the surface
to be sealed in order to obtain perfect tightness. Apply
LOCTITE® 5970 sealer on the gearcase in order to form
a sealing bead of 1.3 - 2.0 mm (0.051 - 0.079 in). The
sealing bead must be homogeneous (no lumps), free of
air bubbles, thinner areas and gaps. Any imperfection
must be corrected as soon as possible. Avoid the excess
of sealer: too much sealing material would leak and pour
out on both sides of the joint parts and, as a consequence,
obstruct the passage of the lubricant. After having applied
the sealer, the parts must be joined within 10 minutes.
73092785 1
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Timing gear housing - Remove

F5A
1. Remove the rear part (1), of the timing gearcase

cover.
73092900 1
Next operation:
Timing gear housing - Install (B.10.A)
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Timing gear housing - Install

F5A
Prior operation:
1. Assemble the front case (1) and tighten the fastening

NOTE: It is absolutely necessary to clean the surface
to be sealed in order to obtain perfect tightness. Apply
LOCTITE® 5970 sealer on the gearcase in order to form
a sealing bead of 1.3 - 2.0 mm (0.051 - 0.079 in). The
sealing bead must be homogeneous (no lumps), free of
air bubbles, thinner areas and gaps. Any imperfection
must be corrected as soon as possible. Avoid the excess
of sealer: too much sealing material would leak and pour
out on both sides of the joint parts and, as a consequence,
73092906 1
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Connecting rod and piston - Remove

Prior operation:
Oil pan - Remove ()
1. Loosen the screws (1) fastening the connecting rod

caps (2) and remove the connecting rod caps.
2. Withdraw the pistons with the connecting rods from
the upper part of the crankcase.
NOTE: Keep the half bearings in their respective housings
since, in case of reuse after the overhaul, they will have to
be reassembled in the same position.
73092817 1
Next operation:
Connecting rod and piston - Install ()
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Connecting rod and piston - Disassemble

Prior operation:
Connecting rod and piston - Remove (B.10.A)
1. Make sure that the piston does not show any signs
of seizing, scoring or cracking. Replace if necessary.
2. Remove the piston rings (2) using the tool
380000324 (1).
73092849 1
3. Remove the snap rings (1) that hold the piston pin in
place using round tipped pliers.
73092863 2
4. Remove the piston pin (1). It may be necessary to

use hammer and wooden dowel to remove the pin.
73092862 3
Next operation:
Connecting rod and piston - Assemble (B.10.A)
84208945 01/06/2009
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Connecting rod and piston Piston - Measure

Prior operation:
Connecting rod and piston - Disassemble (B.10.A)
1. Using a micrometer (2), measure the diameter of the

piston (1) to determine the assembly clearance.
NOTE: The diameter of the piston must be measured at
the point shown in the figure for accurate measurement.
73092850 1
73092852 2
MAIN DATA OF THE PISTON, PINS AND SNAP RINGS
Next operation:
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Piston Pin - Measure

F5C
Prior operation:
1. Measure the diameter of the piston pin (1) with a

micrometer (2).
73092853 1
2. Lubricate the pin (1) and the pin housing in the piston
with engine oil.
3. Insert the pin into the piston. It must be inserted with
slight finger pressure and it should not come out by
gravity.
73092854 2
Next operation:
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Piston Ring - Measure

F5C
Prior operation:
1. Check the thickness of the piston ring (2) with a mi-

crometer (1).
73092855 1
2. Check the clearance between the rings (2) and their

landings on the piston (1) with a feeler gauge (3).
73092856 2
3. The ring (2) of the first landing has a "V" shape. The
clearance (X) between the ring and landing is mea-
sured by setting the piston (1) with the ring in the
cylinder liner (3) so that the ring is exposed half way
out of the cylinder liner.
73092857 3
84208945 01/06/2009
B.10.A / 93
4. Using a feeler gauge (2), check the opening between

the ends of the rings (1).
5. The ring must be inserted in the cylinder liner for an
accurate measurement. If the gap is less than or
greater than as required, replace the rings.
73092858 4
Next operation:
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Connecting rod and piston - Assemble

Prior operation:
1. Throughout the pin (3), connect the piston (2) to the

connecting rod (4) following the indication of the ref-
erence arrow (1) to correctly fix the piston (2) into
the cylinder barrel, also taking into consideration the
numbers printed on the connecting rod (4).
73092862 1
2. Install the snap rings (1) using the round tipped pliers
to hold to the assembly together.
73092863 2
3. Install the piston rings (1) on the piston (2) by using

the pliers 380000221 (3).
4. Direct the ring openings so they are staggered 120 °
apart.
73092849 3
Next operation:
Connecting rod and piston - Install (B.10.A)
84208945 01/06/2009
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Connecting rod and piston - Install

Prior operation:
Connecting rod and piston - Remove ()
1. Fit the half bearings (1) on the connecting rod and

cap.
2. Lubricate the pistons, the snap pins and the cylinder
barrel interior.
73092864 1
3. Using the band 380000220 (2), fit the connecting rod

and piston unit (1) into the cylinder barrel, checking
that:
• The number of each connecting rod corre-
sponds to the coupling cap number.
• The snap rings’ openings must be misaligned
by 120 °.
• All the connecting rod/piston units must have
the same weight.
• The notch on the piston shield must match the
oil nozzles’ position.
73092865 2
84208945 01/06/2009
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73092866 3
Journal Clearance
4. Carefully clean the parts eliminating any oil residuals.
5. Place a piece of calibrated wire (2) on the engine
crankshaft pins (1).
6. Fit the connecting rod caps (3) and the relevant half
bearings (4).
IMPORTANT: Always use new screws in phase of
assembly.
73092867 4
7. Lubricate the fastening screws (1) with engine oil and

tighten them to 45 - 55 N·m (33 - 41 lb ft) using a
torque wrench (2).
73092868 5
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8. Fit the tool 380000304 (1) to the socket wrench and

then further tighten the screws (2) by 65 - 75 °.
73092869 6
9. Remove the cap and measure the clearance by com-

paring the width measured by the calibrated wire (1)
with the scale graduation reported on the calibrated
wire package (2).
10. In case the clearance measured differs from the pre-
scribed value, replace the half bearings and measure
the clearance again.
73092870 7
Next operation:
Oil pan - Install ()
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Flywheel - Remove
F5C
1. Fit tool (1) 380002385 to the flywheel housing and,

using a wrench, lock the flywheel rotation.
2. Loosen the screws fastening the flywheel to the en-
gine drive shaft.
73092772 1
3. Screw two medium length screws in the ports (4), in

order to secure the flywheel (1) with a sling.
4. By means of two guide pins (2) previously screwed
in the engine drive shaft ports (3), guide the flywheel
withdrawal throughout a hoist.
5. Withdraw the flywheel casing grommet.
6. Withdraw the grommet of the timing gearcase.
73092773 2
Next operation:
Flywheel - Install ()
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Flywheel - Install
F5C
Prior operation:
Flywheel - Remove ()
1. Screw two hooks or eyebolts on the flywheel (1)

through the ports (4).
2. By means of a hoister, draw the flywheel up to its
housing inside the casing.
NOTE: The flywheel has a reference dowel that couples
with the relevant seat on the box.
3. Screw two pins (2) of appropriate length into the
shaft’s ports (3) and, using them as a guide, duly fit
the engine flywheel (1) into its casing.
4. Fit the tool 380002385 to the flywheel casing in order
to lock the engine flywheel rotation.
73092773 1
5. Tighten the engine flywheel (2) fastening screws (1)

in the following sequence.
• 25 - 35 N·m (18 - 26 lb ft)
• 85 - 95 °
NOTE: Angular fastening must be executed using tool
380000304. Before assembly, always check that the port
threads and the screws show no trace of wear and dirt.
73092783 2
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Flywheel - Remove
F5A
1. Fit tool (1) 380002385 to the flywheel housing and,

using a wrench, lock the flywheel rotation.
2. Loosen the screws fastening the flywheel to the en-
gine drive shaft.
73092772 1
3. Screw two medium length screws in the ports (4), in

order to secure the flywheel (1) with a sling.
4. By means of two guide pins (2) previously screwed
in the engine drive shaft ports (3), guide the flywheel
withdrawal throughout a hoist.
5. Withdraw the flywheel casing grommet.
6. Withdraw the grommet of the timing gearcase.
73092899 2
Next operation:
Flywheel - Install ()
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Flywheel - Install
F5A
Prior operation:
Flywheel - Remove ()
1. Screw two hooks or eyebolts on the flywheel (1)

through the ports .
2. By means of a hoister, draw the flywheel up to its
housing inside the casing.
NOTE: The flywheel has a reference dowel that couples
with the relevant seat on the box.
3. Screw two pins (2) of appropriate length into the
shaft’s ports (3) and, using them as a guide, duly fit
the engine flywheel (1) into its casing.
4. Fit the tool 380002385 to the flywheel casing in order
to lock the engine flywheel rotation.
73092899 1
5. Tighten the engine flywheel (2) fastening screws (1)

in the following sequence.
• 25 - 35 N·m (18 - 26 lb ft)
• 85 - 95 °
NOTE: Angular fastening must be executed using tool
380000304. Before assembly, always check that the port
threads and the screws show no trace of wear and dirt.
73092905 2
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Balancer - Remove
F5A
Prior operation:
Oil pan - Remove ()
1. Unscrew the screws (1) which fasten the dynamic

balancer (2) and remove it.
73092902 1
Next operation:
Balancer - Install ()
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Balancer - Install
F5A
Prior operation:
Balancer - Remove ()
1. Mount the dynamic balancer (1) taking care that the

reference notches (2) coincide as shown in figure.
76092914 1
Next operation:
Oil pan - Install ()
84208945 01/06/2009
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Cylinder block Bore - Check

Prior operation:
Connecting rod and piston - Remove (B.10.A)
Once engine is disassembled, clean accurately the cylinder

block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case
of uncertain seal or if rusted.
Inspect cylinder bore surfaces; they shall be free from seiz-
ing, scores, ovalization, taper, or excessive wear.
Inspection of cylinder bore to check ovalization, taper, and
wear shall be performed using the bore dial gauge (1) fitted
with the dial gauge previously set to zero on the ring gauge
(2) of the cylinder bore diameter.
NOTE: Should a ring gauge not be available, use a
micrometer for zero-setting. 73092825A 1
Measurements shall be performed on each cylinder at

three different heights in the barrel and on two planes per-
pendicular with each other: one parallel to the longitudinal
axis of the engine (A), and the other perpendicular (B).
Maximum wear is usually found on plane (B) in correspon-
dence with the first measurement.
Should ovalization, taper, or wear be found, bore and grind
the cylinder bores. Cylinder bore regrinding shall be per-
formed according to the spare piston diameter oversized by
0.4 mm (0.016 in) and to the specified assembling clear-
ance.
73092826A 2
84208945 01/06/2009
B.10.A / 105
NOTE: In case of regrinding, all bores shall have the

same oversize 0.4 mm (0.016 in).
73092827 3
84208945 01/06/2009
B.10.A / 106
Cylinder head - Remove

Prior operation:
Rocker assembly Housing - Remove ()
1. Disassemble the cylinder head; loosen the cylinder

head (1) fastening screws (2); hook the brackets with
metal ropes and, throughout a hoister, detach the
cylinder head with valves from the basement.
2. Remove the cylinder head gasket.
73092775 1
Next operation:
Cylinder head - Install ()
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Cylinder head - Install

Prior operation:
Cylinder head - Remove ()
1. Measure the piston projection and refer to the table

to select the appropriate thickness of the gasket.
73092790 1
Piston protrusion (A) Gasket thickness (B)

0.07 - -0.07 mm (0.0028 - -0.0028 in) 0.80 mm (0.031 in)
-0.08 - -0.22 mm (-0.0031 - -0.0087 in) 0.70 mm (0.028 in)
2. Fit the gasket (1) on the block centering it on the pins

(2) as a reference.
73092791 2
84208945 01/06/2009
B.10.A / 108
3. Place the head (2) on the block while aligning the

centering pins.
NOTE: Always use new screws for assembly.
4. Lubricate the head fastening screws (1) and tighten
them to the prescribed torque.
73092775 3
Next operation:
Rocker assembly Housing - Install ()
84208945 01/06/2009
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Cylinder head - Disassemble

Prior operation:
Cylinder head - Remove ()
1. The intake valves (1) and exhaust valves (2) have

different head diameter.
2. Number the valves before removing them from the
cylinder head in order to be able to reassemble them
in the same order in case replacement is not neces-
sary.
73092871 1
3. Valve disassembly must be executed using tool

380000302 (1) to slightly press the plate (3) so that,
compressing the spring (4), it is possible to remove
the keepers (2). Then remove the plate (3) and the
spring (4).
4. Repeat the operation in correspondence of each
valve.
5. Turn the cylinder head upside down and withdraw the
valves (5).
73092872 2
6. Remove the seals (1) and (2) from their valve guides.
73092873 3
Next operation:
84208945 01/06/2009
B.10.A / 110
Cylinder head - Check

Prior operation:
Cylinder head - Disassemble ()
1. Any deformation detected on the whole length of the

cylinder head must not exceed 0.20 mm (0.008 in).
In case higher value is detected, grind the cylinder
head in order to obtain the prescribed value.
73092874 1
Next operation:
Cylinder head - Assemble ()
84208945 01/06/2009
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Cylinder head Valve guide - Measure

Prior operation:
1. Using a bore meter, measure the valve guide inner

diameter.
73092878 1
Next operation:
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Cylinder head Valve seat - Replace

Prior operation:
1. If the valve seat are damaged replace them.

2. With the tools and being careful not to indent the
cylinder heads, remove as much material as possible
form the valve seats until removal from cylinder head
is possible by means of a punch.
3. Heat cylinder head up to 80 - 100 °C (176 - 212 °F) 73092879 1
and with the beater assemble the new valve seats
previously cooled into the cylinder head.
Next operation:
84208945 01/06/2009
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Cylinder head - Assemble

Prior operation:
1. Lubricate the valve stems (1) and fit them in the rel-
evant valve guides in the same position they were
before disassembly.
2. Fit the grommets (2)and (3) to the valve guide using
tool 380000134.
73092881 1
3. Place the spring (4) and the upper plate (3) on the
cylinder head.
4. Using tool 380000302 (1), compress the spring (4)
and constrain the parts to the valve (5) using the
keepers (2).
73092872 2
Next operation:
84208945 01/06/2009
B.10.A / 114
Valve cover - Remove

1. Loosen the screws (1) and remove the tappet covers
(2).
73092766 1
84208945 01/06/2009
B.10.A / 115
Valve cover - Install

1. Replace the gaskets (2) and install the valve covers
(1).
73092797 1
84208945 01/06/2009
B.10.A / 116
Front cover - Install

F5C
1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing’s cover using the centring pins (1) to
correctly position it and then tighten the fastening
73092787A 1
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Front cover - Install

F5A
1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing’s cover using the centring pins (1) to
correctly position it and then tighten the fastening
73092908 1
84208945 01/06/2009
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Rear cover - Install

F5C
1. Accurately clean the timing gearcase and the engine

block.
IMPORTANT: It is absolutely necessary to clean the
surface to be sealed in order to obtain perfect tightness.
Apply LOCTITE® 5970 sealer on the gearcase in order to
form a sealing bead of 1.5 mm (0.059 in). The sealing
bead must be homogeneous (no lumps), free of air
bubbles, thinner areas and gaps. Any imperfection must
be corrected as soon as possible. Avoid the excess of
sealer: too much sealing material would leak and pour out
on both sides of the joint parts and, as a consequence,
73092781 1
84208945 01/06/2009
B.10.A / 119
Rear cover - Install

F5A
1. Accurately clean the timing gearcase and the engine

block.
IMPORTANT: It is absolutely necessary to clean the
surface to be sealed in order to obtain perfect tightness.
Apply LOCTITE® 5970 sealer on the gearcase in order to
form a sealing bead of 1.5 mm (0.059 in). The sealing
bead must be homogeneous (no lumps), free of air
bubbles, thinner areas and gaps. Any imperfection must
be corrected as soon as possible. Avoid the excess of
sealer: too much sealing material would leak and pour out
on both sides of the joint parts and, as a consequence,
73092903 1
84208945 01/06/2009
B.10.A / 120
Wiring harness - Remove

F5C
1. Remove the wiring harness from all electrical equip-

ment.
84208945 01/06/2009
B.10.A / 121
Index
ENGINE - 10.A
Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
F5A
Balancer - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
F5A
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
F5A
Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
F5C
Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
F5C
Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
F5C
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
F5C
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
F5C
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
F5C
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
F5C
Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Connecting rod and piston Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
F5C
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
F5A
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
F5C
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
F5A
Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F5C
Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
F5A
Crankshaft Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Crankshaft Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Crankshaft Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F5C
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
F5A
Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cylinder head Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Cylinder head Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Electronic control Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Electronic control Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
F5C
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454C
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5CE9454G
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE9454E
F5CE9484E
F5CE5454B
F5CE9484C
F5AE9454A
F5AE9484A
F5AE9454D
F5AE9484B
F5AE9484G
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F5C
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F5A
ENGINE - Service instruction Finding T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
ENGINE - Service instruction Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
F5C
Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
F5A
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
F5C
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
F5A
Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
F5C
Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
F5A
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
F5C
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
F5C
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
F5C
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
F5A
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
F5C
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
F5C
Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
F5C
Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
F5C
Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
F5C
Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
F5A
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
F5C
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
F5A
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
F5C
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
F5A
Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
F5C
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Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
F5C
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
F5C
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Valve drive Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Valve drive Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Valve drive Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wiring harness - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F5C
Wiring harness - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Wiring harness - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
F5C
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FUEL AND INJECTION SYSTEM - 20.A
F5A
F5C
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Contents
FUNCTIONAL DATA
FUEL AND INJECTION SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel injection pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel filter system
Fuel filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Priming pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Sensing system
Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5C
SERVICE
FUEL AND INJECTION SYSTEM
Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel injection pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F5C
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F5A
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5A
Fuel filter system

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F5A
Fuel injector
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Priming pump
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
F5A
Fuel line
Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F5C
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F5A
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POWER PRODUCTION - FUEL AND INJECTION SYSTEM
FUEL AND INJECTION SYSTEM - Overview

The engine supply system consists of the following components:
• Fuel tank (aboard the vehicle)
• Fuel delivery and return pipes
• Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicle’s chassis)
• Priming pump, fitted on the engine and driver by the engine camshaft
• Fuel filter (its position on the engine may vary depending on the outfit and use)
• Supply rotary pump
• Injector feed pipe (from the fuel supply pump to the fuel injectors)
• Injectors
73092749 1
SUPPLY SYSTEM DIAGRAM
(1) Injectors (2) Fuel filter (3) Tank (4) Supply pump (5) Ignition pump
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73092750 2
PIPE LAYOUT
(1) Injector feed pipe (5) KSB thermal bulb

(2) Fuel exhaust pipe from injectors (6) Solenoid valve
(3) Supply rotary pump (7) Injector
(4) Union for pressure gauge pipe within LDA intake
manifold
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Working system description

The fuel (5) is primed from the fuel tank from the priming pump (6). The latter is fitted on the engine basement and
is driven by the engine camshaft. Throughout the filter (4), fuel is conveyed to the transfer pump, which is placed
inside the supply rotary pump (2), which is a turbine blade pump type. The supply rotary pump duty is to increase the
fuel pressure based on the increase of engine revolutions’ number. Then, the fuel reaches the valve controlling fuel
pressure within the supply pump. The distributor piston further increases such pressure and delivers the fuel to the
injectors (1) throughout the delivery pipe fitting. The fuel leak (3) from the injectors is recovered and sent back to the
fuel tank.
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Fuel injection pump - Overview

The rotary type supply pump is driven by a gear which is coupled to the engine camshaft gear.
Identification coding example

V rotary distributor piston pump
E pump dimensions
4 four cylinder engines
12 distributor piston size in mm
1150 no. of pump rev./min.
RV right direction rotation
73092752 1
Injection pump section
(1) Membrane (6) Transfer pump (11) Feed pipe fitting

(2) Setting ring (7) Drive shaft (12) Hydraulic head
(3) Feeler pin (8) Cam disk (13) Control plate
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(4) Drive lever (9) Spark lead adjuster (14) Adjusting pin
(5) Speed regulator (10) Distributor piston (15) Counter spring
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Fuel injection pump - Dynamic description

Supply phase
The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the
compression chamber (4) through the feed pipe (1) which is kept open by the solenoid valve (2).
73092753 1
(1) Fuel supply pipe (4) Compression chamber (7) End of delivery port
(2) Solenoid valve (5) Fuel delivery pipe from pump to (8) Cursor
injectors
(3) Axial groove (6) Distributor piston (9) Injector
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Delivery phase
The distributor piston (5) driven by the cam disk, goes up to the T.D.C. and simultaneously rotates on its own axle. The
combination of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within
the chamber (2). The distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to
the injectors (6).
73092754 2
(1) Fuel feed pipe (3) Distributor piston inner pipe (5) Distributor piston
(2) Compression chamber (4) Fuel delivery pipe from pump to (6) Injector
injector
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End of delivery phase

The distributor piston (6) moving towards the T.D.C. connects the high pressure inner chamber to the pipe (1), thereby
establishing pressure balance between the distributor piston inner chamber, the injectors? delivery pipe and the pump
interior. Since such pressure is lower than the one required to start the injector, end of delivery will be determined.
73092755 3
(1) Fuel feed pipe (3) Fuel delivery pipe (5) Cursor
(2) Compression chamber (4) End of delivery pipe (6) Distributor piston
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Engine stop
Engine stop is provoked cutting out the starter contact. The electric flux to the solenoid valve (4) is cut out. The
solenoid valve, throughout its spring (3), drives the mobile cap to the end of stroke (2) and the mobile cap obstructs
the fuel feed pipe (1).
73092756 4
(1) Fuel feed pipe (3) Spring (5) Compression chamber

(2) Mobile cap (4) Solenoid valve
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L.D.A. (Load Delivery Adjustment) device

The duty of the L.D.A. device is to adjust the fuel delivery depending on the air pressure within the intake manifold.
Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4)
there is a conical housing (5) in which the feeling pin runs (6). The setting pin (4) axial motion drives the feeling pin
(6) shift and the latter acts on the stop lever (7). The stop lever rotates on its own axle (8) and acts on the control
plate in order to adjust the fuel delivery depending on the air quantity within the cylinders.
73092757 5
Section of the LDA device
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Fuel filter system Fuel filter - Overview

The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water
from the fuel in which it is contained. At the bottom of the filtering cartridge there may be a water drainage device;
depending on the appliance (use in cold climate conditions), the fuel filter support may be equipped with a heater and
a temperature sensor. Some versions are also equipped with a water detecting sensor at the bottom of the cartridge
filter.
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73092759 1
(1) Fuel filter support (2) Cartridge filter (3) Water drainage device (not
available on all versions)
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Priming pump - Overview

The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the
engine block and driven by the engine camshaft.
73092758 1
(1) Pump (2) Control lever (3) Camshaft
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Sensing system Air temperature-pressure sensor - Overview

F5C
It consists of an NTC temperature sensor and a pressure sensor, both integrated in a single device.
73092811 1
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FUEL AND INJECTION SYSTEM - Bleed

1. Disconnect the fuel filter pipe (1) and act on the prim-
ing pump (2) drainage lever.
2. Continue drainage until fuel discharge is completed.
3. Connect the pipe (1) to the filter.
73092801 1
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Fuel injection pump - Remove

1. Unscrew the pump fastening screws on the rear part
of the gear cover. To disassemble the pump, fit tool to
the pump wheel and fix it with the three screws (1).
Using the specially provided wrench, slowly tighten
the screw (2) holding the rear part of the pump re-
moving the pump completely.
NOTE: Before pump disassembly, check whether a drive
shaft locking system is available for that model. In such
case, using the specially provided tool 380000150, lock
the engine into the position corresponding to T.D.C.
for cylinder 1. Then, throughout the specific locking
system available, lock the pump drive shaft. At this point,
the pump should be in phase and therefore no timing
will be requested in phase of reassembly (unless any 73092763 1
maintenance operation is necessary).
Next operation:
Fuel injection pump - Install (B.20.A)
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Fuel injection pump - Install

F5C
Prior operation:
Fuel injection pump - Remove (B.20.A)
1. Fit the ignition pump gear (1) into its housing.

2. Fit the pre-set ignition pump into its housing on the
engine, inserting the shaft into the gear hole.
3. Tighten the three screw nuts on the rear part of the
timing gearcase and the front cover fixing the shaft
to the gear.
4. With magnetic base dial gauge, check the clearance
among the engine shaft gear and the oil pump gear:
it must be 0.068 - 0.168 mm (0.003 - 0.007 in).
73092787A 1
Next operation:
Fuel injection pump - Timing adjust (B.20.A)
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Fuel injection pump - Timing adjust

F5C
Prior operation:
1. With injection pump inserted in its housing and re-

taining screws released, fit dial gauge 380000228 (2)
and dial gage holder (1), preloading rod by 2.5 mm
(0.098 in).
2. Rotate crankshaft and move from 1st cylinder at TDC
to end of compression phase condition.
3. Reset dial gage and rotate crankshaft in opposite di-
rection to return to 1st cylinder at TDC during com-
pression. In this position, the dial gage fitted on pump
must display values below:
• 0.95 - 1.05 mm (0.037 - 0.041 in) (61 kW en-
gines)
• 0.83 - 0.93 mm (0.033 - 0.037 in) (55 kW en- 73092802 1
gines)
• 0.60 - 0.75 mm (0.024 - 0.030 in) (48 kW en-
gines)
• 0.71 - 0.81 mm (0.028 - 0.032 in) 57 kW and
65 kW engines)
4. Rotate pump counter clockwise if stroke is shorter
or clockwise if stroke is longer till obtaining required
stroke.
5. Lock pump when checking these conditions and lock
related nuts at predefined torque.
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Fuel injection pump - Install

F5A
Prior operation:
Fuel injection pump - Remove (B.20.A)
1. Fit the ignition pump gear (1) into its housing.

2. Fit the pre-set ignition pump into its housing on the
engine, inserting the shaft into the gear hole.
3. Tighten the three screw nuts on the rear part of the
timing gearcase and the front cover fixing the shaft
to the gear.
among the engine shaft gear and the oil pump gear:
it must be 0.068 - 0.168 mm (0.003 - 0.007 in).
73092908 1
Next operation:
Fuel injection pump - Timing adjust (B.20.A)
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Fuel injection pump - Timing adjust

F5A
Prior operation:
1. With injection pump inserted in its housing and re-

taining screws released, fit dial gauge 380000228 (2)
and dial gage holder (1), preloading rod by 2.5 mm
(0.098 in).
2. Rotate crankshaft and move from 1st cylinder at TDC
to end of compression phase condition.
3. Reset dial gage and rotate crankshaft in opposite di-
rection to return to 1st cylinder at TDC during com-
pression. In this position, the dial gage fitted on pump
must display values below:
• 0.83 - 0.93 mm (0.033 - 0.037 in) (55 kW en-
gines)
• 0.71 - 0.81 mm (0.028 - 0.032 in) 48 kW ; 57 73092802 1
kW and 65 kW engines)
4. Rotate pump counter clockwise if stroke is shorter
or clockwise if stroke is longer till obtaining required
stroke.
5. Lock pump when checking these conditions and lock
related nuts at predefined torque.
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Fuel filter system - Remove

F5C
1. Place a container under the diesel fuel filter and un-

screw the water drainage valve (3)under the filter;
completely drain the diesel fuel container.
2. Disassemble the diesel fuel filter (1), the filter support
(2).
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Fuel filter system - Install

F5C
1. Install the fuel filter support (1) and the fuel filter (2).
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Fuel filter system - Remove

F5A
1. Place a container under the diesel fuel filter and un-

screw the water drainage valve (3)under the filter;
completely drain the diesel fuel container.
2. Disassemble the diesel fuel filter (1), the filter support
(2).
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Fuel filter system - Install

F5A
1. Install the fuel filter support (1) and the fuel filter (2).
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Fuel injector - Remove

1. Unscrew the injector support fastening screws (1),
disassemble the injector supports and remove the
injectors (2).
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Fuel injector - Install

1. Install new seals on the injectors.
2. Make the holes (1) for fuel return all face the same
direction.
73092796 1
3. Install the injectors (1) and tighten the fastening

screws (2) to the prescribed torque setting.
73092795 2
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Priming pump - Remove

F5C
1. Remove the priming pump (1).
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Priming pump - Install

F5C
1. Install the priming pump (1).
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Priming pump - Remove

F5A
1. Remove the priming pump (1).
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Priming pump - Install

F5A
1. Install the priming pump (1).
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Fuel line Low pressure - Remove

F5C
1. Remove the L.D.A. pipe. Remove the fuel pipes from

the priming pump (1) to the filter and from the filter to
the ignition pump (2), then fit the specially provided
caps to the pipes, the pumps and the filter. Unscrew
the screws (3), fastening the fuel ignition pipes and
remove them.
73092762 1
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Fuel line Low pressure - Install

1. Reassemble the pipe from the pump to the injector
and tighten the bracket’s fastening screws (3).
2. Reassemble the pipe from the pump to the fuel filter
(2) and from the fuel filter to the priming pump (1).
3. Reassemble the L.D.A. pipe.
73092762 1
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Fuel line Low pressure - Remove

F5A
1. Remove the L.D.A. pipe. Remove the fuel pipes from

the priming pump (1) to the filter and from the filter to
the ignition pump (2), then fit the specially provided
caps to the pipes, the pumps and the filter. Unscrew
the screws (3), fastening the fuel ignition pipes and
remove them.
73092893A 1
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Index

FUEL AND INJECTION SYSTEM - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL AND INJECTION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F5C
Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F5A
Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5C
Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F5A
Fuel filter system Fuel filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel injection pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F5C
Fuel injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F5A
Fuel injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5C
Fuel injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5A
Fuel injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fuel injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fuel line Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F5C
Fuel line Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F5A
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5C
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
F5A
Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5C
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F5A
Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5C
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AIR INTAKE SYSTEM - 30.A
F5A
F5C
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Contents
FUNCTIONAL DATA
AIR INTAKE SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5C
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5A
SERVICE
Turbocharger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5A
Air intake manifold

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5A
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POWER PRODUCTION - AIR INTAKE SYSTEM
AIR INTAKE SYSTEM - Overview

F5C
The boosting system is composed of the following parts:

• Air filter
• Turbocharger
73092748 1
BOOSTING
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AIR INTAKE SYSTEM - Overview

F5A
The boosting system is composed of the following parts:

• Air filter
• Turbocharger
73092891 1
BOOSTING
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Turbocharger - Remove
F5C
1. Remove the turbocharger unit (1).
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Turbocharger - Install
F5C
1. Reassemble the turbocharger (1) unit.

2. Reassemble the pipe (2) and fit the clip in the correct
housing.
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Turbocharger - Remove
F5A
1. Remove the turbocharger unit (1).
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Turbocharger - Install
F5A
1. Reassemble the turbocharger (2) unit.

2. Reassemble the oil delivery pipe (3).
3. Install the oil drain pipe (1).
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Air intake manifold - Remove

1. Remove the intake manifold (1).
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Air intake manifold - Install

F5C
1. Reassemble the whole intake manifold (1) replacing

the gasket (2) and (3).
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Air intake manifold - Install

F5A
1. Reassemble the whole intake manifold (1) replacing

the gasket (2) and (3).
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Index

Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5C
Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5A
Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5C
AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5A
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5C
Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5A
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5C
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5A
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EXHAUST SYSTEM - 40.A
F5A
F5C
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Contents
FUNCTIONAL DATA
EXHAUST SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5A
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454B
Sensing system
Overview EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5C
SERVICE
EXHAUST SYSTEM
Remove EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5C
Install EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

F5C
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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POWER PRODUCTION - EXHAUST SYSTEM
EXHAUST SYSTEM - Overview

EGR (EXHAUST GAS RECIRCULATION)

The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that
produce nitrogen oxides (NOx). The exhaust gas recirculation system (EGR) reduces combustion temperature and
therefore is an efficient NOx emission control system.
INTERNAL EGR
The specific design of intake cams of the internal EGR system allows part of exhaust gas to be recycled to engine
cylinders. This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always
active. Its configuration requires no additional parts such as control valves, pipelines or heat exchangers therefore
engine profile remains unchanged. Besides main lobe, intake cam has an additional lobe as to configuration without
EGR. During concerned cylinder exhaust phase, this lobe allows a shaft advanced opening of intake valve. In this
way, part of the exhaust gas is trapped in the suction duct and later, during cylinder suction phase, this gas is recycled
to cylinder inlet for combustion phase.
73092746 1
Aspiration cam profile
(X) Cam rotation angle (Y) Cam lift
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EXHAUST SYSTEM - Overview

F5CE5454B
EGR (EXHAUST GAS RECIRCULATION)

The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that
produce nitrogen oxides (NOx). The exhaust gas recirculation system (EGR) reduces combustion temperature and
therefore is an efficient NOx emission control system.
EXTERNAL E.G.R.
The external EGR system is a device fitted between the exhaust manifold and the intake manifold. Allows partial
exhaust gas recovery into the engine cylinders after having been cooled throughout a heat exchanger. This way the
combustion temperature maximum values, responsible of the formation of Nitrogen oxides (NOx) can be reduced.
Hence, reducing the aforesaid temperatures by decreasing the concentration of oxygen in the combustion chamber,
the EGR system efficiently controls NOx emissions. The exhaust gases through the conduit (4) and only after re-
ceiving the consent by the electronic control unit EGR, cross the valve (1) and reach the heat exchanger (2) where,
thanks to the engine coolant recycle, are cooled to be then entered into the intake manifold (5).
73092747 1
EXTERNAL E.G.R.
(1) Valve unit (5) Intake manifold

(2) Heat exchanger (6) Exhaust manifold
(3) Heat exchanger (7) Engine head
(4) Exhaust gas pipe
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Sensing system - Overview EGR valve

F5C
73092813 1
(A) Exhaust gas input - (B) Exhaust gas output
Coil characteristic Potentiometer characteristic

Resistance 7.5 - 8.5 Ω Total resistance 4000 Ω
Frequency 100 - 150 Hz Maximum voltage 15 V
Voltage 12 - 16 V Supply current 10 mA
Circuit configuration Voltage divider
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EXHAUST SYSTEM - Remove EGR System

F5C
1. Using pliers, remove the clips (1) and the water deliv-
ery pipe connected to the valve support and the ex-
changer (2). Loosen the clip (3) and detach the pipe
(4), from the EGR valve housing. Unscrew the EGR
fastening screws on the front side (5), and those on
the valve support side (6), then remove the EGR unit.
73092761 1
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EXHAUST SYSTEM - Install EGR System

F5C
1. Place the whole E.G.R. on the intake manifold,

tighten the front side (5) and valve support (6) fas-
tening screws to the prescribed torque.
2. Connect the pipe (4) to the E.G.R. valve housing and
then tighten the clip (3).
3. Reassemble the pipe (2) and, using pliers, fit the rel-
evant clip (1).
73092761 1
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Exhaust manifold - Remove

1. Remove the exhaust manifold (1).
73092766 1
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Exhaust manifold - Install

1. Fit the exhaust manifold (3) with new seal (2) and
tighten the nuts (1) with studs tightening them to the
required torque.
73092793 1
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Index

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUST SYSTEM - Install EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5C
EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454B
EXHAUST SYSTEM - Remove EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5C
Sensing system - Overview EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5C
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ENGINE COOLANT SYSTEM - 50.A
F5A
F5C
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Contents
FUNCTIONAL DATA
ENGINE COOLANT SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5C
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5A
Thermostat
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sensing system
Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Coolant temperature - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5A
Coolant line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5C
Fan and drive

Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5C
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5C
Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5A
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

F5A
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5A
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POWER PRODUCTION - ENGINE COOLANT SYSTEM
ENGINE COOLANT SYSTEM - Overview

F5C
The closed circuit forced circulation engine cooling system is composed of the following parts:
• expansion tank: position, form and dimensions may vary depending on the engine fitting
• radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions
may vary depending on the application
• fan increasing the radiator’s cooling power. This component may vary depending on the application
• heat exchanger cooling the lubricant oil. This component may vary depending on the application
• centrifugal water pump positioned in the front part of the engine block
• thermostat controlling cooling liquid circulation
73092742 1
ENGINE COOLING SYSTEM DIAGRAM
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ENGINE COOLANT SYSTEM - Overview

F5A
The closed circuit forced circulation engine cooling system is composed of the following parts:
• expansion tank: position, form and dimensions may vary depending on the engine fitting
• radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions
may vary depending on the application
• fan increasing the radiator’s cooling power. This component may vary depending on the application
• heat exchanger cooling the lubricant oil. This component may vary depending on the application
• centrifugal water pump positioned in the front part of the engine block
• thermostat controlling cooling liquid circulation
73092890 1
ENGINE COOLING SYSTEM DIAGRAM
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Thermostat - Overview
When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermo-
stat, which cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-engine
circuit, allowing engine heat up quickly. The thermostat valve starts opening at nearly 80 °C (176 °F), allowing water
circulation into the radiator and also obstructing direct return towards the engine. Check the thermostat efficiency and
replace it in case of doubtful functioning.
73092744 1
THERMOSTAT DIAGRAM
(1) Stroke starts at 77 - 81 °C (171 - 178 °F). (2) 7 mm (0.28 in) stroke at 92 - 96 °C (198 - 205 °F).
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Water pump - Overview

The water pump is a centrifugal blade turbine type pump. The pump’s bearing (2) is connected to the impeller’s shaft
as a whole. Water tight between the pump unit (3) and the shaft (2) is ensured by the sheath (4).
73092743 1
WATER PUMP SECTION
(1) Hub (4) Sheath

(2) Shaft with bearing (5) Impeller
(3) Pump unit
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Sensing system Coolant temperature - Overview

The sensor is fitted on the thermostat unit. It consists of two NTC thermistors with two reophores.
73092808 1
Characteristics
Working temperature range
- Connector’s side -40 - 130 °C (-40 - 266 °F) ; 150 °C (302 °F) for less
than 10 min.
- Bulb’s side on engine -40 - 140 °C (-40 - 284 °F)
Voltage 6 - 28 V
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Sensing system Coolant temperature - Overview KSB
73092810 1
Characteristics
Contact closing temperature 60 - 70 °C (140 - 158 °F)
Maximum load on contacts 15 A
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Thermostat - Remove
1. Remove the thermostat unit (1).
73092766 1
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Water pump - Remove

F5C
Prior operation:
1. Remove the water pump (1).
73092770 1
Next operation:
Water pump - Install (B.50.A)
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Water pump - Install

Prior operation:
Water pump - Remove (B.50.A)
1. Fit a new seal (2) on the water pump (1).

2. Assemble the water pump (1).
3. Tighten the fastening screws to the prescribed
torque.
73092789 1
Next operation:
Fan and drive - Install (B.50.A)
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Water pump - Remove

F5A
Prior operation:
1. Remove the water pump (1).
73092898A 1
Next operation:
Water pump - Install (B.50.A)
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Coolant line - Remove

F5C
1. Remove the water delivery pipe (1) from the ex-

changer.
73092760 1
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Fan and drive Belt - Remove

F5C
1. Loosen the screw (1) and the relevant screw nut on

the belt tensioning bracket (3).
2. Loosen the alternator through bolt in order to with-
draw the belt (2).
73092767 1
Next operation:
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Fan and drive Belt tensioner - Remove

F5C
Prior operation:
1. Remove the belt tensioning bracket (1).
73092767 1
Next operation:
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Fan and drive - Remove

F5C
Prior operation:
1. Remove the electromagnetic joint support (1).

2. Loosen the screw (2) and remove the pulley (3).
73092770 1
Next operation:
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Fan and drive - Install

F5C
Prior operation:
Fan and drive - Remove (B.50.A)
1. Install the fan hub (1).

2. Reassemble the pulley (3), tighten the fastening
screw (2) to the prescribed torque setting.
73092792 1
Next operation:
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Fan and drive Belt tensioner - Install

Prior operation:
Fan and drive Belt tensioner - Remove (B.50.A)
1. Install the tensioner (1).
73092767 1
Next operation:
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Fan and drive Belt - Install

Prior operation:
1. Fit the drive belt (1) on the pulley and the guide
rollers.
2. Tension the drive belt by tightening the screw (2).
73092767 1
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Fan and drive Belt - Remove

F5A
1. Loosen the screw (1) and the relevant screw nut on

the belt tensioning bracket (3).
2. Loosen the alternator through bolt in order to with-
draw the belt (2).
73092896 1
Next operation:
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Fan and drive Belt tensioner - Remove

F5A
Prior operation:
1. Remove the belt tensioning bracket (1).
73092896 1
Next operation:
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Fan and drive - Remove

F5A
Prior operation:
1. Remove the electromagnetic joint support (1).

2. Loosen the screw (2) and remove the pulley (3).
73092898A 1
Next operation:
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Fan and drive - Install

F5A
Prior operation:
Fan and drive - Remove (B.50.A)
1. Install the fan hub (1).

2. Reassemble the pulley (3), tighten the fastening
screw (2) to the prescribed torque setting.
73092910 1
Next operation:
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Index

Coolant line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5C
ENGINE COOLANT SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5C
ENGINE COOLANT SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5A
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5C
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5A
Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5C
Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5A
Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5C
Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5A
Fan and drive Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F5C
Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F5A
Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sensing system Coolant temperature - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Thermostat - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5C
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5A
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LUBRICATION SYSTEM - 60.A
F5A
F5C
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Contents
TECHNICAL DATA
Oil pump
Oil filter
FUNCTIONAL DATA
LUBRICATION SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5C
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5A
Oil pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil filter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Blowby re-circulation system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil cooler
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sensing system
Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5C
Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

F5A
SERVICE
Oil pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil pan
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F5A
Oil filter
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5A
Piston lubrication
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Oil cooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5A
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POWER PRODUCTION - LUBRICATION SYSTEM
Oil pump - General specification

Rotating speed 750 - 4200 RPM
Feed pressure 2 - 4 bar (29 - 58 psi)
Rated flow 12.2 - 75.9 l/min (3.2 - 20.1 US gpm)
Oil type SAE 20/30
Max. oil temperature 80 °C (176 °F)
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Oil filter - General specification

Booster pressure 20 bar (290 psi)
Dynamic pressure 0 - 15 bar (0 - 218 psi) per 50,000 cycles
Operating temperature -40 - 140 °C (-40 - 284 °F)
Torque wrench setting 16 - 20 N·m (12 - 15 lb ft)
Maximum flow 50 l/min (13.2 US gpm)
Load loss at the end of life cycle 2.5 bar (36 psi)
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LUBRICATION SYSTEM - Overview

F5C
Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is dis-
tributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat
exchanger, he centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed
air system is also fitted.
73092738 1
LUBRICATION SYSTEM DIAGRAM
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LUBRICATION SYSTEM - Overview

F5A
Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is dis-
tributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat
exchanger, he centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed
air system is also fitted.
73092888 1
LUBRICATION SYSTEM LAYOUT
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Oil pump - Overview
73092739 1
Oil pump
(1) Main gear (6) Cover

(2) Secondary gear (7) Internal rotor
(3) Pump unit (8) Internal rotor
(4) Drive shaft (9) Bush
(5) Secondary shaft
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Oil filter - Overview
73092740 1
Engine oil filter
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(1) Protective cover (2) Cartridge
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Blowby re-circulation system - Overview

On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop
by gravity on the underlying tappet cover (3). The remaining non condensed vapours will be duly conveyed through
the breather (2), for instance by suction.
73092741 1
ENGINE OIL VAPOR RECIRCULATION
(1) Valve (2) Breather (3) Tappet cover
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Oil cooler - Overview
73092745 1
OIL COOLER
The oil cooler within the engine cooling system has the duty to control the engine oil temperature, reducing it by
absorbing heat throughout the engine cooling liquid.
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Sensing system Oil pressure - Overview

F5C
73092809 1
Characteristics
Voltage 12 - 24 V
Contact closure with decreasing pressure 0.2 bar (3 psi)
Contact opening with increasing pressure 0.9 bar (13 psi)
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Sensing system Oil pressure - Overview

F5A
73092919 1
Characteristics
Voltage 12 - 24 V
Calibration 0.6 - 0.9 bar (9 - 13 psi)
Tightening torque 35 N·m (26 lb ft)
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Oil pump - Remove

1. Loosen the screws (1) and remove the oil pump (2).
73092778 1
Next operation:
Oil pump - Install (B.60.A)
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Oil pump - Install

Prior operation:
Oil pump - Remove (B.60.A)
1. Assemble the oil pump (2).

2. Screw the fastening screws (1) without fully locking
them.
among the engine crankshaft gear and the oil pump
gear: It must be between 0.068 - 0.168 mm (0.003 -
0.007 in).
4. Fully tighten the fastening screws (1).
73092784 1
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Oil pan - Remove

F5C
1. Loosen the screws (2), disassemble the plate (3) and

remove the oil pan (1).
NOTE: The shape and dimensions of the oil pan and the
suction rose may vary depending on the engine appliance.
Hence, the figures provide a general indication of the
operation to be executed. Yet, the herein description of
the procedures is applicable.
73092776 1
2. Loosen the suction rose support fastening screws

(1).
3. Loosen the suction rose (3) fastening screws (2) and
then remove the suction rose.
73092777 2
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Oil pan - Install

F5C
1. Reassemble the suction rose tightening the support

fastening screws (1) and the screw fixing the suction
rose (2) to the prescribed torque setting.
73092777 1
2. Fit the new gasket (1) to the oil pan (2).
73092800 2
3. Assemble the oil pan (1) and fit the plate thereon (3).
Tighten the fastening screws (2) to the prescribed
torque setting.
73092776 3
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Oil pan - Remove

F5A
1. Turn the engine upside down.

2. Remove the screws (2) and detach the oil pan (1).
3. Remove the oil pick up tube.
73092901 1
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Oil pan - Install

F5A
1. Instal the oil pick up tube.

2. Mount the oil pan (1) and tighten the screws (2) to
the required torque.
NOTE: Before installing the pan, verify that the threads of
the holes and the screws are not worn and dirty.
73092916 1
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Oil filter - Remove

F5C
1. Remove the oil filter (1) and the oil filter base (2).
73092765 1
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Oil filter - Install

F5C
1. Install the oil filter support (1) and the oil filter (2).
73092765 1
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Oil filter - Remove

F5A
1. Remove the oil filter (1) and the oil filter base (2).
73092894 1
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Oil filter - Install

F5A
1. Install the oil filter support (1) and the oil filter (2).
73092894 1
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Piston lubrication Spray nozzle - Remove

Prior operation:
1. Loosen the fastening screws (1) and disassemble

the oil nozzles (2).
73092821 1
Next operation:
Piston lubrication Spray nozzle - Install (B.60.A)
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Piston lubrication Spray nozzle - Install

Prior operation:
Piston lubrication Spray nozzle - Remove (B.60.A)
1. Fit the nozzles (2) and tighten the fastening screws

(1) to the prescribed torque setting.
73092837 1
Next operation:
Oil pan - Install (B.60.A)
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Oil cooler - Remove

1. Place a container under the heat exchanger (2) to
collect the cooling liquid contained therein.
2. Loosen the screws (1)and disassemble the heat ex-
changer unit (2).
73092769 1
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Oil cooler - Install

1. Reassemble the heat exchanger (1) remember to re-
place the old gasket with a new one; tighten the fas-
tening screws (2) to the prescribed torque setting.
73092769 1
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Oil line - Remove

F5C
1. Loosen the clip and disconnect the pipe (1).

2. Remove oil delivery pipe connected to the tur-
bocharger (2) and then the oil return pipe (3).
73092760 1
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Oil line - Install

F5C
1. Reassemble the oil delivery pipe (2) and the return

pipe (1).
73092760 1
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Oil line - Remove

F5A
1. Remove oil delivery pipe connected to the tur-

bocharger (2) and then the oil return pipe (1).
73092892 1
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Index

Blowby re-circulation system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LUBRICATION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5C
LUBRICATION SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5A
Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Oil cooler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oil filter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F5C
Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5A
Oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5C
Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5A
Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5C
Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F5C
Oil line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5A
Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5C
Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F5A
Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5C
Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5A
Oil pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston lubrication Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5C
Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5A
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STARTING SYSTEM - 80.A
F5A
F5C
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B.80.A / 1
Contents
FUNCTIONAL DATA
Engine starter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5C
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5C
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5C
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5A
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POWER PRODUCTION - STARTING SYSTEM
Engine starter - Overview

F5C
73092815 1
Manufacturer BOSCH
Electrical system 12 V
Rated output 3 kW (4 Hp)
84208945 01/06/2009
B.80.A / 3
Engine starter - Remove

F5C
1. Hold the starter (1), unscrew the fastening screws

and remove the starter.
73092761 1
84208945 01/06/2009
B.80.A / 4
Engine starter - Install

F5C
1. Fit the starter (1) and tighten the fastening screws to

the prescribed torque setting.
73092761 1
84208945 01/06/2009
B.80.A / 5
Engine starter - Remove

F5A
1. Hold the starter (1), unscrew the fastening screws

and remove the starter.
73092892 1
84208945 01/06/2009
B.80.A / 6
Engine starter - Install

F5A
1. Fit the starter (1) and tighten the fastening screws to

the prescribed torque setting.
73092892 1
84208945 01/06/2009
B.80.A / 7
Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5C
Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5A
Engine starter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5C
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5C
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5A
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286 -- 7/09 © 2009 CNH America LLC. All Rights Reserved.
Case IH is a registered trademark of CNH America LLC.
ENGINES
F5A, F5C
Service Manual
84208945 7/09
Replaces 84208195
Printed in U.S.A. CNH America LLC, Racine, WI 53404 U.S.A.

F5A F5C CIH малые до 100

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F5A F5C CIH малые до 100

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ENGINES

Printed in U.S.A. CNH America LLC, Racine, WI 53404 U.S.A.

POWER PRODUCTION ................................................................. B

• Disconnect the batteries prior to performing any work on the equipment.

For engine equipped with an electronic control unit

Respect of the Environment

DESCRIPTION SIZE TORQUE

Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)

Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)

DESCRIPTION SIZE TORQUE

380000134 Valve guide gasket assembly tool

380000150 Tool for engine T.D.C. positioning

380000219 Beater for valve guide disassembly and

380000220 Ring for plunger introduction into the cylinder

380000221 Pliers for plunger snap ring disassembly and

380000222 Sleeker for valve guide

380000228 Dial gauge - 0 - 5 mm

380000229 Dial gauge holding tool for rotatory injection

380000302 Tool for engine valve disassembly and

380000304 Measuring device for angular torque

380000364 Dial gauge holding base for miscellaneous

380000667 Beater for removing/refitting camshaft bushes

380000670 Tool for cartridge filter disassembly

380000978 Rotary stand for overhauling units

380000999 Handle for interchangeable beaters

380001006 Diesel engine cylinder compression control

380002385 Tool for rotating the engine flywheel

380100072 Puller for the gear coupling the injection pump

380100073 Tool for lifting the crankshaft

380100074 Adapter for counterpressure checking in

380100075 Front main seal installation tool

380100076 Rear main seal installation tool

380000134 Valve guide gasket assembly tool

380000150 Tool for engine T.D.C. positioning

380000219 Beater for valve guide disassembly and

380000220 Ring for plunger introduction into the cylinder

380000221 Pliers for plunger snap ring disassembly and

380000222 Sleeker for valve guide

380000228 Dial gauge - 0 - 5 mm

380000229 Dial gauge holding tool for rotatory injection

380000302 Tool for engine valve disassembly and

380000304 Measuring device for angular torque

380000364 Dial gauge holding base for miscellaneous

380000667 Beater for removing/refitting camshaft bushes

380000670 Tool for cartridge filter disassembly

380000978 Rotary stand for overhauling units

380000988 Tool for stopping the engine flywheel

380000999 Handle for interchangeable beaters

380001006 Diesel engine cylinder compression control

380100072 Puller for the gear coupling the injection pump

380100073 Tool for lifting the crankshaft

380100074 Adapter for counterpressure checking in

380100075 Front main seal installation tool

380100076 Rear main seal installation tool

ELECTRICAL POWER SYSTEM - 30.A

ELECTRICAL POWER SYSTEM - 30.A

1. Hold the alternator (1) and detach it from its sup-

1. Install the alternator (1).

ELECTRICAL POWER SYSTEM - 30.A

Connecting rod and piston

Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53