CNH Engine Service Manual F4hfa613c - A - B - D

SERVICE MANUAL
F4HFA413A*E002 / F4HFA613B*E002 /
F4HFA613C*E002 / F4HFA613D*E002 /
F4HFA613F*E003
Tier 2
Engine
Part number 47441596

1st edition English
October 2012
Printed in U.S.A.
Copyright © 2012 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
Contents
INTRODUCTION
Engine....................................................................................... 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001
Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101
Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102

Crankshaft and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103
Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105
Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106
Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110
Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.114
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206

Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.210
Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218
Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250
Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400
Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414
Electrical systems ....................................................................... 55

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.010
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012
Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013
Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014
Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015
Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201
Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202
47441596 09/10/2012
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
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INTRODUCTION
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1
Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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INTRODUCTION
Foreword
Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that may be of assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these
substances.
• Agricultural consultants will, in many cases, be able to help you as well.
Helpful hints
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may
be harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids,
etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in
a proper way to comply with local legislation and available resources.
• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should
not be allowed to get into the soil, but should be collected and disposed of properly.
• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmos-
phere. Your CNH dealer or air conditioning specialist has a special extractor for this purpose and will have to
recharge the system properly.
• Repair any leaks or defects in the engine cooling or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of
oils, coolant, etc.
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INTRODUCTION
Safety rules
Personal safety
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible death or injury.
Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION
followed by special instructions. These precautions are intended for the personal safety of you and those working
with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The
color associated with DANGER is RED.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
The color associated with WARNING is ORANGE.
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury. The color associated with CAUTION is YELLOW.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color
associated with Notice is BLUE.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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INTRODUCTION
Torque
Component Size Specification
Cylinder Head and Components
Plug ¼" 10 - 14 Nm (7.4 - 10.3 lb ft)
½" 20 - 28 Nm (14.8 - 20.7 lb ft)
¾" 31 - 41 Nm (22.9 - 30.2 lb ft)
Grid Heater M6 Nut 6 - 10 Nm (4.4 - 7.4 lb ft)
Intake Manifold M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Engine Lifting Bracket
Rear M12 65 - 89 Nm (47.9 - 65.6 lb ft)
Front M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Cylinder Head M12x1.75x130 mm
First Phase 30 - 40 Nm (22.1 - 29.5 lb ft)
Second Phase 85 - 95 °
Third Phase 85 - 95 °
Cylinder Head M12x1.75x150 mm
Rocker Bracket 31 - 41 Nm (22.9 - 30.2 lb ft)
Rocker Arm Jam Nuts 20 - 28 Nm (14.8 - 20.7 lb ft)
Exhaust Manifold 48 - 58 Nm (35.4 - 42.8 lb ft)
Valve Cover M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Turbocharger
6 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 37 - 49 Nm (27.3 - 36.1 lb ft)
4 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Front Case
Front Cover M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Rear Case
Gear Case M12 Screw 65 - 89 Nm (47.9 - 65.6 lb ft)
M10 Screw 42 - 52 Nm (31.0 - 38.4 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Flywheel Housing M10 75 - 95 Nm (55.3 - 70.1 lb ft)
M12 44 - 54 Nm (32.5 - 39.8 lb ft)
Cylinder Block and Crankshaft Components
Camshaft Retaining Plate M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Camshaft Gear M8 Screw 32 - 40 Nm (23.6 - 29.5 lb ft)
Crankcase Plate M10 Screw 38 - 48 Nm (28.0 - 35.4 lb ft)
Vibration Damper and Adapter M12
Second Phase 90 °
Drive Pulley M10 61 - 75 Nm (45.0 - 55.3 lb ft)
Engine Flywheel M12
Main Caps M12
Second Phase 74 - 86 Nm (54.6 - 63.4 lb ft)
Connecting Rod Caps
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INTRODUCTION

Lubrication System and Components
Oil Pump
First Phase M8 7 - 9 Nm (5.2 - 6.6 lb ft)
Second Phase M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Pressure Relief Valve M22 72 - 88 Nm (53.1 - 64.9 lb ft)
Oil Cooler and Oil Filter Base M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Filter Contact + ¾ Turn
Connection on Filter Base for Turbo Oil 1 ⅛" 20 - 28 Nm (14.8 - 20.7 lb ft)
Supply
Turbo Lubrication Pipe M12 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
Turbo Lubrication Pipe Adapter M12 30 - 40 Nm (22.1 - 29.5 lb ft)
Oil Pan 20 - 28 Nm (14.8 - 20.7 lb ft)
Piston Spray Nozzles M8 12 - 18 Nm (8.9 - 13.3 lb ft)
Electrical Components
Camshaft Sensor M6 Studs 6 - 10 Nm (4.4 - 7.4 lb ft)
M6 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Wiring Bulkhead M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Support Bracket for Injector Wiring M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector Wiring 1.25 - 1.75 Nm (0.92 - 1.29 lb ft)
ECU Cooling Plate M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Outlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Fuel Inlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Crankshaft Speed Sensor M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Coolant Temperature Sensor M14 Screw 17 - 23 Nm (12.5 - 17.0 lb ft)
Oil Pressure / Temperature Sensor M5 Screw 5 - 7 Nm (3.7 - 5.2 lb ft)
Fuel Pressure Sensor 30 - 40 Nm (22.1 - 29.5 lb ft)
Fuel Temperature Sensor M14 17 - 23 Nm (12.5 - 17.0 lb ft)
Air Pressure / Temperature Sensor 5 - 7 Nm (3.7 - 5.2 lb ft)
Engine Oil Level Sensor M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Alternator Support Bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Alternator Tension Bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Starter 37 - 49 Nm (27.3 - 36.1 lb ft)
Fuel System and Components
Feed Pump M8 Studs 10 - 14 Nm (7.4 - 10.3 lb ft)
High Pressure Pump Gear M18 Nut 100 - 110 Nm (73.8 - 81.1 lb ft)
Fuel Pump M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector
First Phase M6 Screw 8.15 - 8.85 Nm (6.0 - 6.5 lb ft)
Second Phase M6 Screw 70 - 80 °
Injector Feed Connector 45 - 55 Nm (33.2 - 40.6 lb ft)
Common Rail M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
High Pressure Fuel Line M14 Fitting 18 - 22 Nm (13.3 - 16.2 lb ft)
High Pressure Pipe Connector M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Filter Bracket M12 Screw 71 - 85 Nm (52.4 - 62.7 lb ft)
Fuel Filter Holder M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Filter Contact + ¾ Turn
Cooling System and Components
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INTRODUCTION

Engine Coolant Inlet M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Fitting on Coolant Inlet 90 ° Elbow 20 - 28 Nm (14.8 - 20.7 lb ft)
Compressor Cooling Pipe 20 - 24 Nm (14.8 - 17.7 lb ft)
Engine Coolant Drain Collector M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Water Pump M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Belt Tensioner M10 37 - 49 Nm (27.3 - 36.1 lb ft)
Idler Pulleys M10 37 - 49 Nm (27.3 - 36.1 lb ft)
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INTRODUCTION
Basic instructions - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. Some information could not be updated due to modifications of a technical or commercial
type, or changes to the laws and regulations of different countries.
In case of questions, refer to your CNH Sales and Service Networks.
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INTRODUCTION
Torque - Minimum tightening torques for normal assembly

METRIC NON-FLANGED HARDWARE
NOM. LOCKNUT LOCKNUT
SIZE CL.8 CL.10
CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9
CLASS 8 NUT CLASS 10 NUT BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.2 N·m (19 lb 2.9 N·m (26 lb 3.2 N·m (28 lb 4.2 N·m (37 lb 2.9 N·m (26 lb
M4 2 N·m (18 lb in)
in) in) in) in) in)
4.5 N·m (40 lb 5.9 N·m (52 lb 6.4 N·m (57 lb 8.5 N·m (75 lb 5.8 N·m (51 lb
M5 4 N·m (36 lb in)
in) in) in) in) in)
7.5 N·m (66 lb 10 N·m (89 lb 11 N·m (96 lb 15 N·m (128 lb 6.8 N·m (60 lb 10 N·m (89 lb
M6
in) in) in) in) in) in)
18 N·m (163 lb 25 N·m (217 lb 26 N·m (234 lb 35 N·m (311 lb 17 N·m (151 lb 24 N·m (212 lb
M8
49 N·m (36 lb 70 N·m (51 lb 33 N·m (25 lb 48 N·m (35 lb
M10 37 N·m (27 lb ft) 52 N·m (38 lb ft)
ft) ft) ft) ft)
M12 64 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft) ft)
158 N·m (116 lb 210 N·m (155 225 N·m (166 lb 301 N·m (222 143 N·m (106 lb 205 N·m (151 lb
M16
ft) lb ft) ft) lb ft) ft) ft)
M20
M24
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
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INTRODUCTION
METRIC FLANGED HARDWARE

NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT
SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10
W/CL8.8 W/CL10.9
BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb 3.1 N·m (27 lb
M4
4.9 N·m (43 lb 6.5 N·m (58 lb 7.0 N·m (62 lb 9.4 N·m (83 lb 4.4 N·m (39 lb 6.4 N·m (57 lb
M5
8.3 N·m (73 lb 11 N·m (96 lb 12 N·m (105 lb 16 N·m (141 lb 7.5 N·m (66 lb 11 N·m (96 lb
M6
M8
54 N·m (40 lb 77 N·m (56 lb
M10 40 N·m (30 lb ft) 57 N·m (42 lb ft) 37 N·m (27 lb ft) 53 N·m (39 lb ft)
ft) ft)
93 N·m (69 lb 100 N·m (74 lb 134 N·m (98 lb
M12 70 N·m (52 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft)
M16
M20
607 N·m (447 lb 809 N·m (597 838 N·m (618 lb 1118 N·m (824 552 N·m (407 lb
M24
ft) lb ft) ft) lb ft) ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
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INTRODUCTION
1. Manufacturer's Identification
2. Property Class
3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate
Class 10 properties, and marks 120 ° apart indicate Class 8.
INCH NON-FLANGED HARDWARE

LOCKNUT LOCKNUT
NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT
GrB W/ Gr5 GrC W/ Gr8
SIZE and NUT and NUT
BOLT BOLT
UN-
UN-
PLATED PLATED PLATED
PLATED
or W/ZnCr W/ZnCr
or PLATED
PLATED GOLD GOLD
SILVER
SILVER
8 N·m (71 lb 11 N·m (97 lb 12 N·m (106 16 N·m (142 12.2 N·m (109 lb
1/4 8.5 N·m (75 lb in)
in) in) lb in) lb in) in)
17 N·m (150 23 N·m (204 24 N·m (212 32 N·m (283 17.5 N·m (155 lb 25 N·m (220 lb
5/16
lb in) lb in) lb in) lb in) in) in)
30 N·m (22 lb 40 N·m (30 43 N·m (31 lb 57 N·m (42 lb
3/8 31 N·m (23 lb ft) 44 N·m (33 lb ft)
ft) lb ft) ft) ft)
48 N·m (36 lb 65 N·m (48 68 N·m (50 lb 91 N·m (67 lb
7/16 50 N·m (37 lb ft) 71 N·m (53 lb ft)
ft) lb ft) ft) ft)
74 N·m (54 lb 98 N·m (73 104 N·m (77 139 N·m (103
1/2 76 N·m (56 lb ft) 108 N·m (80 lb ft)
ft) lb ft) lb ft) lb ft)
107 N·m (79 142 N·m (105 150 N·m (111 201 N·m (148 156 N·m (115 lb
9/16 111 N·m (82 lb ft)
lb ft) lb ft) lb ft) lb ft) ft)
147 N·m (108 196 N·m (145 208 N·m (153 277 N·m (204 153 N·m (113 lb 215 N·m (159 lb
5/8
lb ft) lb ft) lb ft) lb ft) ft) ft)
3/4
7/8
630 N·m (465 841 N·m (620 890 N·m (656 1187 N·m 654 N·m (483 lb 924 N·m (681 lb
1
lb ft) lb ft) lb ft) (875 lb ft) ft) ft)
NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in
through 1 in hardware torque specifications are shown in pound-feet.
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INTRODUCTION
INCH FLANGED HARDWARE

NOM- LOCKNUT LOCKNUT
SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and
INAL GrF W/ Gr5 GrG W/ Gr8
NUT NUT
SIZE BOLT BOLT
UNPLATED PLATED UNPLATED PLATED
or PLATED W/ZnCr or PLATED W/ZnCr
SILVER GOLD SILVER GOLD
1/4 9 N·m (80 lb in) 8 N·m (71 lb in)
in) in) in) in)
5/16
44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb
3/8 33 N·m (25 lb ft) 30 N·m (22 lb ft) 43 N·m (32 lb ft)
ft) ft) ft)
71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb
7/16 53 N·m (39 lb ft) 48 N·m (35 lb ft) 68 N·m (50 lb ft)
ft) ft) ft)
108 N·m (80 lb 115 N·m (85 lb 153 N·m (113 104 N·m (77 lb
1/2 81 N·m (60 lb ft) 74 N·m (55 lb ft)
ft) ft) lb ft) ft)
117 N·m (86 lb 156 N·m (115 165 N·m (122 221 N·m (163 157 N·m (116 lb
9/16 106 N·m (78 lb ft)
ft) lb ft) lb ft) lb ft) ft)
162 N·m (119 lb 216 N·m (159 228 N·m (168 304 N·m (225 147 N·m (108 lb 207 N·m (153 lb
5/8
ft) lb ft) lb ft) lb ft) ft) ft)
3/4
7/8
1
IDENTIFICATION
Inch Bolts and free-spinning nuts
20083682 3
Grade Marking Examples
SAE Grade Identification

1 Grade 2 - No Marks 4 Grade 2 Nut - No Marks
2 Grade 5 - Three Marks 5 Grade 5 Nut - Marks 120 ° Apart
3 Grade 8 - Five Marks 6 Grade 8 Nut - Marks 60 ° Apart
47441596 09/10/2012
12
INTRODUCTION
Inch Lock Nuts, All Metal (Three optional methods)
20090268 4
Grade Identification
Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3)
Grade A No Notches No Mark No Marks
Grade B One Circumferential Notch Letter B Three Marks
Grade C Two Circumferential Notches Letter C Six Marks
47441596 09/10/2012
13
INTRODUCTION
Basic instructions - Shop and Assembly

SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up
the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value
indicated on each shim.
ROTATING SHAFT SEALS

For correct rotating shaft seal installation, proceed as follows:
• before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
• thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
• position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction
and position the grooves so that they will deviate the fluid towards the inner side of the seal.
• coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing
lip and the dust lip on double lip seals with grease.
• insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
• whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes contact
with the thrust element, if required.
• to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
O-RING SEALS
Lubricate the O-RING seals before inserting them in the seats, this will prevent them from overturning and twisting,
which would jeopardise sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or
LOCTITE® RTV 598 or LOCTITE® INSTANT GASKET 587 BLUE. Before applying the sealing compound, prepare the
surfaces as directed on product container or as follows:
• remove any incrustations using a metal brush.
• thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts
cleaner.
SPARE PARTS
Only use "CNH Original Parts" or " CNH Parts".
Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same
parts that are assembled during standard production. Only "CNH Original Parts" or " CNH Parts" can offer this
guarantee.
When ordering spare parts, always provide the following information:
• machine model (commercial name) and serial number
• part number of the ordered part, which can be found in the "Microfiches" or the "Service Parts Catalogue", used
for order processing
47441596 09/10/2012
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INTRODUCTION
PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR WELD-

ING
To avoid damage to the electronic/electrical systems, always observe the following:
1. Never make or break any of the charging circuit connections, including the battery connections, when the engine
is running.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the combine or on any header at-
tached to the combine.
• position the welder ground clamp as close to the welding area as possible
• if welding in close proximity to a computer module, then the module should be removed from the combine
• never allow welding cables to lay on, near or across any electrical wiring or electronic component while
welding is in progress
4. Always disconnect the negative cable from the battery when charging the battery in the combine with a battery
charger.
NOTICE: If welding must be performed on the unit, either the combine or the header (if it is attached), the battery
ground cable must be disconnected from the combine battery. The electronic monitoring system and charging system
will be damaged if this is not done.
Remove the battery ground cable. Reconnect the cable when welding is completed.
WARNING
Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.
Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg or vegetables oil. Call physician immediately. EYES: flush with water for 15 minutes
and get prompt medical attention.
84-110
TOOLS
The tools that CNH suggests and illustrate in this manual have been:
• specifically researched and designed for use with CNH machines
• essential for reliable repair operations
• accurately built and rigorously tested so as to offer efficient and long-lasting operation
By using these tools, repair personnel will benefit from:

• operating in optimal technical conditions
• obtaining the best results
• saving time and effort
• working in safe conditions
NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from
the rear, facing in the direction of travel of the machine during operation.
47441596 09/10/2012
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INTRODUCTION
47441596 09/10/2012
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SERVICE MANUAL
Engine
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
Engine - 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

F4HFA413A*E002 , F4HFA613B*E002 , F4HFA613C*E002 , F4HFA613D*E002 , F4HFA613F*E003
Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101

Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102

Crankshaft and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103

Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105

Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106

Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110

Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.114

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206

Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.210

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218

Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250

Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304

47441596 09/10/2012
10
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400
Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

47441596 09/10/2012
10
47441596 09/10/2012
10
Engine - 10
Engine and crankcase - 001
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.001 / 1
Contents
Engine - 10
FUNCTIONAL DATA
Engine
Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine
Service instruction Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankcase
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSTIC
Engine
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
47441596 09/10/2012
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Engine - Engine and crankcase
Engine - Component localisation

Location of main electrical components
CRIL04D081G01 1
(1) Coolant Temperature Sensor (8) Fuel Temperature Sensor

(2) Electro-Injector (9) EDC7 UC31
(3) Rail Pressure Sensor (10) Crankshaft Sensor
(4) Air Temperature/Pressure Sensor (11) Oil Level Sensor
(5) Engine Starter (12) Engine Oil Temperature/Pressure Sensor
(6) Timing Sensor (13) Heating Element for Pre-Post Heating
(7) Solenoid Valve for Pressure Regulator
The NEF F4HFE engines are fully driven by the electronic engine control module, which is assembled directly to the
engine by means of a heat exchanger enabling it's cooling, utilizing rubber buffers to reduce vibration originated by
the engine.
Through the engine control module it is possible to verify the correct working of the engine.
47441596 09/10/2012
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Engine - Service instruction Maintenance procedures

WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
Failure to comply could result in death or serious injury.
W0371A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
CAUTION
Burn hazard!
Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has
cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.
Failure to comply could result in minor or moderate injury.
C0043A
WARNING
Rotating parts!
The engine is running. Keep clear of rotating fans and belts.
W0275A
Engine oil level check

The check can be made using the dipstick (1) placed on
the right hand side of the EDC.
NOTICE: The check must be executed when the engine is
off and possibly cool.
Draw off the rod from it's slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, pro-
ceed cleaning the rod using a clean cloth with no contami-
nation and put it back in it's slot. Draw it off again and check
the level.
In case the level results being close to the tag showing min-
imum level, provide filling lubrication of the engines com-
ponents.
Add oil through the upper top or through the lateral top (2).
During filling operation, the tops must be removed as well
as the rod in order to make the oil flow easier.
OILFILLH 1
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Combustion system inspection

The check must be executed both when the engine off and
when it is running.
The check operation consists in examining the fuel
pipelines running from the tank to the pre-filter (if provided
in the specific equipment), to the filter, to the high pressure
pump and to the rail diffuser and from this last one to the
head.
Special attention must be paid to the connections on the
high pressure pipelines.
Cooling system inspection

The check must be executed both when the engine is off
and when it is running.
Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
verify the status of the pipes specially close to the holding
strips.
Verify that the radiator is clean, the correct working of the
fan flywheels, the presence of any leakage from the con-
nectors, from the manifold and from the radiating unit.
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any
case every two years.
NOTE: In case of new filling, proceed bleeding the system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious inconve-
nience might be caused to the engine due to the presence
of air pockets in the engine's head.
Lubricating system inspection

The check must be executed both when the engine is off
and when it is running.
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan or from the heat exchanger.
Inspection of water presence within the fuel

filter or pre-filter
The components of the common rail system can be dam-
aged very quickly in presence of water or impurity within
the fuel.
Timely proceed operating on the pre-filter (not available on
the engine block) to carry out the drainage of the water
within the feed circuit.
47441596 09/10/2012
10.001 / 5
Inspection / replacement of blow-by filter

The filter in subject has been developed and equipped for
the collection , filtering and condense of the lubricating oil
vapors.
Within the filter unit (1) two cartridge filters are included (2).
The check of the filtering element is carried out by removing
the cover and drawing off the cartridges (2).
86070785_RESIZE 2
Inspection of drive belt tensioning

The drive belt tensioning control is made using an au-
tomatic tensioning device therefore no intervention is
required apart from checking the wear status of the belt
itself.
Inspection and setting of tappet clearance

Adjust clearance between rockers and valves using
setscrew wrench (1), box wrench (3) and feeler gauge (2).
Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
VALVEADJUST 3
Engine oil and filter replacement

Due to the several applications, the pan shape and the
oil quantity can change slightly. However, the following
operations are valid for all applications.
We recommend to carry out the oil drainage when the en-
gine is hot.
Place a proper container for the oil collecting under the pan
connected with drain plug.
Unscrew the plug and then take out the control dipstick and
the inserting plug to ease the downflow of the lubrication oil.
After the complete drainage, screw the plug and carry out
the clean oil filling.
NOTICE: Use only recommended oil or oil having the re-
quested features for the correct engine functioning. In case
of topping up, don't mix oils having different features. If you
don't comply with these rules, the service warranty is no
more valid.
47441596 09/10/2012
10.001 / 6
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
Whereas you replace the lubrication oil, it is necessary to
replace the filter. According to the application the filter can
be located in different positions: the following procedure is
a valid guide for all applications.
The filter is composed of a support and a filtering cartridge.
For the cartridge replacement use the tool 380000670.
NOTE: The engine oil filter has an internal volume of about
1 l (0.3 US gal).
Replace the filtering cartridge with a new one and screw
manually until when the gasket is in contact with the sup-
port.
Tighten by means of the tool 380000670 of three fourth
turn.
Operate the engine for some minutes and check the level
through the dipstick again. If it is necessary, carry out a
topping up to compensate the quantity of oil used for the
filling of the filtering cartridge.
Fuel filter replacement

According to the applications the filters position and the
quantity can change.
However the following operations are valid for all applica-
tions.
Drain the fuel inside the filter operating the water release
screw. Collect the fuel in a container without impurities.
Unscrew the cartridge by using the 380000670.
Collect the eventual fuel inside the filtering cartridge.
Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.
Screw manually the new filtering cartridge until the gasket
is completely on its seat.
Tighten through the tool 380000670 at a 10 - 15 Nm (7 - 11
lb ft) torque.
Alternator belt replacement

Due to several applications the belt run can change very
much.
For applications with automatic belt tensioner, the proce-
dure is the following:
By means of square wrench of proper size, act on point
(A), indicated in the figure, of the automatic belt tensioner
(1) and release the pressure.
Remove the control belt (2) from the driven and intermedi-
ate pulleys.
Replace the worn belt with a new one.
Place the belt on the pulleys and guide rollers.
Place the automatic tightener in order to key the belt in the
functioning position.
Check proper position in the races of the pulleys.
ALTBELT 4
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Crankcase Bore - Check

Prior operation:
Connecting rod and piston - Remove (10.105)
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 mi- BACD04APH104ASA 1
crometer for zero-setting.
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.
NOTE: In case of regrinding, all bores shall have the same
oversize 0.4 mm (0.016 in).
BAIL07APH372AMA 2
Next operation:
Crankcase - Check (10.001)
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Crankcase - Check
Prior operation:
Crankshaft - Remove (10.103)
Main Bearing Housings

Check main bearing housings as follows:
• fit the main bearing caps on the supports with-
out bearings
• tighten the fastening screws to the specified
torque
• use the proper internal gauge to check whether
the housing diameter is falling within the spec-
ified value.
Replace if a higher value is found.
Checking head supporting surface on cylinder unit

When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm (0.003 in)
Check cylinder unit operating plug (1) conditions, replace
them in case of uncertain seal or if rusted.
CRIL04J058A01 1
Next operation:
Crankshaft Journal - Clearance (10.103)
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Engine - Troubleshooting
Problem Possible Cause Correction
Engine does not develop Clogged air cleaner Inspect and replace air cleaner if necessary
full power
Fuel line obstructed Check for crimped fuel line. Inspect fuel
lifter for cleanliness
Improper injection timing Repair/replace components as required
Improper nozzle injection pressure and an- Check injection timing, inspect for proper
gle injection pressure and angle
Low cylinder compression Check engine compression
Insufficient fuel injection Repair at authorized shop
Improper valve lash adjustment Adjust valves to correct tolerances
Burned, worn or sticking valves Inspect and replace as necessary
Blown head gasket Replace head gasket
Worn or sticking piston rings Overhaul as necessary
Faulty engine stop solenoid Replace stop solenoid
Low oil pressure Engine oil level low Fill to proper level
Wrong grade of oil Replace with correct grade oil
Clogged oil pump filter Change oil and filter
Faulty oil pressure relief valve Replace relief valve
Worn oil pump drive shaft gears, or broken Inspect oil system and components. Re-
oil pipe place defective components
Excessive main or connecting rod bearing Replace bearings or shaft if necessary
clearances
Oil pump axial clearance not properly set Check pump clearance and shim as
needed to proper tolerance.
Engine will not stop Faulty engine stop solenoid Replace the stop solenoid
Faulty starter switch Replace starter switch
Low cylinder Burned, worn or sticking valves Replace valves
compression
Bent valve stem Replace valves
Broken or weak valve spring Replace valve spring
Blown cylinder head gasket Replace head gasket
Worn or sticking piston rings Replace piston rings
Scored piston Replace piston
Poor engine idling Improper injection timing Correct the injection timing
Air in injection pump Purge air from the system
Improper governor adjustment Adjust the governor
Oil pressure warning light Bulb burnt out Replace the bulb
fails to operate
Oil pressure sensor is faulty Replace oil pressure sensor
Warning light circuit faulty Replace warning light circuit
Engine knocks Diluted or thin oil Change engine oil and filter
Insufficient oil supply Check engine oil level
Low oil pressure Inspect lube system for restrictions
Worn crankshaft thrust bearing Replace thrust bearing
Excessive flywheel runout Replace flywheel
Excessive connecting rod or main bearing Replace bearings
clearance
Seized bearing Replace bearing and affected component if
necessary
Clogged oil passage Clean out oil passages
Bent or twisted connecting rod Replace connecting rod
Crankshaft journals out of round Rework or replace crankshaft
Excessive piston to cylinder bore clearance Replace piston with correct oversized pis-
ton
Excessive piston ring side clearance Replace piston rings
Broken or damaged ring Replace piston ring
Excessive piston pin clearance Replace piston pin or bushing
47441596 09/10/2012
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Seized piston Replace piston and, if necessary, engine
block
Piston pin retainer loose or missing Replace retainer
Improper valve lash adjustment Adjust valve lash to specification
Worn valve lifter Replace valve lifter
Excessive timing gear backlash Replace all timing gears
Excessive oil Engine oil level too high Remove excess oil
consumption
Leakage in cylinder head gasket Replace head gasket
Oil loss past the pistons and rings Replace piston rings
Worn, broken, or sticking piston rings Replace piston rings
Clogged return hole of oil ring Unclog return oil hole and replace rings
Worn valves, guides, or seals Replace valves, guides, or seals
Leakage past oil seals and gaskets Replace leaking seals and gaskets
External oil leaks from engine Locate leaks and repair
Engine overheats Insufficient amount of coolant in the radia- Fill coolant to proper level
tor
Hose connection leaking or collapsed hose Tighten hose connection or replace hose
Radiator leakage Locate leak and repair or replace radiator
Loose, worn, or broken V-belt Adjust V-belt tension or replace belt
Radiator fins bent or clogged Straighten out and clean fins
Radiator cap not sealing Replace radiator cap
Thermostat operating improperly Replace thermostat cap
Insufficient amount of oil Fill to proper level
Water pump operating improperly Replace water pump
Improper valve clearance Adjust valve clearance to specification
Restriction in exhaust system Remove restriction
Improperly installed cylinder head gasket Reinstall head gasket in proper position
Rust and/or scale clogged water ports Backflush cooling system
Extended engine idling Shutdown engine during extended idling
periods
Temperature gauge fails Faulty temperature sender Replace temperature switch
to reach normal operating
temperature
Faulty thermostat Replace thermostat
Faulty temperature gauge Replace temperature gauge
Engine does not start Faulty starter switch Replace switch
Insufficient charging or complete discharge Check battery and charging system
of battery
Lack of fuel Fill fuel tank
Air mixed in fuel system Inspect fuel system for tightness
Clogged fuel filter Replace fuel filter
Irregular or faulty fuel supply Replace fuel supply
Glow plug not heating Replace glow plug
Improper lubricating oil viscosity Replace lube oil
Clogged air cleaner Replace air cleaner
Faulty engine stop solenoid Replace solenoid
Burned out fuse Replace fuse
Excessive Exhaust Smoke Air cleaner dirty or restricted Replace air cleaner
Excessive fuel delivery Adjust fuel delivery
Engine stops while Lack of fuel in fuel tank Fill fuel tank
operating
Clogged fuel filter Replace filter
Air mixed in fuel system Inspect for air leaks
Faulty engine stop solenoid Replace solenoid
Burned out fuse Replace fuse
Undesirable exhaust color Unsuitable fuel Replace fuel
(black or light grey)
Excess injection Replace injection pump
Faulty engine component Replace as required
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Over loading Decrease load
Clogged air filter Replace filter
Undesirable exhaust Excess engine oil Drain oil to proper oil level
smoke (white or pale)
Improper lubricating oil viscosity Replace oil with specified viscosity
Faulty injection timing Replace injection pump
47441596 09/10/2012
10.001 / 12
Index
Engine - 10

Crankcase - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Service instruction Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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47441596 09/10/2012
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Engine - 10
Cylinder heads - 101
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.101 / 1
Contents
Engine - 10
SERVICE
Valve cover
Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Valves
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Valve guide
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve seat
Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
47441596 09/10/2012
10.101 / 2
Engine - Cylinder heads
Valve cover Rocker housing - Remove

Prior operation:
Valve cover - Remove (10.101)
1. Unscrew the nuts (3) from the top of the electro-in-

jectors (4) and disconnect the electrical wires.
2. Unscrew the bolts (1) securing the rocker housing
(2).
3. Remove the rocker housing (2) and gasket from the
cylinder head.
ROCKERHOUSING 1
Next operation:
Valve cover Rocker housing - Install (10.101)
47441596 09/10/2012
10.101 / 3
Valve cover Rocker housing - Install

Prior operation:
Rocker arm - Install (10.106)
1. Check the condition of the electrical cables (5) and

connectors (3), replace if damaged by removing the
screw (4).
2. Install a new gasket (1) on the support (2).
VALVEBASEDH 1
3. Install the housing (2) and tighten the screws (1) to

the specified torque.
NOTE: Before any assembly operation always verify that
the hole and bolt threads have no evidence of wear or dirt.
VALVEBASEDH2 2
4. Connect the electrical cables (1) to the injectors (3)

and use the torque wrench (4) to tighten the fastening
nuts (2) to the specified torque.
VALVEBASEDH3 3
Next operation:
Valve cover - Install (10.101)
47441596 09/10/2012
10.101 / 4
Valve cover - Remove

1. Remove the nuts securing the valve cover to base.
2. Remove valve cover and gasket.
BACD04APH004ASA 1
Next operation:
47441596 09/10/2012
10.101 / 5
Valve cover - Install

Prior operation:
1. Install a new gasket (2) on the valve cover (1).

2. Place the valve cover (1) on its seat, and install the
mounting bolts.
VALVECOVER 1
47441596 09/10/2012
10.101 / 6
Cylinder head - Remove

Prior operation:
Fuel injectors - Remove (10.218)
1. Remove the fastening screws (1) from the cylinder

head (2).
NOTE: The highlighted screws are shorter.
CYLHEADF4DF4HE 1
2. Hook brackets (1) with suitable lifting chains and re-

move the cylinder head (2) from the cylinder block
using a hoist.
CYLHEADREMOVE 2
Next operation:
Cylinder head - Check (10.101)
47441596 09/10/2012
10.101 / 7
Cylinder head - Check

Prior operation:
Cylinder head - Remove (10.101)
Checking cylinder head wet seal

This check shall be performed using the proper tools.
1. Use a pump to fill with water heated to approximately
90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of
pressure.
2. Replace the core plugs (1) if leaks are found, use the
proper punch for their removal/refitting.
NOTE: Before refitting, smear the plug surfaces with water
repellent sealant.
3. Replace the cylinder head if leaks are found.
80709 1
Checking cylinder head supporting surface

4. Distortion found along the whole cylinder head shall
not exceed 0.20 mm (0.008 in).
If higher values are found, grind the cylinder head
according to values and indications shown in the fol-
lowing figure.
5. The rated thickness (A) for the cylinder head is
104.75 - 105.25 mm (4.124 - 4.144 in). Maximum
metal removal shall not exceed thickness (B) by 1
mm (0.039 in).
NOTE: After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
70325 2
Next operation:
Cylinder head - Install (10.101)
47441596 09/10/2012
10.101 / 8
Cylinder head - Install

Prior operation:
Cylinder head - Check (10.101)
1. Check the cleanliness of the cylinder head and en-

gine block coupling surface.
2. Taking care not to foul the cylinder head gasket, set
the gasket (1) with the marking "TOP" facing the
head.
3. The arrow shows the point where the gasket thick-
ness is given.
80714 1
4. There are two head gasket thicknesses, ( 1.25 mm

Type A and 1.15 mm Type B).
To determine the correct head gasket to use, piston
protrusion must be measured.
• For each piston, measure protrusion in two
places 180 ° apart, at a distance of 45 mm (1.8
in) from the center of the piston S1 and S2.
Then calculate the average:
• Repeat the operation for pistons 2, 3, 4, 5 and

PROTRUSION 2
6 and calculate the average value.
• If S is > 0.40 mm (0.016 in) use seal type A.

• If S is < 0.40 mm (0.016 in) use seal type B.
5. Before using the fixing screws again, measure them
twice as indicated in the picture, checking D1 and D2
diameters:
if D1 - D2 < 0.1 mm (0.004 in) the screw can be
utilized again;
If D1 - D2 > 0.1 mm (0.004 in) the screw must be
replaced.
the hole and bolt threads have no evidence of dirt or wear.
BACD04APH224ASA 3
47441596 09/10/2012
10.101 / 9
6. Using a suitable hoist (1), set the cylinder head (2)

on the engine block.
CYLHEADREMOVE 4
7. Tighten the cylinder head bolts (2) in the following

order using tool 380000304 for the angle tightening
procedure.
1. Tighten with a torque wrench.
• 12x1.75x130 are torqued to 30 - 40 Nm
(22 - 30 lb ft).
• 12x1.75x150 are torqued to 50 - 60 Nm
(37 - 44 lb ft).
2. Turn the bolt clockwise 85 - 95 °.
3. Turn the bolt clockwise an additional 85 - 95 °.
CYLINDERHEADDH 5
70476 6
Tightening sequence for the 6 cylinder engine.
A = Front of engine
Next operation:
Fuel injectors - Install (10.218)
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10.101 / 10
Valves - Remove
Prior operation:
Cylinder head - Remove (10.101)
1. Intake (1) and exhaust (2) valves heads with the

same diameter. The central notch of the exhaust
valve (2) head distinguishes it from the intake valve.
NOTE: Should cylinder head valves not be replaced, num-
ber them before removing in order to refit them in the same
position.
A = intake side - S = exhaust side
BACD04APH145ASA 1
2. Valve removal shall be performed using tool

380000302 (1) and pressing the cap (3) so that
when compressing the springs (4) the keepers (2)
can be removed. Then remove the cap (3) and the
springs (4).
3. Repeat this operation for all the valves.
4. Overturn the cylinder head and withdraw the valves
(5).
BACD04APH146ASA 2
5. Remove the sealing rings (1) and (2) from the valve
guide.
NOTE: Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
BACD04APH147ASA 3
Next operation:
Valves - Install (10.101)
47441596 09/10/2012
10.101 / 11
Valves - Measure
Prior operation:
Valves - Cleaning (10.101)
VALVE 1
INTAKE AND EXHAUST VALVE MAIN DATA
1. Check the valve stem (1) using a micrometer (2), it
shall be 6.970 - 6.990 mm (0.274 - 0.275 in).
BAPH04APH152ASA 2
Next operation:
47441596 09/10/2012
10.101 / 12
Valves - Cleaning
Prior operation:
Valves - Remove (10.101)
1. Remove carbon deposits from valves using the

proper metal brush.
2. Check that the valves show no signs of seizing, scor-
ing, or cracking.
3. If necessary, rectify the valve seats, taking away the
least amount of material possible.
BAPH04APH151ASA 1
Next operation:
Valves - Measure (10.101)
47441596 09/10/2012
10.101 / 13
Valves Spring - Check

Prior operation:
Before installing the valve springs use tool to check the

springs flexibility. Compare load and elastic deformation
data with those of the new springs in the following table:
50676 1
Height Weight applied

(H) - 47.75 mm (1.880 in) None
(H1) - 35.33 mm (1.391 in) (P) - 320.8 - 358.8 N (72.1 - 80.7 lb)
(H2) - 25.2 mm (0.992 in) (P1) - 702 - 780 mm (27.6 - 30.7 in)
Next operation:
47441596 09/10/2012
10.101 / 14
Valves - Install
Prior operation:
Valves - Cleaning (10.101)
1. Lubricate the valve stems (1) and fit them into the rel-
evant valve guides according to the position marked
at removal.
2. Fit the sealing rings (2) and (3) on the valve guide.
NOTE: Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
80713 1
3. Position on the cylinder head: the springs (4) the

upper cap (3) use tool 380000302 (1) to compress
the spring (4) and lock the parts to the valve (5) by
the keepers (2).
BACD04APH146ASA 2
Next operation:
Cylinder head - Install (10.101)
47441596 09/10/2012
10.101 / 15
Valve guide - Clearance

Prior operation:
1. Use a magnetic base dial gauge (1) set as shown in

the figure, the assembling clearance shall be 0.052 -
0.092 mm (0.002 - 0.004 in).
2. Turn the valve (2) and check that the centering error
is not exceeding 0.03 mm (0.001 in).
80710 1
3. Use a bore dial gauge to measure the inside diameter

of the valve guides, the read value shall comply with
the value shown in the figure.
0B0O200405BACD0 2
Next operation:
47441596 09/10/2012
10.101 / 16
Valve seat - Regrind

Prior operation:
Should slight scratches or burns be found, go over with

the adequate tool (1) according to the inclination values
indicated as follows:
80711 1
70331 2
VALVE SEAT MAIN DATA (4 CYL.)
Should valve seats be not reset just by regrinding, replace
them with spare ones. Using a suitable tool, remove as
much material as possible from the valve seats (take care
not to damage the cylinder head) until they can be ex-
tracted from the cylinder head using a punch.
1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0
°F) and using the proper punch, fit the new valve
seats, previously cooled, into the cylinder head.
2. Therefore, with an adequate tool, go over the valve
seats according to the values stated in the previous
figure.
47441596 09/10/2012
10.101 / 17
70332 3
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
3. After regrinding, check that the valve (3) sink-
ing value is the specified one by using the base
380000364 (2) and the dial gauge 380000228 (1).
80712 4
Next operation:
47441596 09/10/2012
10.101 / 18
Index
Engine - 10

Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve cover Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valve cover Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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47441596 09/10/2012
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Engine - 10
Pan and covers - 102
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.102 / 1
Contents
Engine - 10
SERVICE
Engine oil pan

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine block cover
Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Timing gear housing
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
47441596 09/10/2012
10.102 / 2
Engine - Pan and covers
Engine oil pan - Remove

1. Remove the bolts (2) surrounding the oil sump (1).
2. Remove the plate (2).
3. Disconnect the oil sump (1) from the engine block.
NOTE: The shape and dimensions of the oil pan and of
the suction tube may vary according to the application of
the engine. However, the procedures described are still
applicable.
OILPANH 1
4. Remove the screws (4) and (1) and disassemble the

oil suction tube (5). Remove the screws (2) and dis-
assemble the stiffening plate (3).
OILPICKUPTUBEH 2
Next operation:
Engine oil pan - Install (10.102)
47441596 09/10/2012
10.102 / 3
Engine oil pan - Install

Prior operation:
Engine oil pan - Remove (10.102)
1. Fit the plate (3), the oil pick up tube (5) and tighten
the fastening screws (1), (2) and (4) to the specified
torque.
OILPICKUPTUBEH 1
2. Set the gasket on the oil sump.

NOTE: The pictures of the instructions relating to the oil
pan and to the suction pipe may not reflect the actual shape
and dimensions of your engine equipment. However, the
procedures described are still applicable.
OILPANH2 2
3. Fit the oil sump (1) on the engine block and apply
the mounting plate (3). Tighten the bolts (2) to the
specified torque.
the hole and bolt threads have no evidence of dirt or wear.
OILPANH 3
47441596 09/10/2012
10.102 / 4
Engine block cover Front - Remove

Prior operation:
Crankshaft damper - Remove (10.110)
1. Remove the screws (1) from the front cover. Be sure

to remove the two screws (3) underneath the cover.
NOTE: Take note of screw (1) assembling positions since
they have different lengths.
2. Remove the front cover from the cylinder block.
FRONTCOVERH 1
Next operation:
Engine block cover Front - Cleaning (10.102)
47441596 09/10/2012
10.102 / 5
Engine block cover Front - Cleaning

Prior operation:
Engine block cover Front - Remove (10.102)
1. Remove the sealing ring (2) from the front cover (1).
FRONTCOVERH2 1
2. Clean the sealing surfaces and apply LOCTITE

5205.
FRONTCOVERG 2
Next operation:
Engine block cover Front - Install (10.102)
47441596 09/10/2012
10.102 / 6
Engine block cover Front - Install

Prior operation:
Engine block cover Front - Cleaning (10.102)
1. Install the front cover (2) and tighten the mounting

bolts (1) to the specified torque.
FRONTCOVERD3 1
Next operation:
Crankshaft damper - Install (10.110)
47441596 09/10/2012
10.102 / 7
Engine block cover Rear - Remove

Prior operation:
Engine flywheel - Remove (10.103)
1. Remove the retaining bolts (2) from the rear cover

(1) and withdrawal the cover.
NOTE: Take note of the bolt location due to the different
lengths. This will aid in ease of assembly.
REARCOVERH3 1
Next operation:
Engine block cover Rear - Cleaning (10.102)
47441596 09/10/2012
10.102 / 8
Engine block cover Rear - Cleaning

Prior operation:
Engine block cover Rear - Remove (10.102)
1. Clean the rear cover and it's mating surface on the

timing gear cover.
NOTE: A perfect seal is only obtained by completely clean-
ing the surface to seal. Any imperfection should be cor-
rected as soon as possible. Avoid using excess sealant.
Excessive sealant could squeeze out the sides and cause
blockage of lubrication passages.
2. Apply a thin bead of LOCTITE 5205 (1), a few mil-
limeters thick, to the sealing surface of the cover.
NOTE: After applying the sealant, the cover should be as-
sembled within 10 to 20 minutes.
REARCOVERH 1
Next operation:
Engine block cover Rear - Install (10.102)
47441596 09/10/2012
10.102 / 9
Engine block cover Rear - Install

Prior operation:
NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or
dirt.
1. Install the cover (1) onto the timing gear housing and
install the bolts in same location that they were re-
moved.
2. Tighten them to the prescribed torque.
REARCOVERH2 1
Next operation:
Engine flywheel - Install (10.103)
47441596 09/10/2012
10.102 / 10
Timing gear housing - Remove

1. Remove the screws (2) and disconnect the timing
gear case (1) from the engine block.
NOTE: Mark locations of mounting screws (2) since they
are different sizes. This will make assembly much easier.
TIMINGGEARHOUSI 1
Next operation:
Timing gear housing - Cleaning (10.102)
47441596 09/10/2012
10.102 / 11
Timing gear housing - Cleaning

Prior operation:
Timing gear housing - Remove (10.102)
1. Clean the timing gear housing (1) and it's mating sur-
face on the engine block.
NOTE: A perfect seal is only obtained by completely clean-
ing the surface to seal. Any imperfection should be cor-
rected as soon as possible. Avoid using excess sealant.
Excessive sealant could squeeze out the sides and cause
blockage of lubrication passages.
2. Apply a thin bead of LOCTITE 5205 (2), a few mil-
limeters thick, to the sealing surface of the housing.
NOTE: After applying the sealant, the housing should be
assembled within 10 to 20 minutes.
GEARCASESEAL 1
Next operation:
Timing gear housing - Install (10.102)
47441596 09/10/2012
10.102 / 12
Timing gear housing - Install

Prior operation:
Timing gear housing - Cleaning (10.102)
NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.
1. Install the housing (1) on the engine block.
2. Insert the fastening bolts in the same position found
upon disassembly and tighten them to the prescribed
torque.
GEARCASEINSTALL 1
47441596 09/10/2012
10.102 / 13
Index
Engine - 10

Engine block cover Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine block cover Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
47441596 09/10/2012
10.102 / 14
Engine - 10
Crankshaft and flywheel - 103
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.103 / 1
Contents
Engine - 10
SERVICE
Engine flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crankshaft oil seal
Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft gears
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main bearings
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
47441596 09/10/2012
10.103 / 2
Engine - Crankshaft and flywheel
Engine flywheel - Remove

1. Insert tool 380000988 (2) into flywheel housing (1) to
keep the flywheel (3) from rotating.
FLYWHEELH 1
2. Loosen two bolts opposite each other and place two

guide pins (2) in place of the bolts.
3. Remove the remaining bolts (4) figure 1 securing the
flywheel (1) to the crankshaft.
4. Remove the flywheel locking tool from the flywheel
housing.
5. Insert two bolts of medium length into the threaded
holes (4) at the top of the flywheel to sling the fly-
wheel with a hoist.
6. Remove the flywheel (1) from it's housing.
FLYWHEEL2H 2
Next operation:
Engine flywheel - Check (10.103)
47441596 09/10/2012
10.103 / 3
Engine flywheel - Check

Prior operation:
1. Check the supporting surface of the clutch plate (1)

and if it is scratched, it is necessary to carry out turn-
ing.
2. Check ring gear teeth (2), if breakage or excessive
wear is found, remove the ring gear from the engine
flywheel using a suitable hammer.
3. Heat the ring gear to 150 °C (302 °F)for 15 to 20
minutes.
4. Install the ring gear with the chamfering on the inside
diameter facing the flywheel.
FLYWHEELH3 1
Next operation:
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10.103 / 4
Engine flywheel - Install

Prior operation:
Engine flywheel - Check (10.103)
1. Install two guide pins (2) having suitable length into

crankshaft (3) holes.
2. Using the proper sling and hoist, install the flywheel
(1).
FLYWHEELH4 1
3. Apply tool 380000988 (2) to the flywheel housing to

stop rotation of the flywheel (3).
4. Tighten the bolts (1) securing the flywheel (3) to the
crankshaft (4).
FLYWHEELH5 2
5. Tighten the flywheel bolts (1) in two stages:

1. Torque bolts to 26 - 34 Nm (19 - 25 lb ft).
2. Finish by turning the bolts an additional 55 - 65
°.
NOTE: Torquing to an angle is performed by using the tool
380000304.
Before any assembly operation always verify that the hole
and bolt threads have no evidence of wear or dirt.
FLYWHEELH6 3
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Crankshaft oil seal Front seal - Remove

Prior operation:
1. Remove the ring sealing the engine's driving shaft

from the front cover (6). Use the tool (4) to operate
on the front bar hold of the driving shaft. Through the
steering holes of the tool, perforate the inside hold-
ing ring (1) with a straight way drill with a diameter of
3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).
Fix the tool to the ring tightening the six screws (5)
provided with the equipment. Then proceed remov-
ing the ring (2) by tightening the screw (3).
MAINSEALDH 1
2. Using the specific tie rod (3) of the tool 380000669

and the ancillary lever (4), remove the external hold-
ing ring (2) from the front cover (1).
EXHOLDRINGDH 2
Next operation:
Crankshaft oil seal Front seal - Install (10.103)
47441596 09/10/2012
10.103 / 6
Crankshaft oil seal Front seal - Install

Prior operation:
Crankshaft oil seal Front seal - Remove (10.103)
1. Apply tool (4) to the front crankshaft tang (6) and

secure it by screws (5) and install the new sealing
ring (7). Position part (2) on part (4), tighten nut (3)
until completing installation of the sealing ring (7) into
the front cover (1).
BACD04APH074ASA 1
Next operation:
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10.103 / 7
Crankshaft oil seal Rear seal - Remove

Prior operation:
1. Remove the holding ring of the flywheel cover box

using the tool (3) to operate on the driving shaft's
back bar hold (5).
2. Through the steering holes of the tool, perforate the
inside holding ring with a straight way drill bit with a
diameter of 3.5 mm (0.138 in) for the depth of 5 mm
(0.197 in).
3. Fix the tool (3) to the ring tighten the six screws (4)
provided with the equipment.
4. Then proceed removing the ring (1) by tightening the
screw (2).
REARMAINSEALDH 1
5. Using a specific tie rod (3) of the tool 380000669 and

an ancillary lever (4), remove the external holding
ring (2)from the rear cover (1).
EXHOLDRINGDH 2
Next operation:
47441596 09/10/2012
10.103 / 8
Crankshaft oil seal Rear seal - Install

Prior operation:
Crankshaft oil seal Rear seal - Remove (10.103)
1. Apply tool (6), to the rear crankshaft tang (5), secure

it by screws (4) and install the new sealing ring (3).
Position part (1) on part (5), tighten nut (2) until com-
pleting installation of the sealing ring (3) into the fly-
wheel housing (7).
BACD04APH219ASA 1
Next operation:
47441596 09/10/2012
10.103 / 9
Crankshaft - Remove
Prior operation:
Main bearings - Remove (10.103)
1. Use tool 380000362 (2) and hoist to remove the

crankshaft (1) from the block.
BACD04APH057ASA 1
Next operation:
Main bearings - Install (10.103)
47441596 09/10/2012
10.103 / 10
Crankshaft - Measure
Prior operation:
Crankshaft - Remove (10.103)
Grind journals and crank pins if seizing, scoring or exces-

sive ovalization are found. Before grinding the pins (2)
measure them with a micrometer (1) to decide the final di-
ameter to which the pins are to be ground.
NOTE: It is recommended to insert the found values in the
table below.
NOTICE: Journals and crank pins shall always be ground
to the same undersize class.
Journals and crank pins undersize shall be marked on the
side of the crank arm No.1.
For undersized crank pins: letter M
For undersized journals: letter B
For undersized crank pins and journals: letters MB. BACD04APH108ASA 1
Measuring journals and crank pins
BACD04APH186FSA 2
Fill this table with crankshaft journal and crank pin measured values
* Rated value
47441596 09/10/2012
10.103 / 11
ZEIL06EN0183F0B 3
Crankshaft tolerances
* Measured on a radius greater than 45.5 mm (1.791 in)

** 0.500 mm (0.020 in) between adjacent main journals
Tolerances Tolerance Characteristic Graphic Symbol

Roundness
Shape
Cilindricity
Parallelism
Direction Verticality
Straightness
Position Concentricity or coaxiality
Circular oscillation
Oscillation
Total oscillation
Levels of importance for product characteristics Graphic Symbol

Critical
Important
Secondary
Next operation:
Crankshaft Journal - Clearance (10.103)
47441596 09/10/2012
10.103 / 12
Crankshaft Journal - Clearance

Prior operation:
Crankshaft - Measure (10.103)
1. Install the crankshaft (1).

2. Check the backlash between crankshaft main jour-
nals and the relevant bearings as follows:
BACD04APH057ASA 1
3. Clean accurately the parts and remove any trace of

oil.
4. Position a piece of calibrated wire (3) on the crank-
shaft pins (4) so that it is parallel to the longitudinal
axis;
5. Fit caps (1), including the half bearings (2) on the
relevant supports.
BACD04APH112ASA 2
NOTE: Before using the fixing screws again, measure

them twice as indicated in the picture, checking (D1) and
(D2) diameters:
if (D1)- (D2) < 0.1 mm (0.004 in) the screw can be utilized
again;
if (D1)- (D2) > 0.1 mm (0.004 in) the screw must be re-
placed.
80621 3
47441596 09/10/2012
10.103 / 13
6. Tighten the pre-lubricated screws (1) in the following

three successive stages:
STAGE 1: with torque wrench to 44 - 56 Nm (32.5 -
41.3 lb ft).
STAGE 2: with torque wrench to 74 - 86 Nm (54.6 -
63.4 lb ft).
BACD04APH058ASA 4
7. STAGE 3: with tool 380001001 (1) set as shown,

tighten the screws (2) with 85 - 95 ° angle.
BACD04APH113ASA 5
8. Remove the caps from the supports.

9. The backlash between the main bearings and the
pins is found by comparing the width of the calibrated
wire (2) at the narrowest point with the scale on the
envelope (1) containing the calibrated wire.
The numbers on the scale indicate the backlash in
mm. Replace the half bearings and repeat the check
if a different backlash value is found. Once the spec-
ified backlash is obtained, lubricate the main bear-
ings and fit the supports by tightening the fastening
screws as previously described.
BACD04APH114ASA 6
Checking crankshaft end play

10. This check is performed by setting a magnetic base
dial gauge (2) on the crankshaft (3) as shown in the
figure, standard value is 0.068 - 0.41 mm (0.003 -
0.016 in).
If higher value is found, replace main thrust half bear-
ings of the second last rear support (1) and repeat the
clearance check between crankshaft pins and main
half bearings.
BACD04APH115ASA 7
47441596 09/10/2012
10.103 / 14
Crankshaft gears - Replace

Check that gear toothing (1) is not damaged or worn, oth-
erwise remove it from the crankshaft (2) using the proper
puller (3).
When installing the new gear, heat it to 180 °C (356 °F) for
10 minutes in an oven and then key it to the crankshaft.
CRIL04J068A01 1
47441596 09/10/2012
10.103 / 15
Main bearings - Remove

Prior operation:
1. Remove the screws (1) and the main bearing caps

(2).
BACD04APH043ASA 1
2. The second to last main bearing cap (1) and the rele-
vant support are fitted with shoulder half-bearing (2).
NOTE: Take note of the lower and upper half-bearing as-
sembling positions since in case of reuse they shall be fitted
in the same position found at removal.
BACD04APH044ASA 2
Next operation:
Main bearings - Install (10.103)
47441596 09/10/2012
10.103 / 16
Main bearings - Install

Prior operation:
Main bearings - Remove (10.103)
NOTE: Refit the main bearings that have not been replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 - 0.500
mm (0.010 - 0.020 in) undersize on the internal diameter.
Clean accurately the main half bearings (1) having the lu-
bricating and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
BACD04APH056ASA 1
NOTICE: Do not try to adapt the bearings.
Next operation:
Engine oil pan - Install (10.102)
47441596 09/10/2012
10.103 / 17
Index
Engine - 10

Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Crankshaft gears - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main bearings - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Main bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
47441596 09/10/2012
10.103 / 18
Engine - 10
Connecting rods and pistons - 105
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.105 / 1
Contents
Engine - 10
FUNCTIONAL DATA
Connecting rod and piston

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Connecting rod and piston

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piston
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting rod bearing
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Piston pin bushings
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Engine - Connecting rods and pistons
Connecting rod and piston - Overview
BAPH04APH144ASA 1
(1) Stop rings (5) Bolts

(2) Pin (6) Half bearings
(3) Piston (7) Connecting rod
(4) Split rings (8) Bushing
NOTE: The pistons are supplied spare with the following sizes:
- Standard
- 0.4 mm (0.016 in) oversize.
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Connecting rod and piston - Remove

Prior operation:
1. Loosen the fixing screws (1) and remove the rod caps
(2).
2. Withdraw the piston including the connecting rod
from the top of the engine block.
3. Repeat these steps for the remaining cylinders.
NOTE: Keep the half bearings into their housing since in
case of use they shall be fitted in the same position found
at removal.
BACD04APH042ASA 1
Next operation:
Connecting rod and piston - Install (10.105)
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Connecting rod and piston Connecting rod - Measure
BACD04APH131BSA 1
* Value for the inside diameter to be obtained after driving in connecting rod small end and grinding.
NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recom-
mended not to smooth the knurls.
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CRIL04D023F 2
NOTE: Every connecting rod is marked as follows:
(1) - On the body and cap with a number showing their coupling and the corresponding cylinder. In case of replace-
ment, it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.
(2) - On the body with a letter showing the weight of the connecting rod assembled at production:
- V - 1820 - 1860 g (64.2 - 65.6 oz) (yellow marking)
- W - 1861 - 1900 g (65.6 - 67.0 oz) (green marking)
- X - 1901 - 1940 g (67.1 - 68.4 oz) (blue marking)
Spare connecting rods are of the - W - class with a green marking. Material removal is not allowed.
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Connecting rod and piston - Assemble

Prior operation:
Piston Pin - Remove (10.105)
1. The piston crown is marked as follows:

1. Part number and design modification number.
2. Arrow showing piston assembling direction into
cylinder.
3. Manufacturing date.
4. Stamp indicating the ring carrier US inspection.
BACD04APH136ASA 1
2. Connect piston (2) to connecting rod (4) with pin (3)

so that the reference arrow (1) for fitting the piston (2)
into the cylinder barrel and the numbers (5) marked
on the connecting rod (4) are read as shown in the
figure.
BACD04APH137ASA 2
3. Position the piston (3) on the connecting rod accord-

ing to the diagram shown in the figure and fit the pin
(1) and stop at the stop rings (2).
BACD04APH138ASA 3
Next operation:
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Connecting rod and piston - Install

Prior operation:
Connecting rod and piston Connecting rod - Install (10.105)
1. Lubricate accurately the pistons, including the split

rings and the cylinder barrel inside.
2. Use band 380000325 (1) to fit the connecting rod
- piston assembly (2) into the cylinder barrels and
checking the following:
MID0332A 1
The number of each connecting rod shall correspond to the

cap coupling number.
Split ring openings shall be displaced with each other by
120 °.
Connecting rod - piston assemblies shall have the same
weight.
The arrow (1) marked on the piston crown shall be facing
the front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle position.
BACD04APH061ASA 2
Next operation:
Connecting rod and piston Connecting rod - Install (10.105)
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Piston - Measure
Prior operation:
Piston - Remove (10.105)
1. Using a micrometer (2), measure the diameter of the

piston (1) to determine the assembly clearance.
BAPH04APH123ASA 1
2. The clearance between the piston and the cylinder

barrel can be checked also with a feeler gauge (1)
as shown in the figure.
BACD04APH124ASA 2
Next operation:
Connecting rod and piston - Assemble (10.105)
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Piston Ring - Measure

Prior operation:
1. Use a micrometer (1) to check split ring (2) thickness.
BAPH04APH127ASA 1
2. Check the clearance between the sealing rings (3) of

the 2nd and 3rd slot and the relevant housings on the
piston (2), using a feeler gauge (1).
BAPH04APH128ASA 2
3. Since the first sealing ring is trapezoidal, the clear-

ance between the slot and the ring shall be measured
as follows:
Make the piston (1) protrude from the engine block
so that the ring (2) protrudes half-way from the cylin-
der barrel (3). In this position, use a feeler gauge
to check the clearance (X) between ring and slot.
Found value shall be the specified one.
BAPH04APH129ASA 3
4. Use feeler gauge (1) to measure the clearance be-

tween the ends of the split rings (2) fitted into the
cylinder barrel (3).
BACD04APH130ASA 4
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Next operation:
Piston - Install (10.105)
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Piston Ring - Install

Prior operation:
1. Use pliers 380000221 (3) to fit the split rings (1) on

the piston (2).
NOTICE: Split rings shall be fitted with the marking "TOP"
(4) facing upwards and their openings shall be displaced
with each other by 120 °.
NOTE: Split Rings are supplied spare with the following
sizes:
- standard
- 0.4 mm (0.016 in) oversize.
MID0330A 1
Next operation:
Piston - Install (10.105)
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Piston Pin - Remove

Prior operation:
1. Remove the piston pin (1) by extracting the stop rings

(2) using a scriber (3).
BACD04APH121ASA 1
Next operation:
Piston Pin - Measure (10.105)
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Piston Pin - Measure

Prior operation:
1. To measure the piston pin (1) diameter, use a mi-

crometer (2).
BAPH04APH125ASA 1
2. Lubricate the pin (1) and its seat on the piston hubs
with engine oil; the pin shall be fitted into the piston
with a slight finger pressure and shall not be with-
drawn by gravity.
BAPH04APH126ASA 2
Next operation:
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Piston - Check
1. Once connecting rod - piston assemblies installation
is completed, use dial gauge 380000228 (1) fitted
with base 380000364 (2) to check piston (3) protru-
sion at T.D.C. with respect to the top of the engine
block.
Protrusion shall be 0.28 - 0.52 mm (0.011 - 0.020 in).
BACD04APH143ASA 1
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Connecting rod bearing - Install

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

cap.
NOTE: Refit the bearings that have not been replaced in
the same position found at removal. Do not relocate the
half-bearings.
BAPH04APH059ASA 1
Next operation:
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Connecting rod bearing - Clearance

Prior operation:
1. Clean the parts accurately and remove any trace of

oil.
2. Set a piece of calibrated wire (2) on the crank pins
(1).
3. Fit the connecting rod caps (3) with the relevant half
bearings (4).
NOTE: Before the final fitting of the connecting rod cap fas-
tening screws, check that their diameter measured at the
center of the thread length is not < 0.1 mm (0.004 in) than
the diameter measured at approximately 10 mm (0.394 in)
from the screw end.
BAPH04APH139ASA 1
4. Lubricate the screws (1) with engine oil and then

tighten them to the specified torque using the torque
wrench (2).
BACD04APH140ASA 2
5. Apply tool 380001001 (1) to the socket wrench and

tighten screws (2) to 60 °.
0B00200405BACD0 3
6. Remove the cap and find the existing clearance by

comparing the calibrated wire width (1) with the scale
on the wire envelope (2).
7. If a different clearance value is found, replace the half
bearings and repeat the check.
8. Once the specified clearance has been obtained, lu-
bricate the half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified
torque.
BACD04APH141ASA 4
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10.105 / 17
9. Check manually that the connecting rods (1) are slid-

ing axially on the crank pins and that their end float,
measured with a feeler gauge (2) is 0.10 - 0.33 mm
(0.004 - 0.013 in).
BACD04APH142ASA 5
Next operation:
Piston - Check (10.105)
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Piston pin bushings - Service instruction

Prior operation:
1. Check that the bushing in the connecting rod small

end is free from scoring or seizing and that it is not
loose. Otherwise replace.
2. Removal and refitting shall be performed using the
proper beater.
3. When refitting take care to make the oil holes in the
bushing coincide with the holes in the connecting rod
small end.
4. Grind the bushing to obtain the specified diameter.
Next operation:
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Index
Engine - 10

Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting rod and piston - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting rod bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting rod bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston pin bushings - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Engine - 10
Valve drive and gears - 106
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
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Contents
Engine - 10
FUNCTIONAL DATA
Valve drive and gears

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Rocker arm
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rocker shaft
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Camshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Camshaft bushings
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Camshaft gear
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Engine - Valve drive and gears
Valve drive and gears - Overview

Rocker Assembly Components
ROCKERCOMPONENT 1
(1) Bolts (2) Bracket (3) Shafts (4) Rockers
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Rocker arm - Disassemble

Prior operation:
1. Loosen tappet adjustment jam nuts (1) and unscrew

the adjusting screws.
2. Remove the rocker shaft mounting bolts (2).
3. Remove the rocker assembly (3), which consists of
the pedestal (6), rockers (4), and shaft (5).
4. Remove the valve bridges (7).
5. Remove the push rods (8).
BACD04APH020ASA 1
Next operation:
Rocker shaft - Clearance (10.106)
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Rocker arm - Install

Prior operation:
Camshaft - Install (10.106)
1. Check that the tappet adjusters (1) are loose to pre-

vent their binding on the rods when fitting the rocker
assembly
2. Install the rocker assembly consisting of:
• Bracket (5).
• rockers (3).
• shafts (4).
3. Secure them to the cylinder head by tightening the
fastening screws (2) to a torque of 36 Nm (27 lb ft).
ROCKERASSEMDH 1
Next operation:
Rocker arm - Adjust (10.106)
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Rocker arm - Adjust

Prior operation:
1. Adjust the clearance between the rockers and valves

using a set screw wrench (1), box wrench (3), and
feeler gauge (2).
2. Set the clearance to the following specifications.
• Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012
in)
• Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022
in)
BACD04APH162ASA 1
Next operation:
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Rocker shaft - Clearance

Prior operation:
Rocker arm - Disassemble (10.106)
1. Check that the shaft/rocker coupling surfaces are not

showing excessive wear or damage.
SHAFTMEASURE 1
Next operation:
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Camshaft - Remove
Prior operation:
Camshaft gear - Remove (10.106)
1. Remove the bolts (1)and disconnect camshaft (3)re-

taining plate (2).
NOTE: Take note of the retaining plate (2) assembly posi-
tion.
BACD04APH047ASA 1
2. Carefully extract the camshaft (1) from the cylinder

block.
BACD04APH048ASA 2
Next operation:
Camshaft - Measure (10.106)
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Camshaft - Measure
Prior operation:
Camshaft - Remove (10.106)
1. Set the camshaft on the tailstock using a 1/100 gauge

set on the central support, check whether the align-
ment error is not exceeding 0.04 mm (0.002 in), oth-
erwise replace the camshaft.
2. Check cam lift; found values shall be: 6.045 mm
(0.238 in) for exhaust cams and 7.582 mm (0.299
in) for intake cams, in case of different values replace
the camshaft.
3. Check the camshaft (2) pin diameter using microm-
eter (1) on two perpendicular axes.
BACD04APH117ASA 1
BAIL07APH360FSA 2
NOTE: Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring
replace the camshaft and the bush.
Next operation:
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Camshaft - Install
Prior operation:
1. Lubricate the camshaft bushings and fit the camshaft

(1) taking care not to damage the bushings or the
housings.
CRIL04J056A01 1
2. Set camshaft (3) retaining plate (1) with the slot fac-
ing the top of the engine block and the marking facing
the operator, then tighten the screws (2) to the spec-
ified torque.
CRIL04J064A01 2
Next operation:
Camshaft - End play (10.106)
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Camshaft - End play

Prior operation:
1. Check camshaft end play (1). It shall be 0.10 - 0.36

mm (0.004 - 0.014 in).
CRIL04J065A01 1
Next operation:
Engine block cover Rear - Install (10.102)
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Camshaft Push rod - Install

Prior operation:
1. Before installation be sure to check that there is no

signs of wear or distortion. Intake and exhaust rods
are identical and therefore interchangeable.
PUSHROD 1
2. Install the push rods (2).

3. Install the valve bridges (1) with the marks facing the
exhaust manifold
BACD04APH093ASA 2
Next operation:
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Camshaft Tappets - Remove

Prior operation:
1. Withdraw the tappets (1) from the engine block.
BACD04APH049ASA 1
Next operation:
Camshaft Tappets - Measure (10.106)
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Camshaft Tappets - Measure

Prior operation:
Camshaft Tappets - Remove (10.106)
BAIL07APH361FSA 1
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK
Next operation:
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Camshaft Tappets - Install

Prior operation:
Camshaft Tappets - Measure (10.106)
Lubricate the tappets (1) and fit them into the relevant hous-
ings on the engine block.
CRIL04J063A01 1
Next operation:
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Camshaft bushings - Measure

Prior operation:
1. Camshaft bushing (2) shall be pressed into its hous-

ing. Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush-
ings (2) and intermediate housing (1) diameter. Mea-
surements shall be performed on two perpendicular
axis'.
CRIL04J060A01 1
BAIL07APH367FMA 2
*Height to be obtained after installing the bushing.
Next operation:
Camshaft - Replace (10.106)
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Camshaft bushings - Replace

Prior operation:
Remove and install the bushing (1) using the beater (2) and
the hand-grip 380000145 (3).
NOTICE: When installing the bushing , take note of orien-
tation to make sure the lubricating holes coincide with the
holes on the block housing.
ZEIL06EN0048A0B 1
Next operation:
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10.106 / 17
Camshaft gear - Remove

Prior operation:
Engine block cover Rear - Remove (10.102)
1. Remove the screws (1) securing the camshaft gear

(3) to the camshaft (2).
2. Withdrawal the camshaft gear (3).
CAMGEARH 1
Next operation:
Camshaft gear - Install (10.106)
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10.106 / 18
Camshaft gear - Install

Prior operation:
Camshaft gear - Remove (10.106)
NOTE: For ease of crankshaft rotation, install two pins in the end of the crankshaft.
1. Highlight the timing mark on the crankshaft gear (1)
with a felt tip pen so it's easier to see.
BACD04APH064ASA 1
2. Turn the crankshaft (4) and the camshaft (2) so that

by mounting the drive gear (1) on the camshaft (2),
both timing marks (3) will align properly.
BACD04APH065ASA 2
3. Tighten the bolts (1) that secure the gear (2) to

camshaft (3) to the specified torque.
BACD04APH066ASA 3
Next operation:
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Index
Engine - 10

Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Camshaft bushings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Camshaft bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Camshaft gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rocker arm - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rocker shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve drive and gears - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Balancer and damper - 110
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.110 / 1
Contents
Engine - 10
SERVICE
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Crankshaft damper
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Balancer and damper
Balancer - Remove
Prior operation:
1. Remove the bolts (1) and withdraw the oil pickup

tube.
2. By means of pin (2) lock the dynamic balancer (3) in
the Top Dead Center (TDC) position.
3. Loosen the bolts (4) and remove the dynamic bal-
ancer (3).
DYNAMICBALANCER 1
Next operation:
Balancer - Install (10.110)
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10.110 / 3
Balancer - Install
1. Place the balancer on the engine, install and tighten
the mounting bolts.
RCPH10TLB003BAL 1
2. Install and tighten the oil sump.

3. Remove the retaining bolt previously installed during
the timing adjustment.
4. Install the oil pan on the engine, fill the engine with
oil.
5. Pull the timing lock pin from the cam gear.
RCPH10TLB004BAL 2
6. Start and run engine, check for excessive vibration

and oil leaks.
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Crankshaft damper - Remove

Prior operation:
Belt - Remove (10.414)
1. Remove the bolts (3) securing the vibration damp-

ener (2) and withdrawal the damper (2) and pulley
(1).
VIBDAMPENERH 1
Next operation:
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10.110 / 5
Crankshaft damper - Install

Prior operation:
1. Attach the vibration damper (2) and the pulley (1) to

the crankshaft, and torque the mounting bolts (3) to
45 - 55 N·m (33 - 41 lb ft) then, 90 ° .
VIBDAMPENERH 1
Next operation:
Belt - Install (10.414)
47441596 09/10/2012
10.110 / 6
Index
Engine - 10

Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - 10
Pump drives - 114
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.114 / 1
Contents
Engine - 10
Pump drives - 114
SERVICE
Pump drives
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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10.114 / 2
Engine - Pump drives
Pump drives - Remove

1. Unscrew the cover bolts (3) and remove the cover
(1). Save the cover gasket (4).
2. Remove the power take-off adapter (2). Save the
gasket (4).
AUXDRIVEH 1
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Engine - Pump drives
Pump drives - Install

1. Insert the power take-off adapter (2) with gaskets (4)
and cover (1).
2. Tighten the bolts (3) to the specified torque.
AUXDRIVEH 1
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Index
Engine - 10
Pump drives - 114

Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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47441596 09/10/2012
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Engine - 10
Fuel filters - 206
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.206 / 1
Contents
Engine - 10
Fuel filters - 206
FUNCTIONAL DATA
Fuel heater
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Fuel filters
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filters
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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10.206 / 2
Engine - Fuel filters
Fuel heater - Overview

The ECU drives the filter heater at fuel temperature less than our equal to 5 °C (41 °F).
47441596 09/10/2012
10.206 / 3
Fuel filters - Remove

Prior operation:
Fuel supply lines Low pressure - Disconnect (10.210)
1. Using the tool disassemble the fuel filter (1) and re-
move it from the support (5).
2. Disconnect the electrical connections (2) from the
support (5) including the one for the fuel heater.
3. Disconnect the fuel low pressure pipelines (3) from
the support (5).
4. Disconnect pipeline (4) from the support (5).
5. Remove the sustaining support bracket (5) from the
block.
4442596398GHDC 1
Next operation:
Fuel filters - Install (10.206)
47441596 09/10/2012
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Fuel filters - Install

Prior operation:
Fuel filters - Remove (10.206)
1. Assemble the bracket and support (1) of the fuel filter

(6).
2. Proceed connecting in sequence the pipelines (9) (3)
(4) (5) of the support (1) to the high pressure pump
(8).
3. Connect the pipeline (7) from the high pressure pump
to the common rail.
NOTE: Refer to Common rail lines - Connect (10.218)
for the proper operation of the clamps on the low pressure
fuel lines.
FUELSYSTEMD 1
Next operation:
Fuel supply lines Low pressure - Connect (10.210)
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Fuel filters - Install

1. Install the bracket and the base of the fuel filter.
47441596 09/10/2012
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Index
Engine - 10
Fuel filters - 206

Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Lift pump and lines - 210
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
10.210 / 1
Contents
Engine - 10
FUNCTIONAL DATA
Fuel lift pump

Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Fuel supply lines

Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Lift pump and lines
Fuel lift pump - Sectional view

Gear pump, placed on the rear part of the high pressure pump, whose function is to feed the high pressure pump. It
is driven by the high pressure pump's shaft.
Normal operating condition
BACD04APH163ASA 1
(A) Fuel supply from the primary filter (1) Fuel supply relief valve 5 bar (73 psi)
(B) Fuel supply to the secondary filter (2) Supply pump bypass valve (for bleeding)
47441596 09/10/2012
10.210 / 3
Overpressure condition
BACD04APH164ASA 2
The by-pass valve (1) is activated in case of overpressure on (B) Exhaust unit. The actual pressure, overcoming the
resistance of the valve's spring (1), connects the exhaust with the entry through the gallery (2).
47441596 09/10/2012
10.210 / 4
Jettison condition
BACD04APH165ASA 3
The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system
through the priming pump. In this condition the by-pass (1) keeps closed while the dump by-pass valve (2) opens up
due to the pressure effect on the entry unit so the fuel flows to the exhaust unit (B).
NOTE: The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the
high pressure pump.
47441596 09/10/2012
10.210 / 5
Fuel supply lines Low pressure - Connect

1. Connect the pipeline to the pressure limiter.
2. Connect all the fuel lines between the fuel filter base
and the high pressure pump.
3. Connect the pipeline from the high pressure pump to
the engine control module cooling plate.
4. Connect the pipeline from the high pressure pump to
high pressure common rail.
LPFUELCONNECT 1
47441596 09/10/2012
10.210 / 6
Fuel supply lines Low pressure - Disconnect

1. Disconnect the fuel return pressure limiter (1). Refer
to Common rail lines - Disconnect (10.218).
RETURNLINEF4DEF 1
47441596 09/10/2012
10.210 / 7
Index
Engine - 10

Fuel lift pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel supply lines Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - 10
Fuel injection system - 218
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
Engine - 10
FUNCTIONAL DATA
Fuel injection system

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High pressure pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure regulating valve
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Common rail
Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel injectors
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE
High pressure pump

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Common rail
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Common rail lines
Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel injectors
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Injector fuel lines
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel fillers
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Engine - Fuel injection system
Fuel injection system - Dynamic description
4C0O200406CRILH 1
(1) Electro-injector (5) Pre-filter mounted on the frame

(2) Common rail (6) High-pressure pump
(3) Pressure limiting device for fuel return (7) Mechanical vane pump
(4) Common rail pressure relief valve (8) Fuel filter
The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke
and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
The hydraulic system is implemented by a low pressure circuit and a high pressure circuit
The high pressure circuit is composed of the following pipings:

• piping connecting high pressure pump outlet to rail
• pipings supplying injectors from rail
The low pressure circuit is composed of the following pipings:

• fuel suction piping from tank to pre-filter
• pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump
and pre-filter
• pipings supplying the high pressure pump through the fuel filter
The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.
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Fuel injection system - Plumbing schema

The fuel system is a Common Rail injection system with a CP3 high pressure pump.
The pressure regulator, placed upstream of the high pressure pump, adjusts the fuel flow that is necessary on the low
pressure system. Afterwards, the high pressure pump takes care of supplying the rail properly. This arrangement, by
pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.
Function of the pressure relief valve (2), assembled on the high pressure pump, is keeping the pressure, at the pres-
sure regulator inlet, constant at 5 bar (73 psi). Based on the efficiency the fuel filter.
The pressure relief valve (2) increases fuel flow in the high pressure pump cooling circuit, through inlet and drain
piping (16) from piping (8).
The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from
injectors at a pressure of 1.3 - 2 bar (19 - 29 psi).
Two bypass valves are placed in parallel with the mechanical supply pump.
The bypass valve (18) allows fuel to flow from the mechanical pump outlet to it's inlet, when the fuel filter inlet pressure
exceeds the allowed threshold value.
The bypass valve (17) allows filling the supply system through the manual priming pump (10).
FUELSYSTEMSCHEM 1
(1) High-pressure pump (7) Electro-injector (13) Mechanical supply pump

(2) Low pressure relief valve (8) Return fuel line (14) Fuel filter
(3) Return fuel relief valve (9) ECU cooling plate (15) Pressure regulator
(4) Common rail relief valve (10) Priming pump (16) High pressure pump cooling passage
(5) Common rail (11) Pre-filter (17) By-pass valve
(6) Common rail pressure sensor (12) Fuel tank (18) Charge pressure relief valve
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High pressure pump - Overview

Fuel system operation
The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves
set on the pumping elements at about 2 bar (29 psi).
The amount of fuel supplying the high pressure pump is metered by the pressure regulator placed on the low pressure
system. The pressure regulator is controlled by the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, unable to be
released, is compressed above the supply pressure value existing in the rail.
The generated pressure makes the exhaust valve open and the compressed fuel reaches the high pressure circuit.
The pumping element compresses the fuel till top dead center of the delivery stroke, is reached. Afterwards, the
pressure decreases till the exhaust valve is closed.
The pumping element piston goes back towards bottom dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again
opened and the cycle is repeated.
The delivery valves must always be free in their movements, free from impurities and oxidation.
The rail delivery pressure is modulated between 250 - 1600 bar (3625 - 23200 psi) by the electronic control unit,
through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection - reconnection time on the engine is greatly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high pressure pump is to be removed or installed, be sure that hands and compo-
nents are absolutely clean.
Rail
COMMONRAILOVERV 1
(1) Rail (2) Fuel inlet from (3) Overpressure valve (4) Pressure sensor
high-pressure pump
The rail volume is comparatively small to allow quick pressurization at start-up, at idle and in case of high flow rates.
It has enough volume to minimize system spikes and the use of plenum chambers caused by the opening and closing
of the injectors and by the high pressure pump operation. This function is further enabled by a calibrated hole being
set downstream of the high pressure pump.
A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is feedback
information, where the rail pressure value is checked and if necessary, corrected.
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High pressure pump - External view

Introduction
Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system
makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision
obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and
fuel consumption.
The CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23200 psi).
Description of system
The injection system is composed of an electrical part and a hydraulic part.
Electrical system
The electronic control unit monitors engine control parameters by means of the various sensors on the engine.
HARNESS 1
(1) Fuel pressure sensor (5) Connection to electro-injectors (9) Pressure gauge cabling
(2) Coolant temperature sensor (6) Air temperature/pressure sensor (10) EDC7 UC31 Control unit
(3) Oil temperature/pressure sensor (7) Camshaft sensor (11) Electro-injector
(4) Driving shaft sensor (8) Fuel heater cable and fuel
temperature sensor
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High pressure pump - Dynamic description

CP3 high pressure pump
Pump provided with 3 radial pumping elements driven by the timing system gear, no need for timing. The mechanical
feeding pump driven by the high pressure pump's shaft is assembled to the rear side of the high pressure pump.
NOTE: The high pressure pump unit - feeding pump is not subject to overhaul. Do not disassemble or tamper with
the retaining bolts.
The only serviceable components are the control gear and pressure regulator.
80719 1
(1) Outlet to common rail (4) Drive gear (7) Inlet from primary filter
(2) High pressure pump (5) Supply fuel inlet from filter (8) Outlet to secondary filter
(3) Pressure regulator valve (6) Return to filter (9) Transfer pump
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Inside structure
80720 2
(1) Pumping element (5) Piston

(2) Rotary coupling (6) Eccentric pump shaft
(3) Inlet valve (7) Low pressure fuel inlet
(4) Outlet valve (8) Fuel supply ducts to pumping elements
Every pumping unit is composed of:

• A piston actuated by a three-lobe element floating on the pump shaft. The element, which is floating on an offset
part of the shaft, uses the highest part of the element to actuate the three pistons alternately.
• Cap intake valve.
• Ball delivery valve.
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Working principle
80721 3
(1) Fuel to common rail (5) Pulse Width Modulated (PWM) metered fuel
(2) Outlet valve (6) Low pressure fuel supply
(3) Pumping element (7) PWM pressure regulator valve
(4) Eccentric pump shaft
The pumping element is oriented towards the pump's camshaft. During the intake phase, the pumping element is fed
through the feeding line. The quantity of fuel to flow to the pumping element is determined by the pressure regulating
gauge. The pressure regulating gauge, according to the PWM command received by the engine control module,
stops the fuel flow to the pumping element. During the compression phase of the pumping element, the fuel achieves
the level of pressure determining the opening of the by-pass valve to the common rail, feeding it through the exhaust
unit.
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80722 4
(1) Pumping element inlet passage (6) Pumping element inlet passage
(2) Pump lubrication passage (7) Relief valve outlet passage
(3) Pumping element inlet passgae (8)Relief valve 5 bar (73 psi)
(4) Main supply passage (9) Fuel supply to relief valve and regulator
(5) PWM pressure regulator valve
The figure shows the fuel runs at low pressure inside the pump. The following elements are clearly visible: the main
feeding line to the pumping elements, the feeding lines to the pumping elements, the duct lines run for the pump
lubrication, the pressure gauge, the flow limiting valve to 5 bar (73 psi) and the fuel exhaust flue
The pump shaft is lubricated by the fuel from the feeding and recovery lines.
The pressure gauge determines the quantity of fuel to feed the pumping elements. The excess fuel flows through the
exhaust gallery.
The 5 bar (73 psi) limiting valve, in addition to recovering exhaust fuel as a collector, also functions to keep the
pressure at a constant 5 bar (73 psi) limit at gauge entry.
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80723 5
(1) Fuel exhaust galley (2) Fuel exhaust galley (3) Fuel outlet to rail
This figure shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.
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Pressure regulating valve - Overview

Pressure Regulator
The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure
system; the pressure regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 - 1450 bar (3625 - 21025 psi) by the electronic control unit by
controlling the pressure regulator solenoid valve.
This component is a N.O. solenoid valve.
The solenoid valve impedance is approximately 3.2 Ω.
Pressure Limiter for Fuel Return

It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at pressures of
1.3 - 2 bar (19 - 29 psi). By guaranteeing this pressure to the return fuel, the fuel vapor formation inside the injectors
is avoided, optimizing fuel spraying and combustion.
BACD04APH176ASA 1
(A) - To Tank
(B) - From Injectors
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Common rail Relief valve - Overview
93101562 1
Mounted on the end of the rail, it has the function of protecting the system's components in case the failure of the
rail pressure sensor or the pressure regulator of the CP3 pump causes an excessive pressure increase in the high
pressure plant.
When the rail pressure reaches 2000 bar (29000 psi), the valve initially opens in order to allow the fuel to flow and
subsequently reduce the pressure within the safety limits and then it mechanically regulates the rail pressure to ap-
proximately 1000 bar (14500 psi).
This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of
the fuel preserving the return pipes to tank.
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Fuel injectors - Overview

On NEF TIER IV engines, BOSCH - CRIN2 electro-injectors with 8 hole DLLA type jets with a flow rate of 550 CCM /
30 SEC @ 100 bar (1450 psi).
The injector is similar as construction to the tier 3 injectors, apart from the absence of the plunger return springs.
The injector is composed of two main parts:
• Actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.
• Control solenoid valve composed of a coil, and pilot valve.
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position
93095366 1
(1) Pressure Rod (6) Ball Shutter (11) Supply Duct

(2) Plunger (7) Control Area (12) Control Fuel Outlet
(3) Nozzle (8) Pressure Chamber (13) Electrical Connection
(4) Coil (9) Control Volume (14) Spring
(5) Pilot Valve (10) Control Duct (15) High Pressure Fuel Inlet
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Injection Start
93095367 2
When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct
(12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8)
makes plunger (2) lift, following fuel injection into the cylinder.
Injection End
When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance
as to make plunger (2) go back to its closing position and end the injection process.
NOTE: The injector cannot be overhauled and therefore it must not be disassembled.
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Electro-Injector Solenoid Valves

Each injector is connected to the EDC control unit on connector A.
The Impedance of the coil of each injector is 0.56 - 0.57 Ω.
COVERBASE 3
Reference Description EDC pin

Connector (1)
Pin #1 Cylinder 2 injector 11A
Connector (2)
Connector (3)
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High pressure pump - Remove

Prior operation:
Injector fuel lines - Disconnect (10.218)
Prior operation:
1. Disconnect all fuel lines (4) on the high pressure

pump (2).
2. Remove the mounting nuts (1) and remove the high
pressure pump (2) and feed pump (3) together as
one unit.
HPPUMPDH 1
Next operation:
High pressure pump - Install (10.218)
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High pressure pump - Install

Prior operation:
High pressure pump - Remove (10.218)
Prior operation:
1. Slide the high pressure pump (2) including the feed

pump (3) into place on the rear cover.
2. Install the nuts (1) securing the pump to the rear
cover and tighten to the specified torque.
3. Hook up all fuel lines (4).
HPPUMPDH 1
Next operation:
Injector fuel lines - Connect (10.218)
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Common rail - Install

Prior operation:
1. Install the high pressure fuel rail (2) on the cylinder

head.
2. Tighten the mounting screws (1) to the specified
torque.
3. Connect new fuel pipes (6) to the rail (2) and to the
manifold for electro-injectors (5).
4. Tighten the pipe joints (3) to 20 Nm (14.8 lb ft).
5. Install the low pressure fuel line (4) to the rail (2).
Refer to Common rail lines - Connect (10.218) for
the proper procedure.
RAIL 1
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Common rail lines - Disconnect Low Pressure

1. Hold down the clasp (1) and release the quick fitting
joint.
80628 1
Next operation:
Common rail lines - Connect (10.218)
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Common rail lines - Connect Low Pressure

Prior operation:
Common rail lines - Disconnect (10.218)
1. Connect low pressure lines to the fuel rail by insert-

ing the rapid fitting joint into the connection joint and
press until the clip (1) fastens securely.
2. Check proper fuel connection.
80628 1
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Fuel injectors - Remove

Prior operation:
Fuel fillers - Remove (10.218)
1. Remove the bolts securing the injector to the cylinder

head.
2. Use tool 380001099 (1) to remove the injectors (2)
from the cylinder head.
INJECTORREMOVE 1
Next operation:
Fuel injectors - Install (10.218)
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Injector fuel lines - Connect

1. Connect new fuel pipes (1) between high pressure
rail (3) and fuel manifolds (2).
HPFUELCONNECT 1
2. Pipe connection (1) should be torqued to 20 Nm (15

lb ft) using the proper wrench (4) and torque wrench
(3).
Connections should be tighten by holding the flow
limiting valve hexagon with the proper wrench.
HPFUELTORQUE 2
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Injector fuel lines - Disconnect

1. Disconnect the fuel pipe (4) from the cylinder head
Common rail lines - Disconnect Low Pressure
(10.218). Disconnect the fuel pipes (5) from the rail
(2) and injector manifolds (6).
NOTICE: When releasing pipe (5) connections (6) to rail
(2), use the proper wrench to avoid rotation of flow limiters
(3).
2. Remove the screws (1) and disconnect the rail (2).
COMMONRAILF4HE 1
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Fuel fillers - Remove

Prior operation:
NOTICE: Make sure the area around the fuel manifold is clean. Once they are removed, there is a greater risk of
contaminating the internal components.
1. Remove the nuts (1) and remove the fuel manifolds
(2).
NOTE: Disassembled fuel manifolds must not be used
again. Replace them with new ones during reassembly.
FUELMANIFOLD 1
Next operation:
Fuel fillers - Install (10.218)
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Fuel fillers - Install

Prior operation:
Fuel fillers - Remove (10.218)
1. Fit a sealing ring (3) lubricated with petroleum jelly

on the fuel manifold (2).
2. Install the fuel manifold (2) into the cylinder head so
that the positioning ball (5) is coinciding with the rel-
evant housing (4).
NOTE: After removing fuel manifolds they cannot be used
again. Replace them with new ones.
3. Screw the fastening nuts on without tightening them.
NOTE: During this operation, the injector (1) can be moved
so that the manifold (2)can be properly inserted into the
inlet hole.
FUELMANIFOLDDH 1
4. After everything is in place, tighten the fuel manifold

nuts (2) to 50 Nm (37 lb ft).
NOTICE: Be sure to tighten the screws (1) securing the
injector to the specified torque. Refer to Fuel injectors -
Install (10.218) for the proper procedure.
INJMANIFOLDDH 2
Next operation:
Injector fuel lines - Connect (10.218)
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Index
Engine - 10

Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Common rail Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Common rail lines - Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Common rail lines - Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel fillers - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Fuel fillers - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel injection system - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
High pressure pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
High pressure pump - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
High pressure pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Injector fuel lines - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Injector fuel lines - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pressure regulating valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Engine - 10
Turbocharger and lines - 250
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
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Contents
Engine - 10
SERVICE
Turbocharger
Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Turbocharger oil supply line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Turbocharger and lines
Turbocharger Turbine - Remove

1. Remove the turbo oil supply line (3) from the oil filter
base and from the pipe fitting (4) to the turbine.
2. Remove the nuts securing the turbocharger (1) to the
exhaust manifold (2)and remove it from its seat.
TURBOF4HE 1
Next operation:
Turbocharger Turbine - Install (10.250)
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Turbocharger Turbine - Install

Prior operation:
Turbocharger Turbine - Remove (10.250)
1. With a suitable sling, place the turbocharger (1) on

the exhaust manifold (2) with a new gasket.
2. Tighten the mounting screws (3) to the specified
torque.
TURBOF4DE 1
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Turbocharger - Install
1. Set the turbocharger (1) on the exhaust manifold (2).
2. Torque the nuts (3) to 35 N·m (26 lb ft) then torque
to 46 N·m (34 lb ft).
TURBOF4DE 1
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Turbocharger oil supply line - Install

Oil Fill Tube
1. Install a new O-ring on the oil fill tube (1).
2. Attach the oil fill tube (1) to the engine block using
the three M12x25 bolts.
OILFILLH2 1
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Turbocharger oil supply line - Install

Turbo oil lines
1. Connect the oil supply line (2) between the turbine
(1) and the oil filter base.
OILLINEDH 1
2. Install the oil drain pipe (1) onto the turbo and tighten
the fixing screws.
3. Connect the pipe to the block (2) also.
OILLINEDH2 2
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Index
Engine - 10

Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Turbocharger Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - 10
Intake and exhaust manifolds and muffler - 254
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
Engine - 10
FUNCTIONAL DATA
Intake and exhaust manifolds and muffler

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Intake manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Overview

The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost
feeding pressure, one main body and one compressor.
During engine working process, the exhaust emissions flow through the body of the turbine, causing the turbine disk
wheel's rotation.
The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air is then cooled by the radiator and flown through the piston collector.
The turbocharger is equipped with a transforming valve to regulate the pressure. It is located on the exhaust collector
before the turbine and connected by piping to the induction collector. It's function is to restrict the exhaust of the
emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor,
reaches the prescribed pressure.
The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
BOOSTDIAGRAM 1
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Intake manifold - Remove

1. Loosen the retaining bolts (2) of the intake manifold
(1) and disassemble the intake air heater (3) for the
cold start aid.
INTAKEF4HE 1
Next operation:
Intake manifold - Install (10.254)
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Intake manifold - Install

Prior operation:
Intake manifold - Remove (10.254)
1. Apply LOCTITE 5999to the mounting surface of the

air intake heater (3) on the intake manifold (1).
2. Install the heater (3) and tighten bolts.
3. Assemble the manifold and fasten it to the cylinder
head using screws (2).
INTAKEF4HE 1
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Exhaust manifold - Remove

Prior operation:
Turbocharger Turbine - Remove (10.250)
1. Loosen the bolts (1) and remove the exhaust mani-

fold (2) from the cylinder head.
BAIL06CCM055ASA 1
Next operation:
Exhaust manifold - Install (10.254)
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Exhaust manifold - Install

Prior operation:
Exhaust manifold - Remove (10.254)
1. Connect the exhaust manifold (2) with new gasket.

Tighten the mounting bolts (1) to the specified torque.
EXHAUSTMANIFOLD 1
Next operation:
Turbocharger Turbine - Install (10.250)
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Index
Engine - 10

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake and exhaust manifolds and muffler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Engine lubrication system - 304
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
Engine - 10
FUNCTIONAL DATA
Engine lubrication system

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blowby re-circulation system
SERVICE
Engine oil filter

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine oil pump
Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Blowby re-circulation system
Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piston cooling
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Engine - Engine lubrication system
Engine lubrication system - Exploded view

Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the
block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the
crankshaft, camshaft and to the valve drive.
4C0O200406CRIL0 1
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Blowby re-circulation system - Dynamic description
93101561 1
Version with blow-by filter
The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet
speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual
vapors are removed by piping and filtered by the blow-by filter. In the blow-by filter, part of the vapors condense and
return to the oil sump. The remaining vapors are put back into circulation.
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93101560 2
Version without blow-by filter
The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet
speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual
vapors are conveyed, collected and discharged into the open air through a bleeder.
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Engine oil filter - Remove

1. Use the tool 380000670 to remove the oil filter.
OILFILTERF4HE 1
Next operation:
Engine oil filter - Install (10.304)
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Engine oil filter - Install

Prior operation:
Engine oil filter - Remove (10.304)
1. Lubricate the oil filter O-ring (2) with clean engine oil.
2. Screw the filter (3) onto the base (1) until contact is
made with sealing surface.
3. Tighten the oil filter an additional 3/4 of a turn.
4. Apply a new sealing ring on the oil temperature/pres-
sure sensor (4).
5. Install the sensor (4) onto the filter base (1) and
tighten the screws (5) to the specified torque.
OILFILTERH2 1
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Engine oil pump Gear driven - Remove

Prior operation:
Engine block cover Front - Remove (10.102)
1. Remove the retaining bolts (1) and disconnect the oil

pump (2) from the engine block.
OILPUMPH 1
Next operation:
Engine oil pump Gear driven - Install (10.304)
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Engine oil pump Gear driven - Install

Prior operation:
Engine oil pump Gear driven - Remove (10.304)
1. Install the oil pump (1) into the engine block.

2. Tighten the bolts (2) to the specified torque.
OILPUMPH2 1
Next operation:
Engine block cover Front - Install (10.102)
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Blowby re-circulation system - Remove - External filter

1. Loosen the clamp (1)holding the blow-by tube and
remove the pipe.
2. Remove the screws (2)and remove the blow-by filter,
if applicable.
86070784_RESIZE 1
Next operation:
Blowby re-circulation system - Install (10.304)
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Blowby re-circulation system - Install - External filter

Prior operation:
Blowby re-circulation system - Remove (10.304)
1. Insert the blow-by filter (1) and tighten the bolts (2).
86070785_RESIZE 1
2. Install the cover (1) on the blow-by filter housing (2)

and tighten the mounting screws (3).
86070784_RESIZE 2
3. Connect the pipelines (1) and fix the oil vapor pipes
with the clamps (2).
86070784_RESIZE 3
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Blowby re-circulation system - Remove - Internal filter

1. Pull the plastic fitting (1) out of the top of the valve
cover.
NOTE: The fitting is held in place by a rubber O-ring.
2. Remove the valve cover.
3. Lift the valve cover off of the cylinder head.
4. Remove the plastic retaining nut (2) from the top of
the valve cover.
93110964 1
5. Pull the filter (3) out of the bottom side of the valve
cover.
NOTE: There may be a slight resistance when pulling the
filter from the valve cover due to the O-ring seal.
93110965 2
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Blowby re-circulation system - Install - Internal filter

1. Lubricate the O-ring seal on the filter.
2. Install the filter (1) into the bottom side of the valve
cover.
NOTE: Be sure to connect the hose (2) between the filter
(1) and pressure regulator (3).
93110965 1
3. Install the retaining nut (4) on the top side of the valve
cover.
93110964 2
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Piston cooling Spray nozzle - Remove

1. Remove the main half bearing (1) to avoid damaging
them.
2. Remove the screws (2) and remove the oil nozzles
(3).
BACD04APH046ASA 1
Next operation:
Piston cooling Spray nozzle - Install (10.304)
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Piston cooling Spray nozzle - Install

Prior operation:
Piston cooling Spray nozzle - Remove (10.304)
1. Fit nozzles (2) and tighten the fastening screws (1)

to the specified torque.
CRIL04J066A01 1
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Index
Engine - 10

Blowby re-circulation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Blowby re-circulation system - Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Blowby re-circulation system - Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Blowby re-circulation system - Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Blowby re-circulation system - Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piston cooling Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Engine - 10
Engine cooling system - 400
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
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Contents
Engine - 10
FUNCTIONAL DATA
Engine cooling system

SERVICE
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Coolant thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Engine - Engine cooling system
Engine cooling system - Dynamic description

The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:
• Expansion Tank - Placement, shape and dimension are subject to change according to the engine's equipment.
• Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid
which is then ran through the radiator. Application determines placement and dimensions.
• Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radi-
ator. Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on
application.
• Heat Exchanger - Cools the lubrication oil. Also application specific.
• Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.
• Thermostat - regulates the circulation of the cooling liquid.
• If applicable, the circuit may be extended to the compressor.
ZEIL06EN0105G0B 1
6 cylinder version
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Water pump - Remove

Prior operation:
1. Remove the retaining bolts and withdrawal the water

pump.
BVE0294A 1
Next operation:
Water pump - Install (10.400)
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Water pump - Install

Prior operation:
Water pump - Remove (10.400)
1. Apply a new sealing ring (2) on the water pump (1).
BACD04APH220ASA 1
2. Install the water pump (1) into the engine block (2)
using the two mounting bolts (3).
ZEIL06CS0245A0B 2
3. Tighten the water pump (1) mounting bolts (2) to 20

- 28 N·m (15 - 21 lb ft).
BACD04APH070ASA 3
Next operation:
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Water pump Water manifold - Remove

Prior operation:
Alternator - Remove (55.301)
1. Remove the screws (2) and disconnect the water

manifold (1).
WATERMANIFOLDH 1
Next operation:
Water pump Water manifold - Install (10.400)
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Water pump Water manifold - Install

Prior operation:
Water pump Water manifold - Remove (10.400)
1. Position the water manifold/alternator support (1) so

that the pins (3) and (4) are set against the engine
block.
2. Tighten the mounting bolts (2) to the specified torque.
the hole and bolt threads have no evidence of wear or dirt.
WATERMANIFOLDH2 1
Next operation:
Alternator - Install (55.301)
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Coolant thermostat - Remove

1. Remove the three screws securing the thermostat
housing (1) to the top of the cylinder head.
2. Remove the thermostat (2) and the seal (3) from the
housing (1).
86082981 1
Next operation:
Coolant thermostat - Install (10.400)
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Coolant thermostat - Install

Prior operation:
Coolant thermostat - Remove (10.400)
1. Install the seal (3) around the flange of the thermostat

(2).
2. Install the thermostat (2) into the housing (1) and
secure the assembly to the cylinder head using the
three mounting screws.
86082981 1
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Index
Engine - 10

Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Water pump Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water pump Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - 10
Oil cooler and lines - 408
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
Engine - 10
SERVICE
Engine oil cooler

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - Oil cooler and lines
Engine oil cooler - Remove

Prior operation:
Engine oil filter - Remove (10.304)
1. Unscrew the mounting bolts (1).

2. Remove the oil filter base (2)oil cooler (3), and all
gaskets.
OILCOOLERH 1
Next operation:
Engine oil cooler - Install (10.408)
47441596 09/10/2012
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Engine - Oil cooler and lines
Engine oil cooler - Install

Prior operation:
Engine oil cooler - Remove (10.408)
1. Place a new gasket (1) on the engine block.

2. Install the oil cooler (2).
3. Place a new gasket (3) on the oil cooler.
4. Install the oil filter base (4).
5. Tighten the mounting bolts (5) to the specified torque.
the hole and bolt threads have no evidence of wear or dirt
OILCOOLERH2 1
Next operation:
Engine oil filter - Install (10.304)
47441596 09/10/2012
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Index
Engine - 10

Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fan and drive - 414
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
Engine - 10
Fan and drive - 414
SERVICE
Fan and drive

Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Belt
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Belt tensioner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Idler pulley
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
47441596 09/10/2012
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Engine - Fan and drive
Fan and drive - Remove Support - Remove

Prior operation:
1. Loosen the fastening screws (3) and remove the pul-

ley controlling the fan (2).
2. Proceed detaching the support (1).
FANDRIVEC 1
Next operation:
Fan and drive - Install (10.414)
47441596 09/10/2012
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Fan and drive - Install Support - Install

Prior operation:
Fan and drive - Remove (10.414)
1. Re-attach the support, tightening the screws to the

prescribed torque.
Next operation:
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Belt - Remove
1. Release tension on the belt (1) by pulling back on the
belt tensioner (2).
2. Extract the belt (1) from all the pulleys.
BELT 1
Next operation:
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Belt - Install
Prior operation:
1. Turn the belt tensioner and fit the belt on the pulleys.
66070776 1
Belt Configuration
(1) - Crankshaft (3) - Fan (5) - Alternator

(2) - Fixed Idler Pulley (4) - Water Pump (6) - Tensioner
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Belt tensioner - Remove

Prior operation:
1. Remove the bolt from the center of the belt tensioner

and remove the tensioner.
Next operation:
Belt tensioner - Install (10.414)
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Belt tensioner - Install

Prior operation:
Belt tensioner - Remove (10.414)
1. Install the belt tensioner. Tighten the mounting bolt

to the specified torque.
Next operation:
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Idler pulley - Remove

Prior operation:
1. Remove the retaining bolt from the center of the idler

pulley.
2. Remove the idler pulley.
Next operation:
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Idler pulley - Install

Prior operation:
Idler pulley - Remove (10.414)
1. Install the idler pulley and tighten the retaining bolt in

the center to the specified torque.
Next operation:
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Index
Engine - 10
Fan and drive - 414

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fan and drive - Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fan and drive - Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2012 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CNH Dealer.
47441596 09/10/2012
EN
SERVICE MANUAL
Electrical systems
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
55
Contents
Electrical systems - 55
Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.010

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012

Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013

Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014

Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015

Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201

Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
47441596 09/10/2012
55
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
FUNCTIONAL DATA
Fuel temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel pressure sensor
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Fuel injection system
Fuel temperature sensor - Overview
FUELTEMPH 1
(1) Fuel Temperature Sensor (2) Filter heating resistance
This sensor is identical to the coolant temp sensor.

This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of
the fuel.
The fuel temperature sensor is connected to the control unit on pins 35C - 18C.
The sensor impedance at 20 °C (68 °F) is approximately 2.50 Ω.

1 Ground 35C
2 Temperature signal 18C
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Electrical systems - Fuel injection system
Fuel pressure sensor - Overview
FUELPRESS 1
Mounted on the end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the
value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the
duration of the electrical injection command.
The power supply is 5 Volt.
Reference Description
1 Ground
2 Signal
3 Power supply
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Index

Fuel pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
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Contents
FUNCTIONAL DATA
Engine coolant temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Engine cooling system
Engine coolant temperature sensor - Overview
COOLANTTEMP 1
This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an
indication of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
The sensor is connected to the control unit on pins 15C - 26C.
The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

1 Ground 15C
2 Temperature signal 26C
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Index

Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine oil system - 013
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
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Contents
FUNCTIONAL DATA
Engine oil pressure/temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine oil pressure/temperature sensor

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Engine oil system
Engine oil pressure/temperature sensor - Overview
OILPRESSTEMP 1
This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.
The sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 24C - 28C for temperature and 32C- 27C for pressure.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls
the relative device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

1 Ground 24C
2 NTC signal (temperature) 28C
3 +5 V power input 32C
4 Signal (pressure) 27C
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Engine oil pressure/temperature sensor - Remove

1. Disconnect the wiring harness from the sensor.
OILPRESSTEMPH 1
2. Remove the mounting screws and remove the sen-

sor and O-ring from the oil filter base.
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Engine oil pressure/temperature sensor - Install

1. Install a new O-ring on the oil temperature/pressure
sensor.
2. Install the sensor on the oil filter base and tighten the
mounting bolts to the specified torque.
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Index

Engine oil pressure/temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pressure/temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil pressure/temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine intake and exhaust system - 014
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
FUNCTIONAL DATA
Intake air pressure and temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Intake air pressure and temperature sensor

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Engine intake and exhaust system
Intake air pressure and temperature sensor - Overview
AIRPRESSTEMP 1
This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make
an accurate calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 25C - 36C for temperature and 33C - 34C for pressure.
The power supply is 5 volts.
Voltage at the sensor output is proportional to the detected pressure or temperature.

1 Ground 25C
2 NTC signal (temperature) 36C
3 +5 V power input 33C
4 Signal (pressure) 34C
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Electrical systems - Engine intake and exhaust system
Intake air pressure and temperature sensor - Remove

1. Disconnect the wiring harness from the sensor.
2. Remove the retaining bolt.
3. Remove the sensor and O-ring.
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Index

Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake air pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine control system - 015
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
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Contents
FUNCTIONAL DATA
Engine control unit

Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine wire harness
Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine speed/RPM sensor
Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine timing sensors
Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Engine control unit

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine wire harness
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine speed/RPM sensor
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine timing sensors
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Electrical systems - Engine control system
Engine control unit - Detailed view

EDC7 UC31
CONTROLMODULE 1
(A) Injector connector (B) Vehicle connector (C) Sensor connector
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Engine control unit - Overview

EDC7 UC31 OPERATION
Engine preheating element control

Pre-post heating is activated when any of the following requirements are met. Water, air, or fuel temperature sensors
detect a temperature less than or equal to 5 °C (41 °F).
Phase recognition
Signals transmitted by the camshaft and crankshaft sensors determine which cylinder fuel is to be injected at the time
of starting.
Injection control
On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and
modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds.
Injection pressure closed loop control

On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control
unit administrates the regulator to maintain injection pressure at constantly optimal values.
Pilot and main injection advance control

On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on
the basis of internal mapping.
Idle speed control

The control unit processes signals transmitted by the various sensors and adjust the quantity of fuel injected.
It also controls the pressure regulator and modulates injection duration of the electro-injectors.
Within specific limits, the control unit also monitors battery voltage.
Overheating protection
If the water temperature reaches 110 °C (230 °F), the control unit reduces engine performance.
When the temperature returns below 100 °C (212 °F), the engine resumes normal operation, (in some applications,
the over boosting temperature is the reference temperature).
Maximum engine speed limiting

Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine
speed surpasses these limits the control unit activates power reduction strategies by controlling the electro-injectors.
In some applications the maximum limiting response consists in stopping the engine.
Cut Off
Fuel cut off in release phases is managed by the control unit with the following logical interventions:
• Deactivation of the electro-injectors.
• Reactivation of electro-injectors immediately prior to reaching idle speed.
• Control of fuel pressure regulator.
47441596 09/10/2012
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Smoke control under acceleration

With heavy load demands, in accordance with signals received from the air inlet meter and the engine speed sensor,
the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent
the emission of smoke from the exhaust.
After Run
After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, in-
cluding the faults log so that they will be available the next time the engine is started.
Control of working speed in normal operating conditions

Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions.
If the load causes a reduction in power, the control unit increases torque by increasing the amount of fuel injected in
order to restore the engine to maximum power.
Recovery strategies
Recovery strategies are characterized by certain differences as application varies:
• Control of fuel leaks
In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained
with a low number of RPMs and high torque values in order to inject the maximum quantity of fuel.
• Control of pressure in the rail
When the pressure in the rail exceeds the safety values, the engine reduces power.
• Synchronism problems
In the case of synchronism problems, faulty RPM sensors, the system controls the engine by increasing the
number of RPMs in order to improve interpretation of the signals.
• Power restrictions as operating temperature increases
When the temperature of the charge air rises above 88 °C (190 °F), power reduction is started. When a temper-
ature of 120 °C (248 °F) is reached, performance is further reduced and is comparable to a naturally aspirated
engine.
• Reduction of power as reference temperature varies
In normal operating conditions, the system knows the charge air, oil and water temperatures.
If the temperature of the engine water is not available, the system takes the temperature of the oil as a reference
and when this reaches the threshold of 103 °C (217 °F), it starts to reduce the power available. Upon reaching
113 °C (235 °F), power is reduced to 50 %.
47441596 09/10/2012
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Engine wire harness - Electrical schema
ELECSCHEMH 1
(1) Injectors cylinders 1 and 2 (6) Engine oil pressure/temperature (11) Pressure regulator
(2) Injectors cylinders 3 and 4 (7) Fuel temperature (12) Connector C - Sensors
(3) Injectors cylinders 5 and 6 (8) Coolant temperature (13) Connector A - Injectors
(4) Engine RPM sensor (9) Air pressure/temperature
(5) Timing sensor (10) Fuel pressure
Connector A - Injectors
EDC pin # Function
1 Cylinder 5 injector
7 -
8 -
9 Pressure Regulator
10 Pressure Regulator
47441596 09/10/2012
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Connector C - Sensors
EDC pin # Function
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 Timing sensor
10 Timing sensor
11 -
12 Negative for rail temperature and pressure sensor
13 Positive for rail temperature and pressure sensor
14 Signal from rail temperature and pressure sensor
15 Coolant temperature sensor
16 -
17 -
18 signal from fuel temperature sensor
19 Engine RPM sensor
20 -
21 -
22 -
23 Engine RPM sensor
24 Negative for engine oil pressure and temperature sensor
25 Negative for air temperature and pressure sensor
26 Coolant temperature sensor
27 Signal from engine oil pressure sensor
28 Signal from engine oil temperature
29 -
30 -
31 -
32 Positive for engine oil pressure and temperature sensor
33 Positive for air temperature and pressure sensor
34 Signal from air pressure sensor
35 Negative for fuel temperature sensor
36 Signal from air temperature sensor
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Engine speed/RPM sensor Camshaft - Overview
CAMSENSOR 1
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals
obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated
by this sensor is utilized by the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are no interchangeable because of the different external
shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance is ~900 Ω.

1 Signal 10C
2 Signal 9C
3 Shield -
47441596 09/10/2012
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Engine timing sensors Crankshaft sensor - Overview
CRANKSENSOR 1
This is an inductive sensor located at the left hand side of the engine. The crankshaft sensor produces signals ob-
tained from a magnetic flux field closing through the openings in a tone wheel fitted on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ~900 Ω.
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Engine control unit - Remove

Prior operation:
1. Disconnect the main wiring harness from the elec-

tronic control module (2).
2. Disconnect the low pressure fuel lines that are at-
tached to the control module cooling plate.
3. Remove the three mounting bolts (1) that secure the
control module and the cooling plate to the engine
block.
4. Remove the control module and cooling plate as one
unit.
EDC7H 1
Next operation:
Engine control unit - Install (55.015)
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55.015 / 10
Engine control unit - Install

Prior operation:
Engine control unit - Remove (55.015)
1. Install the electronic control module (2) and cooling

plate on the side of the engine block.
2. Install the mounting bolts (1) and rubber isolators and
tighten to the specified torque.
NOTE: If the rubber isolators are cracked or excessively
deformed, replace them before installation.
EDC7H 1
Next operation:
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Engine wire harness - Disconnect
HARNESS 1
(1) Fuel pressure Sensor (5) Electro-injector (9) Fuel pressure regulator
(2) Coolant temperature sensor (6) Air pressure/temperature sensor (10) EDC 7 UC31
(3) Engine oil temperature sensor (7) Timing sensor (11) Connectors for electro-injectors
(4) Crankshaft speed sensor (8) Fuel temperature sensor
1. Disconnect the engine's cable from the connectors

wiring harness to Electro-Injectors (11); Air Pres-
sure/Temperature Sensor; (6) Fuel Pressure Sensor
(1); Engine Control Module (10); Timing Sensor (7);
Coolant Temperature Sensor (2); Crankshaft Speed
Sensor (4).
HARNESS 2
Next operation:
Engine wire harness - Connect (55.015)
47441596 09/10/2012
55.015 / 12
Engine wire harness - Connect

Prior operation:
Engine wire harness - Disconnect (55.015)
1. Reconnect the engine wiring harness to all the sen-

sors, the engine control module and the common
rail. Refer to Engine wire harness - Disconnect
(55.015) for the harness routing and connections.
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Engine speed/RPM sensor - Install

1. Install a new O-ring on the speed sensor (3).
2. Install the speed sensor (3) on the front cover (1).
3. Tighten the screw (2) to the specified torque.
SPEEDSENSORH 1
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Engine timing sensors - Remove

1. Remove the mounting nut and slide the timing sensor
out of the timing gear housing.
Next operation:
Engine timing sensors - Install (55.015)
47441596 09/10/2012
55.015 / 15
Engine timing sensors - Install

Prior operation:
Engine timing sensors - Remove (55.015)
1. Install a new O-ring on the timing sensor.

2. Slide the sensor over the mounting stud and install
the nut. Tighten to the specified torque.
47441596 09/10/2012
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Index

Engine control unit - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine control unit - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine control unit - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine control unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine speed/RPM sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine timing sensors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine timing sensors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine wire harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine wire harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine wire harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47441596 09/10/2012
55.015 / 17
47441596 09/10/2012
55.015 / 18
Engine starting system - 201
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
55.201 / 1
Contents
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47441596 09/10/2012
55.201 / 2
Electrical systems - Engine starting system
Engine starter - Remove

1. Disconnect the starter cables from the solenoid and
the starter body (2).
2. Remove the three mounting bolts (3) securing the
starter (2) to the flywheel housing (1). Withdraw the
starter (2).
STARTERDH 1
Next operation:
Engine starter - Install (55.201)
47441596 09/10/2012
55.201 / 3
Electrical systems - Engine starting system
Engine starter - Install

Prior operation:
Engine starter - Remove (55.201)
1. Install the starter (2) on the flywheel housing (1) using

the three mounting bolts (3).
NOTE: Before any assembly operation verify that the hole
and bolt threads have no evidence of wear or dirt.
STARTERDH 1
47441596 09/10/2012
55.201 / 4
Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47441596 09/10/2012
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47441596 09/10/2012
55.201 / 6
Cold start aid - 202
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
55.202 / 1
Contents
FUNCTIONAL DATA
Grid heater
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47441596 09/10/2012
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Electrical systems - Cold start aid
Grid heater - Overview
GRIDHEATER 1
The pre-post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post heating operations. The resistance is powered by a contactor.
The resistance impedance is approximately 0.5 Ω.
The control contactor is connected to the control unit (B) connector.

The contactor is tripped with water and/or fuel temperature below 5 °C (41 °F).
The contactor impedance is approximately 15 Ω.
WARNING
This engine is equipped with an intake air (grid) heater. DO NOT use starting fluid on this engine. Use of
starting fluid can cause explosion, personal injury or property damage. Failure to comply could result in
death or serious injury.
M836
47441596 09/10/2012
55.202 / 3
Index

Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47441596 09/10/2012
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Alternator - 301
F4HFA413A*E002
F4HFA613B*E002
F4HFA613C*E002
F4HFA613D*E002
F4HFA613F*E003
47441596 09/10/2012
55.301 / 1
Contents
Alternator - 301
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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55.301 / 2
Electrical systems - Alternator
Alternator - Remove
Prior operation:
1. Remove the cables from the back of the alternator.

2. Remove the retaining bolts (2) securing the alterna-
tor (1) to the support.
3. Remove the alternator (1).
ALTERNATOR 1
Next operation:
Alternator - Install (55.301)
47441596 09/10/2012
55.301 / 3
Electrical systems - Alternator
Alternator - Install
Prior operation:
Alternator - Remove (55.301)
1. Install the alternator (1) and tighten the bolts (2) to

the specified torque.
2. Connect the positive and negative cables onto the
back of the alternator.
ALTERNATOR 1
Next operation:
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55.301 / 4
Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47441596 09/10/2012
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PRINTED IN U.S.A.
47441596 09/10/2012
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380000670 [Oil Filter Wrench] Engine - Service instruction Maintenance procedures 10.001 / 7
380000304 [Angle Torque Cylinder head - Install 10.101 / 10
Thightening Screw Tool]
380000302 [Cylinder Head Valves - Remove 10.101 / 11
Valve Spring Compressor]
380000302 [Cylinder Head Valves - Install 10.101 / 15
Valve Spring Compressor]
380000364 [Comparator Valve seat - Regrind 10.101 / 18
Holder Base For Different
Surveys]
380000228 [Dial Gauge (0 - 5 Valve seat - Regrind 10.101 / 18
mm)]
380000988 [Starter opening Engine flywheel - Remove 10.103 / 3
plate and Flywheel Rotation
Blocker]
380000988 [Starter opening Engine flywheel - Install 10.103 / 5
plate and Flywheel Rotation
Blocker]
380000304 [Angle Torque Engine flywheel - Install 10.103 / 5
Thightening Screw Tool]
380000669 [Seal Extraction Crankshaft oil seal Front seal - Remove 10.103 / 6
Tool]
380000669 [Seal Extraction Crankshaft oil seal Rear seal - Remove 10.103 / 8
Tool]
380000362 [Crankshaft Lifting Crankshaft - Remove 10.103 / 10
Hook]
380001001 [Set Of 2 Gauges Crankshaft Journal - Clearance 10.103 / 14
For Angular Tightening With
1/2” And 3/4” Square Mount]
380000325 [90 - 175mm Connecting rod and piston - Install 10.105 / 8
Diameter Piston Assembly
Band Clamp]
380000221 [Pliers For Piston Ring - Install 10.105 / 12
Piston Rings Removal And
Installation (65 -110 mm)]
380000228 [Dial Gauge (0 - 5 Piston - Check 10.105 / 15
mm)]
380000364 [Comparator Piston - Check 10.105 / 15
Holder Base For Different
Surveys]
380001001 [Set Of 2 Gauges Connecting rod bearing - Clearance 10.105 / 17
For Angular Tightening With
1/2” And 3/4” Square Mount]
380000145 [Camshaft Camshaft bushings - Replace 10.106 / 17
Bushing Remover And
Installer]
380001099 [Fuel Injector Fuel injectors - Remove 10.218 / 22
Extractor]
380000670 [Oil Filter Wrench] Engine oil filter - Remove 10.304 / 6
09/10/2012
7
PRINTED IN U.S.A.
47441596 09/10/2012
EN

CNH Engine Service Manual F4hfa613c - A - B - D

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SERVICE MANUAL

Part number 47441596

Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101

Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102

Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105

Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106

Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110

Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.114

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218

Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250

Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400

Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408

Electrical systems ....................................................................... 55

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012

Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013

Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014

Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015

Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201

Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT

Component Size Specification

Component Size Specification

Basic instructions - Important notice regarding equipment servicing

In case of questions, refer to your CNH Sales and Service Networks.

Torque - Minimum tightening torques for normal assembly

METRIC FLANGED HARDWARE

Metric Hex head and carriage bolts, classes 5.6 and up

Metric Hex nuts and locknuts, classes 05 and up

INCH NON-FLANGED HARDWARE

INCH FLANGED HARDWARE

Inch Bolts and free-spinning nuts

SAE Grade Identification

Inch Lock Nuts, All Metal (Three optional methods)

Basic instructions - Shop and Assembly

ROTATING SHAFT SEALS

PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR WELD-

By using these tools, repair personnel will benefit from:

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101

Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102

Crankshaft and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103

Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105

Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106

Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110

Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.114

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206

Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.210

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218

Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250

Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304

Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

Engine and crankcase - 001

Engine and crankcase - 001

Engine - Component localisation