Silnik FPT F5AE

F5AE9454D / F5AE9454J
F5AE9454L / F5AE9484A
F5AE9484B / F5AE9484G
F5AE9484K / F5CE5454B
F5CE9454E / F5CE9454G
F5CE9484C / F5CE9484E
F5AE5484A /F5AE5484B*A002
F5CE5454G*A001 / F5CE9454C
F5AE5484C*A002 / F5AE9454A
F5EC5454B*A005 / F5CE5454C*A003
Engine
SERVICE MANUAL
Printed in U.S.A. Part number 47388346
© 2012 CNH Industrial America LLC. All Rights Reserved. English
Case is a trademark registered in the United States and many
other countries, owned or licensed to CNH Industrial N.V.,
May 2012
its subsidiaries or affiliates. Replaces part number 84465357
SERVICE MANUAL
F5AE5484A , F5AE5484B*A002 , F5AE5484C*A002 , F5AE9454A , F5AE9454D ,

F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K
, F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 ,
F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C , F5CE9484E
47388346 04/05/2012
EN
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
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
Exhaust Gas Recirculation (EGR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.501
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

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
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Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.989
47388346 04/05/2012
47388346 04/05/2012
INTRODUCTION
47388346 04/05/2012
1
Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K,
F5AE5484B*A002, F5AE5484C*A002
47388346 04/05/2012
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INTRODUCTION
Foreword
This publication contains data, features instructions and methods for performing repair operations on the assembly
and its components and is addressed to qualified, specialized personnel.
Check to make sure you have the right publication related to the component you are about to work on before you start.
Make sure that you have all the necessary safety equipment: safety glasses, helmet, gloves, footwear, etc. Check
that the working lifting and transport equipment is available and in working order. Make sure that vehicle is secured.
Proceed by carefully observing the instructions contained in this publication and use the indicated specific tools to
ensure correct repair procedures and safety of operators.
NOTE: This manual applies to multiple applications, therefore images may not all be accurate.
47388346 04/05/2012
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INTRODUCTION
Safety rules
Standard safety precautions
Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for
consultation.
• Keep working areas as clean as possible.
• Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain
adequate sanitary equipment.
• Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be
checked on a regular basis and personnel must be trained on proper interventions and priorities.
• Keep all emergency exits free of obstructions and clearly marked.
• Smoking in working areas subject to fire danger must be strictly prohibited.
Prevention of injury
• Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to
engines and equipment in motion.
• Wear safety gloves and goggles when performing the following operations:
• Topping off or changing lubrication oils.
• Using compressed air or liquids at a pressure greater than 2 bar (29 psi).
• Wear a safety helmet when working close to hanging loads or equipment working at head level.
• Always wear safety shoes and fitting clothes.
• Use protection cream for hands.
• Change wet clothes as soon as possible.
• In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connec-
tions. Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to
work with electricity.
• Do not smoke or start an open flame close to batteries and any fuel material.
• Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers.
• Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may
occur.
• If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes.
During maintenance
• Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating
pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122
°F).
• Never add coolant to an overheated engine and use only appropriate liquids.
• Always work when the engine is turned off. Certain circumstances require maintenance on a running engine.
Be aware of all the risks involved with such an operation.
• Always use adequate and safe containers for engine fluids and used oil.
• Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents.
• Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated.
Wear a safety mask if necessary.
• Do not leave soiled rags that may contain any flammable substances close to the engine.
• Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake
air in case of engine runaway.
• Never disconnect the batteries while the engine is running.
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INTRODUCTION
• Disconnect the batteries prior to performing any work on the equipment.

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

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

• Respect of the environment should be of primary importance. Take all necessary precautions to ensure person-
nel's safety and health.
• Inform the personnel of the laws regarding the dispensing of used engine fluids.
• Handle batteries with care, storing them in a well ventilated environment and within anti-acid container.
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INTRODUCTION
Torque
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
DESCRIPTION SIZE TORQUE

Oil Pan
Threaded cap with O-ring 45 - 55 N·m (33 - 41 lb ft)
Oil pan spacer M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
- Angle torque 85 - 95 °
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Conical thread cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
Cylinder head M15x1.5
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Exhaust Manifold
Exhaust manifold 10 - 20 N·m (7 - 15 lb ft)
Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)
EGR Unit
Heat exchanger fastening to valve 20 - 30 N·m (15 - 22 lb ft)
unit
Heat exchanger fastening to throw 20 - 30 N·m (15 - 22 lb ft)
EGR fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Valve 5 - 15 N·m (4 - 11 lb ft)
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INTRODUCTION
Manifold fastening nuts 20 - 30 N·m (15 - 22 lb ft)

Manifold fastening rings 5 - 15 N·m (4 - 11 lb ft)
Pulley
Engine crankshaft pulley 335 - 365 N·m (247 - 269 lb ft)
Connecting Rod
Connecting rod cap
- Pre-torque 45 - 55 N·m (33 - 41 lb ft)
Flywheel
Flywheel
Timing
Phonic wheel 12 - 18 N·m (9 - 13 lb ft)
Thrust block 20 - 30 N·m (15 - 22 lb ft)
Gear 31 - 41 N·m (23 - 30 lb ft)
Injector
Injector stud screw 21 - 29 N·m (15 - 21 lb ft)
Injector fastening nut
- Angle torque 25 - 35 N·m (18 - 26 lb ft)
LDA
Manifold side 15 - 25 N·m (11 - 18 lb ft)
Pump side 15 - 25 N·m (11 - 18 lb ft)
Sensors
Crankshaft speed sensor 5 - 15 N·m (4 - 11 lb ft)
Camshaft speed sesnor 5 - 15 N·m (4 - 11 lb ft)
Water temperature sensor 31 - 41 N·m (23 - 30 lb ft)
Oil temperature sensor 20 - 30 N·m (15 - 22 lb ft)
Air pressure sensor 5 - 15 N·m (4 - 11 lb ft)
Fuel filter
Union fixing to support 20 - 30 N·m (15 - 22 lb ft)
Fuel filter 20 - 30 N·m (15 - 22 lb ft)
Supply Pump
Supply pump 20 - 30 N·m (15 - 22 lb ft)
Inlet 20 - 30 N·m (15 - 22 lb ft)
Fast clutch 20 - 30 N·m (15 - 22 lb ft)
Turbocharger
Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)
Oil delivery inlet 20 - 30 N·m (15 - 22 lb ft)
Delivery pipe fastening screw 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to turbo 10 - 20 N·m (7 - 15 lb ft)
Cooling pipe
Water pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Water pipe to the support 20 - 30 N·m (15 - 22 lb ft)
Conical threaded cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Oil
Oil pressure control valve 40 - 50 N·m (30 - 37 lb ft)
Oil dipstick 20 - 30 N·m (15 - 22 lb ft)
Oil inlet pipe 10 - 20 N·m (7 - 15 lb ft)
Pickup tube to block 8 - 12 N·m (6 - 9 lb ft)
Pickup tube support 30 - 40 N·m (22 - 30 lb ft)
Oil filter cartridge union 40 - 50 N·m (30 - 37 lb ft)
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INTRODUCTION
Oil filter 20 - 30 N·m (15 - 22 lb ft)

Oil filter cartridge 16 - 20 N·m (12 - 15 lb ft)
Oil pump
- Stage 1 10 - 20 N·m (7 - 15 lb ft)
- Stage 2 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger
Threaded caps 40 - 50 N·m (30 - 37 lb ft)
Exchanger unit 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Thermostat
Thermostat unit 20 - 30 N·m (15 - 22 lb ft)
Bleed vent 35 - 45 N·m (26 - 33 lb ft)
Fan support
Water pump 20 - 30 N·m (15 - 22 lb ft)
Bearing 35 - 45 N·m (26 - 33 lb ft)
Fan support 20 - 30 N·m (15 - 22 lb ft)
Pulley 35 - 45 N·m (26 - 33 lb ft)
Alternator
Alternator support 45 - 55 N·m (33 - 41 lb ft)
Alternator 45 - 55 N·m (33 - 41 lb ft)
Lifting
Front hook 45 - 55 N·m (33 - 41 lb ft)
Rear hook 65 - 75 N·m (48 - 55 lb ft)
Injection Pump
Pump gear
- Torque 85 - 95 N·m (63 - 70 lb ft)
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INTRODUCTION
Torque
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K, F5AE5484B*A002,
F5AE5484C*A002
DESCRIPTION SIZE TORQUE

Oil Pan
Side cap M6 35 - 45 N·m (26 - 33 lb ft)
Side caps M22 45 - 55 N·m (33 - 41 lb ft)
Front cap M35 35 - 45 N·m (26 - 33 lb ft)
Fixing of sump 65 - 75 N·m (48 - 55 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Exhaust Manifold
Exhaust manifold 30 - 40 N·m (22 - 30 lb ft)
Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)
Pulley
Engine crankshaft pulley 335 - 365 N·m (247 - 269 lb ft)
Connecting Rod
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INTRODUCTION
Connecting rod cap

Flywheel
Flywheel
Timing
Phonic wheel 12 - 18 N·m (9 - 13 lb ft)
Thrust block 20 - 30 N·m (15 - 22 lb ft)
Gear 31 - 41 N·m (23 - 30 lb ft)
Injector
Injector stud screw 21 - 29 N·m (15 - 21 lb ft)
Injector fastening nut
- Angle torque 25 - 35 N·m (18 - 26 lb ft)
LDA
Manifold side 15 - 25 N·m (11 - 18 lb ft)
Pump side 15 - 25 N·m (11 - 18 lb ft)
Sensors
Crankshaft speed sensor 5 - 15 N·m (4 - 11 lb ft)
Camshaft speed sesnor 5 - 15 N·m (4 - 11 lb ft)
Water temperature sensor 31 - 41 N·m (23 - 30 lb ft)
Oil temperature sensor 20 - 30 N·m (15 - 22 lb ft)
Air pressure sensor 5 - 15 N·m (4 - 11 lb ft)
Fuel filter
Union fixing to support 20 - 30 N·m (15 - 22 lb ft)
Fuel filter 20 - 30 N·m (15 - 22 lb ft)
Supply Pump
Supply pump 20 - 30 N·m (15 - 22 lb ft)
Inlet 20 - 30 N·m (15 - 22 lb ft)
Fast clutch 20 - 30 N·m (15 - 22 lb ft)
Turbocharger
Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)
Oil delivery inlet 20 - 30 N·m (15 - 22 lb ft)
Delivery pipe fastening screw 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to turbo 10 - 20 N·m (7 - 15 lb ft)
Cooling pipe
Water pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Water pipe to the support 20 - 30 N·m (15 - 22 lb ft)
Conical threaded cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Oil
Oil pressure control valve 40 - 50 N·m (30 - 37 lb ft)
Oil dipstick 20 - 30 N·m (15 - 22 lb ft)
Oil inlet pipe 10 - 20 N·m (7 - 15 lb ft)
Pickup tube to block 8 - 12 N·m (6 - 9 lb ft)
Pickup tube support 30 - 40 N·m (22 - 30 lb ft)
Oil filter cartridge union 40 - 50 N·m (30 - 37 lb ft)
Oil filter 20 - 30 N·m (15 - 22 lb ft)
Oil filter cartridge 16 - 20 N·m (12 - 15 lb ft)
Oil pump
- Stage 1 10 - 20 N·m (7 - 15 lb ft)
- Stage 2 20 - 30 N·m (15 - 22 lb ft)
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INTRODUCTION
Heat exchanger
Threaded caps 40 - 50 N·m (30 - 37 lb ft)
Exchanger unit 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Thermostat
Thermostat unit 20 - 30 N·m (15 - 22 lb ft)
Bleed vent 35 - 45 N·m (26 - 33 lb ft)
Fan support
Water pump 20 - 30 N·m (15 - 22 lb ft)
Bearing 35 - 45 N·m (26 - 33 lb ft)
Fan support 20 - 30 N·m (15 - 22 lb ft)
Pulley 35 - 45 N·m (26 - 33 lb ft)
Alternator
Alternator support 45 - 55 N·m (33 - 41 lb ft)
Alternator 45 - 55 N·m (33 - 41 lb ft)
Lifting
Front hook 45 - 55 N·m (33 - 41 lb ft)
Rear hook 65 - 75 N·m (48 - 55 lb ft)
Injection Pump
Pump gear
- Torque 85 - 95 N·m (63 - 70 lb ft)
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INTRODUCTION
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SERVICE MANUAL
Engine

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Contents
Engine - 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

F5AE5484A , F5AE5484B*A002 , F5AE5484C*A002 , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B ,
F5AE9484G , F5AE9484K , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E ,
F5CE9454G , F5CE9484C , F5CE9484E
Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101

F5CE9454G , F5CE9484C , F5CE9484E
Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102

F5CE9454G , F5CE9484C , F5CE9484E
Crankshaft and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103

F5CE9454G , F5CE9484C , F5CE9484E
Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105

F5CE9454G , F5CE9484C , F5CE9484E
Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106

F5CE9454G , F5CE9484C , F5CE9484E
Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110

F5CE9454G , F5CE9484C , F5CE9484E
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206

F5CE9454G , F5CE9484C , F5CE9484E
Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.210

F5CE9454G , F5CE9484C , F5CE9484E
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Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218
F5CE9454G , F5CE9484C , F5CE9484E
Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250

F5CE9454G , F5CE9484C , F5CE9484E
Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254

F5CE9454G , F5CE9484C , F5CE9484E
Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304

F5CE9454G , F5CE9484C , F5CE9484E
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400

F5CE9454G , F5CE9484C , F5CE9484E
Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408

F5CE9454G , F5CE9484C , F5CE9484E
Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

F5CE9454G , F5CE9484C , F5CE9484E
Exhaust Gas Recirculation (EGR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.501

F5CE9454G , F5CE9484C , F5CE9484E
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Engine - 10
Engine and crankcase - 001

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Contents
Engine - 10
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE9454C
F5CE9454G
F5CE9454E
F5CE9484E
F5CE9484C
F5AE9454A
F5AE9484A
F5AE9454D
F5AE9484B
F5AE9484G
F5CE5454G*A001
F5CE5454B*A005
F5CE5454C*A003
F5AE5484A, F5AE5484B*A002, F5AE5484C*A002
F5AE9454J
F5AE9454L
F5AE9484K
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5AE5484B*A002, F5AE5484C*A002
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FUNCTIONAL DATA
Engine
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484B*A002, F5AE5484C*A002
SERVICE
Engine
Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F5AE5484B*A002


F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Crankcase
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Engine - Engine and crankcase
Engine - General specification

F5CE9454C
Cycle Diesel 4 strokes

Aspiration Turbocharged
Injection Direct
N. of cylinders 4 In-line
Bore 99 mm (3.898 in)
Stroke 104 mm (4.094 in)
Total displacement 3202 cm³
Compression ratio 17 : 1
Max. power 40 kW (54 Hp) @ 2300 RPM
Max. torque 220 N·m (162 lb ft) @ 1400 RPM
Loadless engine idling 1100 - 1200 RPM
Loadless engine peak 2700 - 2800 RPM

F5CE9454G

Injection Direct
Bore 99 mm (3.898 in)

F5CE9454E

Injection Direct
Bore 99 mm (3.898 in)
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F5CE9484E

Injection Direct
Bore 99 mm (3.898 in)

F5CE9484C

Injection Direct
Bore 99 mm (3.898 in)

F5AE9454A

Aspiration Turbocharged with intercooler
Injection Direct
Bore 99 mm (3.898 in)
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F5AE9484A

Injection Direct
Bore 99 mm (3.898 in)

F5AE9454D

Injection Direct
Bore 99 mm (3.898 in)

F5AE9484B

Injection Direct
Bore 99 mm (3.898 in)
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F5AE9484G

Injection Direct
Bore 99 mm (3.898 in)

F5CE5454G*A001

Injection Direct
Bore 99 mm (3.898 in)
Loadless engine idling 1150 RPM +/- 25 RPM
Loadless engine peak 2750 RPM +/- 25 RPM

F5CE5454B*A005

Injection Direct
Bore 99 mm (3.898 in)
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F5CE5454C*A003

Injection Direct
Bore 99 mm (3.898 in)

F5AE5484A, F5AE5484B*A002, F5AE5484C*A002

Injection Direct
Bore 99 mm (3.898 in)
Max. power 70 kW (95.2 Hp) @ 2300 RPM
Max. torque 380 N·m (280.3 lb ft) @ 1400 RPM

F5AE9454J

Injection Direct
Bore 99 mm (3.898 in)
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F5AE9454L

Injection Direct
Bore 99 mm (3.898 in)

F5AE9484K

Injection Direct
Bore 99 mm (3.898 in)
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Engine - Service limits

Timing
Intake
- Start before T.D.C. 19 °
- End after B.D.C. 37 °
Exhaust
- Start before B.D.C. 61 °
- End after T.D.C. 21 °
Valve Clearance (hot)
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
Valve Clearance (cold)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.20 mm (0.008 in)
Fuel Feed
Injection Type Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2
Cylinder and Crankshaft Unit
Cylinder bore 99.000 - 99.020 mm (3.8976 - 3.8984 in)
Pistons
- Outside diameter 98.908 - 98.918 mm (3.8940 - 3.8944 in)
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Clearance between cylinder bore and piston 0.082 - 0.112 mm (0.0032 - 0.0044 in)
Piston protrusion -0.22 - 0.07 mm (-0.0087 - 0.0028 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
Clearance between piston pin and housing 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Piston ring landings
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
Clearance between Rings and Landings
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Small end bearing housing 39.460 - 39.490 mm (1.5535 - 1.5547 in)
- Big end bearing housing 67.833 - 67.841 mm (2.6706 - 2.6709 in)
- Small end bearing inside diameter 39.570 - 39.595 mm (1.5579 - 1.5589 in)
- Small end bearing inside diameter (installed) 36.010 - 36.020 mm (1.4177 - 1.4181 in)
Connecting rod big end bearing thickness
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Clearance between Piston pin and small end bearing 0.011 - 0.024 mm (0.0004 - 0.0009 in)
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Maximum allowable twist for connecting rod 0.09 mm (0.0035 in) @ 125 mm (4.9213 in)
Crankshaft
- Main journal diameter (1-2-3-4) 76.182 - 76.208 mm (2.9993 - 3.0003 in)
- Main journal diameter (5) 83.182 - 83.208 mm (3.2749 - 3.2759 in)
- Rod journals 64.015 - 64.038 mm (2.5203 - 2.5212 in)
Main bearing thickness 2.165 - 2.174 mm (0.0852 - 0.0856 in)
Main bore diameter (1-2-3-4) 80.588 - 80.514 mm (3.1728 - 3.1698 in)
Main bore diameter (5) 87.588 - 87.614 mm (3.4483 - 3.4494 in)
Clearance between main bearings and journals (1-2-3-4) 0.064 - 0.095 mm (0.0025 - 0.0037 in)
Clearance between main bearings and journals (5) 0.059 - 0.100 mm (0.0023 - 0.0039 in)
Clearance between rod bearing and journals 0.033 - 0.041 mm (0.0013 - 0.0016 in)
Main journal width for thrust bearing on crankshaft 31.85 - 32.150 mm (1.2539 - 1.2657 in)
Main journal width for thrust bearing in cylinder block 32.50 - 32.55 mm (1.2795 - 1.2815 in)
Thrust bearing thickness 2.51 - 2.56 mm (0.0988 - 0.1008 in)
Clearance between the crankshaft and thrust bearing 0.095 - 0.270 mm (0.0037 - 0.0106 in)
Cylinder Head
Valve guide seats in cylinder head 12.960 - 12.995 mm (0.5102 - 0.5116 in)
Valve Guides
- Inside diameter 8.023 - 8.038 mm (0.3159 - 0.3165 in)
Valves (Intake)
- Valve stem diameter 7.985 - 8.000 mm (0.3144 - 0.3150 in)
- Valve face angle 60 °
Valves (Exhaust)
Clearance between Valve stem and Guide 0.040 - 0.053 mm (0.0016 - 0.0021 in)
Valve seat in the cylinder head
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
Valve seat (Exhaust)
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
- Free spring 44.6 mm (1.756 in)
- Under a load of 256 - 284 N (58 - 64 lb) 34 mm (1.339 in)
Under a load of 500 - 556 N (112 - 125 lb) 23.8 mm (0.937 in)
Injector protrusion 1.7 - 2.35 mm (0.0669 - 0.0925 in)
Camshaft bore inside diameter
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Clearance between cam bearings and journals 0.038 - 0.162 mm (0.0015 - 0.0064 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
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- Exhaust 5.5105 mm (0.2169 in)

Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
- Tappet (Upper and Lower) 15.924 - 15.954 mm (0.6269 - 0.6281 in)
- Tappet (Middle) 15.960 - 15.975 mm (0.6283 - 0.6289 in)
Clearance between tappets and housing 0.03 - 0.068 mm (0.0012 - 0.0027 in)
Rocker Assembly
- Rocker Shaft Outside diameter 18.979 - 19.000 mm (0.7472 - 0.7480 in)
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
Clearance between rockers and shaft 0.020 - 0.054 mm (0.0008 - 0.0021 in)
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Engine - Service limits

F5AE5484C*A002
Timing
Intake
- Start before T.D.C. 19 °
- End after B.D.C. 37 °
Exhaust
- Start before B.D.C. 61 °
- End after T.D.C. 21 °
Valve Clearance (hot)
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
Valve Clearance (cold)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Injection Type Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2
Cylinder and Crankshaft Unit
Cylinder bore 99.000 - 99.020 mm (3.8976 - 3.8984 in)
Pistons
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Clearance between cylinder bore and piston 0.082 - 0.112 mm (0.0032 - 0.0044 in)
Piston protrusion -0.22 - 0.07 mm (-0.0087 - 0.0028 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
Clearance between piston pin and housing 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Piston ring landings
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
Clearance between Rings and Landings
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Small end bearing housing 39.460 - 39.490 mm (1.5535 - 1.5547 in)
- Big end bearing housing 67.833 - 67.841 mm (2.6706 - 2.6709 in)
- Small end bearing inside diameter 39.570 - 39.595 mm (1.5579 - 1.5589 in)
- Small end bearing inside diameter (installed) 36.010 - 36.020 mm (1.4177 - 1.4181 in)
Connecting rod big end bearing thickness
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
- Green 1.891 - 1.900 mm (0.0744 - 0.0748 in)
Clearance between Piston pin and small end bearing 0.011 - 0.024 mm (0.0004 - 0.0009 in)
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Maximum allowable twist for connecting rod 0.09 mm (0.0035 in) @ 125 mm (4.9213 in)
Crankshaft
- Main journal diameter (1-2-3-4) 76.182 - 76.208 mm (2.9993 - 3.0003 in)
- Main journal diameter (5) 83.182 - 83.208 mm (3.2749 - 3.2759 in)
- Rod journals 64.015 - 64.038 mm (2.5203 - 2.5212 in)
Main bearing thickness 2.165 - 2.174 mm (0.0852 - 0.0856 in)
Main bore diameter (1-2-3-4) 80.588 - 80.514 mm (3.1728 - 3.1698 in)
Main bore diameter (5) 87.588 - 87.614 mm (3.4483 - 3.4494 in)
Clearance between main bearings and journals (1-2-3-4) 0.064 - 0.095 mm (0.0025 - 0.0037 in)
Clearance between main bearings and journals (5) 0.059 - 0.100 mm (0.0023 - 0.0039 in)
Clearance between rod bearing and journals 0.033 - 0.041 mm (0.0013 - 0.0016 in)
Main journal width for thrust bearing on crankshaft 31.85 - 32.150 mm (1.2539 - 1.2657 in)
Main journal width for thrust bearing in cylinder block 32.50 - 32.55 mm (1.2795 - 1.2815 in)
Thrust bearing thickness 2.51 - 2.56 mm (0.0988 - 0.1008 in)
Clearance between the crankshaft and thrust bearing 0.095 - 0.270 mm (0.0037 - 0.0106 in)
Cylinder Head
Valve guide seats in cylinder head 12.960 - 12.995 mm (0.5102 - 0.5116 in)
Valve Guides
- Inside diameter 8.023 - 8.038 mm (0.3159 - 0.3165 in)
Valves (Intake)
Valves (Exhaust)
Clearance between Valve stem and Guide 0.040 - 0.053 mm (0.0016 - 0.0021 in)
Valve seat in the cylinder head
- Intake 39.987 - 40.013 mm (1.5743 - 1.5753 in)
- Exhaust 43.787 - 43.813 mm (1.7239 - 1.7249 in)
Valve seat (Intake)
- Seat angle 60 °
Valve seat (Exhaust)
- Seat angle 60 °
Valve recess
- Intake 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Valve spring height
- Free spring 44.6 mm (1.756 in)
- Under a load of 256 - 284 N (58 - 64 lb) 34 mm (1.339 in)
Under a load of 500 - 556 N (112 - 125 lb) 23.8 mm (0.937 in)
Injector protrusion 1.7 - 2.35 mm (0.0669 - 0.0925 in)
Camshaft bore inside diameter
-5 59.222 - 59.248 mm (2.3316 - 2.3326 in)
- 2-3-4 50.069 - 50.119 mm (1.9712 - 1.9732 in)
-1 40.069 - 40.119 mm (1.5775 - 1.5795 in)
Camshaft Journals
-5 53.995 - 54.045 mm (2.1258 - 2.1278 in)
- 2-3-4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
-1 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Clearance between cam bearings and journals 0.038 - 0.162 mm (0.0015 - 0.0064 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
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- Exhaust 5.5105 mm (0.2169 in)

Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
- Tappet (Upper and Lower) 15.924 - 15.954 mm (0.6269 - 0.6281 in)
- Tappet (Middle) 15.960 - 15.975 mm (0.6283 - 0.6289 in)
Clearance between tappets and housing 0.03 - 0.068 mm (0.0012 - 0.0027 in)
Rocker Assembly
- Rocker Shaft Outside diameter 18.979 - 19.000 mm (0.7472 - 0.7480 in)
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
Clearance between rockers and shaft 0.020 - 0.054 mm (0.0008 - 0.0021 in)
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Engine - Overview
73092733 1
ENGINE FRONT VIEW
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73092734 2
ENGINE RIGHT SIDE VIEW
73092735 3
ENGINE LEFT SIDE VIEW
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73092736 4
ENGINE REAR VIEW
73092737 5
ENGINE TOP VIEW
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Engine - Overview
73092883 1
ENGINE FRONT VIEW
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73092885 2
73092884 3
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73092886 4
ENGINE REAR VIEW
73092887 5
ENGINE TOP VIEW
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Engine - Overview
93111631 1
ENGINE FRONT VIEW
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93111630 2
93111629 3
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93111632 4
ENGINE REAR VIEW
93111628A 5
ENGINE TOP VIEW
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Engine - Service instruction - Finding Top Dead Center (TDC)

F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K, F5AE5484B*A002
For engines with access to the timing hole in the flywheel housing
1. Fit the tool 380000150 through the case (1) and into
the port on the flywheel, as shown.
2. Using the tool 380000988 (1) rotate the flywheel un-
til the notch (2) is visible in the inspection hole and
cylinder one is at TDC.
NHVM12ENG0004AA 1
For engines without access to the timing hole in the flywheel housing
NOTE: Prior to performing this procedure, ensure that the engine is near cylinder one TDC on the compression stroke
by verifying that both push rods or rocker arm assemblies on number one cylinder are loose. If both push rods or
rocker arms are tight, rotate the engine one full revolution on the crankshaft, in the direction of normal operation, and
re check the push rods or rocker arm assemblies.
1. Fabricate a wire pointer (1) as shown and attach it to
a front cover bolt (2) that is located close to the vibra-
tion damper (3). Position the pointer approximately
1.6 mm (0.0625 in) from the damper.
2. Rotate the engine in the direction of normal opera-
tion.
3. Pry down on the cylinder number one intake valve
and insert a 6.35 mm (0.25 in) spacer between the
valve stem and rocker arm tip to hold the valve open.
93110987 2
4. Slowly rotate the engine to TDC by hand until the

piston contacts the valve and stops rotation. Make a
reference mark (1) on the damper at the pointer.
5. Rotate the engine counter clockwise as viewed from
the front.
6. Remove the spacer.
7. Rotate the engine clockwise approximately 90 ° past
TDC.
8. Pry down on cylinder number one intake valve and
again insert the spacer between the valve stem and
rocker arm tip to hold the valve open. 93110988 3
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10.001 / 25
9. Slowly rotate the engine back to TDC by hand un-

til the piston contacts the valve and stops rotation.
Make another reference mark (1) on the damper at
the pointer.
10. Rotate the engine clockwise.
11. Remove the spacer.
93110989 4
12. Use a flexible tape measure and make a reference

mark (1) at the center point between the two marks
made on the damper. This mark represents true
TDC.
13. Align the center damper mark to the pointer. This
is cylinder number one at TDC on the compression
stroke.
93110990 5
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10.001 / 26

For engines with access to the timing hole in the flywheel housing
1. Fit the tool 380000150 (1) through the case and into
the port on the flywheel, as shown.
2. Using the tool 380000988 (1) rotate the flywheel un-
til the notch (2) is visible in the inspection hole and
cylinder one is at TDC.
73092764 1
For engines without access to the timing hole in the flywheel housing
NOTE: Prior to performing this procedure, ensure that the engine is near cylinder one TDC on the compression stroke
by verifying that both push rods or rocker arm assemblies on number one cylinder are loose. If both push rods or
rocker arms are tight, rotate the engine one full revolution on the crankshaft, in the direction of normal operation, and
re check the push rods or rocker arm assemblies.
1. Fabricate a wire pointer (1) as shown and attach it to
a front cover bolt (2) that is located close to the vibra-
tion damper (3). Position the pointer approximately
1.6 mm (0.0625 in) from the damper.
2. Rotate the engine in the direction of normal opera-
tion.
3. Pry down on the cylinder number one intake valve
and insert a 6.35 mm (0.25 in) spacer between the
valve stem and rocker arm tip to hold the valve open.
93110987 2
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10.001 / 27
4. Slowly rotate the engine to TDC by hand until the

piston contacts the valve and stops rotation. Make a
reference mark (1) on the damper at the pointer.
5. Rotate the engine counter clockwise as viewed from
the front and remove the spacer.
6. Rotate the engine clockwise approximately 90 ° past
TDC.
7. Pry down on cylinder number one intake valve and
again insert the spacer between the valve stem and
rocker arm tip to hold the valve open.
93110988 3
8. Slowly rotate the engine back to TDC by hand un-

til the piston contacts the valve and stops rotation.
Make another reference mark (1) on the damper at
the pointer.
9. Rotate the engine clockwise and remove the spacer.
93110989 4
10. Use a flexible tape measure and make a reference

mark (1) at the center point between the two marks
made on the damper. This mark represents true
TDC.
11. Align the center damper mark to the pointer. This
is cylinder number one at TDC on the compression
stroke.
93110990 5
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10.001 / 28

1. Fit the tool 380000150 through the case and into the
port (1) on the flywheel.
93111650 1
2. Using the tool 380002385 rotate the flywheel until the

notch is visible in the inspection hole (2) and cylinder
one is at TDC.
93111626 2
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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-
crometer for zero-setting. 73092825A 1
Measurements shall be performed on each cylinder at

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

oversize 0.4 mm (0.016 in).
73092827 3
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10.001 / 31
Index
Engine - 10

Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE9454C
F5CE9454G
F5CE9454E
F5CE9484E
F5CE9484C
F5AE9454A
F5AE9484A
F5AE9454D
F5AE9484B
F5AE9484G
F5CE5454G*A001
F5CE5454B*A005
F5CE5454C*A003
F5AE5484A, F5AE5484B*A002, F5AE5484C*A002
F5AE9454J
F5AE9454L
F5AE9484K
Engine - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F5AE5484B*A002
Engine - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
Engine - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5AE5484B*A002, F5AE5484C*A002
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Engine - 10
Cylinder heads - 101

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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
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Valves
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5CE5454C*A003, F5C, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J,
F5AE9454L, F5AE9484K, F5AE5484B*A002, F5AE5484C*A002
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE9454L, F5AE9484K, F5AE5484B*A002, F5AE5484C*A002
Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Valve guide
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Valve seat
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Engine - Cylinder heads
Valve cover Rocker housing - Remove

Prior operation:
Valve cover - Remove (10.101)
1. Loosen the fastening screws (1), remove the over-

head holding the whole rocker arm unit (2) and re-
cover the two gaskets (3).
73092771 1
Next operation:
Valve cover Rocker housing - Install (10.101)
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10.101 / 3
Valve cover Rocker housing - Install

Prior operation:
Valve cover Rocker housing - Remove (10.101)
1. Replace the gaskets (3), reassemble the rocker arm

holding case (2) and tighten the fastening screws (1)
to the prescribed torque setting.
2. After having completed the assembly, check that the
rocker arms are correctly positioned on the valves
and the tappet push rods.
73092771 1
Next operation:
Valve cover - Install (10.101)
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10.101 / 4
Valve cover - Remove

1. Loosen the screws (1) and remove the tappet covers
(2).
73092766 1
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10.101 / 5
Valve cover - Install

1. Replace the gaskets (2) and install the valve covers
(1).
73092797 1
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Cylinder head - Remove

Prior operation:
Rocker arm - Remove (10.106)
1. Remove the bolts (2).

2. Attach lifting eyes to the cylinder head (1).
3. Lift the cylinder head from the block using a suitable
lifting device.
NOTE: Light tapping may be required to release the cylin-
der head from the locating dowels.
4. Remove the cylinder head gasket.
23119867 1
Next operation:
Cylinder head - Install (10.101)
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10.101 / 7
Cylinder head - Install

Prior operation:
Cylinder head - Remove (10.101)
1. Measure the piston protrusion.

2. Refer to the table below to select the cylinder head
gasket with the correct thickness.
73092790 1
(A) Piston protrusion (B) Gasket thickness

0.07 - -0.07 mm (0.0028 - -0.0028 in) 0.80 mm (0.031 in)
-0.08 - -0.22 mm (-0.0031 - -0.0087 in) 0.70 mm (0.028 in)
3. Install the gasket (1) on the cylinder block.

NOTE: Be sure the gasket is fully seated on the locating
dowels (2).
73092791 2
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10.101 / 8
4. Install the cylinder head (1) on the block while align-

ing the locating dowels.
NOTE: Always use new bolts for assembly.
5. Lubricate the head bolts (2).
23119867 3
6. Torque the bolts to the specifications shown in the

table below following the order shown in the figure.
23110998 4
Bolt size Order number Torque value

Phase 1
- M15x1.5x193 1,2,3,4,5,6 120 - 140 N·m (89 - 103 lb ft)
- M12x1.5x165 7,8,9,10 57 - 73 N·m (42 - 54 lb ft)
Phase 2
- M15x1.5x193 1,2,3,4,5,6 85 - 95 °
- M12x1.5x165 7,8,9,10 85 - 95 °
Phase 3
- M15x1.5x193 1,2,3,4,5,6 85 - 95 °
- M12x1.5x165 7,8,9,10 55 - 65 °
Next operation:
Rocker arm - Install (10.106)
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10.101 / 9
Cylinder head - Disassemble

Prior operation:
1. Number the valves before removal to ensure the cor-

rect orientation during assembly.
NOTE: The intake valves (1) and the exhaust valves (2)
are different sizes.
73092871 1
2. Compress the valve spring (4) using tool (1).

3. Remove the keepers (2).
4. Release the tool (1) and remove the cap (3) and
spring (4).
5. Repeat the operation for each valve.
73092872 2
6. Turn the cylinder head upside down and remove the

valves (5).
73092871 3
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10.101 / 10
7. Remove the valve stem seals (1) from the valve

guides.
73092873 4
Next operation:
Cylinder head - Assemble (10.101)
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Cylinder head - Check

Prior operation:
Cylinder head - Disassemble (10.101)
1. Check the bottom surface of the cylinder head for

flatness using a straight edge.
2. Use feeler gauges to check the gaps between the
straight and cylinder head surface.
3. Machine the surface of the cylinder head if values
exceeding 0.20 mm (0.008 in) are found.
NOTICE: Machining should not exceed 0.13 mm (0.005
in). Replace the cylinder head if the surface cannot be
machined to specifications.
4. Check the valve seats for cracks and wear.
Next operation:
Valve guide - Measure (10.101)
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10.101 / 12
Cylinder head - Assemble

Prior operation:
1. Lubricate the valve stems (1) with clean engine oil.

2. Install the valves in the order of disassembly.
3. Install the valve stem seals (2) and (3) on the valve
guide using tool 380000134.
73092881 1
4. Place the spring (4) and the plate (3) over the valve
stem.
5. Compress the spring (4) using tool (1).
6. Install the keepers (2) in the groves of the valve stem
and release the spring pressure.
NOTE: Place a small amount of grease on the inside of the
keepers to hold them in place until the spring pressure is
released.
73092872 2
Next operation:
Cylinder head - Install (10.101)
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10.101 / 13
Valves - Cleaning
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003,
F5C, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K, F5AE5484B*A002,
F5AE5484C*A002
Prior operation:
1. Remove carbon deposits from the valves using a

wire wheel.
2. Check that the valves show no signs of seizure or
cracking. Replace if any defects are found.
93107215 1
Next operation:
Valves - Measure (10.101)
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10.101 / 14
Valves - Measure
F5C, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K, F5AE5484B*A002,
F5AE5484C*A002
Prior operation:
Valves - Cleaning (10.101)
1. Measure the valve stem (1) using a micrometer (2).

The standard value is 7.985 - 8.000 mm (0.314 -
0.315 in).
73092877 1
Next operation:
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10.101 / 15
Valves Spring - Measure

Prior operation:
1. Use the table below to measure the valve spring

height at specific loads. If the values below are not
met, replace the spring.
73092880 1
Height Load
(H) 44.6 mm (1.756 in) 0 N (0 lb)
(H1) 34 mm (1.339 in) 256 - 284 N (58 - 64 lb)
(H2) 23.8 mm (0.937 in) 502 - 554 N (113 - 125 lb)
Next operation:
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10.101 / 16
Valve guide - Measure

Prior operation:
1. Measure the inside diameter of the valve guides.

2. Replace the valve guides if the measurement is not
within 8.023 - 8.038 mm (0.3159 - 0.3165 in).
73092878A 1
Next operation:
Valve seat - Replace (10.101)
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10.101 / 17
Valve seat - Replace

Prior operation:
NOTICE: Use caution to avoid damaging the cylinder head during this procedure.
1. Remove as much material from the valve seats as
possible without damaging the cylinder head.
2. Drive the valve seats from the cylinder head using a
punch.
3. Heat cylinder head to 80 - 100 °C (176 - 212 °F) while
cooling the valve seats.
4. Drive in the new valve seats using an appropriate
punch.
5. Cut the valve seats to the specifications in the table
below.
NHPH12ENG0015AA 1
Valve seat specifications

Intake valve seat (A)
- Seat angle (2) 60 °
Exhaust valve seat (B)
- Seat angle (3) 60 °
Valve recess
- Intake (1) 0.3 - 0.7 mm (0.0118 - 0.0276 in)
- Exhaust (4) 0.3 - 0.7 mm (0.0118 - 0.0276 in)
Next operation:
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10.101 / 18
Index
Engine - 10

Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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 - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5CE5454C*A003, F5C, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L,
F5AE9484K, F5AE5484B*A002, F5AE5484C*A002
Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE9484K, F5AE5484B*A002, F5AE5484C*A002
Valves Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Engine - 10
Pan and covers - 102

47388346 04/05/2012
10.102 / 1
Contents
Engine - 10
SERVICE
Engine oil pan

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5AE5484B*A002, F5AE5484C*A002
Engine block cover

Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5CE5454C*A003, F5AE5484B*A002, F5AE5484C*A002
Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5AE5484B*A002, F5AE5484C*A002
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing gear housing

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE5484B*A002, F5AE5484C*A002
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Engine - Pan and covers
Engine oil pan - Remove

1. Drain the engine oil.

3. Remove the oil pan (1) and plate (3).
NOTE: The figures provided are for reference only. The
shape and dimension of the oil pan and the pick up tube
may vary depending on engine application.
73092776 1
4. Remove the pick up tube support bolts (1).

5. Remove the bolt (2) and remove the pick up tube (3).
73092777 2
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10.102 / 3
Engine oil pan - Install

1. Install a new o-ring on the pick up tube (3).

2. Install the oil pick up tube (3).
3. Torque the tube bolt (2) to 10 N·m (7 lb ft).
4. Torque the support bolts (1) to 45 N·m (33 lb ft).
73092777 1
5. Install the new gasket (1) on the oil pan (2).
73092800 2
6. Install the oil pan (1) with the plate (3).

7. Torque the bolt (2) as follows:
• M10x1.5 = 45 N·m (33 lb ft)
• M8x1.25 = 25 N·m (18 lb ft)
73092776 3
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10.102 / 4
Engine oil pan - Remove

F5AE5484C*A002
1. Turn the engine upside down.

2. Remove the screws (2) and detach the oil pan (1).
3. Remove the oil pick up tube.
73092901 1
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10.102 / 5
Engine oil pan - Install

F5AE5484C*A002
1. Instal the oil pick up tube.

2. Mount the oil pan (1) and tighten the screws (2) to
the required torque.
NOTE: Before installing the pan, verify that the threads of
the holes and the screws are not worn and dirty.
73092916 1
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Engine block cover Front - Install

F5AE5484B*A002, F5AE5484C*A002
1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing's cover using the centring pins (1) to
correctly position it and then tighten the fastening
screws to the prescribed torque.
73092787A 1
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10.102 / 7
Engine block cover Front - Install

1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing's cover using the centring pins (1) to
correctly position it and then tighten the fastening
73092908 1
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10.102 / 8
Engine block cover Rear - Install

1. Accurately clean the timing gearcase and the engine

block.
NOTICE: It is absolutely necessary to clean the surface
to be sealed in order to obtain perfect tightness. Apply
LOCTITE® 5970 sealer on the gearcase in order to form a
sealing bead of 1.5 mm (0.059 in). The sealing bead must
be homogeneous (no lumps), free of air bubbles, thinner
areas and gaps. Any imperfection must be corrected as
soon as possible. Avoid the excess of sealer: too much
sealing material would leak and pour out on both sides of
the joint parts and, as a consequence, obstruct the pas-
sage of the lubricant. After having applied the sealer, the
parts must be joined within 10 minutes.
73092781 1
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10.102 / 9

F5AE5484C*A002

block.
73092903 1
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10.102 / 10


block.
93111626 1
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10.102 / 11
Timing gear housing - Remove

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

cover.
73092774 1
Next operation:
Timing gear housing - Install (10.102)
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10.102 / 12
Timing gear housing - Install

Prior operation:
Timing gear housing - Remove (10.102)
1. Assemble the front case (1) and tighten the fastening

NOTE: It is absolutely necessary to clean the surface to be
sealed in order to obtain perfect tightness. Apply LOCTITE®
5970 sealer on the gearcase in order to form a sealing bead
of 1.3 - 2.0 mm (0.051 - 0.079 in). The sealing bead must
73092785 1
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10.102 / 13
Timing gear housing - Remove

F5AE5484C*A002
1. Remove the rear part (1), of the timing gearcase

cover.
73092900 1
Next operation:
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10.102 / 14
Timing gear housing - Install

F5AE5484C*A002
Prior operation:
1. Assemble the front case (1) and tighten the fastening

NOTE: It is absolutely necessary to clean the surface to be
sealed in order to obtain perfect tightness. Apply LOCTITE®
5970 sealer on the gearcase in order to form a sealing bead
of 1.3 - 2.0 mm (0.051 - 0.079 in). The sealing bead must
73092906 1
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10.102 / 15
Index
Engine - 10

Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5AE5484B*A002, F5AE5484C*A002
Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454C*A003
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5AE5484B*A002, F5AE5484C*A002
Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE5454C*A003
Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE5484B*A002, F5AE5484C*A002
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5CE5454C*A003
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE5484B*A002, F5AE5484C*A002
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454C*A003
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5AE5484B*A002, F5AE5484C*A002
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Engine - 10
Crankshaft and flywheel - 103

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10.103 / 1
Contents
Engine - 10
SERVICE
Engine flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484B*A002, F5AE5484C*A002
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft oil seal

Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F5CE5454C*A003
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F5AE5484B*A002, F5AE5484C*A002
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F5AE5484B*A002, F5AE5484C*A002
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE5484B*A002, F5AE5484C*A002
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5AE5484B*A002, F5AE5484C*A002
Journal - Measure - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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10.103 / 2
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main bearings
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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10.103 / 3
Engine - Crankshaft and flywheel
Engine flywheel - Remove

1. Fit tool (1) 380002385 to the flywheel housing and,

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

order to secure the flywheel (1) with a sling.
4. By means of two guide pins (2) previously screwed
in the engine drive shaft ports (3), guide the flywheel
withdrawal throughout a hoist.
5. Withdraw the flywheel casing grommet.
6. Withdraw the grommet of the timing gearcase.
73092773 2
Next operation:
Engine flywheel - Install (10.103)
47388346 04/05/2012
10.103 / 4
Engine flywheel - Install

Prior operation:
Engine flywheel - Remove (10.103)
1. Screw two hooks or eyebolts on the flywheel (1)

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

in the following sequence.
• 25 - 35 N·m (18 - 26 lb ft)
• 85 - 95 °
NOTE: Angular fastening must be executed using tool
380000304. Before assembly, always check that the port
threads and the screws show no trace of wear and dirt.
73092783 2
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10.103 / 5

F5AE5484C*A002
1. Fit tool 380000150 to the flywheel housing (1).

2. Rotate the engine by hand until the pin locks the en-
gine in place.
3. Loosen the screws fastening the flywheel to the en-
gine drive shaft.
93110995 1
4. Screw two medium length screws in the ports (4), in

order to secure the flywheel (1) with a sling.
5. By means of two guide pins (2) previously screwed
in the engine drive shaft ports (3), guide the flywheel
withdrawal throughout a hoist.
6. Withdraw the flywheel casing grommet.
7. Withdraw the grommet of the timing gearcase.
73092899 2
Next operation:
47388346 04/05/2012
10.103 / 6

F5AE5484C*A002
Prior operation:
1. Screw two hooks or eyebolts on the flywheel (1)

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

in the following sequence.
• 25 - 35 N·m (18 - 26 lb ft)
• 85 - 95 °
NOTE: Angular fastening must be executed using tool
380000304. Before assembly, always check that the port
threads and the screws show no trace of wear and dirt.
73092905 2
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10.103 / 7

1. Install tool 380000732 (1) in the flywheel housing to

lock the flywheel rotation.
NOTE: On some applications, tool 380000988 may be re-
quired to mount tool 380000732 to the starter flange on the
flywheel housing.
73092772 1
2. Loosen the flywheel (1) mounting bolts.

NOTE: Do not remove the bolts at this point.
3. Install two medium length bolts into the threaded
holes (3) in order to attach a lifting device.
4. Remove two mounting bolts and install guide pins (2)
in their place.
5. Attach a lifting device.
6. Remove the remaining mounting bolts.
7. Slide the flywheel along the guide pins.
8. Remove the flywheel from the engine.
93111650 2
Next operation:
47388346 04/05/2012
10.103 / 8

Prior operation:
1. Install two guide pins (2) into the flywheel mounting

holes on the crankshaft.
2. Install two bolts (3) suitable for lifting in the threaded
holes in the flywheel (1).
3. Lift the flywheel up to the guide pins using a lifting
device.
4. Align the locating dowel on the crankshaft with the
hole on the flywheel.
5. Install tool 380000732 (1) in the flywheel housing to
lock the flywheel rotation.
NOTE: On some applications, tool 380000988 may be re-
quired to mount tool 380000732 to the starter flange on the 93111650 1
flywheel housing.
6. Torque the bolts to 25 - 35 N·m (18 - 26 lb ft).
7. Then, turn the bolts an additional 90 °
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10.103 / 9
Crankshaft oil seal Rear seal - Install

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

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

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

sure that the engine crankshaft pin is correctly fitted
into the tool spline in order to avoid damaging it. Fix
it with the screw and install the new seal.
2. Place the outer section of the tool on the previously
fitted one, tighten the screw nut until completely fit-
ting the seal into the casing.
73092788A 1
47388346 04/05/2012
10.103 / 11
Crankshaft oil seal Rear seal - Install

F5AE5484C*A002
1. Fit the specific tool (5) to the rear shank (6) of the
engine drive shaft, fix it with the screws (4) and install
the new seal (3).
2. Position part (1) on part (5), tighten the screw nut
(2) until the seal has been fitted (3) into the flywheel
casing (7).
73092904 1
47388346 04/05/2012
10.103 / 12
Crankshaft oil seal Front seal - Install

F5AE5484C*A002
1. Fit the inner part of tool to the front crankshaft. Make

sure that the engine crankshaft pin is correctly fitted
into the tool spline in order to avoid damaging it. Fix
it with the screw and install the new seal.
2. Place the outer section of the tool on the previously
fitted one, tighten the screw nut until completely fit-
ting the seal into the casing.
73092909 1
47388346 04/05/2012
10.103 / 13
Crankshaft - Remove
Prior operation:
Engine oil pan - Remove (10.102)
1. Using tool 380000362 (1) and a hoist, remove the

engine crankshaft (2) from the crankcase.
73092820 1
Next operation:
Crankshaft - Install (10.103)
47388346 04/05/2012
10.103 / 14
Crankshaft - Remove
F5AE5484C*A002
1. Using tool 380000362 (1) and a hoist, remove the

engine crankshaft (2) from the crankcase.
73092920 1
Next operation:
47388346 04/05/2012
10.103 / 15
Crankshaft - Measure
Prior operation:
Crankshaft - Remove (10.103)
1. In case meshing, scratches or excessive oval shap-

ing is detected on the main journals and crankshaft
bearing pins, it is necessary to grind the pins. Before
proceeding with pin (2) grinding, measure the shaft
pins by means of a micrometer (1) in order to estab-
lish to which diameter the pins must be reduced.
73092838 1
73092839 2
PROSPECT REPORTING MEASUREMENT VALUES OF THE ENGINE DRIVE SHAFT MAIN JOURNALS AND
CRANKSHAFT BEARING PINS
47388346 04/05/2012
10.103 / 16
73092840 3
ENGINE DRIVE SHAFT MAIN TOLERANCES
73092841 4
Next operation:
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10.103 / 17
Crankshaft - Install
Prior operation:
Main bearings - Install (10.103)
1. Install the engine crankshaft (2) using a suitable hoist

(1).
73092820 1
Next operation:
Crankshaft - End play (10.103)
47388346 04/05/2012
10.103 / 18
Crankshaft - Install
F5AE5484C*A002
Prior operation:
1. Install the engine crankshaft (2) using a suitable hoist

(1).
73092920 1
47388346 04/05/2012
10.103 / 19
Crankshaft Journal - Measure - Clearance

Prior operation:
Main journals
1. Clean the crankshaft journals and main bearings.
2. Place a piece of plastic gauge (3) on the surface of
the journal (2) as shown.
3. Install the main bearing caps (1).
73092843 1
4. Lubricate the bolts (1).

6. Then, torque the bolts to 74 - 86 N·m (55 - 63 lb ft)
73092844A 2
7. Then, turn the bolts an additional 90 °.
73092845A 3
47388346 04/05/2012
10.103 / 20
8. Remove the main bearing caps.

9. Compare the widest point of the plastic gauge to the
scale on the package (1).
10. The width of the wire should be between:
• 0.064 - 0.095 mm (0.0025 - 0.0037 in) for jour-
nals 1, 2, 3, 4
• 0.059 - 0.100 mm (0.0023 - 0.0039 in) for jour-
nal 5
11. Replace the bearings if the values above cannot be
obtained and perform the procedure again.
73092846A 4
Connecting rod journals

1. Clean the crankshaft journals and connecting rod
bearings.
2. Place a piece of plastic gauge (3) on the surface of
the journal (2) as shown.
3. Install the connecting rod caps (1).
73092867 5
4. Lubricate the bolts (1).

73092868 6
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10.103 / 21
6. Then, turn the bolts an additional 70 °.
73092869 7
7. Remove the connecting rod caps.

8. Compare the widest point of the plastic gauge to the
scale on the package (1).
9. The width of the wire should be between 0.033 -
0.041 mm (0.0013 - 0.0016 in)
10. Replace the bearings if the value above cannot be
obtained and perform the procedure again.
73092870 8
Next operation:
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10.103 / 22
Crankshaft - End play

Prior operation:
1. Install a dial gauge (1) with a magnetic base (2) on

the cylinder block.
2. Set the gauge perpendicular to the crankshaft (3) as
shown.
3. Push the crankshaft in towards the engine block and
zero the dial gauge.
4. Pull the crankshaft out towards the dial gauge.
5. The measurement should be 0.095 - 0.270 mm
(0.0037 - 0.0106 in). Replace the thrust bearing if
necessary.
73092847A 1
47388346 04/05/2012
10.103 / 23
Main bearings - Remove

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

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

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

move (10.103) for the proper procedure.
4. Remove the crankshaft upper half bearings (1).
73092821 3
Next operation:
Main bearings - Install (10.103)
47388346 04/05/2012
10.103 / 24
Main bearings - Install

1. Carefully clean the crankshaft half bearings (1) hav-
ing lubrication port and fit them in their respective
seats.
NOTICE: If using the old bearings, be sure to place them
back into their original position.
2. Install the bearing with the thrust shoulders in the
correct position.
73092842 1
Next operation:
47388346 04/05/2012
10.103 / 25
Index
Engine - 10

Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454C*A003
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5AE5484B*A002, F5AE5484C*A002
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5CE5454C*A003
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE5484B*A002, F5AE5484C*A002
Crankshaft Journal - Measure - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5CE5454C*A003
Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5AE5484B*A002, F5AE5484C*A002
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5AE5484B*A002, F5AE5484C*A002
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE5484B*A002, F5AE5484C*A002
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5AE5484B*A002, F5AE5484C*A002
Main bearings - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Main bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Engine - 10
Connecting rods and pistons - 105

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10.105 / 1
Contents
Engine - 10
FUNCTIONAL DATA
Connecting rod and piston

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Connecting rod and piston

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Piston
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - Connecting rods and pistons
Connecting rod and piston - Exploded view
73092848A 1
(1) Snap ring (5) Bolts

(2) Pin (6) Half bearings
(3) Piston (7) Connecting rod
(4) Piston rings (8) Bushing
47388346 04/05/2012
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Connecting rod and piston - Remove

Prior operation:

2. Remove the connecting rod caps (2).
3. Push the connecting rod and piston assembly out of
the top of the cylinder.
NOTE: Keep the bearings matched to the connecting rod
in case of reuse after the overhaul.
73092817 1
Next operation:
Connecting rod and piston - Install (10.105)
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10.105 / 4
Connecting rod and piston - Disassemble

Prior operation:
1. Check the piston for signs of seizing, scoring or

cracking. Replace if necessary.
2. Remove the piston rings (2) using the tool
380000324 (1).
73092849 1
3. Remove the snap rings (1).
73092863 2
4. Remove the piston pin (1).

NOTE: It may be necessary to lightly tap the pin to remove.
73092862 3
Next operation:
Connecting rod and piston - Assemble (10.105)
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10.105 / 5
Connecting rod and piston - Assemble

Prior operation:
Connecting rod and piston - Disassemble (10.105)
1. Install the piston pin (3) through the piston (2) and
connecting rod (4).
NOTE: Use the markings on the piston (1) to correctly ori-
ent the piston on the connecting rod. The (→) marks the
front of the engine as viewed from the top.
73092862 1
2. Install the snap rings (1).
73092863 2
3. Install the piston rings (1) using the tool 380000221

(2).
4. Arrange the rings so the end gaps are 120 ° apart.
73092849 3
Next operation:
Connecting rod and piston - Install (10.105)
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10.105 / 6
Connecting rod and piston - Install

Prior operation:
1. Install the bearings (1) on the connecting rod and

cap.
2. Lubricate the piston skirts, rings and the inside of the
cylinder bores.
73092864 1
3. Set the crankshaft for the cylinder to be installed to

Bottom Dead Center (BDC).
4. Align the notch in the piston skirt with the oil spray
nozzle.
5. Orient the openings in the piston rings 120 ° apart.
6. Install the piston ring compressor 380000220.
7. Push the connecting rod and piston assembly into
the cylinder bore.
NOTE: Lightly tapping the top of the piston with a wooden
dowel may be necessary.
73092865 2
8. Install the connecting rod cap.

NOTICE: The connecting rods are fracture split. Ensure
the cap is seated correctly prior to torquing the bolts.
9. Torque the bolts to 50 N·m (37 lb ft) then 70 °.
Next operation:
Engine oil pan - Install (10.102)
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10.105 / 7
Piston - Measure
Prior operation:
1. Measure the diameter of the piston (1) using a mi-

crometer (2).
NOTE: The diameter of the piston must be measured at
the point shown in the figure for accurate measurement.
2. The diameter should be between 98.908 - 98.918
mm (3.8940 - 3.8944 in). Replace if necessary.
73092850 1
Next operation:
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10.105 / 8
Piston Pin - Measure

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

micrometer (2).
2. The pin diameter should be between 36.003 - 36.009
mm (1.4174 - 1.4177 in). Replace if necessary.
73092853 1
3. Lubricate the pin (1) and the pin housing with clean
engine oil.
4. Insert the pin into the piston. It must be inserted with
slight finger pressure and it should not come out by
gravity.
73092854 2
Next operation:
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10.105 / 9
Piston Ring - Measure

Prior operation:
1. Measure the thickness of the piston ring (2) with a

micrometer (1).
2. The thickness should be as follows. Replace if nec-
essary.
• Top – 2.068 - 2.097 mm (0.0814 - 0.0826 in)
• Middle – 1.970 - 1.990 mm (0.0776 - 0.0783 in)
• Bottom – 2.470 - 2.490 mm (0.0972 - 0.0980
in)
73092855 1
3. Insert the rings (2), one at a time into the cylinder

bore (3).
NOTE: Square the rings in the bore by inserting the piston
upside down.
4. Measure the ring end gap using feeler gauges (1).
5. The end gap should be as follows. Replace if neces-
sary.
• Top – 0.20 - 0.35 mm (0.0079 - 0.0138 in)
• Middle – 0.60 - 0.80 mm (0.0236 - 0.0315 in)
• Bottom – 0.30 - 0.60 mm (0.0118 - 0.0236 in)
73092858 2
6. Measure the clearance between the rings (3) and

lands on the piston (2) with a feeler gauge (1).
NOTE: The top ring has a "V" shape. Refer to steps 8 - 11
to properly measure the top ring.
7. The clearance should be as follows. Replace if nec-
essary.
• Middle – 0.06 - 0.100 mm (0.0024 - 0.0039 in)
• Bottom – 0.05 - 0.09 mm (0.0020 - 0.0035 in)
73092856 3
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10.105 / 10
8. Install the top ring (2) on the piston (1).

9. Install the piston into the cylinder bore (3) leaving the
top ring exposed halfway.
10. Measure the clearance (X) using feeler gauges.
11. The clearance should be as follows. Replace if nec-
essary.
• Top – 0.06 - 0.100 mm (0.0024 - 0.0039 in)
73092857 4
Next operation:
47388346 04/05/2012
10.105 / 11
Index
Engine - 10

Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - 10
Valve drive and gears - 106

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10.106 / 1
Contents
Engine - 10
SERVICE
Valve drive and gears

Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rocker arm
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5AE9454L, F5AE9484K, F5A
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE9454L, F5AE9484K, F5A
Camshaft
Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Camshaft bushings
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Engine - Valve drive and gears
Valve drive and gears - Timing adjust

1. Align the tooth on the crankshaft gear (1) that has
the 45 ° bevel, with the timing gear (2) that has two
reference marks as shown in the figure.
2. Rotate the camshaft keeping the timing gear in place
until the camshaft's pin fits into the relevant housing
within the timing gear.
3. Install the screws of the transmission gear without
fully tightening them.
4. With a magnetic base dial gauge, check the clear-
ance among the engine crankshaft gear and the
camshaft gear: it must be 0.068 - 0.168 mm (0.003
- 0.007 in).
5. Tighten the fastening screws of the transmission
gear.
73092907 1
47388346 04/05/2012
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Rocker arm - Remove

F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5C,
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K, F5A
Prior operation:
Valve cover Rocker housing - Remove (10.101)
1. Loosen the rocker arm fastening screw (1) from the

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

the equalizers (2) from the other.
73092780 2
Next operation:
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Rocker arm - Install

F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5C,
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K, F5A
Prior operation:
1. Fit the rocker arms onto the shaft.

2. The intake arms (short) (2) goes on first, and then
the exhaust arms (long) (1).
73092780 1
Next operation:
Valve cover Rocker housing - Install (10.101)
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Camshaft Push rod - Remove

Prior operation:
1. Remove the push rods (1).
23119867 1
Next operation:
Camshaft Push rod - Inspect (10.106)
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10.106 / 6
Camshaft Push rod - Inspect

Prior operation:
Camshaft Push rod - Remove (10.106)
1. Check for wear or seizing on both ends of the push

rods.
2. Roll the push rods on a flat surface to check for de-
formities.
3. Replace the push rods if any of the above conditions
are found.
NOTE: The push rods are interchangeable between intake
and exhaust rockers.
73092794 1
Next operation:
Camshaft Push rod - Install (10.106)
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Camshaft Push rod - Install

Prior operation:
Camshaft Push rod - Inspect (10.106)
1. Install the push rods (1).

NOTE: Be sure the ball end of the push rod is properly
seated in the tappet.
23119867 1
Next operation:
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Camshaft - Remove
Prior operation:
1. Loosen the fastening screws (1) and disassemble

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

bock.
73092823A 2
Next operation:
Camshaft - Install (10.106)
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Camshaft Tappets - Remove

Prior operation:
Camshaft - Remove (10.106)
NOTE: Mark the location of the tappets to ensure the same position during installation.
1. Remove the tappets (1).
73092824A 1
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Camshaft - Measure
Prior operation:
1. Support the ends of the camshaft.

2. Place a dial gauge on the center journal (1).
3. Rotate the camshaft to check for radial move-
ment.Replace the camshaft if the movement ex-
ceeds 0.015 mm (0.0006 in) or there are signs of
wear or seizing on the surfaces. 73092828 1
4. Check the diameter of the camshaft journals (1) on

two perpendicular axis’, using a micrometer (2). Re-
place the camshaft if the values are not within the
specifications shown in the chart below.
73092829 2
Camshaft journal Specifications

1 53.995 - 54.045 mm (2.1258 - 2.1278 in)
2, 3, 4 49.975 - 50.025 mm (1.9675 - 1.9695 in)
5 39.975 - 40.025 mm (1.5738 - 1.5758 in)
Next operation:
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Camshaft Tappets - Install

Prior operation:
Camshaft Tappets - Remove (10.106)
1. Lubricate the tappets (1) with clean engine oil.

2. Install the tappets.
73092834 1
Next operation:
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Camshaft - Install
Prior operation:
1. Lubricate the camshaft journals with clean engine oil.

2. Install the camshaft (1).
NOTE: Be sure not to damage the bushings during instal-
lation.
73092823A 1
3. Install the retainer plate (1).

4. Torque the bolts (2) to 20 - 30 N·m (15 - 22 lb ft).
73092835 2
Next operation:
Camshaft - End play (10.106)
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Camshaft - End play

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

ment should be 0.10 - 0.36 mm (0.004 - 0.014 in).
73092836 1
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Camshaft bushings - Measure

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

1. Use the driver 380000667 (2) and hand grip
380000999 (3) to remove and replace the bushing
(1).
NOTICE: Be sure to align the oil lubrication port in the block
with the hole in the bushing.
73092832 1
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Index
Engine - 10

Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Camshaft Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Camshaft bushings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Camshaft bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE9484K, F5A
Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5AE9484K, F5A
Valve drive and gears - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Balancer and damper - 110

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10.110 / 1
Contents
Engine - 10
FUNCTIONAL DATA
Balancer
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5AE5484B*A002, F5AE5484C*A002
SERVICE
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE5484B*A002, F5AE5484C*A002
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Engine - Balancer and damper
Balancer - Overview
F5AE5484C*A002
73092889 1
Dynamic Balancer
(1) Reference notches for alignment and timing (4) Balancing masses
(2) Thrust washers (5) Shaft
(3) Bushings (6) Case
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Balancer - Remove
F5AE5484C*A002
Prior operation:
1. Unscrew the screws (2) which fasten the dynamic

balancer (1) and remove it.
73092902 1
Next operation:
Balancer - Install (10.110)
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10.110 / 4
Balancer - Install
F5AE5484C*A002
Prior operation:
Balancer - Remove (10.110)
1. Mount the dynamic balancer (1) taking care that the

reference notches (2) coincide as shown in figure.
76092914 1
Next operation:
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10.110 / 5
Index
Engine - 10

Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE5484B*A002, F5AE5484C*A002
Balancer - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5AE5484B*A002, F5AE5484C*A002
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5AE5484B*A002, F5AE5484C*A002
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Engine - 10
Fuel filters - 206

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10.206 / 1
Contents
Engine - 10
Fuel filters - 206
FUNCTIONAL DATA
Fuel filters
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Fuel filters
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE5484B*A002, F5AE5484C*A002
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Engine - Fuel filters
Fuel filters - Overview

The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water
from the fuel in which it is contained. At the bottom of the filtering cartridge there may be a water drainage device;
depending on the appliance (use in cold climate conditions), the fuel filter support may be equipped with a heater and
a temperature sensor. Some versions are also equipped with a water detecting sensor at the bottom of the cartridge
filter.
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73092759 1
(1) Fuel filter support (2) Cartridge filter (3) Water drainage device (not
available on all versions)
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10.206 / 4
Fuel filters - Remove

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

screw the water drainage valve (3)under the filter;
completely drain the diesel fuel container.
2. Disassemble the diesel fuel filter (1), the filter support
(2).
73092765 1
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10.206 / 5
Fuel filters - Install

1. Install the fuel filter support (1) and the fuel filter (2).
73092765 1
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10.206 / 6
Fuel filters - Remove

F5AE5484C*A002
1. Place a container under the diesel fuel filter and un-

screw the water drainage valve (3)under the filter;
completely drain the diesel fuel container.
2. Disassemble the diesel fuel filter (1), the filter support
(2).
73092894 1
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Fuel filters - Install

F5AE5484C*A002
1. Install the fuel filter support (1) and the fuel filter (2).
73092894 1
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10.206 / 8
Index
Engine - 10
Fuel filters - 206

Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE5484B*A002, F5AE5484C*A002
Fuel filters - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484B*A002, F5AE5484C*A002
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Engine - 10
Lift pump and lines - 210

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10.210 / 1
Contents
Engine - 10
FUNCTIONAL DATA
Priming pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Priming pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484B*A002, F5AE5484C*A002
Fuel supply lines

Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5CE5454C*A003
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

F5CE5454C*A003
Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

F5AE5484B*A002, F5AE5484C*A002
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F5AE5484B*A002, F5AE5484C*A002
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Engine - Lift pump and lines
Priming pump - Overview

The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the
engine block and driven by the engine camshaft.
73092758 1
(1) Pump (2) Control lever (3) Camshaft
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10.210 / 3
Priming pump - Remove

1. Remove the priming pump (1).
73092765 1
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10.210 / 4
Priming pump - Install

1. Install the priming pump (1).
73092765 1
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10.210 / 5
Priming pump - Remove

F5AE5484C*A002
1. Remove the priming pump (1).
73092894 1
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10.210 / 6
Priming pump - Install

F5AE5484C*A002
1. Install the priming pump (1).
73092894 1
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10.210 / 7
Fuel supply lines Low pressure - Remove

1. Remove the Load Delivery Adjustment (LDA) pipe.

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

1. Reassemble the pipe from the pump to the injector

and tighten the bracket's fastening screws (3).
2. Reassemble the pipe from the pump to the fuel filter
(2) and from the fuel filter to the priming pump (1).
3. Reassemble the Load Delivery Adjustment (LDA)
pipe.
73092762 1
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10.210 / 9
Fuel supply lines Low pressure - Remove

F5AE5484C*A002
1. Remove the Load Delivery Adjustment (LDA) pipe.

Remove the fuel pipes from the priming pump (1)
to the filter and from the filter to the ignition pump
(2), then fit the specially provided caps to the pipes,
the pumps and the filter. Unscrew the screws (3),
fastening the fuel ignition pipes and remove them.
73092893A 1
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10.210 / 10
Fuel supply lines Low pressure - Install

F5AE5484C*A002
1. Reassemble the pipe from the pump to the injector

and tighten the bracket's fastening screws (3).
2. Reassemble the pipe from the pump to the fuel filter
(2) and from the fuel filter to the priming pump (1).
3. Reassemble the Load Delivery Adjustment (LDA)
pipe.
73092762 1
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10.210 / 11
Index
Engine - 10

Fuel supply lines Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5CE5454C*A003
Fuel supply lines Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5AE5484B*A002, F5AE5484C*A002
Fuel supply lines Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5CE5454C*A003
Fuel supply lines Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5AE5484B*A002, F5AE5484C*A002
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484B*A002, F5AE5484C*A002
Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5AE5484B*A002, F5AE5484C*A002
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Engine - 10
Fuel injection system - 218

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Contents
Engine - 10
FUNCTIONAL DATA
Fuel injection system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Injection pump
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Fuel injection system

Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Injection pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel injectors
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - Fuel injection system
Fuel injection system - Overview
73092749 1
SUPPLY SYSTEM DIAGRAM
(1) Injectors (2) Fuel filter (3) Tank (4) Supply pump (5) Ignition pump
The engine supply system consists of the following components:

• Fuel tank (aboard the vehicle)
• Fuel delivery and return pipes
• Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicle's chassis)
• Priming pump, fitted on the engine and driver by the engine camshaft
• Fuel filter (its position on the engine may vary depending on the outfit and use)
• Supply rotary pump
• Injector feed pipe (from the fuel supply pump to the fuel injectors)
• Injectors
NOTE: Models (F5CE5454G*A001, F5CE5454C*A003, and F5CE5454B*A005) use a remotely mounted electric lift
pump, description will not be accurate.
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73092750 2
PIPE LAYOUT
(1) Injector feed pipe (5) KSB thermal bulb

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

The fuel (5) is primed from the fuel tank from the priming pump (6). The latter is fitted on the engine basement and
is driven by the engine camshaft. Throughout the filter (4), fuel is conveyed to the transfer pump, which is placed
inside the supply rotary pump (2), which is a turbine blade pump type. The supply rotary pump duty is to increase the
fuel pressure based on the increase of engine revolutions' number. Then, the fuel reaches the valve controlling fuel
pressure within the supply pump. The distributor piston further increases such pressure and delivers the fuel to the
injectors (1) throughout the delivery pipe fitting. The fuel leak (3) from the injectors is recovered and sent back to the
fuel tank.
NOTE: Models (F5CE5454G*A001, F5CE5454C*A003, and F5CE5454B*A005) use a remotely mounted electric lift
pump, description will not be accurate.
73092751 3
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Injection pump - Dynamic description

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

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

(2) Mobile cap (4) Solenoid valve
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Load Delivery Adjustment (LDA) device

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

Identification coding example
V rotary distributor piston pump
E pump dimensions
4 four cylinder engines
12 distributor piston size in mm
1150 no. of pump rev/min.
RV right direction rotation
73092752 1
Ref. Description
(1) Membrane
(2) Setting ring
(3) Feeler pin
(4) Drive lever
(5) Speed regulator
(6) Transfer pump
(7) Drive shaft
(8) Cam disk
(9) Spark lead adjuster
(10) Distributor piston
(11) Supply pipe fitting
(12) Hydraulic head
(13) Control plate
(14) Adjusting pin
(15) Counter spring
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Fuel injection system - Bleed

Mechanical transfer pump
1. Disconnect the fuel filter supply line (1) from the filter
base.
2. Operate the manual lever on the fuel supply pump
(2) until fuel is discharged from the line.
3. Connect the supply line.
73092801 1
Electric transfer pump

1. Power the machine on but do not crank the engine.
2. Allow the pump to run approximately 30 s then, at-
tempt to start the engine.
NOTICE: Crank the engine for 20 s then allow a 30 s rest
if needed.
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Injection pump - Remove

1. Set the engine to cylinder number one TDC. Refer to
Engine - Service instruction (10.001) for the proper
procedure.
2. Loosen the injection pump locking bolt (1) and re-
move the spacer plate (2).
NOTE: Do not discard the spacer plate. Retain for future
use.
3. Torque the locking bolt (1) to 33 N·m (24 lb ft).
73092750 1
4. Remove the injection pump drive gear cover.

5. Remove the nut and washer retaining the drive gear
to the injection pump shaft.
73092792 2
6. Install tool 380100072 to the drive gear and remove

the gear.
73092763 3
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7. Remove the fuel filter.

8. Remove the high pressure injection pipes (1) from
the injection pump and nozzles.
9. Loosen the line clamps (2) and remove the pipes
from the engine.
10. Remove the low pressure fuel lines and the return
line banjo fitting (3).
11. Remove the Load Delivery Adjustment (LDA) line
from the top of the injection pump.
12. Disconnect the electrical connection from the KSB
solenoid (4).
13. Disconnect the throttle linkage at fuel injection pump. 73092750 4
14. Remove the injection pump mounting hardware.

15. Slide the fuel injection pump from the engine.
NOTE: The fuel injection pump drive gear is press fit, there-
fore a drive key is not used on the pump drive shaft.
Next operation:
Injection pump - Install (10.218)
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Injection pump - Install

Prior operation:
Injection pump - Remove (10.218)
1. Set the engine to cylinder number one TDC. Refer to

procedure.
2. Clean the injection pump drive shaft and the drive
gear tapers.
NOTICE: Ensure there is no residual film on these parts.
3. Install the injection pump (1) onto the engine.
4. Install the mounting nuts (2) finger tight.
93110992 1
5. Force the injection pump drive gear (1) onto the

pump drive shaft (2).
6. Install the lock washer and nut (3).
7. Snug the nut (3) to 18 N·m (13 lb ft).
NOTE: Do not apply the final toque at this time.
8. Torque the injection pump mounting nuts (2) figure 1
to 25 N·m (18 lb ft).
9. Torque the drive gear mounting nut (3) to 95 N·m (70
lb ft).
93110993 2
10. Loosen the injection pump locking bolt (1).

11. Install the spacer (2) and torque to 33 N·m (24 lb ft).
93110992 3
12. Remove the timing pin from the flywheel housing if

previously installed.
13. The injection pump timing MUST be checked before
proceeding and further. Refer to Injection pump
- Timing adjust (10.218) Hot KSB timing for the
proper procedure.
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14. Install the fuel injection pump drive gear cover (1).
73092792 4
15. Install the high pressure injection pipes (1) and line
clamps (2).
16. Install the low pressure fuel lines and the fuel return
banjo fitting (3).
17. Install the Load Delivery Adjustment (LDA) line to the
top of injection pump.
18. Connect the electrical connection (4) for the KSB so-
lenoid.
19. Install the fuel filter.
93110992 5
20. Bleed the air from the low pressure system using the
following procedure:
1. Loosen the return fitting banjo bolt at the rear
of the injection pump.
2. Turn the ignition switch to the ON position to
energize the fuel shutoff solenoid.
3. Use the hand primer on the low pressure fuel
supply pump to prime the system.
NOTE: If the hand primer does not displace fuel, the pump
may be resting on the high side of the cam lobe. Turn the
engine one revolution, then the hand primer should now
function properly.
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Injection pump - Timing adjust
Prior operation:
Injection pump - Remove (10.218)
Cold KSB timing

1. Place the pump in vice.
2. Remove the plug on the backside of the pump.
3. Install the dial gauge 380000228 (1) and dial gauge
holder into the pump.
4. Turn the pump shaft (2) until tension is relieved and
the pump cam plate is not loading the plunger.
NOTE: Double nut the end of the pump shaft, this will aid
in rotating the pump shaft.
5. Pre load the dial gauge by 3 mm (0.118 in) and zero
the gauge.
6. Turn the pump shaft so that the key way is aligned
closely to the 11 O'clock position while watching the
dial gauge and stop when the correct specification 93101557 1
(below) is reached.
• Specification is 1.60 mm (0.063 in)
• Timing between 1.55 - 1.65 mm (0.061 - 0.065
in)
7. Lock pump in position by removing the spacer plate
(3) and snugging the bolt (4).
NOTE: Do not loosen the locking bolt until the pump is
installed and torqued on the engine.
8. Set the engine to Cylinder 1 top dead center. Refer to
procedure.
9. Install the pump and gear on the engine. Refer to
Injection pump - Install (10.218) for the proper pro-
cedure.
10. Remove the lock screw.
NOTE: Leave the dial gauge in the back of the pump.
11. Rotate the engine one full rotation to #1 TDC while
monitoring the pump pre-travel.
12. Pin the flywheel at #1 TDC and make note of the
reading on the dial gauge. If the reading is within
10 mm (0.394 in), timing is correct.
13. Remove the dial gauge.
14. Install the plug.
15. Install the spacer plate and tighten the lock bolt.
Hot KSB timing

16. Set the engine to T.D.C. refer to Engine - Service
instruction (10.001).
17. Remove the spin-on fuel filter. Do not discard.
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18. Apply 12 volts to the KSB for a minimum of 5 minutes.

12 volts is required to remove the cold-start advance
on the pump in order to check the static (hot) timing.
19. Use a mirror to ensure that the KSB timing is retarded
with the KSB lever (arm) moved forward (toward the
front of the pump) almost against the angle stop (1).
20. Use a 12 mm socket or wrench to remove the plunger
access plug. The access plug is in the center of the
rear end cap of the injection pump.
20111651A 2
21. Install the timing adaptor (2) and the dial indicator (3)
into the hole where you removed the plunger access
plug.
22. If needed, loosen and reposition the bottom two in-
jector lines to allow room for the dial indicator.
23. Tighten the timing adapter.
24. Preload the dial indicator needle to 2.5 mm (0.10 in).
25. Pull outward on the end of the dial indicator stem and
release it to ensure the stem moves freely and does
not bind. If the stem does not move freely, reposition
the dial indicator until the stem moves freely.
20111652 3
26. Slide out the TDC timing pin from the flywheel to
unlock the flywheel.
27. Rotate the engine counter-clockwise until the dial in-
dicator needle drops to a minimum reading and stops
moving. You are now positioned between cam lobes
of the injection pump.
28. Position the dial indicator needle at the zero position.
29. Rotate the engine clockwise until the TDC timing pin
reengages the flywheel and locks it at TDC.
30. Check the injection pump timing.
• Specification is 0.75 mm (0.030 in)
• Timing between 0.65 - 0.85 mm (0.026 - 0.033
in)
31. If only a slight timing adjustment is required, loosen
the pump mounting bolts and rotate the injection
pump.
NOTE: The holes for the mounting bolts are not elongated. Only a slight adjustment can be made by rotating the
injection pump.
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Fuel injectors - Remove

1. Unscrew the injector support fastening screws (1),
disassemble the injector supports and remove the
injectors (2).
73092766 1
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Fuel injectors - Install

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

screws (2) to the prescribed torque setting.
73092795 2
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Index
Engine - 10

Fuel injection system - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuel injection system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Injection pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Engine - 10
Turbocharger and lines - 250

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Contents
Engine - 10
SERVICE
Turbocharger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Turbocharger oil supply line

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Engine - Turbocharger and lines
Turbocharger - Remove
1. Disconnect the oil delivery pipe (2) from the tur-

bocharger.
2. Disconnect the oil drain pipe (3).
3. Remove the turbocharger to intake hose (4).
4. Remove the turbocharger unit (1).
73092760 1
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Turbocharger - Install
1. Reassemble the turbocharger (1) unit.

2. Connect the oil delivery pipe (2) to the turbocharger.
3. Connect the oil drain pipe (3).
4. Install the turbocharger to intake hose (4).
73092760 1
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10.250 / 4

bocharger.
73092892 1
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73092892 1
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10.250 / 6

bocharger.
93111630 1
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93111630 1
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Turbocharger oil supply line - Remove

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

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

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

pipe (1).
73092760 1
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73092892 1
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pipe (1).
73092892 1
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1. Loosen the clip and disconnect the pipe (1).

93111630 1
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pipe (1).
93111630 1
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Index
Engine - 10

Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Turbocharger oil supply line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Turbocharger oil supply line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Turbocharger oil supply line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Engine - 10
Intake and exhaust manifolds and muffler - 254

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Contents
Engine - 10
SERVICE
Intake manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Engine - Intake and exhaust manifolds and muffler
Intake manifold - Remove

1. Remove the intake manifold (1).
73092766 1
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Intake manifold - Install

F5AE5484B*A002, F5AE5484C*A002
1. Reassemble the whole intake manifold (1) replacing

the gasket (2) and (3).
73092799 1
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Intake manifold - Install

1. Reassemble the whole intake manifold (1) replacing

the gasket (2) and (3).
73092912 1
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Exhaust manifold - Remove

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

1. Fit the exhaust manifold (3) with new seal (2) and
tighten the nuts (1) with studs tightening them to the
required torque.
73092793 1
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Index
Engine - 10

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Engine lubrication system - 304

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Contents
Engine - 10
TECHNICAL DATA
Engine oil filter

Engine oil pump
FUNCTIONAL DATA
Engine lubrication system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454C*A003
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484B*A002, F5AE5484C*A002
Engine oil filter

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Blowby re-circulation system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Engine oil filter

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine oil pump

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Piston cooling
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - Engine lubrication system
Engine oil filter - General specification

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

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

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

F5AE5484C*A002
Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is dis-
tributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat
exchanger, the centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed
air system is also fitted.
73092888 1
LUBRICATION SYSTEM LAYOUT
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Engine oil filter - Overview
73092740 1
(1) Protective cover (2) Cartridge
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Engine oil pump - Overview
73092739 1
(1) Main gear (5) Secondary shaft

(2) Secondary gear (6) Cover
(3) Housing (7) Internal rotor
(4) Drive shaft (8) External rotor
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Blowby re-circulation system - Overview

On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop
by gravity on the underlying tappet cover (3). The remaining non condensed vapours will be duly conveyed through
the breather (2), for instance by suction.
73092741 1
ENGINE OIL VAPOR RECIRCULATION
(1) Valve (2) Breather (3) Tappet cover
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Engine oil filter - Remove

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

1. Install the oil filter support (1) and the oil filter (2).
73092765 1
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73092894 1
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73092894 1
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93111635 1
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93111635 1
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Engine oil pump - Remove

Prior operation:
1. Loosen the bolts (1) and remove the oil pump (2).
73092778 1
Next operation:
Engine oil pump - Install (10.304)
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Engine oil pump - Install

Prior operation:
Engine oil pump - Remove (10.304)
1. Install the oil pump (2).

2. Install the bolts (1) and make them snug.
NOTE: Do not fully tighten the bolts at this time.
3. Check the backlash between the crankshaft gear and
the oil pump gear using a dial gauge with magnetic
base. The value must be between 0.068 - 0.168 mm
(0.003 - 0.007 in).
4. Torque the bolts (1) to 10 - 20 N·m (7 - 15 lb ft) then
again at 20 - 30 N·m (15 - 22 lb ft).
73092784 1
Next operation:
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Piston cooling Spray nozzle - Remove

Prior operation:
1. Remove the banjo bolt (1) and remove the oil nozzles
(2).
NHVM12ENG0016AA 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. Install the oil nozzles (2).

NOTICE: Be sure the locating tab on the nozzle is properly
seated against the machined edge of the block to ensure
proper nozzle alignment.
2. Torque the banjo bolts (1) to 18 N·m (13 lb ft).
NHVM12ENG0016AA 1
Next operation:
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Index
Engine - 10

Blowby re-circulation system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine lubrication system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454C*A003
Engine lubrication system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484B*A002, F5AE5484C*A002
Engine oil filter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine oil pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine oil pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Piston cooling Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Engine - 10
Engine cooling system - 400

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Contents
Engine - 10
FUNCTIONAL DATA
Engine cooling system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A, F5AE5484B*A002,
F5AE5484C*A002
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B,
F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K
Water pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Coolant thermostat
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Coolant thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - Engine cooling system
Engine cooling system - Overview

F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A, F5AE5484B*A002, F5AE5484C*A002
73092742 1
(1) Exhaust Gas Recirculation (EGR) cooler (4) Oil cooler (A) Thermostat closed
(2) Cylinder head (5) Coolant inlet (B) Thermostat open
(3) Water pump (6) Coolant outlet
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Engine cooling system - Overview

F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE9454J,
F5AE9454L, F5AE9484K
The closed circuit forced circulation engine cooling system is composed of the following parts:
• expansion tank: position, form and dimensions may vary depending on the engine fitting
• radiator dissipating the heat absorbed by the engine cooling liquid. This component's position and dimensions
may vary depending on the application
• fan increasing the radiator's cooling power. This component may vary depending on the application
• heat exchanger cooling the lubricant oil. This component may vary depending on the application
• centrifugal water pump positioned in the front part of the engine block
• thermostat controlling cooling liquid circulation
73092890 1
ENGINE COOLING SYSTEM DIAGRAM
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Water pump - Overview
73092743 1
(1) Hub (3) Pump housing (5) Impeller

(2) Shaft with bearing (4) Shaft seal (6) O-ring
The water pump circulates coolant thought the engine cooling system. It is a belt driven, centrifugal blade type pump.
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Coolant thermostat - Overview
NHVM12ENG0025AA 1
(1) Thermostat (2) Check ball (3) Housing
The thermostat acts as a temperature operated check valve. When the engine is cold, the valve remains closed and
does not allow the flow of coolant to the radiator. This allows for a faster engine warm up time. When the engine
reaches 80 °C (176 °F) the thermostat opens allowing the coolant to flow to the radiator to maintain the optimum
engine temperature.
The integrated check ball helps bleed the cooling system of trapped air by allowing the air to pass into the radiator to
be released from the system when the thermostat is closed.
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Water pump - Remove

Prior operation:
Belt - Remove (10.414)
1. Remove the water pump (1).
73092770 1
Next operation:
Water pump - Install (10.400)
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Water pump - Remove

F5AE5484C*A002
Prior operation:
1. Remove the water pump (1).
73092898A 1
Next operation:
Water pump - Install (10.400)
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Water pump - Install

Prior operation:
Water pump - Remove (10.400)
1. Install a new seal (2) on the water pump (1).

2. Install the water pump (1).
4. Install the belt. Refer to Belt - Install (10.414) for the
proper procedure.
5. Fill with coolant.
73092789 1
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Coolant thermostat - Remove

1. Remove the thermostat unit (1).
73092766 1
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Index
Engine - 10

Coolant thermostat - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine cooling system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine cooling system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5CE5454C*A003
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE5484B*A002, F5AE5484C*A002
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Engine - 10
Oil cooler and lines - 408

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Contents
Engine - 10
FUNCTIONAL DATA
Engine oil cooler

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine oil cooler

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - Oil cooler and lines
Engine oil cooler - Overview
73092745 1
The oil cooler circulates engine oil through cooling plates that sit in a coolant passage on the right hand side of the
engine. This process transfers heat from the engine oil to the engine coolant.
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Engine oil cooler - Remove

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

1. Reassemble the heat exchanger (1) remember to re-
place the old gasket with a new one; tighten the fas-
tening screws (2) to the prescribed torque setting.
73092769 1
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Index
Engine - 10

Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil cooler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Fan and drive - 414

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Contents
Engine - 10
Fan and drive - 414
SERVICE
Fan and drive

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE5484B*A002, F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5AE5484B*A002, F5AE5484C*A002
Belt
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Belt tensioner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - Fan and drive
Fan and drive - Remove

Prior operation:
1. Remove the fan hub (1).

2. Loosen the screw (2) and remove the pulley (3).
73092770 1
Next operation:
Belt - Install (10.414)
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Fan and drive - Install

Prior operation:
Fan and drive - Remove (10.414)
1. Install the fan hub (1).

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

F5AE5484C*A002
Prior operation:
1. Remove the fan hub (1).

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

F5AE5484C*A002
Prior operation:
Fan and drive - Remove (10.414)
1. Install the fan hub (1).

2. Reassemble the pulley (3), tighten the fastening
screw (2) to the prescribed torque setting.
73092910 1
Next operation:
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Belt - Remove
1. Loosen the screw (1) and the relevant screw nut on
the belt tensioning bracket (3).
2. Loosen the alternator through bolt in order to with-
draw the belt (2).
73092896 1
Next operation:
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Belt - Install
Prior operation:
1. Fit the drive belt (1) on the pulley and the guide
rollers.
2. Tension the drive belt by tightening the screw (2).
73092767 1
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Belt tensioner - Remove

Prior operation:
1. Remove the belt tensioning bracket (1).
73092767 1
Next operation:
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Belt tensioner - Install

Prior operation:
Belt tensioner - Remove (10.414)
1. Install the tensioner (1).
73092767 1
Next operation:
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Index
Engine - 10
Fan and drive - 414

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5CE5454C*A003
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5AE5484B*A002, F5AE5484C*A002
Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5CE5454C*A003
Fan and drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE5484B*A002, F5AE5484C*A002
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Engine - 10
Exhaust Gas Recirculation (EGR) exhaust treatment - 501

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Contents
Engine - 10
FUNCTIONAL DATA
Exhaust Gas Recirculation (EGR) exhaust treatment

Overview - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5AE5484C*A002
Dynamic description - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

F5AE5484C*A002
Overview - Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dynamic description - Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE
Exhaust Gas Recirculation (EGR) exhaust treatment

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE5484C*A002
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE5484C*A002
Exhaust Gas Recirculation (EGR) cooler lines

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5AE5484C*A002
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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment
Exhaust Gas Recirculation (EGR) exhaust treatment - Overview

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

(2) Heat exchanger (6) Exhaust manifold
(3) Water delivery pipe (7) Engine head
(4) Exhaust gas pipe
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Exhaust Gas Recirculation (EGR) exhaust treatment - Dynamic

description - External
73092748 1
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Exhaust Gas Recirculation (EGR) exhaust treatment - Overview -

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

description - Internal
The boosting system is composed of the following parts:

• Air filter
• Turbocharger
73092891 1
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Exhaust Gas Recirculation (EGR) exhaust treatment - Remove

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

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

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

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

changer.
73092760 1
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Index
Engine - 10

Exhaust Gas Recirculation (EGR) cooler lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exhaust Gas Recirculation (EGR) exhaust treatment - Dynamic description - External . . . . . . . . . . . . . . . . . . . . . . . 4
Exhaust Gas Recirculation (EGR) exhaust treatment - Dynamic description - Internal . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust Gas Recirculation (EGR) exhaust treatment - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exhaust Gas Recirculation (EGR) exhaust treatment - Overview - External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust Gas Recirculation (EGR) exhaust treatment - Overview - Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exhaust Gas Recirculation (EGR) exhaust treatment - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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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.
47388346 04/05/2012
EN
SERVICE MANUAL
Electrical systems

47388346 04/05/2012
55
Contents
Electrical systems - 55
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012

F5CE9454G , F5CE9484C , F5CE9484E
Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013

F5CE9454G , F5CE9484C , F5CE9484E
Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014

F5CE9454G , F5CE9484C , F5CE9484E
Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015

F5CE9454G , F5CE9484C , F5CE9484E
Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201

F5CE9454G , F5CE9484C , F5CE9484E
Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.202

F5CE9454G , F5CE9484C , F5CE9484E
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
F5CE9454G , F5CE9484C , F5CE9484E
Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.989

F5AE5484A , F5AE5484B*A002 , F5AE5484C*A002 , F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001
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55

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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
73092808 1
Specifications
Voltage 6 - 28 V
Working temperature range
- Connector's side -40 - 130 °C (-40 - 266 °F)
- Engine side -40 - 140 °C (-40 - 284 °F)
The coolant temperature sensor measures the temperature of the coolant circulating through the engine. The data is
then sent to the Engine Control Unit (ECU).
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Index

Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine oil system - 013

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Contents
FUNCTIONAL DATA
Engine oil pressure sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Engine oil system
Engine oil pressure sensor - Overview
73092809 1
Specifications
Contact closure with decreasing pressure 0.2 bar (3 psi)
Contact opening with increasing pressure 0.9 bar (13 psi)
The oil pressure sensor is located on the top of the oil filter base.
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Index

Engine oil pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine intake and exhaust system - 014

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Contents
FUNCTIONAL DATA
Engine air pressure/temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5AE5484C*A002
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Electrical systems - Engine intake and exhaust system
Engine air pressure/temperature sensor - Overview

73092811 1
The air pressure temperature sensor, located on the intake manifold, is used to measure intake manifold pressure
and temperature after the turbocharger.
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Index

Engine air pressure/temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine control system - 015

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Contents
FUNCTIONAL DATA
Engine timing sensors

Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Electrical systems - Engine control system
Engine timing sensors Crankshaft sensor - Overview

It is an inductive type sensor placed on the front left side of the engine. It generates signals obtained by the magnetic
flow lines closing up through the openings of a tone wheel splined on the engine crankshaft. The same signal is used
to pilot the tachometer fitted on the vehicle instrument panel. It is connected to the Electronic Control Unit pins 25C
(signal) and 24C (signal). The third pin is for shielding. The Sensor's resistance value is nearly 900 Ω.
73092812 1
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Index

Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine starting system - 201

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Contents
FUNCTIONAL DATA
Engine starter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Engine starting system
Engine starter - Overview
73092815 1
Specifications
Manufacturer BOSCH
Electrical system 12 V
Rated output 3 kW (4 Hp)
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Engine starter - Remove

1. Hold the starter (1), unscrew the fastening screws
and remove the starter.
73092892 1
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Engine starter - Install

1. Fit the starter (1) and tighten the fastening screws to
the prescribed torque setting.
73092892 1
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55.201 / 5
Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine starter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cold start aid - 202

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Contents
TECHNICAL DATA
Cold start aid

FUNCTIONAL DATA
Cold start aid

Overview - Timing advance system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Glow plug system
Glow plug - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Glow plug system

Glow plug - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Glow plug - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Cold start aid
Cold start aid - General specification

Protrusion length 30.4 mm +/- 0.25 mm

Diameter of heating element 4 mm +/- 0.1 mm
Heat up time to 850 °C Less than 5 s
Temperature T60 950 - 1010 °C
Switch on current at 11 V Less than 19 A
Operating current at 11 V after 20 s 5 A +/- 1.0 A
Runout heating element 0.4 mm
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Cold start aid - Overview - Timing advance system

The fuel injection pump uses a system to advance the injection pump timing until it reaches normal operating temper-
ature. This system is called KaltStartBeschleuniger (KSB) (Cold Start Timing Advance System).
A normally closed solenoid valve is used to override the transfer pump regulation valve which allows higher pressures
to be made within the pump housing. The higher pressures provide a 5 ° advance that reduces with engine speed.
The solenoid valve is controlled by a coolant temperature sensor. When the coolant temperature reaches 60 - 70 °C
(140 - 158 °F), the contacts in the sensor close to send power to the solenoid valve allowing the fuel injection pump
timing to return to normal.
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Glow plug system Glow plug - Overview

93111647 1
A glow plug typically comprises a heating coil in a metal tube closed at one end and filled with electrically insulating
ceramic powder. The closed end of the metal tube with the heating coil protrudes through a hole in the cylinder head
into the combustion chamber. When the glow plug is electrically energized, its heated portion reaches a surface
temperature of more than 1000°C within a few seconds. The air-fuel spray generated by the injection ignites close to
the glow plug and initiates combustion.
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Glow plug system Glow plug - Remove

NOTE: Three glow plugs (1) have direct access and are easily removed.
NOTE: The fourth glow plug (2) requires removal of the turbo intake (3).
1. Disconnect electrical connections (A) and (B) and
move out of the way.
93111637 1
2. Remove the adjustable pipe connector bolt (4).
93111637 2
3. Loosen the lower pipe connector bolt (5).
93111637 3
47388346 04/05/2012
55.202 / 6
4. Rotate the pipe (6) away from the intake.
93111638 4
5. Remove the four bolts (7) from the heat exchanger

to rear intake flange.
93111638 5
6. Remove the four bolts (8) from the top of the intake.
93111638 6
7. Loosen the two hose clamps (C) from the elbow hose
(9) and remove hose.
93111639 7
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8. Remove the intake (3) and the spacer (10).
93111639 8
93111640 9
NOTE: Now you have free access to remove the fourth glow plug.
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55.202 / 8
Glow plug system Glow plug - Install

1. Install the four new glow plugs and torque to 8 N·m

(70.8 lb in) before installing the air intake manifold.
2. Replace the gaskets and install the spacer (1) and
air intake manifold (2).
93111639 1
3. Install the four bolts (3) through the top of the air
intake.
93111638 2
4. Install the four bolts (4) securing heat exchanger to

the rear air intake flange.
93111638 3
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5. Install the elbow hose (5) and tighten the two hose
clamps (A) securing it from the turbo to the air intake.
93111637 4
6. Rotate the pipe (6) in and secure it to the air intake

(2) with the adjustable pipe connector bolt (7).
93111637 5
7. Tighten the lower pipe connector bolt (8).
93111637 6
8. Connect the two electrical connections (9).
93111637 7
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Index

Cold start aid - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cold start aid - Overview - Timing advance system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Glow plug system Glow plug - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Glow plug system Glow plug - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Glow plug system Glow plug - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Alternator - 301

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Contents
Alternator - 301
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Alternator
Alternator - Remove
Prior operation:
Belt - Remove (10.414).
1. Hold the alternator (1) and detach it from its sup-

port loosening the screw (2). Recover the nut and
washer.
73092768 1
Next operation:
Alternator - Install (55.301)
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Electrical systems - Alternator
Alternator - Install
Prior operation:
Alternator - Remove (55.301)
1. Install the alternator (1).

2. Tighten the bolts by hand until the belt is in place.
3. Once the belt is on the pulleys and tight, the alterna-
tor bolts can be tightened.
73092768 1
Next operation:
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Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Exhaust Gas Recirculation (EGR) electrical system - 989
F5AE5484A , F5AE5484B*A002 , F5AE5484C*A002 , F5CE5454B*A005 ,

F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001
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Contents
FUNCTIONAL DATA
Exhaust Gas Recirculation (EGR) electrical system

Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F5AE5484C*A002
Exhaust Gas Recirculation (EGR) solenoid valve

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5AE5484C*A002
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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system
Exhaust Gas Recirculation (EGR) electrical system - Electrical

schema
73092805 1
20000 - Starter battery 58105 - Engine high water temperature warning light
25201 - Remote control for pre-heating switch 58484 - Diagnosis warning light
48035 - Engine rev. no. sensor 47034 - Engine water temperature sensor for EGR
52502 - Key commutator for services with start 78029 - EGR solenoid valve
61121 - Resistor for engine pre-heating 86020 - EGR control module
58101 - Pre--heating (on) warning light 85156 - Air pressure temperature sensor
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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system
Exhaust Gas Recirculation (EGR) solenoid valve - Overview

73092813 1
(A) Exhaust gas input - (B) Exhaust gas output
Specifications
Coil characteristic
- Resistance 7.5 - 8.5 Ω
- Frequency 100 - 150 Hz
- Voltage 12 - 16 V
Potentiometer characteristic
- Total resistance 4000 Ω
- Maximum voltage 15 V
- Supply current 10 mA
- Circuit configuration Voltage divider
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Index

Exhaust Gas Recirculation (EGR) electrical system - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exhaust Gas Recirculation (EGR) solenoid valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN U.S.A.
47388346 04/05/2012
EN
SPECIAL TOOL INDEX
Genuine IU PAGE
380000150 [Engine P.M.S. Engine - Service instruction - Finding Top Dead Center 10.001 / 25
Positioning Tool]
380000988 [Flywheel Rotation Engine - Service instruction - Finding Top Dead Center 10.001 / 25
Blocker]
Positioning Tool]
380000988 [Flywheel Rotation Engine - Service instruction - Finding Top Dead Center 10.001 / 27
Blocker]
Positioning Tool]
380002385 [Tool For Rotating Engine - Service instruction - Finding Top Dead Center 10.001 / 29
The Engine Flywheel]
380000134 [Valve Guide Seal Cylinder head - Assemble 10.101 / 13
Installer]
380002385 [Tool For Rotating Engine flywheel - Remove 10.103 / 4
380002385 [Tool For Rotating Engine flywheel - Install 10.103 / 5
380000304 [Angle Torque Engine flywheel - Install 10.103 / 5
Thightening Screw Tool]
380000150 [Engine P.M.S. Engine flywheel - Remove 10.103 / 6
Positioning Tool]
380002385 [Tool For Rotating Engine flywheel - Install 10.103 / 7
380000304 [Angle Torque Engine flywheel - Install 10.103 / 7
Thightening Screw Tool]
380000732 [Engine Turning Engine flywheel - Remove 10.103 / 8
Tool]
380000988 [Flywheel Rotation Engine flywheel - Remove 10.103 / 8
Blocker]
380000732 [Engine Turning Engine flywheel - Remove 10.103 / 8
Tool]
380000732 [Engine Turning Engine flywheel - Install 10.103 / 9
Tool]
380000988 [Flywheel Rotation Engine flywheel - Install 10.103 / 9
Blocker]
380000732 [Engine Turning Engine flywheel - Install 10.103 / 9
Tool]
380100076 [Rear crankshaft Crankshaft oil seal Rear seal - Install 10.103 / 10
seal installer]
380000362 [Crankshaft Lifting Crankshaft - Remove 10.103 / 14
Hook]
380000362 [Crankshaft Lifting Crankshaft - Remove 10.103 / 15
Hook]
380000324 [Pliers Connecting rod and piston - Disassemble 10.105 / 5
For Assembling And
Disassembling Piston Split
Rings (110-150 mm)]
380000221 [Pliers For Connecting rod and piston - Assemble 10.105 / 6
Piston Rings Removal And
Installation (65 -110 mm)]
380000220 [Band For Piston Connecting rod and piston - Install 10.105 / 7
Insertion Into Cylinder Sleeves
(60 -125 mm)]
380000667 [Camshaft Bush Camshaft bushings - Replace 10.106 / 16
Assembly And Disassembly
Punch]
04/05/2012
7
Genuine IU PAGE
380000999 [Handle For Camshaft bushings - Replace 10.106 / 16
Interchangeable Beaters]
380100072 [Puller For The Injection pump - Remove 10.218 / 13
Gear Coupling The Injection
Pump To The Engine]
380000228 [Dial Gauge (0 - 5 Injection pump - Timing adjust 10.218 / 17
mm)]
04/05/2012
8
04/05/2012
9
PRINTED IN U.S.A.
47388346 04/05/2012
EN

Silnik FPT F5AE

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Available Formats

F5AE9454D / F5AE9454J

F5AE5484A , F5AE5484B*A002 , F5AE5484C*A002 , F5AE9454A , F5AE9454D ,

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

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 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

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

For engine equipped with an electronic control unit

Respect of the Environment

DESCRIPTION SIZE TORQUE

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

Oil filter 20 - 30 N·m (15 - 22 lb ft)

DESCRIPTION SIZE TORQUE

Connecting rod cap

F5AE5484A , F5AE5484B*A002 , F5AE5484C*A002 , F5AE9454A , F5AE9454D ,

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

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

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

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

Exhaust Gas Recirculation (EGR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.501

Engine and crankcase - 001

F5AE5484A , F5AE5484B*A002 , F5AE5484C*A002 , F5AE9454A , F5AE9454D ,

Engine and crankcase - 001

Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Engine - General specification

Cycle Diesel 4 strokes

Engine - General specification

Cycle Diesel 4 strokes

Engine - General specification

Cycle Diesel 4 strokes

Engine - General specification

Cycle Diesel 4 strokes

Engine - General specification

Cycle Diesel 4 strokes

Engine - General specification

Cycle Diesel 4 strokes

Engine - General specification

Cycle Diesel 4 strokes

F5AE5484A , F5AE5484BA002 , F5AE5484CA002 , F5AE9454A , F5AE9454D ,

F5AE5484A , F5AE5484BA002 , F5AE5484CA002 , F5AE9454A , F5AE9454D ,

F5AE5484A , F5AE5484BA002 , F5AE5484CA002 , F5AE9454A , F5AE9454D ,

F5AE5484A , F5AE5484BA002 , F5AE5484CA002 , F5AE9454A , F5AE9454D ,