P1D32C016 - 11-2014 - EN (1) - Compactado-1-1

CURSOR 13 TDCV ‒ General mechanical overhaul
GENERAL MECHANICAL OVERHAUL 5

ENGINE DISASSEMBLING
GENERAL MECHANICAL OVERHAUL

.540110. ENGINE DISASSEMBLING
Work material
Rotary telescopic stand(range 2000 daN, torque 375 99322230
daNm)
Extraction tool for injectors 99342157
Tool for retaining the flywheel 99360351
Crankshaft lifting tool 99360500
Tool for rocker arm shaft assembly and fitting 99360553
Brackets for fastening engine to 99322230 rotary stand 99361036
Tool for removing the high pressure pump gear 99366198
Socket threaded wrench
Metal ropes
Main action
1. Before mounting the engine on the specified rotating stand, remove the following parts that may interfere with mounting the
brackets.
Tool / Material Product code
2. Disconnect the engine cable from the electrical components and remove it from the engine.
.790510. Air compressor removal

3. Disconnect the water pipes (2).
4. Disconnect the air pipes (1) and (5).
5. Unscrew the screws (4) and remove the air compressor (3).
219030 Figure 1
– printed P1D32C016E1114
6 GENERAL MECHANICAL OVERHAUL
.543075. Oil pressure adjustment valve removal

6. Remove the oil pressure adjustment valve (1).
60486 Figure 2
.543211. Removing the water inlet pipe

7. Loosen the clips securing the sleeve (3) to the thermostat as-
sembly (4).
8. Loosen the screws (2) and remove the water inlet pipe (1)
together with the sleeve (3).
219037 Figure 3
191076 Figure 4
9. Fasten the engine to the specified rotating stand by means of dedicated brackets (1).
Rotary telescopic stand(range 2000 daN, torque 375 daNm) 99322230
.540860. Damper flywheel removal

10. Lock the flywheel using the specified tool (1).
Tool / Material Product
code
71702 Figure 5
11. Remove the damper flywheel (2) turning the screws (1).
181788 Figure 6
.543411. Coolant pump alternator drive belt disassembly

12. Using an appropriate tool (1) turn it in the direction shown by
the arrow and remove the auxiliary component drive belt (2).
Note The flexible belt must be replaced with a new one
every time it is removed from the vehicle.
181789 Figure 7
.760310. Alternator removal

13. Remove the screws (1) and remove the alternator (2).
181790 Figure 8
.543422. Electromagnetic coupling removal

14. Unscrew the screws (1) and remove the electromagnetic coup-
ling (2).
181791 Figure 9
.543210. Water pump removal

15. Remove the automatic tensioner (1), unscrew the screws (2)
and remove the pulley (3), remove the water pump (4), un-
screw the screws (5) and remove the pulley(6).
181792 Figure 10
.543251. Thermostat case removal

16. Remove the air pipe (1), unscrew the screws (3) and remove
the thermostat assembly (2).
219038 Figure 11
.540442. Crankshaft front gasket removal

17. Apply the specified extractor (2) and extract the crankshaft seal
gasket (1); remove the flange (3).
60490 Figure 12
.542410. Turbocharger removal

18. Remove the oil delivery pipe (1) and the oil return pipe (2)
from the turbocharger.
219032 Figure 13
19. Disconnect the coolant pipe (3) from the engine brake device
actuator (2) and remove the exhaust gas outlet pipe (1) to-
gether with the engine brake device.
219033 Figure 14
20. Free the water pipes (3) from the fixing brackets (→) and re-
move them.
21. Loosen the screws securing the exhaust manifold (1) and re-
move it together with the turbocharger (2).
219039 Figure 15
.540720. Exhaust manifold removal

22. Unscrew the screws (1) and the fixing nuts (3). Separate the
exhaust manifold (2) from the turbocharger (4).
191080 Figure 16
.543070. Oil filter removal

23. Unscrew and remove the oil filter (2).
24. Remove the oil filter support (1).
191081 Figure 17
.543110. Heat exchanger removal

25. Unscrew the screws (1) and remove the heat exchanger (2).
191082 Figure 18
.760810. Starter motor disassembly

26. Remove the starter motor (1).
181800 Figure 19
.540710. Intake manifold removal

27. Remove the support for the engine start buttons(3).
28. Loosen the screws (2) and remove the intake manifold (1)
together with the engine preheating resistor.
219034 Figure 20
.766161. Engine control unit removal

29. Detach the fuel piping (1), unscrew the screws (2) and remove
the engine control unit (3).
181802 Figure 21
.540480. Blow-by case removal

30. Unscrew the screws (1) and remove the blow-by case (2).
181803 Figure 22
.540486. Blow-by filter removal

31. Unscrew the screws (1) and remove the blow-by filter (2).
181804 Figure 23
.540452. Timing gear cover disassembly

32. Remove the pipe (1), unscrew the screws (2) and remove the
timing gear cover (3).
181805 Figure 24
.540630. Removal of head cover

33. Unscrew the screws (2) and remove the head cover (1).
181816 Figure 25
.542011. Fuel filter removal

34. Disconnect the pipes (3) from the high-pressure pump.
35. Remove the fuel filter (2) together with the mount (1).
191083 Figure 26
.773010. High pressure pump removal

36. Unscrew the nut (1).
37. Use the specified tool (3) and remove the high pressure pump
control gear (2).
code
Tool for removing the high pressure pump gear 99366198
185514 Figure 27
38. Disconnect pipes (1, 3).

39. Unscrew the screws (4) and remove the high pressure pump
(5).
40. Remove the bracket if necessary (2).
191084 Figure 28
41. Unscrew the retaining screws (1) and remove the flange (2)
supporting the high pressure pump.
160624 Figure 29
42. Unscrew the screws (2) and remove the gear (1) together
with the phonic wheel.
182129 Figure 30
43. Unscrew the screws (2) and remove the thrust plate (1) and
the sheet gasket.
182130 Figure 31
44. Unscrew the screws (2) and remove the idle gear (1).
182131 Figure 32
.540850. Engine flywheel removal

45. Using the specified tool to lock the mounted flywheel (1), un-
screw the retaining screws (2); then remove the tool (1) and
remove the flywheel (3).
code
181810 Figure 33
.540462. Crankshaft rear gasket removal

46. Apply the specified extractor (2) and extract the crankshaft seal
gasket (1).
181811 Figure 34
.540463. Flywheel case removal

47. Remove the cover (3).
48. Unscrew the screws (1) and remove the flywheel case (2).
181813 Figure 35
.543010. Disassembling the oil pump

49. Remove the screws (1) and disassemble the double gear (2).
191085 Figure 36
50. Unscrew the retaining screw (1) and remove the link rod (2).
191086 Figure 37
51. Unscrew the retaining screws (1) and remove the oil pump (2).
191087 Figure 38
.541230. Rocker arm shaft removal

52. Release the check springs (2) of the engine brake lever.
53. Unscrew the screw(1) fixing the rocker arm shaft.
173803 Figure 39
54. Use the specified tool (1) on the rocker arm shaft (2) and
remove the shaft (2) from the cylinder head. Remove the guide
braces (3) from the cylinder head.
code
114025 Figure 40
.774510. Rail removal
183458 Figure 41
55. Unscrew the fittings and remove the high pressure fuel supply pipes (8).
56. Unscrew the fittings from the rail and the injectors and detach the high pressure fuel pipes (1, 2, 3, 4, 5 ) and (6) the fuel
return pipe (7) from the head.
Note The high pressure fuel pipes must be replaced at each disassembly.
57. Disconnect the electrical connection from the pressure sensor (11).
58. Unscrew the retaining screws (9) and remove the rail (10).
.775010. Injector removal
159429 Figure 42
59. Disconnect the electrical connections (1) from the electro-injectors.
60. Disconnect the oil pipe (2) from the engine brake cylinders and the solenoid valve by unscrewing the fittings (3) and (4).
61. Remove the screws (1) from the injector securing (2) brackets.
169827 Figure 43
62. Position the specified tool (1) extract the injectors (2) from the
head.
code
Extraction tool for injectors 99342157
169826 Figure 44
63. Unscrew the screws (3) and remove the engine brake cylinders
(2).
64. Unscrew the screws (1) and remove the engine brake solenoid
valve (4).
183459 Figure 45
.541210. Camshaft removal

65. Install the appropriate plugs in the place of the injectors (1).
66. Extract the camshaft (2).
60514 Figure 46
.540610. Cylinder head removal

67. Unscrew the cylinder head screws (3).
Note The cylinder head fastening screws are to be replaced each time you remove them.
68. Using metal ropes, lift the cylinder head (1).

Tool / Material
Metal ropes
69. Take off the gasket (2).
60515 Figure 47
.540430. Oil sump removal

70. Loosen the screws (2) and remove the engine oil sump (1)
with the spacer (3) and the seal gasket.
60516 Figure 48
.543060. Suction strainer removal

71. Slacken the screws and remove the suction strainer (1).
60517 Figure 49
.540830. Connecting rod removal

72. Turn the crankcase (1) into vertical position.
47574 Figure 50
73. Unscrew the screws (2) fixing the connecting rod cap (3) and
remove it.
Note Keep the connecting rod half-bearings in their respect-
ive housings and/or note down their assembly position
since, if reusing them, they will need to be fitted in the
position found upon removal.
60518 Figure 51
.540830. Axis alignment check

74. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
75. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
76. Set the spindle on the «V» prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 52
.540416. Lower crankcase removal

77. Using an appropriate wrench and the socket threaded wrench
unscrew the screws (1) and (2) and take off the lower crank-
case .
Tool / Material
Socket threaded wrench
Note Note down the assembly position of the top and bot-
tom main half-bearings since, if reusing them, they will
need to be fitted in the position found upon removal.
60519 Figure 53
COMPREHENSIVE CRANKCASE CHECKS
.540810. Crankshaft removal

78. Using the specified tool (1), remove the crankshaft (2).
code
47570 Figure 54
.540816. Main bearings removal

79. Disassemble main half-bearings (1).
47571 Figure 55
.540414. Oil sprayer removal

80. Unscrew the screws and remove the oil sprayers (2).
81. Remove the cylinder sleeves as described in the related paragraph.
Note once the engine disassembly is complete, clean accurately the removed parts and check their integrity.
The following pages give instructions for checks and main measurements to do as to determine whether the parts can
be reused.
.540110. COMPREHENSIVE CRANKCASE CHECKS
Consumables
LOCTITE 270
Work material
Cylinder liner protrusion gauge (to be used with 99360334
99370415-99395603 and special plates)
Spacer (to be used with 99360334) 99360336

Tool for cylinder liner fastening 99360703
Tool to extract cylinder liners (use with special rings) 99360706
Ring (135 mm) (to be used with 99360706) 99360728
Dial gauge base to adjust lay shaft bearings (use with 99370415
99395603)
Set of gauges for angle tightening with square connection 99395216
- 1/2" and 3/4"
Dial gauge (0-5 mm) 99395603
Bore gauge
Ring gauge
Micrometer
Centesimal dial gauge
Tightening torques
Protrusion checking tool screw 225 N⋅m
Screws fixing connecting rod cap 1. Step 1 70 N⋅m
2. Step 2 60°
Technical data
Cylinder liner protrusion compared to the cylinder head supporting surface 0.045 mm to0.075 mm
Heating temperature for gear fitting 180 ℃
Main action
.540410. Crankcase checks
1. After disassembling the engine, thoroughly clean the cylinder-
crankcase assembly.
2. Carefully inspect the crankcase for cracks.
3. Check the condition of casting hole plugs. If the caps are rusted,
or if there is any doubt about the efficiency of the seal, replace
them.
4. When assembling plugs, apply the recommended sealant on
them.
Tool / Material
LOCTITE 270
5. In order to check the inner diameter of cylinder liners and

identify the degree of ovalisation, taper and wear, use bore
meter (2) fitted with a centesimal dial gauge (1) previously re-
set (3) on the 135 mm ring gauge. 34994 Figure 56
Tool / Material
Bore gauge
Centesimal dial gauge
Ring gauge
Note If the 135 mm ring gauge is not available, use a micro-

meter.
6. Measurements should be carried out for every single cylinder

liner at three different heights and on two (A-B) perpendicular
plane levels as illustrated in figure.
60596 Figure 57
1 1st measurement 3 3rd measurement
2 2nd measurement
7. When wear is over 0.150 mm or maximum ovalisation is 0.100

mm compared to the values shown in the figure, replace the
cylinder barrel since it is not possible to grind, lap or dress it.
Note Cylinder liners are equipped with spare parts belonging
to selection class «A».
60595 Figure 58
A, Selection classes Y Selection class marking
B area
8. The illustrated diagram refers to the outer diameters of cylinder

liners (C) and (D) and the inner diameters of their seats (A)
and (B).
60597 Figure 59
60598 Figure 60
9. Cylinder liners can be removed and fitted several times into different housings, if needed.
155934 Figure 61
10. During checks, make sure that the main data for the cylinder liners is the same as in the figure.
.540420. Cylinder liners Removal

11. Position the specified parts (2) and the plate (4), as shown in
the figure, checking that the specified plate (4) rests on the
cylinder liner correctly.
code
Tool to extract cylinder liners (use with special rings) 99360706
Ring (135 mm) (to be used with 99360706) 99360728
12. Fasten the screw nut (1) and take off the cylinder liner (3)
from the crankcase.
47577 Figure 62
.540420. Cylinder liner refitting and protrusion check

13. Always replace water sealing rings (3, 4, 5).
14. Install the adjustment ring (1) on the cylinder liner (2); lubricate
the lower part of the liner and install it in the cylinder unit using
the proper tool.
Note the adjustment ring (1) is equipped with a spare part
having the following thickness: 0.08 mm - 0.10 mm -
0.12 mm - 0.14 mm.
16798 Figure 63
15. Check the protrusion of the cylinder liners using the specific
tool (2) with spacers and tighten the screw (1) to the torque
specified below.
Tightening torque
Protrusion checking tool screw 225 N⋅m

code
Cylinder liner protrusion gauge (to be used with 99370415- 99360334
99395603 and special plates)
60520A Figure 64
16. Using the dial gauge provided with dial gauge stand (3), meas- 0, 045 ÷ 0, 075
ure the cylinder liner protrusion compared to the cylinder head
supporting surface, which must be the value indicated in the fig-
ure. Otherwise, replace the adjusting ring (1), supplied as spare
part in different thicknesses.
Technical data
Cylinder liner protrusion compared to the 0.045 mm to0.075 mm
cylinder head supporting surface

code
Dial gauge (0-5 mm) 99395603
99395603)
60520B Figure 65
17. On completing assembly, lock the cylinder liners (1) on the

crankcase (2) with the specified stud bolts (3).
code
Tool for cylinder liner fastening 99360703
60521 Figure 66
.540810. Crankshaft measurements
181690 Figure 67
18. Check the condition of the crankshaft main journals; there must no be signs of scoring, ovalisation or excessive wear. The
values shown refer to rated pin diameter.
.540811. Measuring main journals

19. Before grinding the pins, using a micrometer (1), measure the
shaft pins (2) and decide, on the basis of the undersizing of
the half-bearings, the final diameter to which the pins are to
be ground.
Tool / Material
Micrometer
Note It is advisable to enter readings in a table.
47535 Figure 68
GROUND
181691 Figure 69
X Main journals fillet detail
20. During the grinding operation, pay attention to the values of the main journal couplings shown in the details X.
Note All journals and crankpins must also be ground to the same undersizing class, in order to avoid any alteration to shaft
balance.
36061 Figure 70
21. Write down the measurements of the main journals and crankpins of the crankshaft in the table.
.540812. Measuring crankpins

22. Before grinding the pins, using a micrometer (1), measure the
shaft pins (2) and decide, on the basis of the undersizing of
the half-bearings, the final diameter to which the pins are to
be ground.
Tool / Material
Micrometer
47536 Figure 71
36061 Figure 72
23. Write down the measurements of the crankpins of the crankshaft in the table.
181692 Figure 73
Y Crankpin fillet detail
24. During the grinding operation, pay attention to the values of the crankpins shown in Y.
Note All journals and crankpins must also be ground to the same undersizing class, in order to avoid any alteration to shaft
balance.
.540816. Defining the diameter class of the seats for half-bearings on the crankcase
190208 Figure 74
25. To identify the diameter class of the seats for the main half-bearings, look at the front part of the crankcase in the position as
indicated in the figure.
190208 Figure 74
DEFINING THE DIAMETER CLASS OF THE SEATS FOR HALF-BEARINGS ON THE CRANKCASE
CLASS RATED DIAMETER OF MAIN BEARINGS
1 106.300 – 106.309
2 106.310 – 106.319
3 106.320 – 106.330
26. Read the 2 sets of numbers on the front part of the crankcase.
Note The first set of digits (four) is the coupling number of the upper and lower crankcase.
The following seven digits, taken individually, are the diameter class of each of the seats they are referred to.
Each of these digits may be 1, 2 or 3.
.540816. Main half-bearings selection
190220 Figure 75
27. Identify the most suitable half-bearings for each of the shaft pins (the half-bearings, if necessary, can have different classes
from one journal to another).
Thickness of the main bearing shells
Main half-bearings
STD +0.127 +0.254 +0.508
Red 3.110 – 3.120 – – –

Red/Black – – – –
Green 3.121 – 3.130 – – –
Green/Black – – – –
Note Depending on the thickness, the half-bearings are selected in classes of tolerance marked by a coloured sign
(red/black - green/black).
The table contains the characteristics of the main bearings available as spare parts in standard measurement (STD).
.540831. Definition of the connecting rod diameter class

28. Select the connecting-rod half bearings by referring to the
markings on the connecting-rod body, in the indicated position.
Note The number indicating the diameter class of the seat
for half-bearings can be: 1, 2 or 3.
155939 Figure 76
1 Standard numbers
2 Letter indicating the weight class
A = 5537 - 5570 g
B = 5571 - 5604 g
C = 5605 - 5637 g
3 Number indicating the selection of the diameter

of the big end bearing seat
1 = 100.000 - 100.010 mm
2 = 100.011 – 100.020 mm
3 = 100.021 – 100.030 mm
4 Engine type
5 Connecting rod identification plate
.540831. Definition of the diameter class of the crankpins (nominal diameter)
190211 Figure 77
29. The diameter class of each connecting rod bearing must be selected before identifying the diameter of each crankpin.
Definition of the diameter class of the crankpins (nominal diameter)
CLASS CRANKPIN NOMINAL DIAMETER
1 95.970 - 95.979
2 95.980 – 95.989
3 95.990 – 96.000
30. In order to identify the diameter class of the crankpins, identify the three sets of figures marked on the front of the crankshaft.
Note The first number, of five digits, is the part number of the shaft.
Below this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the
status of the pins (1 = STD, 2 = - 0.127), the other six digits, taken individually, give the diameter class of each crank-
pin they refer to.
.540831. Selecting the connecting rod half-bearings
190219 Figure 78
31. Identify the most suitable half-bearings for each of the shaft pins (the half-bearings, if necessary, can have different classes
from one journal to another).
Big end half-bearing thickness
Connecting rod
half-bearings
STD +0.127 +0.254 +0.508
Red 1.960 – 1.970 – – –

Red/Black – – – –
Green 1.971 - 1.990 – – –
Green/Black – – – –
Note Depending on the thickness, the half-bearings are selected in classes of tolerance marked by a coloured sign
(red/black - green/black).
The table contains the characteristics of the connecting rod bearings available as spare parts in standard measurement
(STD).
.540831. Main half-bearings selection (nominal diameter pins)

32. Determine the type of connecting rod half-bearing to fit on each pin by following the indications in the table.
Main half-bearings selection (nominal diameter pins)
STD CLASS 1 2 3
Green Green Green

1
Green Green Green
Red Green Green

2
Red Green Green
Red Red Green

3
Red Red Green
.540815. Checking the timing and oil pump gear control

33. Check that the toothing of the gear is neither damaged nor worn; if it is, take it out with an appropriate extractor and replace
it.
34. When fitting the gear (1) on the crankshaft (2), heat it for no
longer than 2 hours in an oven at the temperature indicated
below.
Technical data
Heating temperature for gear fitting 180 ℃
35. Let it cool down after pressing.

36. If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.
108836 Figure 79
.540817. Checking crankshaft thrust clearance

37. Thrust clearance is checked by placing a specific magnetic dial
gauge (1) on the crankshaft (2), as shown in the figure. If you
find an higher clearance than as required, replace the rear main
half-bearings carrying the thrust bearings and repeat the clear-
ance check.
code
Dial gauge (0-5 mm) 99395603
47588 Figure 80
.540831. Checking assembly clearance of crankpins

38. Connect the connecting rods to the relevant journals of the crankshaft, placing a length of calibrated wire on the journals.
39. Mount the connecting rod caps (1) together with half-bearings;
Tighten the connecting rod caps fixing screws (2) to the pre-
scribed torque. Using the specific tool (3), further tighten the
screws with a specific angle.
Tightening torque
Screws fixing connecting rod 1. Step 1
cap 70 N⋅m
2. Step 2
60°

code
Set of gauges for angle tightening with square connection - 99395216
1/2" and 3/4"
47594 Figure 81
Note Lubricate screw threads (2) with engine oil before
assembly.
40. Remove the caps and check the clearance by comparing the
width of the calibrated wire with the scale calibration on the
envelope containing the wire. When assembly is complete:
check the diameter of the screws threading (2) which must not
be less than 13.4 mm, otherwise replace the screw; lubricate
the crankpins and connecting rod bearings; Tighten the screws
(2) as described above.
OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY
.5408. OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY
Work material
Pliers for removing/refitting piston rings (105 -160 mm) 99360184
Reamer
Drift
Feeler gauge
Micrometer
Technical data
Bush diameter 59.060 mm to59.076 mm
Main action
155940 Figure 82
1 Connecting rod body 6 Slotted oil scraper ring with spiral spring
2 Half-bearings 7 Claw seal ring
3 Connecting rod cap 8 Trapezoidal seal ring
4 Cap retaining screws 9 Piston pin
5 Circlip 10 Piston
1. Make sure the pistons do not show any sign of seizing, scoring, cracking or excessive wear; otherwise, replace as necessary.
.540842. Piston rings removal

2. Remove the piston rings from the piston (2) using the specific
set of pliers (1).
code
Note Pistons are equipped with three circlips: a sealing ring,

with trapezoidal section; a sealing ring with chamfer cut;
the third oil scraper.
Note Pistons are grouped into classes A and B for diameter.
155941 Figure 83
.540840. Piston removal

3. Remove the retaining piston rings (2) using round tipped pliers
(1).
155942 Figure 84
4. Remove the piston pin (1). If removal is difficult use the appro-
priate drift.
155943 Figure 85
.540840. Measuring the piston diameter

5. Using a micrometer (2), measure the piston diameter (1) to
determine the assembly clearance; The diameter has to be
detected at the value indicated.
Tool / Material
Micrometer
155944 Figure 86
.540841. Measuring the piston pin diameter

6. Measure pin diameter (2) measuring with a micrometer (1).
Tool / Material
Micrometer
155945 Figure 87
181694 Figure 88
* The distance is measured at the Ø of 130 mm X 0.8 ± 0.1 mm
.540841. Conditions for correct pin-piston coupling

7. During the coupling phase, make sure that the main data for the journal and piston is the same as in the figure.
8. Lubricate the pin (1) and the relevant housings on the internal
piston hubs with engine oil; Pin must be inserted in the piston
with a light finger pressure and it should not come out by grav-
ity.
155946 Figure 89
.540842. Measuring seal rings

9. Check the thickness of the piston ring (2) using a micrometer
(1).
Tool / Material
Micrometer
16552A Figure 90
10. Check the clearance between the sealing rings (2) and the re-
lated housings on the piston (1) using a feeler gauge (3).
Tool / Material
Feeler gauge
181693 Figure 91
11. The sealing ring (2) of the 1st seat is trapezoidal. Clearance "
X" between the sealing ring and its seat is measured by placing
the piston (1) with its ring in the cylinder liner (3), so that the
sealing ring comes half way out of the cylinder liner.
3513 Figure 92
12. Using a feeler gauge (2), check the end gap of the sealing rings
(1) entered in the cylinder liner (3).
Tool / Material
Feeler gauge
13. If the distance between ends is lower or higher than the value
required, replace split rings.
36134 Figure 93
.540830. Connecting rod checks

Caution!
Connecting rods weight class warning during as-
sembly
▶ When installing connecting rods, make sure they all
belong to the same weight class.
14. Data concerning the class section of connecting rod housing and
weight are stamped on the connecting rod.
155939 Figure 94
1 Standard numbers
2 Letter indicating the weight class
A = 5537 -5570 g.
B = 5571 -5604 g.
C = 5605 -5637 g.
3 Number indicating the selection of the diameter

of the big end bearing seat:
1 = 100 - 100.010 mm
2 = 100.011 – 100.020 mm
3 = 100.021 – 100.030 mm
4 Engine type
5 Connecting rod identi-

fication plate
181695 Figure 95
* Dimension to be obtained after driving the bushing
15. During checks make sure that the main data of the bushing, connecting rod, pin and half bearings is that shown in the diagram.
.540830. Axis alignment check

16. Check the parallelism of the connecting rod axis (1) using a
suitable device (5) proceed as follows.
17. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
18. Set the spindle on the «V» prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 96
.540830. Torsion check

19. Check the bend of the connecting rod (5) by comparing two
points (A) and (B) of the pin (3) on the horizontal plane of the
connecting rod axis.
20. Position the mount (1) of the dial gauge (2) so that this pre-
loads by approx. 0.5 mm on the pin (3) at point A and set the
dial gauge to zero (2). Shift the spindle (4) with the connecting
rod (5) and compare any deviation on the opposite side B of
the pin (3): the difference between A and B must not exceed
0.08 mm.
61694 Figure 97
.540830. Bending check

21. Check the bend of the connecting rod (5) by comparing two
points C and D of the pin (3) on the vertical plane of the con-
necting rod axis. Position the vertical support (1) of the dial
gauge (2) so that this rests on the pin (3) at point C.
22. Swing the connecting rod to and fro, establishing the highest
position of the pin and reset the dial gauge (2) in this condition.
23. Move spindle (4) with connecting rod (5) and repeat the
highest point check on opposite side D of pin (3).
24. The difference between points C and D must not exceed 0.08
mm.
61695 Figure 98
.540834. Small end bushing check

25. Check that the bushing in the small end has not come loose and
shows no sign of seizure or scoring. Otherwise replace it.
26. The bushing (2) is removed and fitted with a suitable drift (1).
Tool / Material
Drift
27. When refitting take care to make the oil holes on the bush
coincide with those on the connecting rod small end.
28. Ream the bush to obtain the diameter specified below.
073535 Figure 99
Technical data
Bush diameter 59.060 mm to59.076 mm
Tool / Material
Reamer
073535 Figure 99
.540840. Piston assembly

29. Fit the piston (1) on the connecting rod (2) so that the graphic
symbol (4), showing the assembly position in the cylinder liner,
and the punch marks (3) on the connecting rod face each other
as shown in the figure.
Note The arrow (5) must face the engine flywheel.
1
2
4 5
181833 Figure 100
CYLINDER HEAD OVERHAUL
30. Fit the pin (2) and fasten it on the piston (1) with the piston
rings (3).
181830 Figure 101
.540842. Fitting piston rings

31. Use pliers (3) to fit the piston rings (1) on the piston (2).
code
32. Position the rings so that «TOP»" (4) is facing upwards, direct
the ring openings so they are staggered 180° apart.
155950 Figure 102
.540610. CYLINDER HEAD OVERHAUL
Work material
Punch for valve guide removal 99360143
Tool to remove and refit engine valves (to be used with 99360259
special plates)
Tool for removing and refitting engine valves (to be used 99360261
with special plates)
Tool for engine valves removal and refitting (use with 99360263
99360259)
Tool for valve guide refitting (use with 99360143) 99360296
Adjuster for gasket assembly on valve guide 99360329
99395603)
Sleeker for valve guide 99390330

Dial gauge (0-5 mm) 99395603
Bore gauge
Drift
Feeler gauge
Dial gauge
Micrometer
Grinder
Ruler
Metal brush
Technical data
Intake valves recessing −0.54 mm to−0.86 mm
Exhaust valves recessing −1.65 mm to−1.95 mm
Valve guide standout 30.08 mm to31.2 mm
Cylinder head heating temperature 80 ℃ to100 ℃
Main action
1. Before removing cylinder head, check hydraulic tightness using specific tool; in case of leaks not caused by cup plugs or
threaded plugs, replace cylinder head.
Note When replacing the cylinder head, it is supplied as a spare part with a threaded plug, which must be removed during
assembly.
Note In case of plugs dismounting/replacement, on mounting, apply sealant Loctite 270 or 243 on plugs.
.540662. Valve removal

Note Before removing cylinder head valves, number them in view of their remounting in the same position should they not have
to be overhauled or replaced.
Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.
2. Fit the specific tool (2) and fix it with the bracket (4); screw
using the provided device (1) until you can disassemble the
cotters (3); take out the tool (2) and extract the upper plate
(5), spring (6) and bottom plate (7).
code
99360259)
Tool for removing and refitting engine valves (to be used 99360261
with special plates)
Note Repeat this operation for all the valves.

3. Turn the cylinder head upside down and remove the valves (8).
47583 Figure 103
.540610. Checking the planarity of the head on the cylinder block

4. Check the supporting surface (1) of the head on the cylinder
block with a rule (2) and a feeler gauge (3).
Tool / Material
Ruler
Feeler gauge
5. If deformations exist, surface the head using proper surface

grinder; the maximum amount of material to be removed is 0.2
mm.
Note After levelling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
36159 Figure 104
.540662. Valve descale and check

6. Remove all carbon deposits from the valves using a wire brush.
Tool / Material
Metal brush
48625 Figure 105
155953 Figure 106

* Measurement obtained after fitting the valve guides
7. Check that the valves show no signs of seizure or cracking and also check with a micrometer that the valve stem diameter
comes within the required values: replace the valves if it does not.
8. Regrind the valve seats, if required, using a grinding machine and removing as less material as possible.
155953 Figure 106
Tool / Material
Micrometer
Grinder
9. Use a bore gauge to check that the diameter inside the valve guide corresponds to the value indicated, after fitting.
Tool / Material
Bore gauge
.540661. Regrinding - replacing the valve seats

Note The valve seats are reground whenever the valves or the valve guides are ground and replaced.
181831 Figure 107

1 Intake valve seat 2 Exhaust valve seat
10. When replacing/checking the valve seats, refer to the main data provided in the figure.
11. Check the valve seats (2). If there are light scorings or burnings,
regrind them with a suitable tool (1) according to angles shown
in the previous figure.
12. Having to replace them, with the same tool and taking care not
to affect the cylinder head, remove as much material from the
valve seats as possible until it is possible to extract them from
the cylinder head with a punch.
13. Heat the cylinder head to 80 –100 ºC and, using a drift, fit in the
new valve seats (2), chilled beforehand in liquid nitrogen. Using
tool (1), regrind the valve seats according to the angles shown
in the previous figure.
Technical data
Cylinder head heating temperature 80 ℃ to100 ℃
Tool / Material
41032 Figure 108
Drift
14. After reaming the valve seats, use the specific tool and the dial
gauge to make sure that the valve position, with respect to the
cylinder head surface, is equal to the values specified below:
Technical data
Intake valves recessing −0.54 mm to−0.86 mm
Exhaust valves recessing −1.65 mm to−1.95 mm

code
99395603)
Dial gauge (0-5 mm) 99395603
41032 Figure 108
.540667. Replacing the valve guides

15. Remove the valve guides by means of the specific drift. They
are fitted with the drift equipped with the specific part. The
element determines the exact valve guide fitting position in the
cylinder head; if they are not available, you need to drive the
valve guides into the cylinder head so they protrude by a value
equal to the one given below.
Technical data
Valve guide standout 30.08 mm to31.2 mm

code
Punch for valve guide removal 99360143
Tool for valve guide refitting (use with 99360143) 99360296
16. After installing the valve guides, regrind their bores with a 163815 Figure 109
smoother.
* Measurement to be
Tool / Material Product made after driving in
code the valve guides
Sleeker for valve guide 99390330
.775010. Checking protrusion of injectors

17. Check injector protrusion (2) using a magnetic dial gauge (1).
Tool / Material
Dial gauge
47585 Figure 110
.540665. Valve spring check

18. Before assembly, check the valve spring flexibility using a suitable
tool.
70000 Figure 111
19. Compare the load and elastic deformation data with those of
the new springs indicated in the figure.
108842 Figure 112
.540662. Valve assembly

20. Lubricate the valve stem and insert the valves in the respective
valve guides; fit the lower plates (1).
193982 Figure 113
.540668. Mounting the oil seal ring

21. Using the specific keying device, fit the oil seal ring (2) on the
valve guides (3) and then assemble the valves as follows.
code
Adjuster for gasket assembly on valve guide 99360329
Note Should valves not have been overhauled or replaced,

remount them according to the numbering performed
on dismounting.
Intake valves are different form exhaust valves in that
they have a notch placed at valve head centre.
155958 Figure 114
COMPLETE TIMING SYSTEM OVERHAUL
22. Fit springs (6), upper plate (5).

23. Fit the specific tool (2) and fix it with the bracket (4); screw the
lever (1) until you can assemble the cotters (3); remove the
tool (2).
code
99360259)
Tool to remove and refit engine valves (to be used with 99360259
special plates)
86290 Figure 115
.5412. COMPLETE TIMING SYSTEM OVERHAUL
Work material
Drift to take down and fit back camshaft bushes 99360499
Technical data
Intake valve control cam lift 9.231 mm
Exhaust valve control cam lift 9.5607 mm
Rated assembling clearance between gear bushings and pins 0.045 mm to0.085 mm
Main action
.541254. Replacement gear bush idle gear
1. Replace the bushings (2) when worn.
182092 Figure 116

1 Camshaft 6 Transmission gear
2 Bushing 7 Twin idler gear
3 Pin 8 Crankshaft driving
4 Rod gear
5 Camshaft control gear
2. After driving the bushing, bore it to obtain the diameter shown

in the figure.
Note The bushing must be driven into the gear in the direc-
tion of the arrow setting the latter to the dimension
shown.
3. At the end of the boring operation, check that the gear bush-
ing/journal assembly clearance is equal to the indicated value.
Technical data
Rated assembling clearance between gear 0.045 mm to0.085 mm
bushings and pins
181832 Figure 117
.541254. Replacement of the dual idle gear bushes

4. Replace the bushings (2) when worn.
182092 Figure 118

1 Camshaft 6 Transmission gear
2 Bushing 7 Twin idler gear
3 Pin 8 Crankshaft driving
4 Rod gear
5 Camshaft control gear
5. After driving the bushing, bore it to obtain the diameter shown

in the figure.
Note The bushing must be driven into the gear in the direc-
tion of the arrow setting the latter to the dimension
shown.
6. Check that the nominal assembly clearance between gear bush-
ings and pins is equal to the value stated below.
Technical data
Rated assembling clearance between gear 0.045 mm to0.085 mm
bushings and pins
101601 Figure 119
.541211. Checking cam lift and camshaft journals alignment
47506 Figure 120

7. Place the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) using a dial gauge (2)., comparing the values
with those specified below.
Technical data
Intake valve control cam lift 9.231 mm
Exhaust valve control cam lift 9.5607 mm
47507 Figure 121

8. Still with the camshaft (4) set on the tailstocks (1), check the alignment of the journals (3) with the dial gauge (2); it must not
exceed 0.030 mm. To check the assembly clearance, measure the inside diameter of the bushings and the diameter of the
journals of the camshaft.
47505 Figure 122

9. In order to check the installation clearance, measure the bushing inner diameter and the camshaft pin (1) diameter; the real
clearance is obtained by their difference. If you find any clearances over 0.135 mm, replace the bushings and, if necessary, the
camshaft as well.
187402 Figure 123

10. The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth; whereas, if they show any
signs of seizing or scoring, you should replace the shaft and the relevant bushings.
Tolerance characteristics
TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL
ORIENTATION Perpendicularity
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation
Class of importance product characteristics

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
.541213. Camshaft bushes check
155956 Figure 124

* Bushing inside diameter after driving in
11. The surface of the bushings must show no sign of seizing or scoring; replace them if they do.
12. Measure the bushes inner diameters with a bore meter and replace them, if the value measured exceeds the tolerance value.
107217 Figure 125

A Drift with seat for bushings to insert/extract. F Guide line.
B Dowel pin for positioning bushings. G Guide bushing to secure to the seventh bushing
C Reference mark to insert seventh bushing correctly. mount.
D Reference mark to correctly insert bushings 1, 2, 3, 4, H Plate fixing bushing G to cylinder head.
5, 6. I Grip.
E Guide bush. L Extension coupling.
13. To remove and refit the bushes, use the specific drift.
.541213. Replacing camshaft bushes using beater

.541213. disassembly
Note Position the drift accurately during the phase of removal.
14. Remove the bushings in the following order (7, 6, 5, 4, 3, 2,

1).
code
Note The bushings are extracted from the front of each

seat.
Note Removal does not require the drift extension for bush-
ings 5, 6 and 7 and it is not necessary to use the guide
bushing. For bushings 1, 2, 3 and 4 it is necessary how-
ever to use the extension and the guide bushings.
.541213. assembly 71725 Figure 126

15. To insert the bushing (1, 2, 3, 4 , 5 ), proceed as follows.
107217 Figure 127

16. Assemble the drift together with the extension.
17. Position the bushing to insert on the drift (A) making the grub screw on it coincide with the seat (B) on the bushing.
18. Position the guide bushing (E) and secure the guide bushing (G) on the seat of the 7th bushing with the plate (H).
19. While driving in the bushing, make the reference mark (F) match the mark (M). In this way, when it is driven home, the lub-
rication hole on the bushing will coincide with the oil pipe in its seat.
Note The bushing is driven home when the 1st reference mark (D) is flush with the guide bushing (G).
20. To insert the bushing (6), proceed as follows:

21. Unscrew the grip (I) and the extension (N).
22. Position the extension (N) and the guide bushing (E) as shown
in the figure.
23. Position the bushing to insert on the drift (A) making the grub
screw on it coincide with the seat (B) on the bushing.
24. Position the guide bushing (E) and secure the guide bushing
(G) on the seat of the 7th bushing with the plate (H).
25. While driving in the bushing, make the reference mark (F)
match the mark (M). In this way, when it is driven home, the
lubrication hole on the bushing will coincide with the oil pipe in
its seat. 71723 Figure 128
Note The bushing is driven home when the 1 reference
st
mark (D) is flush with the guide bushing (G).
26. To insert the bushing (7), proceed as follows.

27. Unscrew the grip (I) and the extension (N).
28. Refit the guide (G) from the inside as shown in the figure.
29. Position the bushing on the drift (A) and bring it close up to the
seat, making the bushing hole match the lubrication hole in the
head. Drive it.
30. The 7th bushing is driven in when the reference mark (C) is
flush with the bushing seat.
71724 Figure 129
.541233. Rocker shaft check

Note The camshaft cams directly control the 12 rocker arms for the valves. The intake valve control rocker arms are keyed
on rocker arms shaft directly. Exhaust valves control rocker arms are keyed on rocker arms shaft putting in between the
levers with engine brake control eccentric pin. Rockers slide directly on the cam profiles via rollers. The other end acts
on a bar supported by the stem of the two valves. A pad is placed between the rocker adjusting screw and the bar. Two
lubrication holes are obtained inside the rockers.
073557 Figure 130

31. Check the shaft surfaces for signs of seizure, scoring or wear. Otherwise replace the shaft.
.541231. Exhaust valve rocker arm check

32. The bush surfaces must not show any trace of scoring of ex-
cessive wear; otherwise, replace bushes or the whole rocker.
181688 Figure 131
.541231. Intake valve rocker arms check

155960 Figure 132
.543751. Lever with engine brake control eccentric pin check

92842 Figure 133
ENGINE ASSEMBLY
.540110. ENGINE ASSEMBLY
Consumables
Engine oil
LOCTITE 243
LOCTITE 5970
Work material
Rotary telescopic stand(range 2000 daN, torque 375 99322230
daNm)
Key to fit crankshaft front gasket 99346250
Key to fit crankshaft rear gasket 99346260
Tool for rotating the flywheel 99360321
Clamp for fitting piston into cylinder liner (90 - 175 mm) 99360603
Tool for engine T.D.C. positioning 99360612
Tool for timing of phonic wheel on timing gear 99360613
Tool to check timing (use with 99395606) 99370400
Set of gauges for angle tightening with square connection 99395216
- 1/2" and 3/4"
Gauge for defining the distance between the centres of 99395225
camshaft and timing gear
Gauge to determine centre distance between camshaft 99395226
and high pressure pump
Dial gauge (0-30 mm) 99395606
Centring ring of crankshaft front gasket cover 99396035
Torque wrench
Box wrench
Hooks
Hoist
Tightening torques
Lower crankcase inner tightening screws 1. Pre-tightening 160 N⋅m
2. Angle tightening 60°
Outer screws fixing lower crankcase 1. 30 N⋅m
2. 60°
Screws fixing connecting rod cap 1. Pre-tightening 70 N⋅m
Cylinder head fixing screws (pre-tightening) 1. Pre-tightening 75 N⋅m
2. Pre-tightening 150 N⋅m
ENGINE ASSEMBLY
Cylinder head screws (angle tightening) 1. Angle tightening 90°

Engine flywheel bolts 1. Pre-tightening 120 N⋅m
High-pressure pump flange support screw 24.5 ±2.5 N⋅m
Shoulder plate locking screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 - 10
20 ±2 N⋅m
Idle gear pin screws 1. Pre-tightening 30 N⋅m
Injector bracket fixing screws 30 N⋅m to35 N⋅m
Exhaust brake cylinder fixing screws 16 N⋅m to22 N⋅m
Rail fixing screws 23.5 ±2.5 N⋅m
Electro-injector bracket retaining screws 33 N⋅m to37 N⋅m
High-pressure fuel pipe couplings 42 N⋅m
High-pressure fuel pipe fittings 60 ±2.5 N⋅m
Screws fixing the high pressure fuel supply pipe support brackets to the head 23.5 ±2.5 N⋅m
Fuel return coupling from the rail 50 N⋅m
Fastening screws for rocker arm shaft 1. Until in contact Tightening sequence: 1 - 7
25 N⋅m
2. Tightening sequence: 1 - 7
60 N⋅m
80 N⋅m
60°
Cable clamps 1.5 ±0.25 N⋅m
Camshaft gear fixing screws 1. Pre-tightening 60 N⋅m
Screws fixing pulser ring to timing gear 24.5 ±2.5 N⋅m
Tapper cover fixing screws 8.5 ±1.5 N⋅m
Screws fixing the timing gear cover 10 N⋅m
Blow-by case fixing screws 7 N⋅m
Screws securing heat exchanger 1. 8 N⋅m to15 N⋅m
2. 22 N⋅m to27 N⋅m
Oil filter retainer at the support base 60 ±5 N⋅m
Screws and nuts securing turbocharger 75 N⋅m
Exhaust manifold fixing screws 1. 40 ±5 N⋅m
2. 60 ±5 N⋅m
Oil drain and inlet pipe couplings 22 N⋅m to27 N⋅m
Thermostat case fixing screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6 - 7
27 N⋅m to33 N⋅m
2. Tightening sequence: 8 - 9 - 10 - 11 - 12 - 13 -
14
27 N⋅m to33 N⋅m
Oil pressure regulator valve 23.5 ±2.5 N⋅m
ENGINE ASSEMBLY
Screws fixing the water inlet pipe to the pump 34.5 ±3.5 N⋅m
Technical data
Cam timing dial gauge value 5.95 ±0.05 mm
Main action
1. Fasten the crankcase to the stand using the specific brackets.
Rotary telescopic stand(range 2000 daN, torque 375 daNm) 99322230
.540414. Oil sprayer assembly

2. Mount the oil nozzles (2), making the grub screw match the
hole (3) on the crankcase.
47586 Figure 134
.540816. Main bearings assembly

3. Install the half-bearings (1) on the main bearings in the crank-
case (2).
Note Refit the main bearings that have not been replaced, in
the same position found at removal.
4. If you have to replace the bearings, choose them according to
selection described in chapters Selecting the main half-bearings
(nominal diameter pins) and Main half-bearings selection (recti-
fied) .
49021 Figure 135
ENGINE ASSEMBLY
.540810. Crankshaft assembly

5. Lubricate the half-bearings.
6. Using the specific hoist and hook (1) assemble the crankshaft
(2).
code
Hoist
47570 Figure 136
.540416. lower crankcase assembly

7. Install the half-bearings (1) on the main bearings in the lower
crankcase (2).
49021 Figure 137
8. Apply the silicone onto the crankcase using an appropriate (1)

tool.
Tool / Material
LOCTITE 5970
47595 Figure 138
ENGINE ASSEMBLY
9. Apply the sealant following the diagram in the figure.

Note fit the lower crankcase within 10' of the application of
the sealant.
60632 Figure 139
10. Fit the lower crankcase (1) by means of a suitable hoist and
hooks.
Tool / Material
Hoist
Hooks
60559 Figure 140
11. Using a torque wrench (3) tighten the internal screws (1) to
the required torque, then using a specific tool (4) tighten them
in two phases to the specific angles, following what is indicated
in the chapter Diagram of tightening sequence for main engine
parts ( ➠ Page 15).
Tightening torque
Lower crankcase inner tight- 1. Pre-tightening
ening screws 160 N⋅m
2. Angle tightening
60°
3. Angle tightening
60°

code 47579 Figure 141
Torque wrench
1/2" and 3/4"
Note Always use new screws each time you assemble the
bedplate.
ENGINE ASSEMBLY
12. Using a torque wrench (2), tighten the outer hex-socket screws
(1) to the prescribed torque, then using the specific tool (3)
tighten to an angle.
Tightening torque
Outer screws fixing lower 1. 30 N⋅m
crankcase 2. 60°

code
1/2" and 3/4"
47581 Figure 142
.540831. Rod half-bearing fitting

13. Lubricate the half-bearings (1 ) and fit them in the connecting
rod and the cap.
Note Not finding it necessary to replace the connecting rod
bearings, you need to fit them back in exactly the same
sequence and position as in removal.
If you have to replace the connecting rod bearings,
choose them according to selection described in
chapter Main half-bearings selection ( ➠ Page 37) and
Selecting the connecting rod half-bearings .
Note Do not make any adjustment on the half-bearings.
155951 Figure 143
ENGINE ASSEMBLY
.540840. Assembling connecting rod - piston assemblies in the cylinder liners
187915 Figure 144

1 Connecting rod-piston assembly 4 Arrow indicating the assembly orientation of the con-
2 Marking area on the piston crown of ideogram specify- necting rod - piston assembly (turned towards the
ing the assembly position and the selection class flywheel)
3 Area of connecting rod punch marking
14. Rotate the crankcase placing it vertically.

15. Lubricate the pistons, piston rings and inside the cylinder liners.
16. Using the clamp (1), install the connecting rod-piston assemblies
(2) in the cylinder linings, according to the diagram in the previ-
ous figure.
17. Check that the number of each connecting rod corresponds to
the cap coupling number.
Caution!
Connecting rods Precautions for cylinder liners
▶ During assembly, pay utmost attention to prevent the
connecting rod from hitting against the cylinder liner
walls.
18. Check that the ideogram stamped on the piston crown faces 60616 Figure 145
the engine flywheel; or the recess in the piston skirt matches the
position of oil nozzles.
ENGINE ASSEMBLY

code
Clamp for fitting piston into cylinder liner (90 - 175 mm) 99360603
Note The pistons are supplied as spare parts in class A and

can also be fitted in class B cylinder liners.
Note Before reusing the screws, measure the diameter of

the thread; this has not to be lower than 13.4 mm;
otherwise replace the screw. Before installing, lubricate
the screw thread with engine oil.
19. Connect the connecting rods to the relevant pins of the crank-
shaft, mount the connecting rod caps (1) together with half-
bearings; tighten the connecting rod caps fixing screws (2)
to the prescribed torque. Using the goniometer (3) further
tighten the screws to the angle specified.
Tightening torque
Screws fixing connecting rod 1. Pre-tightening
cap 70 N⋅m
2. Angle tightening
60°

code
1/2" and 3/4" 47594 Figure 146
.540442. Crankshaft front gasket installation

20. By means of centring ring (2), check the exact cover position
(1), otherwise act as necessary and tighten the screws (3).
code
Centring ring of crankshaft front gasket cover 99396035
60563 Figure 147
ENGINE ASSEMBLY
21. Fit precisely the gasket (1), fit the specific keying device (2),
drive in the gasket (1) by screwing the nut (3).
code
Key to fit crankshaft front gasket 99346250
60564 Figure 148
.540610. Cylinder head assembly

22. Check that the pistons: 1 and 6 are exactly at the T.D.C.
23. Put the gasket (2) on the crankcase.
24. Place the cylinder heads (1) on the crankcase.
60515 Figure 149
61270 Figure 150

25. Tighten the fastening screws in the sequence shown in the figure.
Note New screws must be used at each assembly of the head.
Lubricate the thread of the screws with engine oil before assembly.
ENGINE ASSEMBLY
26. Pre-tighten using the torque wrench (1):

Tightening torque
Cylinder head fixing screws 1. Pre-tightening
(pre-tightening) 75 N⋅m
2. Pre-tightening
150 N⋅m
Tool / Material
Torque wrench
60565 Figure 151
27. Perform angle tightening with specific tool (1):

Tightening torque
Cylinder head screws (angle 1. Angle tightening
tightening) 90°
2. Angle tightening
90°

code
1/2" and 3/4"
60566 Figure 152
.543010. Installing the oil pump

28. Install the oil pump (1) and tighten the retaining screws.
191087 Figure 153
ENGINE ASSEMBLY
29. Install the connecting rod (1) and tighten the screw (2) to the
prescribed torque.
191086 Figure 154
30. Install the double gear (2) and tighten the screws (1) to the
prescribed torque.
Note Lubricate the screws (1) with engine oil before as-
sembly.
191085 Figure 155
.540463. Fitting flywheel box

31. Apply the prescribed silicon on the flywheel case using the spe-
cific tool (1) as shown in the figure.
Tool / Material
LOCTITE 5970
Note Fit the flywheel housing within 10' after sealant applica-
tion.
47592 Figure 156
ENGINE ASSEMBLY
32. Use a torque wrench to tighten the screws to the specific tight-
ening torque in the sequence shown in the figure.
182145 Figure 157
.540462. Crankshaft rear gasket assembly

33. Fit precisely the gasket (1), fit the device (2), drive in the gasket
by screwing the nut (3).
code
Key to fit crankshaft rear gasket 99346260
60568 Figure 158
.540850. Engine flywheel assembly

34. Position the flywheel (1) on the crankshaft, lubricate the thread
of the screws (2) with engine oil and screw them down.
35. Block the engine flywheel rotation using the specific tool (3);
tighten the screws (2) in two steps.
code
36. Tighten using a torque wrench (4).

Tightening torque
Engine flywheel bolts 1. Pre-tightening
Lubricant 120 N⋅m
Engine oil
2. Angle tightening
90°
49037 Figure 159
ENGINE ASSEMBLY
Tool / Material
Torque wrench
49037 Figure 159
37. Tighten at angle with specific tool (1).

code
1/2" and 3/4"
49036 Figure 160
.541210. Fitting camshaft

38. Install the high pressure pump support (2) flange and tighten
the retaining screws (1).
160624 Figure 161
ENGINE ASSEMBLY
39. Fit the specific gauge (1) to position the high pressure pump
support flange (2) properly and tighten the screws to the pre-
scribed torque.
Tightening torque
High-pressure pump flange support 24.5 ±2.5 N⋅m
screw

code
Gauge to determine centre distance between camshaft and 99395226
high pressure pump
160655 Figure 162
40. Position the crankshaft with the pistons 1 - 6 at the T.D.C. This
situation occurs when:
41. The hole with one reference mark (5) of the engine flywheel
(4) can be seen through the inspection window.
42. The specific tool (1), through the seat (2) of the engine speed
sensor, enters the hole (3) in the flywheel (4).
code
43. If this condition does not occur, turn the engine flywheel (4)
appropriately.
44. Remove the specific tool (1).
code
182251 Figure 163
45. Fit the camshaft (4), positioning it with the reference marks (→)
as shown in the figure.
46. Lubricate the seal (3) and fit it on the thrust plate (2).
47. Fit the thrust plate (2) with the sheet metal gasket (1) and
tighten the screws (5) to the required torque and according
to the sequence shown in relative chapter DIAGRAM OF
TIGHTENING SEQUENCE FOR MAIN ENGINE PARTS
( ➠ Page 15).
Tightening torque
Shoulder plate locking screws 1. Tightening sequence: 1 - 2 - 3 - 4 -
5
20 ±2 N⋅m
2. Tightening sequence: 6 - 7 - 8 - 9 -
10
20 ±2 N⋅m
182146 Figure 164
ENGINE ASSEMBLY
48. Position the gauge (1). Check and adjust the position of the link
rod (3) for the idle gear; tighten the screw (2) to the specified
torque.
code
Gauge for defining the distance between the centres of 99395225
camshaft and timing gear
160654 Figure 165
49. Fit the idle gear (1) back on and lock the screws (2) to the
required torque.
Tightening torque
Idle gear pin screws 1. Pre-tightening
30 N⋅m
2. Angle tightening
90°
sembly.
182148 Figure 166
50. Position the gear (2), without fully tightening the screws (5),
on the camshaft, positioning it so that the 4 eyelet holes are
centred with regard to the camshaft fastening holes.
sembly.
51. With a magnetic dial gauge (1) check clearance between gears
(2, 3), which must be between 0.074 – 0.195 mm, otherwise
adjust the clearance as indicated hereafter:
52. Loosen the screws (4) fixing the idle gear (3).
53. Loosen the connecting rod fixing screw (2), move the connect-
ing rod (3) in order to obtain the required clearance.
54. Lock the rod fixing screw (2) and the idle gear fixing screws (4)
to the required torque. 182149 Figure 167
ENGINE ASSEMBLY
.775010. Injector assembly

55. Replace the sealing gasket (2) on the injectors(1).
169828 Figure 168
56. Fit the retaining brackets on the injectors (5) and position them
in the relevant seats in the cylinder head.
57. Before tightening the screws (4) to torque, fit the high pressure
fuel pipes referring to the indications provided in chapterRail
installation ( ➠ Page 86) (Operation 774510).
58. After having fitted the fuel pipes, lock the screws (4) securing
the injector brackets to the specified torque.
Tightening torque
Injector bracket fixing screws (4) 30 N⋅m to35 N⋅m
Tool / Material
Torque wrench
59. Fit the engine brake cylinders (1) and (2), using a torque
wrench, fix them to specified torque. 183455 Figure 169
Tightening torque
Exhaust brake cylinder fixing screws 16 N⋅m to22 N⋅m
Tool / Material
Torque wrench
60. Mount the guide braces (3) on the valve stem, all with the
largest hole in the same direction.
ENGINE ASSEMBLY
.774510. Rail installation

Note The high pressure fuel pipes cannot be re-used but must be replaced each time they are removed
61. Connect the oil supply pipe (3) to the engine brake actuators
(2) and engine brake solenoid (1).
183456 Figure 170
183458 Figure 171

62. Fit the rail (10) onto the head and tighten the fixing screws (9) to the specified torque.
Tightening torque
Rail fixing screws (9) 23.5 ±2.5 N⋅m
63. Connect the high pressure fuel pipes and tighten the fittings by hand in the sequence (1, 2, 3, 6, 5, 4) to the rail and the
injectors.
Note Before tightening the couplings to torque make sure that the pipes (1) are not touching each other.
64. Complete injector assembly operations by tightening the fastening screws to the specified torque.
Tightening torque
Electro-injector bracket retaining screws 33 N⋅m to37 N⋅m
65. Complete assembly of HP fuel pipes (1, 2, 3, 6, 5, 4) by first tightening the injector side couplings and then those on the rail
side.
ENGINE ASSEMBLY
Tightening torque
High-pressure fuel pipe couplings 42 N⋅m
66. Connect the HP fuel supply pipes (8) and tighten them to the prescribed torque.
Tightening torque
High-pressure fuel pipe fittings 60 ±2.5 N⋅m
67. Fix the fuel supply pipe support brackets, tightening the screws to the required torque.
Tightening torque
Screws fixing the high pressure fuel supply pipe support brackets to the 23.5 ±2.5 N⋅m
head
68. Connect the fuel return pipe (7) from the rail and tighten to the prescribed torque.
Tightening torque
Fuel return coupling from the rail 50 N⋅m
.541230. Fitting rocker shaft assembly

Note before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed.
69. Apply the specific tool (1) to the rocker arm shaft (2) and
mount the shaft on the cylinder head.
code
116190 Figure 172
70. Screw the screws in four steps as follows:

Tightening torque
Fastening screws for rocker 1. Until in contact
arm shaft Tightening sequence: 1 - 7
25 N⋅m
60 N⋅m
80 N⋅m
60°
Tool / Material Product 183461 Figure 173

code
Torque wrench
ENGINE ASSEMBLY

code
1/2" and 3/4"
183461 Figure 173
71. Fit the engine brake lever retainer springs (1).
185511 Figure 174
72. Attach the electrical connections (1) to the injectors and block
the cables using cable clamps.
Tightening torque
Cable clamps 1.5 ±0.25 N⋅m
183457 Figure 175
ENGINE ASSEMBLY
.541210. Camshaft timing

73. Apply the specific tool (7) and the specific spacer (8) to the
gear casing (3).
code
Note The arrow shows the direction of rotation of the en-

gine when running.
74. Using the above-mentioned tool, turn the engine flywheel (1) in
the direction of rotation of the engine so as to take the piston
of cylinder no.1 to 54° before T.D.C. in the phase of compres-
sion (cylinder 6 in discharge phase).
Note This condition is verified when the hole with two
notches (5) on the engine flywheel (1) is visible
through the small inspection window (2).
185252 Figure 176
75. Check that the specific tool (1) is inserted in the hole (3)
present in the engine flywheel (4) through the seat (2) of the
engine speed sensor; in this condition, the flywheel is in the
reference position (piston no. 1 to 54th before T.D.C.).
code
76. If this condition does not occur, turn and adjust the engine fly-
wheel (4) appropriately.
77. Remove the specific tool (1).
code
71774 Figure 177
ENGINE ASSEMBLY
78. Carefully clean the surface of the head on which the rocker arm
cover rests.
79. Using the specific magnetic base support (2) as shown in the
figure, position the specific dialogue (1) with the flat based rod
(3) positioned on the rocker arm roller (4) which controls the
exhaust valves of cylinder no. 3 and preload to at least 7 mm.
code
Tool to check timing (use with 99395606) 99370400
Dial gauge (0-30 mm) 99395606
185253 Figure 178
Caution!
Dial gauge pointer Pointer correct positioning
▶ Position the flat based dial gauge rod (see detailed part) so that its axis passes through the centre of the roller on
which it is resting.
Caution!
Tolerances measure Checking and overhauling values
▶ During the CHECK phase, not during the engine overhaul phase, the allowed tolerance of the measurement is
between -0.05 - +0.12 mm.
▶ During OVERHAUL, the allowed tolerance is ± 0.05 mm.
177714 Figure 179

80. Using the specific tool turn the crankshaft in the opposite direction of the operating direction until the pointer of the dial
gauge reaches the minimum value beyond which it can no longer fall.
ENGINE ASSEMBLY
Note The measurement must be taken holding the rocker roller in contact with the profile of the exhaust cam of the cam-
shaft.
81. reset the dial gauge.

Note The dial gauge is to be zeroed with the rocker arm
roller in contact with the base radius of the cam profile.
To this end, turn the flywheel until passing the protru-
sions (A-B) and (B-C) on the cam profile connected
to exhaust brake operation. This occurs when the fly-
wheel is turned in the opposite direction of the operat-
ing direction approx. 1 and 1/4 rotations.
185524 Figure 180

α Camshaft rotation D Cam lift in corres-
angle pondence of 54° be-
Y Cam lift based on the fore the top dead
rotation angle of the centre, 1st cylinder
camshaft end of compression
82. Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
83. Check that the required cam lift values are displayed under the
following conditions:
code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the flywheel (4).
185523 Figure 181
ENGINE ASSEMBLY
84. Perform the following if the conditions stated have not been
obtained:
85. Turn the engine flywheel until the dial gauge indicates the re-
quired cam lift.
86. Loosen the screws (2) that fasten the gear (1) to the camshaft
and use the slots on the gear (1).
87. Act on the flywheel to obtain the conditions indicated and while
keeping the cam lift value unchanged.
88. Lock the screws (2) and repeat timing check as described
above.
Note While performing this operation recover the clearance
between the camshaft gears.
182129 Figure 182
89. Tighten the screws (2) to the specified torque.
Tightening torque
Camshaft gear fixing 1. Pre-tightening
screws (2) 60 N⋅m
Lubricant
2. Angle tightening
Engine oil
60°
90. When adjustment via the slots is not sufficient for recovering
the offset, proceed as follows:
91. Lock the screws (2) and turn the engine flywheel a 1/2 turn in
the opposite direction of the operating direction.
92. Turn the engine flywheel in the engine operating direction until
the dial gauge indicates the required camshaft lift value.
Technical data
93. Remove the screws (2) and remove the gear (1) from the
camshaft.
94. Turn the flywheel (4) again until the following conditions occur:
code
◁ The hole with two notches (5) is visible through the small
inspection window.
◁ The specific tool (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the flywheel (4).
185523 Figure 183
ENGINE ASSEMBLY
95. Mount the gear (2) with the 4 slots (1) centred with the fixing
holes of the camshaft. Lock the relevant screws to the required
torque.
Tightening torque
Camshaft gear fixing screws 1. Pre-tightening
Lubricant 60 N⋅m
Engine oil
2. Angle tightening
60°
96. Recover the clearance between the timing system gears by

turning the flywheel in the opposite direction of the engine
rotation direction and subsequently turning it in the engine
rotation direction until the dial gauge shows the specific value.
Check the previously described conditions.
Technical data 194037 Figure 184
.541215. Pulser ring timing

97. Turn the crankshaft bringing cylinder piston no. 1 in compres-
sion stage to TDC; turn the flywheel by about 1/4 turn in op-
posite direction than normal sense of rotation.
98. Turn the flywheel again according to normal direction of ro-
tation (anti-clockwise) until the hole marked with the three
notches can be seen through the inspection hole under the fly-
wheel housing (4).
Note If the engine flywheel does not have 3 notches, to
identify the reference hole simply: turn the flywheel
in the direction opposite of the operating direction un-
til reaching the position marked with 2 notches (54°
before cyl. 1 T.D.C.); continue rotating in the engine
operating direction for 4 holes (remember that each
hole corresponds to a flywheel rotation of 6°).
99. Install the specific tool (5) in the flywheel sensor seat (6).
code
100. Insert the specific tool (2), via the seat of the phase sensor,
onto the tooth (↑) obtained on the phonic wheel.
code
Tool for timing of phonic wheel on timing gear 99360613
101. Should tool (2) fitting be difficult, loosen the screws (3) and
direct the phonic wheel (1) properly to position the tool (2) on
the tooth. Then tighten the screws (3).
185254 Figure 185
ENGINE ASSEMBLY
Tightening torque
Screws fixing pulser ring to timing 24.5 ±2.5 N⋅m
gear (3)
185254 Figure 185
.771010. High pressure pump assembly

102. Bring the flywheel to 36° before TDC of the first cylinder.
Note This position can be obtained by turning the engine flywheel in the direction opposite of the operating direction to
the 30° position marked by THREE notches (4) and continuing to turn the flywheel in the same direction until reach-
ing the next hole (by 6°).
If the engine flywheel does not have 3 notches, to identify the reference hole simply: turn the flywheel in the direc-
tion opposite of the operating direction until reaching the position marked with 2 notches (54° before cyl. 1 T.D.C.);
continue rotating in the engine operating direction for 3 holes (remember that each hole corresponds to a flywheel
rotation of 6°).
103. Insert the specific tool through the seat of the flywheel sensor in the corresponding flywheel hole.
ENGINE ASSEMBLY
104. Mount the HP pump and make sure that the seat of the key (1)
on the pump shaft is facing the pump intakes (2).
187918 Figure 186
105. Tighten the locking screws (1) of the HP pump (2), connect
the fuel pipes (3) tightening the fittings to the prescribed
torque.
Note Make sure that the pipe is not damaged after mounting
and that there are no fuel leaks while engine is running.
The HP pipes that are disassembled cannot be used
again and must be replaced.
182156 Figure 187
106. Install the gear (1) and tighten the nuts (2) to the prescribed
torque.
107. Remove the specific tool.
code
182158 Figure 188
ENGINE ASSEMBLY
.541230. Intake and exhaust rocker arm clearance adjustment

Note The adjustment of clearance between the rocker arms and bridges controlling the intake and exhaust valves must be done
very carefully.
187916 Figure 189

A Hole on flywheel with reference mark, corresponding D Flywheel hole with two notches corresponding to
to the TDC of pistons 1-6 position 54° before TDC of pistons 1-6 (camshaft
B Hole on flywheel with reference mark, corresponding timing reference);
to the TDC of pistons 2-5 E Flywheel hole with three notches corresponding to
C Hole on flywheel with reference mark, corresponding position 30° before TDC of pistons 1-6 (reference to
to the TDC of pistons 3-4 HP fuel pump and timing system phonic wheel timing).
108. In order to perform adjustments correctly, during each rotation phase check the positioning accuracy using the specific pin,
inserting it into the hole marked with a notch on the flywheel corresponding to piston position.
ENGINE ASSEMBLY

109. Take the cylinder whose clearance has to be adjusted into the
combustion phase; the valves of this cylinder are closed while
they balance the symmetric cylinder valves.
Note The correspondence of the symmetrical cylinders is 1 -
6, 2 - 5 and 3 - 4.
110. In order to properly operate, follow these instructions and data
specified on the table.
111. Using a box wrench, remove the adjustment screw fastening
nut (1).
Tool / Material
Box wrench
112. Insert the thickness gauge blade (3) corresponding to the op-
erating clearance shown in the "Characteristics and data" 114287 Figure 190
table.
113. Screw or unscrew the adjustment screw of the rocker arm (2)
with the appropriate wrench.
114. Check that the feeler gauge blade (3) can slide with slight fric-
tion.
115. Lock the nut (1) by stopping the adjustment screw.
116. To carry out the adjustments stated above, the sequence shown in the table is mandatory.
FIRING ORDER 1-4-2-6-3-5
Start and rotation in the engine Adjust valve clearance for cylinder
Balancing cylinder valves no.
direction no.
1 and 6 at T.D.C. 6 1
120
3 4
Angle degree [°]
120
5 2
Angle degree [°]
120
1 6
Angle degree [°]
120
4 3
Angle degree [°]
120
2 5
Angle degree [°]
Note Check during each rotation phase, the accuracy of the position by using the specific pin and inserting it into the hole
marked with a notch on the flywheel corresponding to piston position.
ENGINE ASSEMBLY
.540630. Tappet cover assembly

117. Position the cover and insert all the screws.
118. Replace the screws in the sequence 1-10-20-21-9 and then in
the sequence shown in the figure until contact.
119. Tighten the screws 1-24 in the sequence shown to the required
torque.
Tightening torque
Tapper cover fixing screws 8.5 ±1.5 N⋅m
117545 Figure 191
.542011. Fuel filter assembly

120. Fit the fuel filter mount (1) and tighten the screws (2) to the
specified torque.
121. Screw the fuel filter (3) onto the support to the required
torque.
182091 Figure 192
.540452. Timing gear assembly cover mounting

122. Fit the gasket (2) onto the blow-by case(1).
181826 Figure 193
ENGINE ASSEMBLY
123. Fit the blow-by case (3).

124. Tighten the screws (2) to the specified torque.
Tightening torque
Screws fixing the timing gear cover Tightening sequence: 1 - 21
10 N⋅m
125. Connect the pipe (1).
181805 Figure 194
.540486. Blow-by filter fitting

126. Mount the blow-by case (2) and tighten the screws (1) to the
specified torque.
Tool / Material
LOCTITE 243
Note Upon assembly, apply LOCTITE 243 to the screws (1).
181804 Figure 195
.540480. Blow-by case fitting

127. Fit the blow-by case (2).
181803 Figure 196
ENGINE ASSEMBLY
128. Tighten the screws to the specified torque.

Tightening torque
Blow-by case fixing screws Tightening sequence: A - F
7 N⋅m
155920 Figure 197
.543060. Suction strainer installation

129. Turn the engine and fit the oil suction strainer (1).
60517 Figure 198
.540430. Oil sump assembly

130. Arrange the gasket (4) on oil sump (1), position the spacer (3)
and fit the sump on crankcase screwing up the screws (2) at
prescribed torque.
60665 Figure 199
ENGINE ASSEMBLY
.766161. Engine control unit assembly

131. Assemble the engine ECU (3) by tightening the screws (2) to
the prescribed torque.
132. Connect the pipe (1).
181802 Figure 200
.540710. Inlet manifold assembly

133. Refit the intake manifold (1) and tighten the screws (2) to the
specified torque.
134. Mount the support (3) for engine start buttons.
219034 Figure 201
.760810. Starter motor assembly

135. Mount the starter motor (1) and tighten the relative screws to
the specified torque.
181800 Figure 202
ENGINE ASSEMBLY
.543110. Heat exchanger assembly

136. Fit the heat exchanger (2) and tighten the fixing screws (1)
following the order indicated below.
191082 Figure 203
137. Tighten the fixing screws to the prescribed torque.

Tightening torque
Screws securing heat ex- 1. 8 N⋅m to15 N⋅m
changer 2. 22 N⋅m to27 N⋅m
180274 Figure 204
.543070. Oil filter assembly

138. Fit the oil filter mount (1).
139. Oil and fit new seals.
140. Screw the filter (2) until the seals come in contact with the
resting bases.
141. Tighten the filter to the specified torque.
Tightening torque
Oil filter retainer at the support 60 ±5 N⋅m
base
191081 Figure 205
ENGINE ASSEMBLY
.542410. Turbocharger assembly

142. Fit the turbocharger (4) with a new gasket on the exhaust man-
ifold (2).
143. Tighten the screws (1) and (3) as described in the following
point.
191080 Figure 206
144. Tighten the screws fixing the turbocharger to the required

torque following the sequence indicated in the figure.
Tightening torque
Screws and nuts securing turbochar- 75 N⋅m
ger
Lubricant
Graphitised oil
160652 Figure 207
.540720. Exhaust manifold assembly

145. Fit the exhaust manifold (1) with new gaskets together with the
turbocharger (2).
219039 Figure 208
ENGINE ASSEMBLY
180272 Figure 209

146. Tighten the exhaust manifold fixing screws to the specified torque.
Tightening torque
Exhaust manifold fixing screws 1. 40 ±5 N⋅m
Lubricant
2. 60 ±5 N⋅m
Graphitised oil
147. Fit the pipes (3) on the indicated mounts (→).
219039 Figure 210
148. Connect the exhaust gas pipe (1) together with the engine
brake device.
149. Connect the coolant pipes (3) to the engine brake device actu-
ator(2).
219033 Figure 211
ENGINE ASSEMBLY
150. Connect the oil delivery pipe (1) and the sump oil return pipe
(2) to the turbocharger. Tighten the couplings to the recom-
mended torque.
Tightening torque
Oil drain and inlet pipe couplings 22 N⋅m to27 N⋅m
219032 Figure 212
.543251. Fitting the thermostat case (version with intarder)

151. Fit the thermostat assembly (2) with a new gasket and tighten
the fastening screws (3) to the prescribed torque following the
sequence indicated in the figure below.
152. Fit the air pipe (1).
219038 Figure 213
218128 Figure 214

153. Tightening sequence for the screws securing the thermostat assembly.
ENGINE ASSEMBLY
218128 Figure 214
Tightening torque
Thermostat case fixing screws 1. Tightening sequence: 1 - 2 - 3 - 4 - 5 - 6 - 7
27 N⋅m to33 N⋅m
2. Tightening sequence: 8 - 9 - 10 - 11 - 12 - 13 - 14
27 N⋅m to33 N⋅m
.543411. Water pump assembly

154. Fit the automatic chain tensioner (1), fit the pulley (3) and
tighten the screws (2) to the specified torque.
155. Fit the water pump (4), fit the pulley (5) and tighten the screw
(6).
181792 Figure 215
ENGINE ASSEMBLY
.543422. Electromagnetic coupling assembly

156. Block rotation of the flywheel with the specific tool.
code
157. Fit the electromagnetic coupling (2) and tighten the screws (1)
to the specified torque.
181791 Figure 216
.760310. Alternator assembly

158. Fit the alternator (2) and tighten the screws (1) to the required
torque.
181790 Figure 217
.543411. Coolant pump/alternator drive belt assembly

159. To fit the belt (2) use suitable equipment (1) to adjust the belt
tensioner in the direction indicated by the arrow in the figure.
Note Belt tensioner is automatic; therefore, no further ad-
justments are to be made after mounting.
181789 Figure 218
ENGINE ASSEMBLY
.540860. Damper flywheel installation

160. Fit the damper flywheel (2) by turning the 6 fixing screws (1).
Tool / Material
Engine oil
Note Before installing, lubricate the screw thread (1) with

engine oil.
181788 Figure 219
.540110. Removing the engine from the stand

161. Refill the engine with required oil quantity.
162. Remove engine from rotary stand and take off brackets securing the engine.
.543075. Oil pressure adjustment valve assembly

163. Fit the oil pressure adjustment valve (1) and tighten the fixing
screws to the required torque.
Tightening torque
Oil pressure regulator valve 23.5 ±2.5 N⋅m
60486 Figure 220
ENGINE ASSEMBLY
.543211. Fitting the water inlet pipe

164. Fit the water inlet pipe (1) together with the sleeve (3) and
tighten the screws (2) to the specified torque.
Tightening torque
Screws fixing the water inlet pipe to 34.5 ±3.5 N⋅m
the pump
165. Secure the sleeve (3) to the thermostat assembly (4) and
tighten the relevant clip.
219037 Figure 221
.790510. Air compressor assembly

166. Fit the air compressor (3) and tighten the fastening screws (4)
to the specified torque.
167. Connect the water pipes (2).
168. Connect the air pipes (1) and (5).
219030 Figure 222
CURSOR 13 TDCV ‒ technical specifications
TECHNICAL SPECIFICATIONS 3
Contents
Contents
GENERAL CHARACTERISTICS . . . . . . . . . . . . . . . 5
DATA - INSTALLATION CLEARANCES . . . . . . . . . 7
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 12
LAYOUT OF TIGHTENING SEQUENCE FOR MAIN

ENGINE PARTS . . . . . . . . . . . . . . . . . . . . . . . . 15
Tightening sequence diagram for lower crankcase
fixing screws . . . . . . . . . . . . . . . . . . . . . . . . 16
Outer screws . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head fastening screw tightening
diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Layout of tightening sequence for exhaust manifold
fastening screws . . . . . . . . . . . . . . . . . . . . . . 18
Diagram of tightening sequence for turbocharger
fastening screws and nuts . . . . . . . . . . . . . . . . 18
Diagram of tightening sequence for intake manifold
Diagram of tightening sequence for screws
fastening flywheel housing to crankcase . . . . . . . . 20
Diagram of tightening sequence for screws
fastening thrust plate to cylinder head . . . . . . . . 21
Layout of tightening sequence for screws fastening
blow-by case to gear casing . . . . . . . . . . . . . . . 21
Diagram of tightening sequence for heat exchanger
fixing screws . . . . . . . . . . . . . . . . . . . . . . . . 22
Diagram of tightening sequence for thermostat
Layout tightening sequence for rocker arm cover
Diagram of tightening sequence for alternator
Diagram of the tightening sequence for oil sump
Diagram of the tightening sequence of Blow-by
filter retainer screws . . . . . . . . . . . . . . . . . . . 24
Diagram of the tightening order for pulser ring
fixing screws and nuts . . . . . . . . . . . . . . . . . . 25
Scheme of the tightening order of rocker arms
shafts fastening screws and nuts . . . . . . . . . . . . 25
Diagram of tightening sequence for engine ECU
fastening screws and nuts . . . . . . . . . . . . . . . . 26
GENERAL CHARACTERISTICS
TECHNICAL SPECIFICATIONS
F3H
type
F3HFE611B F3HFE611A
Diesel 4-stroke
Cycle
Power supply Turbocharged with aftercooler
Injection
Direct
Number of cylinders 6 in line
Bore mm 135
Stroke mm 150
Total displacement cm3 12880
Compression ratio 16.5 : 1
kW 368 412
(HP) (500) (560)
Max. power
rpm 1900 1900
Nm 2300 2500
(kgm) (234) (255)
maximum torque
rpm 900-1550 1000-1550
Idle speed with no load rpm 550 ± 50
Maximum engine idle speed rpm 2320 ± 50 2320 ± 50
DISTRIBUTION
start before T.D.C. A = 19°
end after B.D.C. B = 31°
start before B.D.C. D = 50°
End after T.D.C. C= 9°
6 TECHNICAL SPECIFICATIONS
F3H
type
F3HFE611B F3HFE611A
For timing check
mm −
X
mm −
Of operation
mm 0.40 ± 0.05
X
mm 0.60 ± 0.05
The high pressure fuel supply system is managed
by the BOSCH EDC 17. It consists of the CPN
POWER SUPPLY 5.2 high-pressure pump, electro-injectors, hydraulic
accumulator (rail), EDC 17 ECU and pressure and
temperature sensors.
Injection
–
Bosch
Electro-injectors type CRIN 3.3
Firing order 1–4–2–6–3–5
Varying injection pressure bar bar 2000
TURBOCHARGING
GT 4502V EVGT variable geometry with

Turbocharger type:
electronic control system.
Forced by gear pump, pressure relief valve, oil

LUBRICATION
filter
Oil pressure with hot engine (100 °C ± 5 °C):

at idle speed bar 1.5
at max speed bar 4.5 - 5
COOLING By means of centrifugal pump, thermostat for reg-
ulation, fan with electromagnetic coupling, radiator,
heat exchanger.
Water pump drive: Belt driven
Thermostat: No. 1
opening start: 84°C ± 2°C
maximum opening: 94°C ± 2°C
FILLINGS:
Total capacity of 1st filling litres 30.5 - 31
engine sump min level. litres 20
DATA - INSTALLATION CLEARANCES
F3H
type
F3HFE611B F3HFE611A
engine sump max level litres 28

oil change with filter change litres 30.5 - 31
F3H
type
mm
CYLINDER ASSEMBLY AND CRANK GEARS
Cylinder liner housing:
upper –
Ø1
lower –
Cylinder liners:
outer diameter:
upper 153.461 - 153.486
Ø2
lower 151.890 - 151.915
length L 252.2
Cylinder liners - crankcase seat
upper –
lower –
Outer diameter Ø2 −
Cylinder liners:
inner diameter Ø3 135.000 - 135.020
Protrusion X** 0.045 – 0.075
** With a load of 8,000 kg

Pistons:
measuring point X 50
outer diameter Ø 1 Ø1A 134.903 - 134.933
pin housing Ø2 59.063 - 59.093
A* 0.067 - 0.117
Piston - cylinder liners
B* ‒
Piston diameter Ø1 −
Piston protrusion X –
F3H
type
mm
Piston pin Ø3 58.994 - 59.000
Piston pin - pin seat 0.063 - 0.099
X1 2.480 - 2.510
Piston ring slots X2 2.580 - 2.610
X3 4.050 - 4.080
* measured on Ø of 121 mm
** measured on Ø of 120 + 0.15 mm
Piston rings:
trapezoidal sealing S1* 2.296 – 2.340
bevelled S2 2.470 - 2.500
milled scraper ring with slots and internal spring S3 3.970 - 3.990
* measured at 2 mm from Ø at the outside
1 0.140 - 0.214
Piston rings - slots 2 0.065 - 0.140
3 0.060 - 0.110
Piston rings −
Piston ring end gap in cylinder liner:

X1 0.35 - 0.45
X2 0.65 – 0.80
X3 0.40 – 0.75
Connecting rod small end bush seat Ø1 63.000 - 63.030
Connecting rod bearing seat Ø2 100.000 - 100.030
1 100.000 - 100.010
Classes 2 100.011 - 100.020
3 100.021 - 100.030
Bushing diameter at connecting rod small end
external Ø4 63.120 - 63.160
internal Ø3 59.060 - 59.076
Connecting rod half-bearings (S) thickness
Red colour 1.960 – 1.970
Green colour 1.971 - 1.980
Yellow colour* 1.981 - 1.990
* Fitted in production only and not supplied as spares.
Bush at connecting rod small end - housing 0.090 - 0.160
Piston pin - bushing 0.060 – 0.082
Connecting rod half-bearings –
F3H
type
mm
Connecting rod weight

A 5537÷ 5570 g
Class B 5571 ÷ 5604 g
C 5605÷ 5637 g
Measuring point X –
Maximum error in parallelism of connecting rod

⁄⁄ –
axes
Main journals Ø1 nominal value 99.970 – 100.000

1 99.970 – 99.979
Selection class 2 99.980 – 99.989
3 99.990 – 100.000
Crankpins Ø2 nominal value 95.970 - 96.000
1 95.970 - 95.979
Selection class 2 95.980 – 95.989
3 95.990 – 96.000
Main half-bearings S1
Red colour 3.110 – 3.120
Green colour 3.121 – 3.130
Yellow colour* 3.131 – 3.140
Connecting rod half-bearings S2
Red colour 1.960 – 1.970
Green colour 1.971 - 1.980
Yellow colour* 1.981 - 1.990
* The yellow half bearing is mounted only during production
Main bearings Ø3 106.300 - 106.330
1 –
Selection class 2 –
3 –
Main journals half-bearings 0.060 - 0.108
Half-bearings crankpins 0.060 - 0.100
Main half-bearings –
Connecting rod half-bearings –
Thrust main journal X1 47.95 - 48.00
Thrust main bearing X2 40.94 - 40.99
F3H
type
mm
Half thrust washers (thickness) X3 3.38 – 3.43
Crankshaft thrust 0.10 - 0.30
Alignment 1-2 –
Centring 1-2 –
CYLINDER HEAD - TIMING SYSTEM
Valve guide housing on cylinder head Ø1 15.980 - 15.997
Ø2 10.015 - 10.030
Valve guides
Ø3 16.012 - 16.025
Valve guides and seats on the head 0.015 – 0.045
Valve guides –
Valves:
Ø4 9.960 - 9.975
α 60° 30' ± 7' 30''
Ø4 9.960 - 9.975
α 60° +30' ± 7' 30''
Valve stem and related guide 0.040 – 0.070
Housing on head for valve seat:
Ø1 49.185 - 49.220
Ø1 46.985 - 47.020
F3H
type
mm
Outside diameter of valve seats: valve housing inclination on cylinder head:
Ø2 49.260 - 49.275
Ø2 47.060 - 47.075
Valve seat 0.2
X 0.54- 0.86
Recessing
X 1.65- 1.95
Between valve seat and cylinder head 0.040 - 0.090
Valve spring height:

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

Ø 88.000- 88.030
1⇒7
Camshaft journals: 1 ⇒ 7 Ø 82.950 – 82.968
Camshaft bushing outer diameter: Ø 88.153 – 88.183
Bushing inner diameter Ø 83.018 – 83.085
Bushings and seats in cylinder head 0.123 - 0.183
Bushings and supporting pins 0.050 – 0.135
Useful cam height:

9.231
9.5607
Rocker-arm shaft Ø1 41.984 – 42.000
mm
TIGHTENING TORQUES
F3H
type
mm
Internal rocker arm diameter:
42.045 – 42.061
59.000 – 59.019
Rocker arm bush outer diameter:
–
59.070 – 59.110
Rocker arm bush inner diameter:
–
56.045 – 56.064
Bushes and housings:
–
0.051 – 0.110
Rocker arm bushes and shaft:

0.045 - 0.077
Engine brake control lever

Eccentric pin outer diameter Ø2 55.981 – 56.000
Rocker shaft seat Ø1 42.025 – 42.041
Rocker arms and engine brake control lever pin 0.045 – 0.083
Rocker arm shaft and seat on engine brake con-

0.025 – 0.057
trol lever
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
Screws securing the crankcase to the lower crankcase ★
Inner screws First step: pre-tightening 160 16
Inner screws Second step: Angle tightening M18x2 60°
Inner screws Third step: Angle tightening 60°
Outer screws Fourth step: pre-tightening 30 3
M12x1.75
Outer screws Fifth step: Angle tightening 60°
Union for piston cooling nozzle 50 ± 5 5 ± 0.5
pre-tightening 11.5 ± 3.5 1.15 ± 0.35
Screws securing heat exchanger to crankcase ★ M8x1.25
tightening 24.5 ± 2.5 2.4 ± 0.25
Screws fixing suction strainer to bedplate 24.5 ± 2.5 2.4 ± 0.25
First step 45 ± 4.5 4.5 ± 0.45
Screws securing spacer and oil sump ★ M10x1.5
Second step 45 ± 4.5 4.5 ± 0.45
Oil sump drain plug 95 ± 10 9.5 ± 1
Oil level dipstick retainer 39 ± 6 3.9 ± 0.6
Pre-tightening 20 2
Screws securing flywheel case to crankcase ★ M12x1.75
Tightening 63 ± 7 6.3 ± 0.7
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
Screws securing flywheel case to head ★ M10x1.5 44 ± 4 4.4 ± 0.4
First step: pre-tightening 75 7.5
Second step: pre-tightening 150 15
M18x2 screw fixing cylinder head: ♦ (*)
Third step: Angle tightening 90 °
Fourth step: Angle tightening 90 °
First step: pre-tightening 25 2.5
Second step: pre-tightening 60 6
M16x1.5 Screw securing rocker arm shaft ★
Third step: pre-tightening 80 8
Fourth step: Angle tightening 60
Screws fastening oil pressure regulating valve 23.5 ±2.5 2.3 ± 0.2
Rocker arm cover M6x1 fastening screws 8.5 ± 1.5 0.8 ± 0.1
Lock nut for rocker arm adjustment screw M10x1.25 39 ± 5 3.9 ± 0.5
M8x1.25 screws for injector brackets 35 3.5
M8x1.25 Screws securing camshaft shoulder plate First step 20 ± 2 2 ± 0.2
to head ★ Second step 20 ± 2 2 ± 0.2
Screws securing bracket on cylinder head to lift engine M12x1.75 100 ± 10 10 ± 1
First step: pre-tightening 60 6
M14X2 screws fastening the camshaft gear (*)
Second step: Angle tightening 60°
Screw fixing pulser ring to timing gear M8x1.25 24.5 ± 2.5 2.5 ± 0.2
M10x1.5 screws securing exhaust manifold (**) pre-tightening 40 ± 5 4 ± 0.5
★ tightening 60 ± 5 6 ± 0,5
Screws fastening collars on exhaust manifold M6x1 12 ± 0.5 1.2
Screws fastening collars on exhaust pipe 8±2 0.8 ± 0.2
Screws fixing the exhaust brake hydraulic actuator cylinder 19 ± 3 1.9 ± 0.3
M14x2 screws fixing the connecting rod cap
Second step: Angle tightening 60°
M18x1.5 screws fixing the engine flywheel (*)
Second step: Angle tightening 90 °
M14x2 screws fixing the damper flywheel to the First step: pre-tightening 70 7
drive pulley (*) Second step: Angle tightening 50 °
M14x2 screws fixing the drive pulley to the First step: pre-tightening 70 7
crankshaft (*) Second step: Angle tightening 50 °
M12x1.75 screw fixing the intermediate gear pins First step: pre-tightening 30 3
(*) Second step: Angle tightening 90 °
Screw fixing rod to adjust transmission gear M8x1.25 24.5 ± 2.5 2.4 ± 0.2
M8x1.25 screws fixing the oil pump 24.5 ± 2.5 2.4 ± 0.2
M8x1.25 screw fixing crankshaft gasket front cover 24.5 ± 2.5 2.4 ± 0.2
Diesel filter breather 18 ± 2 (1.8 ± 0.2)
M8x1.25 screw fastening fuel filter support 24.5 ± 2.5 2.4 ± 0.2
Fuel filter cap 32.5 ± 2.5 3.2 ± 0.2
Fuel filter drain 1.5 ± 0.5 0.2 ± 0.1
Screw fastening oil filter support M8x1.25 23.5 ±2.5 2.4 ± 0.2
TIGHTENING TORQUES
TORQUE
DETAIL
Nm ° kgm
Oil filter cap 60 ± 5 6 ± 0,5
Oil filter drain plug 6.5 ± 1.5 0.7 ± 0.1
Screw fastening control unit mount 19 ± 3 1.9 ± 0.3
Screws and nuts securing turbocharger M12x1.75 75 7.5
Electrical actuator to turbocharger retainer nut 31.8 ± 1.75 3.2 ± 0.2
Screws fastening actuator bracket mount to turbocharger 22.6 ± 1.7 2.3 ± 0.2
Screws fastening oil return pipe to turbocharger M8x1 24.5 ± 2.5 2.4 ± 0.2
Screws securing thermostat assembly ★ M8x1.25 30 ± 3 3 ± 0.3
Screws securing water pump M8x1.25 24.5 ± 2.5 2.45 ± 0.25
Screws fixing water inlet pipe to crankcase M8x1.25 34.5 ± 3.5 3.4 ± 0.3
Screws fastening fan to electromagnetic coupling M8x1.25 34.5 ± 3.5 3.4 ± 0.4
M12x1.75 screws fixing the electromagnetic coupling to the crankcase 100 ± 5 10 ±0.5
Screw fixing the automatic belt tensioner M10x1.5 50 ± 5 5 ± 0.5
Screws securing steady tensioner M12x1.75 105 ± 5 10.5 ± 0.5
Starter motor fastening screws M12x1.75 74 ± 8 7.4 ± 0.8
Screws securing the air heater and the intake manifold to the cylinder head ★ M10x1.5 50 ± 5 5 ± 0.5
Screws fixing air compressor M12x1.75 74 ± 8 7.4 ± 0.8
Nut fixing air compressor drive gear 170 ± 10 17 ± 1
M12x1.5 screws fastening HP pump to the support plate 37.5 ± 2.5 3.7 ± 0.2
M8x1.25 screws fastening HP pump mounting plate to the timing system casing 24.5 ± 2.5 2.4 ± 0.2
M24x1.5 nut for fixing the high pressure pump gear 250 ± 15 25 ± 1.5
M16x1.5 fuel filler on head 55 ± 5 5.5 ± 0.5
M12x1.75 screws securing the oil pump to the bracket 32.5 ± 2.5 3.3 ± 0.2
M16x1.5 couplings fixing the high pressure fuel pipe to the HP pump 42 4.2
M18x1.5 couplings securing the LP fuel pipe to the HP pump 37 ± 3 3.7 ± 0.3
screws marked with numbers 10 ± 1 1 ± 0.1
M6x1 screws securing Blow-by to timing case ★
screws marked with letters 7±1 0.7 ± 0.1
TI supplier 42 ± 2.5 4,2 ± 0,25
M16x1.5 couplings securing the fuel pipe to rail
Chesini supplier 60 ± 2.5 6 ± 0,25
TI supplier 42 ± 2.5 4,2 ± 0,25
M16x1.5 couplings securing the fuel pipe to injectors
TI supplier 42 ± 2.5 4,2 ± 0,25
M16x1.5 couplings securing the HP pipes to the head
M14x1.5 coupling securing the fuel return pipe to rail 50 5
M8x1.25 screws securing the rail to the head 24.5 ± 2.5 2.5 ± 0.3
M20x1.5 rail pressure relief valve 110 ± 5 11 ± 0,5
M8x1.25 nut fixing the heater electrical connections 16 ± 1 1.6 ± 0.1
pre-tightening 5 0.5
Screws securing Blow-by filter★
tightening 15 1.5
M10x1.5x35
44 ± 4 4.4 ± 0.4
(lower retainer)
Screws fastening alternator support
M10x1.5x60
44 ± 4 4.4 ± 0.4
(lower retainer)
LAYOUT OF TIGHTENING SEQUENCE FOR MAIN ENGINE PARTS
TORQUE
DETAIL
Nm ° kgm
M8x1.25x30 (up-
Screws fastening alternator support 24.5 ± 2.5 2.45 ± 0.25
per retainer)
M10x1.5 44 ± 4 4.4 ± 0.4
Alternator fixing screws
M8x1.25 24.5 ± 2.5 2.45 ± 0.25
Alternator pulley securing 75 7.5
Power steering retainer collar 6 ± 2.5 0.6 ± 0.25
Screws fixing power steering pump to the compressor M10x1.5 46.5 ± 4.5 4.6 ± 0.4
Screws fixing air-conditioner compressor to mount M8x1.25 24.5 ± 2.5 2.4 ± 0.25
Screws fixing the air-conditioner compressor mount M8x1.25 24.5 ± 2.5 2.4 ± 0.25
Fixing screw for guard 24.5 ± 2.5 2.5 ± 0.25
Flywheel rev sensor support fastening 23.5 ±2.5 2.3 ± 0.2
M18x1.5 Rail pressure sensor retainer 70 ± 5 7 ± 0.5
Filter clogging sensor fastening 55 ± 5 5.5 ± 0.5
Water/fuel temperature sensor fastener 35 3.5
Thermometric switch/transmitter fastener 25 2.5
Air temperature transmitter fastener 35 3.5
Pulse transmitter fastener 8±2 0.8 ± 0.2
Pressure sensor retainer on the rocker cover 27.25 ± 2.75 2.7 ± 0.28
Exhaust brake solenoid valve fastener M24x1.5 32 ± 3 3.2 ± 0.3
PWM solenoid valve fastener 8±2 0.8 ± 0.2
Nuts for injector electrical connection 1.5 ± 0.25 0.15
Head wiring connector fixing screw 8±2 0.8 ± 0.2
* Lubricate with engine oil before assembly
** Lubricate with graphitised oil before assembly
☆ Apply LOCTITE 243 before assembly
★ See tightening sequence
540110 LAYOUT OF TIGHTENING SEQUENCE FOR MAIN ENGINE PARTS

F3HFE611
Tightening sequence diagram for lower crankcase fixing screws
60593 Figure 1
First step
Tightening torque
Lower crankcase inner screws Pre-tightening
160 N⋅m
Second step
Technical data
Lower crankcase internal screws (angle closing) 60°
Third step
Technical data
Lower crankcase internal screws (angle closing) 60°
Outer screws
60592 Figure 2
Fourth step
Tightening torque
Lower crankcase external screws Pre-tightening
30 N⋅m
60594 Figure 3
Fifth step
Technical data
Lower crankcase external screws (angle closing) 60°
Cylinder head fastening screw tightening diagram
61270 Figure 4
Tightening torque
Cylinder head fixing screws 1. 75 N⋅m
2. 150 N⋅m
3. 90°
4. 90°
Layout of tightening sequence for exhaust manifold fastening screws
180272 Figure 5
Tightening torque
Exhaust manifold fixing screws 1. Tightening sequence: 1-2-3-4
20 N⋅m
2. Tightening sequence: 5-6-7-8
45 N⋅m
Diagram of tightening sequence for turbocharger fastening screws and nuts
213469 Figure 6
Diagram of tightening sequence for intake manifold fastening screws
218129 Figure 7
Tightening torque
Intake manifold fixing screws 1. Tightening sequence: 1-2-3-4-5-6
45 N⋅m to55 N⋅m
2. Tightening sequence: 1-5-3-4-6-2
45 N⋅m to55 N⋅m
Diagram of tightening sequence for screws fastening flywheel housing to crankcase
180269 Figure 8
Tightening torque
Flywheel housing fastening screws 1. Tightening sequence: 1 – 19
63 ±7 N⋅m
2. Tightening sequence: 20 – 21
44 ±4 N⋅m
Diagram of tightening sequence for screws fastening thrust plate to cylinder head
151833 Figure 9
Tightening torque
Thrust plate fastening screws 1. Tightening sequence: 1-2-3-4-5
18 N⋅m to22 N⋅m
2. Tightening sequence: 6-7-8-9-10
18 N⋅m to22 N⋅m
Layout of tightening sequence for screws fastening blow-by case to gear casing
155920 Figure 10
Tightening torque
Screws fixing blow-by box 1. Tightening sequence: from 1 to 21
9 N⋅m to11 N⋅m
2. Tightening sequence: from A to F
6 N⋅m to8 N⋅m
Diagram of tightening sequence for heat exchanger fixing screws
180274 Figure 11
Tightening torque
Heat exchanger fastening screws 1. 8 N⋅m to15 N⋅m
2. 22 N⋅m to27 N⋅m
Diagram of tightening sequence for thermostat fastening screws
218128 Figure 12
Tightening torque
Thermostat fixing screws 1. Tightening sequence: 1-2-3-4-5-6-7
27 N⋅m to33 N⋅m
2. Tightening sequence: 8-9-10-11-12-13-14
27 N⋅m to33 N⋅m
Layout tightening sequence for rocker arm cover fastening screws
Tightening torque
Tightening
Rocker arm cover fastening screws
(Tighten the screws to contact in the
8.5 ±1.5 N⋅m
following order: 1 - 10 - 20 - 21 - 9
and then according to the diagram)
180275 Figure 13
Diagram of tightening sequence for alternator fastening screws
180276 Figure 14
Alternator support
tightening torque
Detail
Nm kgm
1 Screws fixing the alternator mount to the crankcase 24.5 ± 2.5 2.45 ± 0.25
2 Alternator fixing pin 44 ± 4 4.4 ± 0.4
3 Alternator fixing screw 24.5 ± 2.5 2.45 ± 0.25
4 Screws fixing the alternator mount to the head 24.5 ± 2.5 2.45 ± 0.25
Diagram of the tightening sequence for oil sump fastening screws
155922 Figure 15
Tightening torque
Oil sump fastening screws 1. Tightening sequence: from 1 to 16
40.5 N⋅m to49.5 N⋅m
2. Tightening sequence: from 1 to 4
40.5 N⋅m to49.5 N⋅m
Diagram of the tightening sequence of Blow-by filter retainer screws
160656 Figure 16
Tightening torque
Blow-by filter fixing screws 1. 5 N⋅m
2. 15 N⋅m
Diagram of the tightening order for pulser ring fixing screws and nuts
162194 Figure 17
Tightening torque
Pulser ring locking screw 1. 10 N⋅m
2. 25 N⋅m to32 N⋅m
Scheme of the tightening order of rocker arms shafts fastening screws and nuts
180277 Figure 18
Tightening torque
Rocker arm shaft fixing screws 1. 25 N⋅m
2. 60 N⋅m
3. 80 N⋅m
4. 60°
Diagram of tightening sequence for engine ECU fastening screws and nuts
180271 Figure 19
Fuel pipe couplings

Pipe tightening torque
Detail
mm Nm kgm
M12 x 1.5 6x1 16 ± 2 1.6 ± 0.2
M14 x 1.5 8x1 19 ± 3 1.9 ± 0.3
M18 x 1.5 12 x 1.5 35 ± 5 3.5 ± 0.5
M22 x 1.5 15 x 1.5 37 ± 5 3.7 ± 0.5
M22 x 1.5 16 x 2 39 ± 6 3.9 ± 0.6
Couplings with pressure ring
M26 x 1.5 18 x 2 44 ± 6 4.4 ± 0.6
Pipe tightening torque

Detail
mm Nm kgm
M10 x 1 – 15 ± 1.5 1.5 ± 0.15
M12 x 1.5 – 20 ± 2 2 ± 0.2
M14 x 1.5 – 24 ± 2.4 24 ± 0.24
M16 x 1.5 – 30 ± 3 3 ± 0.3
M22 x 1.5 – 34 ± 3.4 3.4 ± 0.34

Connection couplings
M10 x 1 – 18 ±1.8 1.8 ± 0.18
M12 x 1.5 – 35 ± 3.5 3.5 ± 0.35
M14 x 1.5 – 50 ± 5 5 ± 0.5
M16 x 1.5 – 60 ± 6 6 ± 0.6
M18 x 1.5 – 70 ± 7 7 ± 0.7
M22 x 1.5 – 120 ± 12 12 ± 1.2

Eyelet couplings
Couplings between the fuel supply system and the engine – 32 ± 3.2 3.2 ± 0.32

P1D32C016 - 11-2014 - EN (1) - Compactado-1-1

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CURSOR 13 TDCV ‒ General mechanical overhaul

GENERAL MECHANICAL OVERHAUL 5

GENERAL MECHANICAL OVERHAUL

.790510. Air compressor removal

.543075. Oil pressure adjustment valve removal

.543211. Removing the water inlet pipe

.540860. Damper flywheel removal

.543411. Coolant pump alternator drive belt disassembly

.760310. Alternator removal

.543422. Electromagnetic coupling removal

.543210. Water pump removal

.543251. Thermostat case removal

.540442. Crankshaft front gasket removal

.542410. Turbocharger removal

.540720. Exhaust manifold removal

.543070. Oil filter removal

.543110. Heat exchanger removal

.760810. Starter motor disassembly

.540710. Intake manifold removal

.766161. Engine control unit removal

.540480. Blow-by case removal

.540486. Blow-by filter removal

.540452. Timing gear cover disassembly

.540630. Removal of head cover

.542011. Fuel filter removal

.773010. High pressure pump removal

38. Disconnect pipes (1, 3).

.540850. Engine flywheel removal

.540462. Crankshaft rear gasket removal

.540463. Flywheel case removal

.543010. Disassembling the oil pump

.541230. Rocker arm shaft removal

.774510. Rail removal

.775010. Injector removal

.541210. Camshaft removal

.540610. Cylinder head removal

68. Using metal ropes, lift the cylinder head (1).

69. Take off the gasket (2).

.540430. Oil sump removal

.543060. Suction strainer removal

.540830. Connecting rod removal

.540830. Axis alignment check

.540416. Lower crankcase removal

.540810. Crankshaft removal

.540816. Main bearings removal

.540414. Oil sprayer removal

.540110. COMPREHENSIVE CRANKCASE CHECKS

Spacer (to be used with 99360334) 99360336

5. In order to check the inner diameter of cylinder liners and

Note If the 135 mm ring gauge is not available, use a micro-

6. Measurements should be carried out for every single cylinder

7. When wear is over 0.150 mm or maximum ovalisation is 0.100

8. The illustrated diagram refers to the outer diameters of cylinder

.540420. Cylinder liners Removal

.540420. Cylinder liner refitting and protrusion check

Tool / Material Product

Tool / Material Product

17. On completing assembly, lock the cylinder liners (1) on the

.540810. Crankshaft measurements

.540811. Measuring main journals

Note It is advisable to enter readings in a table.

.540812. Measuring crankpins