SERVICE MANUAL

VIEWS OF THE ENGINE

Figure 1

71696

FRONT VIEW OF ENGINE

Figure 2

71695

LEFT SIDE VIEW OF ENGINE

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Figure 3

73526

RIGHT SIDE VIEW OF ENGINE

Figure 4

71694

REAR VIEW OF ENGINE

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 SERVICE MANUAL

Figure 5

73530

TOP VIEW OF ENGINE

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TECHNICAL DESCRIPTION

ENGINE

TYPE SERIAL NUMBER

F 3 B E 0 6 8 1 A * A 0 0 1 –

Progressive production number

Version no. within D.B.

Holds only for level of gas emissions for same characteristic

curves
Level of engine torque or power

Use (1 truck, ...)

Supply + Injection (TCA, diesel direct injection)

Number of cylinders

Number of strokes and cylinder position (0 = 4 stroke, vertical)

Engine

Development of family with/without same displacement

Engine family

A 540 HP 240 kgm

C 440 HP 214 kgm
E 480 HP 224 kgm

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CHARACTERISTIC CURVES
Figure 6

73551

CHARACTERISTIC CURVES OF ENGINE F3BE0681C

Max. POWER : 324 kW 440 HP 1450 to 1900 rpm

Max. TORQUE : 2100 Nm 224 kgm 1000 to 1470 rpm

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Figure 7

73552

CHARACTERISTIC CURVES OF ENGINE F3BE0681E

Max. POWER : 353 kW 480 HP 1500 to 1900 rpm

Max. TORQUE : 2200 Nm 184 kgm 950 to 1550 rpm

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8

Figure 8

73553

CHARACTERISTIC CURVES OF ENGINE F3BE0681A

Max. POWER : 397 kW 540 HP 1550 to 1900 rpm

Max. TORQUE : 2350 Nm 240 kgm 1000 to 1600 rpm

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GENERAL SPECIFICATIONS

Type F3BE0681C F3BE0681E F3BE0681A

Cycle 4–stroke diesel

Supply Turbocharged with intercooler

Injection Direct

Number of cylinders 6 in line

∅
Bore mm 135

Stroke mm 150

+ + +.. = Total displacement cm3 12880

r Compression ratio 16.5 ± 0.8

Maximum power kW 324 353 397

(HP) (440) (480) (540)

rpm 1450 to 1900 1500 to 1900 1550 to 1900

Maximum torque Nm 2100 2200 2350

(kgm) (214) (224) (240)

rpm 1000 to 1470 950 to 1550 1000 to 1600

Slow running with

no load
rpm 525 ± 25
Fast idling speed with
no load
rpm 2250 ± 20

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Type F3B

A
TIMING SYSTEM

Start before T.D.C. A 17°

End after B.D.C. B 30°

B

Start before B.D.C. D 50°

End after T.D.C. C 9°

To check timing

mm _
X
mm _
X
Operation

mm 0.35 to 0.45
X
mm 0.55 to 0.65

SUPPLY Via fuel pump – Filters

Injection With PDE 31 injectors with electronic adjustment.
type Bosch Injectors–pump controlled by camshaft in head.

Nozzles type –

Injection sequence 1–4–2–6–3–5

bar
Injection pressure bar 1500
Injector setting bar 290 ±12

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Type F3B

Holset
TURBOCHARGING variable
geometry
Turbocharger type HY55 V
Forced via gear pump, pressure relief valve,
LUBRICATION
oil filter
Oil pressure with engine
bar warm (100 ± 5ºC):
at slow running bar 1.5
at fast idling speed bar 5
Via centrifugal pump, thermostat, viscostatic fan,
COOLING
radiator, heat exchanger
Water pump drive With belt
Thermostat N. 1
starts opening: 84 ± 2 ºC
full aperture 94 ± 2 ºC
REPLENISHING
Total capacity
1st filling
liters 35
kg 31.5
Capacity
– engine sump at
minimum level
liters 20
Urania LD5 kg 18
(according to Acea
E3–E5 specification) – engine sump at
Urania Turbo maximum level
(according to Acea liters 28
E2 specification) kg 25.2
– quantity in circulation that
does not return to sump
liters 7
kg 6.3
– quantity contained in
cartridge filter (to add when
changing the cartridge filter)
liters 3
kg 2.7

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ASSEMBLY DATA – CLEARANCE

Type F3B

CYLINDER ASSEMBLY AND CRANK MEMBERS mm

∅1
Cylinder liner seats
top 153.500 to 153.525
∅1
bottom 152.000 to 152.025

Cylinder liners:
outside diameter:
L top 153.461 to 153.486
∅2
bottom 151.890 to 151.915
∅2 length L _
Cylinder liners –
crankcase seats
top 0.014 to 0.039
bottom 0.085 to 0.135

Outside diameter ∅2 _

∅3 Cylinder liners:

X inside diameter ∅3A* 135.000 to 135.013

inside diameter ∅3B* 135.011 to 135.024
protrusion X** 0.045 to 0.075
* Selection class
** Under a load of 8000 kg
Pistons:
∅
∅1
measurement X 20
X
outside diameter ∅1AD 134.881 to 134.893
∅2 outside diameter ∅1BDD 134.892 to 134.894
seat for pin ∅2 54.010 to 54.018
Piston – cylinder liners
A* 0.107 to 0.132
B* 0.107 to 0.132
* Selection class

Piston diameter ∅1 _

X
Piston protrusion X

∅3 Piston gudgeon pin ∅3 53.994 to 54.000

Piston gudgeon pin – pin seat 0.010 to 0.024

D Class A pistons supplied as spares.
DD Class B pistons are fitted in production only and are not
supplied as spares.

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F3B
Type
mm

X1 X1* 3.445 to 3.475

X2 Piston ring slots X2 3.05 to 3.07
X3 5.02 to 5.04
X3 * measured on Ø of 130 mm

Piston rings:
S1 – sealing trapezoidal S1* 3.296 to 3.364
S2 – sealing bevelled S2 2.970 to 2.990
S3 – milled scraper ring with
slots and internal spring S3 4.970 to 4.990
* measured on Ø 130 mm
1 0.081 to 0.179
Piston rings – slots 2 0.060 to 0.100
3 0.030 to 0.070

Piston rings _

X1 Piston ring end opening in

cylinder liner
X2
X1 0.40 to 0.55
X3
X2 0.65 to 0.80
X3 0.40 to 0.75

Small end bushing seat

∅1 Ø1 59.000 to 59.030
Connecting rod bearing seat
Ø2
∅2 1 94.000 to 94.010
Selection class Ø2 2 94.011 to 94.020
3 94.021 to 94.030
∅4 Small end bushing diameter
outside ∅4 59.085 to 59.110
∅3
inside ∅3 54.019 to 54.035
Big end bearing shells S
S Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow 1.986 to 1.995
Small end pushing – seat 0.055 to 0.110
Piston gudgeon pin – bushing 0.019 to 0.041

Big end bearing shells –

Weight of connecting rod

Ag 4661 to 4694
Class Bg 4695 to 4728
Cg 4729 to 4762

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F3B
Type
mm
X
Measurement X 125
Maximum error
on alignment of connecting
rod axes 0.08

Main journals ∅1
– nominal 99.970 to 100.000
– class 1 99.970 to 99.979
– class 2 99.980 to 99.989
∅1 ∅2 – class 3 99.990 to 100.000
Crankpins ∅2
– nominal 89.970 to 90.000
– class 1 89.970 to 89.979
– class 2 89.980 to 89.989
– class 3 89.990 to 90.000
S1 S2 Main bearing shells S1
Red 3.110 to 3.120
Green 3.121 to 3.130
Yellow* 3.131 to 3.140
Big end bearing shells S2
Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow* 1.986 to 1.995

∅3 Main bearing housings ∅3 106.300 to 106.330

Bearing shells – main journals 0.060 to 0.100

Bearing shells – crankpins 0.050 to 0.090
Main bearing shells 0.127 – 0.254 – 0.508
Big end bearing shells 0.127 – 0.254 – 0.508

Main journal for shoulder X1 47.95 to 48.00

X1

Main bearing housing

for shoulder X2 40.94 to 40.99
X2

X3
Half thrust washers X3 3.38 to 3.43

Crankshaft shoulder 0.10 to 0.30

1 2
Alignment 1–2 ≤ 0.025
Roundness 1–2 0.010

Taper 1–2 0.010

* Fitted in production only and not supplied as spares

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Type F3B

CYLINDER HEAD – TIMING SYSTEM mm

∅1

Guide valve seats

on cylinder head ∅1
15.980 to 15.997

∅2

∅2 10.015 to 10.030
Valve guides
∅3 16.012 to 16.025
∅3

Valve guides and seats on head 0.015 to 0.045

Valve guides _

∅4 Valves:

∅4 9.960 to 9.975
α 60° 30′ ± 7′ 30″

∅4 9.960 to 9.975
α α 45° 30′ ± 7′ 30″

Valve stem and relevant guide 0.040 to 0.070

Seat on head for valve seat:

∅1 49.185 to 49.220

∅1 ∅1 46.985 to 47.020

Outside diameter of valve

seats; angle of valve seats
∅2 on cylinder head:

∅2 49.260 to 49.275
α 60° – 30’

α ∅2 47.060 to 47.075
α 45° – 30’

X 0.54 to 0.85
Recessing
X X 1.75 to 2.05

Between valve
seat and head 0.040 to 0.090

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F3B
Type
mm
Valve spring height:
free spring H 72.40
H under a load of:
H1
H2 575 ± 28 N H1 58
1095 ± 54 N H2 45

Injector protrusion X 0.52 to 1.34

X

Seats for camshaft bushings

in cylinder head:
1⇒7 Ø 88.000 to 88.030
∅ ∅ ∅
∅ 2

Camshaft supporting pins:

1⇒7 Ø 82.950 to 82.968
∅ 1 ∅ 3

Outside diameter of
∅ bushings for camshaft: ∅ 88.153 to 88.183

∅ Bushing inside diameter: ∅ 83.018 to 83.085

Bushings and seats in

0.123 to 0.183
cylinder head
Bushings and supporting pins 0.050 to 0.135
Useful cam height
9.231

H 9.5607

11.216

∅ 1
Rocker arm shaft ∅1 41.984 to 42.000

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F3B
Type
mm
Seats for bushings in
rocker arms:
45.000 to 45.016

59.000 to 59.019

∅
46.000 to 46.016

Outside diameter of
bushings for rocker arms:
45.090 to 45.130

∅ 59.100 to 59.140

46.066 to 46.091

Inside diameter of bushings

for rocker arms:
42.025 to 42.041

∅ 56.030 to 56.049

42.015 to 42.071

Bushings and seats:

0.074 to 0.130

0.081 to 0.140

0.050 to 0.091

Rocker arm bushings and shaft:

0.025 to 0.057

0.025 to 0.057

0.015 to 0.087

TURBOCHARGER
Type HOLSET HY 55 V with variable geometry
End play _
Radial play _

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TIGHTENING TORQUES

PART TORQUE
Nm kgm
Screws fixing crankcase base to crankcase (see Fig. 10) ♦
Outside screws M12x1.75 First phase: pre–tightening 30 (3)
Inside screws M18x2 Second phase: pre–tightening 120 (12)
Inside screws Third phase: closing to angle 60°
Inside screws Fourth phase: closing to angle 55°
Outside screws Fifth phase: closing to angle 60°
Piston cooling nozzle union ♦ 35 ±2 (3,5 ±0,2)
Screws fixing heat exchanger to crankcase ♦ (see Fig. 14)
pre–tightening 11.5 ±3.5 (1.15 ±0.35)
tightening 19 ±3 (1.9 ±0.3)
Screws fixing suction strainer to crankcase base ♦ 24.5 ±2.5 (2.4 ±0.25)
Screws fixing oil sump spacer ♦ (see Fig. 15)
pre–tightening 38 (3.8)
tightening 45 (4.5)
Screws fixing gearbox to crankcase M12x1.75 ♦ (see Fig. 16) 63 ±7 (6.3 ±0.7)
Screws fixing control unit to crankcase base ♦ 24 ±2.5 (2.4 ±0.25)
Screws fixing cylinder head (see Fig. 11) ♦
First phase pre–tightening 60 (6)
Second phase pre–tightening 120 (12)
Third phase closing to angle 90°
Fourth phase closing to angle screws no. 4 – 5 – 12 – 20 – 21 45°
Fifth phase closing to angle screws no. 1 – 2 – 3 – 6 – 7 – 8 – 9 – 10 – 11– 65°
14 – 15 – 16 – 17 – 18 – 19 – 22–
23 – 24 – 25 – 26
Screws fixing rocker arm shaft ♦
First phase pre–tightening 100 (10)
Second phase closing to angle 60°
Lock nut for rocker arm adjustment screw ♦ 39 ±5 (3.9 ±0.5)
Screws for injector brackets ♦ 26 (2.6)
Screws fixing plastic cover 8.5 ±1.5 (0.85 ±0.15)
Screws fixing shoulder plate to head ♦ 19 ±3 (1.9 ±0.3)
Screws fixing engine mount bracket to cylinder head
First phase pre–tightening 120 (12)
Second phase closing to angle 45º

♦ Before assembly, lubricate with UTDM oil

• Before assembly, lubricate with graphitized oil

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PART TORQUE
Nm kgm
Screws fixing engine mount bracket to flywheel casing
First phase pre–tightening 100 (10)
Second phase closing to angle 60°
Screws fixing camshaft gear ♦
FFirst phase pre–tighteningirst 60 (6)
Second phase closing to angle 60°
Screws fixing phonic wheel on camshaft gear 8.5 ±1.5 (0.85 ±0.15)
Screws fixing exhaust manifold • (see Fig. 12)
pre–tightening 32.5 (3.2)
tightening 45 (3.2)
Screws fixing engine brake actuator cylinder ♦ 19 (1.9)
Screws fixing connecting rod cap ♦
First phase pre–tightening 60 (6)
Second phase closing to angle 60°
Screws fixing engine flywheel ♦
First phase pre–tightening 120 (12)
Second phase closing to angle 60°
Third phase closing to angle 30°
Screws fixing damper flywheel ♦
First phase pre–tightening 70 (7)
Second phase closing to angle 50°
Screws fixing middle gear pins ♦
First phase pre–tightening 30 (3)
Second phase closing to angle 90°
Screws fixing idle gear adjustment connecting rod: 24.5 ±2.5 (2.45 ±0.25)
Screws fixing oil pump 24.5 ±2.5 (2.45 ±0.25)
Screws fixing crankshaft gasket front cover 24.5 ±2.5 (2.45 ±0.25)
Screws fixing fuel pump / filter mount 19 (1.9)
Screw fixing control unit mount 19 ±3 (1.9 ±0.3)
Screws and nuts fixing turbocharger • (see Fig. 13)
pre–tightening 35 (3.5)
tightening 46 (4.6)
Screw fixing thermostat assembly 19 ±3 (1.9 ±0.3)
Screws fixing water pump 25 (2.5)
Screws fixing fan hub to spacer 30 (3)
Screw fixing fan spacer to pulley 30 (3)
Screws fixing fan mount to crankcase 100 (10)
Screw fixing automatic tensioner to air–conditioner 26 ±3 (2.6 ±0.3)
Screw fixing automatic tensioner to alternator mount 50 ±5 (5 ±0.5)
Screws fixing fixed pulley for auxiliary member drive belt to crankcase 105 ±5 (10.5 ±0.5)
Screws fixing starter motor 74 ±4 (7.4 ±0.4)
Screws fixing air heater 30 ±3 (3 ±0.3)
Screws fixing air compressor 74 ±4 (7.4 ±0.4)

♦ Before assembly, lubricate with UTDM oil

• Before assembly, lubricate with graphitized oil

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PART TORQUE
Nm kgm
Nut fixing air compressor gear ♦ 170 ±10 (17 ±1)
Screws fixing alternator: M 10x1,5 l = 35 mm 30 ±3 (3 ±0.3)
M 10x1,5 l = 60 mm 44 ±4 (4.4 ±0.4)
Screws fixing hydraulic power steering pump 46.5 ±4.5 (4.65 ±0.45)
Screws fixing air–conditioner compressor to the mount 24.5 ±2.5 (2.5 ±0.25)
Screws fixing guard 24.5 ±2.5 (2.5 ±0.25)
Filter clogging sensor fixing 55 ±5 (5.5 ±0.5)
Water / fuel temperature sensor fixing 35 (3.5)
Transmitter / thermometric switch fixing 25 (2.5)
Air temperature transmitter fixing 35 (3.5)
Pulse transmitter fixing 8 ±2 (0.8 ±0.2)
Fixing connections to injector 1.36 ±1.92 (0.13 ±0.19)
Fixing engine brake solenoid valve 32 (3.2)

♦ Before assembly, lubricate with UTDM oil

• Before assembly, lubricate with graphitized oil

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DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS

Figure 9

First phase:
FRONT SIDE pre–tightening
outside screws
30 Nm

60592

Second phase:
FRONT SIDE pre–tightening
inside screws
120 Nm

60593

Third phase:
closing inside
FRONT SIDE screws to angle
60º

60593

Fourth phase:
closing inside
FRONT SIDE screws to angle
55º

60593

Fifth phase:
closing outside
FRONT SIDE screws to angle
60º

60594

DIAGRAM OF TIGHTENING SEQUENCE OF CRANKCASE BASE FIXING SCREWS

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Figure 10

60580

DIAGRAM OF TIGHTENING SEQUENCE OF EXHAUST MANIFOLD FIXING SCREWS

Figure 11

60581

DIAGRAM OF TIGHTENING SEQUENCE OF EXHAUST MANIFOLD FIXING SCREWS

Figure 12

60582

DIAGRAM OF TIGHTENING SEQUENCE OF SCREWS AND NUTS FIXING TURBOCHARGER

ON EXHAUST MANIFOLD

JULY 2002 CTSB 861 23

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Figure 13

60666

DIAGRAM OF TIGHTENING SEQUENCE OF HEAT EXCHANGER FIXING SCREWS

Figure 14

60583

DIAGRAM OF TIGHTENING SEQUENCE OF ENGINE OIL SUMP FIXING SCREWS

Figure 15

73554

DIAGRAM OF TIGHTENING SEQUENCE FOR SCREWS FIXING ROCKER COVER

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Figure 16

60633

DIAGRAM OF TIGHTENING SEQUENCE OF SCREWS FIXING GEARBOX TO CRANKCASE

Tightening sequence

10 screws M12 x 1.75 x 100

2 screws M12 x 1.75 x 70
4 screws M12 x 1.75 x 35
1 screw M12 x 1.75 x 120
: 2 screws M12 x 1.75 x 193

JULY 2002 CTSB 861 25

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TOOLS

TOOL No. DESCRIPTION

99305019 Box with full set of tools for regrinding valve seats

99305047 Appliance to check spring loads

99322230 Rotary telescopic stand

(capacity 2000 daN, torque 375 daN/m)

99340053 Tool to remove crankshaft front gasket

99340054 Tool to remove crankshaft rear gasket

99340205 Percussion extractor

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99342149 Extractor for injector box

99346250 Key to mount crankshaft front gasket

99346251 Key to mount crankshaft rear gasket

99348004 Universal extractor for interiors from 5 to 70 mm

99350072 Socket wrench for screws fastening crankcase to crankcase base

99360143 Drift to fit – remove valve guide

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99360144 Tools (12+6) to hold rocker arm adjustment screw blocks

when removing refitting rocker arm shaft

99360180 Plugs (6) protecting injector seats

99360184 Pliers for removing and refitting piston rings (105–106 mm)

99360261 Tool for removing and refitting engine valves

(use with specific plates)

99360263 Plate for removing and refitting engine valves

(use with 99360261)

99360296 Drift for refitting valve guide (use with 99360143)

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99360314 Tool to remove oil filter (engine)

99360321 Tool to rotate engine flywheel (use with 99360325)

99360325 Spacer (use with 99360321)

99360329 Keying device for mounting gasket on valve guide

99360334 Compression tool to measure cylinder liner protrusion

(use with 99370415–99395603 and specific plates)

99360336 Spacers (use with 99360334)

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99360338 Plate to compress cylinder liners

(use with 99360334–99360336)

99360351 Tool to hold engine flywheel

99360499 Drift to remove and refit camshaft bushings

99360500 Tool to lift crankshaft

99360551 Bracket to remove and refit engine flywheel

99360553 Tool to assemble and install rocker arm shaft

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99360585 Beam to remove and refit engine

99360605 Clamp to insert piston in cylinder liner (60–125 mm)

99360612 Tool to position engine T.D.C.

99360613 Tool for phonic disc timing on camshaft

99360703 Tool to hold cylinder liners

99360706 Tool to extract cylinder liners (use with specific rings)

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99360728 Ring (135 mm) (use with 99360706)

99361036 Brackets fixing engine to rotary stand 99322230

99365056 Tool to upset injector box

99370415 Dial gauge base to measure cylinder liner protrusion

(use with 99395603)

99378100 Tool to punch engine data plates (use with specific punches)

99378103
99378105
99378107 Punches (A, C, E, G) to punch engine data plates
(use with 99378100)

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99389834 Torque screwdriver to calibrate injector solenoid valve

connector retaining nut

99390330 Valve guide smoother

99390772 Tool to remove remains from injector box

99390804 Tool to thread injector boxes to extract (use with 99390805)

99390805 Guide bushing (use with 99390804)

99394015 Guide bushing (use with 99394041 or 99394043)

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Milling cutter to regrind injector seat (use with 99394015)

99394041

Reamer to regrind bottom of injector box (use with 99394015)

99394043

Pair of meters for angular tightening with square 1/2”

99395216 and 3/4” connection

Gauge to determine centre distance between camshaft

99395219 and idle gear

99395363 Complete square to check for connecting rod distortion

99395603 Dial gauge (0 – 5 mm)

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99395687 Bore meter (50 – 178 mm)

Crankshaft front gasket cover centring ring

99396035

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ENGINE REMOVAL–REFITTING
Removal
Figure 17

If washing the engine bay, adequately protect the

! electric/electronic components and their
connections.

- Set the vehicle on the level over a pit. Lock the rear
wheels and tilt up the cab.
- Break the electric circuit by disconnecting the positive
cable of the battery.
- Lift the radiator cowling and tilt up the cab.
- Disconnect the gearbox as described under the relevant
heading, ”Disconnecting the Gearbox”.
- Drain the hydraulic power steering and engine cooling
systems.
- Steps to perform on the engine intake side:
- Disconnect the pipe (8) from the power steering tank (9)
and the pipe (6) from the power steering pump (7).
- Disconnect the pipe (3) from the diesel pump.
- Disconnect the air pipe (12) from the turbocharger
actuator air filter. Disengage the pipe (10) supplying air
to the fan hub from the clamps and the fitting (13).
- Disconnect the tube (4) of the air compressor.
- Disconnect the pipes (5) and (14) from the air com-
pressor, freeing them from the clamps (16) and (18) on
the engine.
- With the hose (2), remove the pipe (5) from the seat on
the intake manifold.
- With the fitting (1), remove the pipe (14).
- Disconnect the coolant piping (17) and (15) and remove
it by freeing it from the clamps.
- Disconnect the engine air intake sleeve (11).

73901

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As a preliminary operation it is wise to disconnect the Figure 18

wiring (11) that will remain fastened to the chassis frame,
proceeding as follows:
- Acting on the air intake side, disengage the wiring (11),
disconnecting it from the engine cable with the connector
(17).
- Disconnect the electrical connection (3) of the hydraulic
power steering tank (4).
- Remove the entire mount of the engine starting and stop-
ping buttons (2) together with the power steering tank
(4), after disconnecting the pipe (5), by taking out the
screws (1).
From the electronic control unit (8), disconnect the bottom
connector (9), proceeding as follows:
- A Lift the safety lever.
- B Move the connector, disconnecting it from the control
unit.
- C Lift the connector, unhooking the stop tooth.
- Disconnect the earth cable (10) from the crankcase and
the electromagnetic clutch cable for the air–condition-
ing compressor, via the connector (12).
- Disconnect the electrical connections (7) on the starter
motor (6).
- Disconnect the electrical connections (15) of the alter-
nator (16).
- Disconnect the electrical connection from the valve on
the control unit (8).
- Disconnect the diesel pipe (18) from the mount of the
control unit (8).
- Then free the wiring (11) from the clamps (14) secured
to the engine air intake duct (13) and carefully place it
away to the side of the vehicle so it will not interfere with
the removal of the engine.

73902

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From underneath the vehicle: Figure 19

- Disconnect the coolant pipe (3) from the engine and
from the radiator, then remove it.
- Disconnect the coolant pipe (2), loosen and remove the
belt (6) from the pulley of the air–conditioning com-
pressor by using the automatic tensioner.
- Disconnect the compressor (9) from the engine mount
(8) by taking out the screws (7) and (10).
- Without disconnecting the pipes of the compressor and
then without discharging the air–conditioning system,
free the pipes (5) from the brackets (1 and 4), suitably tie
the compressor to vehicle so it does not interfere with the
operations of removing the engine.

73903

JULY 2002 CTSB 861 39

 SERVICE MANUAL

Working on the engine exhaust side (driver’s side), proceed Figure 20

as follows:
- Disconnect the air sleeve (6).
- Free the air–conditioning pipes (5) from the clamp (4)
secured onto the manifold (3).
- Disconnect the coolant pipes (9) and (11) from the engine.
- Remove the engine air intake manifold (12), disconnect-
ing it from the sleeve (21), fastenings (8) and (13), flex-
ible sleeve (14); disconnect the oil vapour recovery pipe
(7) and disconnect the air intake pipe of the compressor
(20).
- Disconnect the exhaust pipe (16) by acting on the collar
(15) and remove the bracket (17) by undoing the fas-
teners.
- Anchor the engine to the beam 99360585 and keep the
tool under tension before removing the engine mounts.
- Take out the front (10) and rear (18) and (19) screws fix-
ing the engine mounts on both sides.
- Slowly take the engine out of its bay, drawing it slightly
back so as to free the fan (2) from the bay of the air con-
veyor (1) on the radiator.
- Remove the fan from the hub by using the four screws.
Take out the engine completely, taking care over any in-
terference with the remaining parts secured to the chas-
sis frame, especially the wiring interfering with the
right–hand rear engine mount.
- Disconnect the air bleed pipe (22) from the Intarder
coolant pipe.
If washing the engine, adequately protect the elec-
! tric/electronic components and their connections.

Refitting

To refit the engine, carry out the steps described for removal
in reverse order, taking special care over the steps required
to install the assembly in the engine bay, and keep to the fol-
lowing instructions:
- Check the flexible mountings of the engine and gearbox
assemblies; replace them if deteriorated.
- Check that the parts of the exhaust pipe have not deterio-
rated or are about to deteriorate, in which case they
should be replaced.
- Tighten the screws and/or nuts to the required torque.
- Fill the cooling system with coolant as required under
the relevant heading.
- Bleed the air from the supply system as described under
the relevant heading (542011).

Before bleeding the supply system, connect tubes

! onto the bleed screws located on the pre–filter
mount, filter and front of the cylinder head in order
to recover the fuel in suitable containers during this oper-
ation. In particular, prevent the fuel, on coming out of the
bleed screw on the cylinder head, from fouling the belts driv-
ing the fan, water pump, alternator and air–conditioner com-
pressor, damaging them.
Fit the chassis frame cable to the engine and hook up the con-
- Fill the hydraulic power steering circuit and bleed off the nector to the control unit as described hereunder:
air as described under the relevant heading (501030). A Insert the stop tooth in its seat.
- Check the engine oil level. B Hook up the connector.
C Push the safety lever as far as the stop. 73904

40 CTSB 861 JULY 2002

 SERVICE MANUAL

Filling the cooling system After conscientiously following the above warnings,
proceed as follows:
Preliminary operations
- Remove the cap (2) from the expansion tub (3).
For vehicles equipped with just the standard cab heating - Pour the coolant into the expansion tub (3) till it is quite
system or manual air–conditioning: full.
- Fully open the coolant cock on the instrument panel.

For vehicles equipped with the automatic air–conditioning

system: Bleeding air from the system
- Set the temperature control in the cab on the HI position.

For vehicles equipped with an additional heater:

For vehicles equipped with an additional heater:
- The heater must not be turned on. ! - Turn on the heater.

Operations - Start the engine and keep the speed just above idling for
Place a sheet of cardboard between the coolant radiator and 5 min.
the intercooler radiator in order to shorten the time it takes to
reach the engine’s working temperature (approx. 90°C).
If the tub empties completely during these first few
! minutes, stop and engine and top it up at a slower
rate than before.
Restart the engine.

Filling the system

- After 5 min. running, top up the level of fluid in the

Figure 21
expansion tub, if necessary.
- Close the expansion tub filler with the cap (2).
Take the engine up to top speed so that the coolant
quickly reaches the temperature of full thermostat
opening (approx. 90°C) and keep it in this state until all
the air is bled out of the system.
This is checked by seeing there is no foam or air bubbles
in the tub.
The longest time it takes to bleed the air from the system
completely is approximately 15 minutes from the
moment when the thermostat opens (opening starts
85°±2°C).

44317

GENERAL WARNINGS Do not take the filler cap off the expansion tub until
! Filling must be done with the engine cold. ! the fluid in the system has cooled completely.
The cap (1) must not be removed for any reasons Any topping up must only be done with the engine
whatsoever. cold.
To prevent pockets of air forming in the system, the This is to avoid:
fluid has to be transferred slowly (approximate flow 1 – Operator burns.
rate 8 litres/min). 2 – Damage to the engine since cooling system
For vehicles equipped with an additional heater: the pressurization is only created with the fluid
percentage of glycols in the coolant must be no heating from the condition of the engine cold.
greater than 50%.

JULY 2002 CTSB 861 41

 SERVICE MANUAL

542011 Bleeding air from the supply system

3 2
1

Checks and tests

Before starting the engine, bleed the air from the
supply system, applying special tubes to the bleed Start the engine, leave it running at just a little faster
screws to run the bled fuel off into a specific than idling speed and wait for the temperature of the
container. coolant to reach the level to open the thermostat.
Then, check that:
- Bleed screw (1) on the pre–filter mounting. - No water leaks from the connecting sleeves of the pipes
- Bleed screw (2) on the filter mounting. in the engine cooling and cab heating circuits, tightening
- Bleed screw (4) on the front of the cylinder head. the collars further if this is necessary.
- Work the pump (3) on the pre–filter mounting till fuel - No oil leaks from between the cover and the cylinder
with no air bubbles in it comes out of the screw (1); close head, between the oil sump and the crankcase, between
the screw. the oil filter and its seat, between the heat exchanger and
- Repeat this step for screw (2). the crankcase, or between the various pipes in the
lubrication circuit.
- Repeat this step for screw (4).
- No air leaks from the pipes connected to the pneumatic
components involved in removal.
Under no circumstances let fuel foul the water pump
- The indicator lights on the instrument panel and the
! alternator drive belt, etc.
devices disconnected when removing the engine all work
properly.

42 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 22

Î
Î

73581

LONGITUDINAL SECTION OF THE ENGINE

JULY 2002 CTSB 861 43

 SERVICE MANUAL

Figure 23

71699

TRANSVERSE SECTION OF THE ENGINE

44 CTSB 861 JULY 2002

 SERVICE MANUAL

540110 STRIPPING THE ENGINE ON THE

BENCH Figure 27
Before securing the engine on the rotary stand 99322230,
remove the following parts:
Figure 24

60484

- Using the right tool (3), turn it in the direction shown by

60481 the arrow and remove the air–conditioner drive belt (1).
On the right–hand side of the engine
- Remove the air–conditioner (2) together with the engine
- The fuel cartridge filter (1). mounting.
- The hydraulic power steering tank (2). On the left–hand side of the engine
- The electrical connections. Figure 28
Figure 25

60485

60482 - The engine mounting (1).

- The sound–deadening guard (1).
- The pipes connecting the compressor. Figure 29

Figure 26

60486

60483
- The oil pressure adjustment valve (1).
- The compressor (1) together with the power steering
pump (2).

JULY 2002 CTSB 861 45

 SERVICE MANUAL

Figure 30

73582

Secure the engine to the rotary stand 99322030 with the brackets 99361036 (1, Figure 30).

46 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 31 Figure 34

73585

71702 Remove the alternator (1), electric fan coupling (2),

Remove the entire electric wiring from the sensors and from automatic tensioners (3 and 5), pulley (4), water pump (6)
the electric activators. Lock the engine flywheel with the tool and pulley (7).
(1) 99360351.
Figure 32 Figure 35

60490

73583 Apply the extractor 99340053 (2) and extract the crankshaft
Remove the dampener flywheel (6) by taking out the screws gasket (1). Take off the flange (3).
(5).
Disconnect the pipes (2 and 3) from the V.G.T. solenoid Figure 36
valve (4). Remove the thermostat assembly (1) together with
the solenoid valve (4).
Figure 33

71707
73584
Remove the water pipes (1 and 5), water outlet pipe (1), air
Using an appropriate tool (1), turn it in the direction shown pipe (2) governing the actuators, oil deliver pipes (3), oil
by the arrow and remove the auxiliary member drive belt (2). return pipe (4), turbocharger assembly (6) and exhaust
manifold (7).

JULY 2002 CTSB 861 47

 SERVICE MANUAL

Figure 37 - Air filter for PWN valve (5).

- Intake manifold (6) together with heating element for
pre–heating engine.
- Engine control unit (7).
Figure 40

73586

Using tool 99360314, unscrew the oil filters (3).

- Unscrew the screws (4) and remove the heat exchanger
(5).
- Unscrew the screws (1) and remove the water pipe (2). 60495

- Remove the rocker arm cover (1) and the timing system
Figure 38 cover (2) together with the blow–by filter.

Figure 41

70708
To remove the P.T.O. (if applicable):
60575
- Disconnect the oil pipe (1).
- Unscrew the 4 screws (2) and (3). - Unscrew the screws (2) and remove the gear (1) together
with the phonic wheel.
Figure 39
Figure 42

60494
Remove the following parts: 60497
- Fuel filter mounting (1). - Unscrew the screws (1). Screw one of them down in a
- Fuel pump (2) and relevant pipes. reaction hole to take out the shoulder plate (2). Take off
- Starter motor (3). the sheet metal gasket.
- Mounting for starter motor buttons (4).

48 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 43 Figure 46

60498
60501
Unscrew the screws (2) and remove the idle gear (1).
Unscrew the screws (1) and remove the gearbox (2).
Figure 47

Figure 44

In sequence, take out the: 71709

- P.T.O. driving gear (1);
- idle gear (2);
60499 - oil pump gear (3).
With the engine flywheel locking tool 99360351 (1) fitted, Figure 48
unscrew the fixing screws (2). Take off the tool (1) and
extract the flywheel (3).

Figure 45

60511

- Unhook the engine brake lever retaining springs (3).

- Unscrew the screws (1) to disconnect the electrical
connections from the electro–injectors.
- Unscrew the screws (6) securing the injector wiring to
the head.
- Electrically disconnect the engine brake solenoid valve
60500 (8).
Fit on the extractor 99340054 (2) and extract the gasket (1). - Take out the pipes (5 and 7) supplying the engine brake
cylinders (4).
- Unscrew the screws (2) fixing the rocker arm shaft.
- Unscrew the screws (6) to take out the head injector
wiring. The wiring has to be extracted from the front.

JULY 2002 CTSB 861 49

 SERVICE MANUAL

Figure 49 Figure 52

73533
60515
Using tool 99360144 (3), constrain the blocks (4) to the - Using metal ropes, lift the cylinder head (1).
rockers (2). Apply tool 99360553 (1) to the rocker holder
shaft (5) and remove the shaft (5) from the cylinder head. - Take off the gasket (2).

Figure 50
Figure 53

60513

- Unscrew the screws (2) fixing the brackets (3) and 60516
extract the injectors (1).
- Unscrew the screws (4) and take out the engine brake Unscrew the screws (2) and take out the engine oil sump (1)
cylinders (5). together with the spacer (3) and gasket.
- Unscrew the screws and take out the cylinder with the
solenoid valve of the engine brake (6).
Figure 51 Figure 54

60514 60517

- Insert the plugs 99360180 (1) in place of the injectors. Unscrew the screws and take out the suction strainer (1).
- Extract the camshaft (2).
- Unscrew the screws fixing the cylinder head (3).

50 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 55 Note down the assembly position of the top and

bottom main bearing shells since, if reusing them,
! they will need to be fitted in the position found upon
removal.

Figure 58

47574

Turn the crankcase (1) upright.

Figure 56

47570

Using tool 99360500 (1), remove the crankshaft (2).

Figure 59

60518

Untighten screws (2) fixing the connecting rod cap (3) and
remove it. Remove the connecting rod–piston (1) assembly
from the upper side. Repeat these operations for the other
pistons.
Keep the big end bearing shells in their respective
housings and/or note down their assembly position
! since, if reusing them, they will need to be fitted in
the position found upon removal.

47571

Figure 57
Extract the main bearing shells (1), unscrew the screws and
take out the oil nozzles (2).
Remove the cylinder liners as described under the relevant
heading on page 170.

After removing the engine, you need to clean the

! removed parts thoroughly and check their integrity.
The following pages give the instructions for
making the checks and the main measurements to
make to determine whether the parts can be reused.
60519

Using an appropriate wrench and the hex wrench unscrew

the screws (1) and (2) and take off the crankcase base.

JULY 2002 CTSB 861 51

 SERVICE MANUAL

REPAIRS
540410 CYLINDER BLOCK Figure 62
540420 Checks and measurements X

Figure 60 (Demonstration)

60595
34994
A = Selection class Ø 135.000 to 135.013 mm
The inside diameter of the cylinder liners is checked to
B = Selection class Ø 135.011 to 135.024 mm
ascertain the extent of ovalization, taper and wear using the
X = Selection class marking area
gauge 99395687 (2) fitted with the dial gauge (1), zeroed
beforehand on the ring gauge (3) of diameter 135 mm. On finding maximum wear greater than 0.150 mm or
maximum ovalization of 0.100 mm compared to the values
shown in the figure, you need to replace the cylinder liner as
no grinding, facing or reconditioning is permitted.
If you do not have a ring gauge of diameter 135 mm,
! use a micrometer for this purpose.
! The cylinder liners are supplied as spare parts with
selection class ”A”.

Figure 61
Figure 63

60596 60597

A = Ø 153.500 to 153.525 mm
B = Ø 152.000 to 152.025 mm
1 = 1st measurement C = Ø 153.461 to 153.486 mm
2 = 2nd measurement D = Ø 151.890 to 151.915 mm
3 = 3rd measurement
The diagram shown in the figure gives the outside diameter
of the cylinder liner and inside diameter of its seat.
The measurements have to be made on each single cylinder
liner at three different heights and on two levels (A–B) at The cylinder liners can, if necessary, be extracted and fitted
right angles to each other as shown in Figure 61. several times in different seats.

52 CTSB 861 JULY 2002

 SERVICE MANUAL

Cylinder liners
Figure 64

60598

CRANKCASE ASSEMBLY WITH CYLINDER LINERS

Figure 65

71710
Selection class A mm 135.000 to 135.013
B mm 135.011 to 135.024
MAIN CYLINDER LINER DATA

Figure 66

71711
DETAIL “X”
“Y“ – Selection class marking area

JULY 2002 CTSB 861 53

 SERVICE MANUAL

540420 Replacing the cylinder liners

Removal Figure 69

Figure 67

47577 60520

Position the parts 99360706 (2) and the plate 99360728 (4) Check the protrusion of the cylinder liners with tool 99360334
as shown in the figure, checking that the plate (4) rests on (2) and tightening the screw (1) to a torque of 225 Nm.
the cylinder liner correctly. Using the dial gauge 99395603 supplied as standard with
Screw down the nut of screw (1) and extract the cylinder the dial gauge base 99370415 (3), check that the protrusion
liner (3) from the crankcase. of the cylinder liner over the supporting face of the cylinder
head is 0.045 – 0.075 mm (Figure 70); if this is not so,
replace the adjustment ring (1) (Figure 68), supplied as a
Assembly and checking protrusion spare part with several thicknesses.
Figure 68
Figure 70 0.045 to 0.075

49017
CYLINDER LINER PROTRUSION
Figure 71
16798

Always replace the water seals (3, 4 and 5).

Fit the adjustment ring (1) on the cylinder liner (2).
Lubricate the bottom of it and mount it in the cylinder
assembly using the appropriate tool.

! The adjustment ring (1) is supplied as a spare part

with the following thicknesses: 0.08 mm – 0.10
mm – 0.12 mm – 0.14 mm.

60521
On completing assembly, lock the cylinder liners (1) to the
crankcase (2) with the pins 99360703 (3).

54 CTSB 861 JULY 2002

 SERVICE MANUAL

5408 Crankshaft
Figure 72

Top main bearing shells

Bottom main bearing shells 71712

MAIN DATA OF CRANKSHAFT AND MAIN BEARING SHELLS

Check the state of the main journals and crankpins of the crankshaft. They must not be scored or be too ovalized or worn.
The data given refer to the normal diameter of the journals.
Figure 73 Figure 74

POLISHED POLISHED

GROUND GROUND

GROUND
60603 71713

X. Detail of the main journal unions Y. Detail of the crankpin unions

JULY 2002 CTSB 861 55

 SERVICE MANUAL

540812 Measuring the main journals and crankpins

Before grinding the journals, use a micrometric gauge (1) Figure 77
to measure the journals of the shaft (2) and establish, on the
basis of the undersizing of the spare bearing shells, to what
diameter it is necessary to reduce the journals.

Figure 75

47536

MEASURING THE CRANKPINS

When grinding, pay the utmost attention to the values of the
47535
unions of the main journals and of the crankpins given in
Figure 73 and Figure 74.
MEASURING THE MAIN JOURNALS

It is advisable to note the measurements in a table All the main journals and crankpins should always
! (Figure 76). ! be ground to the same undersizing class so as not
to alter the balance of the shaft.

Figure 76
Table for noting down the measurements of the main journals and crankpins of the crankshaft.

MAIN JOURNALS

Minimum Ğ
Maximum Ğ

Minimum Ğ
Maximum Ğ

CRANKPINS 36061

56 CTSB 861 JULY 2002

 SERVICE MANUAL

Preliminary measurement of data to select main bearing and big end bearing shells
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS: CRANKPINS:
- Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the
crankcase. connecting rod.
- Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount. - Select the class of the bearing shells to mount.

DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase two sets of numbers are marked in the position shown.
- The first set of digits (four) is the coupling number of the crankcase with its base.
- The second set of digits (seven) is the class of diameter of each of the seats referred to.
- Each of these digits may be 1, 2 or 3.

MAIN BEARING
Figure 78 CLASS HOUSING NOMINAL
DIAMETER

106.300 to 106.309

106.310 to 106.319

106.320 to 106.330

47535

JULY 2002 CTSB 861 57

 SERVICE MANUAL

Selecting the main bearing and big end bearing shells

To obtain the required assembly clearances, the main bearing and big end bearing shells have to be selected as
! described hereunder.

This operation makes it possible to identify the most suited bearing shells for each of the journals of the shaft (the bearing shells
may even have different classes for different pins).

Depending on the thickness, the bearing shells are selected Figure 79 gives the specifications of the main bearing and
in classes of tolerance marked by a colour (red–green – big end bearing shells available as spare parts in the
red/black – green/black). standard sizes (STD) and in the permissible oversizes
(+0.127, +0.254, +0.508).

Figure 79

Big end bearing shells STD +0.127 +0.254 +0.508

red 1.965 to 1.975 2.092 to 2.102 2.219 to 2.229

red/black 2.028 to 2.038

green 1.976 to 1.985 2.103 to 2.112 2.230 to 2.239

green/black 2.039 to 2.048

Main bearing shells STD +0.127 +0.254 +0.508

red 3.110 to 3.120 3.237 to 3.247 3.364 to 3.374

red/black 3.173 to 3.183

green 3.121 to 3.130

green/black 3.184 to 3.193

58 CTSB 861 JULY 2002

 SERVICE MANUAL

DEFINING CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (journals with nominal diameter)
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 80 at top):
- The first number, of five digits, is the part number of the shaft.
- Under 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 journals (1 = STD, 2 = –0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins
they refer to (Figure 80 at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows
the status of the journals (1 = STD, 2 = –0.127), the other seven digits, taken singly, give the class of diameter of each
of the main journals they refer to (Figure 80 at bottom).

Figure 80

CLASS CRANKPIN
NOMINAL DIAMETER

89.970 to 89.979

89.980 to 89.989

89.990 to 90.000

MAIN JOURNALS
CLASS NOMINAL DIAMETER

99.970 to 99.979

99.980 to 99.989

MAIN JOURNALS 99.990 to 100.000

JULY 2002 CTSB 861 59

 SERVICE MANUAL

SELECTING THE MAIN BEARING SHELLS

After reading off the data, for each of the main journals, on the crankcase and crankshaft, you choose the type of bearing shells
to use according to the following table:

Figure 81

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

60 CTSB 861 JULY 2002

 SERVICE MANUAL

SELECTING THE MAIN BEARING SHELLS (GROUND JOURNALS)

If the journals have been ground, the procedure described so far cannot be applied.
In this case, it is necessary to check that the new diameter of the journals is as shown in the table and to mount the only type
of bearing shell envisaged for the relevant undersizing.

Figure 82

–0.127
red/black =
mm 3.173 to 3183

green/black =
mm 3.184 to 3.193
CLASS 1 2 3
99.843 green/black green/black green/black
99.852 1
green/black green/black green/black

99.853 red/black green/black green/black

99.862 2
red/black green/black green/black

99.863 red/black red/black green/black

99.873 3
red/black red/black green/black

–0.254

red =
mm 3.237 to 3.247
1 2 3

99.726 red red red

99.746
red red red

–0.508

red =
mm 3.364 to 3.374
1 2 3

99.472 red red red

99.492
red red red

JULY 2002 CTSB 861 61

 SERVICE MANUAL

SELECTING THE BIG END BEARING SHELLS Figure 83

(JOURNALS WITH NOMINAL DIAMETER)
There are three markings on the body of the connecting rod
in the position indicated as ”A”:

1 Letter indicating the class of weight:

VIEW FROM “A”
A = 4661 to 4694 g.
B = 4695 to 4728 g.
C = 4729 to 4762 g.
2 Number indicating the selection of the diameter of the
big end bearing seat:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3 Numbers identifying the cap–connecting rod coupling.

The number, indicating the class of diameter of the bearing

shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal
by following the indications in the table (Figure 78). 47557

Figure 84

STD.

CLASS 1 2 3

green green green

1
green green green

red green green

2
red green green

red red red

3
red red red

62 CTSB 861 JULY 2002

 SERVICE MANUAL

SELECTING BIG END BEARING SHELLS (GROUND JOURNALS)

If the journals have been ground, the procedure described so far cannot be applied.
In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of the
crankpins and to mount the bearing shells identified with the relevant table.
Figure 85

red/black =
mm 2.028 to 2.038 –0.127

green/black =
mm 2.039 to 2.048
CLASS 1 2 3
89.843 green/black green/black green/black
89.852 1
green/black green/black green/black

89.853 red/black green/black green/black

89.862 2
red/black green/black green/black

89.863 red/black red/black green/black

89.873 3
red/black red/black green/black

–0.254

red =
mm 2.092 to 2.102
green =
1 2 3
mm 2.103 to 2.112

89.726 red green green

89.735
red green green

89.736 red red green

89.746
red red green

–0.508

red =
mm 2.219 to 2.229
green =
1 2 3
mm 2.230 to 2.239

89.472 red green green

89.481
red green green

89.482 red red green

89.492
red red green

JULY 2002 CTSB 861 63

 SERVICE MANUAL

540815 Replacing the timing gear

and oil pump Figure 88
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.

Figure 86

47578

3 +– 00.5 Using the tackle and hook 99360500 (1), mount the
crankshaft (2).

49020

When fitting the gear (1) on the crankshaft (2), heat it for
no longer than 2 hours in an oven at a temperature of 180°C.
After driving it in, leave it to cool.
If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.

540811 Checking main journal assembly

clearance

Figure 89
Figure 87

49021
47579

Arrange the bearing shells (1) on the main bearing housings

Mount the oil nozzles (2), making the grub screw match the in the crankcase base (2).
hole (3) on the crankcase. Check the assembly clearance between the main journals of
Arrange the bearing shells (1) on the main bearing the crankshaft and their bearings, proceeding as illustrated
housings. on the following pages.

64 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 90 Figure 91

60559 47578

Set two journals of the crankshaft (2) parallel to the - Lubricate the internal screws (1) with UTDM oil and
longitudinal axis, a section of calibrated wire. Using tighten them with a torque wrench (3) to a torque of
appropriate hooks and tackle, mount the crankcase base (1). 120 Nm, using tool 99395216 (4), to an angle of 60°,
following the diagram of Figure 92.
Figure 92

FRONT SIDE

60593

DIAGRAM OF SEQUENCE FOR TIGHTENING THE SCREWS FIXING

THE BOTTOM CRANKCASE BASE TO THE CRANKCASE
Figure 93 Checking crankshaft end float

Figure 94

- Remove the crankcase base. 47579

The clearance between the main bearings and their journals

is measured by comparing the width taken on by the
calibrated wire (2) at the point of greatest crushing with the 47588
graduated scale on the case (1) containing the calibrated
wire. The end float is checked by setting a dial gauge (1)
The numbers on the scale give the clearance of the coupling 99395603 with a magnetic base on the crankshaft (2) as
in millimetres. If you find the clearance is not as required, shown in the figure. If you find the clearance to be greater
replace the bearing shells and repeat the check. than as required, replace the rear main bearing shells
carrying the thrust bearings and repeat the clearance check.

JULY 2002 CTSB 861 65

 SERVICE MANUAL

5408 Connecting rod piston assembly

Figure 95

60607

PISTON – CONNECTING ROD ASSEMBLY

1. Connecting rod body – 2. Bearing shells – 3. Connecting rod cap – 4. Cap fixing screws – 5. Split ring –
6. Slotted scraper ring with spiral spring – 7. Bevelled seal – 8. V–seal – 9. Piston gudgeon pin – 10. Piston

Check the pistons. They must show no signs of seizure, The pistons are fitted with three rings: the first one is a
scoring, cracking or excessive wear; replace them if they V–seal, the second one a bevelled seal and the third one a
do. scraper ring.
The pistons are selected in two classes, A and B, according
Removal to diameter.

Figure 96 Figure 97

60608 49024

Removing the piston rings from the piston (2) using pliers Removing the split rings (2) retaining the piston gudgeon
99360184 (1). pin using round–nose pliers (1).

66 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 98 Figure 100

49025 32618

Removing the piston gudgeon pin (1). Measuring the diameter of the pin (1) using a micrometer
If removal is difficult, use an appropriate drift. (2).

Measuring piston diameter

Figure 99

Conditions for correct pin–piston coupling

71714

Using a micrometer (2), measure the diameter of the piston

(1) to determine the assembly clearance. The diameter has Figure 101
to be measured at the value shown.

49026

Lubricate the pin (1) and its seats on the hubs inside the
piston with engine oil. The pin has to go into the piston by
lightly pressing it with the fingers and must not drop out.

JULY 2002 CTSB 861 67

 SERVICE MANUAL

Figure 102

73555

MAIN DATA OF THE PISTON, PISTON RINGS AND PIN

* The measurement is made on the Ø of 130 mm.
Figure 104
540842 Piston rings
Figure 103

3513

The seal (2) of the 1st slot has a V shape. The clearance ”X”
between the seal and its seat is measured by setting the
piston (1) with the ring in the cylinder liner (3) so that the
16552
seal comes half out of the cylinder liner.
Check the thickness of the piston ring (2) with a micrometer
(1).
Figure 106
Figure 105

36134

Using a feeler gauge (2), check the opening between the

ends of the seals (1) inserted in the cylinder liner (3).
60610
If you find the distance between the ends is less than or
Check the clearance between the seals (2) and their seats on greater than as required, replace the piston rings.
the piston (1) with a feeler gauge (3).

68 CTSB 861 JULY 2002

 SERVICE MANUAL

540830 Connecting rod

Figure 107

Punched on the big end of the connecting rod are the

data relating to the section in classes relating to the
connecting rod seats and the weights.

On assembling the connecting rods, check

! they are all of the same class of weight. VIEW FROM “A”

Connecting rod punch markings

1 Letter indicating the class of weight:

A = 4661 to 4694 g.
B = 4695 to 4728 g.
C = 4729 to 4762 g.

2 Number indicating the selection of the diameter

of the big end bearing seat:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3
Number indicating the selection of diameter
for the big end bearing housing:

47957

Figure 108

71716

MAIN DATA OF THE BUSHING, CONNECTING ROD, PIN AND BEARING SHELLS
* Measurement to be made after driving in the bushing.

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 SERVICE MANUAL

540834 Bushings
Checking torsion

Figure 110

73535

Check the bushing in the small end has not come loose and
shows no sign of scoring or seizure; replace it if it does.
61694
The bushing (2) is removed and fitted with a suitable drift
(1).
When driving it in, make absolutely sure that the holes for Check the torsion of the connecting rod (5) by comparing
the oil to pass through in the bushing and small end two points (A and B) of the pin (3) on the horizontal plane
coincide. Using a boring machine, rebore the bushing so as of the axis of the connecting rod.
to obtain a diameter of 54.019 – 54.035. 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
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
Checking connecting rods opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.
Figure 109
Checking bending
Figure 111

61696 61695

Check the bending of the connecting rod (5) by comparing

two points C and D of the pin (3) on the vertical plane of the
Checking axis alignment axis of the connecting rod.
Check the alignment of the axes of the connecting rods (1) Position the vertical mount (1) of the dial gauge (2) so that
with device 99395363 (5), proceeding as follows: this rests on the pin (3) at point C.
Fit the connecting rod (1) on the spindle of the tool 99395363 Swing the connecting rod backwards and forwards seeking
(5) and lock it with the screw (4). the highest position of the pin and in this condition zero the
dial gauge (2). Shift the spindle (4) with the connecting rod
Set the spindle (3) on the V–prisms, resting the connecting (5) and repeat the check on the highest point on the opposite
rod (1) on the stop bar (2). side D of the pin (3). The difference between point C and
point D must be no greater than 0.08 mm.

70 CTSB 861 JULY 2002

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Mounting the connecting rod – piston assembly Mounting the piston rings

Figure 112 Figure 114

60614

To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
73536
The rings need to be mounted with the word ”TOP” (4)
facing upwards. Direct the ring openings so they are
The piston (1) has to be fitted on the connecting rod (2) so staggered 120° apart.
that the graphic symbol (4), showing the assembly position
in the cylinder liner, and the punch marks (3) on the
connecting rod are observed as shown in the figure. Fitting the big end bearing shells

Figure 115
Figure 113

1
2

49030
74052

Fit the bearing shells (1), selected as described under the

Fit the pin (2) and fasten it on the piston (1) with the split heading ”Selecting the main and big end bearing shells”, on
rings (3). both the connecting rod and the cap.
If reusing bearing shells that have been removed, fit them
back into their respective seats in the positions marked
during removal.

JULY 2002 CTSB 861 71

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Fitting connecting rod – piston assemblies in Figure 116

the cylinder liners
With the aid of the clamp 99360605 (1, Figure 116), fit the
connecting rod – piston assembly (2) in the cylinder liners,
according to the diagram of Figure 117, checking that:
- The openings of the piston rings are staggered 120°
apart.
- The pistons are all of the same class, A or B.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil nozzles.

60616

The pistons are supplied as spares in class A and Checking piston protrusion
! can be fitted in class B cylinder liners. On completing assembly, check the protrusion of the
pistons from the cylinder liners; it must be 0.12 – 0.42 mm.

Figure 117

60615

ASSEMBLY DIAGRAM OF CONNECTING ROD – PISTON ASSEMBLY IN CYLINDER LINER

1. Connecting rod – piston assembly – 2. Area of punch marking on the top of the piston,
symbol showing assembly position and selection class – 3. Connecting rod punch mark area

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540831 Checking crankpin assembly Checking head bearing surface on cylinder

clearance block
To measure the clearance, carry out the following
operations. Connect the connecting rods to the relevant Figure 120 (Demonstration)
journals of the crankshaft, placing a length of calibrated
wire on the journals.
Figure 118

36159

Check the supporting surface (1) of the head on the cylinder

block with a rule (2) and a feeler gauge (3). If you find any
47594
deformation, level the head on a surface grinder; maximum
Mount the connecting rod caps (1) together with the bearing
amount of material that can be removed 0.2 mm.
shells. Tighten the screws (2) fixing the connecting rod caps
to a torque of 60 Nm (6 kgm). Using tool 99395216 (3),
further tighten the screws with an angle of 60°.
The thread of the screws (2), before assembly, has
! to be lubricated with engine oil. After this process, you need to check the valve
! recessing and injector protrusion.
Remove the caps and determine the clearance by
comparing the width of the calibrated wire with the
graduated scale on the case containing the calibrated wire.
Upon final assembly: check the diameter of the thread of
the screws (2), it must be no less than 13.4 mm; if it is,
change the screw. Lubricate the crankpins and connecting 540622 Valves
rod bearings. Tighten the screws (2) as described above. Decarbonizing and checking valves

540610 CYLINDER HEAD

Removing valves Figure 121
Figure 119

48625
47583
Remove the carbon deposits on the valves with a wire
Mount and secure the tool 99360263 (2) with the bracket brush.
(4). Screw down with the device 99360261 (1) to be able to Check that the valves show no signs of seizure or cracking
remove the cotters (3). Take out the tool (2) and extract the and check with a micrometer that the valve stem diameter
top plate (5), spring (6) and bottom plate (7). comes within the required values (see Figure 122); replace
Repeat this process on all the valves. the valves if it does not.
Turn over the cylinder head and take out the valves (8).

JULY 2002 CTSB 861 73

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Figure 122 Figure 124

41032

71718
Check the valve seats (2). If you find any slight scoring or
MAIN DATA OF VALVES AND VALVE GUIDES burns, regrind them with tool 99305019 (1) according to the
* Measurement to be made after driving in the valve guides angles shown in Figure 122. If it is necessary to replace
them, using the same tool and taking care not to affect the
cylinder head, remove as much material as possible from
Check with a micrometer that the diameter of the valve the valve seats so that, with a punch, it is possible to extract
stems is as indicated. If necessary, grind the valve seats with them from the cylinder head.
a grinding machine, removing as little material as possible.
Heat the cylinder head to 80 – 100°C and, using a drift, fit
in the new valve seats (2), chilled beforehand in liquid
nitrogen. Using tool 99305019 (1), regrind the valve seats
according to the angles shown in Figure 123.
540661 Valve seats
Regrinding – replacing valve seats After regrinding the valve seats, using tool 99370415 and
dial gauge 99395603, check that the position of the valves
in relation to the plane of the cylinder head is:
The valve seats are reground whenever the valves - –0.54 – –0.85 mm (recessing) intake valves
! or valve guides are ground and replaced.
- –1.75 – –2.05 mm (recessing) exhaust valves.

Figure 123

1 2

73555

MAIN DATA OF VALVE SEATS

1. Intake valve seat – 2. Exhaust valve seat

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 SERVICE MANUAL

Checking clearance between valve–stem and 540613 Replacing injector cases

associated valve guide Removal
Using a dial gauge with a magnetic base, check the
clearance between the valve stem and the associated guide.
If the clearance is too great, change the valve and, if
Figure 126
necessary, the valve guide.

540667 Valve guides

Replacing valve guides

Figure 125

71719

60619

The valve guides are removed with the drift 99360143.

They are fitted with the drift 99360143 equipped with part
99360296. To replace the injector case (2), proceed as follows:
Part 99360296 determines the exact position of assembly of
the valve guides in the cylinder head. If they are not - Thread the case (2) with tool 99390804 (1).
available, you need to drive the valve guides into the The steps described in Figs. 126 – 129 – 130 – 131 need to
cylinder head so they protrude by 30.8–31.2 mm be carried out by fixing the tools, with the bracket A, to the
(Figure 125). cylinder head.
After driving in the valve guides, rebore their holes with the
smoother 99390330.

JULY 2002 CTSB 861 75

 SERVICE MANUAL

Figure 127 Assembly

Figure 129

60622

- Lubricate the seals (3) and fit them on the case (4).
Using tool 99365056 (2) secured to the cylinder head
with bracket A, drive in the new case, screwing down
60620
the screw (1) upsetting the bottom portion of the case.
- Screw the extractor 99342149 (2) into the case (3).
Screw down the nut (1) and take the case out of the Figure 130
cylinder head.
Figure 128

60621

- Using the tool 99390772 (2) remove any residues (1) 60623
left in the groove of the cylinder head.
- Using the reamer 99394041 (1–2), rebore the hole in
the case (3).

76 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 131 Figure 133

71720

INJECTOR CASE ASSEMBLY DIAGRAM

60624

- Using the milling cutter 99394043 (1–2), regrind the

injector seat in the case (3).

Checking injector protrusion

Figure 132

47585

Check injector protrusion (2) with the dial gauge (1).

The protrusion must be 0.52 – 1.34 mm.

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 SERVICE MANUAL

5412 Timing system

541211 Checking cam lift and pin alignment

Figure 134

47506

Set the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) with the dial gauge (2); the values are given in the
table on page 133.

Figure 135

47507

Still with the camshaft (4) set on the tailstocks (1), check the alignment of the supporting pins (3) with the dial gauge (2); it
must be no greater than 0.030 mm. If you find a greater misalignment, replace the shaft.

Figure 136
1

47505

To check the assembly clearance, measure the inside diameter of the bushings and the diameter of the pins (1) of the camshaft:
the difference will give the actual clearance.
If you find any clearances over 0.135 mm, replace the bushings and, if necessary, the camshaft as well.

78 CTSB 861 JULY 2002

 SERVICE MANUAL

541210 Camshaft
Figure 137

60626

MAIN DATA OF THE CAMSHAFT AND TOLERANCES

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.

TOLERANCES FEATURE SUBJECT OF TOLERANCE SYMBOL

DIRECTION Perpendicularity ă
POSITION Concentricity or coaxiality
SWING Circular oscillation ½
CLASS OF IMPORTANT ASCRIBED TO PRODUCT CHARACTERISTICS SYMBOL
CRUCIAL 
IMPORTANT Ĩ
SECONDARY Ī

541213 Bushings
Figure 138

60627

MAIN DATA OF THE BUSHINGS FOR THE CAMSHAFT AND SEATS ON THE CYLINDER HEAD
* Bushing inside diameter after driving in

The surface of the bushings must show no sign of seizing If you find a higher value than the tolerance, replace them.
or scoring; replace them if they do. To remove and fit the bushings, use the appropriate drift
Measure the inside diameter of the bushings with a bore 99360499.
gauge.

JULY 2002 CTSB 861 79

 SERVICE MANUAL

Replacing camshaft bushings with drift 99360499

Drift

Figure 139

71721

A = Drift with seat for bushings to insert/extract.

B = Grub screw for positioning bushings.
C = Reference mark to insert seventh bushing correctly.
D = Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (yellow marks).
E = Guide bushing.
F = Guide line.
G = Guide bushing to secure to the seventh bushing mount.
H = Plate fixing yellow bushing to cylinder head.
I = Grip.
L = Extension coupling.

Removal Assembly
Figure 140 Figure 141
Front
Front

Rear
71722
Rear Assemble the drift together with the extension.
To insert bushings 1, 2, 3, 4 and 5, proceed as follows:
1 Position the bushing to insert on the drift (A) making
71725
the grub screw on it coincide with the seat (B)
The sequence for removing the bushings is 7, 6, 5, 4, 3, 2, (Figure 139) on the bushing.
1. The bushings are extracted from the front of the single 2 Position the guide bushing (E) and secure the guide
seats. Removal does not require the drift extension for bushing (G) (Figure 139) on the seat of the 7th bushing
bushings 5, 6 and 7 and it is not necessary to use the guide with the plate (H).
bushing. 3 While driving in the bushing, make the reference mark
For bushings 1, 2, 3 and 4 it is necessary to use the extension (F) match the mark (M). In this way, when it is driven
and the guide bushings. home, the lubrication hole on the bushing will coincide
Position the drift accurately during the phase of removal. with the oil pipe in its seat.
The bushing is driven home when the 1st yellow
reference mark (D) is flush with the guide bushing (G)
(Figure 139).

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 SERVICE MANUAL

Figure 142 540665 Valve springs

Front Figure 144

Rear
70000
71723
Before assembly, the flexibility of the valve springs has to
be checked with the tool 99305047.
To insert the bushing (6), proceed as follows: Compare the load and elastic deformation data with those
of the new springs given in the following figure.
- Unscrew the grip (I) and the extension (N).
- Position the extension (N) and the guide bushing E as
shown in the figure.
- Repeat steps 1, 2, 3.

Figure 143
Front

Figure 145
Free spring
Rear

71724 Valve closed

To insert bushing (7), proceed as follows: 575 ± 28
72,40

- Unscrew the grip (I) and the extension (N). 1095 ± 54

- Refit the guide (G) from the inside as shown in the Valve open
39,75
58

figure.
- 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 home.
The 7th bushing is driven in when the reference mark 71726

(C) is flush with the bushing seat.

MAIN DATA TO CHECK THE SPRING FOR INTAKE
AND EXHAUST VALVES

JULY 2002 CTSB 861 81

 SERVICE MANUAL

Fitting valves and oil seal Figure 147

Figure 146

47583

- Mount the springs (6) and the top plate (5).

- Fit the tool 99360263 (2) and secure it with the bracket
(4). Screw down the lever (1) to be able to fit on the
cotters (3). Take off the tool (2).

49033

Lubricate the valve stems and insert them in their

respective valve guides. Mount the bottom plates (3) with
the key 99360329 and the oil seal (1) on the valve guides
(2). Then go ahead and mount the valves as follows:

5412 ROCKER SHAFT

Figure 148

44925
The cams of the camshaft control the rocker arms directly: 6 for the injectors and 12 for the valves.
The rocker arms run directly on the profiles of the cams by means of rollers.
The other end acts on a crosspiece that rests on the stem of the two valves.
There is a pad between the rocker arm adjustment screw and the crosspiece.
There are two lubrication ducts inside the rocker arms.
The length of the rocker arm shaft is basically the same as that of the cylinder head. It has to be detached to be able to reach
all the parts beneath.

82 CTSB 861 JULY 2002

 SERVICE MANUAL

Shaft

Figure 149

73557

MAIN DATA OF THE ROCKER ARM SHAFT

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.

Rocker arms
Figure 150

SECTION
A–A
SECTION
B–B

Check the surfaces of the bushings, which must

show no signs of scoring or excessive wear; if
they do, replace the rocker arm assembly.

71728

PUMP INJECTOR ROCKER ARMS

Figure 151 Figure 152

SECTION
A–A
SECTION
B–B
SECTION
A–A SECTION
B–B

71729 71730

INTAKE VALVE ROCKER ARMS EXHAUST VALVE ROCKER ARMS

JULY 2002 CTSB 861 83

 SERVICE MANUAL

ENGINE ASSEMBLY ON BENCH

Figure 155
Using the brackets 99361036, secure the crankcase to the
stand 99322230.
Mount the cylinder liners as described on pages 169 – 170.

Figure 153

49021

Arrange the bearing shells (1) on the main bearing housings

in the crankcase base (2).

47586

Mount the oil nozzles (2), making the grub screw coincide
with the hole (3) in the crankcase.
Arrange the bearing shells (1) on the main bearing
housings.

Not finding it necessary to replace the main

! bearings, you need to fit them back in exactly the
same sequence and position as in removal.
If they have to be replaced, choose the main
bearings according to the selection described on
pages 173 – 174 – 175 – 176 – 177.

Figure 154 Figure 156

47595

47570

Lubricate the bearing shells then mount the crankshaft (2) Apply LOCTITE 5699 silicone on the crankcase using the
using the tackle and hook 99360500 (1). appropriate tools (1) as shown in Figure 157.

84 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 157 Figure 160

60632
Sealant application diagram.

Mount the crankcase base within 10 min. of 475

! applying the sealant. Using a torque wrench (3), tighten the inside screws (1)
to a torque of 120 Nm. Then tighten them to an angle of
60° and 55° with tool 99395216 (4) with another two
phases.
Regrind the outside screws (1, Figure 159) with closure
Figure 158 to an angle of 60° using tool 99395216 (4).

60559

Mount the crankcase base (1) using appropriate tackle and

hooks.

Figure 159

47581

Using a torque wrench (2), tighten the outside hex grooved

screws (1) to a torque of 30 Nm, following the diagrams
given on page 202.

JULY 2002 CTSB 861 85

 SERVICE MANUAL

Figure 161

First phase:
FRONT SIDE
pre–tightening
outside screws
30 Nm

60592

Second phase:
FRONT SIDE
pre–tightening
inside screws
120 Nm

60593

Third phase:
FRONT SIDE
closing inside
screws to angle
60º

60593

Fourth phase:
FRONT SIDE
closing inside
ìscrews to angle
55º

60593

Fifth phase:
FRONT SIDE closing outside
screws to angle
60º

60594

DIAGRAM OF TIGHTENING SEQUENCE OF CRANKCASE BASE FIXING SCREWS

86 CTSB 861 JULY 2002

 SERVICE MANUAL

Fitting connecting rod – piston assemblies in Figure 164

cylinder liners
Figure 162

60616

Turn the cylinder block, setting it upright.

49030 Lubricate the pistons, piston rings and inside the cylinder
liners. With the aid of the clamp 99360605 (1) mount the
Not finding it necessary to replace the connecting connecting rod – piston assemblies (2) in the cylinder liners
rod bearings, you need to fit them back in exactly according to Figure 163. Check that:
!
the same sequence and position as in removal. - The number of each connecting rod corresponds to the
If they have to be replaced, choose the connecting cap coupling number.
rod bearings according to the selection described
on pages 173 – 174 – 175 – 178 – 179. - The symbol (2, Figure 163) punched on the top of the
pistons faces the engine flywheel or the recess in the
Lubricate the bearing shells (1 and 3) and fit them on the piston skirt tallies with the position of the oil nozzles.
connecting rod (2) and on the cap (4).
Do not make any adjustment on the bearing shells. The pistons are supplied as spares in class A and
! can also be fitted in class B cylinder liners.
!

Figure 163

1 Connecting rod – piston assembly

2 Area of punch marking on the top of the

piston with the symbol for the mounting
position and selection class.

3 Area of connecting rod punch marking

60615

JULY 2002 CTSB 861 87

 SERVICE MANUAL
Montaje de la culata

Fitting the cylinder head

Figure 165 Figure 168

60515

Check that the pistons 1–6 are exactly at the T.D.C.

47594
Put the gasket (2) on the crankcase.
Mount the cylinder head (1) and tighten the screws as
Before reusing the screws (2), measure the shown in Figs. 169, 170 and 171.
diameter of the thread; it must be no less than 13.4
! mm; if it is, change the screw. Lubricate the thread of the screws with engine oil
Lubricate the thread of the screws with engine oil ! before assembly.
before assembly.

Connect the connecting rods to the relevant pins of the

crankshaft, mount the connecting rod caps (1) together with Figure 169
the bearing shells. Tighten the screws (2) fixing the
connecting rod caps to a torque of 60 Nm (6 kgm). Using tool
99395216 (3), tighten the screws further with an angle of 60°.
Figure 166

61270

Diagram of the tightening sequence of the screws fixing the

cylinder head.
60563

Using the centring ring 99396035 (2), check the exact Figure 170
position of the cover (1). If it is wrong, proceed accordingly
and lock the screws (3).
Figure 167

60565

60564 - Pre–tightening with the torque wrench (1):

Key on the gasket (1), mount the key 99346250 (2) and, 1st phase: 60 Nm (6 kgm).
screwing down the nut (3), drive in the gasket (1). 2nd phase: 120 Nm (12 kgm).

88 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 171
Mount the gearbox within 10 min. of applying the
! sealant.

Figure 174
a

60566

- Closing to angle with tool 99395216 (1):

3rd phase: angle of 90°
4th phase: angle of 45° for screws 4, 5, 12, 13, 20, 21
5th phase: angle of 65° for screws 1, 2, 3, 6, 7, 8, 9, 10,
11, 14, 15, 16, 17, 18, 19, 22, 23, 24, 25, 26.

Figure 172

60633

Using a torque wrench, tighten the highlighted screws with

the following sequence and torque:

10 screws M12 x 1.75 x 100 56 to 70 Nm

2 screws M12 x 1.75 x 70
71773 56 to 70 Nm
4 screws M12 x 1.75 x 35
Mount the oil pump (5), the middle gears (2) together with 56 to 70 Nm
the link rod (1) and the PTO driving gear (3). 1 screw M12 x 1.75 x 120 56 to 70 Nm
Tighten the screws (4) to the required torque.
: 2 screws M12 x 1.75 x 193 56 to 70 Nm
Fitting flywheel box
Figure 173 Figure 175

47592 60568

Apply LOCTITE 5699 silicone on the gearbox using Key on the gasket (1), fit the key 99346251 (2) and,
appropriate tools (1) as shown in the figure. screwing down the nut (3), drive in the gasket.

JULY 2002 CTSB 861 89

 SERVICE MANUAL

540850 ENGINE FLYWHEEL

Fitting engine flywheel
Figure 176

VIEW OF HOLES: VIEW OF

A–B–C HOLES:
D 60668

DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS

A. Hole on flywheel with one reference mark, corresponding to the TDC of pistons 3–4. – B. Hole on flywheel with one
reference mark, corresponding to the TDC of pistons 1–6. – C. Hole on flywheel with one reference mark, corresponding
to the TDC of pistons 2–5. – D. Hole on flywheel with two reference marks, position corresponding to 54°.
Figure 178
If the teeth of the ring gear mounted on the engine
flywheel, for starting the engine, are very
! damaged, replace the ring gear. It must be fitted
after heating the ring gear to a temperature of
approx. 200°C.
a
Figure 177

a
49036

Second and third phase: closing to angle of 60° and 30° with
tool 99395216 (1).

49037

The crankshaft has a locating peg that has to couple

! with the relevant seat on the engine flywheel.

Position the flywheel (1) on the crankshaft, lubricate the

thread of the screws (2) with engine oil and screw them
down. Lock rotation with tool 99360351 (3). Lock the
screws (2) in three phases.
First phase: pre–tightening with torque wrench (4) to a
torque of 120 Nm (12 kgm).

90 CTSB 861 JULY 2002

 SERVICE MANUAL

Fitting camshaft
Figure 179 Figure 181

60570

- Apply the gauge 99395219 (1). Check and adjust the

position of the link rod (3) for the idle gear. Lock the
72436 screw (2) to the required torque.
Position the crankshaft with the pistons 1 and 6 at the top
dead centre (T.D.C.).
This situation occurs when:
1. The hole with reference mark (5) of the engine flywheel
(4) can be seen through the inspection window.
2. The tool 99360612 (1), through the seat (2) of the engine
speed sensor, enters the hole (3) in the engine flywheel (4).
If this condition does not occur, turn the engine flywheel (4)
appropriately.
Remove the tool 99360612 (1).

Figure 180

Figure 182

73843

Fit the camshaft (4), positioning it observing the reference

marks (→) as shown in the figure.
Lubricate the seal (3) and fit it on the shoulder plate (2). 60571
Mount the shoulder plate (2) with the sheet metal gasket (1) - Fit the idle gear (1) back on and lock the screws (2) to
and tighten the screws (5) to the required torque. the required torque.

JULY 2002 CTSB 861 91

 SERVICE MANUAL

Figure 183 Figure 185

5
60572
71775

Position the gear (2) on the camshaft so that the 4 slots are Mount:
centred with the holes for fixing the camshaft, without fully
locking the screws (5). - The injectors (2) and, using a torque wrench, lock the
Using the dial gauge with a magnetic base (1), check that bracket fixing screws to a torque of 26 Nm.
the clearance between the gears (2 and 3) is 0.073 – 0.195 - The exhaust brake cylinders (1) and (4) and, using a
mm; if this is not so, adjust the clearance as follows: torque wrench, fix them to a torque of 19 Nm.
- Loosen the screws (4) fixing the idle gear (3). - The crosspieces (4) on the valve stem, all with the
- Loosen the screw (2, Figure 181) fixing the link rod. largest hole on the same side.
Shift the link rod (3, Figure 181) to obtain the required
clearance.
- Lock the screw (2, Figure 181) fixing the link rod and
screws (4, Figure 183) fixing the idle gear to the Fitting rocker–arm shaft assembly
required torque.

Figure 186
Fitting pump–injectors
Before refitting the rocker–arm shaft assembly,
Figure 184 make sure that all the adjustment screws have been
!
fully unscrewed.

73533

Using tool 99360144 (3), fasten the blocks (4) to the rocker
arms (2).
44908
Apply the tool 99360553 (1) to the rocker arm shaft (5) and
mount the shaft on the cylinder head.
Fit the seals (1) (2) (3) on the injectors.

92 CTSB 861 JULY 2002

 SERVICE MANUAL

Camshaft timing
Figure 187 Figure 190

45261

Lock the screws (2) fixing the rocker–arm shaft as follows:

- 1st phase: tightening to a torque of 100 Nm (10 kgm)
with the torque wrench (1).
- 2nd phase: closing with an angle of 60° using the tool
99395216 (3).

Figure 188

71776

Apply the tool 99360321 (7) and the spacer 99360325 (6)
to the gearbox (3).

The arrow shows the direction of rotation of the

! engine when running.
Using the above–mentioned tool, turn the engine
flywheel (1) in the direction of rotation of the engine
60574 so as to take the piston of cylinder no.1 to
- Mount the engine brake lever retaining springs (3). approximately the T.D.C. in the phase of combustion.
- Connect the pipe (2) to the engine brake cylinders (4) This condition occurs when the hole with one
and to the cylinder with the engine brake solenoid valve reference mark (4), after the hole with two
(1). reference marks (5) on the engine flywheel (1), can
Figure 189 be seen through the inspection window (2).

71777

Mount the electric wiring (2), securing it on the

electro–injectors with a torque screwdriver (1) to a torque
of 1.36 – 1.92 Nm.

JULY 2002 CTSB 861 93

 SERVICE MANUAL

Figure 191 Figure 193

71774

The exact position of piston no.1 at the T.D.C. is obtained

when in the above–described conditions the tool 99360612
(1) goes through the seat (2) of the engine speed sensor into 72436
the hole (3) in the engine flywheel (4).
If this is not the case, turn and adjust the engine flywheel The camshaft is in step if at the cam lift values of
(4) appropriately. 5,31±0,05 mm there are the following conditions:
Remove the tool 99360612 (1). 1) The hole marked with a single reference mark (5) can
be seen through the inspection window.
2) The tool 99360612 (1) through the seat (2) of the engine
speed sensor goes into the hole (3) in the engine
flywheel (4).

Figure 194
Figure 192

60575

60573 If you do not obtain the conditions illustrated in Figure 193

Set the dial gauge with the magnetic base (1) with the rod and described in points 1 and 2, proceed as follows:
on the roller (2) of the rocker arm that governs the injector Loosen the screws (2) securing the gear (1) to the camshaft
of cylinder no.1 and pre–load it by 6 mm. and utilize the slots (1) on the gear (2, Figure 195.)
With tool 99360321 (7) Figure 190, turn the crankshaft Turn the engine flywheel appropriately so as to bring about
clockwise until the pointer of the dial gauge reaches the the conditions described in points 1 and 2 Figure 193, it
minimum value (approx.54 degrees BTDC). being understood that the cam lift must not change at all.
Reset the dial gauge. Lock the screws (2) and repeat the check as described
Turn the engine flywheel anticlockwise until the dial gauge above.
gives a reading for the lift of the cam of the camshaft of Tighten the screws (2) to the required torque.
5.31±0.05 mm.

94 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 195 Mount the gear (2, Figure 195) with the 4 slots (1,
Figure 195) centred with the fixing holes of the camshaft,
locking the relevant screws to the required tightening
torque.
Check the timing of the shaft by first turning the flywheel
clockwise to discharge the cam completely and then turn
the flywheel anticlockwise until the dial gauge gives a
reading of 5.31 ±0.05 mm.
Check the timing conditions described in Figure 193.

71778

When the adjustment with the slots (1) is not sufficient to

recover the difference and the camshaft turns because it is
integral with the gear (2), the reference value of the cam lift
varies accordingly and it is necessary to proceed as follows:
Make sure the screws (2, Figure 194) are locked.
Turn the engine flywheel clockwise by approx. 1/2 turn.
Turn the engine flywheel anticlockwise until the dial gauge
gives a reading of the lift of the cam of the camshaft of 5.31
±0.05 mm.
Take out the screws (2, Figure 194) and remove the gear (2)
from the camshaft.

Figure 196

Phonic wheel timing

Figure 197

72436

Turn the flywheel (4) again to bring about the following

71779
conditions:
In the conditions of tuning the engine, check that the pin
- Double reference mark (5) visible through the bottom 99360613 (2) goes onto the marked tooth of the phonic
inspection window. wheel (1). If this is not so, loosen the screws (3) and adjust
- The tool 99360612 (1) inserted in the hole (3) in the the phonic wheel (1) appropriately.
engine flywheel (4) through the seat (2) of the engine Then tighten the screws (3) to the required torque.
speed sensor.

JULY 2002 CTSB 861 95

 SERVICE MANUAL

Adjusting rocker arm clearance, intake, exhaust and pre–load of pump injector governing rocker arms

Figure 198

60577

ADJUSTING INTAKE, EXHAUST AND INJECTION ROCKER ARMS

The adjustment of the clearance between the rocker arms - With a suitable wrench (4), screw down the
and the crosspieces governing the intake and exhaust valves adjustment screw to take the pumping element to its
and the adjustment of the pre–load of the pump injector limit.
governing rocker arms has to be done very conscientiously. - Tighten the adjustment screw with a torque wrench
to a torque of 5 Nm (0.5 kgm).
Take the cylinder whose clearance you want to adjust into
the combustion phase. The valves of this cylinder are - Unscrew the adjustment screw by 1/2 – 3/4 of a turn.
closed while they balance those of the symmetric cylinder. - Tighten the locking nut to a torque of 39 Nm
The symmetric correspondence of the cylinders is 1 – 6, 2 (3.9 kgm).
– 5 and 3 – 4. FIRING SEQUENCE 1 – 4 – 2 – 6 – 3 – 5
To perform these operations correctly, proceed as described Starting and Balance Adjust Adjust
below and as illustrated in the table. clockwise valves of clearance pre–load of
Adjusting clearance between rocker arms and crosspieces rotation cylinder of valves of injectors of
governing the intake and exhaust valves no. cylinder cylinder no.
no.
- Using a box wrench, loosen the nut (1) locking the 1 and 6 at TDC 6 1 5
adjustment screw.
120º 3 4 1
- Insert the blade of the feeler gauge (3). 120º 5 2 4
- With a suitable wrench, screw or unscrew the 120º 1 6 2
adjustment screw. 120º 4 3 6
- Check that the blade of the feeler gauge (3) can slide 120º 2 5 3
with a light amount of friction.
- Lock the nut (1) holding the adjustment screw still. To perform the above adjustments correctly, it is
! mandatory to follow the sequence given in the
Pre–load of pump injector governing rocker arms
table, checking the position at each phase of
- Using a box wrench, loosen the nut locking the rotation with the pin 99360612 to be inserted in the
adjustment screw of the rocker arms (5) governing the 11th hole of each of the three sectors of 18 holes
pump injector (6). each.

96 CTSB 861 JULY 2002

 SERVICE MANUAL
9

Completing assembly
Figure 199 Complete the engine by fitting or hooking up the following
parts:
- thermostat assembly;
- automatic tensioner, water pump, alternator;
- drive belt.

Figure 201

60495

- Mount the rocker arm cover (1), the plate covering the
gears of the timing system and the blow–by cover (2).

Figure 200

60578

ASSEMBLY DIAGRAM OF FAN – WATER PUMP –

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

60665
- damper flywheel;
- electromagnetic coupling;
- Mount the suction strainer, screwing the screws to the
required torque and set the gasket (4) on the oil sump - starter motor;
(1). Position the spacer (3) and mount the sump on the - fuel pump;
engine crankcase, screwing the screws (2) to the
required torque. - hydraulic power steering tank;
- fuel filter and pipes;
- pre–heating element;
- intake manifold;
- heat exchanger;
- oil filters, lubricating the seals;
- exhaust manifold;
- turbocharger and associated water and oil pipes;
- power take–off (PTO) and associated pipes.

JULY 2002 CTSB 861 97

 SERVICE MANUAL

Figure 203
The fittings of the cooling water and lubricating oil
! pipes of the turbocharger have to be tightened to a
torque of:
- 35 ±5 Nm, water pipe fittings;
- 55 ±5 Nm, oil pipe female fitting;
- 20 to 25 Nm, oil pipe male fitting.

- oil dipstick;
- electrical connections and sensors;
- replenish the engine with the required amount of oil;
- remove the engine from the rotary stand and take off
the brackets (99361036) fixing the engine. 73580

Mount:
To fit the belts (1–3) you need to use appropriate tools (2–4)
- air–conditioner compressor automatic tensioner; on the tensioners, in the direction shown by the arrows.
- drive belt.

The tensioners are automatic, so no further

! adjustment is required after assembly.

Figure 202

60579

COMPRESSOR DRIVE BELT ASSEMBLY DIAGRAM

1. Crankshaft – 2. Air–conditioner compressor.

98 CTSB 861 JULY 2002

 SERVICE MANUAL

5430 LUBRICATION
Figure 204
Engine lubrication is obtained with a gear pump driven
by the crankshaft via gears.
A heat exchanger governs the temperature of the lubri-
cating oil. It houses two oil filters, indicator sensors
and safety valves.

Lubrication circuit

Oil falling
Oil under pressure

B – to cylinders 1 – 2 – 3
DETAIL A C – to cylinder 4
D – to cylinders 5 – 6

Exhaust brake solenoid valve with piston driving the

exhaust brake of the 4th cylinder. 717

JULY 2002 CTSB 861 99

 SERVICE MANUAL

543010 Oil pump

Figure 205 Overpressure valve
Figure 206

73540

60560
MAIN DATA TO CHECK THE OVERPRESSURE
The oil pump (1) cannot be overhauled. On finding any
VALVE SPRING
damage, replace the oil pump assembly.
See under the relevant heading for replacing the gear (2) of
the crankshaft.

Figure 207

73541

OIL PUMP CROSS–SECTION

1. Overpressure valve – 2. Start of opening pressure 10.1 ±0.7 bars.

JULY 2002 CTSB 861 101

 SERVICE MANUAL

Oil pressure control valve Figure 209

Figure 208

73542 73543

The oil pressure control valve is located on the left–hand MAIN DATA TO CHECK THE OIL PRESSURE
side of the crankcase. CONTROL VALVE SPRING
Start of opening pressure 5 bars.
543110 Heat exchanger
Figure 210

73558

73559

HEAT EXCHANGER
The heat exchanger is fitted with: A. Oil filter clogging indicator – B. Oil temperature transmitter –
C. Oil pressure transmitter – D. Filter bypass valve – E. Thermostat – Number of heat exchanger elements: 11.

102 CTSB 861 JULY 2002

 SERVICE MANUAL

By–pass valve This is a new generation of filters that permit much more
thorough filtration as they are able to holder back a greater
Figure 211 amount of particles of smaller dimensions than those held
back by conventional filters with a paper filtering element.
These high–filtration devices, to date used only in
industrial processes, make it possible to:
- reduce the wear of engine components over time;
- maintain the performance/specifications of the oil and
thereby lengthen the time intervals between changes.

External spiral winding

The filtering elements are closely wound by a spiral so that
each fold is firmly anchored to the spiral with respect to the
others. This produces a uniform use of the element even in
73545 the worst conditions such as cold starting with fluids with
The valve quickly opens at a pressure of: 3 bars. a high viscosity and peaks of flow. In addition, it ensures
Thermostatic valve uniform distribution of the flow over the entire length of the
filtering element, with consequent optimization of the loss
Figure 212 of load and of its working life.

Mount upstream
To optimize flow distribution and the rigidity of the
filtering element, this has an exclusive mount composed of
a strong mesh made of nylon and an extremely strong
synthetic material.

73546
Filtering element
Start of opening: Composed of inert inorganic fibres bound with an exclusive
- travel 0.1 mm at a temperature of 82 ±2°C. resin to a structure with graded holes, the element is
End of opening: manufactured exclusively to precise procedures and strict
- – travel 8 mm at a temperature of 97°C. quality control.
Engine oil filters
Mount downstream
Figure 213
A mount for the filtering element and a strong nylon mesh
make it even stronger, which is especially helpful during
cold starts and long periods of use. The performance of the
filter remains constant and reliable throughout its working
life and from one element to another, irrespective of the
changes in working conditions.

Structural parts
The o–rings equipping the filtering element ensure a
perfect seal between it and the container, eliminating
by–pass risks and keeping filter performance constant.
Strong corrosion–proof bottoms and a sturdy internal metal
core complete the structure of the filtering element.
When mounting the filters, keep to the following rules
- Oil and fit new seals.
- Screw down the filters to bring the seals into contact
with the supporting bases.
- Tighten the filter to a torque of 35–40 Nm.

47447

JULY 2002 CTSB 861 103

 SERVICE MANUAL

5432 COOLING

Figure 214

Cooling circuit
Cooling with forced circulation is obtained by a cen-
trifugal pump, driven by the crankshaft with a Poly–V Water leaving the thermostat
type of belt.
Water circulation is governed by a thermostat. Water circulating in the engine

The radiator is vertical, cooled by a fan with an electro- Water entering the pump
magnetic coupling.
For a description of operation and servicing, see the Elec-
tric/Electronic System Repair Manual, print no.
603.43.683.
71736

JULY 2002 CTSB 861 105

 SERVICE MANUAL

543210 Water pump 543250 Thermostat

View of thermostat operation
Figure 215

Figure 217

TO THE
EXPANSION
TUB
45159

TO THE
FROM BY PASS
The water pump is composed of: impeller, bearing, seal and THE ENGINE

ÄÄÄ
driving pulley. 60747

Check that the pump body has no cracks or water

ÄÄÄ Water circulating in the engine

! leakage; if it does, replace the entire water pump.

Figure 218

TO THE
RADIATOR

TO THE
Figure 216 EXPANSION
TUB
TO THE
BY PASS
FROM 60748
THE ENGINE
Water leaving the thermostat

Check the thermostat works properly; replace it if in doubt.

Temperature of start of travel 84°C ±2°C.
Minimum travel 15 mm at 94°C ±2°C.

60631

CROSS–SECTION OF THE WATER PUMP

JULY 2002 CTSB 861 107

 SERVICE MANUAL

5424 TURBOCHARGING
The turbocharging system is composed of:
- an air filter;
- a variable geometry turbocharger;
- an “intercooler” radiator.

Figure 219

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Engine exhaust gas

Intake air

ÓÓ
Compressed air (hot)

ÓÓ
Compressed air (cooled)

71737
TURBOCHARGING DIAGRAM

Turbocharger HOLSET HY 55 V The movement of the device changing the cross–section

Working principle of the flow of exhaust gases is accomplished with a
mechanism operated by a pneumatic actuator.
The variable geometry turbocharger (VGT) is composed
of a centrifugal compressor and a turbine equipped with This actuator is controlled directly by the electronic
a mobile device that, by changing the area of control unit via a proportional solenoid valve.
cross–section of the passage of the exhaust gases going to This device is most closed at low speed.
the turbine, governs the speed.
At high engine speeds, the electronic control system
Thanks to this solution, it is possible to keep the speed of increases the cross–section of the passage to permit the
the gases and turbine high even when the engine is running incoming gases to flow without increasing their speed too
at low speed. much.
By making the gases pass through small cross–sections, Cast in the central body there is a toroidal chamber for the
they flow faster, so that the turbine turns faster as well. coolant to pass through.

108 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 220

71759

1. Air delivery to the intake manifold – 2. Compressor – 3. Air inlet – 4. Actuator –

5. Exhaust gas speed governor – 6. Exhaust gas inlet – 7. Exhaust gas outlet – 8. Turbine

CROSS–SECTION OF MINIMUM CROSS–SECTION OF MAXIMUM

FLOW FLOW
71733 71734

CROSS–SECTION OF TURBOCHARGER
1. Air delivery to the intake manifold – 2. Compressor – 3. Air inlet – 4. Actuator – 5. Exhaust gas flow–rate adjustment ring
–
6. Exhaust gas inlet – 7. Exhaust gas outlet – 8. Turbine – 9. Exhaust gas flow–rate control fork

JULY 2002 CTSB 861 109

 SERVICE MANUAL

Figure 221

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Figure 222 ÖÖÖÖÖÖÖ 60753

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60754

1. Slide guide – 2. Compressor – 3. Slide rods – 4. Compressor fan – 5. Lubrication bushings –

6. Exhaust gas flow–rate adjustment ring – 7. Exhaust gas fan – 8. Gas exhaust body – 9. Locking rings –
10. Oil delivery – 11. Oil outlet – 12. Actuator drive shaft

110 CTSB 861 JULY 2002

 SERVICE MANUAL

Figure 223

71762

Figure 224

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71763
1. Slide guide – 3. Slide rod – 11. Oil outlet – 12. Actuator drive shaft –
13. Actuator – 14. Exhaust gas flow–rate control fork

JULY 2002 CTSB 861 111

 SERVICE MANUAL

Actuator
Figure 225

[bar]

Stroke [mm]
72421

a Gradient characterized by the effect of the

external spring (4).
b Gradient characterized by the effect of the
external (4) and internal (6) springs.

71834

1. Air inlet – 2. Gasket – 3. Piston – 4. External spring – 5. Internal spring control disc – 6. Internal spring –
7. O–ring – 8. Spring holder – 9. Limit stop – 10. Dust seal – 11. Control rod

Working principle Solenoid valve for VGT control

The actuator piston, connected to the drive rod, is controlled This N.C. proportional solenoid valve is located on the
with the compressed air introduced through the air inlet (1) left–hand side of the crankcase under the turbine.
on the top of the actuator.
The electronic control unit, via a PWM signal, controls the
Modulating the air pressure varies the movement of the solenoid valve, governing the supply pressure of the turbine
piston and turbine control rod. As the piston moves, it actuator, which, on changing its position, modifies the
progressively compresses the external spring (4) until the cross–section of the flow of exhaust gases onto the blades
base of the piston reaches the disc (5) controlling the of the impeller and therefore its speed.
internal spring (6).
The VGT solenoid valve is connected to the electronic
On further increasing the pressure, the piston, via the disc control unit between pins A18/A31.
(5), interferes with the bottom limit stop (10).
The resistance of the coil is approx. 20–30 Ohms.
Using two springs makes it possible to vary the ratio
between the piston stroke and the pressure. Approximately
85% of the stroke of the rod is opposed by the external
spring and 15% by the internal one.

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Figure 226

71765

CONTROL AIR SYSTEM DIAGRAM

1) Services tank 4) VGT control solenoid valve

2) Shut–off solenoid valve 5) Actuator pressure sensor
3) Air filter 6) Turbine actuator

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FEEDING
Fuel is supplied via a fuel pump, filter and pre–filter, 6
pump–injectors governed by the camshaft via rocker
arms and by the electronic control unit.

Figure 227

71738

1. Valve for return circuit, starts opening at 3.5 bars – 2. Valve for return circuit, starts opening at 0.2 bars

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Fuel pump Pumping element

Figure 228 The pumping element is operated by a rocker arm governed
directly by the cam of the camshaft.
The pumping element is able to ensure a high delivery
pressure. The return stroke is made by means of a return
spring.

Nozzle
Garages are authorized to perform fault diagnosis solely on
the entire injection system and may not work inside the
injector–pump, which must only be replaced.
A specific fault–diagnosis program, included in the control
unit, is able to check the operation of each injector (it
deactivates one at a time and checks the delivery of the other
73547 five).
A. Fuel inlet – B. Fuel delivery – C. By–pass nut – Fault diagnosis makes it possible to distinguish errors of an
D. Fuel return from the pump–injectors – electrical origin from ones of a mechanical/hydraulic
E. Pressure relief valve – Opening pressure: 5–8 bars origin.
It indicates broken pump–injectors.
Figure 229
It is therefore necessary to interpret all the control unit error
messages correctly.
Any defects in the injectors are to be resolved by replacing
them.

Solenoid valve
The solenoid, which is energized at each active phase of the
cycle, via a signal from the control unit, controls a slide
valve that shuts off the pumping element delivery pipe.
When the solenoid is not energized, the valve is open, the
fuel is pumped but it flows back into the return pipe with the
normal transfer pressure of approximately 5 bars.
When the solenoid is energized, the valve shuts and the
73548
fuel, not being able to flow back into the return pipe, is
CROSS–SECTION OF THE FUEL PUMP pumped into the nozzle at high pressure, causing the needle
1. Oil and fuel leakage indicator to lift.
The amount of fuel injected depends on the length of time
Injector–pump the slide valve is closed and therefore on the time for which
Figure 230 the solenoid is energized.
The solenoid valve is joined to the injector body and cannot
be removed.
On the top there are two screws securing the electrical
wiring from the control unit.
To ensure signal transmission, tighten the screws with a torque
wrench to a torque of 1.36 – 1.92 Nm (0.136 – 0.192 kgm).

775010 Replacing injectors–pump

Injectors have to be replaced with great care (for their
removal see the description on pages 165 and 166, for
fitting them see the description on pages 208 and 209).
44908 If this job is done with the engine on the vehicle,
1. Fuel/oil seal – 2. Fuel/diesel seal – ! before removing the injectors–pump drain off the
3. Fuel/exhaust gas seal fuel contained in the pipes in the cylinder head by
The injector–pump is composed of: pumping element, unscrewing the delivery and return fittings on the
nozzle, solenoid valve. cylinder head.

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Figure 231 Injector Phases

Figure 232

0 411 700 002

XXXXXX XXXX X
868 USA /

For each injector replaced, hook up to the MODUS station

and, when asked by the program, enter the code punched on
the injector (→) to reprogram the control unit.

When checking the clearance of the rocker arms, it

! is important to check the injector–pump pre–load.

60669

1. Fuel valve – 2. Pumping element – 3. Fuel outlet –

4. Filling and backflow passage

Filling phase
During the filling phase the pumping element (2) runs up
to the top position.
After passing the highest point of the cam, the rocker arm
roller comes near the base ring of the cam.
The fuel valve (1) is open and fuel can flow into the injector
via the bottom passage (4) of the cylinder head.
Filling continues until the pumping element reaches its top
limit.

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Figure 233 Figure 234

60670 60671

1. Fuel valve – 2. Pumping element – 3. Fuel outlet – 1 Fuel valve – 2. Pumping element – 3. Fuel outlet –
4. Filling and backflow passage 4. Filling and backflow passage

Injection phase Pressure Reduction phase

The injection phase begins when, at a certain point in the Injection ceases when the fuel valve (1) opens, at a certain
down phase of the pumping element, the solenoid valve point in the down stroke of the pumping element, after the
gets energized and the fuel valve (1) shuts. solenoid valve gets de–energized.
The fuel flows back through the open valve (1), the injector
The moment delivery begins, appropriately calculated by
holes and the passage (4) into the cylinder head.
the electronic control unit, depends on the working
conditions of the engine. The time for which the solenoid valve stays energized,
appropriately calculated by the electronic control unit, is
The cam continues with the rocker arm to push the pumping
the duration of injection (delivery) and it depends on the
element (2) and the injection phase continues as long as the
working conditions of the engine.
fuel valve (1) stays shut.

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