FICFL411S

F1C EuVI Engines S Series

On-Road multipurpose F1CFL411S*A302 S30ENT6K25.00 S30ENT6K26.00 S30ENT6K27.00

Technical and Repair manual

This publication provides unit and relevant component repair data, specifications, instructions and methodologies. This publication has been drawn up for qualified and specialised personnel. Before performing any operation check that the part relevant to the unit on which you must work is available along with all safety devices for accident-prevention, such as, goggles, helmet, gloves, shoes, etc. and hoisting and transporting equipment. Operations are to be performed by following the indications included here, using the special equipment indicated and assuring proper repair, compliance with schedule and operator’s safety requirements. Each repair must aim to restore operating efficiency and safety in compliance with the FPT provisions. FPT cannot be held liable for modifications, alterations or other interventions non authorised by FPT on the vehicle and if the unit is warranted the above mentioned interventions will cause its expiration. FPT is not liable for repairing interventions. FPT will provide further details required to carry out the interventions and all the instructions that are not included on this publication. Data included in this publication may not be up-to-date therefore subject to Manufacturer’s modifications that can be added at any time for technical or commercial purposes and also to meet new law regulations in other Countries. If issues on this publication differ from what is actually noticed on the unit, please get in touch with the FPT network before starting any intervention”. It is forbidden to copy this text or any of its parts and all illustrations included.

Publication edited by: FPT Industrial S.p.A Via Puglia 15, 10156 Torino, Italia www.fptindustrial.com Print P1D32S021 E - 1st Ed. 04.2015

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F1C EuV1 - ENGINES

F1C EuVI Engines S Series

F1C Engines EuVI

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INTRODUCTION

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Introduction Page

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GENERAL INFORMATION . . . . . . . . . . . . . . . .

3

- SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Service operations . . . . . . . . . . . . . . . . . . . . . .

3

GENERAL WARNINGS . . . . . . . . . . . . . . . . . . .

5

GENERAL WARNINGS ON THE ELECTRIC SYSTEM . . . . . . . . . . . . .

7

- Grounding and screening . . . . . . . . . . . . . . . . .

8

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS . . . . . . . . . . . . . . . .

9

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND THE MOST COMMONLY USED DERIVED SIZES . . . . . . . . . . . . . . . . . .

9

PAGE HEADER AND FOOTER INTERPRETATION . . . . . . . .

10

UPDATE DATA . . . . . . . . . . . . . . . . . . . . . . . . .

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INTRODUCTION

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GENERAL INFORMATION Manuals for repairs are split into Parts and Sections, each one of which is marked by a number; the contents of these sections are indicated in the general table of contents. Sections with mechanical contents include technical data, tightening torque collections, tool lists, assembly connections - disconnections, overhauls at the bench, troubleshooting and scheduled maintenance. On sections or parts of the electric/electronic system there are the descriptions of the electric network and the electronic systems assembly, wiring diagrams, electric characteristics of components. Sections 1 and 2 describe the engine and its general features. Section 3 describes the electrical part, concerning wiring, electrical and electronic equipment according to the specific use. Section 4 includes scheduled maintenance. Sections 5 and 6 concern the operations of removal/refitting of the main components and operations of general overhaul of engine fitted on a rotating stand. Section 7 contains the techcnical data of the motor such as installation clearances and tightening torques. Section 8 contains the special tools list. The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians, must comply with to prevent any serious injury. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of symbols has been defined to classify warnings, while another set has been specified for service operations

SYMBOLS Warnings Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

Risk of serious damage to the assembly The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify the warranty.

!

General danger It includes the dangers of above described signals.

Environment protection Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.

NOTE

Indicates an additional explanation for a piece of information.

Service operations Example Ø1

Ø 1 = Housing for connecting rod small end bush. α

Ø2

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Tighten to the specified torque + angle value

Ø 2 = Housing for connecting rod bearings

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INTRODUCTION

Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly

α

ρ

Compression ratio

Tighten to torque

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation Adjustment

Angle Angular value

Visual inspection Fitting position check

Preload

Measurement Value to find Check

Number of revolutions

Equipment

Temperature

Surface for machining Machine finish

bar

Pressure

Interference Strained assembly

Oversized Higher than. Maximum, peak

Thickness Clearance

Undersized Less than. Minimum

Lubrication Damp Grease

Selection Classes Oversizing

Sealant Adhesive Air bleeding

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Temperature < 0 C Cold Winter Temperature > 0 C Hot Summer

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INTRODUCTION

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GENERAL WARNINGS The warnings shown may not be representative of all the dangerous situations that may occur.

!

Therefore, supervisors should be contacted whenever a dangerous situation that has not been described occurs. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check the working condition and suitability of tools not subject to periodic review. The manual handling of loads must be assessed in advance since it also depends not only on weight but also on its size and on the path. Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such tools is strictly permitted by authorised personnel only. Stay at a safe distance from the load and never below it. In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out from accidentally striking workshop personnel. Shop activities performed by two technicians must always been executed with caution; avoid operations that may be dangerous for any collaborators due to lack of field of vision or incorrect position. Keep any personnel not assigned to the operations clear of working area. Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it. Scrupulously observe all safety warnings on the assembly. Do not leave the assembly in motion unattended during repair work. When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands and that the manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp. When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe all the specific safety regulations provided. Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point cards of harmful materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks, in order to prevent sudden fires/explosions. Adequately store inflammable, corrosive and polluting fluids and liquids according towhat provided by regulations in force. Strictly avoid using containers for food to store harmful liquids. Avoid drilling or burning pressurised containers and discard cloths impregnated with inflammable substances into suitable containers. Worn out, damaged or consumable parts must be replaced with original spare parts. During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and stains of liquids and oils. Electric sockets and electrical equipment necessary to perform repair operations must meet safety rules.

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Wear all required P.P.E and garments when called for by the operation at issue. Contact with moving parts may cause serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc. Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside. Do not breathe fumes fromheating orwelding of paint, as they are harmful; operate outdoors or inwell-ventilated areas. Wear an appropriate respirator in the presence of paint dust. Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid direct contact with liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact occurs.

Before overhauling, clean the assemblies and make sure they are integral and complete. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers. Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking nuts with nylon inserts must always be replaced. Avoid contact of rubber with diesel fuel, petrol or other incompatible substances. Before pressure washing mechanical parts, protect electrical connectors and any control units. The tightening of screws and nuts should always be carried out according to directions. FPT’s sales and assistance network is available to provide any clarifications necessary to carry out any repair work not covered by this document. Before welding: - Disconnect all electronic control units and unplug the power cable from the battery’s positive terminal (connecting it to the chassis ground) and connectors. - Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water. - Wait approximately 15 minutes before proceeding with welding. - Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable materials flow when welding. Should the vehicle be subjected to temperatures exceeding 80˚C (dryer ovens), remove the electronic control units.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

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INTRODUCTION

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GENERAL WARNINGS ON THE ELECTRIC SYSTEM

!

When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the chassis earth cable first of all from the negative terminal of the battery. Before connecting the batteries to the system, make sure that the system is suitably insulated. Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from the battery terminals. Do not cause sparks to verify the presence of voltage in a circuit. Do not use a test lamp to verify circuit continuity, but proper control equipment only. Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding, grounding, etc.) conform with the FPT system and that they are carefully restored after repair or maintenance work. Measurements on the ECUs, jack connections and electrical connections of components must be done only on regular test lines, with special jacks and jack bushings. Never use improvised equipment like metal wires, screwdrivers, pins or similar. This may not only cause short circuits, but also damage the jack connectors, resulting in poor contact.

Do not use fast chargers to start up the engine. Start upmust only be performed with either separate batteries or special truck. Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries) may lead to their destruction. Disconnect the batteries from the system during their recharging with an external apparatus. On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening torque. Isolate the circuit prior to disconnecting the junction connector from an electronic control unit. Do not directly supply current to components served by electronic control units with nominal vehicle voltage. The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body. Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.

NOTE

The connectors are shown from cable side. Connector views contained in the manual are representative of cable side.

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Grounding and screening The negative leads connected to a system grounding point must be as short as possible and connected to one another in delta configuration; make sure that they are tightened in an orderly and adequate manner (Figure 1 ref. M). The following precautions must be observed regarding the electronic components: -

The electronic control units must be connected to the circuit’s ground when they have metallic casing.

-

Electronic control unit negative cablesmust be connected to a system ground point, such as the dashboard compartment ground (do not use “serial” or ”chain” connections), and to the negative terminal of the battery/ies.

-

Even if not connected to the circuit ground/battery negative terminal, analog ground (sensors) should have optimal isolation. Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.

-

The metal braid of shielded circuits must be in electric contact only at the end towards the control unit where the signal enters (Figure 2).

-

In the case of junction connectors, the unshielded section d, near the connectors must be as short as possible (Figure 2).

-

The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.

Figure 1

1.

”DELTA” CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT EARTH M

Figure 2

88039

2.

SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR d. DISTANCE ! 0

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INTRODUCTION

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OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Accessory installation, additions and changes on the assembly must be carried out in compliance with the FPT assembly directives. It is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional) sockets in order to simplify and normalise the electrical intervention by fitters.

It is strictly forbidden to carry out any modifications or connections to the electronic control unit wiring. In particular, the data line between the control units (CAN line) is to be considered untouchable.

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND THE MOST COMMONLY USED DERIVED SIZES Power 1 kW 1 kW 1 CV 1 CV 1 hp 1 hp NOTE

= = = = = =

1.36 HP 1.34 hp 0.735 kW 0.986 hp 0.746 kW 1.014 HP

the unit HP is converted into hp for simplicity according to a 1:1 ratio 1 hp = 1 HP

Torque 1 Nm 1 kgm

= =

0.1019 kgm 9.81 Nm

Revolutions per time unit 1 rpm = 0.1047 rad/s 1 rad/s = 9.55 rpm Pressure 1 bar 1 kg/cm2 1 bar NOTE

= = =

1.02 kg/cm2 0.981 bar 105 Pa

Where accuracy is not particularly needed: - the unit Nm is converted into kgm for simplicity according to a ratio of 10:1 1 kgm = 10 Nm; - the unit bar is converted into kg/cm2 for simplicity according to a ratio of 1:1 1 kg/cm2 = 1 bar.

Temperature 0 C = 273.15 K 0 F = 255.37 K 0 C = 32 ˚F (the conversion factor between Celsius and Fahrenheit is 1:1.8) Print P1D32S021 E

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PAGE HEADER AND FOOTER INTERPRETATION Type of engine

Number of printed copies

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Section title

Language Publication

Basic edition referring to closing phase of drafting month-year

Page number

When present, a month-year update (Revi) to the basic edition

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INTRODUCTION

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UPDATE DATA Section

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Section name

Modification description

Page

Date of revision

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F1C EuV1 - ENGINES

F1C Engines EuVI Section

General Specifications

1

Operating diagrams

2

Electrical equipment

3

Scheduled Maintenance

4

Removal/refitting of the main engine components

5

General mechanical overhaul

6

Technical specifications

7

Tools

8

Safety prescriptions

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Appendix

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F1C EuV1 - ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

1

SECTION 1 General Specifications Page

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TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . .

3

COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . .

4

ISOMETRIC VIEWS OF ENGINE . . . . . . . . . . . .

5

POWER - TORQUE CURVES . . . . . . . . . . . . . .

6

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .

8

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

13

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SECTION 1 - GENERAL SPECIFICATIONS

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SECTION 1 - GENERAL SPECIFICATIONS

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TECHNICAL CODE

F1

C

F

L

4

1

1

S

*

A

302

Progressive numbers showing engine variants

Emissions level: A = EuVI

Performances: A = First calibration

B = Second calibration extc.

Application: 0 = Other application 1 = Trucks 2 = Buses eVGT 3 = Industrial / Agricultural

5 = Genset 6 = Marine 7 = Industrial / Agricultural turbo 8 = Cars and derivatives

Engine main characteristics: 0 = Turbocharged CNG 1 = Turbocharged diesel i.d.aftercooled 2 = Naturally Aspirated diesel i.d. 3 = Naturally Aspirated diesel i.i. 4 = Naturally Aspirated petrol 5 = Naturally Aspirated CNG 6 = Turbocharged diesel i.d. 7 = Turbocharged diesel i.i. 8 = Turbochargedpetrol 9 = Turbocharged diesel i.i. aftercooled

No. of cylinders

Cylinder configuration: A = 4 stroke vertical B = 4 stroke horizontal C = 4 stroke vertical with EGR D = 4 stroke horizontal with EGR

E F G L

= = = =

4 stroke vertical with post-treat 4 stroke horizontal with post-treat 4 stroke horizontal with EGR +post treat 4 stroke vertical with EGR + post treat

F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6

Engine family development

F1 = New Engine Family

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SECTION 1 - GENERAL SPECIFICATIONS

F1C EuV1 - ENGINES

COMMERCIAL CODE

S

30

E

N

T

6

Emission levels: A = 2002/88 CE C = Euro 3 D = Double omologation Europe (NRMM) and EPA-USA E = Europe (NRMM) F = Sprinkler G = GAS I = Not emissioned (without omologation) L = Stage IV M = Marine R = R96 omologation S = R96 TIER4B omologation U = EPA - USA X = Stage 3A - Tier 3 Y = Stage 3B - Tier 4A Z = Tier4B 4 = Euro 4 5 = Euro 5 6 = Euro 6

Aspiration: A = Natural S = Supercharged T = Supercharged with aftercooler

Crakcase: N = Not structural (normal distribution) S = Not structural (limited distribution) R = Structural

Injection type: E = Electronic M = Mechanic

Displacement: L *10 for displacement < 10 L

Engine: C = Cursor F = F5 N = NEF S = F1 V = V Series

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ISOMETRIC VIEW OF ENGINE Figure 1

227511

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SECTION 1 - GENERAL SPECIFICATIONS

F1C EuV1 - ENGINES

POWER - TORQUE CURVES Figure 2

S30ENT6K27.00 Max. POWER 95 kW (127 HP) at 3,500 rpm

227513

Max. TORQUE 300 Nm (30.6 kgm) at 1,300 rpm Figure 3

227514

S30ENT6K26.00 Max. POWER 110 kW (150 HP) at 3,500 rpm Max. TORQUE 370 Nm (37.7 kgm) at 1,320 rpm Base - April 2015

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Figure 4

227515

S30ENT6K25.00 Max. POWER 129 kW (173 HP) at 3,500 rpm Max. TORQUE 430 Nm (43.8 kgm) at 1,600 rpm

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SECTION 1 - GENERAL SPECIFICATIONS

F1C EuV1 - ENGINES

ENGINE VIEWS Figure 5

227507

INTAKE SIDE VIEW 1. EGR valve - 2. Hot compressed air outlet pipe - 3. Exhaust manifold protection - 4. Alternator 5. Lubricant oil sump - 6. Engine mount - 7. Turbocharger actuator - 8. Variable geometry turbocharger 9. Flow rate control valve - 10. Exhaust manifold - 11. EGR heat exchanger

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SECTION 1 - GENERAL SPECIFICATIONS

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Figure 6

227506

EXHAUST SIDE VIEW 1. Intake manifold - 2. Lubricant oil filter - 3. Engine coolant inlet pipe to heat exchanger - 4. Water/oil heat exchanger 5. Engine mount - 6. Lubricant oil level dipstick -7. Air compressor - 8. Power steering pump 9. High pressure fuel pump - 10. Thermostat cover -11. Air inlet pipe to intake manifold

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F1C EuV1 - ENGINES

Figure 7

227508

FRONT VIEW 1. Blow-by - 2. Air compressor - 3. Fixed belt tensioner - 4. Damper pulley - 5. Alternator 6. Automatic belt tensioner - 7. Electromagnetic pulley - 8. Lubricant oil filler cap

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Figure 8

227509

REAR VIEW 1. Coolant pipe - 2. Exhaust gas pipe from EGR to intake manifold - 3. Flow rate control valve 4. Engine flywheel - 5. Lubricant oil drain plug - 6. Air compressor 7. Coolant inlet pipe to heat exchanger - 8. Engine flywheel rear protection

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Figure 9

227510

TOP VIEW 1. Air inlet pipe to intake manifold - 2. Lubricant oil filler cap - 3. EGR valve 4. Hot compressed air outlet pipe - 5. EGR heat exchanger - 6. Electro-injectors - 7. Cable on engine cover

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SECTION 1 - GENERAL SPECIFICATIONS

13

GENERAL SPECIFICATIONS Type

F1CFL411S*A302

Cycle

Diesel 4 strokes

Supply

Turbocharged with aftercooler

Injection

Direct

Number of cylinders

4 in line



+

+

Bore

mm

95.8

Stroke

mm

104

cm3

2998

+.. = Total displacement

A TIMING SYSTEM

B

Start before T.D.C.

A

29˚ ± 5˚

end after B.D.C.

B

30˚ ± 5˚

C Start before T.D.C.

D

75˚ ± 5˚

end after B.D.C.

C

30˚ ± 5˚

D FUEL FEED Injection type:

common rail injection system BOSCH EDC17 C49

Injectors BOSCH CRi2-20

Nozzle type

Injection sequence

1-3-4-2

bar

Injection pressure

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bar

2000

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SECTION 1 - GENERAL SPECIFICATIONS

F1C EuV1 - ENGINES

F1CFL411S*A302

Type

Maximum power

Maximum torque

kW (HP)

95 (127)

110 (150)

129 (173)

rpm

3500

3500

3500

Nm (Kgm)

300 (30.6)

370 (37.7)

430 (43.8)

rpm

1300

1320

1600

Slow running of engine with no load

rpm

800  25

Fast idling speed of engine with no load

rpm

4200  50

TURBOCHARGING

With aftercooler

Turbocharger type Actuator minimum flow

GARRETT water and oil cooled variable geometry kg/hr

160 ± 5.0

Vacuum 0 bar

mm

Valve fully open

Vacuum 20 kPa

mm

1.5 ÷ 4.0

Vacuum 64.7 kPa

mm

10 ÷ 12.5

Actuator calibration:

forced by gear pump, pressure relief valve, oil filter with total filtering integral cartridge

LUBRICATION

bar

Oil pressure with engine hot (100C 5C): at idling speed

bar

1.5  0.3

at top speed

bar

4.5  0.5

COOLING Water pump control:

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by centrifugal pump, thermostat for adjustment, coolant temperature, sensor, heat exchanger by belt

Thermostat: brand: start of opening:

WAHLER 79 C  2 C

end of opening

94 C  2 C

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SECTION 1 - GENERAL SPECIFICATIONS

15

F1CFL411S*A302

Type Cooling circuit (1) Total capacity

l (kg)

6.9 (6.2)

Lubrication circuit Total capacity (2)(3)

l (kg)

7.3 (6.6)

Oil sump capacity: Oil sump at minimum level Oil sump at maximum level

l (kg) l (kg)

4.29 (3.86) 6.60 (5.94)

Power steering oil capacity (5)

l (kg)

-

Fuel tank capacity (4)(5)

l (kg)

-

Urea total capacity (6)

l (kg)

25 (22.5)

(1) The amounts indicated relate to the standard configuration of the engine only. Use a 50% mixture of water and Paraflu HT even during the summer months. As an alternative to Paraflu HT use another product that complies with ASTM D-6210 international standard. (2)Only use lubricants which meet the international standards 5W-30/0W-30; ACEA C2. Recommended oil is URANIA DAILY FE - URANIA DAILY LS. The oil used is considered to be acceptable until a quantity equalling 0.5% of fuel consumption is reached. (3) The quantities shown refer to the first refilling and concern the refilling of engine, oil sump and filter. (4) Use fuel compliant to the EN 590 international standard. (5) Refer to the indications of the vehicle manufacturer. (6) Use an AdBlue 32.5% solution in water compliant to the ISO 22241 international standard.

!

Warning — Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.

!

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the equipment assembled by vehicle manufacturer shall always be in compliance with torque, power and number of revs based on which the engine has been designed.

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SECTION 1 - GENERAL SPECIFICATIONS

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F1C EuV1 - ENGINES

SECTION 2 - OPERATING DIAGRAMS

1

SECTION 2 Operating diagrams Page

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COMMON RAIL INJECTION SYSTEM . . . . . . .

3

- General specifications . . . . . . . . . . . . . . . . . . .

3

- Electric system . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Main sensors . . . . . . . . . . . . . . . . . . . . . . . . . .

5

- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . .

9

- Injection system main components . . . . . . . . .

12

- Electro-injectors CRI2-20 . . . . . . . . . . . . . . . .

15

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

17

- General specification . . . . . . . . . . . . . . . . . . . .

17

- Lubrication system main components . . . . . . .

18

OIL VAPOUR RECIRCULATION (BLOW-BY) .

21

- General specifications . . . . . . . . . . . . . . . . . . .

21

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .

22

- General specifications . . . . . . . . . . . . . . . . . . .

22

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

- Cooling system main components . . . . . . . . .

23

TURBOCHARGING SYSTEM . . . . . . . . . . . . . .

24

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Turbocharging system main components . . . .

25

EXHAUST GAS RECIRCULATION (EGR) . . . .

28

- System layout . . . . . . . . . . . . . . . . . . . . . . . . .

28

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

- E.G.R. Assembly (Exhaust Gas Recirculation) .

29

- E.G.R. Assembly . . . . . . . . . . . . . . . . . . . . . . . .

30

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Page TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .

31

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

EXHAUST GAS POST-TREATMENT SYSTEM (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

- System description . . . . . . . . . . . . . . . . . . . . .

32

- ATS principle layout . . . . . . . . . . . . . . . . . . . .

32

- EMS System layout (DeNOx PC/LD 3.1) . . . .

33

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

- Hardware scheme . . . . . . . . . . . . . . . . . . . . . .

35

- Hydraulic scheme . . . . . . . . . . . . . . . . . . . . . .

35

- AdBlue Specifications . . . . . . . . . . . . . . . . . . .

36

- Main components of the ATS system . . . . . .

37

- ATS system main sensors . . . . . . . . . . . . . . . .

42

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F1C EuV1 - ENGINES

COMMON RAIL INJECTION SYSTEM General specifications The common rail injection system is a high-pressure electronic injection system for fast diesel engines with direct injection.

3

SECTION 2 - OPERATING DIAGRAMS

- these pressures can be modulated between 150 bar up to the maximum operating pressure of 2000 bar, irrespective of the speed of rotation and engine load; - capacity to operate at very high speeds (up to 6000 rpm); - injection control precision (injection duration and advance);

Its main features comprise:

- lower fuel consumption;

- availability of high injection pressure values (2000 bar);

- lower emissions.

Electric system Figure 1

227518

1. Air inlet from aftercooler temperature sensor - 2. Pre/heater glow plugs - 3. Air pressure and temperature sensor 4. Oil pressure switch - 5. Fuel flow regulator on pump - 6. Coolant temperature sensor - 7. Segment speed sensor 8. Pressure regulating valve on rail - 9. Pressure sensor on rail Print P1D32S021 E

Base - April 2015

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Figure 2

227517

1. EGR valve - 2. Increment speed sensor - 3. Alternator - 4. VGT position sensor 5. Flow rate control valve - 6. Electro-injectors - 7. Exhaust gas temperature sensor

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F1C EuV1 - ENGINES

Main sensors Fuel pressure sensor Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The signal provided by the sensor is used by the engine management control unit to adjust the injection pressure and duration.

Fuel temperature sensor on fuel filter (not supplied by FPT) Integrated in the fuel filter, it measures the fuel temperature and transmits it to the electronic control unit. When the fuel temperature is too high (ambient temperature condition, engine at full load and tank in reserve), correct lubrication of the high-pressure pump is no longer assured. On the basis of the values received, the control unit determines the density and volume of the fuel, correcting the delivery limiting engine performance.

SECTION 2 - OPERATING DIAGRAMS

5

Segment speed sensor It is an Hall effect type sensor positioned on the camshaft pulley. It generates signals obtained from lines of magnetic flux that close through a notch in the pulley. The signal generated by this sensor is used by the control unit as a reduntant signal to measure the different engine speeds.

Oil pressure switch It is fitted on the water/oil heat exchanger and measures the engine oil pressure. The signal detected is sent to the control unit. Air inlet from aftercooler temperature sensor.

Air inlet from aftercooler temperature sensor It is fitted on the intake manifold air inlet pipe. It measures the air temperature coming from the aftercooler.

Air pressure and temperature sensor Positioned on the intake manifold, it measures the pressure of the boost air introduced into the intake manifold. This value will, together with the lambda probe and air temperature sensor values, allow the electronic control unit to accurately determine the amount of air fed into the cylinders and manage the injectors by adjusting the fuel supply accordingly, reducing noxious emissions and improving both consumption levels and performance. Inside the sensor there is an electronic temperature correction circuit to optimize the measurement of the pressure in relation to the intake air temperature.

Coolant temperature sensor This sensor provides the control unit with an index of thermal status of the engine in order to determine corrections of the fuel delivery, injection pressure, EGR injection advance when starting cold (if equipped) and warm-up.

Increment speed sensor It is an inductive sensor placed on the pulser ring mounted on the crankshaft front end. It generates signals obtained from magnetic flux lines which close through the pulser ring teeth. The engine management control unit uses this signal to measure the rpm of the engine, its angular position and to operate the electronic rev counter.

Print P1D32S021 E

Base - April 2015

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System description

Checking fuel temperature

The system makes pre-injection (pilot injection) possible before the TDC with the advantage of decreasing the derivative of the pressure in the combustion chamber, lowering the noise level of combustion, which is typical of direct injection engines.

With the fuel temperature greater than 75C, detected by the sensor on the fuel filter, the control unit operates the pressure regulator to decrease the line pressure (injection times are not changed).

The control unit controls the amount of fuel injected, adjusting the line pressure and injection times. The information the control unit processes to regulate the amount of fuel to be injected includes: The information the control unit processes to regulate the amount of fuel to be injected includes: - Engine speed; - Coolant temperature;

If the temperature exceeds 90C, the power is reduced to 60%.

Checking engine coolant temperature The control unit detects the temperature of the engine coolant fluid, of the boost air and of the fuel; if necessary, it controls theelectromagnetic cooling fan (Baruffaldi) and switches on the coolant fluid warning light.

Checking quantity of fuel injected

- Turbo charging pressure;

According to the signals from the sensors and the mapped values, the control unit:

- Air temperature;

- operates the pressure regulator;

- Intake air quantity;

- varies the ”pilot” injection time to 2200 rpm;

- Battery voltage;

- varies the ”main” injection time.

- Diesel pressure;

Checking idling adjustment

- Accelerator pedal position.

The control unit processes the signals coming from the various sensors and regulates the amount of fuel to inject, controlling the pressure regulator and altering the injector injection times.

Electronic injection control The system calculates the injection modes by processing the following parameters: - Engine rpm.

Within certain thresholds the rpm takes account of the battery voltage.

- Engine coolant fluid temperature.

Fuel cut-off in release phase

- Intake air capacity. - Battery voltage.

In the phase of releasing the throttle pedal the control unit actuates the following logic elements:

- Fuel pressure.

- it cuts off supply to the electro-injectors;

- Accelerator pedal position.

- it partially reactivates supply to the electro-injectors before reaching idling speed;

The fuel pressure can reach a maximum of 2000 bars. Up to 2800 rpm pre-injection is also carried out in order to reduce the typical noise of direct injection. Pre-injection advance angles, the distance between pre-injection and main injection and advance angles of main injection vary according to the instantaneous engine operating conditions.

Self-diagnosis System diagnosis is performed by means of diagnostic instruments (no Blink Code is used).

Immobilizer recognition (if present) When the control unit receives the signal of the key on ”MAR” it communicates with the immobilizer control unit to enable starting.

- it operates the fuel pressure regulator.

Checking cylinder balancing on idling According to the signals received from the sensors, the control unit controls the regularity of the torque at idling speed: - it varies the amount of fuel injected into the single electro-injectors (injection time).

Checking regular engine rotation (anti-sawing) It ensures regular engine rotation at a constant rate while increasing revs. The control unit processes the signals received from the sensors and determines the amount of fuel to be injected via: - the pressure regulator; - the electro-injector opening time.

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SECTION 2 - OPERATING DIAGRAMS

7

Checking smokiness at exhaust on acceleration

Checking injection pressure closed cycle

The engine control unit, using the signals from the rpm sensor and from the air flow rate meter, acting on the pressure regulator and altering the injection time for the injectors to control the exhaust fumes during heavy acceleration.

Depending on the engine load, determined by processing the signals from the various sensors, the control unit operates the regulator to obtain optimum line pressure.

Checking exhaust gas recirculation

Fuel supply The fuel supply is calculated in relation to:

Depending on the engine load and the signal from the accelerator pedal sensor, the control unit limits the amount of air taken in, actuating partial suction of the exhaust gases.

- accelerator pedal position

Checking top speed limit

- quantity of air introduced.

Depending on the number of revs, the control unit actuates two action strategies:

The outcome may be corrected in relation to:

- at 4250 rpm it cuts off the fuel, decreasing the electro-injector opening time;

Or to avoid:

- over 5000 rpm it deactivates the electro-injectors.

- engine speed

- the water temperature. - noise - smoke

Checking regular rotation on acceleration

- overloading

Regular progression is assured in all conditions by the control of the pressure regulator and the electro-injector opening time.

- overheating

Checking pre/heating glow plug control unit

The delivery can be modified in the case of:

The injection control unit times the operation of the preheating glow plug control unit depending on the engine temperature during start-up and post-start-up.

- action of external devices (ASR, MSR, HBA)

Checking activation of air-conditioning system

After determining the mass of air introduced by measuring its volume and temperature, the control unit calculates the corresponding mass of fuel to inject into the relevant cylinder (mg per delivery) also taking into account the temperature of the diesel.

The control unit operates the air-conditioning compressor: - switching it on/off when the relative switch is pressed; - momentarily turning it off (approximately 6 sec.) if the engine coolant reaches the set temperature.

Checking fuel pump Irrespective of the speed, the control unit: - supplies the auxiliary fuel pump with the key on MAR; - cuts off auxiliary pump supply if the engine is not started up within a few seconds.

Checking fuel preheating It times operation of diesel warming in relation to ambient temperature.

Checking cylinder position During each turn of the engine, the control unit recognizes which cylinder is in the power stroke and operates the injection sequence for the appropriate cylinder.

Checking pilot and main injection timing According to the signals from the various sensors, including the absolute pressure sensor built into the control unit, the control unit determines the optimum point of injection according to internal mapping.

Print P1D32S021 E

- turbine over-revving.

- serious trouble decreasing the load or stopping the engine.

The fuel mass calculated in this way is first converted to volume (mm3 per delivery), and then in crank degrees, i.e. in injection duration.

Correcting flow rate according to water temperature A cold engine meets with greater resistance during operation: friction is high, the oil is still very viscous, and the various clearances are not yet optimized. In addition, the injected fuel tends to condense on the metal surfaces that are still cold. The fuel supply for a cold engine is therefore greater than for a warm one.

Correcting flow rate to avoid noise, smoke or overloading The behaviour that could lead to this kind of trouble is well known. The designer has therefore included special instructions in the control unit to avoid it.

De-rating In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in proportion to the temperature reached by the coolant.

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Turbine speed setting

Warm starting

The advance (start of delivery, expressed in degrees) may be different from one injection to the next, also differentiated from one cylinder to another.

If the reference temperatures all exceed 10C, when the key makes contact the indicator light comes on for approximately 2 sec., for a short test, and then goes out. It is now possible to start up the engine.

It is calculated, similarly to the delivery, in relation to the engine load (accelerator position, engine speed and air introduced). The advance is appropriately corrected: - in phases of acceleration; - according to the water temperature. And also to obtain: - lower emissions, noise and overloading; - better vehicle acceleration. An extremely high advance is set on starting, depending on the water temperature. Feedback from the start of delivery is supplied by the change in impedance of the injector solenoid valve.

Speed governor The electronic speed regulator has the same characteristics as traditional units (min/max, speeds) but is stable in ranges in which mechanical regulators are imprecise.

Engine starting During the first few turns of the engine, the timing and cylinder no. 1 recognition signals (flywheel sensor and camshaft sensor) are synchronized. The accelerator pedal signal is ignored on starting. Starting delivery is set only according to water temperature, by a special map. When the control unit detects such speed and acceleration of the flywheel as to be able to consider the engine started up and no longer driven by the starter motor, it re-enables the accelerator pedal.

Cold starting If even just one of the three temperature sensors (water, air or diesel) records a temperature lower than 10C, pre-post heating is activated.

Run up When the key makes contact, the control unit transfers the information stored in memory when the engine was last stopped into the main memory (see After Run) and makes a diagnosis of the system.

After run Whenever the engine is switched off with the key, the control unit stays powered for a few seconds by the main relay. This makes it possible for the microprocessor to transfer some data from the main memory (volatile) to a non-volatile memory, which can be erased and written over (EEPROM), so as to make it available at the next start up (see Run Up). These data basically consist of: - various settings (engine idling adjustment, etc.); - settings of some components; - fault memory. The process lasts a few seconds, typically from 2 to 7 (depending on the amount of data to save), after which the control unit sends a command to the main relay and makes it disconnect from the battery.

NOTE It is extremely important for this procedure not to be broken off, for example by switching off the engine with the battery cut-out, or by disconnecting the battery cut-out before 10 seconds have passed since switching off the engine. If this happens, the functioning of the system is ensured, but repeated interruptions may damage the control unit.

When the key makes contact the pre-heating indicator light comes on and stays on for a length of time that varies in relation to the temperature (while the glow plugs in the cylinder head heat the air), then flashes. It is now possible to start up the engine. When the motor is running this indicator light goes out, while the glow plugs continue to be powered for a certain length of time (variable) for post-heating. If, with the indicator light flashing, the engine is not started up within 20-25 seconds (inattention time), the operation is cancelled so as not to run down the batteries pointlessly. The pre-heating curve is also variable in relation to the battery voltage.

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SECTION 2 - OPERATING DIAGRAMS

9

Cut-off

Synchronization search

This function cuts off fuel delivery when the vehicle is decelerating (accelerator pedal released).

If there is no signal from the camshaft sensor, the control unit is anyhow able to recognize the cylinders into which the fuel is to be injected.

Cylinder balancing The individual balance of the cylinders contributes to improving comfort and driveability. This function allows an individual and personalized check on the fuel flow rate and the start of the supply for each cylinder, in a way that is different from one cylinder to another, to compensate for injector tolerances. The control unit does not directly evaluate the differences in injector flow rate: calibration takes place by entering the injector bar code using the diagnostic instrument (see ”replacing an injector”).

If this occurs when the engine is already running, the combustion sequence has already been acquired, so the control unit continues with the sequence on which it has already been synchronized. If this occurs when the engine is already stationary, the control unit activates one injector; within 2 rounds of the crankshaft, in that cylinder a combustion will start. Then the crankshaft speeds up and the control unit manages to synchronise the ignition order and to start the engine.

Hydraulic system Figure 3

227516

A. High pressure - B. Low pressure - C. Backflow 1. Common Rail - 2. Fuel return pipe from injectors - 3. Fuel return pipe from rail 4. Fuel pipe from pump to tank -5. Fuel pipe from filter to pump - 6. High pressure pump 7. High pressure pipe from pump to rail - 8. Electro-injectors - 9. High pressure pipes from rail to injectors.

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Base - April 2015

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Operation

The high-pressure circuit is made up of the following pipes:

In this injection system, the flow regulator, located above the high-pressure pump, regulates the flow of fuel needed in the low pressure system. Subsequently the high-pressure pump correctly supplies the hydraulic accumulator.

- pipe connecting the high-pressure pump outlet to the hydraulic accumulator (rail);

This solution, only pressurising the necessary fuel, improves the energy efficiency and limits heating the fuel in the system. The relief valve fitted on the high-pressure pump has the function of keeping the pressure, at the pressure regulator inlet, constant at 5 bars; irrespective of the efficiency of the fuel filter and of the system before it. The action of the relief valve causes an increase in the flow of fuel in the high-pressure pump cooling circuit. The high-pressure pump continuously maintains the fuel at the working pressure, irrespective of the timing and the cylinder that is to receive the injection and accumulates it in a duct common to all the electro-injectors. At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit. When the solenoid valve of an electro-injector is energized by the control unit, fuel taken straight from the common rail is injected into the relevant cylinder. The hydraulic system consists of a low-pressure fuel recirculation circuit and a high-pressure circuit.

Base - April 2015

- hydraulic accumulator (rail); - pipes feeding the electro-injectors from the hydraulic accumulator. The low-pressure circuit is made up of the following pipes: - fuel intake pipe from the tank to the filter; - pipe assembly made up of the following: - feed pipe from the fuel filter to the high-pressure pump; - fuel return pipe from the high-pressure pump to the tank; - fuel return pipe from the injectors to the pipe delivering fuel back to the tank. Due to the very high pressure that builds within this hydraulic system, the following precautions must be observed for safety reasons: - avoid connecting high-pressure pipe fittings with approximate tightening; - avoid disconnecting the high-pressure pipes when the engine is running (DO NOT make any attempt at bleeding: this is absolutely useless and dangerous!). To ensure correct operation of the system, it is essential that the low-pressure circuit is intact. Therefore, avoid any attempt at modification or alteration and intervene immediately if a leak is identified.

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SECTION 2 - OPERATING DIAGRAMS

11

Fuel system layout Figure 4

221412

1. Pressure limiter valve - 2. High-pressure delivery pipe, - 3. Common Rail return pipe - 4. Electro-injectors 5. DRV pressure control valve - 6. Common Rail - 7. Fuel pressure sensor - 8. Electro-injector return pipe 9. Filter with water separator - 10. Tank - 11. Electric fuel pump - 12. Electric fuel pump intake filter 13. Electric fuel pump non-return valve - 14. High-pressure pump - 15. Mesh filter-valve

a. b. c. d.   * ** Print P1D32S021 E

4.4 bar () 4.4 bar () p ≤ 2 bar p ≤ 10 bar relative pressure absolute pressure optional overpressure valve 3.3 ± 0.1 bar

Fc in pressure chamber (8) lifting peg (2), with fuel being consequently introduced into cylinders. - ”end of injection” 50704

The coil (4) is de-energized and makes the shutter (6) return to its closed position. This recreates such a balance in the forces as to make the pin (2) return to its closed position and consequently end injection.

1. Pressure rod - 2. Pin - 3. Nozzle - 4. Coil - 5. Pilot valve 6. Ball shutter - 7. Control area - 8. Pressure chamber 9. Control volume - 10. Low pressure fuel return 11. Control duct - 12. Power supply pipe - 13. Electric connection - 14. High-pressure fuel inlet fitting - 15. Spring

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SECTION 2 - OPERATING DIAGRAMS

17

General specification

Engine oil is drawn up from the sump by the oil pump via the suction strainer and delivered under pressure to the heat exchanger where it is cooled.

The engine is lubricated by forced circulation performed by the following parts:

The oil continues through the oil filter and goes to lubricate the relevant parts through ducts or pipes.

- a gear oil pump with built-in depressor (GPOD);

At the end of the lubrication cycle, the oil returns to the sump by gravity.

LUBRICATION

- a pressure relief valve integrated in the oil pump; - a heat exchanger made up of five elements; - a mono-filtering oil filter with incorporated safety valve.

The oil filter can be excluded by the safety valve built into it if it gets clogged. In addition, the lubricating oil feeds the chain hydraulic tightening devices for the control of the auxiliary elements and the timing system and the hydraulic tappet.

Figure 13

227519

A. Oil under pressure - B. Oil in freefall - C. Coolant D. Pressure regulating valve closed - E. Pressure regulating valve open. 1. Oil pump - 2. Suction strainer - 3. Oil sump - 4. Turbocharger oil outlet pipe 5. Turbocharger oil inlet pipe - 6. Oil introduction - 7. Water oil heat-exchanger Print P1D32S021 E

Base - April 2015

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SECTION 2 - OPERATING DIAGRAMS

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Lubrication system main components Oil and vacuum pump unit

Figure 17

Figure 14

88691

SECTION A-A 230349

Technical data

1. Oil pump - 2. Vacuum pump. 3. Oil pressure adjusting valve

NOTE

Should the unit be faulty, not due to the oil pressure adjusting valve, change the whole unit.

Section Figure 15

88689

SECTIONS OF OIL PUMP/DEPRESSOR UNIT 1. Oil input pipe from cylinder block - 2. Oil suction pipe 3. Oil pressure adjusting valve - 4. Oil delivery pipe 5. Vacuum pump air suction pipe - 6. Vacuum pump oil suction pipe..

Figure 16

88690

SECTION B-B

Base - April 2015

Oil pump technical data Transmission ratio Displacement Number of teeth Height Minimum speed Maximum speed Overspeed Forced overspeed Pressure at maximum regulator valve aperture Speed Torque Power absorbion Vacuum pump technical data Transmission ratio Displacement Volume to drain Rotor diameter Number of blades Height Minimum speed Maximum speed Overspeed Forced overspeed Theoric flow rate at minimum (air) Actual flow rate at minimum atmosferic pressure (air)

1 23.52 cm3 7 18 mm. 780 rpm 3500 rpm 4200 rpm 4900 rpm 13 bar 3500 rpm 4 Nm 1047 W

1 150 cm3 4.5 l. 45.5 mm. 1 23.9 mm. 780 rpm 3500 rpm 4200 rpm 4900 rpm 117 l/min 76 l/min

Theoric flow rate at maximum speed (air) Actual flow rate at minimum atmosferic pressure (air)

525 l/min 128 l/min

Speed Torque Power absorbion

3500 rpm 1 Nm 262 W Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 2 - OPERATING DIAGRAMS

Oil pressure adjusting valve

19

Oil filter

Figure 18

Figure 21

88626

1. Valve - 2. Spring A. Oil intake from sump - B. Oil delivery to crankcase C. Oil return from crankcase - D. Oil discharge hole E. Oil discharge hole Pressure at opening start: 4.4 bar Description of oil pressure adjusting valve closed If in pipe C the oil pressure is below 4.4 bar, the valve (1) closes the holes D - E.

Figure 19

88061

Oil filter with built in by-pass valve — differential opening pressure 2.5  0.2 bar.

Water/oil heat exchanger

88627

Figure 22

Oil pressure adjusting valve open If in pipe C the oil pressure is equal or above 4.4 bar, the valve (1), as a result of the pressure itself, wins through the spring reaction (2) and goes down, thus opening communication between the delivery pipe A and the suction pipe B, through draining holes D-E, and therefore the pressure drops. When the pressure falls below 4.4 bar, the spring (2) takes the valve (1) to the initial position of closed valve.

Figure 20

107752

88058

HEAT EXCHANGER COMPONENT DETAILS 1. Heat exchanger made up of five elements - 2. Gasket 3. Box - 4. Pipe union - 5. Screw - 6. Oil filter support 7. Oil pressure switch - 8. Screw - 9. Gasket 10. Gasket

If the oil pressure regulator valve (1) malfunctions, replace the entire vacuum pump oil pump assembly (GPOD).

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SECTION 2 - OPERATING DIAGRAMS

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Heat exchanger operation Figure 23

227520

A. Cold oil from heat exchanger to cylinder block - B. Cold oil from heat exchanger to oil filter C. Hot oil from cylinder block to heat exchanger 1. Heat exchanger - 2. Heat exchanger body - 3. Oil filter support - 4. Oil filter

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F1C EuV1 - ENGINES

OIL VAPOUR RECIRCULATION (BLOW-BY) General specifications Part of the gas produced by combustion leaks out of the piston gaskets into the sump and mixes with the oil vapour it contains. This mixture is conveyed upwards by the chain housing and is partially separated from the oil by a device located at the top of the timing system cover and sent into the air intake circuit.

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SECTION 2 - OPERATING DIAGRAMS

The device is essentially composed of a rotary filter (3) fitted to the high pressure pump/camshaft control shaft (1) and a cover (2).

Figure 24

221431

A. Gas with oil content above 10g/h - B. Gas with oil content of 0.2 g/h - C. Condensed oil that returns to the oil sump 1. Shaft - 2. Cover - 3. Rotary filter - 4. Chamber - 5. Pipe

Operation The mixture passes through the rotary filter (3), where the oil is partially separated by centrifugal force, and condenses on the walls of the cover, after which it returns to the lubrication circuit.

Pipe (5), conveying the oil vapours to the turbocharger inlet, comes with an optional electrical heating element which is actuated when the ignition key is turned.

The purified mixture is sent via the holes in the shaft (1), into the air conveyer upstream of the turbocharger.

Its function is to prevent the oil vapour from solidifying and the steam (found in the same) from freezing when the external temperature is low, thus causing the gas pressure to increase in the engine base, with resulting risk of oil leakage from the crankcase seal rings.

The part of the oil contained in the mixture exiting from the rotary filter (3) condenses in the chamber (4) and drains into the chain housing.

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COOLING SYSTEM General specifications The engine cooling system is the type with forced circulation in a closed circuit. It comprises the following parts: - An expansion tank whose plug has two valves incorporated in it: an outlet and an inlet, which govern the pressure of the system (not supplied by FPT). - A coolant level sensor at the base of the expansion tank (not supplied by FPT). - A pressure switch notifies to the control unit when pressure inside expansion tank exceeds 0.4 bar value; in this case, the central unit reduces engine performance level by modifying injection flow rate (De-rating) (not supplied by FPT).

- An engine cooling module to dissipate the heat taken from the engine by the coolant with a heat exchanger for the intercooler (not supplied by FPT). - A heat exchanger to cool the lubricating oil. - A centrifugal water pump incorporated in the crankcase. - An electric fan comprising an electromagnetic coupling on whose shaft a hub turns idle that is fitted with an axially mobile metal plate on which is mounted the impeller (not supplied by FPT). - A 3-way thermostat governing the circulation of the coolant.

Figure 25

227521

A. Cold - B. Very hot - C. Hot - D. Thermostat closed - E. Thermostat opened 1. Rear cover- 2. Thermostat - 3. Very hot water from thermostat to radiator 4. Water inlet from radiator to heat exchanger 5. Water/oil heat exchanger - 6. Water pump 7. Water inlet from expansion tank to pump - 8. Blow-by heater - 9. Water outlet to cylinder block 10. Turbocharger -11. Water outlet from EGR to expansion tank- 12. EGR heat exchanger

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SECTION 2 - OPERATING DIAGRAMS

Water pump

Operation The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylinder head.

Figure 27

When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid is channelled from here to the radiator and cooled by the fan. The pressure in the system due to the change in temperature is governed by the outlet and inlet valves incorporated in the expansion tank filler plug. The outlet valve has a double function: - to keep the system slightly pressurized so as to raise the boiling point of the coolant; - to discharge into the atmosphere the excess pressure produced in case of high coolant temperatures. The function of the inlet valve is to permit transferring the coolant from the expansion tank to the radiator when a lower pressure is created in the system due to the reduction in volume of the coolant as a result of its temperature lowering.

227522

1. Electromagnetic pulley - 2. Fixing screws 3. Gasket - 4. Water pump body The water pump cannot be overhauled. If coolant leakage or damage to the component or seals is identified, it must be replaced.

Cooling system main components Thermostat Figure 26

Testing table Time Description (sec.) Fixture clamping pressure Fill time Test time Test pressure Loss accepted

/ 15 10 / 10

Pressure (Bar) 100 ÷ 150 / / 1.2 0.002

150684

The by-pass thermostat needs no adjustment. If there is any doubt about its operation, replace it. The thermostat casing is fitted with the thermometric switch/transmitter and water temperature sensor. Start of stroke at 79 ± 2 C = 0.1 mm. End of stroke at 94 ± 2C = 7 mm.

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TURBOCHARGING SYSTEM Figure 28

227523

A. Air at atmospheric temperature - B. Exhaust gas - C. Cold compressed air - D. Hot compressed air - E. Cold exhaust gas 1. EGR group - 2. Variable geometry turbocharger - 3. Exhaust manifold - 4. Intake manifold

Description The turbocharging system comprises an air filter, turbocharger and aftercooler (air filter and aftercooler not supplied by FPT). The air filter is the dry type comprising a filtering cartridge to be periodically replaced.

Base - April 2015

The function of the turbocharger is to use the energy of the engine’s exhaust gas to send pressurized air to the cylinders. The aftercooler consists of a radiator integrated in the engine coolant radiator with the function of lowering the temperature of the air leaving the turbocharger before it is delivered to the cylinders.

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SECTION 2 - OPERATING DIAGRAMS

25

Turbocharging system main components Variable geometry turbocharger Figure 29

227549

A. Intake air - B. Compressed air - C. Exhaust gas 1. Oil delivery pipe - 2.Water delivery pipe - 3. Oil return pipe - 4. VGT actuator - 5. Turbocharger body 6.Water return pipe The variable geometry turbocharger consists of the following: - centrifugal compressor;

Operation at low engine rpm Figure 30

- turbine; - set of mobile blades; - a pneumatic actuator controlling the moving vanes. The actuator is controlled by a vacuum via a proportional solenoid valve controlled by the engine management control unit. The variable geometry makes it possible to: - increase the speed of the exhaust gases at the turbine at low engine speeds; - slow down the speed of the exhaust gases at the turbine at high speeds; In order to maximise the volumetric performance of the engine even from low rpm speeds (with the engine under a load). The turbocharger will be cooled by the engine coolant and engine oil through internal ducts. The actuator is equipped with a position sensor which communicates directly with the control unit.

126017

1. Turbine - 2. Mobile blades When engine is running at low speed, the exhaust gases show weak kinetic energy; under these conditions a traditional turbine shall rotate slowly, thus providing a limited booster pressure. In the variable geometry turbine (1), the mobile blades (2) are set to max. closed position and the small through-sections between the blades increase the inlet gas speed. Higher inlet speeds involve higher tip speeds of the turbine and therefore of the turborcharger. Engine speed increase results in a gradual increase of exhaust gas kinetic energy, and also in turbine (1) speed and booster pressure increase.

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Base - April 2015

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SECTION 2 - OPERATING DIAGRAMS

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Operation at high engine rpm

Proportional solenoid valve description

Figure 31

Figure 32

224836 126018

1. Turbine - 2. Mobile blades - 3. Pneumatic actuator

This causes the speed of the turbine (1) to increase, this building turbocharging pressure. The control unit, through the actuator control solenoid valve, modulates the vacuum acting on the diaphragm, so actuator (3) controls through the tie rod, the gradual opening of the mobile blades (2) until reaching the max. open position. Blade through-sections results larger thus producing a speed decrease in exhaust gas flow through the turbine (1) with speeds equal to or lower than those of the low rpm condition. Turbine (1) speed is therefore adjusted to a proper value enabling suitable engine operation at high speed

1. Output to pneumatic valve 2. Vacuum system supply input - 3. Electrical connection 4. Atmospheric pressure intake The solenoid valve modulates the low pressure controlling the turbocharger actuator, taken from the air circuit of the servo brake, according to the information exchanged between the electronic control unit and the sensors of: engine rpm, throttle pedal position and pressure/temperature fitted on the intake manifold. As a result, the actuator varies the aperture of the turbocharger throttle that adjusts the flow of exhaust gases.

Pneumatic actuator description Figure 33

227525

1. Electrical connection - 2. Diaphragm - 3. Control rod The actuator consists of a diaphragm (2) connected to the control rod (3), and it is vacuum controlled. The proportional solenoid valve modulates the depression that controls the turbocharger actuator, according to the operating conditions of the engine. The modulated depression then changes the movement of the diaphragm (2) and therefore the control rod (3). In VGT versions (fitted with a variable geometry turbine), the actuator varies the opening of the blades of the turbocharger that control the flow of exhaust gases and it is fitted with a position sensor. Base - April 2015

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SECTION 2 - OPERATING DIAGRAMS

Throttle valve The throttle valve is positioned at the turbocharger exhaust gas outlet, it’s controlled by an electric actuator via signals from the engine management control unit. The main newfeature is an electric actuatorwhich allows the exhaust gas outlet to be choked to increase the outlet temperature.

27

This possibility is exploited in order to quickly bring catalytic converter up to standard thermal conditions (reduction of emissions when is cold). A second function of the throttle valve is the engine brake. The use of the engine brake with the throttle valve on the exhaust allows use of the service brake system to be limited and therefore reduces brake wear. The engine brake is cooled by the engine coolant.

Figure 34

230348

1. Throttle valve - 2. Exhaust gas outlet - 3. Electric connection

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Base - April 2015

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EXHAUST GAS RECIRCULATION (EGR) System layout Figure 35

221430

1. Air charger intercooler outlet temperature sensor - 2. Air from intercooler - 3. Coolant temperature sensor - 4. Air and temperature sensor - 5. RPM sensor - 6. EGR flow regulating valve 7. Air coming from filter - 8. Air to intercooler - 9. Engine brake - 10. Exhaust gas 11. Control unit EDC17 CP52

Operation The control unit electronic control unit processes the information coming from the: atmospheric pressure sensor, water temperature sensor, engine rpm sensor, accelerator pedal potentiometer and, in accordance with suitably programmed modes in its memory, operate the opening of the plate in the E.G.R. valve by means of a PWM signal. In this way, some of the exhaust gases are sent towards the heat exchanger where they are cooled and directed to the chamber for the throttle valve assembly to be mixed with the

Base - April 2015

air coming from the intercooler and flow to the intake manifold. If the vehicle is fitted with a D.P.F. catalytic converter, at the same time, the control unit, adapts the flow rate of the fuel to be injected into the cylinders depending on the quantity of “recirculated” exhaust gases. When the engine is running and the recirculation of the gases is not required (regeneration of the particulate filter, starting, engine cold, idle speed, load request, high altitude), the control unit control signal is cancelled.

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29

EGR group assembly (exhaust gas recirculation) Figure 36

227524

1. Exhaust gas pipe from exhaust manifold to EGR valve - 2. Engine coolant pipe to turbocharger - 3. Collar 4. Rear cover gasket - 5. Rear cover - 6. Exhaust gas pipe from EGR to intake manifold - 7. Gasket - 8. Engine coolant pipe 9. EGR heat exchanger - 10. EGR valve - 11. Engine coolant outlet pipe to expansion tank

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Base - April 2015

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E.G.R. Assembly Figure 37

230347

A. Engine coolant - B. Exhaust gas 1. Heat exchanger - 2. Flow regulation valve

The E.G.R. assembly (Exhaust gas recirculation) comprises a heat exchanger (1) and a flow regulation valve (2). The heat exchanger (1) has the task of lowering the temperature of the exhaust gases which are partly sent to the intake manifold. This operation has only one aim: to lower the combustion temperature of the mixture. This takes place because the exhaust gases, totally inert, mix with the mixture and slow down combustion. Lowering this temperature produces a considerable decrease in NOx (nitrogen oxide) emissions which are harmful to the environment. The body of the heat exchanger is composed of a tube bundle cooled on the outside by the coolant fluid circulating in the enigne. Some of the exhaust gases destined for ”recirculation” pass inside the tube bundle and are cooled. The flow regulation valve (2) is fitted on the end of the heat exchanger. The adjustment of the amount of recirculation exhaust gases takes place by means of an electrically operated plate valve. The valve is cooled by the engine coolant coming out of the heat exchanger thereby ensuring it is more efficient and lasts longer.

Base - April 2015

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TIMING SYSTEM

31

Figure 39

Figure 38

88055

1. Rocker arm - 2. Reaction hydraulic tappet - 3. Valve assembly - 4. Camshaft on exhaust side - 5. Camshaft on suction side - 6. Camshaft control chain. 88342

Description

TIMING SYSTEM AND AUXILIARY SYSTEM DIAGRAM

The timing system is the type with a twin camshaft in the overhead and four valves per cylinder with hydraulic tappets.

1. Camshaft control gears - 2. Single chain - 3. Hydraulic chain tightener - 4. Mobile pads - 5. Drive gear on driving shaft - 6. Fixed skids - 7. Oil pump/depressor control shaft gear - Hydraulic power steering pump - 8. Double chain 9. High pressure pump control shaft gear.

The control is transmitted by two chains: - a double chain by 3/8” is set in motion by the driving shaft and sets the control shafts in motion: oil pump/depressor — high pressure pump;

Figure 40

- a single chain is set in motion by the high pressure control shaft gear and sets the camshafts in motion.

TOP DEAD CENTER

The camshaft gears are mutually interchangeable and are fitted with slots to make it possible for the phase sensor to detect the phase. The rocker arms, one for the valve, are kept in contact with the corresponding cam by an hydraulic tappet, thus eliminating the need for regular adjustments.

NOTE Change both chains, even if only one of them is faulty.

221427

BOTTOM DEAD CENTER TIMING SYSTEM DIAGRAM A - INTAKE:

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start before TDC end after BDC

29˚ ± 5˚ 30˚ ± 5˚

B - EXHAUST: start before TDC end after BDC

75˚ ± 5˚ 30˚ ± 5˚ Base - April 2015

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EXHAUST GAS POST-TREATMENT SYSTEM (ATS) System description FPT-Industrial has chosen the combination of EGR (Exhaust Gas Recirculation), DOC (Diesel Oxidation Catalyst) + DPF (Diesel Particulate Filter) and SCR (Selective Catalyst Reduction) as Euro VI emission abatement system for small industrial engines (F1C engine, 3.0L). The optimized combination of EGR and aftertreatment technologies is the key choice for an optimal small industrial engine installation on vehicles, still guarantying good emission conversion efficiency and low fuel consumption. Engine and vehicle fuel efficiency can then be lowered through the optimization of AdBlue/DEF (Diesel Exhaust Fluid) injection on the basis of typical mission profile.

ATS principle layout To restrict the emissions in the exhaust to within the limits prescribed by legal regulations, an exhaust gas post-treatment system (ATS) has been adopted combining two devices: - a catalytic converter/particulate filter for the treatment of the HC (unburnt hydrocarbons), the CO (Carbon monoxide) and the particulate; - the DeNOx device for the treatment of NOx (nitrogen oxide). Figure 41

224811

ATS = After Treatment System - DPF = Diesel Particulate Filter - DOC = Diesel Oxidation Catalyst CRT = Continuously Regenerating Trap - CUC = Clean Up Catalyst SCR = Selective catalyst reduction Functional requirements - Very good low temperature performance of SCR catalyst, to comply with the cold part of emission cycles, through improved AdBlue/DEF hydrolysis and DOC / DPF / SCR matching. - Improved dosing system accuracy to limit NH3 slip while achieving NOx conversion ~ 90% in the whole operating speed and load range, both in steady-state and transient conditions. - Thermal management to heat up the aftertreatment system as quick as possible.

Base - April 2015

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33

EMS System layout (DeNOx PC/LD 3.1) Figure 42

221445

The ATS system is controlled electronically by the engine management control unit which on the basis of the engine rpm, torque delivered, the exhaust temperature, the quantity of nitrogen oxides and the intake air humidity, adjusts the flow rate of the AdBlue solution to be introduced into the system. The pump module picks up the reagent solution from the tank and sends it under pressure to the mixing and injection module to be injected into the exhaust pipe. The ATS system consists essentially of: 1.

Exhaust gas temperature sensor T1 (Toxi)

2.

Oxi-catalyst

3.

Exhaust gas temperature sensor T2 (Tpre)

4.

Diesel Particulate Filter (DPF)

5.

Delta-P Sensor (Pdiff)

6.

SCR catalyst upstream temperature sensor

7.

Urea Dosing unit

8.

Urea Tank

9.

Supply Module (splashing, measures, heating)

10. Urea Level sensor (CCLS) 11. Engine Control Unit (EDC17C49) 12. Mixer 13. SCR catalyst downstream temperature sensor 14. NOx sensor upstream SCR 15. NOx sensor downstream SCR 16. Concentration level sensor 17. NH3 sensor

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Operation Figure 43

224812

1. NOx sensor upstream DOC - 2. Delta-P Sensor (Pdiff)- 3. Dosing module - 4. NOx sensor downstream SCR 5. NH3 sensor - 6. SCR catalyst downstream temperature sensor- 7. SCR catalytic converter - 8. SCR catalyst upstream temperature sensor - 9. Diesel Particulate Filter (DPF) - 10. Exhaust gas temperature sensor T2 (Tpre) - 11. Oxi-catalyst 12. Exhaust gas temperature sensor T1 (Toxi) In the first stage the exhaust gases leaving the turbine encounter the Oxi-catalist (11) in which the hydrocarbons (HC) and carbon monoxide (CO) are transformed, through oxidation reactions, into carbon dioxide (CO2) andwater (H2O). Subsequently the exhaust gases pass through the DPF particulate filter (9)which holds back the carbonaceous particles forming the particulate. In order for the systemto remain efficient, it needs to be regenerated and for this purpose there is a differential pressure sensor (2) which, by detecting the difference in input and outlet pressure is able to provide the control unit with an index for the clogging of the filter. The particulate filter regeneration is performed through the Exhaust Flap device to choke the outlet section of the exhaust gas from the turbine creating a dummy load to the engine. This way the exhaust gases reach the filter at a high temperature and the particles of the particulate burn keeping the filter clean. In the second phase the dosing module (3), through an injector placed in the exhaust pipe upstream of the SCR catalytic converter (7), introduces a solution of water and urea (AdBlue) into the exhaust gas. The first stage of the process takes place in the first part of the SCR catalytic converter: due to the effect of the exhaust gas temperature, the reagent solution evaporates instantly and is hydrolysed to ammonia (2NH3) and carbon dioxide (CO2); at the same time, the solution evaporates lowering the exhaust gas temperature to levels close to the optimum temperature required for the process. Exhaust gases containing ammonia at the temperature required for the reaction enter the SCR catalytic converter (7), where the second stage of the process takes place: by reacting with the oxygen in the exhaust gas the ammonia is converted into free nitrogen (N2) and water vapour (H2O). The Clean Up Catalyst (CUC) is in the end section of the catalytic converter and serves to oxidise the excess urea produced by the engine in the transient operating phases. The amount of AdBlue injected is controlled through a NH3 sensor (5) fitted on the outlet pipe of the silencer, which detects the presence of ammonia in the exhaust gas and sends a signal to the engine management control unit thereby providing a feedback signal. The engine control unit, on the basis of the engine rpm, torque, exhaust gas temperature, intake air humidity, amount of nitrogen oxide and the amount of urea present in the exhaust gas, detected by the respective sensors, regulates the flow of AdBlue to be injected into the system.

Base - April 2015

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35

Hardware scheme Figure 44

SCR

224813

Adblue: Aqueous Urea Solution 32.5% according to DIN 70070 1. NH3 slip prevention coating - 2. Dosing module - 3. Heated pressure pipe - 4. Reagent tank 5. Reagent pump (functional unit)

Hydraulic scheme Figure 45

6

224814

1. Backflow throttle - 2. Reagent tank - 3. Tank heating device - 4. Pick up filter - 5. Reagent temperature sensor - 6. Reagent level sensor - 7. Pressure sensor - 8. Reverting valve - 9. Reagent flow to dosing module - 10. Pressure pipe heating device 11. Supply module heating device - 12. Reagent pump CHARACTERISTICS Supplier:

NOMINAL Bosch

Supply pressure:

5 bar

Actuator control:

EDC

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AdBlue Specifications ISO 22241 / AUS32 / DIN V 70070 Urea 32,5% - solution in water

Urea content Density at 20˚C Refracting index at 20˚C Alcalinity as NH3 Biuret Aldehyde Insolubles Phosphate (PO4) Calcium Iron Copper Zinc Crromium Nickel Aluminium Magnesium Sodium Potassium

Base - April 2015

Min. 31,8 1,087 1,3814

Max. 33,2 1,093 1,3843 0,2 0,3 5 20 0,5 0,5 0,5 0,2 0,2 0,2 0,2 0,5 0,5 0,5 0,5

% by weight g/cm3 % % mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg

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37

Main components of the ATS system Diesel particulate filter and diesel oxidation catalyst Figure 46

224818

A. Inlet - B. Outlet 1. NOX sensor - 2. Exhaust gas temperature sensor T2 (Tpre) - 3. Delta-P sensor (Pdiff) - 4. Delta-P sensor (Pdiff) 5. Exhaust gas temperature sensor T1 (Toxi) This first stage is made up of a DOC (Diesel Oxidation Catalyst) followed by a DPF (Diesel Particulate Filter) in which the exhaust gas is cleaned of the HC (unburnt hydrocarbons), CO (carbon monoxide) and the parti culate. Selective catalyst reduction and Clean up catalyst Figure 47

A. Inlet - B. Outlet

224819

1. SCR catalyst downstream temperature sensor - 2. Mixing pipe - 3. Dosing module 4. SCR catalyst upstream temperature sensor This second stage is made up of a SCR (Selective Catalyst Reduction) and a CUC (Clean Up Catalyst), upstream of which is the AdBlue dosing module; the reactions to reduce the NOx (nitrogen oxide) takes place in this catalytic converter. Print P1D32S021 E

Base - April 2015

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Supply Module Figure 48

224815

1. Pressure sensor - 2. Reverting valve - 3. Cover - 4. Cover - 5. Heating element inside - 6. Hydraulic connector to dosing valve - 7. Outlet filter serviceable The AdBlue supply module consists mainly of a diaphragm pump which takes up the AdBlue from the tank and sends it to the dosing module. It is equipped with a circuit connected to the engine cooling systemwhich, in low temperatures, stops the AdBlue fromfreezing. Inside there is a pressure sensor. The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and are dependent on the operating conditions of the engine and from the signals sent by the sensors. To prevent any damage to the pump and the dosing module, the supply module contains a filter which cleans the AdBlue of any impurities.

Base - April 2015

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SECTION 2 - OPERATING DIAGRAMS

Dosing Module Figure 49

224820

1. Gasket - 2. V-clamp - 3. Cooling body - 4. Valve housing - 5. Hydraulic connector - 6. EIectrical connector The dosing module is controlled by the engine control unit. Its function is to dose the AdBlue to be injected into the exhaust pipe upstream of the SCR catalytic converter. It is fitted on the catalytic converter and while in operation it is subject to high temperatures. For this reason it is connected to the engine cooling circuit by means of the pipes. DOSING MODULE CHARACTERISTICS Supplier: Dosing quantity: Spray angle: Cooling concept: Valve control: Hydraulic connector:

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NOMINAL Bosch Min. 15g/h Max. 3200 g/h 16˚ Passive cooling EDC (PWM controled) SAE J2044 Quick connector 1/4”

Base - April 2015

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SECTION 2 - OPERATING DIAGRAMS

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Reducing agent tank Figure 50

224816

1. Melting pot - 2. Supply module Tank unit will be provided already assembled with melting pot and supply module, leakage test already performed. Adblue tank material: HDPE - Volume: 25 lt The melting pot includes: Level sensor: 3 pin discrete level sensor Tank heater: Electrically (PTC) Reagent temperature: NTC Supply module includes: Reagent pump: membrane pump Reverting valve: 4/2 way valve Pressure sensor: relative pressure sensor Supply module heater: Electrically (PTC)

Base - April 2015

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41

Melting pot Figure 51

224817

1. Helicoil inserts - 2. Reservoir pot - 3. Bayonet locking ring - 4. Level sensor - 5. Melting pot cover Helicoil inserts: fixation of supply module. Reservoir pot: contains urea suction line, tank heating, level sensor. Bayonet locking ring: welded to tank case, twist-and-lock connection to melting pot. Level sensor: measuring outside of pot. Melting pot cover: fixed to tank case, interface between inside and outside of tank. Power switch Figure 52

224821

1. Pressure pipe heater - 2. Supply module heater - 3. Tank heater - 4. Engine control unit The power switch is used for controlling and monitoring the electrical power supply of electric heating elements in the Reagent system. The controlling of the power output stage is carried out by EDC.

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ATS system main sensors NH3 sensor Figure 53

185027

1. Heater (+) - 2. Trim resistor - 3. Trim resistor ground - 4. EMF_2 - 5. Heater (-) - 6. Temp sensing - 7. Signal ground 8. EMF_1 The NH3 sensor is connected to the engine management control unit and by detecting the amount of ammonia (NH3) present in the exhaust gas leaving the catalytic converter it allows an exact adjustment of the amount of AdBlue to be injected. NH3 SENSOR CHARACTERISTICS Supplier: Temperature gas at the sensor: Installation torque: Installation angle: Bending radius for the cable coming out the sensor: Bending radius for the free flexible cable: Temperature range:

NOMINAL Delphi < 700 ˚C 50 ± 10 Nm 16˚ to 30˚ > 20 mm > 10 mm -40 ˚C to +900 ˚C (peak: 1,000 ˚C)

Technical characteristics: - The first resonant frequency of the NH3 sensor is above 2,500 Hz; a modal analysis at the sensor’s location in the exhaust system is recommended to assure the sensor is not excited to resonance. - The sensor is tested to sinusoidal vibration levels up to 60g peak at 2,500 Hz; random vibration levels of 35g RMS and 115g peak are performed in a bandwidth between 50 and 2,000 Hz. - Minimum system supply voltage must be greater than 10 V. To provide sufficient heater power to ensure the sensor will function under all operating conditions. Positioning recommendations: - Avoid positions in dead / shaded space (positioning not shortly after bending or sharp edges or NOx-sensor). - No external injection of air/gas upstream or close to the sensor. - Sheltered position (protection against splash water, stones etc.).

Base - April 2015

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NH3 controller Figure 54

185028

A. Vehicle side connector - B. Sensor side connector. 101. Power supply - 102. CAN LINE HIGH - 103. CAN LINE LOW - 104. Ground. 201. Heater (+) - 202. Trim resistor - 203. Trim resistor ground - 204. EMF_2 - 205. Heater (-) 206. Temp sensing - 207. Signal ground - 208. EMF_1 NH3 CONTROLLER CHARACTERISTICS Operating voltage Average current Peak current Operating limit values Tightening torque:

NOMINAL 10 to 32 V 1.2 A 4.0 A -40 to 105 ˚C 11.5 ± 1.5 Nm

Positioning recommendations: - Regarding vibration measurements on the controller, the best location is on the cast cover but since this might not be a convenient location for installation on a vehicle, an accelerometer mounted on the plastic is fine. - The controller is tested at random vibration level 6grms with 18g peak in the bandwidth between 10 Hz to 2,000 Hz.

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Nitrogen oxide detecting sensor Figure 55

102302

1. Positive - 2. Ground connection - 3. CAN LINE LOW - 4. CAN LINE HIGH - 5. Spare The NOx sensor detects the amount of nitrogen oxide present in the exhaust gas entering and leaving the catalytic converter. On the basis of this information the engine control unit adjusts the amount of AdBlue to be injected and also measures the efficiency of the catalytic converters. Tightening torque: 50 ± 10 Nm Temperatures Ambient temperature: Wire temperature: Maximum exhaust gas temperature: Maximum sensor hexagon screw temperature: Maximum sensor grommet temperature: Pre-heating sensor temperature:

- 40 to +105 ˚C (+105 to +115 ˚C allowed for up to 10 min) 230 ˚C allowed for 100 h 800˚C (950˚C allowed for up 100 h) 620˚C (650˚C allowed for up 100 h) 200˚C (230˚C allowed for up 100 h) 80˚ to 120˚C

Electrical characteristics NOx SENSOR CHARACTERISTICS Minimum supply voltage (ECU): Minimum supply voltage (Sensor Heater): Standard supply voltage: Maximum supply voltage (Sensor Heater): Typical supply current: Peak supply current at switch on: Inrush current for loading of Input Caps: Maximum supply power: CAN line voltage: Max load dump protection for 12V version: Base - April 2015

NOMINAL 9V 12 V 13.5 V 16.0 V < 1.5 A 16 A > 20 A 20 W -3 to 6 V 34 V Print P1D32S021 E

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45

Exhaust gas temperature sensor Figure 56

224823

1. Electrical connection - 2. Lead wire - 3. Housing - 4. Sheath pin - 5. Protection tube Figure 57

224822

OPERATING CIRCUIT It has the function of sending information to the control unit regarding the temperature of the exhaust gas entering and exiting the catalyst that is necessary for calculating the amount of urea to inject in the system. EXHAUST GAS TEMPERATURE SENSOR CHARACTERISTICS Power supply Nominal resistance at a temperature -15 to 900 ˚C Vibration limit 0 to 500 Hz Vibration limit 500 to 1300 Hz Vibration limit 1300 to 4000 Hz - Applied electric power shall not be 10 mW or more.

NOMINAL 5V 54.9 to 0.0389 k 30 G 3G 30 G

- Tightening torque shall be 30 ± 6 Nm. - Sensor is delivered with anti-seize grease applied at its threads. In case of remounting, grease shall be applied to threads, ”NEVER-SEEZ”, pure Nickel special grade. - An adequate extra-length of wire harness shall be secured on sensor side in order to prevent mechanical stress applied on internal connections of sensor. - Max pulling force of cable shall be 100 N. - The angle between lead wire and radial direction of sensor body shall be 30˚ or more (as shown on the drawing). Print P1D32S021 E

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Differential pressure sensor The differential pressure sensor (1), connected downstream and upstream of the DPF particulate filter, measures the corresponding difference in pressure. Figure 58

224824

1. Electrical connection - 2. Connections to DPF particulate filter This difference in pressure is converted into a voltage signal sent to the engine management control unit and consists of a clogging index of the DPF particulate filter.

Base - April 2015

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47

Lambda sensor The lambda probe detects the percentage of NOx (nitric oxide) found in the exhaust gas. If the NOx value exceeds the specified value, the control unit will actuate the injectors by adjusting the fuel supply. Figure 59

224825

1. Electrical connection - 2. Sensor Installation instructions: - Sensor must be installed at angles  10 ˚C fron horizontal. - With respect to the exhaust-gas flow path, positioning the sensor axis at 90˚ is ideal. A slope of up to -30˚is permissible. - Tightening torque shall be 50 ± 10 Nm. Bending radius flexible cable: - A minimum bend radius of 20 mm (long grommet) or 12 mm (short grommet) must be adhered to with respect to the “neutral filament”. - The first mounting point of the sensor cable should lie approx. 200 mm to 400 mm after the end of the grommet, depending on the possible movements of the exhaust system.

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SECTION 3 - ELECTRICAL EQUIPMENT

1

SECTION 3 Electrical equipment Page

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LOCATION OF THE MAIN ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .

3

EDC 17 C49 ELECTRONIC CONTROL UNIT .

5

VEHICLE SIDE ELECTRICAL WIRING . . . . . . . .

6

- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

- ECU connection to the injection cable on vehicle side (housing B) . . . . . . . . . . . . . . . . . . . . . . . .

7

ENGINE SIDE ELECTRICAL WIRING . . . . . . . .

10

- Topographic view . . . . . . . . . . . . . . . . . . . . . .

10

- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

- ECU connection to the injection cable on engine side (housing A) . . . . . . . . . . . . . . . . . . . . . . .

13

MAIN ELECTRICAL/ELECTRONIC EQUIPMENT

15

- Pressure regulator valve on HP pump . . . . . . .

15

- Electro-Injectors CRi2.20 . . . . . . . . . . . . . . . . .

15

- Rail pressure sensor . . . . . . . . . . . . . . . . . . . .

16

- Pressure regulating valve on rail . . . . . . . . . . .

16

- Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . .

16

- VGT position sensor . . . . . . . . . . . . . . . . . . . .

17

- EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

- Driving shaft and camshaft unit . . . . . . . . . . . .

18

- Air temperature and pressure sensor . . . . . . .

20

- Engine coolant temperature sensor . . . . . . . .

21

- Exhaust gas temperature sensor . . . . . . . . . . .

22

- Air inlet from aftercooler temperature sensor

23

- Oil pressure switch . . . . . . . . . . . . . . . . . . . . .

23

- Pre/heater glow plug control unit . . . . . . . . . .

24

- Pre/heater glow plugs . . . . . . . . . . . . . . . . . . .

24

- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Starter motor . . . . . . . . . . . . . . . . . . . . . . . . .

26

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2

SECTION 3 - ELECTRICAL EQUIPMENT

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

3

LOCATION OF THE MAIN ELECTRICAL COMPONENTS

Figure 1

227518

FRONT VIEW OF ENGINE, INTAKE SIDE 1. Air inlet from aftercooler temperature sensor - 2. Pre/heater glow plugs - 3. Air pressure and temperature sensor 4. Oil pressure switch - 5. Fuel flow regulator on pump - 6. Coolant temperature sensor - 7. Segment speed sensor 8. Pressure regulating valve on rail - 9. Pressure sensor on rail

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SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Figure 2

227517

FRONT VIEW OF ENGINE, EXHAUST SIDE 1. EGR valve - 2. Increment speed sensor - 3. Alternator - 4. VGT position sensor - 5. Flow rate control valve 6. Electro-injectors - 7. Exhaust gas temperature sensor

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

5

EDC 17 C49 ELECTRONIC CONTROL UNIT Figure 3

128680

The control unit is a ”flash EPROM” and thus can be reprogrammed remotely without modifying the hardware. The control unit processes the signals from the sensors by applying software algorithms and controls the actuators (especially the electroinjectors and pressure regulator). It records, in the non-volatile memory area, the information on the engine parameters originally set or acquired during engine operation. The injection control unit has the absolute pressure sensor built in to further improve the control of the injection system. The control unit is mounted on the left-hand side of the engine bay and is connected to the vehicle’s wiring harness by two connectors. - 60-pin connector (A)A for the components on the engine; - 94-pin connector (K) for the components on the vehicle. In addition to managing the functions of the system described in the relevant chapter, the control unit is also interfaced with the other electronic systems on board the vehicles, such as: ABS - EBD, cruise control, speed limiting device, immobilizer, EGR, preheating glow plugs. On vehicles equipped with catalytic D.P.F., the control unit handles the regeneration system itself; Consequently, after having performed any of the following operations: - replacing one or more injectors; - replacing all injectors; - replace flow rate meter (flow meter); - replacing the hydraulic accumulator (common rail) pressure sensor; - replacing the EDC 17 C49 control unit; - engine oil change; - replacing D.P.F. catalytic converter; - filter differential pressure (p) sensor replacement; - replacing components relating to emissions; - necessity to perform a forced regeneration.

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Base - April 2015

6

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

VEHICLE SIDE ELECTRICAL WIRING Diagram Figure 4

224830

1. Fuel temperature sensor - 2. WIF switch - 3. Fuel heater - 4. Exhaust gas temperature sensor (inlet DPF) 5. Particle filter differential pressure sensor -6. Exhaust gas temperature sensor (PreoxiCat) - 7. A/C request 8. Air charger intercooler outlet temperature sensor -9. Reverse gear switch - 10. A/C compressor - 11. +50 starter 12. Alternator D+ - 13. Pre/heater glow plugs - 14. Pre/heater glow plugs control unit - 15. FAN2 relay - 16. FAN1 relay 17. A/C compressor relay - 18. Electric fuel pump relay - 19. Fuel filter heating relay - 20. Reduntant brake switch signal 21. Brake main switch - 22. Clutch switch signal - 23. Hot-film air mass filter with heater - 24. Lambda sonde 25. Accelerator pedal position sensor - 26. Key switch “15” - 27. Main relay xxA

DRAFT Base - April 2015

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

7

ECU connection to the injection cable on vehicle side (housing B) Figure 5

85708

Pin 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32

224835

Description Main relay xxA V2 Main relay xxA V2 Main relay xxA V2 Lambda sonde Air charger intercooler temperature sensor Particle filter, differential pressure sensor Accelerator pedal position sensor Accelerator pedal position sensor Hot-film air mass filter with heater Hot-film air mass filter with heater Hot-film air mass filter with heater Glow control unit (GCU2) Main relay xxA WIF switch -

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SECTION 3 - ELECTRICAL EQUIPMENT

Pin 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

F1C EuV1 - ENGINES

Description Fuel temperature sensor Particle filter, differential pressure sensor Accelerator pedal position sensor Accelerator pedal position sensor Reverse gear switch Clutch switch signal FAN 2 relay Key switch 15 Fuel temperature sensor Particle filter, differential pressure sensor Accelerator pedal position sensor Accelerator pedal position sensor Lambda sonde Lambda sonde Reduntant brake switch signal Glow control unit (GCU2) Fuel filter heating relay FAN 1 relay Electric fuel pump relay

DRAFT Base - April 2015

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F1C EuV1 - ENGINES

Pin 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

SECTION 3 - ELECTRICAL EQUIPMENT

9

Description A/C request Exhaust gas temperature sensor n.1 (PreoxiCat) Exhaust gas temperature sensor n.1 (PreoxiCat) Exhaust gas temperature sensor n.2 (inlet DPF) Exhaust gas temperature sensor n.2 (inlet DPF) Lambda sonde Lambda sonde Brake main switch Air charger intercooler temperature sensor AC compressor relay

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Base - April 2015

10

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

ENGINE SIDE ELECTRICAL WIRING Topographic view Figure 6

227528

1. Current sypply glow relay - 2. Vehicle side connection - 3. VGT actuator - 4. Glow plugs control unit 5. Boost pressure with air temperature sensor - 6. Coolant temperature sensor - 7. Oil pressure switch 8. High pressure pump fuel metering unit - 9. Air charger from aftercooler temperature sensor - 10. Pressure control valve 11. Segment speed sensor camshaft - 12. Electro-injector cylinder 1 -13. Increment speed sensor crankshaft 14. VGT position sensor - 15. EGR valve actuator - 16. Electro-injector cylinder 2 - 17. Electro-injector cylinder 3 18. Electro-injector cylinder 4 - 19. ECU connection - 20. EGR cooler outlet temperature sensor - 21. Section glow plugs 22. Rail pressure sensor

Base - April 2015

Print P1D32S021 E

1. ECU connection- 2. Rail pressure control valve - 3. Fuel metering unit - 4. Increment speed sensor crankshaft 5. Segment speed sensor camshaft -6. Coolant temperature sensor - 7. EGR cooler outlet temperature sensor 8. VGT position sensor - 9. Electro-injector cylinder 2 - 10. Electro-injector cylinder 4 11. Electro-injector cylinder 3 - 12. Electro-injector cylinder 1

227526

F1C EuV1 - ENGINES

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SECTION 3 - ELECTRICAL EQUIPMENT

11

Diagram Figure 7

Base - April 2015

1. ECU connection- 2. Rail pressure sensor - 3. Boost pressure sensor with air temperature sensor 4. EGR position sensor actuator- 5. Engine brake position sensor actuator -6. Reduction agent dosing valve 7. Air charger fron aftercooler temperature sensor - 8. Pre/heater glow plugs - 9. Pre/heater glow plugs control unit 10. Oil pressure switch - 11. VGT actuator

227527

12 SECTION 3 - ELECTRICAL EQUIPMENT

Base - April 2015

F1C EuV1 - ENGINES

Figure 8

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

13

ECU connection to the injection cable on engine side (housing A) Figure 9

85708

Pin 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

221442

Description Connection of solenoid valve 21 (injector on cylinder 3) (injector on cylinder 2) Rduction agent dosing valve VGT actuator Oil pressure switch VGT position sensor Engine brake position sensor actuator EGR valve position sensor actuator Boost pressure sensor with air temperature sensor Rail pressure sensor Segment speed sensor camshaft Segment speed sensor camshaft Fuel metering unit Connection of solenoid valve 11 (injector on cylinder 1) Connection of solenoid valve 12 (injector on cylinder 4) Reduction agent dosing valve Engine brake position sensor actuator EGR valve position sensor actuator Boost pressure sensor with air temperature sensor Rail pressure sensor EGR cooler outlet temperature sensor Segment speed sensor camshaft Rail pressure control valve Connection of solenoid valve 21 (injector on cylinder 3) Connection of solenoid valve 11 (injector on cylinder 1) -

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Base - April 2015

14 Pin 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Description Engine brake position sensor actuator EGR valve position sensor actuator VGT position sensor Engine brake position sensor actuator EGR valve position sensor actuator Boost pressure sensor with air temperature sensor Rail pressure sensor EGR cooler outlet temperature sensor Increment speed sensor crankshaft Rail pressure control valve Connection of solenoid valve 22 (injector on cylinder 2) Connection of solenoid valve 12 (injector on cylinder 4) Engine brake position sensor actuator EGR valve position sensor actuator VGT position sensor Boost pressure sensor with air temperature sensor Coolant temperature sensor Coolant temperature sensor Increment speed sensor crankshaft Fuel metering unit

Base - April 2015

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F1C EuV1 - ENGINES

15

SECTION 3 - ELECTRICAL EQUIPMENT

MAIN ELECTRICAL/ELECTRONIC EQUIPMENT

Electro-Injectors CRi2.20 Figure 11

Pressure regulator valve on HP pump Figure 10

224251

The new high pressure fuel pump is supplied by Bosch, model CP4.1 (one plunger), it can pressurise the fuel circuit up to 2000 bar. 224833

A solenoid valve controlled directly by the engine control unit regulates the fuel supply. It is fitted with a 2-pin connector to enable the solenoid valve to be controlled by the engine control unit.

PIN 1 2

DESCRIPTION Power supply Signal

ECU PIN 15 60

1. Positive - 2. Negative The injectors are activated by a solenoid with a servo valve which allows faster and more flexible management of injection events (IRS: Injection Rate Shaping). The head of the electro-injector has a fitting for the electrical connector. They are mounted on the cylinder overhead and are connected individually to the control unit.

PIN 1 2 1 2 1 2 1 2

Print P1D32S021 E

DESCRIPTION Cylinder 1 Cylinder 1 Cylinder 2 Cylinder 2 Cylinder 3 Cylinder 3 Cylinder 4 Cylinder 4

ECU PIN 16 32 2 46 1 31 17 48

Base - April 2015

16

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Rail pressure sensor

Throttle valve

Fitted to a rail end, it measures fuel pressure present to the purpose of determining existing fuel pressure.

Figure 13

Pressure value is used to control pressure and determine injection electric control duration.

Pressure regulating valve on rail Controls the pressure in the Rail in relation to the engine load. At too high pressures, the valve opens to return some of the fuel from the rail to the tank via the recovery circuit; at too low pressures, the valve closes to separate the high and low pressure sides from each other. The valve is a solenoid operated valve controlled by the PWM signals of the engine management control unit. The control unit controls the valve after processing the signals from the various sensors of the engine: engine speed, load, air intake, air pressure, engine and fuel temperature. The pressure is controlled by varying the return flow to the tank.

229367

1. Electrical connection - 2. Control actuator The throttle valve is positioned at the turbocharger exhaust gas outlet, it’s controlled by an electric actuator via signals from the engine management control unit. The main newfeature is an electric actuator which allows the exhaust gas outlet to be choked to increase the outlet temperature.

Figure 12

This possibility is exploited in order to quickly bring catalytic converter up to standard thermal conditions (reduction of emissions when is cold). A second function of the throttle valve is the engine brake. The use of the engine brake with the throttle valve on the exhaust allows use of the service brake system to be limited and therefore reduces brake wear. The engine brake is cooled by the engine coolant. Figure 14 224834

A. Pressure sensor - B. Pressure regulating valve

RAIL PRESSURE SENSOR PIN OUT PIN 1 2 2

DESCRIPTION Ground Pressure signal Power supply

ECU PIN 26 41 11 224847

MOTORIZED THROTTLE VALVE PIN OUT

PRESSURE REGULATING VALVE PIN OUT

PIN 1 2

Base - April 2015

DESCRIPTION Ground Power supply

ECU PIN 30 45

PIN 1 2 4 5 6

DESCRIPTION DC motor (+) Signal Ground DC motor (+) Power supply

ECU PIN 49 38 23 34 8 Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

VGT position sensor

17

EGR valve

Figure 15

Figure 17

229368 229369

1. Electrical connection - 2. Pneumatic actuator In the variable geometry turbochargers, the driving rotor is surrounded by mobile blades, whose movement is controlled by a pneumatic actuator that is directly controlled by the engine control unit via the modulating solenoid valve. The movement of the mobile blades outside of the driving turbine determines the variation in the angle of incidence of the exhaust gas with the blades of the rotor itself. Based on the rotation speed, they are closed or opened to influence the speed or the capacity depending on the actual speeds.

1. Electrical connection - 2. EGR valve The control unit processes the information coming from the atmospheric pressure sensor, water temperature sensor, engine rpm sensor, accelerator pedal potentiometer and, in accordance with suitably programmed modes in its memory, operate the opening of the plate in the E.G.R. valve by means of a PWM signal. In this way, some of the exhaust gases are sent towards the heat exchanger where they are cooled and directed to the chamber for the throttle valve assembly to bemixed with the air coming from the aftercooler and flow to the intake manifold.

To make it possible for the engine control unit to be precisely aware of the position of the mobile blades; a position sensor is fit on the pneumatic control actuator. Figure 18

Figure 16

224847 224848

VGT POSITION SENSOR PIN OUT PIN 1 2 3 Print P1D32S021 E

DESCRIPTION Ground Signal Power supply

ECU PIN 37 53 7

EGR VALVE PIN OUT PIN DESCRIPTION 1 DC motor (+) 2 Signal 4 Ground 5 DC motor (+) 6 Power supply

ECU PIN 50 39 24 35 9 Base - April 2015

18

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Driving shaft and camshaft unit Figure 19

3

4

1 2

162263

1. Increment speed sensor - 2. Phonic wheel on crankshaft - 3. Segment speed sensor - 4. Camshaft pulley

Increment speed sensor (crankshaft)

Figure 20

The crankshaft is fitted with a pulser ring. The sensor detects the teeth as they pass it and sends the control unit the information required to calculate the engine speed. The variation of the signal generated by the lack of some teeth (synchronisation gap) occurring at each crankshaft turn is the reference signal which enables the control unit to detect the lead of the pair of pistons 1-4 with respect to PMS. This signal is also used by the control unit to detect the engine rotation speed, the duration of injection and to control the rev counter.

221433

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

19

Segment speed sensor (camshaft)

Figure 21

A semiconductor layer, immersed in a magnetic field and through which current flows, generates a potential difference (called Hall voltage) at its ends. If current intensity remains constant, the generated voltage depends only on the magnetic field strength: periodical variation of field strength is enough to obtain a modulated electric signal. The smooth portion of the phonic wheel (distributing shaft pulley) covers, while moving, the sensor, thus blocking the magnetic field with resulting low output signal. On the contrary, the sensor generates a high signal next to the openings and when a magnetic field is available. Phase sensor signals are acquired, and the engine position is recognized according to the sequence of the phonic wheel notches. The mounting function makes it possible to identify signal errors and interferences (if any). The resulting signal is supplied to the processor that controls the injection system. 224850

Figure 22

ENGINE SPEED SENSOR PIN OUT PIN 1 2

DESCRIPTION Ground Signal

ECU PIN 44 59

221434

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Base - April 2015

20

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Figure 23

Figure 24

224247

PIN 1 2 3 4

DESCRIPTION Ground NTC signal Power supply Temp. signal

ECU PIN 25 55 10 40

224849

Figure 25

TIMING SENSOR PIN OUT PIN 1 2 3

DESCRIPTION Ground Signal Power supply

ECU PIN 28 14 13

Air temperature and pressure sensor 224838

This component incorporates a temperature sensor and a pressure sensor. It is fitted on the engine intake manifold and measures the maximumflow rate of the intake air which is used to accurately calculate the amount of fuel to be injected at each cycle.

SIGNAL EVALUATION WITH LOAD RESISTOR TO UH = 5.5 TO 16V Figure 26

It is connected to the central unit on connector “A”. Technical data Pressure range Temperature range

20 ÷ 300 kPa -40 ÷ 130˚ C

224839

SIGNAL EVALUATION WITH LOAD RESISTOR TO GROUND Base - April 2015

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

Figure 28

21

Figure 29

150730

OPERATING GRAPH 214595

Engine coolant temperature sensor

WIRING DIAGRAM

This sensor is located on the thermostat box. It detects the temperature of the coolant fluid to give the control unit information about the engine temperature conditions.

Figure 27

Figure 30

214598 224837

PIN 1 2

Print P1D32S021 E

DESCRIPTION Temperature signal Ground

ECU PIN 57 58

Base - April 2015

22

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Exhaust gas temperature sensor Figure 31

102303

Figure 32

102304

FUNCTIONAL WIRING DIAGRAM 1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Ground cable (white) - 6. Sensor. It has the function of sending information to the control unit regarding the temperature of the exhaust gas exiting the EGR heat exchanger. CHARACTERISTICS OF EXHAUST GAS TEMPERATURE SENSOR Power supply Output voltage @ Temperature -40 to 300 ˚C Pull up resistance Lead resistance PIN 1 2

Base - April 2015

DESCRIPTION Temperature signal Ground

VALUE 5.00 V ± 0.1% 1.222 to 2.242 V 1,000  ± 0.1% 1

ECU PIN 42 27

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

23

Oil pressure switch

Air inlet from aftercooler temperature sensor

It is fitted on the water/oil heat exchanger and measures the engine oil pressure.

It is fitted on the intake manifold air inlet pipe. It measures the air temperature coming from the aftercooler.

The signal detected is sent to the engine management control unit by the pin 6. Contact pressure 0.5-0.7 bar

Figure 33

Figure 34

221436

221437

WIRING DIAGRA,M Figure 35 PIN 1

DESCRIPTION Signal

ECU PIN 6

214595

WIRING DIAGRA,M

Print P1D32S021 E

Base - April 2015

24

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Pre/heater glow plug control unit

Figure 36

The engine control unit, in the phase of: - starting; - post-starting. times the operation of the glow plug control unit according to the engine temperature. Glow plugs drive is through glow plugs pre-heating control unit depending on engine temperature under direct control of the engine control unit. The pre-heating ECU contains an “intelligent” contactor that sends feedback to the ECU communicating any faults with the pre-heating ECU or shorting to earth of the glow plugs. Preheat centre pin-out 31 - Mass 86 -

Start switch (+15)

ST -

EDC electronic centre (pin B42)

DI -

EDC electronic centre (pin B37)

30 -

Battery positive (+30)

G1 -

Preheat plugs

G2 -

Preheat plugs

G3 -

Preheat plugs

G4 -

Preheat plugs

003332t

PREHEAT CENTRE Figure 37

Pre/heater glow plugs CONTROL VALUES With constant di 11V power supply: - maximum current absorbed

18 A

- in 5”

11  1,5 A

- in 30”

6  0.9 A

- temperature after 7” - torque

850C 8-10 Nm

221439

ELECTRICAL DIAGRAM Figure 38

75579

PRE/HEAT GLOW PLUG Base - April 2015

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F1C EuV1 - ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

25

Alternator Supplier Technical data Weight Voltage @  0 rpm Voltage @ 1,800 rpm Voltage @  6,000 rpm Direction of rotation

BOSCH 14V-210A MFR OWC 7.5 kg 1,400 A 100 A 210 A clockwise

Figure 39

224829

A. TERMINAL L - B. TERMINAL DFM - C. VDA connector 2 ways type A D. REGULATOR - E. Customer connection Figure 40

224828

CHARACTERISTIC CURVES

REGULATOR CHARACTERISTIC CURVE (8VR-MFR)

Pin DFM

Description Digital Field Monitor

BS

+ 30

15

Power supply +15

L

Failed recharge signal

W

Battery recharge warning light

B1+

Positive 1

B2+

Positive 2

Print P1D32S021 E

CABLING DIAGRAM (MFR)

Base - April 2015

26

SECTION 3 - ELECTRICAL EQUIPMENT

F1C EuV1 - ENGINES

Starter motor Supplier Nominal voltage Power rating Number of poles Gear ratio 5 Direction of rotation

BOSCH 12V R 78 - M55 6 5 Right

Figure 41

227562

1. Collector bearing - 2. Plate - 3. Pole housing - 4. Drive end shield - 5. Relais - 6. Closure caps Figure 42

227563

ELECTRIC DIAGRAM

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 4 - SCHEDULED MAINTENANCE

1

SECTION 4 Scheduled Maintenance Page

Print P1D32S021 E

SCHEDULED MAINTENANCE . . . . . . . . . . . . .

3

- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Extraordinary interventions - daily checks . . . .

3

MAINTENANCE PROCEDURES . . . . . . . . . . . .

5

- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

- Periodic maintenance . . . . . . . . . . . . . . . . . . .

7

- Extraordinary maintenance . . . . . . . . . . . . . . .

11

Base - April 2015

2

SECTION 4 - SCHEDULED MAINTENANCE

Base - April 2015

F1C EuV1 - ENGINES

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F1C EuV1 - ENGINES

SECTION 4 - SCHEDULED MAINTENANCE

3

SCHEDULED MAINTENANCE Introduction To ensure best operating conditions, on the following pages are indicated the checks, tests and adjustments which shall be carried out on the different parts at the established time. The frequency of the maintenance operations are indicative since the engine use and its characteristics are essential in evaluating replacements and checks. Not only it is permitted, but we also suggest that the staff in charge of maintenance should also perform those checking andmaintenance operations which do not fall among those listed below, but are recommended by good-practices and particular conditions of use of the engine. Furthermore, in case of clearmalfunctioning of the engine, for example excessive grade of smoke of exhaust gases, high temperature of the coolant or low oil pressure, prompt measures must be taken to verify the causes of the defect. Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with accident-prevention laws for the safety of the staff in charge of maintenance.

Extraordinary interventions - daily checks Before starting, it is recommended to carry out a series of simple checks that can significantly help avoid problems, also of a series nature, while the engine is operating. These checks are usually performed by the vehicle operators and drivers. - Checking the levels and checking for any leaks from the fuel, cooling and lubrication circuits. - Informing maintenance personnel if any problems are found; top up if necessary. After starting the engine and with the engine operating, perform the following checks and controls: - Checking for any leaks from the fuel, cooling and lubrication circuits. - Making sure there is no unusual noise or knocking during operation. - Using the vehicle instruments to check the specified pressure, temperature values, etc. - Visually checking the smoke (colour of the exhaust gas). - Visually checking the level of the coolant in the expansion tank. NOTE

The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. The maintenance operations are valid only if the Manufacturer fully complies with all the installation prescriptions provided by FPT. Furthermore, the equipment assembled by the Manufacturer shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

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Base - April 2015

4

SECTION 4 - SCHEDULED MAINTENANCE

Checks Engine lubricant oil level check Engine coolant level check Engine visual inspection Air filter & housing cleanness check(**) Electrolyte level in batteries check/top up and terminals cleaning (**) Tension and condition check of auxiliary members’ belt Exhaust duct(s) condition check Periodic maintenance Water drainage from the fuel pre filter(**) Condensed water drainage from fuel tank Engine lubricant oil replacement Lubricant oil filter replacement Fuel pre-filter replacement (**) Fuel filter replacement (*) (**) Power steering oil replacement Air filter cleaning (**) Air filter replacement (**) Auxiliary members belt replacement Heat exchanger (radiator) cleaning (**) Extraordinary maintenance Turbocharger visual inspection Engine coolant replacement Pre-heating glow plug replacement Auxiliary members’ belt tensioning device replacement Timing system chain and tensioning device replacement Particulate filter replacement

F1C EuV1 - ENGINES

Frequency (***) Daily Daily 15 days 1 month 6 months 6 months 6 months Frequency (***) Weekly Weekly 24,000 km / 600 hours / 1 year(3) 24,000 km / 600 hours / 1 year(3)(4) 24,000 km / 600 hours / 1 year(1) 24,000 km / 600 hours / 1 year(1)(4) 24,000 km / 600 hours / 1 year 1 year 3 years(2) 96,000 km / 2,400 hours / 4 years(5) 96,000 km / 2,400 hours / 4 years Frequency (***) 2 years 2 years 160,000 km / 4,000 hours / 5 years 160,000 km / 4,000 hours / 5 years 240,000 km / 6,000 hours / 5 years 120,000 km / 3,000 hours / 5 years

(1) Maximum period for using good quality fuel (EN 590 standard). It is reduced based on the dependency on fuel contamination and on the alarm signals for pre-filter/filter clogging and/or water in the filter. The filter clogging warning requires its replacement. If the water alarm is not disabled after draining, the filter needs to be replaced. (2) Early filter cloggingis usually due to enviromental conditions. For this reason, the filter should be changed if clogging is signalled by the related sensor, regardless of the prescriptions, that shall be observed if no specific indications have been provided. (3) Frequency applicable to lubricants which meet the international standards 5W-30/0W-30; ACEA C2; recommended oil is URANIA DAILY FE - URANIA DAILY LS. (4) Use only filters with the following features: - filtering degree < 12 m, - filtering efficiency ß > 200. (5) Replace every 60.000 km under harsh conditions of use (dust and/or heat). (*) If the “clogged filter” warning lamp lights up on the instrument panel, the filter must be replaced before the programmed replacement interval. (**) Frequencies valid only if the components are supplied by FPT. (***) Action needed @ km/hour/temporal (whichever occurs first).

!

Checks, inspections and changes are indicative and must integrate specifications for vehicles equippedwith the F1C EuVI engine. The data are only valid if the fitter observes all the installation regulations provided by FPT.

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 4 - SCHEDULED MAINTENANCE

5

MAINTENANCE PROCEDURES

Engine coolant level check

Checks

Proceed only with engine not running and at low temperature to avoid any risk of burns.

Engine lubricant oil level check

With the engine at low temperature, make sure that the fluid level in the expansion tank is above the minimum level.

Figure 1

Visually check that the fluid level is not more than 2/3 of the height of the tank in order to enable any increase in volume of the fluid caused by the temperature increase. Top up the tank if necessary, using a 50% mixture of water and Paraflu HT even during the summer months. As an alternative to Paraflu HT use another product which complies with ASTM D-6210 international standard. NOTE

229366

In the event that only the heat exchanger without the expansion tank is available on the vehicle, refill it if necessary, paying attention that the fluid does not saturate the internal volume of the exchanger in order to enable any increase in volume of the fluid caused by the temperature increase.

The check must be performed when the engine is stopped and possibly cold. The check is carried out with the flexible dipstick (2). Remove the dipstick (2) from its housing and check that the level is between the minimum and maximum ends etched on it. If the reading is unclear, clean the dipstick (2) with a cloth with no looses threads and put it back in its seat. Take it off again and check the level. If the level is insufficient, it is necessary to top up with lubricant oil which meets the international standards 5W-30/0W-30; ACEA C2; recommended oil is URANIA DAILY FE - URANIA DAILY LS. Remove the lubricant oil cap (1) and pour engine lubricant oil through the hole. Always make sure to add oil with the same characteristics as the one contained in the sump. Mixtures which do not ensure the proper lubrication of the internal parts of the engine are not permitted.

!

The engine oil is highly pollutant and toxic. In case of contact with skin, wash thoroughly with water and detergent. Suitably protect skin and eyes; proceed in accordance with accident prevention standards. Suitably dispose of the residuals and in accordance with regulations.

Print P1D32S021 E

!

When the engine is warm, a pressure liable to cause hot liquid to be expelled with extreme violence is created within the cooling circuits. This results in a danger of burning.

Engine visual inspection Before starting, it is recommended to carry out a series of simple checks that can significantly help avoid problems, also of a series nature, while the engine is operating. These checks are usually performed by the vehicle operators and drivers. Check the levels and check for any leaks from the fuel, cooling and lubrication circuits. Inform maintenance personnel if any problems are found; top up if necessary. After starting the engine and with the engine operating, perform the following checks and controls: Check for any leaks from the fuel, cooling and lubrication circuits. Make sure there is no unusual noise or beating during operation. Use the vehicle instruments to check the foreseen pressure, temperature values, etc. Visually check the smoke (colour of the exhaust gas). Visually check the level of the coolant in the expansion tank.

Base - April 2015

6

SECTION 4 - SCHEDULED MAINTENANCE

F1C EuV1 - ENGINES

Air filter & housing cleanness check (supplied on demand)

Electrolyte level in batteries check/top up and terminals cleaning (supplied on demand).

Only proceed with the engine stopped.

Place the batteries on a level surface, then proceed as follows. Visually check that the fluid level is between the “Min” and “Max” limits; in the absence of references, check that the fluid covers the Lead plates inside the elements.

Figure 2

Top up with distilled water only those elements in which the level is below the minimum. Contact specialised technical staff if the battery needs recharging. On this occasion, make sure that the terminals and clamps are clean, properly locked and protected by vaseline.

! 229365

If all the elements of the battery need refilling with a considerable quantity of distilled water, contact specialised technical personnel in order to perform a diagnostic check on the efficiency state of the recharge system and battery.

Remove the cover (1) of the filter housing and extract the cartridge paying attention that the dust does not get into the sleeve. Blow the filtering element by means of dry and compressed air, acting from the inside outwards (max. pressure: 200 kPa). Avoid using detergents; do not use diesel oil. Never hit the filtering element by means of tools, and check its condition before reinstalling it. In the event that breakages or tears take place, or it is not possible to remove the impurities, replace it.

!

The batteries contain sulphuric acid, which is extremely caustic and corrosive; always wear protective gloves and goggles when topping them up. Whenever possible it is recommended that this control be carried out by specialised personnel. Do not smoke or use live flames near the batteries during the control, and make sure that the room you are working in is adequately ventilated.

Check that the gasket base is in good condition. Reassembly the filtering element and close the housing.

!

Figure 3

Take care to ensure that the parts are reassembled correctly. Imperfect assembly might result in unfiltered air being sucked into the engine, causing serious damage.

225112

Some types of battery have a single cover for all the inspection plugs to access the elements, use a lever as shown in the figure.

Base - April 2015

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F1C EuV1 - ENGINES

7

SECTION 4 - SCHEDULED MAINTENANCE

Tension and conditions check of auxiliary member belt’s Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning. Figure 4

Periodic maintenance Water drainage from the fuel pre-filter (supplied on demand) Depending on its use, some vehicles adopt a fuel pre-filter as well. The high risk of refuelling with fuel that is polluted by foreign bodies and water makes it advisable to carry out this control every time you refuel. Proceed with the engine stopped. Figure 5

229364

Check that the belt (1) is not torn or worn, and that there are no lubricants or fuel on it. If this is not the case, replace them. At the same time, make sure that the tensioning device is working properly. 229363

Exhaust duct(s) condition check Visually check that the exhaust gas system is not blocked, corroded or damaged. In the event of any problems, perform the operations necessary to restore the exhaust duct.

Place a container under pre-filter to collect the fluid. Unscrew the tap plug (1) in the bottom part of the filter; in some lay-outs the plug includes a sensor to detect the presence of water in the diesel. Drain off liquid until only “diesel” can be seen. Close the plug again, tightening it completely by hand. Dispose of the drained fluids according to current requirements.

Condensed water drainage from fuel tank Perform the drainage/suction of water, condensation and impurities from the fuel tank/s by following the instructions contained in the manual supplied by the tank manufacturer. Proceed as necessary based on the structure or location of the tank: engines that operate in adverse environments and conditions and/or that are refuelled using drums or jerry cans, require more attention when cleaning the tank.

Engine lubricant oil replacement The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force. Place a suitable container to collect the oil as it drains out. Print P1D32S021 E

Base - April 2015

8

SECTION 4 - SCHEDULED MAINTENANCE

F1C EuV1 - ENGINES

Figure 6

Only use filters with a filtration level equivalent to the ones you are replacing (see the table at the beginning of section 4). Place a container under the filter support, to collect the used oil. Figure 8

229361

Pull out the oil dipstick (1). Figure 7

227800

Unscrew the filter (1) and remove it. Ref. (1)

No. 1

Description M22x1.5

Carefully clean the surfaces of the support that are in contact with the seal. Moisten the new filter seal with a thin layer of oil. 229362

Unscrew the filler cap (2) at the top of the engine.

Manually tighten the new filter (1) on the support until it comes into contact with the seal. Additionally tighten it using a specific tool to the torque indicated in the table.

Unscrew the drain plug (1) and drain the oil into a container Ref. (1)

No. 1

Description M22x1.5x10

Wait until the oil sump has completely emptied, then retighten the lubricant oil drain plug (1) under the sump at the torque indicated in the table. Ref.

No.

Description

(1)

1

M22x1.5x10

Ref.

No.

(1)

1

Description M22x1.5

Tightening torques 25 ± 2,5 Nm

Operate the engine for a few minutes and then check the level using the dipstick. If necessary, top up to compensate for the quantity of oil used to fill up the filtering cartridge.

Tightening torques 50 ± 5 Nm

Proceed with the refilling operation: Add the specified quantity of lubricant oil that meets the international standards 5W-30/0W-30; ACEA C2; recommended oil is URANIA DAILY FE - URANIA DAILY LS.

Lubricant oil filter replacement Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 4 - SCHEDULED MAINTENANCE

9

Fuel pre-filter replacement (supplied on demand)

Fuel filter replacement (supplied on demand)

Only proceed with the engine stopped.

Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.

Figure 9

Only use filters with a filtration level equivalent to the ones you are replacing (see the table at the beginning of section 4). Disconnect the electrical connection and the fuel pipes. Loosen the screws and remove the support including the filter. Remove the connector from the filter housing. Remove the filter housing from the support and remove the filtering element. Moisten the new filter seal with diesel or engine oil. Hand screw the new filter into place until the seal gasket touches the support, then lock by a further 3/4 of a turn. 229360

Remove the prefilter by unscrewing it.

Insert the connector into its seat and refit the fuel filter in the engine compartment, reversing the operation described previously.

Check that the new filter has performance levels that satisfy the needs of the engine (e.g. by comparing them with the old one).

Do not fill up the new filter before it is fitted to the support, to avoid inserting harmful impurities into the injection system and circuit.

Moisten the new filter seal with diesel or engine oil. Hand screw the new filter into place until the seal gasket touches the support, then lock by a further 3/4 of a turn. Place the water presence sensor in its seat, taking care to couple the threads correctly.

In the event that fuel pipings have to be disconnected, clean with the utmost care the fittings before connecting them again. Make sure that the seal is appropriate by starting the engine. If leakages occur take adequate countermeasures against this immediately.

Loosen the bleeder screw (2) on the pre-filter support and activate the hand pump (1) until the supply circuit is full. Ensure that any fuel coming out is not dispersed into the environment. Lock the bleeder screw tightly. Start the engine and run it at idle for a few minutes to eliminate any residual air. NOTE

!

Never loosen the high pressure common rail injection circuit fitting in any way. Do not carry out un necessary and dangerous bleeding attempt.

!

Do not smoke or use open flames during this operation. Do not inhale the vapours that exit the filter.

Should it be necessary to accelerate the bleeding phase, the hand pump can be used during start-up.

Print P1D32S021 E

Base - April 2015

10

SECTION 4 - SCHEDULED MAINTENANCE

F1C EuV1 - ENGINES

Power steering oil replacement

Heat exchanger (radiator) cleaning (supplied on demand)

Only proceed with the engine stopped. Open the cap of the storage tank and proceed depending on the necessity related to the vehicle building.

Figure 11

Air filter cleaning (supplied on demand) Refer to the instructions provided for Air filter & housing cleaness check.

Air filter replacement (supplied on demand) Refer to the instructions provided for Air filter & housing cleaness check.

Auxiliary members’ belt replacement Figure 10 229359

Check that the air intake surfaces of the radiators are free of impurities (dust, mud, straw etc.). Clean them if necessary using compressed air or steam. When using compressed air, it is required to use suitable personal protections for hands, face and eyes.

229364

Using a suitable tool remove the A/C compressor belt (2). Using the specific wrench on the automatic belt tensioner (3), reduce the tension of the belt (1) and remove it from alternator, water pump, crankshaft pulley, compressor and fixed guide roller. Using a specific wrench on the automatic belt tensioner (3), fit the belt (1) on the pulleys and fixed guide roller, making sure that the ribs on the belt fit properly into the grooves on the pulley. Additional adjustments are not required. The belt (1) tension is adjusted automatically by the calibrated spring in the automatic belt tensioner (3). Using a suitable tool fit the A/C compressor belt (2). Operate the engine for a few hours and check that the auxiliary members’ belt (1) is properly fitted.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

11

SECTION 4 - SCHEDULED MAINTENANCE

Extraordinary maintenance

Pre-heating glow plug replacement

Turbocharger visual inspection

To perform this operation correctly, proceed as described in section 5 “PRE/HEATER GLOW PLUGS REMOVAL/REFITTING” chapter.

Only proceed when the engine is not turning over. Visually check that the turbine and compressor impellers and the relative inlet and outlet ducts are not obstructed or damaged, otherwise replace them.

Engine coolant replacement.

Auxiliary members’ replacement

belt

tensioning

device

Figure 12

Only proceed when the engine is not turning and is at low temperature in order not to run the risk of burns. In the event that a mixture of PARAFLU HT and water is used, the density value is equal to 1.0675 g/cm3 (at a temperature of 15˚C ). For replacing the coolant, observe the following procedure: Use suitable containers to ensure that the coolant is not dispersed in the environment. Loosen the retaining elements and remove the sleeves that couple the engine circuit with the heat exchanger and wait for them to empty completely. Once emptied, restore the condition of the circuit, ensuring the perfect seal of the sleeves. Refill the circuit according to the requirements specified: Use a 50% mixture of water and Paraflu HT even during the summer months. As an alternative to PARAFLU HT use another product which complies with ASTM D-6210 international standard. Refill the engine and the exchanger until the exchanger is completely filled.

227797

Using a suitable tool remove the air compressor belt (2). Using the specific wrench on the automatic belt tensioner (4), reduce the tension of the belt (1) and remove it. Undo the screw (3) and remove the automatic belt tensioner (4).

With the filler plug open, start the engine and idle it for approx. 1 minute. This phase helps to completely bleed the air contained in the cooling circuit.

Ref. (3)

Stop the engine and then top up the incomplete quantity.

Fit the automatic belt tensioner (4) and tighten the screw (3) to the torque indicated in the table.

When the engine is cold, make sure that the coolant level is a few centimetres below the filling hole. In the event of an externally located level indicator as regards the heat exchangers, proceed with the top up operation by making sure that the coolant does not overfill the internal volume of the exchanger in order to allow the expansion of coolant volume during increases in temperature.

No. 1

Description M10x1.5x45

Ref.

No.

Description

(3)

1

M10x1.5x45

Tightening torques 45 ± 5 Nm

Using a specific wrench on the automatic belt tensioner (4), fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley. Using a suitable tool fit the air compressor belt (2).

The failure to observe the aforesaid procedure does not guarantee the presence of the correct quantity of coolant in the engine.

Timing system replacement

chain

and

tensioning

device

To perform this operation correctly, proceed as described in section 5 “CYLINDER HEAD REMOVAL/REFITTING“ chapter.

!

When the engine is hot, pressure builds up in the cooling circuits which may eject hot liquid violently, resulting in a risk of burns. Open the filler cap of the coolant tank only if necessary and only when the engine is cold.

Print P1D32S021 E

Base - April 2015

12

SECTION 4 - SCHEDULED MAINTENANCE

F1C EuV1 - ENGINES

Particulate filter replacement The particulate filter is designed to filter particulate particles that are deposited between the ceramic structure pores. When necessary (time intervals or loss in pressure along the filter), the filter is cleaned bringing the temperature of the exhaust gases to 630ºC; to do this, an exothermic reaction must be created in the catalytic converter by injecting a small quantity of fuel after the top dead centre with a delay that allows vaporization in the combustion chamber without burning. When the vaporised fuel reaches the catalytic converter, if the temperature is at least 230˚C, the catalysts allows the start of the combustion bringing the DPF to a temperature of 630˚C. The control unit, acting at the time of the post-injection and on the quantity of oxygen (closure of the throttle valve), maintains the optimum regeneration temperature. During the regeneration stage, the E.G.R. is closed to prevent the intake of the vapours produced into the cylinder. The filter regeneration is not possible when it presents signs of damaging: in this case proceed to the particulate filter replacement. The filter regeneration requires that all the parameter counters are reset, as: the quantity of particulate/ashes accumulated in the new filter is zero; in the case of simultaneous replacement of the particulate filter and the engine oil is necessary to reset the amount of post-injected fuel. All the regeneration parameters must be reset because, to all intents and purposes, this is a new life cycle. If you do not zero: the ash counter, the frequency of the regenerations will be greater than required with an unnecessary increase in consumption, the thermal fatigue of the particulate filter and, in extreme cases, an unfounded request to change the engine oil; the Oxicat ageing function with a risk of unjustified post-injection quantities; the post-injection fuel counter, may make an early request to change the engine oil.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

1

SECTION 5 Removal/Refitting of the main engine components Page

Print P1D32S021 E

ENGINEWIRING REMOVAL/REFITTING ............

5

- Removal ................................................................................

5

- Refitting ..................................................................................

6

LOW PRESSURE FUEL PIPE GROUP AND FUEL RECOVERY PIPE REMOVAL/REFITTING

7

- Removal ................................................................................

7

- Refitting ..................................................................................

8

HIGH PRESSURE FUEL PIPE FROM PUMP TO RAIL REMOVAL/REFITTING ..................................

10

- Removal ................................................................................

10

- Refitting ..................................................................................

11

ELECTRO-INJECTORS REMOVAL/REFITTING .

12

- Removal ................................................................................

12

- Refitting ..................................................................................

13

FUEL MANIFOLD PIPE REMOVAL/REFITTING ..............................................

15

- Removal ................................................................................

15

- Refitting ..................................................................................

16

OIL FILTER REMOVAL/REFITTING ..........................

18

- Removal ................................................................................

18

- Refitting ..................................................................................

18

WATER/OIL HEAT EXCHANGER REMOVAL/REFITTING ..............................................

19

- Removal ................................................................................

19

- Refitting ..................................................................................

20

HIGH PRESSURE PUMP REMOVAL/REFITTING

21

- Removal ................................................................................

21

- Refitting ..................................................................................

23

Base - April 2015

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SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

Page

Page

ELECTRIC EXHAUST GAS FLAP REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

26

AUXILIARY DRIVE BELT AND AUTOMATIC BELT TENSIONER REMOVAL/REFITTING . . . . . . .

49

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

TURBOCHARGER OIL DELIVERY PIPE GASKET REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

27

CRANKSHAFT FRONT SEAL RING REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

50

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

TURBOCHARGER/EXHAUST MANIFOLD GROUP REMOVAL/REFITTING . . . . . . . . . . .

28

TIMING SYSTEM LOWER COVER REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

52

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

- Checking and adjusting the actuator . . . . . . . .

31

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

DEPRESSOR/OIL PUMP REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

56

EGR GROUP REMOVAL/REFITTING . . . . . . . . .

34 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 WATER PUMP REMOVAL/REFITTING . . . . . . . .

61

PRE HEATING GLOW PLUGS REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

37

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

CRANKSHAFT REAR SEAL RING REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

62

THERMOSTAT REMOVAL/REFITTING . . . . . . .

41 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

INTAKE MANIFOLD REMOVAL/REFITTING . . .

42

SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

63

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

BLOW-BY REMOVAL/REFITTING . . . . . . . . . . .

48

ALTERNATOR REMOVAL/REFITTING . . . . . . .

65

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

3

Page POWER STEERING PUMP REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

67

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67

CYLINDER HEAD REMOVAL/REFITTING . . . . .

69

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73

OIL SUMP REMOVAL/REFITTING . . . . . . . . . . .

80

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

Print P1D32S021 E

Base - April 2015

4

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Base - April 2015

F1C EuV1 - ENGINES

Print P1D32S021 E

F1C EuV1 - ENGINES

5

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

ENGINE WIRING REMOVAL/REFITTING Removal Disengage the engine wiring cover from the cylinder overhead, disengage the pins from the relative brackets and remove the engine wiring. Disconnect the following electrical connections Figure 13

227787

REAR VIEW OF ENGINE, INTAKE SIDE 1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor - 4. Engine brake actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch - 7. Fuel flow regulator on high pressure pump - 8. Air charger intercooler outlet temperature sensor - 9. Coolant temperature sensor -10. Air pressure and temperature sensor 11. Pressure regulating valve on rail - 12. Segment speed sensor

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Base - April 2015

6

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

Figure 14

227788

FRONT VIEW OF ENGINE, EXHAUST SIDE 1. Air charger intercooler outlet temperature sensor - 2. Coolant temperature sensor - 3. Segment speed sensor 4. EGR valve - 5. Increment speed sensor - 6. VGT position sensor - 7. Engine brake actuator

Refitting Fit the engine wiring, engage the pins in the relative brackets and engage the engine wiring cover in its housing on the cylinder overhead. Connect the following electrical connections: - FRONT VIEW OF ENGINE, EXHAUST SIDE 1. Air charger intercooler outlet temperature sensor - 2. Coolant temperature sensor - 3. Segment speed sensor 4. EGR valve - 5. Increment speed sensor - 6. VGT position sensor - 7. Engine brake actuator - REAR VIEW OF ENGINE, INTAKE SIDE 1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor - 4. Engine brake actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch - 7. Fuel flow regulator on high pressure pump - 8. Air charger intercooler outlet temperature sensor - 9. Coolant temperature sensor -10. Air pressure and temperature sensor 11. Pressure regulating valve on rail - 12. Segment speed sensor

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

LOW PRESSURE FUEL PIPE GROUP AND FUEL RECOVERY PIPE REMOVAL/REFITTING

7

Figure 17

Removal Place a suitable container, to collect any fuel which may leak out. In order to facilitate the operations, remove the engine wiring as described in the relative procedure. Figure 15

229303

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. Ref. (2)

No. 1

Description M8x1.25

Figure 18 229299

Lift the retaining clips (1) in the direction shown by the arrow and disconnect the fuel recovery pipe (2) from the electro-injectors. Open the retaining clip (3). Figure 16

229310

Using tool 99360076 remove the oil filter (1) from the water/oil heat exchanger (2). Ref. (1)

No. 1

Description M22x1.5

229300

Loosen the clamp and disconnect the fuel return pipe (1) from the fuel manifold pipe (2).

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Base - April 2015

8

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

Refitting

Figure 19

Figure 21

229311

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase.

227802

Adjust the quick connector (2) and disconnect the fuel return pipe from the high pressure pump.

Fit the low pressure pipes group together with the fuel recovery pipe from electro-injectors and engage the group in the intermediate retaining clips.

Loosen the clamp (1) and disconnect the fuel supply pipe from the high pressure pump.

Fit the bracket fixing the low pressure pipes duplex anchorage and tighten the screws (2) to the torque indicated in the table. Fit the bracket fixing the low pressure pipes group to the intake manifold and tighten the screw (1) to the torque indicated in the table.

Figure 20

Ref.

No.

(1) (2)

1 2

Description M6x1 M6x1X10

Tightening torques 25 ± 2.5 10 ± 1

Figure 22

227802

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase. Undo the bracket screw (1), fixing the low pressure pipes group to the intake manifold. Undo the screws (2) fixing the duplex pipe anchorage bracket, and remove the low pressure pipes group together with the fuel recovery pipe. 229311

Ref. (1) (2)

No. 1 2

Description M6x1 M6x1x10

Connect the fuel supply pipe to the high pressure pump and close the clamp (1). Connect the fuel return pipe to the high pressure pump and engage the quick connector (2). Tie the intermediate retaining clip securing the low pressure pipes group to the cranckcase.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 23

9

Figure 25

229310

229300

Place the oil filter (1) on the water/oil heat exchanger (2) and tighten to the torque indicated in the table.

Connect the fuel return pipe (1) to the fuel manifold pipe (2) and close the relative clamp.

Ref.

No.

(1)

1

Description M22x1.5

Tightening torques 25 ± 2.5

Figure 26

Figure 24

229302

Fit and connect the fuel recovery pipe (2) to the elctro-injectors and close the retaining clips (1) in the way shown by the arrow. 229303

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table. Ref.

No.

(2)

1

Print P1D32S021 E

Description M8x1.25

Close the intermediate retaining clip (3). Fit the engine wiring as described in the relative procedure.

Tightening torques 25 ± 2.5

Base - April 2015

10

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

HIGH PRESSURE FUEL PIPE FROM PUMP TO RAIL REMOVAL/REFITTING

F1C EuV1 - ENGINES

Figure 29

Removal Place a suitable container, to collect any fuel which may leak out. In order to facilitate the operations, remove the engine wiring as described in the relative procedure. Figure 27

229304

Undo the fitting (2) and disconnect the high pressure fuel pipe from the high pressure pump. Undo the bracket nut (1) and remove the high pressure fuel pipe.

229303

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. Ref. (2)

No. 1

Description M8x1.25

Ref. (1) (2)

No. 1 1

Description M8x1.25 M16x1

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Figure 28

218891

Undo the fitting (1) and disconnect the high pressure fuel pipe from the fuel manifold pipe. Ref. (1)

No. 1

Base - April 2015

Description M15x1

Print P1D32S021 E

F1C EuV1 - ENGINES

11

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

Figure 31

Figure 30

α α

218891

229304

Fit the new high pressure fuel pipe and tighten the bracket nut (1) to the torque indicated in the table. Connect the high pressure fuel pipe to the high pressure pump and tighten the fitting (2) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

(1)

1

(2)

1

Description M8x1.25 M16x1 1st phase 2nd phase

Connect the high pressure fuel pipe to the fuel manifold pipe and tighten the fitting (1) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

(1)

1

Description

Tightening torques

M15x1

Tightening torques 25±2.5

1st phase 2nd phase

24±2 90˚

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - re-use the disassembled pipelines.

25±2 90˚

Figure 32

229303

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table. Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25±2.5

Fit the engine wiring as described in the relative procedure. Print P1D32S021 E

Base - April 2015

12

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

ELECTRO-INJECTORS REMOVAL/REFITTING

F1C EuV1 - ENGINES

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Removal Place a suitable container, to collect any fuel which may leak out. Disconnect the electro-injectors electrical connections. In order to facilitate the operations, remove the engine wiring as described in the relative procedure.

Figure 35

Figure 33

229306

229299

Lift the retaining clips (1) in the direction shown by the arrow and disconnect the fuel recovery pipe (2) from the electro-injectors. Open the retaining clip (3).

Undo the screws (1) and remove the brackets (2) securing the electro-injectors (3) to the cylinder overhead. Ref. (1)

No. 4

Description M8x1.25x80

Using tool 99342153 to extract the electro-injectors from the cylinder overhead.

Figure 34

NOTE

This procedure has to be done to avoid damage of the electro-injectors s electrical connector.

Figure 36

229305

Using tool 99317915 (rail side) and tool 99352115 (electroinjectors side), undo the fittings on the fuel manifold pipe (1), and on the electro-injectors (2), then remove the high pressure fuel pipes. Ref. (1) (2)

No. 4 4

Description M15x1 M14x1.5

227791

Remove the bracket (1). Using an hammer and Ø3,5 max punch, remove the pins (2). When the bracket (1) is reassembled, rotate it about 3˚ ÷ 4˚ in this direction from the original position.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

13

Refitting

Figure 37

NOTE

Thoroughly clean the seat of the electro injectors, taking care that no foreign bodies enter the cylinder liners.

Figure 38

88244

Apply tool 99342153 (1), using the screw holes of securing electro-injector’s brackets and extract the electroinjectors (2) from the cylinder overhead (3). NOTE

After removal, mark the injector with the cylinder number of belonging, for a proper calibration of the codes IMA; or in case of replacement, we want to make laboratory analysis. Also make sure that the seal is not left in the injector seat engine head.

217915

Fit a new seal (3) on the electro-injectors (1) and mount them in the overhead (2) in the same position as they has been removed. Figure 39

229306

Fit the brackets (2), securing the electro-injectors (3) to the overhead and screw down the screws (1) without tightening them completely.

Print P1D32S021 E

Base - April 2015

14

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 40

F1C EuV1 - ENGINES

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working; Figure 42

229307

Connect the new high pressure fuel pipes to the fuel manifold pipe (1) and to the electro injectors (2), then tighten the electro-injectors bracket screws (3) to the torque indicated in the table. Ref.

No.

Description

(3)

4

M8x1.25x80

Tightening torques 29±1.45

Figure 41

229302

Fit and connect the fuel recovery pipe (2) to the elctro-injectors and close the retaining clips (1) in the way shown by the arrow. Close the intermediate retaining clip (3). Connect the electroinjectors electrical connections. Fit the engine wiring as described in the relative procedure.

α

229305

Using the 99317915 (rail side) and 99352115 (electro-injectors side) wrenches, the torque wrenches 99389829 (rail side) and 99389831 (electro-injectors side), tighten the high pressure fuel pipe fittings (1) and (2) to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

(1)

4

(2)

4

Description

Tightening torques

M15x1

Base - April 2015

1st phase 2nd phase M14x1.5 1st phase 2nd phase

24±2 90˚ 25±2 50˚

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

FUEL MANIFOLD PIPE REMOVAL/REFITTING

15

Figure 45

Removal Place a suitable container, to collect any fuel which may leak out. Disconnect the rail pressur sensor and the pressure regulating valve electrical connections from the fuel manifold pipe. In order to facilitate the operations, remove the engine wiring as described in the relative procedure. Figure 43

229305

Using tool 99317915 (rail side) and tool 99352115 (electroinjectors side), undo the fittings on the fuel manifold pipe (1), and on the electro-injectors (2), then remove the high pressure fuel pipes. Ref. (1) (2) 229299

No. Description 4 M15x1 4 M14x1.5

Figure 46

Lift the retaining clips (1) in the direction shown by the arrow and disconnect the fuel recovery pipe (2) from the electro-injectors. Open the retaining clip (3). Figure 44

229303

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. 229300

Loosen the clamp and disconnect the fuel return pipe (1) from the fuel manifold pipe (2).

Print P1D32S021 E

Ref. (2)

No. 1

Description M8x1.25

Base - April 2015

16

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 47

F1C EuV1 - ENGINES

Figure 49

217924

Undo the fitting (1) and disconnect the high pressure fuel pipe from the fuel manifold pipe. Ref. (1)

229308

Undo the screws (1) and remove the fuel manifold pipe (2). Ref. (1)

No. Description 1 M15x1

No. Description 2 M8x1.25

Refitting

Figure 48

Figure 50

229304

Undo the fitting (2) and disconnect the high pressure fuel pipe from the high pressure pump. Undo the bracket nut (1) and remove the high pressure fuel pipe. Ref. (1) (2)

No. Description 1 M8x1.25 1 M16x1

229308

Fit the fuel manifold pipe (2) in its housing on the overhead and tighten the screws (1) to the torque indicated in the table. Ref.

No.

(1)

2

Description M8x1.25

Tightening torques 29±1.45

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

17

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 51

Figure 53

α

229304

229303

Fit the new high pressure fuel pipe and tighten the bracket nut (1) to the torque indicated in the table.

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table.

Connect the high pressure fuel pipe to the high pressure pump and tighten the fitting (2) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

(1)

1

(2)

1

Description M8x1.25 M16x1 1st phase 2nd phase

Tightening torques 25±2.5

Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25 ± 2.5

Figure 54

25±2 90˚ α

Figure 52

229305

Using the 99317915 (rail side) and 99352115 (electro-injectors side) wrenches, the torque wrenches 99389829 (rail side) and 99389831 (electro-injectors side), tighten the high pressure fuel pipe fittings (1) and (2) to the torque indicated in the table.

α

Use tool 99395216 for angle tightening. 217924

Connect the high pressure fuel pipe to the fuel manifold pipe and tighten the fitting (1) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

Description

Tightening torques

M15x1 (1)

1

Print P1D32S021 E

1st phase 2nd phase

Ref.

No.

(1)

4

(2)

4

Description

Tightening torques

M15x1 1st phase 2nd phase M14x1.5 1st phase 2nd phase

24±2 90˚ 25±2 50˚

24±2 90˚ Base - April 2015

18

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

OIL FILTER REMOVAL/REFITTING Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - re-use the disassembled pipelines.

Removal Place a suitable container, to collect any fuel which may leak out. Figure 57

Figure 55

229309 229300

Connect the fuel return pipe (1) to the fuel manifold pipe (2) and close the relative clamp.

Using tool 99360076 remove the oil filter (1) from the water/oil heat exchanger (2). Ref. (1)

Figure 56

No. Description 1 M22x1.5

Refitting Figure 58

229302

Fit and connect the fuel recovery pipe (2) to the elctro-injectors and close the retaining clips (1) in the way shown by the arrow. Close the intermediate retaining clip (3). Connect the rail pressure sensor and the pressure regulating valve electrical connections on the fuel manifold pipe. Fit the engine wiring as described in the relative procedure.

Base - April 2015

229309

Place the oil filter (1) on the water/oil heat exchanger (2) and tighten to the torque indicated in the table. Ref.

No.

(1)

1

Description M22x1.5

Tightening torques 25±2.5

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

WATER/OIL HEAT EXCHANGER REMOVAL/REFITTING

19

Figure 61

Removal Place a suitable container, to collect any engine oil which may leak out. Disconnect the oil pressure sensor electrical connection from the water/oil heat exchanger. In order to facilitate the operations, remove the engine wiring as described in the relative procedure. Figure 59

229311

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase. Adjust the quick connector (1) and disconnect the fuel return pipe from the high pressure pump. Loosen the clamp (2) and disconnect the fuel supply pipe from the high pressure pump. Figure 62 229303

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. Ref. (2)

No. Description 1 M8x1.25

Figure 60

227802

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase. Undo the bracket screw (1), fixing the low pressure pipes group to the intake manifold. Undo the screws (2) fixing the duplex pipe anchorage bracket, and move aside the low pressure pipes group together with the fuel recovery pipe from electro-injectors.

229310

Using tool 99360076 remove the oil filter (1) from the water/oil heat exchanger (2). Ref. (1)

Ref. (1) (2)

No. Description 1 M6x1 2 M6x1x10

No. Description 1 M22x1.5

Print P1D32S021 E

Base - April 2015

20

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 63

F1C EuV1 - ENGINES

Figure 65

229312

227802

Undo the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder.

Fit the low pressure pipes group together with the fuel recovery pipe from electro-injectors and engage the group in the intermediate retaining clips.

Undo the screws (1) and remove the water/oil heat exchanger (2) with the relative gasket and the engine cooling water pipe. Ref. (1) (3)

Fit the bracket fixing the low pressure pipes duplex anchorage and tighten the screws (2) to the torque indicated in the table. Fit the bracket fixing the low pressure pipes group to the intake manifold and tighten the screw (1) to the torque indicated in the table.

No. Description 8 M8x1.25x30 1 M8x1.25

Refitting Figure 64

Ref.

No.

(1) (2)

1 2

Description M6x1 M6x1X10

Tightening torques 25 ± 2.5 10 ± 1

Figure 66

229312

Fit the water/oil heat exchanger (2), with a new gasket and tighten the screws (1) to the torque indicated in the table. Tighten the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder to the torque indicated in the table. Ref.

No.

Description

(1) (3)

8 1

M8x1.25x30 M8x1.25

Base - April 2015

Tightening torques 25±2.5 25±2.5

229311

Connect the fuel supply pipe to the high pressure pump and close the clamp (1). Connect the fuel return pipe to the high pressure pump and engage the quick connector (2). Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25 ± 2.5

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

21

HIGH PRESSURE PUMP REMOVAL/REFITTING

Figure 67

Removal Place a suitable container, to collect any engine oil and fuel which may leak out. Disconnect the fuel flow regulator from the high pressure pump In order to facilitate the operations, remove the engine wiring as described in the relative procedure. Figure 69

229310

Place the oil filter (1) on the water/oil heat exchanger (2) and tighten to the torque indicated in the table. Ref.

No.

(1)

1

Description M22x1.5

Tightening torques 25±2.5

Figure 68 229303

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. Ref. (2)

No. Description 1 M8x1.25

Figure 70

229303

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table. Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25 ± 2.5

Connect the oil pressure sensor electrical connection on the water/oil heat exchanger. Fit the engine wiring as described in the relative procedure.

218891

Undo the fitting (1) and disconnect the fuel high pressure pipe from the fuel manifold pipe Ref. (1)

Print P1D32S021 E

No. Description 1 M15x1

Base - April 2015

22

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 71

F1C EuV1 - ENGINES

Figure 73

229304

227801

Undo the fitting (2) and disconnect the high pressure fuel pipe from the high pressure pump.

Loosen clamp (1), disconnect the quick- connector (2) to remove both the low pressure pipes from the high pressure pump and take them out from the clips.

Undo the bracket nut (1) and remove the high pressure fuel pipe. Ref. (1) (2)

Figure 74

No. Description 1 M8x1.25 1 M16x1

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Figure 72 227803

Undo the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder. Undo the screws (1) and remove the water/oil heat exchanger (2) with the relative gasket and the engine cooling water pipe. Ref. (1) (3)

No. Description 8 M8x1.25x30 1 M8x1.25

Unscrew and remove the screw (5), unscrew and remove screws (1) with their washers (3). 227800

Using tool 99360076 remove the oil filter (1) from the water/oil heat exchanger. Ref. (1)

No. Description 1 M22x1.5

Base - April 2015

Remove the high pressure pump (2) from its support (4). Ref. (1) (5)

No. Description 2 M8x1.25x90 1 M6x1x20

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

23

Refitting

Figure 75

If a new high pressure pump is fitted, it is delivered by Bosch in its stable position (BDC) with flange fitted. If the high pressure pump is not replaced, it must be positioned in its stable position (BDC) by turning the control shaft as appropriate. The relative position between control shaft and pump axis is determined by the flange fitted on the pump. Figure 76

229313

Unscrew and remove the screw (5), unscrew and remove screws (1) with their washers (3). Remove the high pressure pump (2) from its support (4). Ref. (1) (5)

No. Description 2 M8x1.25x90 1 M6x1x20 220106

Remove the inspection caps from the overhead and turn the crankshaft with a suitable wrench until you can see the camshaft timing hole, and fit specific tools 99360614 (1). Ref. (-)

Print P1D32S021 E

No. 2

Description M14x1.5x10

NOTE

To reinstall the high pressure pump, the camshafts and crankshaft must be in phase.

NOTE

Two revolutions of the crankshaft correspond to one revolution of the camshafts.

Base - April 2015

24

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 77

F1C EuV1 - ENGINES

Figure 79

229313 220130

Lubricate a new seal ring (3) and fit it to the high pressure pump. Make sure the flange (4) is fitted to the high pressure pump. Make sure the high pressure pump is in stable equilibrium, with the one of the two recesses (1) on the flange (4) in line with the reference on the pump itself (2). Fit the pump (2) in such a way that the teeth of the control shaft engage in the cross housings (1). Figure 78

Fit the high pressure pump (2) vertically as shown in the previous figure onto the support (4) and rotate it in an anticlockwise direction until the mounting bolt holes are aligned. Tighten screw (5) and screws (1) with their washers (3) to the torque indicated in the table. Remove specific tools 99360614 and reinstall the camshaft timing inspection caps on the cylinder overhead. Ref.

No.

Description

Tightening torques

(1) (5) (-)

2 1 2

M8x1.25x90 M6x1x20 M14x1.5x10

25±2.5 25±2.5 25±2.5

Figure 80

227803

Fit the water/oil heat exchanger (2), with a new gasket and tighten the screws (1) to the torque indicated in the table. Tighten the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder to the torque indicated in the table. 135043

Make sure you are in vertical mounting position.

Base - April 2015

Ref.

No.

Description

(1) (3)

8 1

M8x1.25x30 M8x1.25

Tightening torques 25 ± 2.5 25 ± 2.5 Print P1D32S021 E

F1C EuV1 - ENGINES

25

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 81

Figure 83

α

227801

229304

Connect both low pressure pipes supported by the clips to the high pressure pump and fit a new clamp (1) and engage quick-connector (2).

Fit the new high pressure fuel pipe and tighten the bracket nut (1) to the torque indicated in the table.

Figure 82

Connect the high pressure fuel pipe to the high pressure pump and tighten the fitting (2) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

(1)

1

(2)

1

Description M8x1.25 M16x1 1st phase 2nd phase

Tightening torques 25±2.5 25±2 90˚

Figure 84 227800

Place the oil filter (1) on the water/oil heat exchanger and tighten to the torque indicated in the table. Ref.

No.

(1)

1

Description M22x1.5

Tightening torques 25 ± 2.5

α

218898

Connect the high pressure fuel pipe to the fuel manifold pipe and tighten the fitting (1) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

Description

Tightening torques

M15x1 (1)

Print P1D32S021 E

1

1st phase 2nd phase

24±2 90˚ Base - April 2015

26

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - re-use the disassembled pipelines.

F1C EuV1 - ENGINES

ELECTRIC EXHAUST GAS FLAP REMOVAL/REFITTING Removal Figure 86

Figure 85

229314

Disconnect the exhaust gas flap electrical connection (1). 229303

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table. Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25 ± 2.5

Connect the fuel flow regulator to the high pressure pum p.

Unlock the V-clamp (2), disconnect and remove the electric exhaust gas flap (3) from the turbocharger. Ref. (2)

No. Description 1 M8x70

Refitting Figure 87

Fit the engine wiring as described in the relative proce dure.

229314

Fit the electric exhaust gas flap (3) onto the turbocharger and tighten the V-clamp (2) to the torque indicated in the table. Connect the exhaust gas flap electrical connection (1).

Base - April 2015

Ref.

No.

(2)

1

Description M8x70

Tightening torques 12±1

Print P1D32S021 E

F1C EuV1 - ENGINES

27

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

TURBOCHARGER OIL DELIVERY PIPE GASKET REMOVAL/REFITTING

Refitting Figure 90

Removal Figure 88

230346

Replace the gasket with a new one and reassemble the interface connector (1) to the torque indicated in the table. 230345

If necessary, drain the cooling water from engine.

Ref.

No.

Undo the union (4) and disconnect the turbocharger water return pipe (5) from the turbocharger.

(1)

1

Description M14x1.5

Tightening torques 27 ± 3 Nm

Undo the bracket screws (6) and move the turbocharger water return pipe (5) aside. Ref. (4) (6)

No. Description 1 M14x1.5 2 M8x1.25x16

Undo the fittings (1 and 3) and remove the turbocharger oil delivery pipe (2). Ref. (1) (3)

No. 1

Description M14x1.5

Figure 89

230346

Remove the interface connector to turbocharger oil delivery pipe (1) with the relative gasket. Ref. (1)

No. Description 1 M14x1.5

Print P1D32S021 E

Base - April 2015

28

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

TURBOCHARGER/EXHAUST MANIFOLD GROUP REMOVAL/REFITTING

Figure 91

Removal Place a suitable container, to collect any coolant or oil which may leak out. Figure 92

230345

Fit the turbocharger oil delivery pipe (2) then tighten the fittings (1) and (3) to the torque indicated in the table. Ref.

No.

(1) (3)

2

Description

Tightening torques

M14x1.5

40 ± 4 Nm

Tighten the bracket screws (2) to the torque indicated in the table. Connect the turbocharger water return pipe to the turbocharger and tighten the union (1) to the torque indicated in the table. Ref.

No.

Description

(1) (2)

1 2

M14x1.5 M8x1.25x16

NOTE

Tightening torques 40±4 25±2.5

220107

Disconnect the VGT position sensor electrical connection (1) from the turbocharger actuator. Undo the bracket screw (2), securing the turbocharger actuator to the engine mount. Ref. (2)

No. Description 1 M8x1.25x20

Figure 93

Before closing the oil inlet pipe at the prescribed torque, block the rotation of interface connector, to avoid gasket deformation due to excessive torque on the gasket with consequent oil leakage.

217929

Undo the screws (1), the fitting (2) and remove the oil return pipe from the turbocharger and from the crankcase with the relative gasket. Ref. (1) (2)

Base - April 2015

No. Description 2 M6x1x16 1 M22x1.5

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 94

29

Figure 96

229314

Disconnect the exhaust gas flap electrical connection (1). Unlock the V-clamp (2), disconnect and remove the electric exhaust gas flap (3) from the turbocharger. Ref. (2)

No. Description 1 M8x70

214665

Undo the union (1) and disconnect the turbocharger water return pipe from the turbocharger.

Figure 95

Undo the bracket screws (2) and move the turbocharger water return pipe aside. Ref. (1) (2)

No. Description 1 M14x1.5 2 M8x1.25x16

Figure 97

214647

Undo the screws (2) and remove the union bracket (3). Undo the screws (1) and disconnect the union bracket (5) from the EGR heat exchanger. Disconnect and remove the turbocharger air outlet pipe (4). Ref. (1) (2)

No. Description 2 M8x1.25x20 2 M6x1x18

229315

Undo the fittings (1) and (5), then remove the turbocharger oil delivery pipe (6). Undo the screws (2) and remove the exhaust manifold guard (3) taking care to retrieve all the spacers. Undo the union (4) and disconnect the turbochargerwater delivery pipe from the cranckase.

Print P1D32S021 E

Base - April 2015

30

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Ref. (1) (5)

No.

Description

2

M14x1,5

(2) (4)

4 1

M6x1.25x14 M14x1.5

F1C EuV1 - ENGINES

Figure 100

Figure 98

229316

Undo the screws (1), disconnect and remove the exhaust gas delivery pipe from the EGR valve and from the exhaust manifold. Remove the relative gaskets. Ref. (1)

No. Description 4 M8x1.25x20

218885

Undo the nuts (3) and separate the turbocharger (2) from the exhaust manifold (1), remove the gasket.

Figure 99 Ref. (3)

No. Description 4 M8x1.25

If necessary undo the union and disconnect the water delivery pipe from the turbocharger. Ref. (-)

NOTE

229317

Undo the nuts (1) securing the exhaust manifold to the cylinder head.

No. Description 1 M14x1.5

Make sure all turbocharger pipes are whole, clean and free from foreign bodies. Furthermore, check that the sealing gaskets operate correctly and that the connection sleeves are fastened.

Remove the exhaust manifold-turbocharger group (2) and the relative gasket, taking care to retrieve all the spacers. Ref. (1)

No. Description 10 M8x1.25

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

31

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Checking and adjusting the actuator

Refitting

Figure 101

Figure 102

221447

Cover air, exhaust gas and lubricant inlets and outlets. Clean the turbocharger outside accurately using anticorrosive and antioxidant fluid and check the actuator (4). Clamp the turbocharger in a vice. Apply vacuometer 99367121 (1) pipe to actuator (4) hose. Apply themagnetic base gauge (2) to exhaust gas inlet flange in the turbine. Set gauge (2) feeler pin on tie rod (3) end and set gauge (2) to zero. Operate the vacuum pump and check whether the tie rod (3) stroke values correspond to the vacuum values shown in the following table: - vacuum 0

Kpa

Fully open valve

- vacuum 20 Kpa

Valve stroke 1.5 - 4.0 mm

- vacuum 60 Kpa

Valve stroke 10 - 12.5 mm

218885

If previously removed, connect the water delivery pipe to the turbocharger and tighten the union to the torque indicated in the table. Ref.

No.

(-)

1

Description M14x1.5

Tightening torques 35±3.5

NOTE

The turbocharger shall be replaced if a different value is found and/or if the vacuum value falls during the check.

Approach the turbocharger with a new gasket, to the exhaust manifold and tigheten the nuts (3)to the torque indicated in the table.

NOTE

NOT ALLOWED ARE: - any replacement or regulation of the actuator, since the calibration of such component is made in an optimal way for each turbocharger and is guaranteed for the turbocharger;

Ref.

No.

(3)

4

Description M8x1.25

Tightening torques 25±2.5

- any operation on nut and ring nut, since such operation does not change engine supply characteristics but may impair engine reliability and duration. Ring nut is sealed with antitempering yellow paint. In case of engines under guarantee, each above specified intervention and/or alteration to paint applied on ring nut causes the lapse of the guarantee. Print P1D32S021 E

Base - April 2015

32

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 103

F1C EuV1 - ENGINES

Figure 105

229317

229315

Place a new metallic gasket and fit the exhaust gas turbocharger group (2) on the cylinder head with the spacers.

Fit the exhaust manifold guard (3) with the spacers and tighten the screws (2) to the torque indicated in the table.

Tighten the nuts (1) to the torque indicated in the table.

Fit the turbocharger oil delivery pipe (6) then tighten the fittings (1) and (5) to the torque indicated in the table.

Ref.

No.

Description

(1)

10

M8x1.25

Tightening torques 25±2.5

Figure 104

Connect the turbocharger water delivery pipe to the cranckase and tighten the union (4) to the torque indicated in the table. Tightening torques

Ref.

No.

(1) (5)

2

M14x1,5

40±4

(2) (4)

4 1

M6x1.25x14 M14x1.5

18 40±4

Description

229316

Place new gaskets and connect the exhaust gas delivery pipe (2) to the exhaust manifold and to the EGR valve and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

Tightening torques

(1)

4

M8x1.25x20

25±2.5

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

33

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 106

Figure 108

229314

Fit the electric exhaust gas flap (3) onto the turbocharger and tighten the V-clamp (2) to the torque indicated in the table. Ref.

No.

(2)

1

Description

214665

Tighten the bracket screws (2) to the torque indicated in the table. Connect the turbocharger water return pipe to the turbocharger and tighten the union (1) to the torque indicated in the table. Ref.

No.

Description

Tightening torques

(1) (2)

1 2

M14x1.5 M8x1.25x16

40±4 25±2.5

M8x70

Tightening torques 12±1

Connect the exhaust gas flap electrical connection (1). Figure 109

Figure 107

217929

Fit the turbocharger oil outlet pipe, and tighten the fitting to the cranckase (2) and the bracket screws (1) to the torque indicated in the table.

214647

Ref.

No.

(1) (2)

2 1

Description M6x1x16 M22x1.5

Tightening torques 10±1 45±4.5

Connect the turbocharger air outlet pipe (4) to the turbocharger, place the union bracket (3) and tighten the screws (2) to the torque indicated in the table. Connect the union bracket (5) to the EGR heat exchanger and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1) (2)

2 2

M8x1.25x20 M6x1x18

Print P1D32S021 E

Tightening torques 28±2.8 10±1 Base - April 2015

34

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

EGR GROUP REMOVAL/REFITTING

Figure 110

Removal Place a suitable container, to collect any coolant or oil which may leak out. Disconnect the EGR valve electrical connection Figure 111

220107

Tighten the bracket screw (2), securing the turbocharger actuator to the engine mount, to the torque indicated in the table. Ref.

No.

Description

Tightening torques

(2)

1

M8x1.25x20

25±2.5

Connect the VGT position sensor electrical connection (1) to the turbocharger actuator.

217933

Undo the screw (1) to open the fixing collar and disconnect the exhaust gas delivery pipe from the EGR heat exchanger. Ref. (1)

No. Description 1 M6x1

Figure 112

217934

Open the clamp and disconnect the enginecoolant delivery pipe from the EGR heat exchanger.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 113

Figure 115

214647

Undo the screws (2) and remove the union bracket (3). Undo the screws (1) and disconnect the union bracket (5) from the EGR heat exchanger. Disconnect and remove the turbocharger air outlet pipe (4). Ref. (1) (2)

35

No. Description 2 M8x1.25x20 2 M6x1x18

229316

Undo the screws (1), disconnect and remove the exhaust gas delivery pipe (2) from the EGR valve and from the exhaust manifold. Remove the relative gaskets. Ref. (1)

No. Description 4 M8x1.25x20

Figure 116

Figure 114

229319

Undo the screws (1) and remove the EGR group (2). 229318

Undo the fitting (1) and (4) and remove the turbocharger oil delivery pipe (5). Ref. (1) (4)

No. 2

Ref. (1) (1)

No. Description 3 M8x1.25x80 1 M8x1.25x95

Description M14x1,5

Undo the screws (2) and remove the exhaust manifold guard (3) taking care to retrieve all the spacers. Ref. (2)

No. Description 4 M6x1.25x14

Print P1D32S021 E

Base - April 2015

36

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

F1C EuV1 - ENGINES

Figure 119

Figure 117

229318 229319

Fit the EGR group (2) on the overhead and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1) (1)

3 1

M8x1.25x80 M8x1.25x95

Tightening torques 25±2.5 25±2.5

Figure 118

Fit the exhaust manifold guard (3) with the spacers and tighten the screws (2) to the torque indicated in the table. Fit the turbocharger oil delivery pipe (5) then tighten the fittings (1) and (4) to the torque indicated in the table. Ref.

No.

(1 (4)

1

M14x1,5

(2)

4

M6x1.25x14

Description

Tightening torques 40±4 18

Figure 120

229316

Place new gaskets and connect the exhaust gas delivery pipe (2) to the exhaust manifold and to the EGR valve. Tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1)

4

M8x1.25x20

Base - April 2015

Tightening torques 25±2.5

214647

Connect the turbocharger air outlet pipe (4) to the turbocharger, place the union bracket (3) and tighten the screws (2) to the torque indicated in the table. Connect the union bracket (5) to the EGR and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1) (2)

4 2

M8x1.25x20 M6x1x18

Tightening torques 28±2.8 10±1

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

37

PRE HEATING GLOW PLUGS REMOVAL/REFITTING

Figure 121

Removal Place a suitable container, to collect any engine oil and fuel which may leak out. Disconnect the glow plugs electrical connections and the air temperature sensor electrical connection from the air inlet ppe. In order to facilitate the operations, remove the engine wiring as described in the relative procedure. Figure 123 217934

Connect the engine coolant delivery pipe to the EGR heat exchanger and close the relative clamp (1). Figure 122

229303

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. Ref. (2)

No. 1

Description M8x1.25

217933

Connect the exhaust gas delivery pipe to the EGR heat exchanger, close the collar and tighten the screw (1) to the torque indicated in the table. Ref.

No.

(1)

1

Description M6x1

Figure 124

Tightening torques 5±0.5

Connect the EGR valve electrical connection

218891

Undo the fitting (1) and disconnect the high pressure fuel pipe from the fuel manifold pipe. Ref. (1)

Print P1D32S021 E

No. Description 1 M15x1

Base - April 2015

38

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 125

F1C EuV1 - ENGINES

Figure 127

229304

227801

Undo the fitting (2) and disconnect the high pressure fuel pipe from the high pressure pump.

Loosen clamp (1), disconnect the quick- connector (2) to remove both the low pressure pipes from the high pressure pump and take them out from the clips.

Undo the bracket nut (1) and remove the high pressure fuel pipe.. Ref. (1) (2)

Figure 128

No. Description 1 M8x1.25 1 M16x1

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Figure 126 227802

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase. Undo the bracket screw (1), fixing the low pressure pipes group to the intake manifold. Undo the screws (2) fixing the duplex pipe anchorage bracket, and move aside the low pressure pipes group together with the fuel recovery pipe. Ref. (1) (2)

No. Description 1 M6x1 2 M6x1x10

227800

Using tool 99360076 remove the oil filter (1) from the water/oil heat exchanger. Ref. (1)

No. Description 1 M22x1.5

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

39

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

Figure 129

Figure 131

229320

Undo the screws (1), remove the air inlet pipe (2) from the intake manifold with the gasket and the air temperature sensor. Ref. (1)

No. 4

Description M8x1.25x25

Figure 130

229321

Fit the glow plugs (1) in their housing on the cylinder head and using the torque wrench 99389819 with the bush SP. 2275, tighten them to the torque indicated in the table. Ref.

No.

(1)

4

Description M8x1

Tightening torques 9±1

Figure 132

229321

Unsing a suitable tool, undo and remove the glow plugs (1) from the cylinder head. Ref. (1)

No. 4

Print P1D32S021 E

Description M8x1

229320

Fit the air inlet pipe (2) on the intake manifold, together with the new gasket and the air temperatur sensor, then tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1)

4

M8x1.25x25

Tightening torques 25±2.5

Base - April 2015

40

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 133

F1C EuV1 - ENGINES

Figure 135

227802

227800

Fit the low pressure pipes group together with the fuel recovery pipe from electro-injectors and engage the group in the intermediate retaining clips.

Place the oil filter (1) on the water/oil heat exchanger and tighten to the torque indicated in the table.

Fit the bracket fixing the low pressure pipes duplex anchorage and tighten the screws (2) to the torque indicated in the table.

Ref.

No.

(1)

1

Fit the bracket fixing the low pressure pipes group to the intake manifold and tighten the screw (1) to the torque indicated in the table. Ref.

No.

(1) (2)

1 2

Description M6x1 M6x1X10

Description M22x1.5

Tightening torques 25 ± 2.5

Figure 136

Tightening torques 25 ± 2.5 10 ± 1

Figure 134

α

229304

Fit the new high pressure fuel pipe and tighten the bracket nut (1) to the torque indicated in the table.

227801

Connect both low pressure pipes supported by the clips to the high pressure pump and fit a new clamp (1) and engage quick-connector (2).

Base - April 2015

Connect the high pressure fuel pipe to the high pressure pump and tighten the fitting (2) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

(1)

1

(2)

1

Description M8x1.25 M16x1 1st phase 2nd phase

Tightening torques 25±2.5 25±2 90˚

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

41

THERMOSTAT REMOVAL/REFITTING

Figure 137

Removal Figure 139

α

218891

Connect the high pressure fuel pipe to the fuel manifold pipe and tighten the fitting (1) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

Description

Tightening torques

M15x1 (1)

1

1st phase 2nd phase

24±2 90˚

220128

Disconnect the engine coolant temperature sensor electrical connection (1). Undo the screws (2) and remove the thermostat cover, the thermostat and the relative gasket.

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - re-use the disassembled pipelines.

Ref. (2)

No. Description 4 M8x1.25x20

Figure 138

229303

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table. Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25 ± 2.5

Connect the glow plugs electrical connections and the air temperature sensor to the air inlet pipe. Fit the engine wiring as described in the relative procedure. Print P1D32S021 E

Base - April 2015

42

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

F1C EuV1 - ENGINES

INTAKE MANIFOLD REMOVAL/REFITTING Removal

Figure 140

Place a suitable container, to collect any fuel which may leak out. Disconnect the air temperature sensor and the air temperature/pressure sensor electrical connections from the air inlet pipe and from the intake manifold. In order to facilitate the operations, remove the engine wiring as described in the relative procedure. Figure 141

220128

Fit the thermostat cover, together with the thermostat and the relative gasket on the cylinder head and tighten the screws (2) to the torque indicated in the table. Connect the engine coolant temperature sensor electrical connection (1). 229299

Ref.

No.

Description

(1)

4

M8x1.25x20

Tightening torques 25±2.5

Lift the retaining clips (1) in the direction shown by the arrow and disconnect the fuel recovery pipe (2) from the electro-injectors. Open the retaining clip (3). Figure 142

229300

Loosen the clamp and disconnect the fuel return pipe (1) from the fuel manifold pipe (2).

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 143

43

Figure 145

229303

229304

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump.

Undo the fitting (4) and disconnect the high pressure fuel pipe from the pump.

Ref. (2)

No. 1

Description M8x1.25

Undo the bracket nut (1) and remove the high pressure fuel pipe. Ref. (1) (2)

Figure 144

No. 1 1

Description M8x1.25 M16x1

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Figure 146

218891

Undo the fitting (1) and disconnect the fuel high pressure pipe from the fuel manifold pipe. Ref. (1)

No. 1

Description M15x1

227800

Using tool 99360076 remove the oil filter (1) from the water/ oil heat exchanger. Ref. (1)

Print P1D32S021 E

No. 1

Description M22x1.5

Base - April 2015

44

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 147

F1C EuV1 - ENGINES

Figure 149

227801

229320

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase.

Undo the screws (1), remove the air inlet pipe (2) from the intake manifold with the gasket and the air temperature sensor..

Loosen the clamp (1) and disconnect the fuel supply pipe from the high pressure pump. Adjust the quick connector (2) and disconnect the fuel return pipe from the high pressure pump.

Ref. (1)

No. 4

Description M8x1.25x25

Figure 150

Figure 148

229322

227802

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase. Undo the bracket screw (1), fixing the low pressure pipes group to the intake manifold.

Undo the screws (1) and disconnect the exhaust gas delivery pipe (2) from the intake manifold. Remove the relative gasket. Ref. (1)

No. 2

Description M8x1.25x30

Undo the screws (2) fixing the duplex pipe anchorage bracket, and remove the low pressure pipes group together with the fuel recovery pipe. Ref. (1) (1)

No. Description 1 M6x1 2 M6x1x10

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

45

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

Figure 151

Figure 152

229323

If necessary to facilitate the operation undo the nut (1) and remove the air temperature/pressure sensor with the relative o-ring. Ref. (1)

No. 1

Description M6

Undo the two plugs (3) on the intake manifold, in order to reach the screws below. Undo the screws (2), (4) and (5) securing the intake manifold to the cylinder head. Remove the intake manifold (6) and the relative gasket. Ref. (2) (4) (5) (3)

No. 2 6 1 2

Print P1D32S021 E

Description M8x1.25x60 M8x1.25x40 M8x1.25x140 M24x1.5

229323

Fit the intake manifold (6) with a new gasket on the cylinder head and tighten the screws (2), (4) and (5) to the torque indicated in the table. Fit the two threaded plugs (3) on the intake manifold and tighten them to the torque indicated in the table. Ref.

No.

(2) (4) (5) (3)

2 6 1 2

Description M8x1.25x60 M8x1.25x40 M8x1.25x140 M24x1.5

Tightening torques 25±2.5 30±3 30±3 30±3

If previously removed, fit the air temperature/pressure sensor on the intake manifold and tighten the nut (1) to the torque indixcated in the table. Ref.

No.

(1)

1

Description M6

Tightening torques 10±1

Base - April 2015

46

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 153

F1C EuV1 - ENGINES

Figure 155

229322

227802

Place a new gasket and connect the exhaust gas delivery pipe (2) to the intake manifold, tighten the screws (1) to the torque indicated in the table.

Fit the low pressure pipes group together with the fuel recovery pipe from electro-injectors and engage the group in the intermediate retaining clips.

Ref.

No.

Description

(1)

2

M8x1.25x30

Tightening torques 25±2.5

Fit the bracket fixing the low pressure pipes duplex anchorage and tighten the screws (2) to the torque indicated in the table. Fit the bracket fixing the low pressure pipes group to the intake manifold and tighten the screw (1) to the torque indicated in the table.

Figure 154 Ref.

No.

(1) (2)

1 2

Description M6x1 M6x1x10

Tightening torques 25±2.5 25±2.5

Figure 156

229320

Fit the air inlet pipe (2) on the intake manifold, together with the new gasket and the air temperature sensor, then tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1)

4

M8x1.25x25

Tightening torques 25±2.5

227801

Connect the fuel supply pipe to the high pressure pump and close the clamp (1). Connect the fuel return pipe to the high pressure pump and engage the quick connector (2). Tie the intermediate retaining clip securing the low pressure pipes group to the cranckcase.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

47

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 157

Figure 159

α

218891 227800

Place the oil filter (1) on the water/oil heat exchanger and tighten to the torque indicated in the table. Ref.

No.

(1)

1

Description M22x1.5

Tightening torques 25±2.5

Connect the high pressure fuel pipe to the fuel manifold pipe and tighten the fitting (1) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. Ref.

No.

Description

Tightening torques

M15x1

Figure 158 (1)

1

1st phase 2nd phase

24±2 90˚

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - re-use the disassembled pipelines.

α

Figure 160

229304

Fit the the fuel high pressure pipe and tie the intermediate retaining clip (5). Tighten the bracket nut (1) to the torque indicated in the table. Connect the fuel high pressure pipe to the pump and tighten the fitting (4) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table. Use tool 99395216 for angle tightening. 229303

Ref.

No.

(1)

1

(4)

1

Print P1D32S021 E

Description M8x1.25 M16x1 1st phase 2nd phase

Tightening torques 25±2.5 25±2 90˚

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table. Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25±2.5

Base - April 2015

48

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

BLOW-BY REMOVAL/REFITTING

Figure 161

Removal Figure 163

229300

Connect the fuel return pipe (1) to the fuel manifold pipe (2) and close the relative clamp. 229324

Figure 162

Undo the nut (1) fixing the blow-by pipe bracket to the cylinder head. Undo the screws (2) and remove the cover (3) complete with blow-by pipe. Remove the piston ring and the centrifugal filter. Ref. (1) (2)

NOTE

No. 1 3

Description M8x1.25 M6x1x18

The centrifugal filter and the seal ring of the cover must be changed at every removal.

229302

Fit and connect the fuel recovery pipe (2) to the elctro-injectors and close the retaining clips (1) in the way shown by the arrow. Close the intermediate retaining clip (3). Connect the air temperature sensor and the air temperature/ pressure sensor electrical connections to the air inlet pipe and to the intake manifold. Fit the engine wiring as described in the relative procedure.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

49

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

AUXILIARY DRIVE BELT AND AUTOMATIC BELT TENSIONER REMOVAL/REFITTING

Figure 164

Removal Figure 165

229324

Fit a new centrifugal filter and a new piston ring. Fit the cover (3), tighten the screws (2) to the torque indicated in the table.

Using a suitable tool remove the A/C compressor belt (2).

Fit the blow-by pipe bracket on the cylinder head and tighten the nut (1) to te torque indicated in the table.

Using the specific wrench on the automatic belt tensioner, reduce the tension of the belt (1) and remove it.

Ref.

No.

(2) (1)

3 1

Description M6x1x18 M8x1.25

Tightening torques 10±1 25±2.5

227797

Undo the screw (3) and remove the automatic belt tensioner (4). Ref. (3)

No. Description 1 M10x1.5x45

Refitting Figure 166

227797

Fit the automatic belt tensioner (4) and tighten the screw (3) to the torque indicated in the table. Ref.

No.

Description

(3)

1

M10x1.5x45

Tightening torques 45 ± 5

Using a specific wrench on the automatic belt tensioner (4), fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley. Using a suitable tool fit the A/C compressor belt (2). Print P1D32S021 E

Base - April 2015

50

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

CRANKSHAFT FRONT SEAL RING REMOVAL/REFITTING

F1C EuV1 - ENGINES

Figure 169

Removal Figure 167

229327

Undo the screw (1) and detach the damper pulley (2).

229325

Stop the rotation of the engine flywheel (2) by means of tool 99360306 (1).

Ref. (1)

No. 1

Description M20x1.5x58

Figure 170

Figure 168

229326

Using a suitable tool remove the A/C compressor belt (2). Using the specific wrench on the automatic belt tensioner, reduce the tension of the belt (1) and remove it.

221408

Mount the extractor 99340062 (1) on the crankshaft, close the screw (2) on the crankshaft hole by hand, then with a key close for another 45˚±15˚. NOTE

Base - April 2015

The extractor doesen’t need an angular position (can rotate 360˚).

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 171

51

Figure 174

221409

221411

Block the extractor closing the nut (1) by hand, then with a key close for another 45˚±15˚.

Unscrew the nut (1), then the screw (2) until the extractor come out with the gasket.

Refitting

Figure 172

Figure 175

221421

Pierce the gasket with the punch (1), using a hammer, stroke until it arrive at the shoulder of the extractor.

229328

Thoroughly clean the seat of the cover seal ring (5), screw part (3) of the specific tool 99346258 into the crankshaft shank.

Figure 173

Lubricate the shank of the crankshaft and the outer surface of part (3) and fit the new seal ring (4). Position part (1) on part (3); screw down the nut (2) to fit the seal (4) fully inside the cover (5). Remove the tool 99346258 (1).

221410

Tighten the screw (1) by hand. NOTE

Three screws at 120˚ are sufficient.

Print P1D32S021 E

Base - April 2015

52

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

TIMING SYSTEM LOWER COVER REMOVAL/REFITTING

Figure 176

Removal Figure 178

229327

Fit the damper pulley (2) and tighten the screw (1) to the torque indicated in the table. Ref.

No.

Description

(1)

1

M20x1.5x58

Tightening torques 350±17.5

229325

Stop the rotation of the engine flywheel (2) by means of tool 99360306 (1). Figure 179

Figure 177

229326

229324

Using a specific wrench on the automatic belt tensioner, fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley.

Undo the nut (1) fixing the blow-by pipe bracket to the cylinder head.

Using a suitable tool fit the A/C compressor belt (2). Remove the tool 99360306 used to stop the rotation of the engine flywheel.

Undo the screws (2) and remove the cover (3) complete with blow-by pipe. Remove the piston ring and the centrifugal filter. Ref. (1) (2)

NOTE

Base - April 2015

No. 1 3

Description M8x1.25 M6x1x18

The centrifugal filter and the seal ring of the cover must be changed at every removal.

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 180

53

Figure 182

229329

Using a suitable tool remove the A/C compressor belt (2). Using the specific wrench on the automatic belt tensioner, reduce the tension of the belt (1) and remove it. Figure 181

221408

Mount the extractor 99340062 (1) on the crankshaft, close the screw (2) on the crankshaft hole by hand, then with a key close for another 45˚±15˚. NOTE

The extractor doesen’t need an angular position (can rotate 360˚).

Figure 183

229330

Undo the screw (3) and detach the damper pulley (4). Ref. (3)

No. 1

Description M20x1.5x58

Undo the screw (1) and remove the A/C compressor belt tensioner (2). Ref. (1)

No. 1

Print P1D32S021 E

Description M8x1.25x45

221409

Block the extractor closing the nut (1) by hand, then with a key close for another 45˚±15˚.

Base - April 2015

54

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 184

F1C EuV1 - ENGINES

Figure 187

221421

229331

Pierce the gasket with the punch (1), using a hammer, stroke until it arrive at the shoulder of the extractor.

Undo the screws (1) and remove the timing system lower cover (2) and the gasket.

Figure 185

Ref. (1) (1)

No. 9 7

Description M8x1,25x30 M8x1,25x16

Refitting Figure 188

221410

Tighten the screw (1) by hand. NOTE

Three screws at 120˚ are sufficient. 229331

Figure 186

Fit the cover (2) with a new gasket and screw the screws (1) without tighten them completely.

221411

Unscrew the nut (1), then the screw (2) until the extractor come out with the gasket.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

55

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 189

Figure 191

229328

229330

Thoroughly clean the seat of the cover seal ring (5), screw part (3) of the specific tool 99346258 into the crankshaft shank.

Fit the damper pulley (4) and tighten the screw (3) to the torque indicated in the table.

Lubricate the shank of the crankshaft and the outer surface of part (3) and fit the new seal ring (4).

Ref.

No.

Description

(3)

1

M20x1.5x58

Position part (1) on part (3); screw down the nut (2) to fit the seal (4) fully inside the cover (5).

Tightening torques 350±17.5

Fit the A/C compressor belt tensioner (2) and tighten the screw (1) to the torque indicated in the table.

Figure 190 Ref.

No.

Description

(1)

1

M8x1.25x45

Tightening torques 25±2.5

Figure 192

229332

Mount tool 99396039 (1), for centering cover (4), into centrifugal filter seat and tighten screws (3) at the torque indicated in the table. Ref.

No.

Description

(3) (3)

9 7

M8x1.25x30 M8x1.25x16

Tightening torques 25±2.5 25±2.5

Remove the 99346258 (2) and 99396039 (1) tools.

Print P1D32S021 E

229329

Using a specific wrench on the automatic belt tensioner, fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley. Using a suitable tool fit the A/C compressor belt (2).

Base - April 2015

56

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

DEPRESSOR/OIL PUMP REMOVAL/REFITTING

Figure 193

Removal Place a suitable container to collectany engine oil which may leak out. Figure 194

229324

Fit a new centrifugal filter and a new piston ring. Fit the cover (3), tighten the screws (2) to the torque indicated in the table. Fit the blow-by pipe bracket on the cylinder head and tighten the nut (1) to te torque indicated in the table. Ref.

No.

(2) (1)

3 1

Description M6x1x18 M8x1.25

Tightening torques 10±1 25±2.5

229325

Stop the rotation of the engine flywheel (2) by means of tool 99360306 (1). Figure 195

Remove the tool 99360306 used to stop the rotation of the engine flywheel.

229324

Undo the nut (1) fixing the blow-by pipe bracket to the cylinder head. Undo the screws (2) and remove the cover (3) complete with blow-by pipe. Remove the piston ring and the centrifugal filter. Ref. (1) (2)

NOTE

Base - April 2015

No. 1 3

Description M8x1.25 M6x1x18

The centrifugal filter and the seal ring of the cover must be changed at every removal.

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 196

57

Figure 198

229329

Using a suitable tool remove the A/C compressor belt (2). Using the specific wrench on the automatic belt tensioner, reduce the tension of the belt (1) and remove it. Figure 197

221408

Mount the extractor 99340062 (1) on the crankshaft, close the screw (2) on the crankshaft hole by hand, then with a key close for another 45˚±15˚. NOTE

The extractor doesen’t need an angular position (can rotate 360˚).

Figure 199

229330

Undo the screw (3) and detach the damper pulley (4). Ref. (3)

No. 1

Description M20x1.5x58

Undo the screw (1) and remove the A/C compressor belt tensioner (2). Ref. (1)

No. 1

Print P1D32S021 E

Description M8x1.25x45

221409

Block the extractor closing the nut (1) by hand, then with a key close for another 45˚±15˚.

Base - April 2015

58

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 200

F1C EuV1 - ENGINES

Figure 202

221421

221411

Pierce the gasket with the punch (1), using a hammer, stroke until it arrive at the shoulder of the extractor.

Unscrew the nut (1), then the screw (2) until the extractor come out with the gasket.

Figure 201

Figure 203

221410 229331

Tighten the screw (1) by hand. NOTE

Base - April 2015

Three screws at 120˚ are sufficient.

Undo the screws (1) and remove the timing system lower cover (2) and the gasket. Ref. (1) (1)

No. 9 7

Description M8x1,25x30 M8x1,25x16

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 204

59

Figure 206

229333

229331

Undo the screws (3) and disassemble the depressor/oil pump unit (2).

Fit the cover (2) with a new gasket and screw the screws (1) without tighten them completely.

Remove the coupling drive (1). Figure 207 Ref. (3)

No. 5

Description M8x1.25x60

Refitting Figure 205

229328

Thoroughly clean the seat of the cover seal ring (5), screw part (3) of the specific tool 99346258 into the crankshaft shank. Lubricate the shank of the crankshaft and the outer surface of part (3) and fit the new seal ring (4). 229333

Position the coupling drive (1) in the gear.

Position part (1) on part (3); screw down the nut (2) to fit the seal (4) fully inside the cover (5).

Fit the oil pump/depressor unit (2) by inserting a new gasket. Tighten the screws (3) to the torque indicated in the table. Ref.

No.

Description

(3)

5

M8x1.25x60

Print P1D32S021 E

Tightening torques 25±2.5

Base - April 2015

60

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 208

F1C EuV1 - ENGINES

Figure 210

229332

229329

Mount tool 99396039 (1), for centering cover (4), into centrifugal filter seat and tighten screws (3) at the torque indicated in the table.

Using a specific wrench on the automatic belt tensioner, fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley.

Ref.

No.

Description

(3) (3)

9 7

M8x1.25x30 M8x1.25x16

Tightening torques 25±2.5 25±2.5

Using a suitable tool fit the A/C compressor belt (2). Figure 211

Remove the 99346258 (2) and 99396039 (1) tools. Figure 209

229324

Fit a new centrifugal filter and a new piston ring. Fit the cover (3), tighten the screws (2) to the torque indicated in the table. 229330

Fit the damper pulley (4) and tighten the screw (3) to the torque indicated in the table. Ref.

No.

Description

(3)

1

M20x1.5x58

Tightening torques 350±17.5

Fit the A/C compressor belt tensioner (2) and tighten the screw (1) to the torque indicated in the table. Ref.

No.

Description

(1)

1

M8x1.25x45

Base - April 2015

Fit the blow-by pipe bracket on the cylinder head and tighten the nut (1) to te torque indicated in the table. Ref.

No.

(2) (1)

3 1

Description M6x1x18 M8x1.25

Tightening torques 10±1 25±2.5

Remove the tool 99360306 used to stop the rotation of the engine flywheel.

Tightening torques 25±2.5

Print P1D32S021 E

F1C EuV1 - ENGINES

61

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

WATER PUMP REMOVAL/REFITTING

Refitting

Removal

Figure 214

Place a suitable container, to collect any coolant which may leak out. Figure 212

229335

Fit the water pump (5) with a new gasket and tighten the screws (4) to the torque indicated in the table.

Using a suitable tool remove the A/C compressor belt (2).

Fit the electromagnetic pulley (3) on the water pump, tighten the nuts (1) and the ring nut (2) to the torque indicated in the table.

Using the specific wrench on the automatic belt tensioner, reduce the tension of the belt (1) and remove it.

Ref.

229326

Figure 213

(4) (2) (1)

No.

Description

2 3 1 4

M8x1.25x45 M10x1.5x55 M30x1 M6x1

Tightening torques 25±2.5 50±5 150±15 10±1

Figure 215

229335

Undo the ring nut (2), the nuts (1) and remove the electromagnetic pulley (3). Undo the screws (4) and remove the water pump (5) with the relative gasket. 229326

Ref. (1) (2) (4)

No. 4 1 2 3

Print P1D32S021 E

Description M6x1 M30x1.5 M8x1.25x45 M10x1.5x55

Using a specific wrench on the automatic belt tensioner, fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley. Using a suitable tool fit the A/C compressor belt (2).

Base - April 2015

62

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

CRANKSHAFT REAR SEAL RING REMOVAL/REFITTING

F1C EuV1 - ENGINES

Figure 218

Removal Figure 216

225110

To mount the tool 99340060 it is necessary to perform the following operations: 229336

- unscrew the extractor central screw (2) almost completely.

Block rotation of the flywheel (2) with the specific tool 99360306 (1).

- loosen the three screws (1) to enlarge the three flanges (3) in order to hold them over the ring (4) of the seal.

Undo the screws (3) and remove the flywheel (2).

- tighten the screws (1) until the flanges hold over the seal ring.

Ref. (3)

No. 8

Description M12x1.25x51

- finally tighten the central screw (2) and extract the seal ring.

Remove the tool 99360306 (1). NOTE

Figure 217

Ensure that the flanges are driven into the entire circumference of the seal ring: an improper positioning of the tool could make necessary a complete dismantling of the crankshaft to extract the seal ring.

Refitting Figure 219

229337

Apply specific tool 99340060 (2) to the rear seal ring (1) and extract it from the cranckase.

229338

Thoroughly clean the seal ring seat. Lubricate the rear end of the crankshaft with engine oil. Apply specific tool part 99346259 (4) to the rear crankshaft tang, secure it by screws (3) and fit the new sealing ring (5). Position part (1) on part (4); screw down the nut (2) to fit the seal (5) fully inside the crankcase. Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

63

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING

Figure 220

Removal Figure 221

α

229336

Mount the flywheel (2) and screw down the screws (3) without tighten them completely. Fit specific tool 99360306 (1) onto the crankcase to lock rotation of the flywheel (2). Using tool 99395216 for angle tightening, tighten the screws (3) retaining the flywheel (2) to the torque indicated in the table. Ref. (3)

No. 8

Description

Tightening torques

M12x1.25x51 1st phase 2nd phase

30±1.5 Nm 90˚

229339

Disconnect the phase sensor electrical connection (4). In order to facilitate the operation, disengage the engine wiring cover from the cylinder overhead and move aside. Undo the nuts (1), the screws (2) and remove the timing system upper cover (3). Ref. (1) (2)

No. 2 7

Description M6x1 M6x1x30

Figure 222

229340

Remove the inspection caps (1) from the overhead. Ref. (1)

No. 2

Description M14x1.5x10

Turn the crankshaft clockwise so that specific pins 99360614 can be inserted through the cap holes.

Print P1D32S021 E

Base - April 2015

64

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

Refitting

Figure 223

NOTE

Replace with new ones: the seal rings, gaskets, safety circlips. Before assembly, lubricate the seal rings with engine oil.

Figure 225

229341

Undo the screws (1) retaining the gear wheel intake side. Ref. (1)

No. 1

Description M12x1.75x40

Figure 224 229342

Fit the upper chain guide (6), drive in the nuts (5) and tighten them to the torque indicated in the table. Fit the side chain guide (1), drive in the screws (2 and 3) and tighten them to the torque indicated in the table. Fit the plug (4) with a new gasket and tighten it to the torque indicated in the table. Ref.

229342

Support the timing chain so that it remains tense with one clamp.

(2) (3) (4) (5)

No.

Description

Tightening torques

2

M6x1x20

10±1

1 2

M26x1.5x16 M6x1

50±5 10±1

Figure 226

Remove the plug (4) and undo the screw (3). Undo the retaining screw (2) and remove the side chain guide (1). Undo the retaining nuts (5) and remove the upper chain guide (6). Ref. (5) (2) (3) (4)

No. 2

Description M6x1

2

M6x1x20

1

M26x1.5x16 229341

NOTE

Base - April 2015

Pay close attention that the lower screw retaining the side chain guide does not fall within the timing compartment. If necessary, use a magnetized bushing or apply mastic to the bush body itself.

Fit the the gear wheel intake side and tighten the screws (1) to the torque indicated in the table. Ref.

No.

(1)

1

Description M12x1.75x40

Tightening torques 110±5.5 Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

65

ALTERNATOR REMOVAL/REFITTING

Figure 227

Removal Figure 229

229340

Remove the specific pins 99360614. Place the two inspection plugs (1) in their housing on the overhead, tightening them to the torque indicated in the table. Ref.

No.

Description

(1)

2

M14x1.5x10

Tightening torques 25±2.5

229326

Using a suitable tool remove the A/C compressor belt (2). Using the specific wrench on the automatic belt tensioner, reduce the tension of the belt (1) and remove it. Figure 230

Figure 228

229343

229339

Undo the screw (3) and bolt (1), then remove the alternator (2) from its support.

Fit a new gasket on the cover (3). Fit the cover (3), on the cylinder overhead and tighten the screws (2) and the nuts (1) to the torque indicated in the table.

Ref. (3) (1)

No. Description 1 M10x1.25x30 1 M10x1.25x130

Engage the engine wiring cover in its housing on the cylinder overhead. Connect the phase sensor electrical connection (4). Ref.

No.

(1) (2)

2 7

Print P1D32S021 E

Description M6x1 M6x1x30

Tightening torques 10±1 10±1

Base - April 2015

66

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 231

F1C EuV1 - ENGINES

Figure 233

225111

229343

If necessary, replace the alternator freewheel (2) as follows:

Fit the alternator (2) in its support, tighten the screw (3) and bolt (1) to the torque indicated in the table.

- Remove the freewheel cap (5). - Fit specific tool 99358026 (3, 4) as shown in the figure. - Block the rotation of the alternator freewheel (2) with part (4) and unscrew the shaft (1) of the alternator (6) with part (3). Ref. (1)

No. Description 1 M16x1.5

Ref.

No.

(3) (1)

1 1

Description M10x1.25x30 M10x1.25x130

Tightening torques 50 ± 5 50 ± 5

Figure 234

Refitting Figure 232

229326

Using a specific wrench on the automatic belt tensioner, fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley. 225111

Using a suitable tool fit the A/C compressor belt (2).

If previously removed, fit the new alternator freewheel (2) in the reverse order. The freewheel (2) must be secured to the shaft (1), applying to the shaft a maximum specified torque indicated in the table. Ref.

No.

(1)

1

Base - April 2015

Description M16x1.5

Tightening torques 80 ± 5

Print P1D32S021 E

F1C EuV1 - ENGINES

67

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

POWER STEERING PUMP REMOVAL/REFITTING

Figure 237

Removal Figure 235

229345

Remove the coupling (1) from the drive shaft (2).

Refitting 229303

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. Ref. (2)

Figure 238

No. Description 1 M8x1.25

Figure 236

229345

Fit the coupling (1) in its housing on the drive shaft (2).

229344

Undo and remove the screw (1) and the screws (2) with their washer. Remove the power steering pump (3) from its support. Ref. (1) (2)

No. Description 1 M10x1.25x30 1 M10x1.25x110

Print P1D32S021 E

Base - April 2015

68

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 239

F1C EuV1 - ENGINES

Figure 240

229344

229303

Fit the power steering pump (3) with a new gasket, tighten the screw (1) and the screw (2) with their washer to the torque indicated in the table.

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table.

Ref.

No.

(1) (2)

1 1

Description M10x1.25x30 M10x1.25x110

Tightening torques 40 ± 4 40 ± 4

NOTE

Replace with new ones: the seal rings, gaskets. Before assembly, lubricate the seal rings with engine oil.

NOTE

After refitting, top up the power steering circuit and bleed air.

Base - April 2015

Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25 ± 2.5

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

69

CYLINDER HEAD REMOVAL/REFITTING Removal Figure 241

229346

Remove the engine wiring (1) as described in the relative procedure.

Remove the electric exhaust gas flap (5) as described in the relative procedure.

Remove the timing system upper cover (2) as described in the ”SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING” procedure.

Remove the turbocharger/exhaust manifold group (4) as described in the relative procedure.

Remove the timing system lower cover (3) as described in the relative procedure.

Print P1D32S021 E

Remove the EGR group (6) as described in the relative procedure.

Base - April 2015

70

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

Figure 242

229347

Remove the low pressure fuel pipe group (3), together with the fuel return pipe as described in the relative procedure.

Remove the electro-injectors (1) as described in the relative procedure.

Remove the high pressure fuel pipe from pump to rail (4) as described in the relative procedure.

Remove the thermostat (5) as described in the relative procedure.

Remove the fuel manifold pipe (2) as described in the relative procedure.

Remove the intake manifold (6) as described in the relative procedure.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 243

71

Figure 245

229348

229350

Undo the bracket screw (1) securing the coolant delivery pipes group (2) to the cylinder overhead.

Undo the two plugs (1) on the tappet cover in order to fit the timing tools 99360614.

Open the clip (6) securing the EGR exhaust gas temperature sensor. Undo the screws (5) and remove the rear cover (3) and the relative gasket, together with the exhaust gas pipe (4) and the coolant delivery pipes group (2). Ref. (1) (5) (5)

No. 1 3 4

Description M8x1.25 M8x1.25x35 M8x1.25x45

Ref. (1)

No. 2

Description M14x1.5x10

Rotate the crankshaft and fit the timing tools 99360614 on the overhead and 99360615 onto the crankshaft. Figure 246

Figure 244

229349

Undo and remove the chain anti-return hydraulic tensioner (1).

227805

Ref. (1)

No. 1

Description M22x1.5x22

Undo and remove the glow plugs (1) from the cylinder head. Ref. (1)

No. 4

Print P1D32S021 E

Description M8x1

NOTE

The chain hydraulic tensioners are equipped with an anti-return device; it is therefore necessary to replace the chain tensioners each time they are removed.

Base - April 2015

72

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 247

F1C EuV1 - ENGINES

Figure 249

227815

229275

Undo the screw (5), keep the washer (6) and remove the exhaust camshat gear (7).

Undo the screws (1) and remove the bracket (2).

Undo the screw (3), keep the washer (4), remove the intake camshaft gear (2) and the single link timing chain (1).

Ref. (1)

Ref. (3) (5)

No. 2

Description

No. 2

Description M8x1.25x16

Figure 250

M12x1.75x40

Figure 248

230341

Undo the fixing screws (1) and take off the over-head (2) from the cylinder head (3). 227816

Remove the plug (4) and undo the screw (3). Undo the retaining screw (2) and remove the side chain guide (1).

Ref. (1) (1)

No. 10 20

Description M8x1.25x40 M8x1.25x77

Undo the retaining screw (5) and remove the upper chain guide (6). Ref. (5) (2) (3) (4)

No. 2

Description M6x1

2

M6x1x20

1

M26x1.5x16

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 251

NOTE

73

Check the protrusion of the pistons (2) as described under the relevant heading to check the possibility of facing the crankcase if it has deformed.

Refitting Figure 254

88281

Remove the hydraulic tappets (1) with the rocker arms. Remove the gasket (2). Figure 252

224215

Check that contact surfaces of the cylinder head and crankcase are clean. Place the cylinder head dowels on the crankcase (if they were removed previously). Place a new cylinder head gasket (1) with the tickness indicated in the Section 6 ”Checking piston protrusion” paragraph with the writing ”TOP” facing the cylinder head. It is absolutely necessary to keep the cylinder head gasket sealed in its packaging and remove it just before fitting to avoid getting it dirty.

88282

Undo the screws (1) and remove the cylinder head (2).

!

Ref. (1) (1) (1) (1)

Figure 255

No. 6 4 4 1

Description M15x1.5x193 M12x1.5x165 M8x1.25x117 M8x1.25x58

Figure 253

α

88354

Mount the cylinder head (2) on the crankcase.

224215

Screw down the fixing screws (3) and tighten them, in three successive stages, following the order and methods shown in the following figure, using tool 99395216 for the angle closing.

Remove the cylinder head gasket (1). Print P1D32S021 E

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74

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 256

F1C EuV1 - ENGINES

Figure 258

88355 230341

Ref.

(1)÷(6)

No.

6

(7)÷(10)

4

A

4 1

Description M15x1.5x193 1st phase 2nd phase 3rd phase M12x1.5x165 1st phase 2nd phase 3rd phase M8x1.25x117 M8x1.25x58

Tightening torques

Mount the overhead (2) on the cylinder head (3) together with the tools 99360614 for the timing and tighten the fixing screws (1) to the torque indicated in the table.

130±6.5 Nm 90˚ 90˚ 65 ± 3.25 Nm 90˚ 60˚ 25 ± 2.5 Nm 25 ± 2.5 Nm

Remove the tools SP. 2264 previously mounted. Ref.

No.

Description

(1) (1)

10 20

M8x1.25x40 M8x1.25x77

Tightening torques 25±2.5 25±2.5

Figure 259

Figure 257

229275

Fit the bracket (2) on the overhead and tighten the screws (1) to the torque indicated in the table. 88356

Position the cylinder head extension dowels on the cylinder head (if they were removed previously).

Ref.

No.

Description

(1)

2

M8x1.25x16

Tightening torques 25±2.5

Thoroughly clean the hydraulic tappets (2), lubricate them and place them in the cylinder head (3), positioning the rocker arms (1) on the valves correctly. Place a new cylinder head extension gasket (5) in its seat. Insert the two tools SP. 2264 (4) into the electro-injector seats for subsequent centring of the overhead on the cylinder head.

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 260

75

Figure 262

227816

229288

Fit the upper chain guide (6), drive in the screws (5) and tighten them to the torque indicated in the table.

Position the single link chain (4) on the gear (3) and fit the latter on the camshaft of the exhaust valves.

Fit the side chain guide (1), drive in the screws (2 and 3) and tighten them to the torque indicated in the table.

Drive in the fastening screw (1) with the washer (2) without tightening it completely.

Fit the plug (4) with a new gasket and tighten it to the torque indicated in the table. Ref. (2) (3) (4) (5)

No.

Description

NOTE

The gear (3) must be mounted with the markings inwards. In the gear (3) there is a larger hole for adjustment, which fits onto the pin on the exhaust camshaft shank.

NOTE

The chain arm (4) between the two gears must be tensioned.

Tightening torques

2

M6x1x20

10±1

1 2

M26x1.5x16 M6x1

50±5 10±1

Figure 261

88358

Position the single link chain (1) on the drive gear (5) and on the intake camshaft gear (2). Mount the gear in such a way that fitting on intake valve timing system shaft dowel makes slots A to result to be positioned as in figure. Drive in the fastening screw (4) with the washer (3) without tightening it completely. NOTE

The chain arm (1) between the two gears must be tensioned.

Print P1D32S021 E

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76

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 263

F1C EuV1 - ENGINES

Figure 265

230342

229294

Screw on the chain anti-return hydraulic tensioner (2) and tighten to the torque indicated in the table.

Make sure that the chain (1) in the tract between the gear (2) and gear (3) is tensioned.

Ref.

No.

Description

(2)

1

M22x1.5x22

Tightening torques 50±2.5

From the opening in the overhead, press on the tab (3) of the secondary tensioner arm (4) with a screwdriver and push the piston (1) of the chain anti-return hydraulic tensioner (2) fully down.

Tighten the fastening screw of the gear (3) on the exhaust valve camshaft to the torque indicated in the table. Ref.

No.

(3)

1

Description M12x1.75x40

Tightening torques 110±5.5

Figure 266

Release the secondary tensioner arm (4) and check that the piston (1) protrudes from its seat, thus tensioning the chain (5).

!

The hydraulic chain tensioners (with anti-return device) can absolutely never be re-used. Whenever the piston has inadvertently been made to come out of the new chain tensioner, it must be replaced; it cannot be reset.

Figure 264 230343

Remove tools 99360614 (1) and fit the two inspection caps in their housing tightening to the torque indicated in the table. Ref.

No.

Description

(-)

2

M14x1.5x10

Tightening torques 25±2.5

229293

Tighten the fastening screw of the gear (1) on the intake valve camshaft to the torque indicated in the table. Ref.

No.

(1)

1

Base - April 2015

Description M12x1.75x40

Tightening torques 110±5.5 Print P1D32S021 E

F1C EuV1 - ENGINES

77

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 267

Figure 268

229348

227805

Fit the exhaust gas pipe (4), on the cylinder head, together with the rear cover (3) and a new gasket and tighten the screws (5) to the torque indicated in the table.

Fit the pre/heater glow plugs (1) in their housing on the cylinder head using the SP.2275 tool and torque wrench 99389819, then tighten them to the torque indicated in the table.

Engage the EGR exhaust gas temperature sensor electrical connection (6) to the bracket and to the intermediate clips. Fit the bracket securing the coolant delivery pipes group (2) to the cylinder overhead and tighten the screw (1) to the torque indicated in the table. Ref.

No.

Description

(1) (5) (5)

1 3 4

M8 x1.25 M8x1.25x35 M8x1.25x45

Print P1D32S021 E

Ref.

No.

(1)

4

Description M8x1

Tightening torques 9±1

Tightening torques 25±2.5 25±2.5 25±2.5

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SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

F1C EuV1 - ENGINES

Figure 269

229347

Remove the intake manifold (6) as described in the relative procedure.

Remove the fuel manifold pipe (2) as described in the relative procedure.

Remove the thermostat (5) as described in the relative procedure.

Remove the high pressure fuel pipe from pump to rail (4) as described in the relative procedure.

Remove the electro-injectors (1) as described in the relative procedure.

Remove the low pressure fuel pipe group (3), together with the fuel return pipe as described in the relative procedure.

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

79

Figure 270

229346

Remove the EGR group (6) as described in the relative procedure.

Remove the timing system lower cover (3) as described in the relative procedure.

Remove the turbocharger/exhaust manifold group (4) as described in the relative procedure.

Remove the timing system upper cover (2) as described in the ”SIDE/UPPER CHAIN GUIDE REMOVAL/REFITTING” procedure.

Remove the electric exhaust gas flap (5) as described in the relative procedure.

Print P1D32S021 E

Remove the engine wiring (1) as described in the relative procedure.

Base - April 2015

80

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

OIL SUMP REMOVAL/REFITTING

F1C EuV1 - ENGINES

Refitting

Removal

Figure 273

Place an appropriate container for the oil collection under the sump in correspondence with the drain plug. Open the oil filler inlet on the cylinder overhead and take out the oil level dipstick to allow the oil to flow more freely. Figure 271

230419

Fit the oil sump (2) with a new gasket and the oil pan frame (3), than tighteen the screws (1) to the torque indicated in the table.

230418

Unscrew the drain plug (1) and let the oil in the sump drain out completely. Ref. (1)

No. 1

NOTE

Description M22x1.5x10

It is recommended that the oil drained while hot.

Rotate the engine through 180˚ on the overhaul stand. Figure 272

Ref.

No.

Description

(1)

13

M8x1.25x35

Tightening torques 25±2.5

Place the oil drain plug (4) and tighteen it to the torque indicated in the table. Ref.

No.

Description

(4)

1

M22x1.5x10

Tightening torques 50±5

Rotate the engine through 180˚ on the overhaul stand. Proceed to refill with the specified oil. Operate the engine for a few minutes and then check the level using the dipstick: the level must come close to the MAX notch which can be seen on the dipstick. If this is not the case, top-up as necessary the engine lubricant oil with the specified quantity and quality of lubricant oil. NOTE

Only use recommended oils or oils with the properties required for proper engine operation. Failure to observe these standards will invalidate the service warranties.

230344

Undo the screws (1) and remove the oil sump (2) with the gasket and its oil pan frame (3). Ref. (1)

No. 13

Base - April 2015

Description M8x1.25x35

Print P1D32S021 E

F1C EuV1 - ENGINES

Print P1D32S021 E

SECTION 5 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS

81

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F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

1

SECTION 6 General mechanical overhaul Page

Print P1D32S021 E

ENGINE DISASSEMBLING ON BENCH . . . . . .

3

- Removal of components hindering bracket assembly . . . . . . . . . . . . . . . . . . . . . . .

3

- Fitting the engine on the rotating stand . . . . .

7

- Engine disassembling (components on top side part 1) . . . . . . . . . .

7

- Engine disassembling (components on exhaust side) . . . . . . . . . . . .

9

- Engine disassembling (components on intake side side) . . . . . . . . . .

11

- Engine disassembling (components on front side) . . . . . . . . . . . . . .

13

- Engine disassembling (components on rear side) . . . . . . . . . . . . . . .

19

- Engine disassembling (components on top side part 2) . . . . . . . . . .

20

- Engine disassembling (components on bottom side) . . . . . . . . . . . .

21

CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Checking head mating surface on cylinder block

25

- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Main bearing shells selection . . . . . . . . . . . . . .

29

- Main bearings shell position . . . . . . . . . . . . . . .

31

- Standard main journals (STD) . . . . . . . . . . . . .

33

- Undersized main journals (-0.127 mm) . . . . .

36

- Undersized main journals (-0.254 mm) . . . . .

37

- Undersized main journals (-0.508 mm) . . . . .

38

- Big end bearing shell selection . . . . . . . . . . . .

39

- Big end bearing shells position . . . . . . . . . . . . .

40

- Standard cranckpins (STD) . . . . . . . . . . . . . .

41

- Undersized cranckpins (-0.127) . . . . . . . . . . .

42

Base - April 2015

2

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Page

Page

- Undersized cranckpins (-0.254) . . . . . . . . . . .

43

- Checking crankshaft end float . . . . . . . . . . . . .

61

- Undersized cranckpins (-0.508) . . . . . . . . . . .

43

- Engine assembling (components on bottom side) . . . . . . . . . . . .

64

- Engine assembling (components on top side part 1) . . . . . . . . . .

65

- Engine assembling (components on rear side) . . . . . . . . . . . . . . .

66

- Engine assembling (components on front side part 1) . . . . . . . . .

67

- Engine assembling (components on intake side ) . . . . . . . . . . . . .

76

- Engine assembling (components on exhaust side ) . . . . . . . . . . .

78

- Engine assembling (components on top side part 2) . . . . . . . . . . . . . . . . . . . . .

80

- Removing the engine from the rotating stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83

- Connecting rod - piston assembly . . . . . . . . .

44

- Cylinder head components . . . . . . . . . . . . . . .

49

- Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

- Valves guide . . . . . . . . . . . . . . . . . . . . . . . . . .

52

- Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

- Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . .

55

- Rocker arms - tappets . . . . . . . . . . . . . . . . . . .

55

- Assembling valves . . . . . . . . . . . . . . . . . . . . . .

56

- Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

- Assembling overhead components . . . . . . . . .

59

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

60

- Refitting of components hindering bracket assembly . . . . . . . . . . . . . . . . . . . . . .

83

- Crankcase components assembly . . . . . . . . . .

60

CHECKS AND INSPECTIONS . . . . . . . . . . . . . .

88

- Cranckshaft assembly . . . . . . . . . . . . . . . . . . .

60

- Low pressure supply circuit diagnostics . . . . .

89

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

3

SECTION 6 - GENERAL MECHANICAL OVERHAUL

ENGINE DISASSEMBLING ON BENCH In order to apply the brackets 99361041 to the engine block to fix it on to the stand 99322205 for the overhaul, it is necessary to perform the following operations.

Removal of components hindering bracket assembly Engine wire removal Disengage the engine wiring cover from the cylinder overhead, disengage the pins from the relative brackets and remove the engine wiring. Disconnect the following electrical connections: Figure 1

227787

REAR VIEW OF ENGINE, INTAKE SIDE 1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor 4. Engine brake actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch 7. Fuel flow regulator on high pressure pump 8. Air charger intercooler outlet temperature sensor - 9. Coolant temperature sensor 10. Air pressure and temperature sensor - 11. Pressure regulating valve on rail - 12. Segment speed sensor

Print P1D32S021 E

Base - April 2015

4

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 2

227788

FRONT VIEW OF ENGINE, EXHAUST SIDE 1. Air charger intercooler outlet temperature sensor - 2. Coolant temperature sensor - 3. Segment speed sensor 4. EGR valve - 5. Increment speed sensor - 6. VGT position sensor - 7. Engine brake actuator

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Disengage the engine wiring cover from the cylinder overhead, disengage the pins from the relative brackets and remove the engine wiring.

5

Exhaust side enginemount and turbocharger oil outlet pipe removal Figure 4

Intake side engine mount Figure 3

227789

Undo the screws (1), and remove the Intake side engine mount (2), Ref. (1) (1)

No. 1 2

Description M10x1.25x95 M10x1.25x50

Place a suitable container, remove the plug from the oil sump and drain the engine oil. Ref. -

No. 1

Description M22x1.5x10

Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water.

214660

Undo the screws (1), the fitting (2) and remove the oil return pipe from the turbocharger and from the crankcase with the relative gasket. Undo the screws (3),(4) and the bracket screw (6) then remove the exhaust side engine mount (5). Ref. (1) (2) (3) (4) (6)

No. 2 1 2 1 1

Description M6x1x16 M22x1.5 M10x1.25x85 M10x1.25x50 M8x1.25x20

Electric exhaust gas flap removal Figure 5

Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.

214646

Unlock the V-clamp (1) and remove the electric exhaust gas flap (2) from the turbocharger. Ref. (1) Print P1D32S021 E

No. 1

Description M8x70 Base - April 2015

6

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Turbocharger air outlet pipe removal

Turbocharger - Exhaust manifold group removal

Figure 6

Figure 8

214647

Undo the screws (2) and remove the union bracket (3). Undo the screws (1) and disconnect the union bracket (5) from the EGR heat exchanger. Disconnect and remove the turbocharger air outlet pipe (4) with the bracket. Ref. (1) (2)

No. 2 2

Description M8x1.25x20 M6x1x18

229316

Undo the screws (1), disconnect and remove the exhaust gas delivery pipe. Remove the relative gaskets. Ref. (1)

No. 4

Description M8x1.25x20

Figure 9

Turbocharger oil delivery pipe and exhaust manifold guard removal Figure 7

229315

220125

Undo the fittings (1) and (5), then remove the turbocharger oil delivery pipe (6).

Undo the fitting (1) and disconnect the turbocharger water return pipe from the turbocharger.

Undo the screws (2) and remove the exhaust manifold guard (3) taking care to retrieve all the spacers.

Undo the bracket screws (2), and move the turbocharger water return pipe (1) aside.

Undo the union (4) and disconnect the turbocharger water delivery pipe from the cranckase. Ref. (1) (5) (2) (4)

No.

Description

2

M14x1,5

4 1

M6x1.25x14 M14x1.5

Base - April 2015

Ref. (1) (2)

No. 1 2

Description M14x1.5 M8x1.25x16

Print P1D32S021 E

F1C EuV1 - ENGINES

7

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Electro-Injectors and fuel manifold pipe (rail) removal

Figure 10

NOTE

Place a suitable container to collect the fuel as it drains out of the pipes.

Figure 12

229317

Undo the nuts (1) securing the exhaust manifold to the cylinder head. Remove the exhaust manifold-turbocharger group (2) and the relative gasket, taking care to retrieve all the spacers. Ref. (1)

NOTE

No. 10

Description M8x1.25

230352

Block the turbocharger air/exhaust gas inlets and outlets to prevent foreign bodies getting inside.

Lift the retaining clips (1) in the direction shown by the arrow and disconnect the fuel recovery pipe (2) from the electro-injectors, open the retaining clip (3) and move the fuel recovery pipe aside. Figure 13

Fitting the engine on the rotating stand. Fit the brackets 99361041 to the crankcase and use these to secure the engine to the rotary stand 99322205.

Engine disassembling (components on top side part 1). Air inlet pipe removal Figure 11

229305

Using tool 99317915 (rail side) and tool 99352115 (electroinjectors side), undo the fittings on the fuel manifold pipe (1), and on the electro-injectors (2), then remove the high pressure fuel pipes. Ref. (1) (2)

No. 4 4

Description M15x1 M14x1.5

227790

Undo the screws (2), remove the air inlet pipe (1) and the flange (3) from the intake manifold, together with the gasket and the air charger intercooler outlet temperature sensor. Ref. (2)

No. 4

Print P1D32S021 E

Description M8x1.25x25

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Base - April 2015

8

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 14

Figure 16

88244 229306

Undo the screws (1) and remove the brackets (2) securing the electro-injectors (3) to the cylinder overhead.

Apply tool 99342153 (1), using the screw holes of securing electro-injector’s brackets and extract the electro injectors (2) from the cylinder overhead (3).

Ref. (1)

NOTE

No. 4

Description M8x1.25x80

Using tool 99342153 to extract the electro-injectors from the cylinder overhead. NOTE

This procedure has to be done to avoid damage of the electro-injectors’s electrical connector.

After removal, mark the injector with the cylinder number of belonging, for a proper calibration of the codes IMA; or in case of replacement, we want to make laboratory analysis. Also make sure that the seal is not left in the injector seat engine head.

Figure 17 Figure 15

227792

227791

Remove the bracket (1). Using an hammer and 3,5 max punch, remove the pins (2). When the bracket (1) is reassembled, rotate it about 3˚ ÷ 4˚ in this direction from the original position.

Base - April 2015

Undo the screw (2) fixing the oil level dipstick upper bracket to the intake manifold and extract the oil level dipstick (1) from the oil sump. Ref. (2)

No. 1

Description M8x1.25

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

9

Engine disassembling (components on exhaust side)

Figure 18

EGR group removal Figure 19

227793

Undo the fittings (1) and (4), the bracket nut (2), and remove the high pressure fuel delivery pipe. Loosen the clamp (5) and disconnect the fuel return pipe from the fuel manifold pipe. Undo the screws (7), open the relative band and remove the fuel manifold pipe (6) from the cylinder overhead. Ref. (1) (2) (4) (7)

No. 1 1 1 2

Description M16x1 M8x1.25 M15x1 M8x1.25x35

Because of the high pressure in the pipelines running from the fuel feed pump to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working;

Print P1D32S021 E

227794

Undo the screw (1) to open the fixing collar for the exhaust gas pipe. Losen the clamp (2) and disconnect the EGR heat exchanger engine coolant delivery pipe. Undo the screws (5) fixing the exhaust gas pipe to the intake manifold; open the clip (6) securing the EGR exhaust gas temperature sensor. Undo the rear cover screws (4) and remove the exhaust gas pipe group (3), together with the rear cover and the relative gasket. Ref. (1) (4) (4) (5)

No. 1 3 4 2

Description M6x1 M8x1.25x35 M8x1.25x45 M8x1.25x30

Base - April 2015

10

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Auxiliary drive belt - automatic belt tensioner removal

Figure 20

Figure 22

227795

Losen the clip-sleeve (1) and disconnect the EGR heat exchanger engine coolant delivery pipe (2) from EGR. Undo the bracket screw (4) securing the coolant delivery pipes to the cylinder overhead. Remove the coolant delivery pipes group (3). Ref. (4)

No. 1

227797

Using a suitable tool remove the A/C compressor belt (2). Using the specific wrench on the automatic belt tensioner, reduce the tension of the belt (1) and remove it. Undo the screw (3) and remove the automatic belt tensioner (4).

Description M8x1.25

Ref. (3)

Figure 21

No. 1

Description M10x1.5x45

Alternator removal Figure 23

227796

Undo the screws (1) and remove the EGR group (2). Ref. (1) (1)

No. 3 1

Description M8x1.25x80 M8x1.25x95

227798

Undo the screw (3) and bolt (1), then remove the alternator (2) from its support. Ref. (3) (1)

Base - April 2015

No. 1 1

Description M10x1.25x30 M10x1.25x130

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

11

Low pressure pipes group removal

Figure 24

Figure 26

227799

Undo the fixing screws (1) then remove the alternator support (2). Ref. (1) (1) (1)

No. 1 1 2

227801

Loosen the clamp (1) and disconnect the fuel pipe fromfilter to high pressure pump.

Description M8x1.25x70 M8x1.25x35 M8x1.25x30

Adjust the quick connector (2) and disconnect the fuel pipe from the high pressure pump to tank. Figure 27

Engine disassembling (components on intake side) Oil filter removal Figure 25

227802

Release the intermediate retaining clip securing the low pressure pipes group to the cranckcase. Undo the bracket screw (1), fixing the low pressure pipes group to the intake manifold. 227800

Using tool 99360076 remove the oil filter (1) from the water/oil heat exchanger. Ref. (1)

No. 1

Print P1D32S021 E

Description M22x1.5

Undo the screws (2) fixing the duplex pipe anchorage bracket, and remove the low pressure pipes group together with the fuel recovery pipe from electroinjectors. Ref. (2) (1)

No. 2 1

Description M6x1x10 M6x1

Base - April 2015

12

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Water/oil heat exchanger removal

Thermostat removal

Figure 28

Figure 30

227803

214644

Undo the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder.

Undo the screws (1) and remove the thermostat cover (2), with the thermostat and the relative gasket.

Undo the screws (1) and remove the water/oil heat exchanger (2) with the relative gasket and the engine cooling water pipe.

Ref. (1)

Ref. (1) (3)

No. 8 1

No. 4

Description M8x1.25x20

Intake manifold removal

Description M8x1.25x30 M8x1.25

Figure 31

High pressure pump removal Figure 29

227804

If necessary to facilitate the operation undo the nut (1) and remove the air temperature/pressure sensor with the relative o-ring. 229313

Unscrew and remove the screw (5), unscrew and remove screws (1) with their washers (3). Remove the high pressure pump (2) from its support (4). Ref. (1) (5)

No. 2 1

Description M8x1.25x90 M6x1x20

Ref. (1)

Description M6

Undo the two threaded plugs (3) on the intake manifold, in order to reach the screws below. Undo the screws (2), (4) and (5) securing the intake manifold to the cylinder head. Remove the intake manifold (6) and the relative gasket. Ref. (2) (4) (5) (3)

Base - April 2015

No. 1

No. 2 6 1 2

Description M8x1.25x60 M8x1.25x40 M8x1.25x140 M24x1.5 Print P1D32S021 E

F1C EuV1 - ENGINES

13

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Pre/heater glow plugs removal

Water pump and 3 speed electromagnetic pulley removal

Figure 32

Figure 34

227805

227807

Undo and remove the glow plugs (1) fromthe cylinder head.

Undo the ring nut (2), the nuts (1) and remove the electromagnetic pulley (3).

Ref. (1)

No. 4

Description M8x1

Undo the screws (4) and remove the water pump (5) with the relative gasket.

Engine disassembling (components on front side)

Ref. (1) (2)

Blow-by removal

(4)

Figure 33

No. 4 1 2 3

Description M6x1 M30x1.5 M8x1.25x45 M10x1.5x55

Timing sensor and timing system upper cover removal Figure 35

227806

Undo the nut (1) fixing the complete blow-by pipe bracket to the cylinder head. Undo the screws (2) and remove the cover (3) complete with blow-by pipe. Remove the piston ring and the centrifugal filter. Ref. (1) (2)

NOTE

No. 1 3

Description M8x1.25 M6x1x18

The centrifugal filter and the seal ring of the cover must be changed at every removal.

Print P1D32S021 E

217902

Undo the screw (3), and remove the phase sensor (4). Undo the nuts (1), the screws (2) and remove timing system upper cover (5). Ref. (1) (2) (3)

No. 2 7 1

Description M6x1 M6x1x30 M6x1x16

Base - April 2015

14

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Dumper pulley and crankshaft front gasket removal

Figure 38

Figure 36

227808

Stop the rotation of the engine flywheel (2) by means of tool 99360306 (1).

221408

Mount the extractor 99340062 (1) on the crankshaft, tighten the screw (2) on the crankshaft hole by hand, then with a key close for another 30˚ ÷ 60˚.

Figure 37 NOTE

The extractor doesen’t need an angular position (can rotate 360˚).

Figure 39

227809

Undo the screw (3) and detach the damper pulley (4). Ref. (3)

No. 1

Description M20x1.5x58

Undo the screw (1) and remove the A/C compressor belt tensioner (2). Ref. (1)

No. 1

Base - April 2015

Description M8x1.25x45

221409

Block the extractor closing the nut (1) by hand, then with a key close for another 30˚ ÷ 60˚.

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

15

Timing system lower cover removal

Figure 40

Figure 43

221421

Pierce the gasket with the punch (1), using a hammer, stroke until it arrive at the shoulder of the extractor.

227810

Undo the screws (1) and remove the timing system lower cover (2) and the gasket.

Figure 41

Undo the screw and remove the engine increment speed sensor (3). Ref. (1) (1) (3)

No. 9 7 1

Description M8x1.25x30 M8x1.25x16 M6x1x12

Depressor/oil pump unit removal Figure 44 221410

Tighten the screw (1) by hand. NOTE

Three screws at 120˚ are sufficient.

Figure 42

227811

Undo the screws (3) and disassemble the depressor/oil pump unit (2). Remove the coupling drive (1). Ref. (3)

No. 5

Description M8x1.25x60

221411

Unscrew the nut (1), then the screw (2) until the extractor come out with the gasket.

Print P1D32S021 E

Base - April 2015

16

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Camshaft gears and upper timing chain removal

Figure 47

Figure 45

227812

227813

Undo the two plugs (1) on the tappet cover in order to fit the timing tools 99360614. Ref. (1)

No. 2

Undo and remove the chain anti-return hydraulic tensioner (1) and chain standard hydraulic tensioner (5). Undo the bolt shoulder (3), disassemble and remove the secondary tensioner arm (2). Disassemble and remove the primary tensioner arm (4).

Description M14x1.5x10

Ref. (1) (5) (3)

Figure 46

No. 1 1 1

NOTE

Description M22x1.5x22 M22x1.5x22 M10x1.5

The chain hydraulic tensioners are equipped with an anti-return device; it is therefore necessary to replace the chain tensioners each time they are removed.

Figure 48

227814

Rotate the crankshaft and fit the timing tools 99360614 (1) on the overhead.

227815

Undo the screw (5), keep the washer (6) and remove the exhaust camshat gear (7). Undo the screw (3), keep the washer (4), remove the intake camshaft gear (2) and the single link timing chain (1). Ref. (3) (5) Base - April 2015

No. 2

Description M12x1.75x40 Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Side/upper chain guide removal

High pressure drive gear and lower chain removal

Figure 49

Figure 51

227816

Remove the plug (4) and undo the screw (3). Undo the retaining screw (5) and remove the upper chain guide (6). Ref. (5) (2) (3) (4)

No. 2

17

227819

Stop the rotation of the high pressure pump control shaft (1) by inserting the suitable wrench inside it. Figure 52

Description M6x1

2

M6x1x20

1

M26x1.5x16

Side/lower fixed pads removal Figure 50

227820

Undo the screw (3) and remove the shaft with the drive gear (2) from the high pressure pump control shaft (1). Ref. (3)

No. 1

Description M12x1.5x42.5

Figure 53

227818

Undo the screws (2) and remove the side fixed pad (1). Undo the screws (4) and remove the lower fixed pad (3). Ref. (2) (4)

No.

Description

4

M8x1.25x35

227821

Remove the gear (1) and the double link chain (2) from the high pressure pump control shaft. Print P1D32S021 E

Base - April 2015

18

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 54

Figure 56

227822

Remove the high pressure pump control shaft (3).

Undo the screws (1 and 2) and remove the A/C compressor support (3).

Undo the nuts (2) and remove the support (1). Ref. (2)

No. 3

227825

Ref. (1) (2)

Description M8x1.25

Power steering pump, A/C compressor and A/C compressor support removal

No. 2 2

Description M8x1.25x20 M8x1.25x130

Power steering control shaft removal Figure 57

Figure 55

227529

227823

Undo and remove the screw (1) and the screw (2) with their washer. Remove the power steering pump (3) from its support. Ref. (1) (2)

No. 1 1

Description M10x1.25x30 M10x1.25x110

Stop the rotation of the hydraulic power steering pump control shaft (1) by inserting tool 99360187 (3) in the shaft and fastening the tool on the support (4) by means of the screws (2). Ref. (2)

No. 2

Description M10x1.25

Undo the screws (4) and remove the A/C compressor (5). Ref. (4)

No. 4

Base - April 2015

Description M8x1.25x90

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

19

Engine disassembling (components on rear side)

Figure 58

Engine flywheel removal Figure 60

227530

Undo the screw(3) and remove the gear (2) for the hydraulic power steering control shaft (1). Ref. (3)

No. 1

Description M12x1.25x42.5

227532

Block rotation of the flywheel (2) with tool 99360306 (1).

Undo the fixing screws and remove the tool 99360187 for locking the rotation of the power steering pump shaft..

Undo the screws (3) and remove the engine flywheel (2). Ref. (3)

Figure 59

No. 8

Description M12x1.25x51

Figure 61

227531

Remove the hydraulic power steering control shaft (3). Undo the nuts (2) and remove the power steering support (1). Ref. (2)

No. 3

Print P1D32S021 E

Description M8x1.25

227533

Undo the stud (2), the threaded bushes (1) and remove the rear protection (3) from crankcase. Ref. (1) (2)

No. 2 1

Description M12x1.5x22.5 M6x1.25

Base - April 2015

20

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Engine disassembling (components on top side part 2)

Figure 62

Over head removal Figure 64

227534

Apply specific tool 99340060 (2) to the rear seal ring (1) and extract it from the cranckase. Figure 63

229275

Undo the screws (1) and remove the bracket (2). Ref. (1)

No. 2

Description M8x1.25x16

Figure 65

225110

To mount the tool 99340060 it is necessary to perform the following operations: - unscrew the extractor central screw (2) almost completely. - loosen the three screws (1) to enlarge the three flanges (3) in order to hold them over the ring (4) of the seal.

229298

- tighten the screws (1) until the flanges hold over the seal ring.

Undo the fixing screws (1) and take off the over-head (2) from the cylinder head (3).

- finally tighten the central screw (2) and extract the seal ring. NOTE

Base - April 2015

Ref. (1) (1)

No. 10 20

Description M8x1.25x40 M8x1.25x77

ensure that the flanges are driven into the entire circumference of the seal ring: an improper positioning of the tool could make necessary a complete dismantling of the crankshaft to extract the seal ring.

Print P1D32S021 E

F1C EuV1 - ENGINES

21

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Hydraulic tappets removal

Figure 68

Figure 66

224215

88281

Remove the cylinder head gasket (1).

Remove the hydraulic tappets (1) with the rocker arms. Remove the gasket (2).

NOTE

Cylinder head removal

Check the protrusion of the pistons (2) as described under the relevant heading to check the possibility of facing the crankcase if it has deformed.

Figure 67

Engine disassembling (components on bottom side) Oil sump removal Rotate the engine through 180˚ on the overhaul stand. NOTE

Place a suitable container below the sump to collect the oil as it drains out of the drain plug.

Figure 69 Undo the screws (1) and remove the cylinder head (2). Ref. (1) (1) (1) (1)

No. 6 4 4 1

Description M15x1.5x193 M12x1.5x165 M8x1.25x117 M8x1.25x58

229276

Undo the screws (2) and remove the oil sump (1) with the gasket and its oil pan frame (3). Ref. (2)

Print P1D32S021 E

No. 13

Description M8x1.25x35

Base - April 2015

22

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Engine oil suction pipe removal NOTE Figure 70

Mark the connecting rods and caps with the cylinder number to which they belong and the respective fitting positions; keep the half-bearings in their respective housings. If some components are re-used they must be fitted in the same positions they were in before being dismantled.

Lower cylinder block removal Figure 72

229277

Undo the screws (2) and remove the engine oil suction pipe (1) with the relative gasket. Ref. (2)

No. 3

Description M6x1x12

Pistons and caps removal 214653

Figure 71

Using a suitable tool undo the screws (1), (3), (4) and remove the lower cylinder block (2). Ref. (1) (3) (4)

No. 17 2 10

Description M8x1.25x77.5 M8x1.25x40 M12x1.5x125

Figure 73

214652

Bring pistons 1 and 4 close to BDC. Take out the screws (2) and remove the connecting rod caps (3) for cylinders 1 and 4. Slide out pistons 1 and 4 complete with connecting rods. Remove the pistons, caps, connecting rods from cylinders 2 and 3, following the same procedure. Ref. (2)

No. 8

Base - April 2015

Description M11x1.25x51

88289

NOTE

Note the assembly position of the top main bearing shells (2) on the lower cylinder block (1) since, if they are reused, they will need to be fitted in the position found during removal.

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Cranckshaft removal

23

Replacing timing control gear On finding the timing control gear teeth (1) damaged or worn, remove them from the crankshaft (2) using a suitable extractor.

Figure 74

The new gear is fitted onto the crankshaft by heating it to a temperature of 180˚C for no longer than 15 minutes. On completing assembly and after the gear has cooled, it must withstand a torque of 150 Nm without slipping. Cooling piston nozzles removal Figure 76

87793

With the aid of a hoist and a rope, remove the crankshaft (1). NOTE

Note the assembly position of the top main bearing shells (2) since, if they are reused, they will need to be fitted in the position found during removal.

The central half-bearing (3) is fitted with shoulder half-rings. Replacing phonic wheel

75290

Take out the couplings (1) and remove the oil jets (2). Figure 75 Ref. (1)

NOTE

No. 4

Description M10x1

On completing engine removal, it is necessary to clean the removed parts thoroughly and check their integrity. The following pages give the instructions for the main checks and measurements to make in order to determine whether the parts can be reused.

87792

Undo the screw (1) and remove the phonic wheel (2) from the cranckshaft (3). Fit a new phonic wheel (2) on the cranckshaft (3) and tighteen the screws (1) to the torque indicated in the table. Ref.

No.

(1)

3

Print P1D32S021 E

Description M6x1x15

Tightening torques 15 Nm

Base - April 2015

24

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 78

CHECKS Cylinder block Checking cylinder liners Figure 77

186835

18837

The measurements must be made for each single cylinder at three different heights up the liner and on two planes at right angles to each other: one parallel to the longitudinal axis of the engine (B) and the perpendicular (A); the greatest wear is generally found on this last plane with the first measurement.

After disassembling the engine, thoroughly clean the cylinder crankcase assembly.

On finding ovalization, taper or wear, go ahead and bore/grind and finish the face of the cylinder liners.

Use the rings provided to carry the cylinder block.

The refacing of the cylinder liners should be done in relation to the diameter of the pistons supplied as spare parts oversized by 0.4 mm of the nominal value and to the prescribed assembly clearance.

Check thoroughly that no cracks are to be noticed on the crankcase. Check the condition of casting hole plugs. If the caps are rusted, or if there is any doubt about the efficiency of the seal, replace them.

Figure 79

When assembling plugs, apply sealant Loctite 270 on them. Inspect the surfaces of the cylinder liners; they should not be scored, seized, ovalized, conical or worn to excess. Check the inner diameter of the cylinder liners to ascertain the extent of ovalization, taper and wear, using the bore meter (1) fitted with a dial gauge previously reset on the ring gauge of the diameter of the cylinder liner or on a micrometer.

87782

Base - April 2015

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

25

Checking head mating surface on cylinder block

Figure 80

Figure 81

88290

See that the head mating surface, on the cylinder block, has no deformation. This check can be made, after taking out the grub screws (3), with a surface plate spread with carbon black or with a calibrated rule (1) and a feeler gauge (2). After ascertaining the areas of deformation, level the bearing surface with a grinding machine.

224203

* Surface roughness parameters: R1 Rz Ra W1

= = = <

4 ÷ 10 m 3 ÷ 8 m 0,25 ÷ 0,6 m 1.5 m

NOTE The crankcase can only be surfaced after making sure that, on completing the work, the piston protrudes from the cylinder liner by no more than the prescribed value.

Crankshaft Measuring main journals and crankpins Figure 82

Permissible surface porosity for machined cylinder (see figure above)

ZONE B1 = Area of greatest mechanical stress, segment/liner contact: No.2 non-continuous porosities are permissible max. 0.5x0.5.

ZONE B2 = Surface involved in segment rubbing: No.2 non-contiguous porosities are permissible max. 1x0.8.

C 100%

C 100%

75298

On finding signs of seizure, scoring or excessive ovalization on main journals and crankpins, it is necessary to regrind the pins. Before grinding the pins (2), measure the shaft pins with a micrometer (1) to establish to what diameter it is necessary to decrease the pins.

NOTE It is advisable to enter the measurements in a table. See the following figure.

Print P1D32S021 E

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

NOMINAL VALUE

Figure 83

NOMINAL VALUE

MINIMUM  MAXIMUM 

NOMINAL VALUE MINIMUM  MAXIMUM  87784

TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS

NOTE The main journals and crankpins must always be ground to the same undersize class. The undersizing performed, on the main journals or crankpins, must be marked by punching on the side of crank arm no. 1.

Base - April 2015

For undersized crankpins, letter M. For undersized main journals, letter B. For undersized crankpins and main journals, letter MB. The undersize classes are: 0.127 - 0.254 - 0.508 mm.

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27

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Checking crankshaft Figure 84

87785

MAIN CRANKSHAFT TOLERANCES TOLERANCES SHAPE ORIENTATION POSITION OSCILLATION

TOLERANCE CHARACTERISTIC

GRAPHIC SYMBOL

Circularity Cylindricality Parallelism Perpendicularity Concentricity or coaxiality Circular oscillation Total oscillation

CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL

CRITICAL IMPORTANT SECONDARY

Figure 85 NOTE The checks on the tolerances indicated in the figures must be made after grinding the crankshaft pins. SYMMETRY BETWEEN CRANKPINS 1. Crankpins 2. Main journals 3. Normal position

MAIN

JOURNALS

AND

After grinding, keep to the following: round off and deburr the edges of the holes for lubrication of the main journals and crankpins.

229278

Print P1D32S021 E

Follow the measurements of corner rounding deburring holes shown in the following figures, (main journal on timing side). Base - April 2015

28

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Main journal on timing system side

Journal on flywheel side

Figure 86

Figure 89

honed

Before rolling

max. 0.1 on 360

honed

waviness in circumferential direction waviness in axial direction

87787

Intermediate journals no. 2 - 4 Figure 87

RACE AREA FOR ALL MAIN JOURNALS (MACHINED BY TURNING)

87790

Before rolling

max. 0.1 on 3605

Crankpins Figure 90

max. 0.13 on 360

honed

*

Before rolling

honed

87791

As far as both values are concerned, for the whole 360.

87788

NOTE Since, during the 0.127 - 0.254 and 0.508 mm undersizing on the diameter of the crankpins and main journals, the rolled portion of the side races of the pins may get involved, it is necessary to turn the races keeping to the data given in the figure and to do the rolling keeping to the following instructions.

Intermediate journal no. 3 Figure 88

Rolling force: - 1st main journal 925 25 daN. - 2nd - 3rd - 4th - 5th main journal 1850 50 daN. - crankpin 1850 50 daN. - Rolling turns: 3 approach, 12 effective, 3 out. Before rolling

max. 0.1 on 360

smooth

- Rolling speed: 56 rpm. - Reduction of the connecting rod pin slot diameter after rolling: 0.15  0.30 mm*. 217913

MAIN DATA OF MAIN JOURNALS AND CRANKPINS

Base - April 2015

- Reduction of the journal slots after rolling: 0.15  0.30 mm. * Measured with calibrated rollers  2.5 mm. Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

29

Main bearing shells selection Selection of main bearing shells No. 1-2-3-4-5 During the preliminary stages (points 1 and 2) identify the main bearing shell class in relation to the crankshaft and crankcase selected; this operation is essential for cases in which the exact positions of the bearing shells were not marked during removal. The operation consists in identifying the classes from the codes on the components (measuring thickness, as a solution to possible fading of colour of identification), and then using these in the corresponding charts to select the main bearing shells: - Identification of crankshaft codes Figure 91

227251

A. Crankpin (1=standard, 2=undersized) - B. Crankpin classes (indicates class from 1 to 3 for pins no. 1-2-3-4 - see ”Table for selection of big end bearing shells”) - C. Main journals (1=standard, 2=undersized) - D. Main bearing shell classes (indicates class from 1 to 9 for pins no. 1-2-3-4-5 - see ”Table for selection of main bearing shells No. 1-2-3-4-5”, row ”X”) - Identification of crankshaft codes

Print P1D32S021 E

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 92

227252

D. Main bearing shell classes (indicates class from 1 to 9 for pins no. 1-2-3-4-5 - see ”Table for selection of main bearing shells No. 1-2-3-4-5”, row “Y”)

Base - April 2015

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

Main bearings shell position Lower main bearing shells Figure 93

227284

1. Coupling between bearing shell notch and lower crankcase seat spotface - 2. Coupling of the lower bearing shells and lower crankcase - 3. Lower crankcase

NOTE

Always couple the bearing shell with the spotface on the lower crankcase (1); failure to do so will cause bearing shell rotation and seizure of the crankshaft.

Print P1D32S021 E

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Upper bearing shells Figure 94

227290

1. Upper bearing shells - 2. Upper thrust bearing shells

NOTE

Base - April 2015

Always couple the bearing shell with the spotface on the crankcase; failure to do so will cause bearing shell rotation and seizure of the crankshaft.

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33

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Standard main journals (STD) NOTE

Before removing the bearings from their seats make sure that they have been numbered. The following images show two possible numbering methods as way of example.

The main bearing shells can be used again during engine re-assembly if they have no visible surface cracks or damage and if each of their thickness falls into the specified ranges. Figure 95

227289

Print P1D32S021 E

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Table for selection of main bearing shells No. 1-2-3-4-5 Figure 96

227253

X. Crankshaft no. 1-4, d = 76 [mm]; no. 5, d = 83 [mm]. - Y. Crankcase no. 1-4, D = 80 [mm]; no. 5, D = 83 [mm]. d+: Diameter of pin on crankshaft

D+: Diameter of main journal on crankcase

A: Class A - Red

C Class C - Green

B: Class B - Blue

D Class D - Brown

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

35

Diameter of seats - main journals Location 1÷4 5 1÷4 5

d+ d+ D+ D+

Diameter 76 mm 83 mm 80 mm 87 mm

Technical data Clearance of main journals - half bearings STD NOTE

0.044 ÷ 0.075 mm

If the bearings on the same pin have different thickness, always fit the thickest bearings towards the lower crankcase side.

Main bearing shell selection class (STD) Class

A B C D key P R np

Print P1D32S021 E

Thickness

2.155 ÷ 2.165 ÷ 2.175 ÷ 2.185 ÷

2.164 2.174 2.184 2.194

Colour

Standard No. 1-2-4 Top

Red Blue Green Brown

P R P np

Standard No. 3 (axial) Top P R P np

Standard No. 1-2-3-4 Lower P R P P

Standard No. 5 Top

Top

P R P np

P R P P

Pre-installed during production Pre-installed during production / spares Not received

Base - April 2015

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Undersized main journals (-0.127 mm) Figure 97

227254

W. Crankshaft no. 1-4, d = 76 [mm]; no. 5, d = 83 [mm]. - Z. Crankcase no. 1-4, D = 80 [mm]; no. 5, d = 83 [mm]. d+: Diameter of pin on crankshaft

D+: Diameter of main journal on crankcase

G: Class G - Red/Black

L Class L - Green/Black

N Class N - Yellow/Black

M Class M - Brown/Black

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

37

Diameter of seats - main journals Location 1÷4 5 1÷4 5

d+ d+ D+ D+

Diameter 76 mm 83 mm 80 mm 87 mm

Technical data Clearance of main journals - half-bearings -0.127 mm

NOTE

0.044 ÷ 0.075 mm

If the bearings on the same pin have different thickness, always fit the thickest bearings towards the lower crankcase side.

Main bearing shell selection class (-0.127 mm) Class

G N L M key P R np

Thickness

2.218 ÷ 2.227 2.228 ÷ 2.237 2.238 ÷ 2.247 2.248 ÷ 2.257

Colour

Red/Black Yellow/Black Green/Black Black/Brown

Standard No. 1-2-4 Top P P P np

Standard No. 3 (axial) Top P P P np

Standar d No. 1-2-3-4 Lower P P P P

Standard No. 5 Top

Top

P P P np

P P P P

Pre-installed during production Pre-installed during production / spares Not received

Undersized main journals (-0.254 mm) Diameter of seats - main journals Crankshaft Crankcase

Technical data Clearance of main journals - half-bearings -0.254 mm

Print P1D32S021 E

Location 1÷4 5 1÷4 5

Diameter d = 75.928 ÷ 75.954 mm d = 82.928 ÷ 82.954 mm D = 80.588 ÷ 80.614 mm D = 87.588 ÷ 87.614 mm

0.032 ÷ 0.102 mm

Base - April 2015

38

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Main bearing shell selection class (-0.254 mm) Class Thickness Colour

key P R np NOTE

2.292 ÷ 2.301

-

F1C EuV1 - ENGINES

Standard No. 1-2-4 Top R

Standard No. 3 (axial) Top R

Standar d No. 1-2-3-4 Lower R

Standard No. 5 Top

Top

R

R

Pre-installed during production Pre-installed during production / spares Not received For the axial bearing (in position 3), use two pre-assembled split-rings with mobile clearance.

Undersized main journals (-0.508 mm) Diameter of seats - main journals Location 1÷4 5 1÷4 5

Crankshaft Crankcase

Diameter d = 75.674 ÷ 75.700 mm d = 82.674 ÷ 82.700 mm D = 80.588 ÷ 80.614 mm D = 87.588 ÷ 87.614 mm

Technical data Clearance of main journals - half-bearings -0.508 mm

0.032 ÷ 0.102 mm

Main bearing shell selection class (-0.508 mm) Class

key P R np

NOTE

Base - April 2015

Thickness

2.419 ÷ 2.428

Colour

-

Standard No. 1-2-4 Top R

Standard No. 3 (axial) Top R

Standar d No. 1-2-3-4 Lower R

Standard No. 5 Top

Top

R

R

Pre-installed during production Pre-installed during production / spares Not received

For the axial bearing (in position 3), use two slackened pre-assembled split-rings.

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

39

Big end bearing shell selection During the preliminary stages (points 1 and 2) identify the big end bearing shells class in relation to the crankshaft and connecting rods selected; this operation is essential for cases in which the exact positions of the bearing shells were not marked during removal. The codes on the components (shaft and connecting rods) are required to this end. - Identifying the connecting rod codes Figure 98

227285

A. Blank vendor (1 digit) - B. Weight class (2 digits) - C. Diameter class (1 digit) D. Progressive serial number (4 digits 0000 - 9999) - E. Day of production (3 digits 001 - 365).

- Identification of crankshaft codes See previous paragraph

Print P1D32S021 E

Base - April 2015

40

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Big end bearing shells position Figure 99

227288

1. Connecting rod - 2. Coupling between bearing shell notch and connecting rod spotface - 3. Coupling between big end bearing shell and connecting rod (piston side) - 4. Coupling between bearing shell notch and lower rod cap - 5. Coupling between big end bearing shell and lower rod cap

NOTE

Base - April 2015

Always couple the bearing shell with the connecting rod (2, 4); failure to do so will cause bearing shell rotation and seizure of the crankshaft.

Print P1D32S021 E

F1C EuV1 - ENGINES

41

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Standard crankpins (STD) Table for selection of big end bearing shells (STD)

210312

210309

STD

CLASS

X 67.833 ÷ 67.840

O 67.841 ÷ 67.848

2A

A+B

A+B

2B

2B

B+C

1 64.038 ÷ 64.031

2 64.030 ÷ 64.023

3 64.022 ÷ 64.015 210310

Technical data Clearance of half-bearings - crankpins (STD) NOTE

0.027 ÷ 0.059 mm

If the bearings on the same pin are of a different thickness always fit the thickest ones on the side of the stem.

Print P1D32S021 E

Base - April 2015

42

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Big end bearing shell selection class (STD) Upper bearing shell (no. 1-4) Thickness Colour Red 1.882 ÷ 1.886 Blue 1.887 ÷ 1.891 Green 1.892 ÷ 1.897

Class A B C key P R np

Type P R P

Class A B C

Lower bearing shell (no. -4) Thickness Colour Red 1.878 ÷ 1.882 Blue 1.883 ÷ 1.887 np 1.888 ÷ 1.893

Type P R np

Pre-installed during production Pre-installed during production / spares Not received

Undersized crankpins (-0.127 mm)

210312

210309

CLASS

-0.127

X 67.833 ÷ 67.840

O 67.841 ÷ 67.848

2D

D+E

D+E

2E

2E

E+F

1 63.911 ÷ 63.904

2 63.903 ÷ 63.896

3 63.895 ÷ 63.888 210310

key D, E, F

Big end bearing shell class

Technical data Clearance of crankpins - half-bearings -0.127 mm NOTE

Base - April 2015

0.027 ÷ 0.059 mm

If the bearings on the same pin are of a different thickness always fit the thickest ones on the side of the stem.

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

43

Big end bearing shell selection data (-0.127 mm) Class D E F key P R np

Upper bearing shell (no. 1-4) Thickness Class Red/Black 1.946 ÷ 1.950 Yellow/Black 1.951 ÷ 1.955 Green/Black 1.956 ÷ 1.961

Thickness P P P

Class D E F

Lower bearing shell (no. 1-4) Thickness Class Red/Black 1.942 ÷ 1.946 Yellow/Black 1.947 ÷ 1.951 Green/Black 1.952 ÷ 1.957

Thickness P P np

Pre-installed during production Pre-installed during production / spares Not received

Undersized crankpins (-0.254 mm) Diameter of crankpin (crankshaft) d = 63.784 ÷ 63.761

Diameter of connecting rod (diameter class) D = 67.833 ÷ 67.848

Technical data Clearance of crankpins - half-bearings -0.254 mm

Class key P R np

Upper bearing shell (no. 1-4) Thickness Colour 2.005 ÷ 2.014

Type R

0.027 ÷ 0.082 mm

Class D

Lower bearing shell (no. 1-4) Thickness Colour 2.001 ÷ 2.010

Type R

Pre-installed during production Pre-installed during production / spares Not received

Undersized crankpins (-0.508 mm) Diameter of crankpin (crankshaft) d = 63.530 ÷ 63.507

Diameter of connecting rod (diameter class) D = 67.833 ÷ 67.848

Technical data Clearance of crankpins - half-bearings -0.508 mm

Class key P R np

Print P1D32S021 E

Upper bearing shell (no. 1-4) Thickness Class 2.132 ÷ 2.141

0.027 ÷ 0.082 mm

Thickness R

Class D

Lower bearing shell (no. 1-4) Thickness Class 2.128 ÷ 2.137

Thickness R

Pre-installed during production Pre-installed during production / spares Not received

Base - April 2015

44

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Disassembly of connecting rod and piston

Connecting rod — piston assembly Figure 100

Figure 101

75393

Remove the piston rings (1) from the piston (2) using pliers 99360183 (3). 75392

Figure 102

PISTON — CONNECTING ROD ASSEMBLY 1. Piston — 2. Piston ring — 3. Pin — 4. Trapezoidal ring — 5. Oil scraper ring — 6. Slotted oil scraper ring with spiral spring — 7. Connecting rod body — 8. Bearing shells — 9. Connecting rod cap — 10. Cap fixing screws. Check the pistons. They must show no signs of seizure, scoring, cracking or excessive wear; replace them if they do.

NOTE The pistons are supplied as spare parts with the standard, normal and 0.4mm oversize diameters together with rings, pin and retaining rings. 75394

Remove the piston (1) from the connecting rod, taking out the piston ring (2) and extracting the pin (3).

Figure 103

229279

MAIN DATA FOR MAHLE, PINS AND PISTON RINGS * The value is measured at 1.5 mm from the outer diameter ** The value of the diameter measured is 92.5 mm Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Checking piston diameter

45

Conditions for correct pin-piston coupling

Figure 104

Figure 107

87794

Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance. The diameter has to be measured at the value shown.

75397

NOTE The pistons are supplied as spare parts with the standard, normal and 0.4mm oversize diameters together with rings, pin and retaining rings.

Lubricate the pin (1) and its seat on the hubs of the piston (2) with engine oil. The pin must go into the piston by lightly pressing with the fingers and must not drop out by gravity.

Checking piston rings Figure 105

Figure 108

74947

88300

The clearance between the piston and cylinder liner can also be checked using a feeler gauge (1) as illustrated in the figure.

The trapezoidal split rings (1st slot) and the oil scraper rings (2nd slot) have the word TOP etched in them; when fitting them on the piston, the word TOP must be facing upwards.

Checking piston pins Figure 106

Figure 109

214626

Measuring the diameter of the piston pin (1) with a micrometer (2). Print P1D32S021 E

214633

Check the thickness of the piston rings (2) with a micrometer (1). Base - April 2015

46

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 110

Figure 112

88301

75398

Check the clearance between the trapezoidal ring (2) (1st slot) and the associated slot on the piston with a feeler gauge (1), proceeding as follows: insert the piston into the cylinder liner so that the ring (2) comes approximately half way out of it.

Check the clearance between the piston rings (2) of the 2nd and 3rd slot and the associated seats on the piston (3) with a feeler gauge (1).

Figure 111

Figure 113

214628

DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING 1. Piston slot - 2. Trapezoidal piston ring - 3. Cylinder liner 75399

Using a feeler gauge (Previous figure), check the clearance (X) between the ring (2) and the slot (1); this clearance must have the prescribed value.

Base - April 2015

Check the opening between the ends of the piston rings (2) inserted in the cylinder liner using a feeler gauge (1).

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Checking connecting rods

47

Figure 115

Figure 114

217909

224205

MAIN DATA OF THE CONNECTING ROD, BUSHING, PISTON PIN AND BEARING SHELLS * Internal diameter to obtain after driving into the small end and grinding with a reamer. ** Dimension cannot be measured in the free state. *** Thickness of the bearing shell supplied as a spare part. Check rod quotas, bushing, piston pin and half bearing shown in the figure. The cap of each connecting rod is marked with an alphanumeric code, as indicated in the following figure.

NOTE

A.

One character number showing the supplier raw

B.

Two characters number showing weight class

C.

One character O or X showing diameter class

D.

Four characters serial number (from 0000 to 9999)

E.

Three characters number showing production day (from 001 to 365)

Checking Bushing Check that the bush in the small end has not come loose and shows no sign of seizure or scoring. If it does, replace the complete connecting rod.

Checking connecting rod alignment Figure 116

The connecting rods are supplied as spare parts with the diameter of the big end 67.833 - 67.848 mm marked with the letter O and the weight class marked with the number 22-23-32-33. In addition, it could be stamped with the number of the cylinder in which it is fitted. In the event of replacement it is therefore necessary to number the new connecting rod with the same number as the one replaced. The numbering must be done on the opposite side to the bearing shell retaining slots. It is not permissible to remove material. 61696

Check the alignment of the connecting rod axes (1) using the tool (5) as follows: - fit the connecting rod (1) on the tool (5) spindle and secure it with the screw (4); - set the spindle (3) on the V-prisms, resting the connecting rod on the stop bar (2).

Print P1D32S021 E

Base - April 2015

48

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Checking connecting rod torsion

Checking connecting rod deflection

Figure 117

Figure 118

61694

61695

Check the torsion of the connecting rod (5) by comparing two points (A and B) of the pin (3) on the horizontal plane of the connecting axis.

Check the deflection of the connecting rod (5) comparing two points (C and D) of pin (3) on the vertical plane of the connecting axis.

Position the dial gauge (2) support (1) to obtain a preload of 0.5 mm on the pin (3) in point A and then set the dial gauge (2) to zero.

Position the vertical mount (1) of the dial gauge (2) so that this rests on the pin (3) at point (C).

Shift the spindle (4) with the connecting rod (5) and compare any deviation on the opposite side (B) of the pin (3): the difference between (A) and (B) must not exceed 0.08 mm.

Swing the connecting rod backwards and forwards seeking the highest position of the pin and zero the dial gauge (2). Shift the spindle with the connecting rod (5) and repeat the check on the highest point on the opposite side (D) of the pin (3). The difference between points (C) and (D) must not exceed 0.08 mm.

Assembling connecting rod-piston assembly Figure 119

87797

The roof of the piston is stamped with the engine type (1), class selection (2) and supplier (3); the direction of installation of the piston in the lining (4). Mark (5) signifies that it has passed the 1st slot insert adhesion test.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

49

Assembling piston rings

Figure 120

Figure 122

41097

Fit the piston rings (1) on the piston (2) using the pliers 99360183 (3).

NOTE The 1st and 2nd slot rings need to be mounted with the word ”TOP” facing upwards. 87798

Connect the piston (1) to the connecting rod (2) together with its cap so that the piston assembly reference, position of the connecting rod and of the cap are observed as shown in the figure. Figure 121

NOTE Check that the piston rings opening are offset by 120˚.

Cylinder head components Cylinder head components disassembly Figure 123

75394

Position the piston (1) on the connecting rod, insert the pin (3) and secure it with the split rings (2).

229280

Apply the support SP. 2271 (2) on the cylinder head and tighten the support in a vice. Undo the screws and remove the lifting brackets (1).

Ref. (1) (1) Print P1D32S021 E

No. 4 2

Description M8x1.25x20 M8x1.25x25 Base - April 2015

50

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Disassembling valves

Figure 126

Figure 124

88426 223212

The intake (1) and exhaust (2) valves have the same diameter mushroom.

Previously disassemble the valves using tool SP.2271.

The central cavity () of the mushroom of the intake valve (1) is distinguished from that of the exhaust valve (2).

Fit part (1) of tool 99360260 onto the cylinder head (2) and secure it with the screws (3).

NOTE Before removing the valves from the cylinder heads, number the valves in order to refit them correctly if they are not changed.

NOTE

A = intake side — S = exhaust side Figure 125

Remove the intake (1) and exhaust (2) valves.

Checking cylinder head seal Check the hydraulic seal using a suitable tool. Pump in water heated to approx. 90C at a pressure of 2  3 bars. Replace the cup plugs if they are found to leak at oil, using a suitable drift for their removal — assembly.

NOTE Before mounting the plugs, apply LOCTITE 270 water-reacting sealant on their sealing surfaces.

223213

Fit part (3) of tool 99360260 onto part (5), screw down the nut (1) so that on compressing the springs (8) it is possible to remove the cotters (6). Then take out the plates (7) and the springs (8). Using suitable pliers, remove the oil seal (9). Repeat these operations on the remaining valves. Turn the cylinder head over and remove tool SP.2271.

Base - April 2015

If there is any leakage from the cylinder head, it must be replaced.

Print P1D32S021 E

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51

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Checking cylinder head mating surface

Valves Cleaning, checking and grinding valves

Figure 127

Figure 128

88331

The mating surface of the head (1) with the cylinder block is checked using a rule (2) and a feeler gauge (3). The deformation found on the entire length of the cylinder head must be no greater than 0.20 mm. For greater values, regrind the cylinder head according to the values and instructions given in the following figure. The nominal thickness A of the cylinder head is 112 0.1 mm; the maximum permissible removal of metal must not exceed a thickness of 0.2 mm.

0,6



 224207

MAIN DATA OF INTAKE AND EXHAUST VALVES

Removing deposits, refacing and checking valves Figure 129

NOTE After regrinding, check the valve recessing and if necessary regrind the valve seats. The prescribed value is 0.375 - 0.625 for both intake and exhaust valves.

204301

Remove the carbon deposits on the valves with a wire brush. Check that the valves show no signs of seizure, cracking or burning.

Print P1D32S021 E

Base - April 2015

52

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Valve guides Replacing valve guide

Figure 130

Figure 132

18882

Use a micrometer (2) to measure the valve stem (1): it must have the value indicated in the Figure 128. If necessary, grind the valve seats by means of the grinding machine, and remove as little material as possible. 87800

Check that measures made after driving in the valve guides are as specified in the figure.

Checking clearance between valve stem and valve guide and centring valves

MAIN DATA OF VALVE GUIDES — SEATS Valve guide seat inside  Valve guide outside 

9.980  10.000 mm 10.028  10.039 mm

Figure 131 Figure 133

88332

The checks are made using a dial gauge (2) with a magnetic base, positioned as illustrated. The assembly clearance is 0.033 — 0.063 mm for exhaust valves and 0.023 - 0.053 for intake valves.

88333

Remove the valve guides (2) with the SP.2312 tools.

Making the valve (1) turn, check that the centring error is no greater than 0.03 mm.

Base - April 2015

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53

Boring valve guides

Figure 134

Figure 135

88334

Warm up the cylinder head to 80  100C and, by means of beater SP.2312 (1) fitted with element SP.2311 (2), fit the new valve guides (3) previously lubricated with engine oil. Driving force 4.2  12 KN (430  1250 kg) If the above mentioned tools are not available, fit the valve guides by positioning them in the cylinder head according to the value shown in the previous Figure 132.

Print P1D32S021 E

88335

After driving in the valve guides (2), regrind them with the SP.2310 sleeker.

Base - April 2015

54

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Valve seats Regrinding - replacing valve seats Figure 136

87801

Check the valve seats. On finding any slight scoring or burns, regrind them with an appropriate tool according to the angles given the figure. Having to replace them, with the same tool and taking care not to affect the cylinder head, remove as much material from the valve seats as possible until, with a punch, it is possible to extract them from the cylinder head.

Mount the valves, block the seat of the electro-injectors and glow plugs; using a suitable tool, check the seal of the valves/seats. Figure 138

Heat the cylinder head to 80  100C and, using a suitable drift, fit in it the new valve seats, previously chilled in liquid nitrogen. Using a specific tool, regrind the valve seats according to the angles given in the figure. Figure 137

88337

Using a dial gauge (1), check that, from the plane of the cylinder head, the valve recessing (2) and the protrusion of the injector (3) and of the glow plug have the prescribed value: 88336

Using the milling cutter (1), clean the injector seat of any deposits.

Base - April 2015

- Valve recessing: 0.375  0.625 mm. - Injector protrusion: -0.10  0.40 mm. - Glow plug protrusion: 3.47 4.07 mm.

Print P1D32S021 E

F1C EuV1 - ENGINES

55

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Valve springs

Rocker arms — tappets

Figure 139

Figure 140

50676

Prior to assembling, check the valve spring flexibility using a suitable tool. Compare the load and elastic deformation data with those of the new springs indicated in the table. To make the control of the springs for the intake valves and exhaust check the main data shown in the table.

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Height mm H 55.05 H1 45 H2 35

Under a load of N Free P 320  16 P1 657  30

75461

COMPLETE ROCKER ARM ASSEMBLY The rocker arm assembly is composed of the rocker arm (1), hydraulic tappet (3), made integral with each other by the clip (2). Figure 141

214658

CROSS-SECTION OF THE HYDRAULIC TAPPET A = 30.65  0.2, end of stroke B = 33.79  0.45, working position C = 5,7 mm.

Print P1D32S021 E

Base - April 2015

56

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 142

87802

MAIN DATA HYDRAULIC TAPPETS — SEATS

Checks

Figure 144

The sliding surface of the tappets must have no scoring/dents; replace them if they do. Using a micrometer, measure the diameter of the tappets and, using a bore meter, measure the diameter of the seats in the cylinder head; the difference in the measurements will give the assembly clearance.

Assembling valves Figure 143

223214

Fit the springs (3) and the plates (2) on the cylinder head (4). Figure 145

87803

NOTE Before valves mounting, use the sp.2271 tool for cylinder head support. Lubricate the stem of the valves (1) and insert them into the associated valve guides (4) according to the position marked during removal. Using tool SP.2264 (2), mount the oil seals (3) on the valve guides (4). NOTE The suction valves (5) are different from the exhaust ones for a slot () in the centre of the valve head. Base - April 2015

223215

Fit part (7) of tool 99360260 onto part (4), screw down the nut (1) so that on compressing the springs (3) it is possible to install the cotters (2). Unscrew the nut (1) and check that the the cotters are installed correctly. Repeat these operations on the remaining valves. Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 146

Ref. (1)

No. 3

57

Description M6x1x20

Figure 149

229280

Fit the lifting brackets (1) on the cylinder head and tighten the screws to the torque indicated in the table. Remove the support SP. 2271 (2) from the cylinder head. Ref. (1) (1)

No. 4 2

Description M8x1.25x20 M8x1.25x25

Tightening torques 25±2.5 Nm 25±2.5 Nm 88341

Overhead Overhead components removal

Tilt the over-head (1) and take care not to damage the seats, then take off the camshafts (2 and 3) from the overhead.

Figure 147

Camshaft Checks The surfaces of the shaft supporting pins and of the cams must be finely honed; if there is any sign of meshing or scoring, replace the shaft. Figure 150

217911

Using a suitable tool, remove the lock plugs (1) with the seal rings from the overhead. Figure 148

75474

Using a micrometer (1), measure the diameter of the pins (2) of the camshaft and, using a bore meter, measure the diameter of the supporting seats in the overhead. The difference between these two measurements gives the existing clearance. The nominal assembly clearance is 0.032 ÷ 0.087 mm. 229281

Undo the screws (1) and remove the shoulder plate (2).

Print P1D32S021 E

Base - April 2015

58

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Checking cam lift and pin alignment Figure 151

87806

Place the shaft (1) on the parallels and use a centesimal dial gauge fitted on the central support to check that the alignment error does not exceed 0.04 mm; otherwise, change the shaft. Check also the cam lift: it must correspond to the prescribed value; if different values are detected, change the shaft.

Figure 152

224208

MAIN DATA, CAMSHAFT PINS AND SEATS 1. Intake valve camshaft seats — 2. Exhaust valve camshaft seats — 3. Intake valve camshaft — 4. Exhaust valve camshaft.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Assembling overhead components

59

Figure 155

Figure 153

217911

Fit the lock plugs (1) with the seal rings on the overhead,

Figure 154

229281

Fit the shoulder plate (2) and drive in the screws (1), then tighten them to torque indicated in the table.

Ref. (1)

No. 3

Description M6x1x20

Tightening torques 10 ± 1 Nm

Figure 156

88344

Lubricate the support pins of the suction camshafts (2) and exhaust camshafts (4) and fit them on the overhead (1). 229282

NOTE During this operation do not exchange the assembly position of the shafts.

Position the camshafts (1 and 2) so that the pins 99360614 (3) can be inserted in the camshaft slots through the over-head threaded holes.

The suction camshaft can be recognised (2) through the dowel (3) on the front side and the retainer on the rear side. In addition, take care not to damage the support seats of the over-head shafts.

Print P1D32S021 E

Base - April 2015

60

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Thoroughly clean the top main bearing shells (1) and position them in the crankcase.

ENGINE ASSEMBLY Crankcase components assembly The following parts must be replaced with new ones at the time of assembly: retaining rings, seals and gaskets, screws whose thread is coated with sealant.

NOTE The middle half ring (2) is fitted with thrust washers.

Cranckshaft assembly Main journal fitting and clearance check

Figure 157

Figure 159

75306

Fit on the oil spray nozzles (2) and tighten the couplings (1) to torque indicated in the table. Ref. (1)

No. 4

Description M10x1

Tightening torques 27.5±2.5 Nm

Assembling main bearings

90064

Mount the crankshaft (1). Check the clearance between the crankshaft main journals and their respective bearings, working as follow:

Figure 158

Clean accurately the parts and remove any trace of oil; Lay down pieces of calibrated wire on the journals, parallel to the longitudinal axis. Figure 160

88345

NOTE Not having found it necessary to replace the main bearings, they need to be fitted back on in the same sequence and position found upon disassembly. 88289

The main bearings (1) are supplied as spare parts undersized on the inside diameter by 0.127, 0.254, 0.508 mm.

Thoroughly clean the bottom main bearing shells (2) and mount them in the crankcase base (1).

NOTE Do not do any accommodating on the bearings.

Base - April 2015

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SECTION 6 - GENERAL MECHANICAL OVERHAUL

61

Checking crankshaft end float

Figure 161

Figure 163

α

88293

88292

The end float is checked by setting a dial gauge (2) with a magnetic base on the crankshaft (1) as shown in the figure. The normal assembly clearance is 0.040 - 0.240 mm.

Mount the crankcase base (12) and using the tool 99395216 (11) for the angle closing, tighten the fixing screws to the torque indicated in the table, following the sequence shown in the figure:

If you find the clearance to be greater than as required, replace the rear main bearing shells carrying the thrust bearings and repeat the clearance check between the crankshaft pins and the main bearing shells.

Ref.

No.

(1)÷(10)

10

-

17 2

Description Tightening torques M12x1.5x125 1st phase 50±5 Nm 2nd phase 60˚ 3rd phase 60˚ M8x1.25x77.5 25±2.5 Nm M8x1.25x40 25±2.5 Nm

Figure 162

If the end float of the crankshaft does not come within the prescribed values, it is necessary to grind the crankshaft and accordingly change the main bearing shells.

NOTE The middle main bearing has half thrust washers integrated in it, so it performs the function of a thrust bearing. It is supplied as a spare part only with the normal shoulder thickness.

75310

Undo the screws and remove the lower cylinder block. The clearance between the main bearings and the related pins can be found by comparing the width of the calibrated wire (1) at the greatest squeezing point, with the graduation of the scale shown on the casing which holds the calibrated wire. The numbers shown on the scale indicate the clearance in millimetres of the coupling; it must be 0.012 ÷ 0.122. If the clearance is not as prescribed, change the bearing shells and repeat the check. Print P1D32S021 E

Base - April 2015

62

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Crankcase base assembly

Figure 166

Figure 164

α

88294

Thoroughly clean the crankcase / crankcase base mating surface. Apply, on base, sealant LOCTITE 510, as indicated in the scheme. The sealant must result to be even, not patchy.

NOTE Mount the crankcase base within 10 minutes of applying the sealant.

217912

Tighten the outer screws (1) and (2) to the torque indicated in the table. Ref. 1 2

No. 17 2

Description M8x1.25x77.5 M8x1.25x40

Tightening torques 25±2.5 Nm 25±2.5 Nm

Assembling rear seal Figure 167

Figure 165

α

220287

88292

Mount the crankcase base (12) and using tool 99395216 (11) for the angle closing, tighten the screws to the torque indicated in the table, following the sequence shown in the figure: Ref.

No.

(1)÷(10)

10

Base - April 2015

Carefully clean the seal seat. Apply sealant LOCTITE 5205 on the sealing ring (1), in the two zones at the opposite sides, covering a section of about 30˚ as indicated in the figure. Lubricate the rear shank of the crankshaft with engine oil. Fit part (2) of tool 99346259 onto the rear shank of the crankshaft; secure it with the screws (3) and key the fresh seal (1) onto it. Position part (4) on part (2); screw down the nut (5) to fit the seal (1) fully inside the crankcase.

Description Tightening torques M12x1.5x125 1st phase 50±5 Nm 2nd phase 60˚ 3rd phase 60˚ Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Assembling connecting rod - piston assembly in cylinder barrels Figure 168

63

Measuring crankpin assembly clearance Figure 169

88302

88303

Lubricate the pistons well, including the piston rings and the inside of the cylinder liners.

Remove the connecting rod cap involved and carefully clean the crankpin (4) and the connecting rod half-bearing (1), eliminating all traces of oil.

Rotate the crankshaft and bring the crankpins of pistons 1 and 4 close to BDC. With the aid of the clamp 99360605 (2), fit the connecting rod - piston assembly (1) in the cylinder liners, checking that: - The number of each connecting rod corresponds to the cap mating number.

Position a length of calibrated wire (3) with a graduated scale (2) on the crankpin (4). Figure 170

- The openings of the piston rings are staggered 120˚ apart. - The pistons are all of the same weight. - 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 spray nozzles.

α

Fit the connecting rod caps of pistons 1 and 4, respecting the order they were in before dismantling and screw in the retaining bolts without tightening. Fit the pistons, caps, connecting rods and half-bearings for cylinders 2 and 3 by following the same procedure. 88326

Fit the connecting rod caps (3) with the associated bearing shells. Using tool 99395216 (1) for the angle closing, tighten the screws (2) to the torque indicated in the table. NOTE

If it was not necessary to replace the connecting rod bearings, they must be fitted in exactly the same order and position they were found in before dismantling.

Print P1D32S021 E

Ref.

No.

(2)

8

Description Tightening torques M11x1.25x51 1st phase 50±2.5 Nm 2nd phase 70˚

Base - April 2015

64

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Undo the screws and remove the connecting rod caps. The clearance between the connecting rod bearings and the connecting rod is measured by comparing the width assumed by the calibrated wire, at the point of greatest crush, with the gradation of the scale printed on the calibrated wire casing.

Engine assembling (components on bottom side) Engine oil suction pipe refitting Figure 171

The numbers shown on the scale indicate the coupling clearance (in millimetres). If the measured clearance differs from the recommended one, replace the bearings and repeat the check. On obtaining the prescribed clearance, lubricate the connecting rod bearing shells and fit them permanently by tightening the connecting rod cap fixing new screws as described prevously.

!

The connecting rod cap fixing screws must always be replaced for permanent assembly. Manually check that the connecting rods slide axially on the pins of the crankshaft. 229277

Fit the engine oil suction pipe (1) and tighten the screws (2) to the torque indicated in the table.

Checking piston protrusion

Ref. (2)

Figure 172

No. 3

Description M6x1x12

Tightening torques 10 ± 1

Oil sump refitting Figure 173

88327

At the end of the connecting rod-piston assembly refitting, check the piston protrusion (2) at the T.D.C. compared to the top level of the cylinder block by means of a dial gauge (1) and relevant base 99370415 (use with 99395603). These values depend on the type of cylinder head gasket used; below the summary table: Piston protrusion [mm]* 0.3 ÷ 0.4 0.4 ÷ 0.5 0.5 ÷ 0.6

Gasket thickness Piston protrusion [mm] max. difference [mm]** 1.1 ± 0.04 0.15 1.2 ± 0.04 1.3 ± 0.04

* 4 pistons max. protrusion ** The difference between the minimum and maximum protrusions of the four pistons must be ≤ 0.15 mm. Base - April 2015

229283

Fit a new gasket on the oil sump (1) and place them on the cranckcase; suddenly place the oil pan frame (3) on the cranckcase and tighteen the screws (2) to the torque indicated in the table. Ref. (2)

No. 13

Description M8x1.25x35

Tightening torques 25 ± 2.5

Place the oil sump drain plug (4) and tighten it to the torque indicated in the table. Ref. No. Description Tightening torques (4) 1 M22x1.5x10 50 ± 10 Rotate the engine through 180˚ on the overhaul stand. Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Engine assembling (components on top side part 1)

65

Figure 176

Cylinder head refitting Figure 174

88355

Ref.

No.

(1)÷(6)

6

Place the cylinder head dowels on the crankcase (if they were removed previously).

(7)÷(10)

4

Place a new cylinder head gasket (1) with the tickness indicated in the “Checking piston protrusion” paragraph with the writing “TOP” facing the cylinder head.

A

4 1

224215

Check that contact surfaces of the cylinder head and crankcase are clean.

Description Tightening torques M15x1.5x193 1st phase 130±6.5 Nm 2nd phase 90˚ 3rd phase 90˚ M12x1,5x165 1st phase 65 ± 3.25 Nm 2nd phase 90˚ 3rd phase 60˚ M8x1.25x117 25 ± 2.5 Nm M8x1.25x58 25 ± 2.5 Nm

Hydraulic tappets refitting It is absolutely necessary to keep the cylinder head gasket sealed in its packaging and remove it just before fitting to avoid getting it dirty.

!

Figure 177

Figure 175

α 88356

Position the cylinder head extension dowels on the cylinder head (if they were removed previously).

88354

Mount the cylinder head (2). Screw down the fixing screws (3) and tighten them, in three successive stages, following the order and methods shown in the following figure, using tool 99395216 for the angle tightening.

Print P1D32S021 E

Thoroughly clean the hydraulic tappets (2), lubricate them and place them in the cylinder head (3), positioning the rocker arms (1) on the valves correctly. Place a new cylinder head extension gasket (5) in its seat. Insert the two tools SP. 2264 (4) into the electro-injector seats for subsequent centring of the overhead on the cylinder head.

Base - April 2015

66

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Overhead refitting

Engine assembling (components on rear side)

Figure 178

Engine flywheel refitting Figure 180

229298

Mount the overhead (2) on the cylinder head (3) together with the tools 99360614 for the timing and tighten the fixing screws (1) to the torque indicated in the table. Remove the tools SP. 2264. Ref.

No.

Description

(1) (1)

10 20

M8x1.25x40 M8x1.25x77

Tightening torques 25±2.5 25±2.5

Figure 179

227533

Fit the rear protection (3) on the crankcase and tighten the stud (2) and the threaded bushes (1) to the torque indicated in the table. Ref.

No.

(1) (2)

2 1

Description M12x1.5x22.5 M6x1.25

Tightening torques 5 ± 0.5 10 ± 1

Figure 181

229275

Fit the bracket (2) on the overhead and tighten the screw (1) to the torque indicated in the table. Ref.

No.

Description

(1)

2

M8x1.25x16

Tightening torques -

227532

Mount the engine flywheel (2) and screw down the screws (3), without tightening. Place tool 99360306 (1) onto the crankcase to block rotation of the engine flywheel (2). Tighteen the screws (3) fixing the engine flywheel (2) to the torque indicated in the table, using tool 99395216 for the angle tightening. Ref.

No.

(3)

8

Description M12x1.25x51 1st phase 2nd phase

Tightening torques 30 ± 1.5 90˚

Remove the tool 99360306 (1). Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Engine assembling (components on front side part 1)

67

Figure 184

Power steering control shaft refitting Figure 182

227529

229284

Rotate the driving shaft so that the tool 99360615 (1) can be inserted in the shaft crank hole through the cylinder block hole, in order to stop the engine in the timing system setting condition.

Stop rotation of the hydraulic power steering pump control shaft (1) inserting in the latter the tool 99360187 (3) and fastening the tool on the support (4) by means of the screws (2). Figure 185

Figure 183

227530

Fit the gear (2) on the hydraulic power steering pump control shaft (1). Drive in the screw (3) without locking it. 227531

Lubricate new power steering support seal rings with engine oil and fit them on the support. Place the power steering support (1) in its housing and tighten the nuts (2) to the torque indicated in the table. Fit the hydraulic power steering pump control shaft (3). Ref.

No.

(2)

3

Print P1D32S021 E

Description M8x1.25

Tightening torques 25±2.5

Base - April 2015

68

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Power steering pump, A/C compressor and A/C compressor support refitting Figure 186

High pressure drive gear and lower chain refitting Lubricate new high pressure pump support seal rings with engine oil and fit them on the support. Figure 188

227825

Fit the A/C compressor support (3), drive the screws (1 and 2) and tighten them to the torque indicated in the table. Ref.

No.

(1) (2)

2 2

Description M8x1.25x20 M8x1.25x130

Tightening torques 25 ± 2.5 25 ± 2.5

128158

The drive wheel (1) has a hole (2) for a reference pin on its rear face. The front face of the drive wheel (1) has a reference notch which must be held vertical when adjusting the timing of the pump. The driving shaft (3) has a seat (4) for a reference pin (5). The position of the seat (4) of the pin on the spindle (3) has been set sop as to ensure synchronisation of the pump and crankshaft.

Figure 187

Figure 189

227823

Fit the A/C compressor (5) on its support and tighten the screws (4) to the torque indicated in the table. Ref.

No.

Description

(4)

4

M8x1.25x90

Tightening torques 25 ± 2.5

Fit the power steering pump (3) with a new gasket, tighten the screw (1) and the screw (2) with their washer to the torque indicated in the table. Ref.

No.

(1) (2)

1 1

Base - April 2015

Description M10x1.25x30 M10x1.25x110

Tightening torques 40 ± 4 40 ± 4

227822

Fit the support (1), drive in the nuts (2) and tighten them to the torque indicated in the table. Fit the high pressure pump control shaft (3) of the high pressure pump. Ref.

No.

(2)

3

Description M8x1.25

Tightening torques 25±2.5

Print P1D32S021 E

F1C EuV1 - ENGINES

69

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 190

Figure 192

229285

227820

Check that the drive shaft (2) is positioned with the pin (1) at the top (as indicated by the arrow).

Fit the shaft with the drive gear (2) on the high pressure pump control shaft (1). Drive in the fastening screw (3) without tightening.

Figure 191

Side/lower fixed pads refitting Figure 193

229286

Using tool 99360615 (4), rotate the crankshaft until the crankshaft timing adjustment tool can be positioned correctly. Position a new double link chain (6) on the gears (2, 3 and 5) and fit the gear (2) on the shaft (1) so that branches A and B of the chain (6) are under tension.

229287

Check the condition of the fixed pads, replace them if they are worn. Fit the side fixed pad (1) and drive in the fastening screws (2), then tighten them to the torque indicated in the table. Fit the lower fixed pad (3) and drive in the fastening screws (4), then tighten them to the torque indicated in the table.

Print P1D32S021 E

Ref.

No.

Description

(2) (4)

2 2

M8x1.25x35 M8x1.25x35

Tightening torques 25±2.5 25±2.5

Base - April 2015

70

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Side/upper chain guide refitting NOTE

Figure 194

The chain arm (1) between the two gears must be tensioned.

Figure 196

227816

Fit the upper chain guide (6), drive in the screws (5) and tighten them to the torque indicated in the table. Fit the side chain guide (1), drive in the screws (2 and 3) and tighten them to the torque indicated in the table. Fit the plug (4) with a new gasket and tighten it to the torque indicated in the table. Ref. (2) (3) (4) (5)

No.

Description

229288

Position the single link chain (4) on the gear (3) and fit the latter on the camshaft of the exhaust valves. Drive in the fastening screw (1) with the washer (2) without tightening it completely.

Tightening torques

2

M6x1x20

10±1

1 2

M26x1.5x16 M6x1

50±5 10±1

NOTE

The gear (3) must be mounted with the markings inwards. In the gear (3) there is a larger hole for adjustment, which fits onto the pin on the exhaust camshaft shank.

NOTE

The chain arm (4) between the two gears must be tensioned.

Upper timing chai n and camshaft gear refitting Figure 195

88358

Position the single link chain (1) on the gear (5) and gear (2). Mount the gear in such a way that fitting on intake valve timing system shaft dowel makes slots A to result to be positioned as in figure. Drive in the fastening screw (4) with the washer (3) without tightening it completely.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

71

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 197

Figure 198

229289

229290

Check the conditions of the primary and secondary tensioner arm (3 and 1), if worn out change them.

Tighten the fastening screw of the gear (1) on the hydraulic power steering control shaft to the torque indicated in the table.

Position the primary and secondary tensioner arm (3 and 1) and clamp them on the cylinder block by the bolt shoulder (2) and tighten it to the torque indicated in the table. Ref.

No.

(2)

1

Description M10x1.5

Tightening torques 40±2

Ref.

No.

(1)

1

Description M12x1.25x42.5

Tightening torques 130±13

Figure 199

Drive in the chain standard hydraulic tensioner (4) and tighten it to the torque indicated in the table. Ref.

No.

Description

(4)

1

M22x1.5x22

!

Tightening torques 50±2.5

The chain standard hydraulic tensioner can absolutely never be re-used. Whenever the piston has inadvertently been made to come out of the new chain tensioner, it must be replaced; it cannot be reset. 229291

Stop the rotation of the high pressure pump control shaft (1) by inserting a suitable wrench inside it.

Print P1D32S021 E

Base - April 2015

72

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 200

Figure 201

229292

229293

Screw on the chain anti-return hydraulic tensioner (2) and tighten to the torque indicated in the table.

Tighten the fastening screw of the gear (1) on the intake valve camshaft to the torque indicated in the table.

Ref.

No.

Description

(2)

1

M22x1.5x22

Tightening torques 50±2.5

From the opening in the overhead, press on the tab (3) of the secondary tensioner arm (4) with a screwdriver and push the piston (1) of the chain anti-return hydraulic tensioner (2) fully down.

Ref.

No.

(1)

1

Description M12x1.75x40

Tightening torques 110±5.5

Figure 202

Release the secondary tensioner arm (4) and check that the piston (1) protrudes from its seat, thus tensioning the chain (5).

!

The hydraulic chain tensioners (with anti-return device) can absolutely never be re-used. Whenever the piston has inadvertently been made to come out of the new chain tensioner, it must be replaced; it cannot be reset. 229294

Make sure that the chain (1) in the tract between the gear (2) and gear (3) is tensioned. Tighten the fastening screw of the gear (3) on the exhaust valve camshaft to the torque indicated in the table.

Base - April 2015

Ref.

No.

(3)

1

Description M12x1.75x40

Tightening torques 110±5.5

Print P1D32S021 E

F1C EuV1 - ENGINES

73

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Timing sensor and timing system upper cover refitting

Figure 203

Figure 205

227814

Remove tools 99360614 (1) and fit the two inspection caps in their housing tightening to the torque indicated in the table.

217916

Fit a new gasket (6) on the cover (5). Ref.

No.

Description

(-)

2

M14x1.5x10

Tightening torques 25±2.5

Figure 204

Fit the cover (7), on the cylinder overhead tighten the screws (2) and the nuts (1) to the torque indicated in the table. Place the phase sensor (4) and tighten the screw (3) to the torque indicated in the table. Ref.

No.

(1) (2) (3)

2 7 1

NOTE

Description M6x1 M6x1x30 M6x1x16

Tightening torques 10±1 10±1 10±1

Insert the gasket into the seat in the cover with the “blade” part facing towards the engine. Align the three references (A, B, C) on the gasket with the respective seats in the cover.

229334

Make sure that the chain (1) in the tract (A) is tensioned. Tighten the fastening screw of the stem with the drive gear (2) on the high pressure pump control stem to the torque indicated in the table. Ref.

No.

(2)

1

Description M12x1.5x42.5

Tightening torques 110±11

Remove the suitable wrench used to stop of the high pressure pump control shaft.

Print P1D32S021 E

Base - April 2015

74

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Depressor/oil pump unit refitting

Figure 208

Figure 206

229297

229295

Drive in the element (3) of tool 99346258 in the driving shaft tang.

Position the coupling drive (1) in the gear (5). Fit the oil pump/depressor unit (2) with a new gasket and tighten the screws (3) to the torque indicated in the table. Remove crankshaft timing adjustment tool 99360615 (4). Ref.

No.

Description

(3)

5

M8x1.25x60

Clean accurately the seat of the cover seal ring (1).

Tightening torques 25±2.5

Lubricate the tang of the driving shaft and the element outside (3) and fit flush the new seal ring on this element (2). Position the element (5) on element (3), lock the nut (4) until fitting the seal ring (2) completely in the cover (1). Figure 209

Timing system lower cover refitting Figure 207

229296

Mount tool 99396039 (1), for centering cover (4), into centrifugal filter seat and tighten screws (3) at the torque indicated in the table. 227810

Fit the cover (2) with a new gasket. Drive in the screws (1) without tightening them completely. Fit the engine increment speed sensor and tighten the screw (3) to the torque indicated in the table. Ref.

No.

(3)

1

Base - April 2015

Description M6x1x12

Ref.

No.

Description

(3) (3)

9 7

M8x1.25x30 M8x1.25x16

Tightening torques 25±2.5 25±2.5

Remove the 99346258 (2) and 99396039 (1) tools.

Tightening torques 10±1

Print P1D32S021 E

F1C EuV1 - ENGINES

75

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Water pump and 3 speed electromagnetic pulley refitting

Figure 212

Figure 210

227809

227807

Fit the water pump (5) with a new gasket and tighten the screws (4) to the torque indicated in the table. Fit the electromagnetic pulley (3) on the water pump, tighten the nuts (1) and the ring nut (2) to the torque indicated in the table Ref. (4) (2) (1)

No.

Description

2 3 1 4

M8x1.25x45 M10x1.5x55 M30x1 M6x1

Tightening torques 25±2.5 50±5 150±15 10±1

Fit the damper pulley (4) and tighten the screw (3) to the torque indicated in the table. Ref.

No.

Description

(3)

1

M20x1.5x58

Tightening torques 350±17.5

Fit the A/C compressor belt tensioner (2) and tighten the screw (1) to the torque indicated in the table. Ref.

No.

Description

(1)

1

M8x1.25x45

Tightening torques 25±2.5

Blow-by refitting Figure 213

Dumper pulley refitting Figure 211

227806

Fit a new centrifugal filter and a new piston ring. 227808

Stop the rotation of the engine flywheel (1) by means of tool 99360306 (2).

Print P1D32S021 E

Fit the cover (3), tighten the screws (2) to the torque indicated in the table. Fit the blow-by pipe bracket on the cylinder head and tighten the nut (1) to te torque indicated in the table. Ref.

No.

(2) (1)

3 1

Description M6x1x18 M8x1.25

Tightening torques 10±1 25±2.5

Base - April 2015

76

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

If previously removed, fit the air temperature/pressure sensor on the intake manifold and tighten the nut (1) to the torque indicated in the table.

Engine assembling (components on intake side ) Pre/heater glow plugs refitting Figure 214

Ref.

No.

(1)

1

Description M6x1

Tightening torques 10±1

Thermostat refitting Figure 216

227805

Fit the pre/heater glow plugs (1) in their housing on the cylinder head using the SP.2275 tool and torque wrench 99389819, then tighten them to the torque indicated in the table. Ref.

No.

(1)

4

Description M8x1

Tightening torques 9±1

Intake manifold refitting Figure 215

214644

Fit the thermostat in its housing on the cylinder head. Fit the thermostat cover (2), together with the relative gasket and the coolant temperatur sensor and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1)

4

M8x1.25x20

Tightening torques 25±2.5

227804

Fit the intake manifold (6) with a new gasket on the cylinder head and tighten the screws (2), (4) and (5) to the torque indicated in the table. Fit the two threaded plugs (3) on the intake manifold and tighten them to the torque indicated in the table. Ref.

No.

(2) (4) (5) (3)

2 6 1 2

Base - April 2015

Description M8x1.25x60 M8x1.25x40 M8x1.25x140 M24x1.5

Tightening torques 25±2.5 30±3 30±3 30±3 Print P1D32S021 E

F1C EuV1 - ENGINES

77

SECTION 6 - GENERAL MECHANICAL OVERHAUL

High pressure pump refitting

Figure 219

Figure 217

229313

227804

Lubricate a new seal ring (3) and fit it to the high pressure pump. Make sure the flange (4) is fitted to the high pressure pump. Make sure the high pressure pump is in stable equilibrium, with the one of the two recesses (1) on the flange (4) in line with the reference on the pump itself (2). Figure 218

Fit the high pressure pump (2) vertically as shown in the previous figure onto the support (4) and rotate it in an anticlockwise direction until the mounting bolt holes are aligned. Tighten screw (5) and screws (1) with their washers (3) to the torque indicated in the table. Ref.

No.

Description

(1) (5)

2 1

M8x1.25x90 M6x1x20

Tightening torques 25±2.5 25±2.5

Water/oil heat exchanger refitting Figure 220

227803

Fit the water/oil heat exchanger (2), with a new gasket and tighten the screws (1) to the torque indicated in the table. Tighten the screw (3) fixing the engine cooling water pipe bracket to the feeding pump holder to the torque indicated in the table.

135043

The figure shows the vertical position of high pressure pump assembly.

Ref.

No.

Description

(1) (3)

8 1

M8x1.25x30 M8x1.25

Tightening torques 25±2.5 25±2.5

The high pressure pump can rotate through ± 45˚.

Print P1D32S021 E

Base - April 2015

78

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Oil filter refitting

Low pressure pipes group refitting Figure 221

Figure 223

227802

227800

Fit the low pressure pipes group together with the fuel recovery pipe from electro-injectors and engage the group in the intermediate retaining clips.

Place the oil filter (1) on the water/oil heat exchanger and tighten it to the torque indicated in the table.

Fit the bracket fixing the low pressure pipes duplex anchorage and tighten the screws (2) to the torque indicated in the table.

Ref.

No.

(1)

1

Fit the bracket fixing the low pressure pipes group to the intake manifold and tighten the screw (1) to the torque indicated in the table. Ref.

No.

(1) (2)

1 2

Description M6x1 M6x1x10

Tightening torques 25±2.5 10±1

Description M22x1.5

Tightening torques 25±2.5

Engine assembling (components on exhaust side ) Alternator support refitting Figure 224

Figure 222

227799

Fit the alternator support (2) on the crankcase and tighten the fixing screws (1) to the torque indicated in the table. 227801

Connect the fuel supply pipe to the high pressure pump and close the clamp (1).

Ref.

No.

Connect the fuel return pipe to the high pressure pump and engage the qick connector (2).

(1) (1) (1)

1 2 1

Base - April 2015

Description M8x1.25x70 M8x1.25x30 M10x1.25x35

Tightening torques 30±3 30±3 50±5

Print P1D32S021 E

F1C EuV1 - ENGINES

79

SECTION 6 - GENERAL MECHANICAL OVERHAUL

EGR group refitting

Alternator refitting Figure 225

Figure 227

227798

227796

Fit the alternator (2) in its support, tighten the screw (3) and bolt (1) to the torque indicated in the table.

Place the EGR group (2) on the overhead and tighten the screws (1) to the torque indicated in the table.

Ref.

No.

(3) (1)

1 1

Description M10x1.25x30 M10x1.25x130

Tightening torques 50 ± 5 50 ± 5

Auxiliary drive belt - automatic belt tensioner refitting

Ref.

No.

Description

(1) (1)

3 1

M8x1.25x80 M8x1.25x95

Tightening torques 25±2.5 25±2.5

Figure 228

Figure 226

227795

227797

Fit the automatic belt tensioner (4) and tighten the screw (3) to the torque indicated in the table. Ref.

No.

Description

(3)

1

M10x1.5x45

Tightening torques 45 ± 5

Using a specific wrench on the automatic belt tensioner (4), fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley.

Fit the engine coolant delivery pipes group (3) by connecting the pipes (2) to the EGR heat exchanger and close the clip-sleeve (1). Fit the bracket securing the coolant delivery pipes group (3) to the cylinder overhead and tighten the screw (4) to the torque indicated in the table. Ref.

No.

(4)

1

Description M8x1.25

Tightening torques 25±2.5

Using a suitable tool fit the A/C compressor belt (2).

Print P1D32S021 E

Base - April 2015

80

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Engine assembling (components on top side part 2)

Figure 229

Fuel manifold pipe and electro-injectors refitting Figure 230

α 227794

Fit the exhaust gas pipe (3), on the cylinder head, together with the rear cover and a new gasket and tighten the screws (4) to the torque indicated in the table. Place a newgasket connect the exhaust gas pipe to the intake manifold and tighten the screws (5) to the torque indicated in the table. Connect the exhaust gas pipe to the EGR heat exchanger, close the collar and tighten the screw (1) to the torque indicated in the table.

227793

Fit the fuel manifold pipe (6) in its housing on the overhead, close the relative band and tighten the screws (7) to the torque indicated in the table.

Connect the engine coolant delivery pipe and close the clamps (2).

Connect the high pressure pipe (3) to the fuel manifold and to the high pressure pump, tighten the fitting (1 and 4) with specific series wrench 99317915 and specific torque wrench 99389829 to the torque indicated in the table.

Engage the EGR exhaust gas temperature sensor electrical connection (6) to the bracket and to the intermediate clips.

Tighten the bracket nut (2) to the torque indicated in the table. Use tool 99395216 for angle tightening.

Ref.

No.

Description

(1) (4) (4) (5)

1 3 4 2

M6x1 M8x1.25x35 M8x1.25x45 M8x1.25x30

Tightening torques 5±0.5 5±0.5 5±0.5 5±0.5

Connect the fuel return pipe (5) to the fuel manifold pipe and close the clamp. Ref.

No.

(1)

1

(2)

1

(4)

1

(7)

2

Tightening torques

M16x1

!

Base - April 2015

Description 1st phase 2nd phase M8x1.25 M15x1 1st phase 2nd phase M8x1.25x35

25±2 90˚ 25±2.5 24±2 90˚ 29±1.45

Because of the high pressure in the pipelines running from the fuel feed pump to the injectors, it is absolutely required NOT to: - re-use the disassembled pipelines.

Print P1D32S021 E

F1C EuV1 - ENGINES

81

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 231

Figure 233

227792

229306

Insert the oil level dipstick (1) into the oil sump and tighten the screw (2) fixing the oil level dipstick upper bracket to the intake manifold to the torque indicated in the table.

Fit the brackets (2), securing the electro-injectors to the overhead and screw down the screws (1) without tightening them completely.

Ref.

No.

(2)

1

Description M8x1.25

Tightening torques 25 ± 2.5

Figure 234

Figure 232

229307

217915

Fit a new seal (3) on the electro-injectors (1) and mount them in the overhead (2).

Print P1D32S021 E

Connect the newhigh pressure fuel pipes to the fuelmanifold pipe (1) and to the electro injectors (2), then tighten the electro-injectors bracket screws (3) to the torque indicated in the table. Ref.

No.

Description

(3)

4

M8x1.25x80

Tightening torques 29±1.45

Base - April 2015

82

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Figure 235

Figure 236

α

229305

230353

Using the 99317915 (rail side) and 99352115 (electroinjectors side) wrenches, the torque wrenches 99389829 (rail side) and 99389831 (electro-injectors side), tighten the high pressure fuel pipe fittings (1) and (2) to the torque indicated in the table.

Fit and connect the fuel recovery pipe (2) to the elctro-injectors and close the retaining clips (1) in the direction shown by the arrow.

Use tool 99395216 for angle tightening.

Air inlet pipe refitting

Ref.

No.

(1)

4

(2)

4

Description M15x1

M14x1

!

Tightening torques

1st phase 2nd phase

24±2 90˚

1st phase 2nd phase

25±2 50˚

Close the intermediate retaining clip (3).

Figure 237

Because of the high pressure in the pipelines running from the fuel feed pump to the injectors, it is absolutely required NOT to: - re-use the disassembled pipelines. 227790

Fit the air inlet pipe (1) on the intake manifold, together with the flange (3) and a new gasket, then tighten the screws (2) to the torque indicated in the table.

Base - April 2015

Ref.

No.

Description

(2)

4

M8x1.25x25

Tightening torques 25±2.5

Print P1D32S021 E

F1C EuV1 - ENGINES

83

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Removing the engine from the rotating stand

Figure 239

Remove the engine from the rotary stand 99322205 and remove the the brackets 99361041 from the crankcase.

Refitting of components hindering bracket assembly Turbocharger - Exhaust manifold group refitting Figure 238

220125

229317

Place a new metallic gasket and fit the exhaust gas turbocharger group (2) on the cylinder head. Then tighten the nuts (1) to the torque indicated in the table. Ref.

No.

Description

(1)

10

M8x1.25

Print P1D32S021 E

Tightening torques 25±2.5

Tighten the bracket screws (2), securing the turbocharger water return pipe group to the cylinder head to the torque indicated in the table. Connect the turbocharger water return pipes group to the turbocharger and tighten the union (1) to the torque indicated in the table. Ref.

No.

Description

(1) (2)

1 2

M14x1.5 M8x1.25x16

Tightening torques 40±4 25±2.5

Base - April 2015

84

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Turbocharger air outlet pipe refitting

Figure 240

Figure 242

229316

Fit the exhaust gas delivery pipe (2) with new gaskets, connect it to the exhaust manifold and to the EGR valve and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1)

4

M8x1.25x20

Tightening torques 25±2.5

Turbocharger oil delivery pipe and exhaust manifold guard refitting Figure 241

2144647

Connect the turbocharger air outlet pipe (4) to the turbocharger, place the union bracket (3) and tighten the screws (2) to the torque indicated in the table. Connect the union bracket (5) and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1) (2)

4 2

M8x1.25x20 M6x1x18

Tightening torques 28±2.8 10±1

Electric exhaust gas flap refitting Figure 243

229315

Fit the turbocharger oil delivery pipe (6) and tighten the fittings (1) and (5) to the torque indicated in the table. Connect the turbocharger water delivery pipe to the cranckase and tighten the union (4) to the torque indicated in the table. Fit the exhaust manifold guard (3) with the spacers and tighten the screws (2) to the torque indicated in the table. Ref. (1) (5) (2) (4)

No.

Description

Tightening torques

2

M14x1,5

40±4

4 1

M6x1.25x14 M14x1.5

18 40±4

Base - April 2015

214646

Fit the electric exhaust gas flap (2) onto the turbocharger and tighten the V-clamp (1) to the torque indicated in the table. Ref.

No.

(1)

1

Description M8x70

Tightening torques 12±1

Print P1D32S021 E

F1C EuV1 - ENGINES

85

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Exhaust side engine mount and turbocharger oil outlet pipe refitting

Intake side engine mount refitting Figure 245

Figure 244

227789

Fit the intake side engine mount (2) and tighten the screws (1) to the torque indicated in the table.

214646

Ref.

No.

(1) (1)

1 2

Description M10x1.25x95 M10x1.25x50

Tightening torques 50±5 50±5

Fit the turbocharger oil return pipe, and tighten the fitting to the cranckase (2) and the bracket screws (1) to the torque indicated in the table. Fit the exhaust side engine mount and tighten the the screws (3) and (4) to the torque indicated in the table. Tighten the union bracket screw (6) to the torque indicated in the table. Ref.

No.

(1) (2) (3) (4) (6)

2 1 2 1 1

Print P1D32S021 E

Description M6x1x16 M22x1.5 M10x1.25x85 M10x1.25x50 M8x1.25x20

Tightening torques 10±1 45±4.5 50±5 50±5 25±2.5

Base - April 2015

86

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

Engine wire refitting Fit the engine wiring, engage the pins in the relative brackets and engage the engine wiring cover in its housing on the cylinder overhead. Connect the following electrical connections: Figure 246

227787

REAR VIEW OF ENGINE, INTAKE SIDE 1. Electro-injectors 1,2,3,4 - 2. Fuel pressure sensor on rail - 3. EGR exhaust gas temperature sensor 4. Engine brake actuator - 5. Pre/heater glow plugs - 6. Oil pressure switch - 7. Fuel flow regulator on high pressure pump 8. Air charger intercooler outlet temperature sensor - 9. Coolant temperature sensor 10. Air pressure and temperature sensor - 11. Pressure regulating valve on rail - 12. Segment speed sensor

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

87

Figure 247

227788

FRONT VIEW OF ENGINE, EXHAUST SIDE 1. Air charger intercooler outlet temperature sensor - 2. Coolant temperature sensor - 3. Segment speed sensor 4. EGR valve - 5. Increment speed sensor - 6. VGT position sensor - 7. Engine brake actuator When fitting is completed, top-up the engine lubricant oil with the specified quantity and quality.

!

Only use recommended oils or oils with the properties required for proper engine operation.Failure to observe these standards will invalidate the service warranties. Check the oil level with the oil level dipstick: the level must come close to the MAX notch which can be seen on the dipstick.

Print P1D32S021 E

Base - April 2015

88

SECTION 6 - GENERAL MECHANICAL OVERHAUL

F1C EuV1 - ENGINES

CHECKS AND INSPECTIONS The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored. Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check: - There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings. - Carefully check the fuel connection pipes to the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting covers. - Cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings. - There is no fuel leakage from fuel pipelines. - There is no blow-by from pneumatic pipes (if provided). - Verify correct working of the lighting leds of the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection. - Check and blow by with care the engine cooling system, carrying out frequent drainage.

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 6 - GENERAL MECHANICAL OVERHAUL

89

Low pressure supply circuit diagnostics Figure 248

Diagnosis methodology: complete the ”vehicle acceptance” card. Connect the diagnosis instrument 99305454 to the vehicle diagnosis socket and carry out the engine test analysis: If the result of the ”Run-up Test” gives a high negative deviation (DEV%) on one cylinder and a correct compression value, go straight to the “electro-injectors removal/refitting” procedure described in section 5; otherwise proceed with the analyses described below, where the advice for correct diagnosis will be listed. NOTE

Low pressure, in either the feed circuit or the return circuit, has a direct affect on the high pressure system. The electronic diagnosis instruments are unable to identify faults in the low pressure (except control of the electric pump supply relay).

Connect pressure gauge D (using specific tool) between outlet E of the fuel filter (2) and the fuel delivery pipe (4) to the high pressure pump (1). Connect pressure gauge B (using specific tool) between outlet G of the high pressure pump (1) and the fuel recirculation pipe. Start the engine, keep the speed at 1500 rpm. and compare the pressure values read with those given in the tables A2 and A3. Print P1D32S021 E

146611

Turn off the engine, disconnect pressure gaugeD and restore the connection of the pipe (4) to the fuel filter (2). Connect pressure gauge D between fuel inlet F of the filter (2) and the fuel pipe (3) from the tank. Start the engine, keep the speed at 1500 rpm. and compare the pressure values read with those given in the tables A1 - A3. Table A1 Low pressure at filter inlet Pressure value readings (P) Pressure gauge bar “D” 4.4  p  5.8 Table A1 Low pressure at filter inlet Pressure value readings (P) Pressure gauge bar “D” 4.4  p  6.0 Table A1 Low pressure at filter inlet Pressure value readings (P) Pressure gauge bar “B” 2 Base - April 2015

90

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Base - April 2015

F1C EuV1 - ENGINES

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

1

SECTION 7 Technical specifications Page

Print P1D32S021 E

ASSEMBLY DATA — CLEARANCES . . . . . . . . .

3

TIGHTENING TORQUES . . . . . . . . . . . . . . . . .

8

Base - April 2015

2

SECTION 7 - TECHNICAL SPECIFICATIONS

Base - April 2015

F1C EuV1 - ENGINES

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

3

ASSEMBLY DATA — CLEARANCES

F1CFL411S*A302

Type CYLINDER ASSEMBLY AND CRANK MEMBERS 1 Cylinder liners: 1

1 X 2

Pistons: supplied as spares type measurement outside diameter seat for pin

MAHLE X 1 2

X

3

Piston protrusion from crankcase

Piston gudgeon pin

1

X

3

Piston gudgeon pin — pin seat

Print P1D32S021 E

58 95.543  95.557 36.003  36.009 0.245  0.269

Piston — cylinder liners Piston diameter

95.802  95.812

0.4

0.3  0.6

35.990  35.996 0.007  0.019

Base - April 2015

4

SECTION 7 - TECHNICAL SPECIFICATIONS

F1C EuV1 - ENGINES

Type

F1CFL411S*A302

CYLINDER ASSEMBLY AND CRANK MEMBERS X1* X1 Piston ring slots X2 X2 X3 X3 * measured on  of 92.8 mm Piston rings: S1* S1 S2 S2 S3 S3 * measured at 1.5 mm from the external .

mm 2.200  2.230

Piston rings — slots

1 2 3

Piston rings X1 X2

2.540  2.560 2.068  2.097 1.970  1.990 2.470  2.495

0.103  0.162 0.060  0.100 0.545  0.590 0.4

Piston ring end opening in cylinder liner: X1 X2 X3

0.20  0.35 0.60  0.80 0.30  0.60

Ø1

39.460  39.490

Connecting rod bearing seat* Ø2

67.833  67.848

X3

1

2.050  2.070

Small end bushing seat

2

* connecting rod supplied as spare part Small end bushing diameter

4 3 S

outside

4

39.570  39.595

inside

3

36.010  36.020

Big end bearing shells supplied as spare part - top - bottom

S S

Small end bushing — seat (interference) Piston gudgeon pin — bushing Big end bearing shells

1.882  1.887*/1.887  1.892**/1.892  1.897*** 1.878  1.883*/1.883  1.888**/1.888  1.893*** 0.08  0.135 0.007  0.019 0.127 - 0.254 - 0.508

* RED - ** BLUE - *** GREEN

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

F1CFL411S*A302

Type CYLINDER ASSEMBLY AND CRANK MEMBERS X

Measurement Maximum error on alignment of connecting rod axes

1

2

S1

S 2

3

Main journals No. 1-2-3-4 No. 5 Crankpins Main bearing shells

125

=

0.09

1 2

Main bearing housings  3 No. 1-2-3-4 No. 5 Bearing shells main journals

76.182  76.208 83.182  83.208 64.015  64.038 2.155  2.164 2.165  2.174 2.175  2.184 2.185  2.194 1.882 ÷ 1.887*/1.887 ÷ 1.892**/1.892 ÷ 1.897*** 1.878 ÷ 1.883*/1.883 ÷ 1.888**/1.888 ÷ 1.893***

80.588  80.614 87.588  87.614 0.012  0.122

Bearing shells — crankpins

0.009  0.077 0.127  0.254  0.508 0.127  0.254  0.508

Main bearing shells Big end bearing shells

X

mm

X

S1^ Red Blue Green Brown Big end bearing shells - top S2^ - bottom S2^ ^ supplied as spare parts

Main journal for shoulder

5

X1

32.500  32.550

Main bearing housing for shoulder X2

30.650  31350

Half thrust washers

32.310  32.460

1

X

2

X3

Crankshaft shoulder

X3

0.040  0.240

* RED - ** BLUE - *** GREEN Print P1D32S021 E

Base - April 2015

6

SECTION 7 - TECHNICAL SPECIFICATIONS

F1C EuV1 - ENGINES

F1CFL411S*A302

Type CYLINDER HEAD — TIMING SYSTEM  1

mm

Guide valve seats on cylinder head

1

9.980  10.000

2

6.023  6.038

3

10.028  10.039

 2

Valve guides  3 Valve guides and seats on head (interference) Valve guides  4

0.028  0.059 0.05 - 0.10 - 0.25

Valves:



4 

5.985  6.000 60 7.5’

4 

5.975  5.990 60  7.5’

Valve stem and relevant guide 0.023  0.053 0.033  0.063 Seat on head for valve seat: 1

34.490  34.515

1

34.490  34.515

Outside diameter of valve seats; angle of valve seats on cylinder head: 2 

34.595  34.610 60  1˚

2 

34.595  34.610 60  1˚

 1

 2



X Recessing Between valve seat and head Valve seats Base - April 2015

X

0.375  0.625

X

0.375  0.625 0.08  0.12 0.08  0.12 Print P1D32S021 E

F1C EuV1 - ENGINES

SECTION 7 - TECHNICAL SPECIFICATIONS

F1CFL411S*A302

Type CYLINDER HEAD — TIMING SYSTEM Valve spring height: free spring under a load of: H H1 H 2 N320  16 N657  30

Injector protrusion

7

mm H

55.05

H1 H2

45 35

-0.10  0.40

X

X



Seats for tappets on cylinder head normal 

12.016  12.034

Normal diameter tappets

11.988  12.000



0.016  0.046

Between tappets and seats Camshaft pin seats in cylinder overhead 17 





1 2 3

48.988  49.012

1 2 3

48.925  48.950

46.988  47.012 35.988  36.012

 2 Camshaft supporting pins:

1

2

3

H H

Print P1D32S021 E

35.925  35.950 0.032  0.087

Supporting pins and seats Useful cam height H

46.925  46.950

3.622 4.328

Base - April 2015

8

SECTION 7 - TECHNICAL SPECIFICATIONS

F1C EuV1 - ENGINES

TIGTHENING TORQUES PART Camshaft shoulder plate (3 screws M6x1x20) Engine hook (4 screws M8x1.25x20) (2 screws M8x1.25x25) Piston cooling nozze (4 screws M10x1) Phonic wheel (3 screws M6x1x15) Lower cylinder block (17 screws M8x1.25x77.5) (2 screws M8x1.25x40) (10 screws M12x1.5x125) 1st phase 2nd phase 3rd phase Engine oil suction pipe (3 screws M6x1x12)

TORQUE Nm

kgm

10 ± 1

1 ± 0.1

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

27.5 ± 2.5

2.75 ± 0.25

15

1.5

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

50 ± 5

5.0 ± 0.5 60˚ 60˚

10 ± 1

1 ± 0.1

Oil sump (13 screws M8x1.25x35)

25 ± 2.5

2.5 ± 0.25

Oil sump drain plug (M22x1.5x10)

50 ± 10

5.0 ± 0.1

Connecting rod caps (8 screws M11x1.25x51) 1st phase 2nd phase Cylinder head (6 internal screws M15x1.5x193) 1st phase 2nd phase 3rd phase (4 internal screws M12x1.5x165) 1st phase 2nd phase 3rd phase (4 external screws M8x1.25x117) (1 external screw M8x1.25x58) Cylinder overhead (10 screws M8x1.25x40) (20 screws M8x1.25x77) Flywheel rear protection (1 stud M6x1.25) (2 threaded bush M12x1.5x22.5) Engine flywheel assembly (8 screws M8x1.25x51) 1st phase 2nd phase

50 ± 2.5

5.0 ± 0.25 70˚

130 ± 6.5

13.0 ±0.65 90˚ 90˚

65 ± 3.25

6.5 ±0.325 90˚ 60˚

25 ± 1.25 25 ± 1.25

2.5 ±0.125 2.5 ±0.125

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

10 ± 1 5 ± 0.5

1.0 ± 0.1 0.5 ± 0.05

30 ± 3

3.0 ± 0.3 90˚

Hydraulic power steering support (3 nuts M8x1.25)

25 ± 2.5

2.5 ± 0.25

Hydraulic power steering pump control shaft (1 screw M12x1.25x42.5)

130 ± 13

13.0 ± 1.3

High pressure pump support (3 nuts M8x1.25)

25 ± 2.5

2.5 ± 0.25

Base - April 2015

Print P1D32S021 E

F1C EuV1 - ENGINES

PART

SECTION 7 - TECHNICAL SPECIFICATIONS

9

TORQUE Nm

kgm

High pressure pump control shaft (1 screw M12x1.5x42.5)

110 ± 11

11.0 ± 1.1

Side/lower fixed pad (4 screws M8x1.25x35)

25 ± 2.5

2.5 ± 0.25

50 ± 5

5.0 ± 0.5

10 ± 1 10 ± 1

1.0 ± 0.1 1.0 ± 0.1

110 ± 5.5

11.0 ±0.55

40 ± 2

4.0 ± 0.2

Cylinder head plug (1 plug M26x1.5x16) Upper/side chain guide (2 nuts M6x1) (2 screws M6x1x20) Camshaft gears (2 screw M12x1.75x40) Primary and secondary tensioner arms (1 pin M10x1.5) Intermediate controls assembly (Chain anti-return hydraulic tensioner M22x1.5x2) (Chain standard hydraulic tensioner M22x1.5x2) Inspection caps on overhead (2 caps M14x1.5x10)

50 ± 5 50 ± 5

5.0 ± 0.5 5.0 ± 0.5

25 ± 2.5

2.5 ± 0.25

Depressor/oil pump unit (5 screws M8x1.25x60)

25 ± 2.5

2.5 ± 0.25

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

25 ± 2.5

2.5 ± 0.25

Damper pulley (1 screw M20x1.5x58)

350 ± 17.5

35.0 ±1.75

Segment speed sensor (1 screw M6x1)

8 ± 0.5

0.8 ± 0.05

10 ± 1 10 ± 1

1.0 ± 0.1 1.0 ± 0.1

25 ± 2.5 50 ± 5

2.5 ± 0.25 5.0 ± 0.5

10 ± 1 150 ± 15

1.0 ± 0.1 15 ± 1.5

10 ± 1

1.0 ± 0.1

Blow-by complete pipe (1 nut M8x1.25)

25 ± 2.5

2.5 ± 0.25

Oil level dipstick pipe bracket (1 screw M8x1.25)

25 ± 2.5

2.5 ± 0.25

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

25 ± 2.5

2.5 ± 0.25

40 ± 4 40 ± 4

4.0 ±0. 4 4.0 ±0. 4

Timing system lower cover (7 screws M8x1.25x16) (9 screws M8x1.25x30) A/C compressor belt tensioner (1 screw M8x1.25x45)

Timing system upper cover (2 nuts M6x1) (7 screws M6x1x30) Water pump (2 screws M8x1.25x45) (3 screws M10x1.5x55) Electromagnetic pulley (4 nuts M6x1) (1 ring nut M30x1.5) Blow-by cover (3 nuts M6x1x18)

A/C compressor support (2 screws M8x1.25x130) (2 screws M8x1.25x20) A/C compressor (4 screws M8x1.25x90) Power steering pump (1 screw M10x1.25x30) (1 screw M10x1.25x110)

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SECTION 7 - TECHNICAL SPECIFICATIONS

PART Pre/heater glow plugs (M8x1) Intake manifold (2 screws M8x1.25x60) (6 screws M8x1.25x40) (1 screw M8x1.25x140) (2 plugs M24x1.5) Air temperature and pressure sensor on intake manifold (1 nut M6x1) Thermostat cover (4 screws M8x1.25x20) Coolant temperature sensor (M12x1.5) High pressure pump (2 screws M8x1.25x90) (1 screw M6x1x20) Water/oil heat exchanger (8 screws M8x1.25x30) Low pressure pipes group bracket (1 screw M6x1) Duplex pipe support bracket (2 screws M6x1x14) Alternator support (2 screws M8x1.25x30 (1 screw M8x1.25x70 (1 screw M8x1.25x35) Alternator (1 screw M10x1.25x30) (1 bolt M10x1.25x130) Alternator shaft freewheel (M16x1.5) Increment speed sensor (1 screw M6x1x12) Automatic belt tensioner (1 screw M8x1.25x45) Exhaust manifold (10 nut M8x1.25) Exhaust manifold guard (4 screws M6x1.25x14) Turbocharger (4 nuts M8x1.25) Turbocharger water delivery pipe (2 unions M14x1.5) Turbocharger oil delivery pipe (2 fittings M14x1.5) Turbocharger water return pipe (1 union M14x1.5) (2 bracket screws M8x1.25x16) Turbocharger oil return pipe (2 screws M6x1x16) (1 fitting M22x1.5)

Base - April 2015

F1C EuV1 - ENGINES

TORQUE Nm 9 ± 0.9

kgm 0.9 ± 0.09

25 ± 2.5 30 ± 3 30 ± 3 30 ± 3

2.5 ± 0.25 3.0 ± 0.3 3.0 ± 0.3 3.0 ± 0.3

10 ± 1

1.0 ± 0.1

25 ± 2.5

2.5 ± 0.25

20 ± 5

2.0 ± 0.5

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

25 ± 2.5

2.5 ± 0.25

25 ± 2.5

2.5 ± 0.25

10 ± 1

1.0 ± 0.1

30 ± 3 30 ± 3 50 ± 5

3.0 ± 0.3 3.0 ± 0.3 5.0 ± 0.5

50 ± 5 50 ± 5

5.0 ± 0.5 5.0 ± 0.5

80 ± 5

8.0 ± 0.5

8±2

0.8 ± 0.2

45 ± 5

4.5 ± 0.5

25 ± 2.5

2.5 ± 0.25

18

1.8

25 ± 2.5

2.5 ± 0.25

40 ± 4

4.0 ± 0.4

40 ± 4

4.0 ± 0.4

40 ± 4 25 ± 2.5

4.0 ± 0.4 2.5 ± 0.25

10 ± 1 45 ± 4.5

1.0 ± 0.1 4.5 ± 0.45

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F1C EuV1 - ENGINES

PART Turbocharger oil delivery pipe connector (1 fitting M14x1.5) Turbocharger - air duct pipe union bracket (2 screws M6x1x10) Turbocharger air duct - EGR union bracket (4 screws M8x1.25x20) Turbocharger - engine mount union bracket (1 screw M8x1.25x20) EGR group (3 screws M8x1.25x80) (1 screw M8x1.25x95) Exhaust gas delivery pipe (EGR/exhaust manifold) (4 screws M8x1.25x20) Engine coolant delivery pipe group (1 screw M8x1.25) EGR exhaust gas pipe group (2 screws M8x1.25x30) Rear cover (3 screws M8x1.25x35) (4 screws M8x1.25x45) EGR exhaust gas pipe group collar (1 screw M6x1) Fuel manifold pipe (rail) (2 screws M8x1.25x35) High pressure fuel delivery pipe bracket (1 nut M8x1.25) High pressure fuel delivery pipe (pump/rail) (1 fitting M16x1 - pump side) 1st phase 2nd phase (1 fitting M15x1 - rail side) 1st phase 2nd phase Electro-injector securing bracket (4 screws M8x1.25x80) High pressure fuel pipes (4 fittings M14x1.5 - electro-injector side) 1st phase 2nd phase (4 fittings M15x1 - rail side) 1st phase 2nd phase Air inlet pipe (4 screws M8x1.25x25) Exhaust side engine mount (1 screw M8x1.25x50) (2 screws M10x1.25x85) Intake side engine mount (2 screws M10x1.25x50) (1 screw M10x1.25x95)

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SECTION 7 - TECHNICAL SPECIFICATIONS

11

TORQUE Nm

kgm

27 ± 3

2.7 ± 0.3

10 ± 1

1.0 ± 0.1

28 ± 2.8

2.8 ± 0.28

25 ± 2.5

2.5 ± 0.25

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

25 ± 2.5

2.5 ± 0.25

25 ± 2.5

2.5 ± 0.25

25 ± 2.5

2.5 ± 0.25

25 ± 2.5 25 ± 2.5

2.5 ± 0.25 2.5 ± 0.25

5 ± 0.5

0.5 ± 0.05

29 ± 1.45

2.9 ±0.145

25 ± 2.5

2.5 ± 0.25

25 ± 2

2.5 ± 0.2 90˚

24 ± 2

2.4 ± 0.2 90˚

29 ± 1.45

2.9 ±0.145

25 ± 2

2.5 ± 0.2 50˚

24 ± 2

2.4 ± 0.2 90˚

25 ± 2.5

2.5 ± 0.25

50 ± 5 50 ± 5

5.0 ± 0.5 5.0 ± 0.5

50 ± 5 50 ± 5

5.0 ± 0.5 5.0 ± 0.5

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SECTION 7 - TECHNICAL SPECIFICATIONS

PART Oil filter (M22x1,5) Pressure sensor on rail (M18x1.5) Oil pressure switch (M8x1.25x20) Coolant temperature sensor (M12x1.5) Air temperature sensor (M12x1.5) Air temperature/pressure sensor (M6) High pressure pump flow regulator (2 screws M6)

Base - April 2015

F1C EuV1 - ENGINES

TORQUE Nm

kgm

25 ± 2.5

2.5 ± 0.25

140

14

35 ± 3.5

3.5 ± 0.35

20 ± 5

2.0 ± 0.5

15 ± 1.5

1.5 ± 0.15

5

0.5

6.5 ± 0.5

0.65 ± 0.05

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F1C EuV1 - ENGINES

SECTION 8 - TOOLS

1

SECTION 8 Tools Page

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TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . .

8

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2

SECTION 8 - TOOLS

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F1C EuV1 - ENGINES

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F1C EuV1 - ENGINES

SECTION 8 - TOOLS

3

TOOLS TOOL NO.

NAME

99305454

Tool to check the diesel supply circuit and the common-rail injection system

99317915

Set of 5 insert box wrenches 9x12 (14-15 17-18 19 mm)

99322205

Assemblies overhaul revolving stand (bearing capacity 1000 daN, torque 120 daN/m)

99340060

Tool to remove crankshaft rear gasket

99340062

Tool to remove crankshaft front gasket

99342153

Tool to remove injectors

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Base - April 2015

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SECTION 8 - TOOLS

F1C EuV1 - ENGINES

TOOLS TOOL NO.

NAME

99346258

Key for crankshaft front gasket installation and timing cover centering

99346259

Crankshaft rear seal installer

99360076

Remover cartridge filter

99352115

Wrench (17 mm) for injector pipes torque closure

99358026

Wrench for removing and refitting the alternator pulley

99360183

Piston ring removal and refitting pliers (65-110 mm)

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 8 - TOOLS

5

TOOLS TOOL NO.

NAME

99360187

Oil pump drive shaft retaining tool

99360260

Engine valves remover/installer

99360306

Flywheel restrainer

99360605

Compression tool for fitting engine piston (65-125 mm)

99360614

Tool for camshaft timing

99360615

Tool for crankshaft timing

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Base - April 2015

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SECTION 8 - TOOLS

F1C EuV1 - ENGINES

TOOLS TOOL NO.

NAME

99361041

Brackets fixing engine to revolving stand 99322205

99367121

Manual pump for measuring pressure and vacuum

99370415

Comparator holder base for different surveys (use with 99395603)

99389813

Torque meter spanner (20-120 Nm) with 1/2” square attachment

99389817

Torque meter spanner (60-320 Nm) with 1/2” square attachment

99389818

Torque meter spanner (150-800 Nm) with ½” square attachment

Base - April 2015

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F1C EuV1 - ENGINES

SECTION 8 - TOOLS

7

TOOLS TOOL NO.

NAME

99389819

Torque meter spanner (0-10 Nm) with 1/4” square attachment

99389829

9x12 snap coupling torque wrench (5-60 Nm)

99389831

Torque meter spanner (10-60 Nm) with 3/8” square attachment

99389832

Snap coupling torque wrench 14x18 plus 1/2” square attachment (60-320 Nm)

99395216

Pair of gauges for angular tightening with 1/2” and 3/4” square connections

99395603

Dial gauge (0-5 mm)

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Base - April 2015

8

SECTION 8 - TOOLS

F1C EuV1 - ENGINES

TOOLS TOOL NO.

NAME

99396039

Centering ring for timing gear cover (use with 99346258)

EXPERIMENTAL TOOLS This section shows the working drawings for the experimental tools (S.P.) used in overhauling the engine described in this section, which may be made by the repair shops.

Base - April 2015

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F1C EuV1 - ENGINES

Print P1D32S021 E

SECTION 8 - TOOLS

9

Base - April 2015

10

SECTION 8 - TOOLS

Base - April 2015

F1C EuV1 - ENGINES

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F1C EuV1 - ENGINES

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SECTION 8 - TOOLS

11

Base - April 2015

12

SECTION 8 - TOOLS

Base - April 2015

F1C EuV1 - ENGINES

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F1C EuV1 - ENGINES

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SECTION 8 - TOOLS

13

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SECTION 8 - TOOLS

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F1C EuV1 - ENGINES

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F1C EuV1 - ENGINES

APPENDIX

1

Appendix Page

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SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . .

3

- Standard safety prescriptions . . . . . . . . . . . . . .

3

- Prevention of injury . . . . . . . . . . . . . . . . . . . . .

3

- During maintenance . . . . . . . . . . . . . . . . . . . . .

3

- Respect of the Environment . . . . . . . . . . . . . . .

4

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2

APPENDIX

Base - April 2015

F1C EuV1 - ENGINES

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F1C EuV1 - ENGINES

APPENDIX

3

SAFETY PRESCRIPTIONS Standard safety prescriptions

- Do not execute any intervention if not provided with necessary instructions.

Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.

- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur.

- Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation. - Keep working areas as clean as possible, ensuring adequate aeration. - Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. - Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities. - Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines. - Smoking in working areas subject to fire danger must be strictly prohibited. - Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.

Prevention of injury - Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion. - Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed:  2 bar)

- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.

During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50 ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. - Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil. - Keep the engine clean from oil tangles, diesel fuel and or chemical solvents. - Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas aerated. Whenever necessary wear safety mask. - Do not leave rags impregnated with flammable substances close to the engine. - Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate. - Do not utilize fast screw-tightening tools. - Never disconnect batteries when the engine is running. - Disconnect batteries before any intervention on the electrical system.

- Wear safety helmet when working close to hanging loads or equipment working at head height level.

- Disconnect batteries from system aboard to load them with the battery loader.

- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.

- After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

- Use protection cream for hands. - Change wet cloths as soon as possible - In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections. Ensure that hands and feet are dry and execute working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material.

- Do not disconnect and connect electrical connections in presence of electrical feed. - Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning.

- Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.

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APPENDIX

- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved. - Do not modify fuel systems or hydraulic system unless specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80 ºC temperature.

F1C EuV1 - ENGINES

Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted. - Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger. - Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.

- Do not paint the components and the electronic connections. - Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.

Base - April 2015

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