Error
Error
Figure 11 Figure 12
60670 60671
1. Fuel valve - 2. Pumping element - 3. Fuel outlet - 1. Fuel valve - 2. Pumping element - 3. Fuel outlet -
4. Filling and backflow passage. 4. Filling and backflow passage.
Figure 27 Figure 30
60514
ENGINE ASSEMBLY
Figure 31
60515
Figure 29 Using the centring ring 99396035 (2), check the exact position
of the cover (1). If it is wrong, proceed accordingly and lock
the screws (3).
Figure 32
101606
60564
Loosen screws (3), then remove sump (1) complete with Key on the gasket (1), mount the key 99346250 (2) and,
spacer (2) and seal gasket (4). screwing down the nut (3), drive in the gasket (1).
Figure 33 Figure 36
60515
60566
Check that the pistons 1-6 are exactly at the T.D.C. - Closing to angle with tool 99395216 (1):
Put the gasket (2) on the crankcase. 3rd phase: angle of 120°.
Mount the cylinder head (1) and tighten the screws as shown 4th phase: angle of 60°.
in Figs. 34 — 35 — 36.
Figure 37
NOTE Lubricate the thread of the screws with engine oil
before assembly.
α
Figure 34
60567
Mount the oil pump (4), the intermediate gears (2) together
with the link rod (1) and lock the screws (3) in two phases:
61270 pre-tightening 30 Nm.
closing to angle 90°.
Diagram of the tightening sequence of the screws fixing the
cylinder head. Figure 38
Figure 35
47592
Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
Figure 63
99272
Figure 69 Figure 72
1 12 11 10 3
13 9
14 8
4 5 6 7 2 45362
Figure 70
Install intake manifold (3) with a new seal and lock retaining
screws (2) at prescribed torque.
Install support (1) and lock retaining screws at prescribed
torque.
Figure 73
107977
Install ECU (2) and lock retaining screws (1) at prescribed Install fuel filter (5) and lock it at prescribed torque. Install
torque. supply pump (3) and connect it to pipelines (1, 2 and 4).
Figure 71
Figure 74
107976
107978
Install power takeoff (2) with a new retaining ring and lock
retaining screws (1) at prescribed torque. Install starter motor
Install bracket (3) complete with sedimentation tank filter (2) (3) and lock retaining screws at prescribed torque.
and lock screws (1) at prescribed tightening torque.
Replace fuel sedimentation tank prefilter Check Blow-by filter conditions by means of a clogging
indicator
Figure 86 Figure 88
108397
Disconnect electric connector. Unlock prefilter (1) and
change it. Before refitting a new cartridge, wet seal with fuel
oil or engine oil. Lock cartridge by hand till in contact with
support, then lock it by ¾ of a rev. at predefined tightening
torque. 72563
Figure 89
Fuel filter change
Figure 87
107903
108398
Visually check that belt (1) is not worn out not broken; replace
Use tool 99360314 to remove fuel filter (1). it, if required, as mentioned below.
Before fitting the new cartridge, wet seal with fuel oil or engine
oil. Lock the new one by hand and carefully check that rubber Water pump/alternator control belt change
seal and contact surface are clean and in perfect conditions. In order to remove and refit belt (1), operate using a specific
Lock cartridge by hand till contact with support and then lock tool on belt tensioner (2) in direction shown by arrow.
it for ¾ of a rev. at prescribed tightening torque.
Bleed air from supply system as described in paragraph below.
Check for any water in the fuel filter Lock plus (3) under oil sump at predefined tightening torque.
Pour oil in prescribed quantity and quality in engine through
NOTE The components of the system can be damaged filler (2) of tappet cover.
very quickly in presence of water or impurity within
- After the complete drainage, screw the plug and carry out
the fuel.
the clean oil filling.
Take prompt action on the filter to drain off the
water in the fuel circuit.
NOTE Use only the recommended oil or oil having the re-
Fuel filter is equipped with pump screw-valve to drain the quested features for the corrrect motor function-
water eventually mixed with fuel. ing.
In case of topping up, don’t mix oils having different
Place a container underneath the filter and slightly loosen the features.
screw. Drain the water eventually contained in the filter’s If you don’t comply with theses rules, the service
bottom. warranty is no more valid.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.
- Check the level through the dipsick until when the filling
Engine oil change is next to the maximum level notch indicated on the dip-
sick.
Figure 90
Engine oil filter change
Figure 91
85493
Figure 1
47576
By means of proper and splined wrenches, untighten the
screws (1) and (2) and remove the under-block (3).
NOTE Note down the assembly position of the top and
bottom main bearing shells since, if reusing them,
they will need to be fitted in the position found
upon removal.
Figure 4
47574
Figure 2
47570
Remove the crankshaft (2) with tool 99360500 (1).
Figure 5
47575
47571
Figure 37 Figure 38
60559 47578
Set two journals of the crankshaft (2) parallel to the - Lubricate the internal screws (1) with UTDM oil and
longitudinal axis, a section of calibrated wire. Using tighten them with a torque wrench (3) to a torque of
appropriate hooks and tackle, mount the crankcase base (1). 120 Nm, using tool 99395216 (4), to an angle of 60°,
following the diagram below.
Figure 39
FRONT SIDE
60593
Figure 41
60607
Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Removal
Figure 51 Figure 52
60608 49024
Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin split rings (2) using the round tipped
(1). pliers (1).
Base - March 2006 Print P4D32C001 E
34 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES
73535
Check the bushing in the small end has not come loose and 61694
shows no sign of scoring or seizure; replace it if it does.
The bushing (2) is removed and fitted with a suitable drift (1). Check the torsion of the connecting rod (5) by comparing
When driving it in, make absolutely sure that the holes for the two points (A and B) of the pin (3) on the horizontal plane
oil to pass through in the bushing and small end coincide. of the axis of the connecting rod.
Using a boring machine, rebore the bushing so as to obtain Position the mount (1) of the dial gauge (2) so that this
a diameter of 54.019 — 54.035. pre-loads by approx. 0.5 mm on the pin (3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.
Checking connecting rods
Figure 65 Checking bending
Figure 67
61696 61695
Figure 72
61831
Figure 93
60626
Bushings
Figure 94
60627
MAIN DATA OF THE BUSHINGS FOR THE CAMSHAFT AND SEATS ON THE CYLINDER HEAD
* Bushing inside diameter after driving in
The surface of the bushings must show no sign of seizing or If you find a higher value than the tolerance, replace them.
scoring; replace them if they do. To remove and fit the bushings, use the appropriate drift
Measure the inside diameter of the bushings with a bore 99360499.
gauge.
Print P4D32C001 E Base - March 2006
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 49
TIGHTENING TORQUE
TORQUE
PART
Nm kgm
Capscrews, undercrankcase to crankcase ♦
M12x1.75 outer screws Stage 1: pretightening 30 (3)
M 17x2 inner screws Stage 2: pretightening 120 (12)
Inner screws Stage 3: angle 60°
Inner screws Stage 4: angle 55°
Outer screws Stage 5: angle 60°
Piston cooling nozzle union ♦ 35 ± 2 (3.5 ± 0.2)
Capscrews, heat exchanger to crankcase ♦
pretightening 11.5 ± 3.5 (1.15 ± 0.35)
tightening 19 ± ≤ (1.9 ± 0.3)
Piston cooling nozzle union ♦ 24.5 ± 2.5 (2.4 ± 0.25)
Spacer and oil sump capscrews ♦
pretightening 38 (3.8)
tightening 45 (4.5)
M 12x1.75 screws, gear case to crankcase ♦ 63 ± 7 (6.3 ± 0.7)
M 12x1.75 screws, gear case to crankcase ♦ 24 ± 2.5 (2.4 ± 0.25)
Cylinder head capscrews ♦
Stage 1: pretightening 60 (6)
Stage 2 pretightening 120 (12)
Stage 3: angle 90°
Stage 4: angle 65°
Rocker shaft capscrew ♦
Stage 1: pretightening 80 (8)
Stage 2: angle 60°
Locknut, rocker adjusting screw ♦ 39 ± 5 (3.9 ± 0.5)
Capscrews, injector securing brackets ♦ 26 (2.6)
Capscrews, injector securing brackets ♦ 8.5 ± 1.5 (0.8 ± 0.15)
Capscrews, thrust plates to head ♦ 19 ± 3 (1.9 ± 0.3)
Screw fastening the engine supporting bracket to the cylinder head
Stage 1: pretightening 120 (12)
Stage 2: angle 45°
♦ Before assembly, lubricate with UTDM oil
• Before assembly, lubricate with graphitized oil
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections
efficiency of earth and mass electrical connections. in presence of electrical feed.
Ensure that hands and feet are dry and execute working - Before proceeding with pipelines disassembly
operations utilizing isolating foot-boards. Do not carry (pneumatic, hydraulic, fuel pipes) verify presence of liquid
out working operations if not trained for. or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
- Put the dirty rags with oil, diesel fuel or solvents in injury and poisoning.
anti-fire specially provided containers.