F4HFE413K

NEF 45 TIER 4B/STAGE IV
Technical repair manual

I
Print notes
Product: NEF 45 TIER 4B/STAGE IV
Construction
Language: ENG
Name: P2D32N029E0115 ENG
Publication status: 26.06.2015
FPT Industrial S.p.A.

Via Puglia 15
10156 Torino
Italy
Figures and words: FPT Industrial S.p.A. 2015

All rights reserved.
www.fptindustrial.com
P2D32N029E0115
Contents II
Technical repair manual 1

Principles 2
Operating diagrams 3
Electric/electronic system 4
Scheduled maintenance 5
Removal-refitting of the main
engine components 6
General mechanical overhaul 7
technical specifications 8
Equipment 9
safety regulations 10
III Contents
NEF 45 TIER 4B/STAGE IV Technical repair manual
Contents 1
Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
INTRODUCTION 3
Contents
Contents
SYMBOLS - WARNINGS . . . . . . . . . . . . . . . . . . . 5
SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . . 6
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . 7
GENERAL WARNINGS REGARDING THE

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . 8
Grounding and screening . . . . . . . . . . . . . . . . . . . . 9
Optional electrical and mechanical parts

installations . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Conversions between the main units of measurement

of the international system and the most commonly
used derived sizes . . . . . . . . . . . . . . . . . . . . . . . 11
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Revolutions per time unit . . . . . . . . . . . . . . . . 11
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Temperature . . . . . . . . . . . . . . . . . . . . . . . . 11
Update data . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
P2D32N029E0115
4 INTRODUCTION
P2D32N029E0115
INTRODUCTION 5
SYMBOLS - WARNINGS
INTRODUCTION
This document provides data, specifications, instructions and methods to perform repair interventions on the assembly and its com-
ponents.
Anyhow, this document is addressed to qualified and specialised personnel.
Before performing any intervention, check that the document relating to the vehicle model on which the intervention is being per-
formed is available and also make sure that all accident prevention devices, including but not limited to, goggles, helmet, gloves,
shoes, as well as work equipment, lifting and transport equipment, etc., are available and efficient, and also make sure that the unit is
in safety conditions for intervention.
Carrying out interventions which fully comply with the indications given here, as well as the use of the specific equipment indicated,
ensures repair interventions are carried out correctly, timings are respected and the operator's safety is safeguarded.
Each repair intervention must be finalised to the recovery of functionality, efficiency and safety conditions that are provided by
Iveco.
Each intervention on the unit aimed at a modification, alteration or other which has not been authorised by FPT relieves FPT of any
liability, and, in particular, where the assembly is covered by a warranty, each intervention will immediately invalidate the warranty.
FPT declines any liability for repair work.
FPT is available to provide any information necessary for the execution of the interventions and to provide instructions for any
cases and situations not covered in this publication.
The data contained in this issue may not be up-to-date due to possible modifications made by the Manufacturer for technical or
commercial reasons, or to adaptations required by laws in force in different countries.
In the event of discordance between the information in this publication and the actual assembly, please contact the FPT network
before performing any interventions.
The complete or partial reproduction of the text or illustrations herein is forbidden.
Manuals for repairs are split into Sections, each one of which is marked by a numeral; 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, overhauls at the bench, diagnostics
and scheduled maintenance
In the electrical/electronic system section there are the descriptions of the electric network and the electronic systems of the as-
sembly, wiring diagrams, electrical characteristics of components and the component codes.
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

Failure to comply with these prescriptions can result in the risk of serious injury.
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
Includes the dangers of both above described signals.
Environmental 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.
P2D32N029E0115
6 INTRODUCTION
SYMBOLS - SERVICE OPERATIONS
SYMBOLS - SERVICE OPERATIONS

Removal
Intake
Disconnect
Refitting
Exhaust
Connect
disassembly
operation
Disassembly
assembly
Compression ratio
Composition
Tolerance
Tighten to the specified torque
Weight difference
Tighten to the specified torque + angle value Rolling torque
Press or caulk Rotation
Adjustment Angle
regulation Angle value
Visual inspection
Preload
Assembly position check
Measurement
Value to be measured Revolutions per time unit
check
Equipment Temperature
Surface for machining

Pressure
Machined finished product
Oversized
Interference
Greater than ...
Forced assembly
Maximum
Undersized
Thickness
Lesser than ...
Clearance
Minimum
Lubricate Selection
Dampen Classes
Grease Oversizes
Temperature < 0 C
Sealant
Cold
Glue
Winter
Temperature > 0 C
Bleeding air Hot
Summer
P2D32N029E0115
INTRODUCTION 7
GENERAL WARNINGS
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 the specific and general equipment according to that prescribed in the respective use and maintenance handbooks. Check the working
condition and suitability of tools not subject to periodic review.
Manual handling of loads must be previously appraised regarding the weight, size and path.
Handling with mechanical equipment must be done using appropriate lifts and hoists, in terms of weight, 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.
Remove the expansion tank cap only when the engine is cold, unscrewing it carefully to allow the residual pressure in the system to es-
cape.
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. Suitably store flammable, corrosive and pollutant fluids and liquids in accordance with current regulations. 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.
Wear, where required by the operation, garments and protection provided for by accident prevention rules; contact with moving parts can
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 from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas. Wear an appro-
priate 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.
P2D32N029E0115
8 INTRODUCTION
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
Before overhauling, clean the assemblies and make sure they are intact and complete. Place in an orderly fashion and in appropriate con-
tainers the parts removed or disassembled with their respective fixing elements (screws, nuts, etc.).
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 should be carried out in strict compliance with specific regulations in force.
GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the chassis ground 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 termin-
als.
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 ECUs, on plug-connectors as well as on electrical connections can be made only on suitable testing lines, by means of
special plugs and plug-type bushes. Do not use in any case inappropriate means as metallic threads, screwdrivers, clips or similar. In addition
to the risk of causing a short circuit, this might damage plug-type connections and this would then give rise to contact problems.
P2D32N029E0115
INTRODUCTION 9
Grounding and screening
Do not use fast chargers to start up the engine. Start up must 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 before recharging them by means of an external unit.
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.
Key storage procedures are affected by electromagnetic disturbances such as cell phones and the like. Therefore, during key storage:
1. Make sure there are no sources of disturbance near the keys or in the cab.
2. Keys not inserted in the panel must be at least 1 metre away.
Note The connectors are viewed from the cable side. Connector views contained in the manual are representative of cable side.
For fuse identification and rating, comply with the indications present in the vehicle, since their identification or rating may be
subject to changes.
Grounding and screening
185272 Figure 1
The negative conductors connected to a system ground point must be as short as possible and connected with each other in star
shape, so trying that their tightening is organised and appropriate ref. (M).
P2D32N029E0115
10 INTRODUCTION
Optional electrical and mechanical parts installations
d
C
d
C
88039 Figure 2
The following precautions must be observed regarding the electronic components:
electronic control units must be connected to the system ground when equipped with metal housings.
Electronic control unit negative cables must be connected to a system ground point, such as the dashboard compartment
ground (avoiding "serial" or "chain" connections), as well as to the negative terminal of the battery/is.
Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal insula-
tion. Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
The metal braid of the shielded circuits must be in contact only at the control unit side to which the signal is to be sent.
In the case of junction connectors the unshielded section (d), near to the latter, must be as short as possible.
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.
Optional electrical and mechanical parts installations

Accessory installation, additions and changes on the vehicle 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.
Any exception to the assembly directives must be authorized by FPT.
lack of observance of above described prescriptions involves guarantee lapse.
It is strictly forbidden to carry out any modifications or connections to the electric control unit wiring. In particular,
the data line between the control units (CAN line) is to be considered untouchable.
P2D32N029E0115
INTRODUCTION 11
Conversions between the main units of measurement of the international system and the most commonly
Conversions between the main units of measurement of the international system and the most
commonly used derived sizes
Power
1 kW=1.36 HP
1 kW = 1.34 hp
1 CV = 0.735 kW
1 CV = 0.986 hp
1 hp = 0.746 kW
1 hp = 1.014 CV
Note The CV unit is converted into hp for simplicity according to a ratio of 1:1 1 hp = 1 CV
Torque
1 Nm = 0.102 kgm
1 kgm=9.81 Nm
Note Unless there is a specific need for accuracy, the unit Nm is converted into kgm for simplicity according to a ratio of 10:1,
i.e. 1 kgm = 10 Nm.
Revolutions per time unit

1 rpm = 0.1047 rad/s
1 rpm = 9.55 rad/s
Pressure
1 bar=1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 10 5 Pa
Note The unit bar is converted into kg/cm for simplicity according to a ratio of 1:1 1 kg/cm = 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)
P2D32N029E0115
12 INTRODUCTION
Update data
Update data
Section Section name Description of modification Page Revision date
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV Principles
Contents 1
Contents
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
Principles 3
Contents
Contents
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . 5
Identification plate . . . . . . . . . . . . . . . . . . . . . . 5
APPROVAL PLATE . . . . . . . . . . . . . . . . . . . . . . . 6
APPROVAL PLATE . . . . . . . . . . . . . . . . . . . . . 6
CORRESPONDENCE BETWEEN TECHNICAL

CODES AND COMMERCIAL CODES . . . . . . . . . . . 6
CORRESPONDENCE BETWEEN TECHNICAL
CODES AND COMMERCIAL CODES . . . . . . . . . 6
TECHNICAL CODES . . . . . . . . . . . . . . . . . . . . . . 7
TECHNICAL CODES . . . . . . . . . . . . . . . . . . . 7
COMMERCIAL CODES . . . . . . . . . . . . . . . . . . . . 7
COMMERCIAL CODES . . . . . . . . . . . . . . . . . . 7
ISOMETRIC VIEW . . . . . . . . . . . . . . . . . . . . . . . . 8
ISO VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHARACTERISTIC CURVES . . . . . . . . . . . . . . . . 10
Maximum power 125 kW . . . . . . . . . . . . . . . . 10
Maximum power 89 kW . . . . . . . . . . . . . . . . . 11
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . 12
GENERAL CHARACTERISTICS . . . . . . . . . . . . . . 16
GENERAL CHARACTERISTICS . . . . . . . . . . . . 16
P2D32N029E0115
4 Principles
P2D32N029E0115
Principles 5
Identification plate
Principles
229413 Figure 1
1. Serial number 2. Version name
P2D32N029E0115
6 Principles
APPROVAL PLATE
APPROVAL PLATE
APPROVAL PLATE
225750 Figure 2
1. Model 7. Date of manufacture (mm/yy)
2. Month and year of manufacture 8. Engine serial number
3. Theoretical code to be completed as the master data 9. Customer engine drawing number
4. Engine family 10. Power class
5. Engine serial number to be assigned in the manufactur- 11. Model year
ing plant 12. Rated power
6. Barcode 13. Displacement (litres)
14. Engine family
CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES

54 CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES
Technical codes Commercial Codes

F4HFE413K*B010 N45ENTHW20.50
F4HFE413T*B005 N45ENTHW21.50
P2D32N029E0115
Principles 7
TECHNICAL CODES
TECHNICAL CODES
54 TECHNICAL CODES
The technical code is assigned during production; it is used to identify the main characteristics, characterise the application and the
corresponding level of power output.
F4HFE413K*B010
F4HFE413T*B005
F4HFE413K*B010 - ENGINE FAMILY IDENTIFICATION
F4HFE413K*B010 - Non structural crankcase - Application OFF-ROAD
F4HFE413K*B010 - ENGINE WITH HW DESIGNED FOR TIER4/EURO6
F4HFE413K*B010 - CYLINDER CONFIGURATION (E = 4-stroke vertical with post-treatment device)
F4HFE413K*B010 - NUMBER OF CYLINDERS
F4HFE413K*B010 - MAIN ENGINE CHARACTERISTICS (1 = Direct injection turbodiesel with aftercooler)
F4HFE413K*B010 - APPLICATION (3 = Industrial/agricultural)
F4HFE413K*B010 - Engine torque or power level
F4HFE413K*B 010 - Level of emissions (B = Tier 4 full / Stage IV)
F4HFE413K*B010 - VARIANTS TO THE BASIC ENGINE: the first number refers to the injection system (0 = 4-valve Com-
mon Rail) whereas the other numbers refer to the engine configuration.
COMMERCIAL CODES
54 COMMERCIAL CODES
The purpose of the commercial name is to make the information regarding engine characteristics easy to understand, by joining
engines from different families, origins and applications for which they are intended. The commercial code cannot be used for tech-
nical purposes in order to completely identify the parts that make up the engine, referring to the serial number otherwise indic-
ated as ENGINE S/N, as the identification.
N45ENTHW20.50
N45ENTHW21.50
N45ENTHW20.50 ENGINE FAMILY IDENTIFICATION (N = NEF)
N45ENTHW20.50 - DISPLACEMENT: 45 = 4,500 hp NOMINAL (for NEF the first digit is also the number of cylinders)
N45E NTHW20.50 - FUEL SUPPLY: E = ELECTRONICALLY CONTROLLED INJECTION
N45ENTHW20.50 - CRANKCASE: N = NOT STRUCTURAL (NORMAL DISTRIBUTION)
N45ENTHW20.50 - AIR INTAKE: T = INTERCOOLED TURBOCHARGED
N45ENTHW20.50 - EMISSION LEVEL: H = Tier 4 full / Stage IV
P2D32N029E0115
8 Principles
ISOMETRIC VIEW
N45ENTHW20.50 - ENGINE CONTROL UNIT: W = EDC17CV41
N45ENTHW20.50- Progressive engine variants
ISOMETRIC VIEW
540110 ISO VIEW
225741 Figure 3
P2D32N029E0115
Principles 9
ISOMETRIC VIEW
225742 Figure 4
F4HFE413 is an in-line 4-cylinder turbo engine with intercooler and 4 valves per cylinder; it belongs to the NEF series and operates
according to a 4-stroke diesel cycle.
The engine's fuel system is electronically controlled and based on the direct injection of the fuel in the combustion chamber by
means of a high pressure pump and the common rail.
The intake and exhaust valves are timed with the camshaft tappets, the push rods and the rocker arm assembly.
P2D32N029E0115
10 Principles
CHARACTERISTIC CURVES
Maximum power 125 kW
229415 Figure 5
A. Power curve B. Torque curve
P2D32N029E0115
Principles 11
Maximum power 89 kW
229414 Figure 6
A. Power curve B. Torque curve
P2D32N029E0115
12 Principles
ENGINE VIEWS
ENGINE VIEWS
540110 ENGINE VIEWS
Left side view
LEFT SIDE VIEW
225731 Figure 7
1. Common rail 5. Lubricating oil drain plug
2. Flywheel housing 6. Engine control unitEDC17CV41
3. High pressure fuel pump 7. Air preheating element (Grid Heater)
4. Engine oil sump
P2D32N029E0115
Principles 13
ENGINE VIEWS
Right side view

RIGHT SIDE VIEW
225732 Figure 8
1. Tappet cover 5. Starter motor
2. Lifting eyelet 6. Engine coolant pipes for the motorised throttle valve
3. Alternator actuator (Exhaust flap)
4. Oil filter
P2D32N029E0115
14 Principles
ENGINE VIEWS
Front view
FRONT VIEW
225733 Figure 9
1. Engine cable 6. Alternator support/engine coolant inlet pipe
2. Fan control pulley 7. Water pump
3. Guide pulley 8. Automatic belt tensioner
4. Fuel filter 9. turbocharger
5. Crankshaft pulley
P2D32N029E0115
Principles 15
ENGINE VIEWS
Rear view
REAR VIEW
225734 Figure 10
1. Motorised throttle valve (Exhaust flap) 5. Engine flywheel
2. Lubricating oil delivery pipe to turbocharger 6. Blow-by filter
3. Exhaust manifold; 7. Intake manifold
4. Lubricating oil drain pipe from turbocharger 8. Lifting eyelet
P2D32N029E0115
16 Principles
GENERAL CHARACTERISTICS
Top view
TOP VIEW
225740 Figure 11
1. Auxiliary assembly drive belt 3. Engine lubricating oil filler cap
2. Gear case 4. Thermostat
Type F4HFE413K*B010 F4HFE413T*B005
Cycle Diesel 4-stroke
Power supply Turbocharged with intercooler
Injection Direct
Number and arrangement of

4, in line
cylinders
P2D32N029E0115
Principles 17
Bore mm 104
Stroke mm 132
Total displacement cm3 4.485
Compression ratio 17 : 1 18 : 1
kW 125 89
Max. power (CV) (170) (121)
r.p.m 2.200 2.200
Nm 710 539
Maximum torque (kgm) (72,38) (54,94)
r.p.m 1.500 1.250
Idle speed with no load r.p.m 750 100
Maximum engine idle

r.p.m 2.375 50
speed
TURBOCHARGING Turbocharger with intercooler
Turbocharger type HONEYWELL GARRETT GT2556N
Forced by means of gear pump, pressure relief valve, oil filter, heat
LUBRICATION
exchanger with 5 elements
Oil pressure with engine
warmed up (120 C)
- at idle speed bar 0.6
- at maximum speed bar 3.5
COOLING By centrifugal pump, thermostat, radiator, heat exchanger, intercooler
Water pump drive Belt driven
Thermostat
- opening start C 79 2
- max. opening C 96
P2D32N029E0115
18 Principles
REFILLING
Cooling circuit (1)
litres 7
Lubrication circuit :
(2)
litres
- total capacity (3)
14,33 (12,9)
(kg)
Periodic replacement:
- oil sump at minimum litres
8,6 (7,7)
level (kg)
- oil sump at maximum litres
12,33 (11,1)
level (kg)
Fuel tank (4)
litres
Urea tank (5)
litres 43 / 65
(1) The indicated quantities refer only to the engine in the standard configuration. Use a mixture of 50% water and Actifull OT CONCEN-
TRATE (or Actifull OT PREMIX without the addition of water), also during the summer months. Alternatively to 'Actifull OT, use another
product that complies with the FPI9.COOL002 and/or ASTM D-6210 specifications.
(2) Only use lubricants that comply with the international standards API CJ-4 / ACEA E9. The recommended oil is SAE 10W-40, which
complies with the specifications FPI9.LUBR001. FPT recommends using original lubricants AkcelA or AmbrA in compliance with standard
SAE 10W-40. Oil consumption is considered acceptable up to a quantity equal to 0.5% of fuel consumption.
(3) The quantities indicated relate to the first refuel only and are relative to the engine, oil sump and filter filling.
(4) Use STANDARD fuel in compliance with standards ASTM D975 or EN 590. The information regarding the capacity of the fuel tank is
the responsibility of the vehicle/equipment manufacturer as it is subject to variations depending on the different vehicle/equipment configur-
ations.
(5) Use only AdBlue/DEF (32.5% solution in water) in compliance with specification ISO 22241.
TIMING SYSTEM
start before T.D.C. A 8.5
end after B.D.C. B 8.5
start before B.D.C. D 51
End after T.D.C. C 12.5
For timing check
mm 0.20 0.30
X

mm 0.46 0.56
High pressure fuel supply controlled by BOSCH EDC17CV41

POWER SUPPLY Composed of CP 3.3 high-pressure pump, injectors, hydraulic accumulator
(rail), EDC control unit, pressure and temperature sensors
Electro-injectors type CRIN2 CRIN2-16

Nozzle type DLLA 137 PV3 198 878 0 433 172 376
P2D32N029E0115
Principles 19
Firing order 1-3-4-2
Injector calibration bar 1600
P2D32N029E0115
20 Principles
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV Operating diagrams
Contents 1
Contents
Operating diagrams . . . . . . . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
Contents
Contents
SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 5
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . 5
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 8
Supply system components . . . . . . . . . . . . . . . . . 11

Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mechanical supply pump . . . . . . . . . . . . . . . . . 12
BOSCH CP3 high pressure pump . . . . . . . . . . . 14
LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . 16
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LUBRICATION CIRCUIT COMPONENTS . . . . . 19
OIL VAPOUR RECIRCULATION SYSTEM . . . . . . . 25

Principles . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OIL VAPOUR RECIRCULATION SYSTEM
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . 26
COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . 26
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . 26
COOLING CIRCUIT COMPONENTS . . . . . . . . 28
INTAKE AND EXHAUST SYSTEM . . . . . . . . . . . . 31

Turbocharging . . . . . . . . . . . . . . . . . . . . . . . 31
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . 31
Turbocharger actuator . . . . . . . . . . . . . . . . . . 33
Motorised throttle valve . . . . . . . . . . . . . . . . . 35
EXHAUST GAS POST-TREATMENT

SYSTEM(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Principles . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ATS components . . . . . . . . . . . . . . . . . . . . . 43
P2D32N029E0115
4 Operating diagrams
P2D32N029E0115
SUPPLY SYSTEM
Operating diagrams
SUPPLY SYSTEM
5420 Principles
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, while the injection precision, obtained by
the electronic system control, optimizes the engine performance, reducing emissions and consumption.
5420 ELECTRICAL SYSTEM
225718 Figure 1
1. Electro-injector 7. Electronic engine boxEDC17CV41
2. Motorised throttle valve actuator (Exhaust Flap) 8. Crankshaft rpm sensor (incremental speed)
3. Air temperature and boost pressure sensor 9. In-line diagnostics connector (EOBD)
4. Camshaft timing sensor (segmental speed) 10. Engine oil temperature and pressure sensor
5. High pressure fuel pump dosing module 11. Coolant temperature sensor
6. Fuel temperature sensor 12. Rail pressure sensor
P2D32N029E0115
SUPPLY SYSTEM
5420 Fuel system sensors

Through the sensors, present on the engine, the ECU controls the engine operation.
Air pressure/temperature sensor

This component includes a temperature and a pressure sensor. Fit on the intake manifold, it measures the maximum flow rate of
the introduced air, which is used to accurately calculate the quantity of fuel to be injected at each cycle. The voltage at the outlet is
proportional to the pressure or temperature measured by the sensor.
Engine oil temperature and pressure sensor

Like the air temperature/pressure sensor, it is fit on the engine oil filter in a horizontal position. It measures the engine oil temperat-
ure and pressure.
Fuel pressure sensor

Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure.
The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injec-
tion electronic command.
Fuel temperature sensor

This sensor is the same as the previous one. It detects the temperature of the fuel to give the control unit information about the
fuel oil temperature conditions.
Coolant temperature sensor

This is a variable resistance sensor that is able to measure coolant temperature and transmit a signal to the control unit reflecting
the thermal conditions of the engine.
Crankshaft sensor
This is an inductive sensor placed in the front of the engine. Signals generated through the magnetic flow that closes on the phonic
wheel change their frequencies depending on crankshaft rotation speed.
Timing sensor
This is an inductive sensor placed in the rear left area of the engine. It generates signals obtained from magnetic flux lines which
close through the holes situated in gears force fitted to the camshaft.
The signal this sensor generates is used by the electronic control unit as an injector timing signal. Although it is similar to the fly-
wheel sensor, it is NOT interchangeable as its form is different.
5420 System operation

Self-diagnostics
The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.
P2D32N029E0115
SUPPLY SYSTEM
Engine pre-heating resistance management

The pre-post heating is activated when even only one of the water, air or fuel temperature sensors signals a temperature that is
less than 5 C.
Synchronization search
By means of signals coming from camshaft sensor and crankshaft sensor, the cylinder on which fuel must be injected is recognised
upon startup.
Injection control
The control unit, depending on information coming from sensors, controls the flow regulator, and changes pre-injection and main
injection modes.
Closed loop injection pressure management

Depending on engine load, measured by processing signals coming from various sensors, the control unit controls the regulator in
order to always have the optimum pressure.
Pilot and main injection advance control

The control unit, depending on signals coming from various sensors, computes the optimum injection point according to an internal
mapping.
Idle speed control

The control unit processes the signals originating from the various sensors and regulates the quantity of injected fuel. It controls
the pressure regulator, varies the injection time of the electro-injectors. It also takes the battery voltage into account within certain
thresholds.
Maximum speed limiting

Approaching the peak rpm, the ECU limits the fuel flow by reducing the opening time of the electro-injectors.
The maximum engine speed is 2375 50 rpm. The control unit deactivates the electro-injectors above this speed.
Cut Off
Fuel cut off upon deceleration is controlled by the control unit performing the following logics:
it cuts off supply to the electro-injectors;

it re-activates the electro-injectors shortly before idle speed is reached;
operates the fuel flow regulator.
Smokiness on acceleration control

With important load requests, the control unit, depending on signals received by air inlet meter and engine speed sensor, controls
the flow regulator and changes the injectors actuation time, in order to avoid exhaust smokes.
P2D32N029E0115
SUPPLY SYSTEM
Checking fuel temperature

When the fuel temperature exceeds 78 C (measured by the sensor located on the fuel filter) the control unit reduces the injec-
tion pressure. If the temperature exceeds 90 C, the power is reduced to 60%.
After Run
The control unit microprocessor allows storing certain EPROM data, among which failure memory and Immobilizer information, in
order to make them available upon the following startup.
5420 HYDRAULIC SYSTEM

The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder
that has to receive the injection and accumulates fuel in a common duct for all electro-injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place
in the related cylinder.
HYDRAULIC SYSTEM
225719 Figure 2
1. Electro-injector 5. High pressure fuel pump
2. Common Rail 6. Fuel filter
3. Quick coupling for fuel return pipe 7. Electronic engine boxEDC17CV41
4. Fuel to tank return pipe 8. Fuel delivery fuel pipe to the Common Rail
P2D32N029E0115
SUPPLY SYSTEM
A. High pressure C. Fuel discharge

B. Low pressure
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit. The high pressure circuit consists of the
following pipes:
pipe connecting the high-pressure pump outlet to the common rail;

Common Rail;
pipes supplying the electro-injectors from the Common Rail.
The low-pressure circuit is made up of the following pipes:
fuel intake pipe from tank to prefilter with a priming pump;

pipes supplying the mechanical pump via the heat exchanger of the engine control unit;
pipes supplying the high-pressure pump through the fuel filter.
The fuel drain circuit from Common Rail, injectors and the high pressure pump return flow complete the system.
P2D32N029E0115
SUPPLY SYSTEM
5420 Fuel system diagram

Fuel system diagram
ECU
225720 Figure 3
1. Fuel tank 10. High pressure pump reflux pipe
2. Pre-filter 11. Quick coupling for fuel return pipe from injectors
3. Manual pump 12. Return pipe
4. Control unit 13. Common rail maximum pressure valve
5. Fuel filter 14. Common rail
6. Flow rate modulator 15. Pressure sensor
7. High-pressure pump 16. Injector
8. Pressure relief valve on the high pressure pump, 5 bar 17. By-pass valve
9. Mechanical supply pump 18. By-pass valve
A. Outlet connection to the high pressure pump D. Inlet connection for the fuel drain from the common
B. Outlet connection for the fuel drain in the tank rail and injectors
C. Inlet connection for the fuel drain from the high pres- E. Inlet connection from the mechanical fuel pump
sure pump F. High pressure
G. Low pressure
H. Fuel discharge
P2D32N029E0115
Supply system components
The flow regulator (6), located upstream of the high pressure pump, controls the flow of the fuel needed in the low pressure
system. Subsequently, the high pressure pump correctly supplies the rail. This solution of pressurising only the necessary amount
of fuel improves the energy performance and limits fuel heating in the system.
The function of the relief valve (8), mounted on the high-pressure pump, is to maintain the pressure, at the flow regulator inlet,
constant at 5 bar, regardless of the efficiency of the fuel filter and of the system situated upstream.
The quick coupling for the fuel return pipe (11) housed on the cylinder head, fit on the injector return, limits the return flow from
the injectors.
Two by-pass valves are placed in parallel to the mechanical fuel pump. The by-pass valve (17) permits the fuel to flow from the
exit of the mechanical pump to its inlet when the inlet pressure of the fuel filter exceeds the permitted limit. The by-pass valve
(18) makes it possible to fill the fuel system via the manual priming pump (3).

773110 Fuel pre-filter
The high water separation type fuel filter is mounted on vehicle
chassis and on the cartridge base (3) has a sensor (4) for detect-
ing water in the fuel.
The filter bracket houses a manual priming pump (5) and a screw
(2) for bleeding the air from the system.
The presence of condensate in the filter is signalled by sensor (4)
when a warning light on the instrument panel comes on.
70494 Figure 4
P2D32N029E0115
542010 Fuel filter

It is located on the crankcase in the circuit between the fuel pump
and the high pressure pump (CP3). The following is located on the
support: the fuel temperature sensor and the heater elements.
The fuel temperature indicated by the relative sensor to the
EDC17CV41 control unit makes it possible to accurately calculate
the flow rate of the fuel to be injected in the cylinders.
The electric heater is activated when the fuel temperature is less
than 0 C and deactivated when the fuel temperature exceeds 5 C.
99231 Figure 5
1. Fuel filter support 4. Fuel filter
2. Fuel temperature 5. Adapter
sensor 6. Heater connector
3. Electric fuel heater 7. Gasket
Fuel filter connections:

A. Outlet connection D. Inlet connection for
to the high pressure the fuel drain from
pump the common rail and
B. Outlet connection for injectors
the fuel drain in the E. Inlet connection from
tank the mechanical fuel
C. Inlet connection for pump
the fuel drain from
the high pressure
pump
773010 Mechanical supply pump

The mechanical fuel pump is a gear pump that is assembled on the rear part of the high pressure pump that it supplies. It is con-
trolled by the high pressure pump shaft.
P2D32N029E0115
Normal operating condition
72592 Figure 6
A. Fuel inlet from tank 1,2 By-pass valves in closed position
B. Fuel outlet to filter
Output overpressure condition
72593 Figure 7
The by-pass valve (1) is triggered when overpressure is generated at the output (B). The pressure, overcoming the elastic resist-
ance of the valve spring (1), puts the output in communication with the input via the duct (2).
Air bleeding conditions
72594 Figure 8
The by-pass valve (2) is triggered when, with the engine off, you want to fill the fuel system using the priming pump. In this situation
the by-pass valve (1) remains closed and the by-pass valve (2) opens due to the effect of the inlet pressure and the fuel flows to
the outlet (B).
Note The mechanical supply pump cannot be replaced individually, so it must not be removed from the high pressure pump.
P2D32N029E0115
771010 BOSCH CP3 high pressure pump

The CP3 high pressure pump is a pump with three radial plungers controlled by the timing gear, and does not require timing. The
mechanical fuel pump that is controlled by the high pressure pump shaft is fit on the rear side of the high pressure pump.
Note The high pressure pump cannot be overhauled and therefore it must not be removed and the fastening screws must not
be tampered with. The only operation that is possible is the replacement of the drive gear.
High-pressure pump
72595 Figure 9
1. Connection between fuel outlet and rail 6. Fuel outlet to filter support fitting
2. High-pressure pump 7. Fuel inlet from control unit heat exchanger fitting
3. Fuel flow regulator 8. Fuel outlet from mechanical pump to filter fitting
4. Drive gear 9. Mechanical supply pump
5. Fuel inlet fitting from filter
P2D32N029E0115
High-pressure pump internal structure
70498 Figure 10
1. Cylinder 5. Piston
2. Three lobe element 6. Pump shaft
3. Cap intake valve 7. Low pressure fuel inlet
4. Ball delivery valve 8. Fuel canals to power plungers
Each pump unit consists of:
a piston (5) actuated by a three lobe floating element (2) on the pump shaft (6). The element (2), floating on an offset part
of the shaft , does not rotate with the shaft (6) during the shaft's rotation but is only moved in a circular movement along a
wider range, with the resulting alternate actuation of the three pumping elements;
cap intake valve (3);
ball delivery valve (4).
P2D32N029E0115
LUBRICATION CIRCUIT
LUBRICATION CIRCUIT
5430 Principles
The forced circulation lubrication is carried out by the rotor oil pump, housed in the front part of the crankcase and driven by the
straight-toothed gear keyed to the crankshaft tang.
The lubricant oil is conveyed from the oil sump to the crankshaft, to the camshaft and to the valve control.
Lubrication also includes the heat exchanger, the turbocharger and the compressor if there is a compressed air system.
All these components often vary depending on use and are therefore dealt with in the specific part of the manual.
P2D32N029E0115
LUBRICATION CIRCUIT
Operation diagram
225726 Figure 11
1. Lubricating oil delivery pipe to turbocharger 7. Oil sump
2. Lubricant oil filler cap 8. Oil intake suction strainer
3. Rocker shaft lubrication 9. Transversal crankshaft channels
4. Camshaft bush 10. Piston cooling nozzles
5. Main half-bearings 11. Rotor oil pump
6. Connecting rod half-bearings 12. Lubricating oil drain pipe from turbocharger
P2D32N029E0115
LUBRICATION CIRCUIT
225726 Figure 11
13. Oil filter 14. Heat exchanger lubricant oil / coolant
A. Pressurised oil delivery course C. Drain off oil

B. Oil return to sump by fall D. Oil inlet
P2D32N029E0115
LUBRICATION CIRCUIT
LUBRICATION CIRCUIT COMPONENTS

543010 Oil pump
225727 Figure 12
Housed in the front of the crankcase, the oil pump (1) is a rotary pump (2) driven by a spur gear fit on the crankshaft tang.
Note Since the oil pump (1) cannot be overhauled, it must be replaced when damaged.
P2D32N029E0115
LUBRICATION CIRCUIT
543110 Heat exchanger
200097 Figure 13
1. Oil filter support 4. Internal heat exchanger gasket
2. Lubricant pressure control valve 5. Heat exchanger lubricant oil / coolant
3. By-pass valve to cut out clogged oil filter 6. Gasket between heat exchanger and crankcase
P2D32N029E0115
LUBRICATION CIRCUIT
543075 Oil pressure regulator valve
107418 Figure 14
Loosen the plug (1), withdraw the spring (2) and the relief valve (3) from the support (4).
Check that the valve (3) is not scored and is sliding smoothly into its seat. The spring (2) shall not be broken or yielded.
Pressure regulation at oil temperature of 100 C:
1.2 bar min pressure;

maximum pressure 3.8 bar;
By-pass valve (5) to cut off clogged oil filter.
P2D32N029E0115
LUBRICATION CIRCUIT
MAIN DATA TO CHECK THE PRESSURE RELIEF VALVE SPRING
107419 Figure 15
Max section :
20 cm3/1 at a pressure of 0.83 bar and high oil temperature of 26.7
C.
70482 Figure 16
540430 Engine oil sump

The oil sump (3) is fastened elastically to the crankcase by means of an aluminium plate (2) that not only improves the seal, but
also reduces noise. This type of gasket can be replaced only if deteriorated or broken and does not require replacement each time
it is removed.
P2D32N029E0115
LUBRICATION CIRCUIT
Engine oil sump
225730 Figure 17
1. Engine lubricant intake suction strainer 4. Engine lubricating oil drain plug
2. Aluminium plate for fastening the engine oil sump 5. Engine oil sump fastening screws
3. Engine oil sump
P2D32N029E0115
LUBRICATION CIRCUIT
543070 Oil filter
219417 Figure 18
1. Cartridge 2. Protection cover
P2D32N029E0115

540480 Principles
225721 Figure 19
1. Tappet cover with oil vapour separator 3. Blow-by filter
2. Oil vapour breather pipe (intake recirculation) 4. Oil recovery channel to sump
A. Oil vapour path C. Condensed oil path

B. Filtering oil vapour breather path
Description
The oil vapour recirculation circuit permits the separation and the condensation of the oil vapours contained in the gas originating
from the crankcase for recovery in the sump. The remaining gas is then introduced in the intake circuit to be again burnt in the
combustion chamber.
This gas consists of a mixture of air, combustion vapours and lubricant.
The gas originating from the crankcase rises up to the cylinder head, and is sent to the blow-by filter (3) by the separator (1) loc-
ated inside the tappet cover, whose form and position determines an increase in the release speed of the oil vapours and at the
same time condensates a part of them.
The condensed oil returns to the sump while the residual steam is directed, collected and filtered in the blow-by filter (3).
An additional part of the vapours condense in the blow-by filter (3) and return to the oil sump via the channel (4) whereas the
remaining part is not released to the atmosphere but is recirculated in the intake through the breather pipe (2).
P2D32N029E0115
COOLING CIRCUIT
540480 OIL VAPOUR RECIRCULATION SYSTEM COMPONENTS.

Blow-by filter
The filter is connected to the breather of the crankcase and fit near
it; the pressurised oily vapours pass through the filtering element that
separates the oil from the gas and the residual impurities.
209217 Figure 20
1. Retaining screws 3. Filtering oil vapour
2. Blow-by filter cartridges
COOLING CIRCUIT
5432 Principles
The engine cooling system, of the closed-loop forced-circulation type, is generally composed of the following components:
expansion tank: the position, shape and dimensions can change depending on the engine version
radiator, which has the task of dissipating the heat taken from the engine by the coolant. Also the position and dimensions of
this component can change depending on the version;
viscostatic fan with the task of increasing the dissipating radiator power: also it is part of the specific engine version;
a heat exchanger to cool the lubricant: also it is part of the specific engine version;
centrifugal water pump set in the front part of the engine block;
a thermostat to control coolant circulation;
The circuit can also extend to the compressor if the construction provides for its presence.
P2D32N029E0115
COOLING CIRCUIT
225722 Figure 21
1. Engine coolant outlet pipe (to the radiator) / Thermo- 5. Engine coolant inlet pipe (from the radiator) / lower
stat cover alternator support
2. Temperature control thermostat 6. Heat exchanger lubricant oil / coolant
3. Cylinder head 7. Coolant delivery/return pipes for cooling the motor-
4. Water pump ised throttle valve actuator
A. Coolant outlet from the cylinder head (to the radi- C. Coolant recirculating in the engine
ator) D. Coolant exiting the thermostat
B. Engine coolant inlet to the water pump (from the E. Coolant for cooling the motorised throttle valve actu-
radiator) ator
F. Coolant entering the pump
P2D32N029E0115
COOLING CIRCUIT
COOLING CIRCUIT COMPONENTS

543210 Water pump
70486 Figure 22
The water pump is located in a hollow obtained in the cylinder block and is driven by and a poly-V belt.
An automatic tensioner keeps the belt tension.
Pump performance
Pump performance
Coolant temperature 100 5 C
Concentration of antifreeze 50%
Parameters
Pump speed [rpm] Flow rate [l/min] Pressure [bar]
5.000 210 2,00 - 2,45
2.500 110 0,50 - 0,65
543250 Thermostat
The thermostat, located in the cylinder head, is of the by-pass type and doesn't need regulations.
If there are doubts as to its proper functioning, replace it.
The main components of a thermostat are: thermal motor, including a valve fastened to a piston integrated in a special wax, flange,
spring and frame.
The thermostat has a pin that permits the air trapped in the cooling system to pass in the thermostat and be released from the
system.
The thermostat has two important functions:
P2D32N029E0115
COOLING CIRCUIT
It heats the engine faster, blocking the circulation of the coolant between the engine and the radiator until the engine reaches
its predefined temperature.
It controls the operating temperature of the engine by opening and closing in response to specific changes in the coolant tem-
perature in order to maintain the engine temperature within the desired range.
Thermostat operating diagram
209191 Figure 23
1. Flange 6. Flange seal
2. Stem (piston) 7. Main spring
3. Chassis 8. Wax element
4. Minimum stroke at the temperature of full opening 9. By-pass valve
5. Pin
Thermostat performance
Minimum permitted operating temperature -40 C
Maximum permitted operating temperature 135 C
P2D32N029E0115
COOLING CIRCUIT
Maximum permitted peak temperature (5 minutes) 150 C
Max differential operating pressure 3 bar
Start opening 79 2 C
Complete opening temperature 96 C
Minimum stroke at the temperature of full opening 7.5 mm
543250 Operation description

With the engine cold, the thermostat is normally closed; the restriction of the flow to the radiator makes it possible to heat
the engine;
When heating the engine, the increase in heat causes the wax to melt, which expands and acts against a piston inside a rubber
bellows;
This lifts the piston, which opens the thermostat so that the coolant can start to circulate between the engine and the radiator;
With the increase in heat, the thermostat continues to open until the engine is cooled sufficiently;
If the temperature of the circulating coolant starts to decrease, the wax element will contract, permitting the closure of the
thermostat due to the effect of the spring's action and reducing the flow of the coolant towards the radiator.
Functional diagram
A. Closed thermostat (coolant B. Open thermostat (coolant
supply to the water pump supply to the radiator)
via the by-pass duct)
209198 Figure 24
P2D32N029E0115
INTAKE AND EXHAUST SYSTEM

5424 Turbocharging
Description
228658 Figure 25
1. Air filter 3. Exhaust
2. turbocharger 4. Intercooler
The supercharging system consists of: an air filter (1), a turbocharger (2) and the intercooler (3).
The air filter is a dry type comprising a filtering cartridge that should be periodically replaced.
The function of the turbocharger is to use the energy of the engine's exhaust gas to deliver pressurized air to the cylinders.
The intercooler consists of a radiator mounted on the engine coolant radiator with the function of lowering the temperature of
the air leaving the turbocharger.
542410 turbocharger
The turbocharger is installed on the exhaust manifold.
P2D32N029E0115
225724 Figure 26
A. Compressed air (to the intercooler) 1. turbocharger
B. Intake air (from the filter) 2. Waste-Gate valve
C. Exhaust gas (from the exhaust manifold to the motor- 3. Exhaust manifold.
ised throttle valve)
The turbocharger mainly consists of:
a central casing housing a shaft supported by bushings at whose opposite ends are fitted the turbine and the compressor
wheels;
a turbine casing and a compressor casing mounted on the end of the central body;
overpressure relief valve (waste-gate) applied on the turbine casing. The function of this valve is to choke the exhaust gas
outlet, by conveying part of the gas directly into the exhaust pipe, when the turbocharging pressure downstream of the tur-
bocharger reaches the calibration value
P2D32N029E0115
Throttle valve
75532 Figure 27
A. Closed throttle valve B. Throttle valve open
SECTION SHOWING A TURBOCHARGER WITH A WASTE-GATE VALVE
Note Verifying an anomalous operation of the engine, due to the booster system, it is recommended, before performing con-
trols on the turbocharger, to check the efficiency of the sealing gaskets and the fixing of the connection sleeves, making
sure of clogging absence inside intake sleeves, air cleaner or inside radiators.
If the turbocharger damage is due to a lack of lubrication, check that the oil circulation pipes are not burst or clogged, in
which case replace them or repair the fault
542451 Turbocharger actuator

The turbocharger is equipped with a pressure regulating valve fit on the exhaust manifold upstream of the turbine and controlled
by a pneumatic actuator, connected by a pipe to the intake manifold.
Its purpose is to limit the quantity of the exhaust gas that acts on the turbine, sending a part directly into the exhaust pipe when the
boost pressure downstream of the compressor reaches the maximum prescribed value.
P2D32N029E0115
Check and adjustment

1. Pump 4. Knurled ring nut.
2. Magnetic stand gauge. 5. Nut.
3. Tie rod. 6. Actuator.
62873 Figure 28
Cover air, exhaust gas and lubricant inlets and outlets.

Thoroughly clean the outside of the turbocharger using anticorrosive and antioxidant fluid and check the actuator (6).
Clamp the turbocharger in a vice.
Disconnect the actuator pipe (6) and fit the manual pump pipe (1) to the actuator pipe filler.
Apply the magnetic stand gauge (2) to the exhaust gas inlet flange in the turbine.
Set the gauge (2) feeler pin on the end of the tie rod (3) and set gauge (2) to zero .
Use the pump (1) to blow compressed air into the actuator (6) at the specified pressure, making sure that this value stays constant
for the entire duration of the check, if not replace the actuator (6).
Manual pump for measuring pressure and vacuum (99367121)
In this set-up, the tie rod must have travelled by the specified distance.
Note During the operation, beat the actuator (6) slightly in order to eliminate possible sticking of the actuator internal spring.
If a different value is found, loosen the nut (5) and operate properly the knurled ring nut (4).
P2D32N029E0115
543712 Motorised throttle valve
201014 Figure 29
A throttle valve operated by an electric actuator is introduced into the exhaust pipe downstream of the turbine.
The valve is controlled by the control unit via an electric actuator cooled by the engine coolant.
The main innovation is that the electric actuator makes it possible to block the outlet of the exhaust gas to increase its temperature.
This makes it possible to quickly bring the catalytic converter to its operating temperature (reduction of cold engine emissions).
P2D32N029E0115
EXHAUST GAS POST-TREATMENT SYSTEM(ATS)

5074 Principles
A
B
C
D
E
229424 Figure 30
P2D32N029E0115
A. Low pressure fuel D. AdBlue

B. High pressure fuel E. Electric line
C. Engine coolant
1. Fuel pre-filter with heater (O) sensor for detecting 18. Exhaust gas temperature sensor upstream of DOC
water in the filter (V) (T4) (V)
2. EDC17CV41 engine control unit 19. NOx sensor downstream of SCR with control unit
3. Fuel filter with temperature sensor (V)
4. Fuel filter 20. NOx sensor upstream of DOC with control unit (V)
5. High pressure fuel pump 21. NH sensor control unit (V)
6. High pressure fuel pump dosing valve 22. NH(V) sensor
7. Supercharging pressure (P2) and air temperature 23. Exhaust gas temperature sensor downstream of SCR
(intake manifold) sensor (V)
8. Grille heater relay 24. Exhaust gas temperature sensor upstream of SCR (V)
9. Grille heater element for engine preheating 25. Dosing moduleDeNOx 2.5 (DM) (V)
10. overpressure valve 26. Feeder moduleDeNOx 2.2 (SM) (V)
11. Common rail 27. Urea quality sensor (UQS) with control unit (V)
12. Rail pressure sensor(RDS4) 28. Tank level sensorDEF/AdBlue (V)
13. Segmental timing speed sensor (camshaft) 29. DEF/AdBlue(V) tank temperature sensor
14. Injectors(CRIN2) 30. Engine oil temperature and pressure sensor
15. Flywheel incremental speed sensor (crankshaft) 31. Engine coolant temperature sensor
16. Intake air humidity and temperature sensor 32. Engine coolant 3-way valve (V)
17. Motorised throttle valve (discharge valve) (CAN
node)
Provided on the vehicle (V)
Optional(O)
In order to reduce the exhaust gas emissions within the limits foreseen by current standards, it is necessary to adopt the exhaust
gas post-treatment system ATS which combines two devices:
a catalytic converter consisting of two stages: the first stage consists of a DOC catalytic converter; the second stage consists of
a SCR catalytic converter (including the CUC), upstream of which there is the AdBlue dosing module.
the DeNOx 2.2 device for treating NOx (nitrogen oxides).
The ATS system is controlled by the EDC17CV41 electronic control unit that, based on the engine speed, delivered torque, ex-
haust gas temperature, quantity of nitrogen oxide and intake air humidity, adjusts the flow rate of the AdBlue solution to be added
to the system.
The pump module takes the reagent solution from the tank and sends it under pressure to the mixing and injection module to be
introduced into the exhaust pipe.
185021 Figure 31
The catalytic converters serve two purposes:
P2D32N029E0115
185021 Figure 31
in the first stage, consisting of the Diesel Oxidation Catalyst (DOC) , the exhaust gases are cleaned of unburned hydrocar-
bons(HC) and carbon monoxide(CO).
in the second stage, consisting of the Selective catalyst reduction (SCR) and the Clean Up Catalyst (CUC) upstream of which
the AdBlue dosing module and mixer are fitted, the reduction of the nitrogen oxide(NOx) takes place.
During the first stage, the exhaust gas exiting the turbine comes across the DOC catalytic converter in which the hydrocarbons
(HC) and the carbon monoxide (CO) added to the oxygen (O) are transformed into carbon dioxide (CO) and water (HO)
through oxidation reactions.
In the second phase the dosing module, located in the exhaust pipe located upstream of the SCR, catalytic converter, introduces a
water and urea (AdBlue) solution in the exhaust gas through a dosing injector.
The final phase of the process takes place in the SCR catalytic converter: due to the effect of the exhaust gas temperature, the re-
agent solution evaporates instantly and is hydrolysed to ammonia (NH) and carbon dioxide (CO) at the same time; the evapora-
tion of the solution lowers the exhaust gas temperature to levels close to the optimal temperature required for the process.
By reacting with the oxygen in the exhaust gas the ammonia is converted into free nitrogen (N) and water vapour (HO).
The electronic control unit, on the basis of the engine rpm, delivered 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 rate
of the (AdBlue) solution to be introduced into the system.
The quantity of introduced AdBlue is controlled by the NH sensor located downstream of the SCR.
It detects the presence of ammonia in the exhaust gas and sends a signal to the engine management control unit providing a feed-
back signal.
P2D32N029E0115
A B C
229425 Figure 32
A. Engine coolant C. AdBlue
B. Electric line
1. CAN LINE 13. NOx sensor

2. TankAdBlue 14. Exhaust gas temperature sensor downstream of SCR
3. Tank level sensorAdBlue 15. Clean Up Catalyst (CUC)
4. Urea quality sensor (UQS) 16. Selective Catalyst Reduction (SCR)
5. AdBlue temperature sensor 17. Exhaust gas temperature sensor upstream of SCR
6. Engine control unit(EDC17CV41) 18. Mixer
7. Humidity and temperature sensor (after the air filter) 19. Dosing moduleDeNOx 2.5
8. NOx sensor control unit 20. Diesel Oxidation Catalyst (DOC)
9. NH sensor control unit 21. Exhaust gas temperature sensor upstream of DOC
10. Feeder moduleDeNOx 2.2 22. NOx sensor
11. Urea pressure sensor 23. Engine coolant 3-way valve
12. NH sensor 24. NOx sensor control unit
The ATS system consists essentially of:
a Diesel Oxidation Catalyst (DOC) catalytic converter;
P2D32N029E0115
a Selective Catalyst Reduction (SCR) catalytic converter;
a Clean Up Catalyst (CUC) filter;
a tank of reagent solution (water + urea: AdBlue) with level indicator, temperature sensor and urea quality sensor;
a HO switching valve;
one feeder module;
one dosing module;
three exhaust gas temperature sensors;
a humidity sensor fit on the engine air intake pipe downstream of the air filter;
two sensors for detecting the quantity of nitrogen oxide (NOx);
a sensor for detecting the presence of ammonia (NH) at the exhaust gas outlet.
ATS system heating/cooling system

The system has two functions:
continuous cooling of the dosing module;
heating of theAdBlue tank, AdBlue supply module and pipes and also cooling of the dosing module.
P2D32N029E0115
A
B
185022 Figure 33
COOLING CONDITIONS
A. Engine coolant B. AdBlue
1. Dosing module 4. AdBlue tank

2. engine 5. Feeder module
3. Engine coolant 3-way valve
Given the unfavourable assembly position from the point of view of cooling and given the high temperatures that the exhaust gas
reach downstream of the catalytic converter, the dosing module is connected to the engine cooling circuit and continuously cooled.
P2D32N029E0115
A
B
185023 Figure 34
A. Engine coolant B. AdBlue
1. Dosing module 4. TankAdBlue

2. engine 5. Feeder module
3. Engine coolant 3-way valve
Keep in mind that the AdBlue could freeze at temperatures below 11C.
When the temperature of the AdBlue in the tank goes below the acceptable limits, the switching valve (3) is activated, permitting
the flow of coolant to enter the heating coil inside the tank (4) and therefore in the supply module (5).
In this phase, the engine cooling temperature is such that it acts as a heater for the components mentioned above.
Then, the coolant is sent to the dosing module to lower its temperature.
AdBlue specifications
ISO 22241 / AUS32 / DIN V 70070.
Solution of 32.5% urea in water
Min. Max.
% of
Urea content. 31.8 33.2
weight
Refraction index at
1.087 1,93 g/cm
20C.
Alkalinity analogue to
1.3814 0.2 %
NH3.
P2D32N029E0115
Min. Max.
Biuret. 0.3 %
Aldehyde. 5 mg/kg
Insolubles. 20 mg/kg
Phosphate(PO4) . 0.5 mg/kg
Calcium. 0.5 mg/kg
Iron. 0.5 mg/kg
Copper. 0.2 mg/kg
Zinc. 0.2 mg/kg
Chrome. 0.2 mg/kg
Nickel. 0.2 mg/kg
Aluminium. 0.2 mg/kg
Magnesium. 0.5 mg/kg
Sodium. 0.5 mg/kg
Potassium 0.5 mg/kg
5074 ATS components

Tank
The tank, equipped with a level sensor, contains the reducing substance comprising a solution of 32.5% urea and water, known as
AdBlue.
The inlet has a mesh filter.
A urea quality sensor and a temperature sensor are built into the tank.
Note FPT recommends that the AdBlue is kept at a temperature of less than 50C in the tank during operation.
Tank ventilation: the circuit must be protected from dust.
P2D32N029E0115
AdBlue fluid level gauge control
215388 Figure 35
1. IntakeAdBlue 8. Engine coolant inlet
2. ReturnAdBlue 9. Intake pipeAdBlue
3. Engine coolant outlet 10. filter
4. Engine coolant outlet pipe 11. Lower plate (NTC AdBlue temperature sensor)
5. AdBlue heating coil 12. Float (AdBlue level sensor)
6. Engine coolant inlet pipe 13. Pipe Reed
7. Connector 14. AdBlue return pipe
The AdBlue fluid level indicator control is composed of:
a float (level sensor);
an NTC temperature sensor;
a fluid heating coil in the case of low temperatures.
Frozen AdBlue can be warmed using a coolant heating coil (5).

A solenoid operated by the control unit regulates the flow of fuel in the AdBlue tank heater/circuit.
The Urea quality sensor is integrated in the tank to meet the antitampering prescriptions.
P2D32N029E0115
Note Seal the connectors with a water tight seal before checking the AdBlue tank for leaks.
type NTC;
Temperature sensor:
1 kOhm +/-5% at 25C;
Recommended level sensor 70 Ohm at low level;
specifications: 20 Ohm at low level;
Electric connections
Ref. Description.
1. Level
2. Common ground
3. NTC signal (temperature)
215389 Figure 36
DeNOx 2.2 (SM) supply module.

The AdBlue supply module is composed mainly of a membrane
pump that takes the AdBlue from the tank and sends it to the dos-
ing module.
It is equipped with a circuit connected to the engine cooling system
which, in case of low temperatures, prevents the AdBlue from freez-
ing. It contains 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 depend-
ent on the operating conditions of the engine and on the signals sent
by the sensors.
Electrical power supply requirements for the DeNOx 2.2 (SM) sup-
ply module for 7,2 Kg/h.
185025 Figure 37
1. Main filter. 6. AdBlue return pipe to
2. Electrical connector. the tank.
3. Pressure compensa- 7. Pump heating module
tion diaphragm. liquid outlet pipe.
4. Supply pipe from the 8. Delivery pipe to the
tank. dosing module
5. Pump heating module
liquid inlet pipe.
P2D32N029E0115
To prevent damaging the pump and the dosing module, the supply
module contains a filter that removes all impurities from the AdBlue.
To replace the filter, refer to the "Replacing the AdBlue filter" pro-
cedure described in the "ATS SYSTEM SCHEDULED MAINTEN-
ANCE".
185029 Figure 38
1. Coolant connector 4. AdBlue outlet to the
2. AdBlue inlet from the dosing module
tank 5. Pressure sensor
3. AdBlue return flow to 6. Main filter
the tank 7. Diaphragm pump
8. 4/2 way valve
Dosing moduleDeNOx 2.5 (DM)

The dosing module is controlled by the engine control unit. Its pur-
pose is to measure the AdBlue solution to be introduced in the ex-
haust pipe upstream of the SCR catalytic converter.
It is fit on the catalytic converter and while operating, it is constantly
subjected to high temperatures, therefore it is connected to the
engine cooling circuit via the pipes (3).
AdBlue pressure.
Max. injection pressureAdBlue 9 bar
Hydraulic capacity of the DeNOx 2.2 (DM) dosing module

Normal circulation with no injection: ~ 8 kg/h
Maximum with small urea injector ~ 15 kg/h (8 kg/h + 7 kg/h)
193974 Figure 39
Maximum with large urea injector ~ 20 kg/h (8 kg/h + 12 kg/h)
1. Electrical connector 3. Engine coolant in-
2. AdBlue inlet let/outlet
P2D32N029E0115
Engine coolant 3-way valve
180580 Figure 40
1. Electrical connector 3. Dosing module coolant pipe
2. AdBlue tank heating fluid pipe 4. Engine coolant pipe
The switching valve is a 2 position/3 way solenoid valve. Based on the temperature measured by the NTC sensor, the switching
valve opens or closes the passage of the engine coolant in the AdBlue tank heating coil. The cooling circuit of the dosing module
always remains open.
The first position, in fact, allows the cooling of the dosing module DM - Dosing Module, while the second position allows the cool-
ing of the AdBlue tank, the SM - Supply Module and the relative pipes, and also the heating of the DM.
P2D32N029E0115
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV Electric/electronic system
Contents 1
Contents
Electric equipment . . . . . . . . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
Electric equipment 3
Contents
Contents
Location of engine electrical components . . . . . . . . . . 5
E.C.U. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EDC17CV41 electronic control unit . . . . . . . . . . 7
EDC system operation . . . . . . . . . . . . . . . . . . . 8
Pin out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE SIDE WIRING . . . . . . . . . . . . . . . . . . . 15

Cable on engine . . . . . . . . . . . . . . . . . . . . . . 15
Wiring-topographic diagram - Engine side . . . . . . 18
Electronic components . . . . . . . . . . . . . . . . . . . . 19
Electro-injectors . . . . . . . . . . . . . . . . . . . . . . 19
Engine speed sensor on timing system . . . . . . . . 20
Engine speed sensor (crankshaft sensor) . . . . . . . 21
Air temperature and boost pressure sensor . . . . . 22
Engine oil temperature and pressure sensor . . . . . 23
Fuel pressure sensor . . . . . . . . . . . . . . . . . . . 24
Coolant temperature sensor . . . . . . . . . . . . . . 25
Fuel temperature sensor . . . . . . . . . . . . . . . . . 26
High pressure fuel pump dosing unit . . . . . . . . . . 28
Preheating resistor (Grid Heater) . . . . . . . . . . . 29
Motorised throttle valve actuator (Exhaust
flap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Starter motor . . . . . . . . . . . . . . . . . . . . . . . 33
ATS SYSTEM ELECTRICAL COMPONENTS . . . . . . 35

AdBlue liquid temperature and level indicator . . . . 35
AdBlue module connector . . . . . . . . . . . . . . . . 36
Exhaust gas inlet temperature sensor . . . . . . . . . 37
Nitrogen oxide detecting sensor . . . . . . . . . . . . 38
Temperature sensor/air humidity . . . . . . . . . . . . 42
Ammonia detection control unit (NH3) . . . . . . . . 44
NH3 ammonia sensor . . . . . . . . . . . . . . . . . . . 48
P2D32N029E0115
4 Electric equipment
P2D32N029E0115
Location of engine electrical components
Electric equipment
229416 Figure 1
1. Electro-injectors 2. Motorised throttle valve actuator connector (Exhaust
flap)
P2D32N029E0115
229416 Figure 1
3. Rail pressure sensor 9. EDC17CV41 engine control unit
4. Air temperature and boost pressure sensor 10. Crankshaft speed sensor (incremental speed)
5. Starter motor 11. Engine oil temperature and pressure sensor
6. Camshaft timing sensor (segmental speed) 12. Alternator
7. Fuel temperature sensor 13. Coolant temperature sensor
8. High pressure fuel pump dosing unit
P2D32N029E0115
E.C.U.
E.C.U.
766161 EDC17CV41 electronic control unit
The control unit is a flash e.p.r.o.m which can be reprogrammed externally without the need to intervene on the hardware.
The ECU processes the signals from the sensors by applying software algorithms and controls the actuators (especially the electro-
injectors and pressure regulator).
It records, in the non-volatile memory area, the information on the engine parameters originally set or acquired during engine op-
eration.
The control unit is fitted on the left-hand side of the engine and is connected to two connectors:
1. one connector for the engine cable (electro-injector and sensor connector);
2. one connector for the chassis cable.
To reduce the number of connections, the length of the connection cables with the injectors and, as a result, disturbances in the
transmitted signal, the control unit is mounted directly on the engine by means of a heat exchanger that cools it, using elastic dowels
which reduce the vibrations transmitted by the engine.
Internally, there is an ambient pressure sensor that is used to further improve injection system management.
It is also equipped with a very advanced self-diagnosis system and it is capable of recognizing and memorizing, in function of the
environmental conditions, the possible anomalies, even of an intermittent type, that occurred on the system during operation, en-
suring a more correct and reliable repair action with the help of the FPT diagnostic instruments.
P2D32N029E0115
E.C.U.
Location of EDC 17 control unit connectors
227159 Figure 2
1. Engine cable connector 2. Chassis side cable connector
766161 EDC system operation

The electronic control unit EDC17 CV41 manages the following main functions:
Fuel injection
Turbine geometry variation
Exhaust brake engagement
Self-diagnostics
Recovery
Also permits:
Interfacing with other on-board electronic systems (where present)

Diagnosis
Fuel dosing
The fuel metering is calculated in relation to:
the position of the accelerator pedal by the VCM (Vehicle Control Module);
engine speed;
P2D32N029E0115
E.C.U.
the amount of air introduced.
The outcome may be corrected in relation to:
water temperature;
fuel temperature (DIESEL DENSITY).
or to avoid
overloading;
overheating;
turbine over-revving.
The delivery can be modified in the case of:
the engine brake or brake pedal being activated (signals via CAN);
a limiting device cutting in (ASR, speed limiting device, etc.) (signals via CAN);
activation of the ANTIPOLLUTION devices: p sensor, NOx sensor, NH3 sensor.
serious trouble decreasing the load or stopping the engine.
Once the control unit has determined the mass of the introduced air and measured its pressure and temperature, it calculates the
corresponding fuel load needed to inject into the cylinder (mg. per delivery). It also takes diesel temperature into account (density).
The fuel load calculated in this way is converted into crank degrees i.e. injection advance and duration.
Correcting flow rate according to water temperature

When cold, the engine encounters greater resistance in operating: there is greater mechanical friction, the oil is still very viscous, the
various clearances are not yet optimised.
In addition to this, injected fuel tends to condense on the still cold metallic surfaces.
The fuel supply for a cold engine is therefore greater than for a warm one.
De-rating
In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in proportion to the tem-
perature reached by the coolant. The control unit considers the oil temperature in case of a water temperature sensor failure.
Turbine speed
Turbine speed is adjusted continuously and corrected if needed through geometry variation.
Closed loop injection pressure management

Based on engine load, determined by the processing of signals coming from the various sensors, the control unit controls the pres-
sure regulator to always ensure an optimal pressure (TARGET PRESSURE). The control unit controls the result (INJECTION
PRESSURE) using the sensor on the COMMON RAIL.
Injection advance electronic control

The advance (starting moment, expressed in degrees) may be different from one injection to the next, and in a differentiated man-
ner from one cylinder to another, and is calculated, similarly to the flow rate, on the basis of engine load (accelerator pedal position,
engine speed and introduced air).
The advance is appropriately corrected:
in acceleration phases;
according to the coolant temperature;
and also to obtain:
P2D32N029E0115
E.C.U.
lower emissions, noise and overloading:

better vehicle acceleration.
When starting the engine, a high degree of advance is used based on water temperature.
the feedback from the start of delivery is supplied by the change in impedance of the injector solenoid valve.
Engine speed limiter

The control unit controls the engine speed at all rev ranges and in particular:
at idle;
at top speed.
Starting the engine

During the initial driven engine revolutions, the timing and recognition signals are synchronised for cylinder no.1 (flywheel sensor
and camshaft sensor). Upon ignition, the signal of the accelerator pedal that arrives via CAN is ignored. The delivery of the diesel
upon ignition is set exclusively based on the temperature of the water by means of a specific map. When the control unit detects a
number of revolutions as well as a flywheel acceleration such to consider the engine as started and no longer driven by the starter
motor, it re-enables the accelerator pedal signal.
Cold starting
Pre-post heating is activated when just one of the three sensors (water, air or fuel) registers a temperature lower than 10 C.
Upon activation of the key contact, the pre-heating warning light turns on the electronic dashboard (cluster display) and remains on
for a variable amount of time depending on the temperature (while the heating element at the intake manifold heats the air), then
it flashes. At this point the engine can be started.
When the engine is running, the warning lamp goes out but the heater element continues working for a certain (variable) period of
time for post-heating.
If, with the warning lamp blinking, the engine is not started within 20-25 seconds (absence time) the operation is cancelled in order
not to discharge the batteries.
The pre-heating curve is also variable in relation to the battery voltage.
Warm starting
When the ignition key is inserted and the reference temperature exceeds 10C, a warning light turns on for approximately 2
seconds as a short test, then goes out. At this point the engine can be started.
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
Each time the engine is turned off with the key, the control unit continues to operate for a few seconds thanks to the internal
MAIN RELAY.
This permits the microprocessor to transfer some data from the main memory (volatile) to a non volatile, erasable and rewritable
memory (EEPROM), to make it available for the next start (see: Run Up).
The data mainly consists of:
various settings (engine idling, etc.);

calibration of certain components;
faults memory.
P2D32N029E0115
E.C.U.
This procedure lasts a few seconds, typically from 40 to 120 (depending on the quantity of data to save), after which the ECU de-
activates the main power supply.
Note This procedure should never be interrupted, for instance by switching off the engine with the battery isolator or discon-
necting the battery isolator before at least 10 seconds have passed after the engine is switched off.
If this happens, system functionality remains guaranteed until the fifth time it is turned off incorrectly (also non consecutively) after
which an error is stored in the faults memory and upon the following engine start-up, the engine will function with reduced per-
formance while the EDC warning light remains on.
Repeated interruptions of the procedure could in fact lead to damage to the control unit.
Cut - off
This function cuts off fuel feed during deceleration and during engine braking etc.
Cylinder Balancing
This function permits individual, customised control over the delivery of fuel and the start of delivery for each cylinder, which can
even differ from one cylinder to another, to compensate for the hydraulic tolerances of the injector.
The difference in fuel feed to each cylinder is not signalled by the ECU but by an IVECO system.
Synchronisation Search
If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.
If this takes place when the engine is already running, the fuel flow is already acquired as a result of which the ECU continues with
the sequence already synchronized.
If this takes place when the engine is stopped, the control unit excites only one solenoid valve. Within a maximum of 2 revolutions
of the crankshaft, injection will take place in that cylinder. This means that the control unit simply needs to synchronise with the
firing sequence and start the engine.
766161 Pin out

Colour key
C Orange N Black
A Light blue W Light brown
B White S Pink
L Blue R Red
G Yellow V Green
H Grey Z Purple
M Brown
189005 Figure 3
Pin Out ( Page 12)
P2D32N029E0115
E.C.U.
Pin Out
Pin no. Wire colour Component
01. V Low signal injector 1, bank 2, cylinder 3
02. H Low signal injector 2, bank 2, cylinder 2
03. Spare
04. Spare
05. Spare
Ground (frequency input 3) engine oil temperat-
06. Z
ure and pressure sensor
07. BN Air temperature and boost pressure sensor supply
08. Spare
09. Spare
10. Spare
11. HB Rail pressure sensor supply
12. C Fuel temperature sensor signal
13. BC Engine oil temperature sensor signal
14. Spare
15. Spare
16. Spare
Motorised throttle valve actuator (Exhaust flap):
17. LV
Controller Area Network 2 high (CAN H)
Motorised throttle valve actuator (Exhaust flap):
18. BV
Controller Area Network 2 low (CAN L)
19. Spare
20. Spare
21. Spare
22. Spare
23. Spare
24. Spare
25. R High signal injector 1, bank 2, cylinder 3
26. G High signal injector 2, bank 2, cylinder 2
27. Spare
28. Spare
29. Spare
30. Spare
31. R Engine oil temperature and pressure sensor supply
32. Spare
33. Spare
34. Spare
35. V Engine oil pressure sensor signal
36. HR Rail pressure sensor signal
37. LG Air temperature and boost pressure sensor signal
38. Spare
39. G Coolant temperature sensor signal
40. Spare
P2D32N029E0115
E.C.U.

41. Spare
42. Spare
43. Spare
44. Spare
45. Spare
46. Spare
47. Spare
48. Spare
49. L High signal injector 1, bank 1, cylinder 1
50. N High signal injector 2, bank 1, cylinder 4
51. Spare
52. Spare
53. Spare
54. Spare
55. Spare
56. Spare
57. Spare
58. GV High pressure fuel pump dosing unit supply
Shared ground (analogue input 18) coolant/fuel
59. H-L
temperature sensor
60. HV Rail pressure sensor ground
61. Spare
62. Spare
63. Spare
64. Spare
Crankshaft speed sensor (incremental speed)
65. N
ground
Crankshaft speed sensor (incremental speed)
66. B
signal
67. N Camshaft timing sensor (segmental speed) ground
68. B Camshaft timing sensor (segmental speed) signal
69. H Speed sensor shielding
70. Spare
71. Spare
72. Spare
73. B Low signal injector 1, bank 1, cylinder 1
74. M Low signal injector 2, bank 1, cylinder 4
75. Spare
76. Spare
77. Spare
78. Spare
79. Spare
80. Spare
81. Spare
P2D32N029E0115
E.C.U.

82. Spare
83. GN High pressure fuel pump dosing unit signal
84. Spare
85. Spare
86. TW Air temperature and boost pressure sensor signal
87. Spare
88. Spare
89. Spare
Air temperature and boost pressure sensor
90. BV
(analogue input 5) ground
91. Spare
92. Spare
93. Spare
94. Spare
95. Spare
96. Spare
P2D32N029E0115
ENGINE SIDE WIRING
ENGINE SIDE WIRING

7691 Cable on engine
Cable on engine
225748 Figure 4
P2D32N029E0115
ENGINE SIDE WIRING
225748 Figure 4
1 Engine oil temperature and pressure sensor 5 Motorised throttle valve actuator (Exhaust flap)
2 Engine coolant temperature sensor 6 Electro-injector connector (cylinders 3-4)
3 Rail pressure sensor 7 Air temperature and boost pressure sensor
4 Electro-injector connector (cylinders 1-2) 8 Camshaft timing sensor (segmental speed)
P2D32N029E0115
ENGINE SIDE WIRING
9 Fuel temperature sensor 12 Crankshaft speed sensor (incremental speed)

10 High pressure fuel pump dosing unit 13 EDC17CV41 engine control unit
11 In-line connector
P2D32N029E0115
ENGINE SIDE WIRING
7691 Wiring-topographic diagram - Engine side
225749 Figure 5
KEY ( Page 19)
P2D32N029E0115
Electronic components
KEY
Ref. Description
1 EDC17CV41 engine control unit 96 pin connector
2 Fuel temperature sensor
3 Coolant temperature sensor
4 Engine oil temperature and pressure sensor
5 Air temperature and boost pressure sensor
6 Motorised throttle valve actuator (Exhaust flap)
7 In-line connector
8 Camshaft timing sensor (segmental speed)
9 Crankshaft speed sensor (incremental speed)
10 High pressure fuel pump dosing unit
11 Rail pressure sensor
12 Electro-injector cylinder 4
E1 Electro-injector connector (cylinders 1-2)
E2 Electro-injector connector (cylinders 3-4)
775010 Electro-injectors
The electro-injector essentially consists of two parts:
an actuator- spray nozzle consisting of a pressure rod (1), a
needle (2) and a nozzle (3);
driving solenoid valve consisting of a coil (4) and pilot valve (5).
The N.O. type solenoid valve checks the lift of the nozzle needle.
227111 Figure 6
P2D32N029E0115
Beginning of injection
Upon being supplied with power, the coil moves up the shutter.
The fuel in the control volume flows back towards the return duct resulting in a pressure drop in control volume.
At the same time, the fuel pressure in the pressure chamber causes the needle to rise resulting in the fuel being injected into the
cylinder.
End of injection
When power to the coil is cut off, the shutter closes again so as to re-create an equilibrium which moves the needle back into its
closed position and stops the injection process.
This is an N.O. solenoid valve.
They are connected separately to the EDC ECU on connector 2.
The resistance of the coil of each individual injector is:
Technical data
Injector coil resistance 0.56 to0.57
764264 Engine speed sensor on timing system

It is an inductive sensor. It generates signals obtained from magnetic flux lines which close through the holes situated in gears force
fit on the camshaft. The signal this sensor generates is used by the electronic control unit as an injector timing signal.
Though it is similar to the engine speed sensor, it is NOT interchangeable as it has a different shape.
The sensor resistance value is:
Technical data
resistance 900
P2D32N029E0115
227112 Figure 7
Sensor pin-out
Ref Description Pin ECM
1 Signal 67
2 Signal 68
3 Shielding
764263 Engine speed sensor (crankshaft sensor)

It is an inductive sensor. It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the
phonic wheel fit on the crankshaft.
The sensor resistance value is:
Technical data
resistance 900
P2D32N029E0115
227113 Figure 8
Sensor pin-out
1 Signal 65
2 Signal 66
3 Shielding
772646 Air temperature and boost pressure sensor

This component incorporates a temperature sensor and a pressure sensor.
It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the
exact amount of fuel to be injected at each cycle.
It runs on 5 Volts.
The output voltage is proportional to the pressure (or temperature) measured by the sensor.
P2D32N029E0115
227114 Figure 9
Sensor pin-out
1 Ground 90
2 Temperature signal 37
3 Power supply +5V 07
4 Pressure signal 86
764251 Engine oil temperature and pressure sensor

It is fit on the engine oil filter mount.
It measures the engine oil temperature and pressure.
It runs on 5 Volts.
The signal detected is transmitted to the EDC Control Unit, which itself controls the indicator on the instrument panel (low pres-
sure warning light and indicator).
The oil temperature is not shown by any of the instruments and is only used by the control unit.
P2D32N029E0115
227115 Figure 10
Sensor pin-out
Ref Description ECM pin (X2)
1 Ground 06
3 Power supply +5V 31
4 Pressure signal 35
774511 Fuel pressure sensor

Assembled on one end of the rail, measures the existing fuel pressure and informs the control unit (feed - back).
The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
It runs on 5 Volts.
P2D32N029E0115
227116 Figure 11
Sensor pin-out
Pin Description Pin ECM
1 Ground 60
2 Signal 36
3 Power supply 11
764254 Coolant temperature sensor

It is an N.T.C. sensor and is positioned on the water outlet manifold from the left side head of the engine. It determines the coolant
temperature for the various control logics of operation of the engine when hot or cold and identifies the need to enrich the mix-
ture when the engine is cold or reduce fuel injection when it is hot.
Its resistance is:
resistance
Conditions: Temperature: 20 2.50 k
P2D32N029E0115
227117 Figure 12
Pin - Out coolant temperature sensor
Pin Description Pin ECM
1 Signal 39
2 Ground 59
772656 Fuel temperature sensor

It is a variable resistance sensor. It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume
and adjust the delivery.
Its resistance is:
resistance
Conditions: Temperature: 20 2.5 k
The ECU controls the control contactor to heat the filter to the fuel temperature:
Technical data
Fuel temperature 5
P2D32N029E0115
227118 Figure 13
Sensor pin-out
1 Signal 12
2 Ground 59
P2D32N029E0115
771034 High pressure fuel pump dosing unit
227119 Figure 14
Situated at the inlet of the high pressure pump on the low pressure system, this flow regulator adjusts the quantity of fuel reaching
the high pressure pump on the basis of the commands received from the electronic control unit.
It mainly consists of the following parts:
tapered shutter;
valve control pin;
pre-load spring;
coils.
In the absence of a control signal, the pressure regulator is normally open, and thus the high pressure pump is in maximum delivery
mode.
The control unit regulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying fuel to the high
pressure pump.
This component cannot be replaced individually and thus should not be dismantled.
The quantity of fuel that powers the high pressure pump is dosed by the load regulator on the low pressure system; the flow regu-
lator is managed by the control unit.
The delivery pressure to the rail is regulated between 250 and 1600 bar by the control unit acting on the pressure regulator solen-
oid valve.
It is a N.O. solenoid valve.
Its resistance is:
P2D32N029E0115
Technical data
Pressure regulator solenoid valve resistance 3.2
It is connected to control unit on pins 58 - 83.
761910 Preheating resistor (Grid Heater)

This element is located on the intake manifold.
It is used to warm up the air in the pre-post heating phase. It is powered by a contactor.
Technical data
Resistance ~ 0.5
Grid Heater performance
2.4 kW to 24 V
Isolated ground
Controlled by the ECU17CV41 engine control unit
Installed on the intake manifold
1. Ground cable terminal

2. Positive cable terminal
227120 Figure 15
P2D32N029E0115
543760 Motorised throttle valve actuator (Exhaust flap)
225725 Figure 16
is an electromechanical actuator that moves the throttle valve on the exhaust.
ExFlp actuator pin-out

Pin Function
1 Power supply
2 Ground
3
4 Low CAN line
5 High CAN line
760310 Alternator
It is frontally located on the right-hand side of the engine and is controlled by the auxiliary assembly belt.
P2D32N029E0115
Technical view
215010 Figure 17
Wiring Diagram
A. Alternator B. Voltage regulator
165891 Figure 18
P2D32N029E0115
Characteristic curves
Alternator 70A
A Current at +25 C C Power curve
B Current at +80 C D Efficiency (25 C)
165893 Figure 19
Characteristics
Direction of rotation: clockwise
Technical data
Rated voltage 28 V
Nominal supply current 70 A
Continuous maximum speed 12,000 rpm
Power absorption (stand-by) 1 mA
Operating temperature range 40 to100
P2D32N029E0115
760810 Starter motor

Isometric view
165897 Figure 20
Technical view
50. Terminal 50 30. Terminal 30
215012 Figure 21
P2D32N029E0115
Wiring Diagram
165899 Figure 22
EW : PULL-IN WINDING
HW : HOLD-ON WINDING
Characteristics
Supplier: BOSCH
Technical data
Rated voltage 24 V
Power 4 kW
Number of pins: 4
Rotation : RIGHT
Tightening torques
tightening torque
M10 nut (terminal 30) 24 4 Nm
M6 nut (terminal 50) 2.4 Nm to3 Nm
P2D32N029E0115
ATS SYSTEM ELECTRICAL COMPONENTS

507424 AdBlue liquid temperature and level indicator
Description
220065 Figure 23
1 AdBlue liquid suction pipe 5 Engine coolant inlet pipe
2 AdBlue liquid return pipe 6 Float
3 Engine coolant output pipes 7 AdBlue liquid heating coil
4 NTC sensor
AdBlue level - temperature indicator - Pin - Out

Pin Description
1 AdBlue level signal
2 Ground
3 AdBlue temperature signal
Functional wiring diagram

1 Level 3 Temperature
2 Ground
220066 Figure 24
The AdBlue fluid level gauge control consists of a device made up of a set of resistors, a float, a NTC temperature sensor, and a
coil used to heat the fluid under low temperature conditions.
It informs the ECU of changes in the current due to the resistance, caused by the position of the float in relation to the level of the
AdBlue liquid.
The NTC temperature sensor controls the diverter valve that, based on the temperature, closes or opens the flow of the hot
engine cooling liquid in the heating coil.
P2D32N029E0115
technical specifications
Technical data
Maximum voltage 48 V
Maximum current 300 mA
Max. power 125 mW
Operating temperature 44 to85
NTC sensor resistance at 25 C

Conditions: Temperature: 25 1 k 5 %
507410 AdBlue module connector
178259 Figure 25
AdBlue module pin-out

Pin Function
1
2 Urea pressure sensor power supply (+5V)
3 Urea pressure sensor signal
4 Urea pressure sensor ground
5
6
7
8 Ground for urea module electropump (diaphragm)
9 Urea module electropump supply (diaphragm)
10 PWM signal for urea module electropump (diaphragm)
11 Inversion solenoid valve power supply
12 Inversion solenoid valve signal
P2D32N029E0115
507434 Exhaust gas inlet temperature sensor
199254 Figure 26
102304 Figure 27
1 Power supply voltage (+5V 0.1%) 4 Grey signal cable
2 Variable outlet voltage (see table) 5 White ground cable
3 Connector 6 Sensor
The purpose of this sensor is to send to the control unit the temperature of the exhaust gas entering and exiting the catalytic con-
verter, which is necessary for calculating the quantity of urea to introduce in the system.
In the case of replacement the sensor tightening torque is:
( Page 38)
tightening torque
Sensor tightening torque 45 4.5 Nm
P2D32N029E0115
EXHAUST GAS TEMPERATURE

RATED
SENSOR CHARACTERISTICS
Power supply 5 V 0.1 %
Output voltage at temperature -40 to
0.727 V to2.297 V
1000 C
Pull-up resistance 1,000 0.1 %
Cable resistance 1
507435 Nitrogen oxide detecting sensor
102302 Figure 28
1. Positive. 3. CAN L line.
2. Ground
P2D32N029E0115
4. CAN H line. 5. Spare
Its function is to inform the control unit of the AdBlue liquid metering and the catalytic converter efficiency.
The NOx sensor consists of a ceramic sensor and an electronic control unit that is connected with a cable as shown in the figure.
The electronic unit transforms the analogue signal into a digital signal to be sent directly on the CAN network.
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 effi-
ciency of the catalytic converters.
( Page 41)
NOx control unit
A B
191884 Figure 29
A Technical view C Recommended assembly position
B Perspective view 1 Horizontal position
P2D32N029E0115
Technical data
Min. supply voltage 14 V
Max. supply voltage 32 V
Average supply current 0.6 A
Peak current at activation 12 A
Maximum power absorbed 20 W
If the voltage is higher than the maximum value, the sensor stops operating. It restarts to function when the voltage limits return
within their prescribed values.
The sensor is protected also if the power supply connection should be inverted.
191886 Figure 30
Pin - Out NOx sensor upstream

Pin Function
1 Power supply +15
2 Ground
3 ENGINE CAN L line
4 ENGINE CAN H line
5 Ground (jumpered with pin 2)
Pin - Out NOx sensor downstream

Pin Function
1 Power supply +15
2 Ground
3 ENGINE CAN L line
4 ENGINE CAN H line
5
P2D32N029E0115
NOx Sensor
191885 Figure 31
A Technical view 2 Vertical exhaust pipe position
B Recommended assembly position 3 Horizontal exhaust pipe position
1 NOx Sensor
Supplier: CONTINENTAL
Technical data
Maximum operating temperature (exhaust gas) Less800
Operating voltage 16 V to36 V
NOx SENSOR CHARACTERISTICS RATED

40 to105
Ambient temperature for electronics: (+105 to +115 C permitted for up to 10
min)
230
Wire temperature:
permitted up to 100 h
P2D32N029E0115
507436 Temperature sensor/air humidity

Connector
165909 Figure 32
Electric block diagram
102312 Figure 33
1 Ground A Sample frequency generator
2 Temperature B Reference oscillator
3 Power unit C NTC temperature sensor
4 Percent of Humidity D Low pass amplifier filter
This component incorporates a temperature sensor and a humidity sensor.

This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to the
control unit.
These data are used by the ECU to determine the level of nitrogen oxide emissions.
It runs on 5 Volts.
Pin - Out air temperature/humidity sensor

Ref. Description Pin EDC (X2)
1 +5 V 90
2 Humidity signal 15
3 Ground 43
P2D32N029E0115
Humidity sensor technical specifications
Technical data
Rated voltage 5V
Absorbed current (max) 10 mA
Output impedance 70
Operating humidity: 0% RH to 100% RH
Humidity sensor table

Output voltage [mV]
RH % Minimum Rated Maximum
10 1145 1205 1265
15 1249 1355 1416
20 1440 1500 1560
25 1583 1640 1697
30 1717 1770 1823
35 1848 1905 1962
40 1969 2,030 2091
45 2090 2155 2220
50 2207 2275 2343
55 2328 2400 2472
60 2444 2520 2596
65 2561 2640 2719
70 2687 2770 2853
75 2800 2895 2982
80 3914 3020 3126
85 3024 3150 3276
90 3137 3285 3433
95 3240 3410 3581
Voltage at the output is proportional to the humidity detected by the sensor.
Technical characteristics of the temperature sensor
Technical data
Rated voltage 5V
Absorbed current (max) 10 mA
Max. power
Conditions: Temperature: 25 100 mW
P2D32N029E0115
Temperature sensor table

Output resistance []
C Minimum Rated Maximum
40 39714 42172 44742
30 23441 24750 26129
20 14268 14995 15745
10 8937 9348 9770
0 5750 5988 6230
10 3792 3933 4074
20 2560 2644 2729
30 1759 1817 1875
40 1229 1274 1319
50 875 910 946
60 634 662 690
70 467 489 511
80 349 367 385
90 265 279 293
The output resistance is inversely proportional to the temperature detected by the sensor.
5074 Ammonia detection control unit (NH3)

The sensor detects the presence of ammonia (NH3) in the exhaust gas exiting the catalytic converter and sends this signal to the
NH3 control unit.
This information that the NH3 control unit transmits to the engine control unit via the CAN line permits a more precise adjustment
of the AdBlue quantity to be injected.
P2D32N029E0115
185028 Figure 34
A. Vehicle connectors 102. Can H.
B. Sensor connector. 103. Can L.
101. Power supply 104. Ground.
SENSOR CHARACTERISTICSNH NOMINAL

Volt [V]
Operating voltage
10 32
Average current 1.2 A
Max current 4.0 A
Celsius []
Temperature / percentage of humidity
-40 105
P2D32N029E0115
NH3 control unit
A B
191881 Figure 35
A Technical view B Perspective view
P2D32N029E0115
Recommended assembly position
A B
191882 Figure 36
A Control unit in a horizontal position 1 Recommended position
B Control unit in a vertical position
Supplier: DELPHI
Technical data
Operating voltage 10 V to32 V
Rated voltage 24 V
Average absorbed current 1.2 A
Maximum current absorbed 4A
Working temperature 40 to105
Storage temperature 40 to125
NH3 control unit connectors

J1 J2
191883 Figure 37
J1 Vehicle connectors J2 Sensor connector
Pin - Out connector J1 (vehicle)

Pin Description
1 Power supply +15
2 CAN H network
3 CAN L network
4 Ground
P2D32N029E0115
Pin - Out connector J2 (sensor)

Pin Description
1 Heater
2 Adjustment resistance
3 Adjustment resistance ground
4 EMF_2
5 Heater
6 Temperature signal
7 Ground signal
8 EMF_1
507437 NH3 ammonia sensor

NH3 sensor
191887 Figure 38
A Technical view 2 Vertical exhaust pipe position
B Recommended assembly position 3 Horizontal exhaust pipe position
1 Connector connecting with the NH3 control unit
P2D32N029E0115
Ammonia sensor pin - out

Pin Description
1 Heater
2 Adjustment resistance
3 Adjustment resistance ground
4 EMF_2
5 Heater
6 Temperature signal
7 Ground signal
8 EMF_1
The NH sensor is connected to the engine control unit and, by detecting the presence of ammonia (NH) in the exhaust gas
exiting the catalytic converter, this permits a more accurate adjustment of the quantity of AdBlue to be injected.
Supplier: DELPHI
Technical data
Maximum operating temperature (exhaust gas) Less700
P2D32N029E0115
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV Scheduled maintenance
Contents 1
Contents
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . 3
ATS SYSTEM SCHEDULED MAINTENANCE . . . . . 19
P2D32N029E0115
2 Contents
P2D32N029E0115
SCHEDULED MAINTENANCE 3
Contents
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checks and scheduled maintenance procedures . . . . . . 5
CHECKS TO PERFORM DURING PERIOD OF

USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Check engine oil level . . . . . . . . . . . . . . . . . . . . 6
Checking the engine coolant level . . . . . . . . . . . . 7
Engine visual inspection . . . . . . . . . . . . . . . . . . . 7
Check tension and condition of ancillary belt . . . . . 8
PERIODICAL MAINTENANCE . . . . . . . . . . . . . . . . 9
Draining the water from the fuel pre-filter . . . . . . . 9
Engine lubricant oil change . . . . . . . . . . . . . . . . . 9
Engine oil filter removal - refitting . . . . . . . . . . . 10
Removal - refitting the fuel filter . . . . . . . . . . . . 11
Removal-refitting of ancillary belt . . . . . . . . . . . 13
Change blow-by filter . . . . . . . . . . . . . . . . . . . 14
UNSCHEDULED MAINTENANCE . . . . . . . . . . . . 14
Tappet clearance adjustment . . . . . . . . . . . . . . 14
Change the engine coolant . . . . . . . . . . . . . . . . 17
P2D32N029E0115
4 SCHEDULED MAINTENANCE
P2D32N029E0115
Introduction
SCHEDULED MAINTENANCE
M 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 frequencies of the maintenance operations are indicative since the engine use and its characteristics are essential to evaluate
replacements and checks.
Not only it is permitted, but we also suggest that the staff in charge of maintenance should also perform those checking and main-
tenance 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 clear malfunctioning of the engine, for example excessive noise of exhaust gases, high temperature of the
coolant or low oil pressure, prompt measures must be taken to verify the causes of the anomaly.
We also remind that any maintenance operation, even the easiest ones, shall be performed in compliance with accident-prevention
laws for the safety of the staff in charge of maintenance.
Scheduled Maintenance comprises the following checks and maintenance operations:
Checks to perform during period of use

Periodical maintenance
Unscheduled maintenance
M Checks and scheduled maintenance procedures
Checks (during periods of use) Frequency

Check engine lubricant oil level Daily
Checking the engine coolant level Daily
Engine visual inspection 50 hours (7)
Check cleanliness of the air filter and seat (**) 1 month

Check tension and condition of ancillary belt 300 hours (8)
Check the condition of the exhaust duct(s) 6 months
Periodical maintenance Frequency

Draining the water from the fuel prefilter (if present) 150 hours (8)
Draining condensate water from the fuel tank 150 hours (8)
Change engine lubricant oil (*) 600 hours (2) (3)
Replace the oil filter (*) 600 hours (2) (3) (4)
Replace the fuel pre-filter (if present) 600 hours (1) (2) (5)
Fuel filter replacement 600 hours (1) (2) (4)
Replace the air filter (**) 1,200 hours (5)
Ancillary belt replacement 1,200 hours (6)
Clean the heat exchanger (radiator) (**) 1,200 hours (5)
Change blow-by filter 1,500 hours (2)
Unscheduled maintenance Frequency

Visually inspect turbocharger 1,200 hours (5)
P2D32N029E0115
CHECKS TO PERFORM DURING PERIOD OF USE
Unscheduled maintenance Frequency

Adjustment of valve/rocker arm clearance 2,400 hours
Change the engine coolant 3,000 hours (5)
(*) Frequency for application on machines to be built: -100 hours for a standard application.
(**) The indicated frequencies are only valid for components supplied by FPT.
(1) Maximum period relative to the use of high quality fuel (ASTM D975 or EN 590 specifications); this is reduced based on fuel
contamination and alarm signals based on the clogging of the filter and/or the presence of water in the prefilter. The filter clogging
signal requires it to be replaced. If the signal of water present in the prefilter does not turn off after draining it, the filter must be
replaced.
(2) To be performed every year even if the specified operating hours interval has not been reached.
(3) The frequencies apply to lubricants that comply with international standards API CJ-4 / ACEA E9 as specified in the REFILLING
section.
(4) Only use filters with the following characteristics: - degree of filtering < 12 m - filtering efficiency 99.5% ( > 200).
(5) To be performed every two years even if the specified operating hours interval has not been reached.
(6) To be performed every three years even if the specified operating hours interval has not been reached.
(7) To be performed every 15 days even if the specified operating hours interval has not been reached.
(8) To be performed every six months even if the specified operating hours interval has not been reached.

.543070. Check engine oil level
Main action
1. The check must be performed when the engine is stopped and
possibly cold.
2. Make sure that the engine or that the machine in which it is
installed is on a flat surface.
3. Use the oil dipstick to check that the lubricant oil level falls
between the Min and Max markings.
4. If it is difficult to perform the measurement, clean the oil dip-
stick using a clean cloth without any loose threads, and re-fit the
dipstick into its housing. Remove it again and check the level.
5. If the level is too low, top-off using lubricant oil compliant to the
specifications in the table "General specifications - REFILLING".
6. To top-off, remove the lubricant oil filling cap (1) and pour
engine lubricant oil through the hole.
7. Always make sure to add oil that has the same characteristics of 225735 Figure 1
the one contained in the sump. Mixtures are not permitted that
cannot guarantee the correct lubrication of the engine parts.
P2D32N029E0115
Caution!
Disposal Engine oil
The engine oil is highly pollutant and noxious.
In case of contact with skin wash thoroughly with water and detergent.
Adequately protect skin and eyes; take measures as set forth by safety regulations.
Caution!
Disposal Engine oil
Dispose of residuals in an adequate manner that complies with laws in force.
8. Make sure that the dipstick is inserted completely and that the oil filler cap is completely tightened in a clockwise direction.
5432 Checking the engine coolant level

Carry out he procedure only while engine is OFF and at low temperature in order to prevent risk of burns.
Remove the pressurization cap from the expansion tank.

Visually check that the coolant in the expansion tank is above the minimum level.
If necessary, top up the expansion tank with a mixture of 50% water and Actifull OT CONCENTRATE (or Actifull OT PRE-
MIX without the addition of water), as indicated in the section "General specifications - REFILLING". Do not completely fill the
expansion tank.
When the engine is cold, make sure that the coolant in the expansion tank 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.
Caution!
Hot coolant Pay attention to the hot coolant
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 coolant tank cap only if necessary and only when the engine is cold.
540110 Engine visual inspection

After starting the engine and with the engine running, perform the following checks and inspections:
Check for any leaks from the fuel, coolant and lubricant circuits.
Make sure that there are no unusual noises or clinks while the engine is running.
Check the vehicle's pressure and temperature, along with other parameters, using its devices.
Visually check the exhaust smoke (colour of the exhaust emissions).
Visually check the level of the coolant in the expansion tank.
P2D32N029E0115
.543411. Check tension and condition of ancillary belt
Main action
1. Visually check that the ancillary belt (3) is not worn or damaged;
if yes, replace it as described in the procedure Removal-refitting
of ancillary belt ( Page 13).
2. Use a inch square wrench to check the efficiency of the auto-
matic belt tensioner (1).
225739 Figure 2
P2D32N029E0115
PERIODICAL MAINTENANCE
.773110. Draining the water from the fuel pre-filter
Main action
1. Proceed with the engine off.
2. Place a container below the pre-filter to collect the fluid.
3. Unscrew the cap (2) located in the lower part of the pre-filter
(1); in some configurations the cap includes a sensor (3) for
detecting the presence of water in the fuel.
4. Drain the fluid until only fuel exits.
Caution!
Environment pollution Risk of groundwater pollution
The disposal of all liquids and fluids should be carried
out in strict compliance with regulations in force.
5. Once bleeding is complete, tighten the cap (2) on the pre-filter

(1) and, if applicable, connect the electric connector (3).
227104 Figure 3
.543070. Engine lubricant oil change

Tightening torques
Lubricant drain plug on the sump (1 M22x1.5 plug) 50 5 Nm
P2D32N029E0115
Main action
1. Carry out he procedure only while engine is OFF and at low
temperature in order to prevent risk of burns.
2. Place a suitable container for catching oil below the engine lub-
ricant oil drain plug (2).
3. Extract the engine lubricant oil level dipstick .
4. Drain the engine lubricant oil by removing the plug (2) from
the oil sump.
5. In order to facilitate engine lubricant oil drainage, remove the oil
dipstick and remove the engine lubricant oil filler plug (1).
6. Wait until the oil sump (3) is completely empty, then tighten
the oil drain plug (2) to the specified torque.
tightening torque
Lubricant drain plug on the sump (1 50 5 Nm 225736 Figure 4
M22x1.5 plug) (2)
7. Refill through the hole located on the tappet cover, using lub-
ricant oil compliant to the specifications in the table "General
specifications - REFILLING".
8. Use the oil dipstick to check that the level of engine lubricant oil
exceeds the "Max" limit.
9. If it is difficult to perform the measurement, clean the oil dip-
stick using a clean cloth without any loose threads, and re-fit the
dipstick into its housing. Remove it again and check the level.
10. Tighten the lubricant oil filling plug (1).
Caution!
Disposal Engine oil
The engine oil is highly pollutant and noxious.
In case of contact with skin wash thoroughly with water and detergent.
Adequately protect skin and eyes; take measures as set forth by safety regulations.
Caution!
Disposal Engine oil
Dispose of residuals in an adequate manner that complies with laws in force.
11. Make sure that the dipstick is inserted completely and that the oil filler cap (1) is completely tightened in a clockwise direction.
.543070. Engine oil filter removal - refitting
Work material
Extraction tool for cartridge filters 99360076
Tightening torques
Oil filter (1 M27x2 coupling) 20 2 Nm
P2D32N029E0115
Main action
.543070. Removal
1. Position a container to collect the used oil below the filter
mount (1).
2. Use the specific tool to unscrew and remove the oil filter (3)
from the filter mount (1) and recover the gasket (2).
Threaded parts
Oil filter (1 M27x2 coupling) (3)
Tool / Material Product

code
225737 Figure 5
.543070. Refitting
3. Moisten the gasket (2) with a thin layer of oil and place it in its
seat on the oil filter (3).
4. Manually tighten the oil filter (3) on the mount (1) until fit up
against the gasket (2).
5. Using specific tool, further tighten the oil filter (3) to the spe-
cified torque:
tightening torque
Oil filter (1 M27x2 coupling) (3) 20 2 Nm

code
6. Operate the engine for a few minutes and then check the level 225737 Figure 6
using the dipstick. Top up if necessary to compensate for the oil
used for filling the filtering cartridge.
.542010. Removal - refitting the fuel filter
Work material
Tightening torques
Fuel filter (1 M20x1.5 adaptor) 20 2 Nm
P2D32N029E0115
Main action
.542010. Removal
1. Position a container to collect the diesel below the filter mount
(1).
2. Use the specific tool to unscrew and remove the fuel filter (5)
from the relative filter mount (1) and recover the gasket (4).
Threaded parts
Fuel filter (1 M20x1.5 adaptor) (5)

code
Note Pay attention to the electric fuel pre-heater (3) and the
relative electric connections.
225738 Figure 7
.542010. Refitting
3. Moisten the gasket (4) of the fuel filter (5) with a thin layer of
engine oil.
4. Manually tighten the fuel filter (5) on the mount (1) until it fits
up against the gasket (4).
5. Using specific tool, further tighten the fuel filter (5) to the spe-
cified torque:
tightening torque
Fuel filter (1 M20x1.5 adaptor) (5) 20 2 Nm
6. After replacing the fuel filter(5) there may be oil bubbles in the
fuel circuit. 225738 Figure 8
7. Bleed the residual air from the fuel filter (5) by loosening the
breather plug (2) and connecting it to a suitable container with
a transparent flexible pipe.
8. Start the manual fuel pre-filter pump until the fuel exiting the
bleeder plug (2) is completely free of air bubbles.
9. Tighten the bleeder plug (2) to the specified torque.
10. Start the engine and let it run idle for a few minutes to remove
any residual air.
P2D32N029E0115
.543411. Removal-refitting of ancillary belt
Main action
.543411. Removal
1. Use an appropriate tool (7) on the automatic belt tensioner
(1) and remove the ancillary drive belt (2) from the alternator
pulley (8), from the water pump pulley (6), fan pulley (3),
crankshaft pulley with damper (5) and from the pulley (4) .
227359 Figure 9
.543411. Refitting
2. Using a suitable tool (7) work on the automatic belt tensioner
(1) and fit the new auxiliary drive belt(2).
3. Make sure the belt (2) is correctly inserted in the alternator
pulley (8), the water pump pulley (6), the fan pulley (3), the
crankshaft pulley with damper (5) and the pulley (4).
4. Fully rotate the crankshaft twice to ensure that the new ancillary
belt (2) has settled.
227359 Figure 10
P2D32N029E0115
UNSCHEDULED MAINTENANCE
.540480. Change blow-by filter

Main action
1. Unscrew the fastening screws (1) and remove the Blow-by
filter cover (2).
2. Replace and install the two cartridge filters (3) included in the
filtering unit (2).
3. Fit the blow-by filter cover (2) and tighten the fastening screws
(1).
Note The blow-by filter was designed to collect, filter and
condensate the lubricant vapours. Carry out the pro-
cedure only while engine is OFF and at low temperat-
ure in order to prevent risk of burns.
209217 Figure 11
.541230. Tappet clearance adjustment
Work material
Tool to rotate flywheel (use with 99360222) 99360221
Pinion (use with 99360221) 99360222
Feeler gauge
Allen key
Box wrench
Tightening torques
Tappet adjusters (8 M8x1.25 nuts) 24 4 Nm
Technical data
Intake valve 0.25 0.05 mm
Exhaust valve 0.50 0.05 mm
P2D32N029E0115
Main action
70520 Figure 12
1. Adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (3) and feeler gauge (2).
The operating clearance is:
Technical data
Note The adjustment of clearance between the rocker arms and intake and exhaust valve control bridges must be done
very carefully.
2. Take the cylinder in which the clearance must be adjusted to the burst phase; these cylinder valves are closed while the sym-
metric cylinder valves are balanced.
Note The correspondence of the symmetrical cylinders is 1 - 4, 2 - 3.
3. Using a box wrench(3) loosen the nut locking the adjustment screw.
Tool / Material
Box wrench
4. Insert the feeler gauge blade (2) corresponding to the specified operating clearance.
Tool / Material
Feeler gauge
5. Screw or unscrew the adjustment screw of the rocker arm using the Allen wrench (1).
Tool / Material
Allen key
6. Check that the feeler gauge blade (2) can slide with slight friction.
Tool / Material
Feeler gauge
7. Keeping the adjustment screw stationary, tighten the locking nut to a torque of:
P2D32N029E0115
tightening torque
8. To carry out the adjustment correctly, the firing sequence shown in the table must be followed.
FIRING SEQUENCE 1-3-4-2
Start and rotation in the engine Adjust valve clearance for cylinder
Balancing cylinder valves no.
direction no.
1 and 4 at T.D.C. 4 1
180 2 3
180 1 4
180 3 2
9. To carry out clearance adjustment of the valve - rocker arm assembly more quickly, proceed as follows.
10. Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked with an asterisk as shown in the table
below:

cylinder No. 1 2 3 4
intake * *
exhaust * *
below:

intake * *
exhaust * *
Conditions
rear side of the engine flywheel
P2D32N029E0115
143281 Figure 13
To rotate the crankshaft, fit the specific tool (2) in the seat of the electric starter motor housed in the flywheel housing
(1).
Tool / Material Product code
Pinion (use with 99360221) 99360222
.506010. Change the engine coolant

Main action
Caution!
High engine temperature Precautions when checking coolants
Given the high temperatures which are reached inside the engine, do not carry out operations immediately after the
engine has stopped but wait until the temperature has fallen.
Protect eyes and skin from any unexpected high pressure jets of coolant.
1. Only proceed when the engine is not turning over.
Caution!
Engine fluid at high pressure Precautions when checking coolants
When the engine is hot, a pressure is stabilised in the cooling circuits which is able to eject the hot liquid in a very
violent manner, resulting in a risk of burns.
2. Place a container for collecting coolant under the heat exchanger (radiator).
3. Remove the pressurization cap from the expansion tank.
4. Loosen the fastening elements and remove the coupling sleeves connecting the engine cooling circuit to the heat exchanger.
5. Drain the coolant from the heat exchanger (radiator) and wait until it is completely empty.
P2D32N029E0115
6. After draining it, reconnect the cooling circuit making sure that the sleeves are perfectly sealed.
7. Fill the engine and heat exchanger until completely filling the cooling circuit with a mixture of 50% water and Actifull OT
CONCENTRATE (or Actifull OT PREMIX without the addition of water), as indicated in the "Technical specifications -
REFILLING" section. Do not completely fill the expansion tank.
8. With the coolant filler plug open, start the engine and let it idle for approx. one minute. This helps to completely release all
the air from the cooling circuit.
9. Stop the engine and top off if necessary.
10. When the engine is cold, make sure that the coolant in the expansion tank is a few centimetres below the filling hole.
11. 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.
P2D32N029E0115
ATS SYSTEM SCHEDULED MAINTENANCE 19
Contents
Contents
Maintenance services schedule for ATS system . . . . . 21
P2D32N029E0115
20 ATS SYSTEM SCHEDULED MAINTENANCE
P2D32N029E0115
ATS SYSTEM SCHEDULED MAINTENANCE 21
Maintenance services schedule for ATS system
ATS SYSTEM SCHEDULED MAINTENANCE

M Maintenance services schedule for ATS system
Scheduled Maintenance consists of operations that must be performed on the components of the ATS system within the set time
range.
Also, in the case of evident system malfunction, it is necessary to adopted timely measures to verify the cause of the defect.
To schedule the work, observe the following chart:
Periodical maintenance Action

Tank filler filter (300 or 100* m) No regular service planned (clean if necessary)
Supply module pre-filter (100 or 70* m) Clean with water each time the oil is changed
Supply module intake filter (100 m) No regular service planned (replace if necessary)
Replacement every 3,600 hours or every 2 years
Supply module main filter (depending on which of the indicated conditions
takes place first)
Supply module reflux filter (100 m) No regular service planned (replace if necessary)
Dosing valve filter (36 m) No applicable service
* only for applications operating in dusty environments.
P2D32N029E0115
22 ATS SYSTEM SCHEDULED MAINTENANCE
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV Removal-refitting of the main engine
Contents 1
Contents
Removal - refitting of main components . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
Removal - refitting of main components 3
Contents
Contents Cylinder head removal-refitting . . . . . . . . . . . . . . . 53
Removal-refitting of ancillary belt . . . . . . . . . . . . . . . 5 Removal - refitting of the crankshaft drive pulley . . . . 57
Alternator removal-refitting . . . . . . . . . . . . . . . . . . 5 Removal - refitting of the crankshaft front cover seal

ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal - refitting of the automatic belt tensioner . . . . 6
Removal - refitting of the engine flywheel . . . . . . . . . 61
Water pump removal-refitting . . . . . . . . . . . . . . . . 7
Removal - refitting of the crankshaft rear seal
Removal - refitting of the thermostat . . . . . . . . . . . . 8 ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal - refitting of the starter motor . . . . . . . . . . 9
Engine cable removal-refitting . . . . . . . . . . . . . . . . 11
Removal - refitting of the engine brake . . . . . . . . . . 13
Turbocharger removal-refitting . . . . . . . . . . . . . . . 15
Engine oil filter removal - refitting . . . . . . . . . . . . . 19
Heat exchanger removal-refitting . . . . . . . . . . . . . . 20
Oil sump removal-refitting . . . . . . . . . . . . . . . . . . 22
Removal - refitting of the fuel pipes . . . . . . . . . . . . 24
Removal - refitting the fuel filter . . . . . . . . . . . . . . 28
Removal - Refitting vehicle fuel filter mount . . . . . . . 29
Removal - refitting of the high pressure pump . . . . . . 31
Common rail removal-refitting . . . . . . . . . . . . . . . 33
Removal - refitting of the EDC 17 control unit . . . . . 35
Removal - refitting the tappet cover . . . . . . . . . . . . 38
Removal - refitting of the oil vapour recirculation

system (blow-by) . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal - refitting the electro-injector wirings . . . . . 40
Removal - refitting of the electro-injectors . . . . . . . . 42
Removal - refitting of the rocker arm unit . . . . . . . . 45
Heater Removal and Refitting . . . . . . . . . . . . . . . . 49
Intake manifold removal-refitting . . . . . . . . . . . . . . 50
Exhaust manifold removal-refitting . . . . . . . . . . . . . 52
P2D32N029E0115
4 Removal - refitting of main components
P2D32N029E0115
Removal-refitting of ancillary belt
Removal - refitting of main components

.543411. Removal-refitting of ancillary belt
Main action
.543411. Removal
1. Use an appropriate tool (7) on the automatic belt tensioner
(1) and remove the ancillary drive belt (2) from the alternator
pulley (8), from the water pump pulley (6), fan pulley (3),
crankshaft pulley with damper (5) and from the pulley (4) .
227359 Figure 1
.543411. Refitting
2. Using a suitable tool (7) work on the automatic belt tensioner
(1) and fit the new auxiliary drive belt(2).
3. Make sure the belt (2) is correctly inserted in the alternator
pulley (8), the water pump pulley (6), the fan pulley (3), the
crankshaft pulley with damper (5) and the pulley (4).
4. Fully rotate the crankshaft twice to ensure that the new ancillary
belt (2) has settled.
227359 Figure 2
.760310. Alternator removal-refitting
Tightening torques
Alternator and fastening bracket 1. (1 M10x1.5x30 screw) 43 6 Nm
2. (1 M10x1.5x110 screw) 43 6 Nm
P2D32N029E0115
Removal - refitting of the automatic belt tensioner
Preliminary actions
Remove the ancillary belt. ( Page 5)
Main action
.760310. Removal
1. Unscrew the screws (1, 3) and remove the alternator (4) from
the support bracket (2).
Threaded parts
Alternator and fastening 1. (1 M10x1.5x30 screw)
bracket (1,3) 2. (1 M10x1.5x110 screw)
227360 Figure 3
.760310. Refitting
2. Place the alternator (4) in its seat and fasten it with the support
bracket(2) and tighten the fastening screws(1,3) to a torque of:
tightening torque
bracket (1,3) 43 6 Nm
2. (1 M10x1.5x110 screw)
43 6 Nm
227360 Figure 4
Next actions
Refit the ancillary belt. ( Page 5)
.543417. Removal - refitting of the automatic belt tensioner
Tightening torques
Automatic belt tensioner (1 screw M10x1.5x70) 43 6 Nm
P2D32N029E0115
Water pump removal-refitting
Preliminary actions
Main action
.543417. Removal
1. Unscrew the fastening screw (2) and remove the automatic
belt tensioner (3) from the mount (1).
Threaded parts
Automatic belt tensioner (1 screw M10x1.5x70) (2)
225743 Figure 5
.543417. Refitting
2. Position the automatic belt tensioner (3) in its seat on the
mount (1) and tighten the fastening screw(2) to a torque of:
tightening torque
Automatic belt tensioner (1 screw 43 6 Nm
M10x1.5x70) (2)
225743 Figure 6
Next actions
.543210. Water pump removal-refitting
Tightening torques
Water pump (2 screws M8x1.25x35) 24 4 Nm
P2D32N029E0115
Removal - refitting of the thermostat
Preliminary actions
Main action
.543210. Removal
1. Position a suitable container to collect any coolant which may
leak out.
2. Unscrew the fastening screws(3) and remove the water pump
(2) recovering the gasket (1).
Threaded parts
Water pump (2 screws M8x1.25x35) (3)
227361 Figure 7
.543210. Refitting
3. Apply a new sealing ring (1) to the water pump (2).
4. Position the water pump in its seat (2), tighten the fastening
screws (3) to a torque of:
tightening torque
Water pump (2 screws 24 4 Nm
M8x1.25x35) (3)
227361 Figure 8
Next actions
.543250. Removal - refitting of the thermostat
Tightening torques
Thermostat cover (3 M6x1x12 screws) 13.5 1.5 Nm
P2D32N029E0115
Removal - refitting of the starter motor
Main action
.543250. Removal
1. Unscrew the fastening screws (1).
Threaded parts
Thermostat cover (3 M6x1x12 screws) (1)
2. Remove the engine coolant delivery pipe (2) and the thermo-
stat (3) complete with the gasket from its seat in the cylinder
head (4) .
227362 Figure 9
.543250. Refitting
3. Fit the thermostat (3) complete with the gasket from its seat in
the cylinder head (4) and the engine coolant outlet pipe (2).
4. Tighten the fastening screws (1) to a torque of:
tightening torque
Thermostat cover (3 M6x1x12 13.5 1.5 Nm
screws) (1)
227362 Figure 10
.760810. Removal - refitting of the starter motor
Tightening torques
Starter motor 1. (3 M10x1.5 nuts) 43 6 Nm
2. (3 M10x1.5x50 studs) 25 5 Nm
P2D32N029E0115
Removal - refitting of the starter motor
Main action
.760810. Removal
1. Make sure that the electric starter motor(2) is suitably suppor-
ted.
2. Unscrew the fastening nuts (4) and remove the electric starter
motor (2).
3. Unscrew the studs (1) if necessary from the flywheel housing
(3).
Threaded parts
Starter motor (1, 4) 1. (3 M10x1.5 nuts)
2. (3 M10x1.5x50 studs)
225878 Figure 11
.760810. Refitting
4. Screw the captive screws (1) into the flywheel housing (3).
5. Fit the electric starter motor (2) on the studs (1).
6. Tighten the fastening nut (4) to a torque of:
tightening torque
43 6 Nm
2. (3 M10x1.5x50 studs)
25 5 Nm
225878 Figure 12
P2D32N029E0115
Engine cable removal-refitting
.769140. Engine cable removal-refitting
Main action
.769140. Removal
225718 Figure 13
1. Disconnect the engine cable from the control unit (7), from the motorised throttle valve actuator (2) and from all sensors
and transmitters with which it is connected.
P2D32N029E0115
Engine cable removal-refitting
2. To remove the engine cable (6) open the clips (2,4) fastening
the engine cable to the crankcase, to the intake manifold and to
the tappet cover, unscrewing the relative nuts (3,5).
225881 Figure 14
.769140. Refitting
3. Correctly position the engine cable (6) and close the clips (2,4)
retaining the engine cable to the crankcase, to the intake mani-
fold and to the tappet cover, tightening the relative nuts (3,5).
225881 Figure 15
P2D32N029E0115
Removal - refitting of the engine brake
225718 Figure 16
4. Connect the engine cable to the connector from the control unit (7), the motorised throttle valve actuator (2) and to all the
sensors and transmitters indicated in the figure.
.543710. Removal - refitting of the engine brake
Tightening torques
Upper part of the electric actuator coolant return 1. (1 M10x1 fitting) 20 Nm
pipe joint 2. (1 M12x1.5 nut) 45 Nm
Motorised throttle valve fastening collar on the exhaust (1 M6x1x50 screw) 5.75 0.55 Nm
P2D32N029E0115
Removal - refitting of the engine brake
Main action
.543710. Removal
1. Disconnect the electrical connection (2) from the electric actu-
ator (1) of the motorised throttle valve.
2. Partially remove the coolant pipes by acting on the couplings (3)
and connect them to the sides of the electric actuator (1) of
the motorised throttle valve.
Threaded parts
Upper part of the electric 1. (1 M10x1 fitting)
actuator coolant return pipe
2. (1 M12x1.5 nut)
joint (3)
227363 Figure 17
3. Unscrew the screw (4) to loosen the V tightening collar (3) and
remove the motorised throttle valve (1) from the turbocharger
(2).
Threaded parts
Motorised throttle valve fastening collar on the exhaust (1 M6x1x50
screw) (4)
227364 Figure 18
.543710. Refitting
4. Fit the motorised throttle valve (1) on the turbocharger (2).
5. Turn the screw (4) and tighten the V tightening union (3) to a
torque of:
tightening torque
Motorised throttle valve fastening 5.75 0.55 Nm
collar on the exhaust (1 M6x1x50
screw) (4)
227364 Figure 19
P2D32N029E0115
Turbocharger removal-refitting
6. Connect the coolant pipes to the electric actuator (1) and

tighten the unions (3) to a torque of:
tightening torque
actuator coolant return pipe 20 Nm
joint (3)
2. (1 M12x1.5 nut)
45 Nm
7. Connect the electrical connection (2) to the electric actuator

(1) of the motorised throttle valve.
227363 Figure 20
.542410. Turbocharger removal-refitting
Tightening torques
Lubricant delivery pipe to turbocharger (2 11/16-16 M16 unions) 36 5 Nm
Turbocharger lubricant return pipe (2 M8x1.25x25 screws) 23 2 Nm
Turbocharger on the exhaust manifold 1. (4 M8x1.25 nuts) 24 4 Nm
2. (4 M8x1.25x40 studs) 11 3 Nm
Main action
.542410. Removal
1. Position a suitable container to collect the oil.
2. Unscrew the unions (1) and (3) and disconnect the pipe (2)
delivering lubricant to the turbocharger that connects the upper
part of the heat exchanger to the turbocharger.
Threaded parts
Lubricant delivery pipe to turbocharger (2 11/16-16 M16 unions) (1, 3)
227365 Figure 21
P2D32N029E0115
3. Unscrew the screws (3, 6) fastening the retaining bracket (5)

of the turbocharger lubricant oil return pipe (1).
4. Unscrew the screws (2) fastening the lubricant return pipe
(1) from the lower part of the turbocharger and recover the
relative gasket.
Threaded parts
Turbocharger lubricant return pipe (2 M8x1.25x25 screws) (2)
5. Remove the union (4) from the crankcase and disconnect the
lubricant return pipe (1).
227366 Figure 22
.543710. Removal
6. Disconnect the electrical connection (2) from the electric actu-
ator (1) of the motorised throttle valve.
7. Partially remove the coolant pipes by acting on the couplings (3)
and connect them to the sides of the electric actuator (1) of
the motorised throttle valve.
Threaded parts
2. (1 M12x1.5 nut)
joint (3)
227363 Figure 23
8. Unscrew the screw (4) to loosen the V tightening collar (3) and
remove the motorised throttle valve (1) from the turbocharger
(2).
Threaded parts
screw) (4)
227364 Figure 24
P2D32N029E0115
9. Position a suitable container to collect the coolant.

10. Unscrew the fastening nut (6) and remove the electric actuator
coolant delivery pipe (1).
11. Unscrew the fastening nut (5) and remove the bracket (4)
retaining the electric actuator coolant return pipe (2).
12. Unscrew the fastening nut (3) and remove the upper part of
the electric actuator coolant return pipe (2).
13. The electric connector of the throttle valve was removed previ-
ously.
227367 Figure 25
14. Unscrew the fastening nuts (1) and disconnect the turbochar-
ger (2) together with the waste-gate valve and the relative gas-
ket (3).
15. Unscrew the studs (4) if necessary from the exhaust manifold
(5).
Threaded parts
Turbocharger on the exhaust 1. (4 M8x1.25 nuts)
manifold (1) 2. (4 M8x1.25x40 studs)
227368 Figure 26
.542410. Refitting
16. If removed, tighten the studs (4) on the exhaust manifold (5) .
17. Fit the turbocharger (2), together with the waste-gate valve, on
the exhaust manifold (5) and insert a new gasket (3).
18. Tighten the fastening nuts (1) to a torque of:
tightening torque
manifold (1) 24 4 Nm
2. (4 M8x1.25x40 studs)
11 3 Nm
227368 Figure 27
P2D32N029E0115
19. Fit the upper part of the electric actuator coolant return pipe
(2) and tighten the fastening nut (3) to the specified torque.
20. Fit the bracket (4) retaining the electric actuator coolant re-
turn pipe (2) and tighten the fastening nut (5) to the specified
torque.
21. Fit the electric actuator coolant delivery pipe (1) and tighten
the fastening nut (6) to the specified torque.
22. The electric connector of the throttle valve actuator will be
reattached later.
227367 Figure 28
.543710. Refitting
23. Fit the motorised throttle valve (1) on the turbocharger (2).
24. Turn the screw (4) and tighten the V tightening union (3) to a
torque of:
tightening torque
screw) (4)
227364 Figure 29
25. Connect the coolant pipes to the electric actuator (1) and
tighten the unions (3) to a torque of:
tightening torque
joint (3)
2. (1 M12x1.5 nut)
45 Nm
26. Connect the electrical connection (2) to the electric actuator

(1) of the motorised throttle valve.
227363 Figure 30
P2D32N029E0115
Engine oil filter removal - refitting
27. Fit the lubricant return pipe(1) and insert the union (4) with a
new seal in the crankcase.
28. Tighten the screws (2) fastening the lubricant return pipe (1)
in the lower part of the turbocharger after inserting the relative
gasket.
tightening torque
Turbocharger lubricant return pipe 23 2 Nm
(2 M8x1.25x25 screws) (2)
29. Fit the bracket retaining (5) the lubricant return pipe (1) from
the turbocharger and tighten the fastening screws (3, 6).
227366 Figure 31
30. Fit the pipe (2) delivering lubricant to the turbocharger that
connects the upper part of the heat exchanger to the tur-
bocharger and tighten the unions (1) and (3) to a torque of:
tightening torque
Lubricant delivery pipe to 36 5 Nm
turbocharger (2 11/16-16 M16
unions) (1, 3)
227365 Figure 32
.543070. Engine oil filter removal - refitting
Work material
Tightening torques
P2D32N029E0115
Heat exchanger removal-refitting
Main action
.543070. Removal
1. Position a container to collect the used oil below the filter
mount (1).
2. Use the specific tool to unscrew and remove the oil filter (3)
from the filter mount (1) and recover the gasket (2).
Threaded parts

code
225737 Figure 33
.543070. Refitting
3. Moisten the gasket (2) with a thin layer of oil and place it in its
seat on the oil filter (3).
4. Manually tighten the oil filter (3) on the mount (1) until fit up
against the gasket (2).
5. Using specific tool, further tighten the oil filter (3) to the spe-
cified torque:
tightening torque

code
6. Operate the engine for a few minutes and then check the level 225737 Figure 34
using the dipstick. Top up if necessary to compensate for the oil
used for filling the filtering cartridge.
.543110. Heat exchanger removal-refitting
Tightening torques
Engine oil temperature and pressure sensor (2 M6x1x20 screws) 10 2 Nm
Heat exchanger and oil filter mount (15 M8x1.25x35 screws) 26 4 Nm
Preliminary actions
1. Remove the alternator. ( Page 6)
2. Remove the engine oil filter. ( Page 20)
3. Position a suitable container to collect any engine oil which may leak out.
P2D32N029E0115
Heat exchanger removal-refitting
Main action
.543110. Removal
1. Unscrew the unions (6) and disconnect the pipe (1) delivering
oil to the turbocharger from the mount (5) of the heat ex-
changer/oil filter.
Threaded parts
Lubricant delivery pipe to turbocharger (2 11/16-16 M16 unions) (6)
2. Disconnect the connector (2) for the engine oil pressure and
temperature sensor (3).
3. Unscrew the fastening screws(4) and remove the engine oil
pressure and temperature sensor (3).
Threaded parts
Engine oil temperature and pressure sensor (2 M6x1x20 screws) (4)
227369 Figure 35
4. Unscrew the fastening screws(2) and remove the mount (3)

of the heat exchanger/oil filter, the heat exchanger (5) and the
relative gaskets (1, 4).
Threaded parts
Heat exchanger and oil filter mount (15 M8x1.25x35 screws) (2)
227370 Figure 36
.543110. Refitting
5. On the crankcase, fit a new gasket (1), the heat exchanger (5),
a new gasket (4) and the mount (3) of the heat exchanger/oil
filter.
Note Before each assembly operation, check that the thread
on the holes and the screws shows no sign of wear or
dirt.
6. Fit the fastening screws (2) and tighten them to a torque of:
tightening torque
Heat exchanger and oil filter mount 26 4 Nm
(15 M8x1.25x35 screws) (2)
227370 Figure 37
P2D32N029E0115
Oil sump removal-refitting
7. Install the pipe (1) delivering lubricant to the turbocharger on

the mount (5) of the heat exchanger/oil filter and tighten the
unions (6) to a torque of:
tightening torque
unions) (6)
8. Install the engine oil pressure and temperature sensor(3) with a

new seal ring on the mount (5) of the heat exchanger/oil filter.
9. Tighten the screws (4) fastening the engine oil pressure and
temperature sensor(3) to a torque of:
tightening torque
Engine oil temperature and pressure 10 2 Nm 227369 Figure 38
sensor (2 M6x1x20 screws) (4)
10. Connect the connector of the engine cable (2) to the engine oil
pressure and temperature sensor (3).
Next actions
1. Refit the engine oil filter. ( Page 20)
2. Check the oil level with the dipstick: the level must be close to the MAX notch on the dipstick itself. Otherwise top-up the
necessary quantity.
3. Refit the alternator. ( Page 6)
.540430. Oil sump removal-refitting
Tightening torques
Engine oil sump 1. (22 screws) 24 4 Nm
2. (2 screws) 24 4 Nm
Main action
.540430. Removal
1. Place an appropriate container for the oil collection under the
oil sump (3) in correspondence with the drain plug (2).
Note It is recommended that the oil is drained while hot.
2. To aid the flow of the oil, unscrew the oil filler cap (1) on the
tappet cover and remove the oil dipstick.
3. Unscrew the drain plug (2) and let all the lubricant contained in
the oil sump (3) drain out completely.
Threaded parts
Lubricant drain plug on the sump (1 M22x1.5 plug) (2)
225736 Figure 39
P2D32N029E0115
Oil sump removal-refitting
4. Unscrew the screws (4), remove the oil sump (2) recovering
the gasket (1).
Threaded parts
Engine oil sump (4) 1. (22 screws)
2. (2 screws)
225744 Figure 40
.540430. Refitting
5. Position the gasket (1) on the oil sump (2).
Note If not faulty the gasket can be reused.
6. Fit the oil sump (2) in position on the crankcase and tighten the
fastening screws (4) to a torque of:
tightening torque
24 4 Nm
2. (2 screws)
24 4 Nm
225744 Figure 41
Caution!

Only use recommended oils or oils with the properties required for proper engine operation.
If topping up, do not mix oils with different properties.
Failure to observe these standards will invalidate the service warranties.
7. Using a new gasket, tighten the drain plug (2) in the oil sump
(3) and tighten it to a torque of:
tightening torque
Lubricant drain plug on the sump (1 50 5 Nm
M22x1.5 plug) (2)
8. Proceed with filling with clean oil and check the oil level with
the dipstick: the level must be close to the MAX notch on the
dipstick itself. Otherwise top-up the necessary quantity through
the filler cap (1).
225736 Figure 42
P2D32N029E0115
Removal - refitting of the fuel pipes
.542020. Removal - refitting of the fuel pipes
Work material
Set of 5 insert wrenches 9x12 (14-15-17-18-19 mm) 99317915
Coupling torque wrench 9X12 (5-60 Nm) 99389829
Tightening torques
Bracket retaining the delivery fuel pipe from the 1. (1 M8x1.25x16 screw) 25 Nm
pump to the rail 2. (1 M8x1.25x20 screw) 25 Nm
Pipe delivering fuel from the pump to the rail (2 1. Step 1 - Tightening with 10 Nm
M14x1.5 unions) torque wrench to torque
2. Step 2 - Angle tightening 55
Pipes delivering fuel to the electro-injectors (8 1. Step 1 - Tightening with 10 Nm
Preliminary actions
Remove the engine cable. ( Page 11)
Main action
.542020. Removal
1. Disconnect the low pressure fuel pipes (1, 2, 3, 4, 5) between
the fuel filter mount, the high pressure pump and the control
unit heat exchanger.
225745 Figure 43
P2D32N029E0115
2. Disconnect the low pressure unions (3) from the rail,(2) from
the cylinder head and(5) from the filter mount, as shown in the
following figure, and remove the fuel pipe (4) returning from
the rail and the electro-injectors.
3. Unscrew the fastening screws (10, 11) and remove the bracket
retaining the fuel pipe (7).
Threaded parts
Bracket retaining the delivery 1. (1 M8x1.25x16 screw)
fuel pipe from the pump to
2. (1 M8x1.25x20 screw)
the rail (10, 11)
4. Unscrew the fastening screws (8, 9) and remove the bracket

Threaded parts 225746 Figure 44
2. (1 M8x1.25x20 screw)
the rail (8, 9)
5. Unscrew the high pressure unions(1, 6) and remove the deliv-

ery fuel pipe (7) from the high pressure pump to the rail.
Threaded parts
Pipe delivering fuel from the 1. Step 1 - Tightening with torque
pump to the rail (2 M14x1.5 wrench to torque
unions) (1, 6) 2. Step 2 - Angle tightening
6. To disconnect a low pressure fuel pipe from the relevant con-

nection fitting, hold and press the clip (1) and extract the quick-
release coupling (2).
116237 Figure 45
P2D32N029E0115
7. Disconnect the high pressure fuel delivery pipes (1) acting on

the rail side (3) unions (4) and on the manifold side unions (2)
for electro-injectors.
Threaded parts
Pipes delivering fuel to the 1. Step 1 - Tightening with torque
electro-injectors (8 M14x1.5 wrench to torque
225894 Figure 46
.542020. Refitting
8. Fit the high pressure fuel delivery pipes (1) by first manually
positioning the nuts (4) on the common rail side (3) and then
the nuts (2) on the manifold side for the electro-injectors.
9. First tighten the nuts (2) on the manifold side for the electro-
injectors to a torque of 10 Nm and then the nuts (4) on the
common rail side (3).
10. After tightening the screws fastening the common rail to the
intake manifold, first tighten the nuts (4) on the common rail
side (3) and then the nuts (2) on the manifolds side for the
electro-injectors in two steps to a torque of:
tightening torque
unions) (2, 4)
225894 Figure 47
10 Nm
2. Step 2 - Angle tightening
55

code
Note The high pressure fuel delivery pipes must be replaced

each time they are disconnected.
The pipe unions must be tightened to the specified
torque using the specified coupling torque wrench
together with a wrench with an insert.
P2D32N029E0115
11. Fit the delivery fuel pipe (7) from the high pressure pump to
the rail and tighten the high pressure unions(1, 6) to a torque
of:
tightening torque
unions) (1, 6) 10 Nm
55

code
225746 Figure 48
Note The high pressure fuel delivery pipe must always be

replaced each time it is removed.
12. Install the bracket retaining the fuel pipe (7) and tighten the
fastening screws (8, 9) to a torque of:
tightening torque
fuel pipe from the pump to 25 Nm
the rail (8, 9)
2. (1 M8x1.25x20 screw)
25 Nm
13. Install the bracket retaining the fuel pipe (7) and tighten the
fastening screws (10, 11) to a torque of:
tightening torque
the rail (10, 11)
2. (1 M8x1.25x20 screw)
25 Nm
14. Fit the fuel pipe (4) returning from the rail and the electro-
injectors and connect the low pressure unions (3) to the rail,
(2) to the cylinder head and (5) to the filter mount as shown in
the following figure.
P2D32N029E0115
Removal - refitting the fuel filter
15. Connect the low pressure fuel pipes (1, 2, 3, 4, 5) to the fuel
filter mount, the high pressure pump and the control unit heat
exchanger.
225745 Figure 49
16. Connect pipeline by means of quick coupling (2), press it till

retainer (3) is secured.
Note Check proper fuel pipe connection.
116237 Figure 50
Next actions
Refit the engine cable. ( Page 12)
.542010. Removal - refitting the fuel filter
Work material
Tightening torques
P2D32N029E0115
Removal - Refitting vehicle fuel filter mount
Main action
.542010. Removal
1. Position a container to collect the diesel below the filter mount
(1).
2. Use the specific tool to unscrew and remove the fuel filter (5)
from the relative filter mount (1) and recover the gasket (4).
Threaded parts

code
225738 Figure 51
.542010. Refitting
3. Moisten the gasket (4) of the fuel filter (5) with a thin layer of
engine oil.
4. Manually tighten the fuel filter (5) on the mount (1) until it fits
up against the gasket (4).
5. Using specific tool, further tighten the fuel filter (5) to the spe-
cified torque:
tightening torque
6. After replacing the fuel filter(5) there may be oil bubbles in the
fuel circuit. 225738 Figure 52
7. Bleed the residual air from the fuel filter (5) by loosening the
breather plug (2) and connecting it to a suitable container with
a transparent flexible pipe.
8. Start the manual fuel pre-filter pump until the fuel exiting the
bleeder plug (2) is completely free of air bubbles.
9. Tighten the bleeder plug (2) to the specified torque.
10. Start the engine and let it run idle for a few minutes to remove
any residual air.
.542014. Removal - Refitting vehicle fuel filter mount
Tightening torques
Fuel temperature sensor (1 M14x1.5x12 union) 24 4 Nm
Fuel filter mount (2 M12x1.75x30 screws) 80 8 Nm
P2D32N029E0115
Removal - Refitting vehicle fuel filter mount
Preliminary actions
Remove the fuel filter. ( Page 29)
Main action
.542014. Removal
1. Disconnect the low pressure fuel pipes (1,3,4,6) from the fuel
filter mount (5).
2. Disconnect the electrical connections of the fuel temperature
sensor (8) and the timing sensor (2).
Threaded parts
Fuel temperature sensor (1 M14x1.5x12 union) (8)
3. Unscrew the fastening screws (7) and remove the fuel filter
cover (5) from the crankcase.
Threaded parts
Fuel filter mount (2 M12x1.75x30 screws) (7)
225877 Figure 53

116237 Figure 54
.542014. Refitting
5. Fit the fuel filter mount (5) on the crankcase and tighten the
fastening screws (7) to the specified torque:
tightening torque
Fuel filter mount (2 M12x1.75x30 80 8 Nm
screws) (7)
6. Connect the low pressure fuel pipes (1,3,4,6) to the fuel filter
mount (5).
7. Fit the fuel temperature sensor (8) housed in the fuel filter
mount (5) and tighten it to a torque of:
tightening torque
Fuel temperature sensor (1 24 4 Nm
M14x1.5x12 union) (8)
225877 Figure 55
8. Connect the electrical connections of the fuel temperature
P2D32N029E0115
Removal - refitting of the high pressure pump

116237 Figure 56
Next actions
Refitting the vehicle fuel filter. ( Page 29)
.771010. Removal - refitting of the high pressure pump
Tightening torques
High pressure fuel injection pump 1. (3 M8 nuts) 24 4 Nm
2. (3 M8x1.25x50 studs) 11 3 Nm
Preliminary actions
Removing the fuel filter support. ( Page 30)
Main action
.771010. Removal
227107 Figure 57
P2D32N029E0115
Removal - refitting of the high pressure pump
2. Disconnect the electrical connection from the pressure regu-

lator.
3. Act on the quick connections (2, 3) and disconnect the fuel
return pipe (4).
4. Unscrew the unions (1, 5) fastening the delivery pipe(8) to the
common rail and to the fuel high pressure pump.
Threaded parts
5. Unscrew the screws (6, 7, 9, 10) of the relative retainer brack-

ets and remove the fuel delivery pipe (8).
2. (1 M8x1.25x20 screw)
the rail (6, 7, 9, 10)
6. Make sure that the high pressure fuel pump (2) is suitably sup-
ported.
7. Unscrew the fastening nuts (1) and remove the high pressure
pump (2), complete with the mechanical feed pump (5), flange
and gear (4) from the gear case.
8. Unscrew the studs (3) if necessary from the gear case.
Threaded parts
High pressure fuel injection 1. (3 M8 nuts)
pump (1, 3) 2. (3 M8x1.25x50 studs)
229418 Figure 59
.771010. Refitting
9. If removed, tighten the studs (3) in the gear case.
10. Fit the high pressure fuel pump(2), complete with the mechan-
ical feed pump (5), flange and drive gear(4).
11. Tighten the fastening nuts (1) to a torque of:
tightening torque
pump (1, 3) 24 4 Nm
2. (3 M8x1.25x50 studs)
11 3 Nm
229418 Figure 60
P2D32N029E0115
Common rail removal-refitting
12. To connect the low pressure fuel pipe to the connection fitting,
insert the quick-fit coupling (1) into the connection fitting and
push in until the catch (2) engages.
227108 Figure 61
13. Connect the high pressure delivery fuel pipe (8) with the high
pressure pump and the common rail and tighten the unions to
(1, 5) a torque of:
tightening torque
55
14. Fasten the high pressure fuel delivery pipe (8) to the crankcase
using the relative brackets and tighten the fastening screws (6,
7, 9, 10) to a torque of:
229417 Figure 62
tightening torque
the rail (6, 7, 9, 10)
2. (1 M8x1.25x20 screw)
25 Nm
15. Connect the fuel return pipe (4) using the relative quick con-
nections (2, 3) .
16. Connect the electrical connection of the pressure regulator.
Next actions
Refitting the fuel filter support. ( Page 30)
.774510. Common rail removal-refitting
Tightening torques
P2D32N029E0115
Common rail removal-refitting
Pipes delivering fuel to the electro-injectors (8 2. Step 2 - Angle tightening 55

M14x1.5 unions)
Common Rail (3 M8x1.25x125 screws) 36 5 Nm
Main action
.774510. Removal
1. Disconnect the connector from the rail pressure sensor(5) and
partially disconnect the engine cable as described in the Engine
cable removal-refitting ( Page 11) procedure.
2. Position a suitable container to collect the fuel.
3. Disconnect the low pressure fuel return pipe (3) from the rail.
4. Unscrew the union (4) and disconnect the fuel delivery pipe
from the high pressure pump to the common rail (2).
Threaded parts
unions) (4) 2. Step 2 - Angle tightening
5. Unscrew the unions (1) and disconnect the high pressure

fuel delivery pipes from the common rail (2) to the 229419 Figure 63
electro-injectors.
Threaded parts
unions) (1) 2. Step 2 - Angle tightening
6. Unscrew the screws (1) and remove the common rail (3),
together with the engine cable retainer plate (2), from the
intake manifold(4).
Threaded parts
Common Rail (3 M8x1.25x125 screws) (1)
229420 Figure 64
P2D32N029E0115
Removal - refitting of the EDC 17 control unit
.774510. Refitting
7. Fit the common rail (3), together with the engine cable retainer
plate (2), on the intake manifold (4) and tighten the fastening
screws(1) to a torque of:
tightening torque
Common Rail (3 M8x1.25x125 36 5 Nm
screws) (1)
229420 Figure 65
8. Connect the fuel delivery pipes to the electro-injectors to the

common rail (2) and tighten the unions (1) to a torque of:
tightening torque
unions) (1) 10 Nm
55
9. Connect the fuel delivery pipe from the high pressure pump to
the common rail (2) and tighten the union (4) to a torque of:
tightening torque
Pipe delivering fuel from the 1. Step 1 - Tightening with torque 229419 Figure 66
unions) (4) 10 Nm
55
10. Connect the low pressure fuel return pipe (3) from the rail to
the common rail (2).
11. Connect the connector to the rail pressure sensor(5) and com-
plete the connection of the engine cable as described in the
relative procedure Engine cable removal-refitting ( Page 11).
.766161. Removal - refitting of the EDC 17 control unit
Tightening torques
Control unit with fuel heat exchanger (3 M8x1.25x45 screws) 14 Nm
P2D32N029E0115
Main action
.766161. Removal
227107 Figure 67
2. Disconnect the engine cable connector (1) from the engine

control unit (2).
3. Act on the quick connection (5) and disconnect the low pres-
sure fuel pipe that connects the heat exchanger of the engine
control unit (2) to the high pressure pump.
4. Disconnect the in-line engine cable connector (6) from the
engine control unit fastening bracket (2).
229421 Figure 68
5. Unscrew the fastening screws (2) and remove the engine elec-
tronic control unit (1) together with the heat exchanger.
Threaded parts
Control unit with fuel heat exchanger (3 M8x1.25x45 screws) (2)
229422 Figure 69
P2D32N029E0115
.766161. Refitting
6. Fit the engine control unit (1) including the heat exchanger, on
the crankcase and tighten the fastening screws (2) to a torque
of:
tightening torque
Control unit with fuel heat ex- 14 Nm
changer (3 M8x1.25x45 screws) (2)
Note It is recommended that the supporting elastic parts are

replaced
229422 Figure 70
7. To connect the low pressure fuel pipe to the connection fitting,

insert the quick-fit coupling (1) into the connection fitting and
push in until the catch (2) engages.
227108 Figure 71
8. Connect the in-line engine cable connector (6) to the engine

control unit fastening bracket (2).
9. Connect the low pressure fuel pipe (4) that connects the heat
exchanger of the engine control unit (2) to the high pressure
pump using a quick connection (5).
10. Connect the engine cable connector (1) to the engine control
unit (2).
229421 Figure 72
P2D32N029E0115
Removal - refitting the tappet cover
.540630. Removal - refitting the tappet cover
Tightening torques
Tappet cover (4 M8x1.25 flanged nuts) 24 4 Nm
Dual threaded shank screws fastening the tappet cover (4 M8x1.25 dual threaded shank 11 3 Nm
screws)
Preliminary actions
Remove the oil vapour recirculation system .(Blow-by) ( Page 39)
Main action
.540630. Removal
1. Unscrew the flanged nuts (2), recover the elastic inserts (1)
and remove the tappet cover (5) together with the engine
lubricant filler cap (6) from the mount for the electro-injector
wiring, recovering the relative gasket (3).
Threaded parts
Tappet cover (4 M8x1.25 flanged nuts) (2)
2. Unscrew the screws with a dual threaded shank (4) from the
electro-injector wiring mount.
Threaded parts
Dual threaded shank screws fastening the tappet cover (4 M8x1.25 dual
threaded shank screws) (4)
225906 Figure 73
.540630. Refitting
3. Screw the dual threaded shank screws (4) onto the electro-
injector wiring mount.
tightening torque
Dual threaded shank screws fasten- 11 3 Nm
ing the tappet cover (4 M8x1.25
dual threaded shank screws) (4)
4. Place a new gasket (3) on the tappet cover (5).

5. Restore the engine lubricant filler cap (6).
6. Fit the tappet cover (5) on the electro-injector wiring mount,
position the elastic inserts (1), tighten the flanged nuts (2) and
tighten them to a torque of:
tightening torque
Tappet cover (4 M8x1.25 flanged 24 4 Nm 225906 Figure 74
nuts) (2)
P2D32N029E0115
Removal - refitting of the oil vapour recirculation system (blow-by)
Next actions
Refit the oil vapour recirculation system .(Blow-by) ( Page 39)
.540480. Removal - refitting of the oil vapour recirculation system (blow-by)
Tightening torques
Oil vapour breather pipe (1 M6x1 screw) 10 2 Nm
Oil vapour recirculation pipe (2 M12x1.5 screws) 20 4 Nm
Blow-by filter (3 screws M6x1) 10 2 Nm
Main action
.540480. Removal
1. Position a suitable container to collect the oil. Unscrew the
fastening screw (1), loosen the clips (4) and remove the
breather pipe (3).
Threaded parts
Oil vapour breather pipe (1 M6x1 screw) (1)
2. Unscrew the unions (2, 6) and remove the oil vapour recircula-
tion pipe (5).
Threaded parts
Oil vapour recirculation pipe (2 M12x1.5 screws) (2, 6)
3. Unscrew the fastening screws (8) and remove the blow-by

filter (7) from the flywheel housing.
Blow-by filter (3 screws M6x1) (8)
.540480. Refitting
4. Fit the blow-by filter (7) in position on the flywheel housing and
tighten the fastening screws (8) to the specified torque.
tightening torque
Blow-by filter (3 screws M6x1) (8) 10 2 Nm
5. Install the oil vapour recirculation pipe (5) and tighten the uni-
ons (2, 6) to the specified torque.
tightening torque
Oil vapour recirculation pipe (2 20 4 Nm
M12x1.5 screws) (2, 6)
6. Insert the vapour breather pipe (3) in the union located on

the timing gear case and fasten it with the clips (4). Tighten the
screw (1) fastening the tappet cover to the specified torque.
225899 Figure 76
P2D32N029E0115
Removal - refitting the electro-injector wirings
tightening torque
Oil vapour breather pipe (1 M6x1 10 2 Nm
screw) (1)
225899 Figure 76
.769142. Removal - refitting the electro-injector wirings
Work material
Torque screwdriver (1-6 Nm) for adjusting the locking 99389834
nut of the injector solenoid valve connectors
Tightening torques
Electro-injector wiring (8 M4 nuts) 1.5 0.25 Nm
Electro-injector wiring support 1. (3 screws M8x1.25x70) 24 4 Nm
2. (2 screws M8x1.25x50) 24 4 Nm
Electro-injector wiring connectors (2 M6x1x16 screws) 10 2 Nm
Preliminary actions
Remove the tappet cover. ( Page 38)
Main action
.769142. Removal
1. Remove the nuts (2) and disconnect the electrical cables from
the electro-injectors (3).
Threaded parts
Electro-injector wiring (8 M4 nuts) (2)
2. Remove the screws (1, 5) and disconnect the electro-injector

wiring mount (4) together with the gasket from the cylinder
head.
Threaded parts
Electro-injector wiring sup- 1. (3 screws M8x1.25x70)
port (1, 5) 2. (2 screws M8x1.25x50)
229423 Figure 77
P2D32N029E0115
Removal - refitting the electro-injector wirings
3. Cut straps fastening wiring harness (1) to support (4).

4. Unscrew the screws (2) fastening the connectors (3) and re-
move the wiring (1) from the mount (4).
Threaded parts
Electro-injector wiring connectors (2 M6x1x16 screws) (2)
227097 Figure 78
.769142. Refitting
5. Install the wiring (1) on the mount (4).
6. Tighten the screws (2) fastening the connectors (3) to a torque
of:
tightening torque
Electro-injector wiring connectors 10 2 Nm
(2 M6x1x16 screws) (2)
7. Use the clips to bind the wiring (1) to the mount (4).
227097 Figure 79
8. Install the electro-injector wiring mount (4) together with

a new gasket on the cylinder head and tighten the fastening
screws(1, 5) to a torque of:
tightening torque
port (1, 5) 24 4 Nm
2. (2 screws M8x1.25x50)
24 4 Nm
9. Connect the electrical cables to the electro-injectors (3) and

tighten the fastening nuts (2) to a torque of:
tightening torque
Electro-injector wiring (8 M4 1.5 0.25 Nm 229423 Figure 80
nuts) (2)

code
Torque screwdriver (1-6 Nm) for adjusting the locking nut 99389834
of the injector solenoid valve connectors
P2D32N029E0115
Removal - refitting of the electro-injectors
Next actions
Refit the tappet cover. ( Page 38)
.775010. Removal - refitting of the electro-injectors
Consumables
Vaseline
Work material
Extraction tool for injectors 99342101
Torque wrench
Tightening torques
Electro-injector brackets (8 M6x1x35 screws) 1. Step 1 - Tightening with 3.5 0.35 Nm
torque wrench to torque
Fuel manifolds for electro-injectors on the cylinder head (4 M22x1.5x9.5 nuts) 55 5 Nm
Preliminary actions
1. Remove the engine cable. ( Page 11)
2. Remove the electro-injector wiring. ( Page 40)
3. Remove the rocker assembly. ( Page 46)
4. Remove the intake manifold. ( Page 51)
Main action
.775010. Removal
1. Remove the screws (1) and disconnect the mount (2) fastening
Threaded parts
Electro-injector brackets (8 1. Step 1 - Tightening with torque
M6x1x35 screws) (1) wrench to torque
2. Remove the nuts (5) and extract the fuel manifolds (6) from
the cylinder head.
Threaded parts
Fuel manifolds for electro-injectors on the cylinder head (4 M22x1.5x9.5 225910 Figure 81
nuts) (5)
P2D32N029E0115
Note Disassembled fuel manifolds (6) must not be used

again, but replaced with other new ones.
To make it easier to disassemble the fuel manifolds (6)
unscrew the screws (4) and remove the lifting eyelet
(3). When removal is complete, refit the removed
lifting eyelet needed for hoisting the cylinder head.
3. After removing the brackets fastening the electro-injectors

using the specific tool (1) remove the electro-injectors (2)
from the cylinder head (3).
code
225911 Figure 82
.775010. Refitting
4. Fit both a new sealing ring (2) lubricated with Vaseline and a
new sealing washer (3) on the electro-injector (1).
Tool / Material
Vaseline
70338 Figure 83
5. Fit the electro-injectors (1) on the cylinder head seats, directed

so that the fuel inlet hole (2) is facing the fuel manifold seat (3)
side.
6. Position the electro-injector fastening brackets (1) and screw in
the screws without tightening them.
227355 Figure 84
P2D32N029E0115
7. Fit a new sealing ring (4) lubricated with Vaseline on the fuel
manifold (5) and fit it into the cylinder head seat so that the
positioning balls (3) coincide with the relevant housing (2).
227356 Figure 85
8. During the operation position the electro-injector (1) so that

the fuel manifold is inserted correctly in its fuel inlet hole (2).
70339 Figure 86
9. Tighten the nuts (5) fastening the fuel manifolds (6) without
locking them.
10. Use a torque wrench to gradually and alternatively tighten the
screws (1) of the brackets fastening(2) the electro-injectors
(7) to the tightening torque and angle specified in the relative
table.
tightening torque
3.5 0.35 Nm
25
3. Step 3 - Angle tightening 225910 Figure 87
25
25
Tool / Material
Torque wrench
P2D32N029E0115
Removal - refitting of the rocker arm unit

To make it easier to refit the fuel manifolds (6) un-
screw the screws (4) and remove the lifting eyelet (3).
When refitting is complete, refit the removed lifting
eyelet needed for hoisting the engine.
11. Tighten the nuts (5) securing the fuel manifolds (6) to a torque
of:
tightening torque
Fuel manifolds for electro-injectors 55 5 Nm
on the cylinder head (4
M22x1.5x9.5 nuts) (5)
Next actions
1. Refit the intake manifold. ( Page 51)
2. Refit the rocker arm unit. ( Page 46)
3. Refit the electro-injector wiring. ( Page 41)
4. Refit the engine cable. ( Page 12)
.541230. Removal - refitting of the rocker arm unit
Work material
Pinion (use with 99360221) 99360222
Feeler gauge
Allen key
Box wrench
Tightening torques
Rocker arm unit (8 M8x1.25 screws) 36 5 Nm
Technical data
Preliminary actions
Remove the tappet cover. ( Page 38)
P2D32N029E0115
Main action
.541230. Removal
1. Loosen the tappet adjustment nuts(3) and unscrew the relative
adjustment screws.
2. Remove the screws (4), disassemble the rocker arm unit con-
sisting of: mount (2), rocker arms (1) and spindles (5).
Threaded parts
Rocker arm unit (8 M8x1.25 screws) (4)
225908 Figure 88
3. Remove the push rods (2) from the cylinder head (3) and
remove the valve control bridges (1).
225909 Figure 89
.541230. Refitting
4. Insert the push rods(2) in the cylinder head (3).
5. Position the control bridges (1) on valves with marks () facing
the exhaust manifold.
225909 Figure 90
P2D32N029E0115
6. Check that the tappet adjustment nuts (3) and the relative
adjustment screws are loosened to prevent their sticking on
the push rods when refitting the rocker arm unit.
7. On the cylinder head, fit the rocker arm units consisting of:
mount (2), rocker arms (1) and spindles (5).
8. Tighten the screws(4) fastening the rocker arm units to the
cylinder head to a torque of:
tightening torque
Rocker arm unit (8 M8x1.25 36 5 Nm
screws) (4)
225908 Figure 91
70520 Figure 92
Technical data
very carefully.
P2D32N029E0115
Tool / Material
Box wrench
Tool / Material
Feeler gauge
Tool / Material
Allen key
Tool / Material
Feeler gauge
tightening torque
direction no.
1 and 4 at T.D.C. 4 1
180 2 3
180 1 4
180 3 2
below:

intake * *
exhaust * *
below:

intake * *
exhaust * *
Conditions
P2D32N029E0115
Heater Removal and Refitting
143281 Figure 93
(1).
Pinion (use with 99360221) 99360222
Next actions
Refit the tappet cover. ( Page 38)
.761910. Heater Removal and Refitting
Tightening torques
Heater for cold ignition (6 M6x1x16 screws) 10 2 Nm
P2D32N029E0115
Intake manifold removal-refitting
Main action
.761910. Removal
1. Remove the fastening screws (3) and disconnect the air
heater(2) for cold ignition from the intake manifold, recovering
the relative gasket (1).
Threaded parts
Heater for cold ignition (6 M6x1x16 screws) (3)
225896 Figure 94
.761910. Refitting
2. Fit the cover (2) or air heater for cold ignition (if present), to-
gether with a new gasket (1), in the seat of the intake manifold
and tighten the fastening screws (3) to a torque of:
tightening torque
Heater for cold ignition (6 10 2 Nm
M6x1x16 screws) (3)
225896 Figure 95
.540710. Intake manifold removal-refitting
Consumables
LOCTITE 5970
Tightening torques
Air temperature and pressure sensor (1 M6x1x20 screw) 10 2 Nm
Intake manifold 1. (1 M8x1.25x70 screw) 24 4 Nm
2. (6 screw M8x1.25x25) 24 4 Nm
Preliminary actions
1. Remove heater. ( Page 50)
2. Remove the common rail. ( Page 34)
P2D32N029E0115
Intake manifold removal-refitting
Main action
.540710. Removal
1. Remove the screw (2) and disassemble the air pressure and
temperature sensor (3) housed in the intake manifold (4).
Threaded parts
Air temperature and pressure sensor (1 M6x1x20 screw) (2)
2. Remove the screws (1, 5) and disconnect the intake manifold

(4) from the cylinder head.
Threaded parts
Intake manifold (1, 5) 1. (1 M8x1.25x70 screw)
2. (6 screw M8x1.25x25)
225897 Figure 96
.540710. Refitting
3. The figure indicates the "INTAKE MANIFOLD SEALANT AP-
PLICATION DIAGRAM".
4. Carefully clean the intake manifold and the cylinder head (2).
5. Perfect seal is only obtained by cleaning accurately the surface
to seal.
6. Apply the specified sealant on the intake manifold in order to
form a seam (1) with a diameter of a few mm.
Tool / Material
LOCTITE 5970
7. Application must be uniform (no lumps), without any air

bubbles, thin areas or gaps.
8. Any flaws must be corrected in as short a time as possible.
9. Avoid using too much material to seal the joint.
227358 Figure 97
10. Excess sealant will come out on both sides of the joint with the
risk of clogging.
11. After applying the sealant, the joint shall be assembled immedi-
ately (max. 10 minutes).
12. Fit the intake manifold (4) on the cylinder head and tighten the
fastening screws (1, 5) to the specified torque:
tightening torque
24 4 Nm
2. (6 screw M8x1.25x25)
24 4 Nm
13. Fit the air pressure and temperature sensor (3) housed in the
intake manifold (4) and tighten the screw (2) to the specified
torque.
225897 Figure 98
P2D32N029E0115
Exhaust manifold removal-refitting
tightening torque
Air temperature and pressure 10 2 Nm
sensor (1 M6x1x20 screw) (2)
225897 Figure 98
Next actions
1. Refit the common rail. ( Page 35)
2. Refit the vehicle heater. ( Page 50)
.540720. Exhaust manifold removal-refitting
Tightening torques
Exhaust manifold (8 screws M10x1.5x65) 55 3 Nm
Preliminary actions
Remove the turbocharger. ( Page 15)
Main action
.540720. Removal
1. Remove the screws (3, 4) recovering the spacers (2) and dis-
connect the exhaust manifold (5) together with the relative
gaskets (6) from the cylinder head (1).
Threaded parts
Exhaust manifold (8 screws M10x1.5x65) (3, 4)
225898 Figure 99
P2D32N029E0115
Cylinder head removal-refitting
.540720. Refitting
2. Fit the exhaust manifold (5) in position together with the new
gaskets (6) on the cylinder head (1) and tighten the fastening
screws (3, 4) together with the spacers (2) to the specified
torque, following the tightening order and methods shown in
tightening torque
Exhaust manifold (8 screws 55 3 Nm
M10x1.5x65) (3, 4)
Note Always replace the gaskets (6) with new spare parts.
Check the thread of the fastening screws: it must not
show signs of wear or deposits of dirt.
225898 Figure 100
3. Diagram of tightening sequence for exhaust manifold fastening

screws.
Note A = Front side
200095 Figure 101
Next actions
Refit the turbocharger. ( Page 17)
.540610. Cylinder head removal-refitting
Work material
Arm for engine removal and refitting 99360595
Set of gauges for angle tightening with square connection 99395216
- 1/2" and 3/4"
Torque wrench
Tightening torques
Cylinder head 1. Step 1 - (8 M12x1.75x130 35 5 Nm
screws )
2. Step 1 - (10 55 5 Nm
M12x1.75x150 screws )
P2D32N029E0115
Preliminary actions
1. Remove the engine cable. ( Page 11)
2. Remove the thermostat. ( Page 9)
3. Remove the fuel pipes. ( Page 24)
4. Remove the common rail. ( Page 34)
5. Remove the rocker assembly. ( Page 46)
6. Remove the electro-injectors. ( Page 42)
7. Remove the exhaust manifold. ( Page 52)
8. Remove the intake manifold. ( Page 51)
Main action
.540610. Removal
1. Remove the cylinder head (3) fastening screws (1, 2).
Threaded parts
Cylinder head (1, 2) 1. Step 1 - (8 M12x1.75x130 screws
)
2. Step 1 - (10 M12x1.75x150 screws
)
225912 Figure 102
Caution!
Engine lifting Lift the engine only by using the specific tool for engine removal and refitting and the specific lifting eye-
lets.
The only method recommended for lifting the engine consists in using the specific tool for engine removal and re-
fitting and the specific lifting eyelets provided together with it. As the tool is adjustable, make sure that the lifting
points keep the engine balanced, as shown in the figure. Use a hoist to lift the engine slowly with a longitudinal load,
as an angular load considerably reduces the lifting capacity.
Handle all the parts with great care. Never place hands or fingers between parts. Wear suitable personal protective
equipment such as a visor, gloves and safety shoes.
2. Hook the lifting eyelets (1, 3) with metal cables or by means

of the specific tool (2) and use the lifting device to detach the
cylinder head (6) from the crankcase (5).
code
3. Recover the cylinder head gasket (4) from the crankcase (5).
225913 Figure 103
P2D32N029E0115
.540610. Refitting
4. Check that the mating surfaces of the cylinder head and crank-
case are clean.
5. There are two types of cylinder head gaskets (2):

Type A is 1.25 mm thick
Type B is 1.15 mm thick
6. Check the average protrusion S of the pistons as indicated in

the relative procedure. If S > 0.40 mm use the type A gasket. If
S 0.40 mm use the type B gasket.
7. Keep the cylinder head gasket (2) clean.
8. Fit the cylinder head gasket (2) with the marking ALTO facing
the head itself.
9. Pay attention to the cable reference dowels (1, 3) present on 227353 Figure 104
the surface of the crankcase.
10. The thickness of the cylinder head gasket (2) is indicated on the
tab (4).
11. After correctly positioning the cylinder head gasket (4) on the
crankcase (5) hook the lifting eyelets (1, 3) using metal ropes
or by means of the specific tool (2) and use the lifting device to
place the cylinder head (6) on the crankcase (5).
code
Note If the valves were removed from the cylinder head,

refit them before installing the cylinder head on the
crankcase.
225913 Figure 105
Conditions
In case of re-use of the cylinder head fastening screws:
perform two measurements of the diameter of the fasten-

ing screws as shown in the figure, measuring diameters D1
and D2: if D1-D2 <0.1 mm the screw can be reused; if
D1-D2 >0.1 mm the screw must be replaced.
75703 Figure 106
P2D32N029E0115
12. After fitting the cylinder head (4), screw in the fixing screws
(1, 3) and tighten them in three stages, following the order and
methods shown in the following figure.
tightening torque
)
35 5 Nm
2. Step 1 - (10 M12x1.75x150 screws
)
55 5 Nm
90
90

code
Set of gauges for angle tightening with square connection - 99395216
1/2" and 3/4"
Note The screws (1, 3) must be lubricated prior to the as-

sembly of the cylinder head (4).
Note Use specific tool (2) for angle tightening.

dirt.
13. Diagram of the tightening sequence for the cylinder head fixing
screws:
Tool / Material
Torque wrench
Note The screws must be tightened following a "spiral" se-

quence, starting from the centre and proceeding out- 203452 Figure 108
ward.
Next actions
1. Refit the intake manifold. ( Page 51)
2. Refit the exhaust manifold. ( Page 53)
3. Refit the electro-injectors. ( Page 43)
4. Refit the rocker arm unit. ( Page 46)
5. Refit the common rail. ( Page 35)
6. Refit the fuel pipes. ( Page 26)
7. Refit the thermostat. ( Page 9)
8. Refit the engine cable. ( Page 12)
P2D32N029E0115
Removal - refitting of the crankshaft drive pulley
.540821. Removal - refitting of the crankshaft drive pulley
Work material
- 1/2" and 3/4"
Torque wrench
Tightening torques
Crankshaft pulley (6 M12x1.25x78.5 screws) 1. Step 1 - Tightening with 50 5 Nm
Preliminary actions
Main action
.540821. Removal
1. Unscrew the fastening screws (3), recover the spacer (4) and
remove the crankshaft pulley (2) from the crankshaft (1).
Threaded parts
Crankshaft pulley (6 1. Step 1 - Tightening with torque
M12x1.25x78.5 screws) (3) wrench to torque
225905 Figure 109
.540821. Refitting
2. Fit the spacer(4) and the crankshaft pulley (2) on the crank-
shaft (1), screw on the fastening screws (3) and tighten them in
two steps:
tightening torque
50 5 Nm
90

code
225905 Figure 110
1/2" and 3/4"
Torque wrench
P2D32N029E0115
Removal - refitting of the crankshaft front cover seal ring
Note Use specific tool for angle tightening.
Note The flywheel clamping tool can make it easier to install

the crankshaft pulley.
225905 Figure 110
Next actions
.540442. Removal - refitting of the crankshaft front cover seal ring
Work material
Extraction tool for crankshaft front ring seal 99340055
Key to fit crankshaft front gasket 99346252
Extraction tool for gaskets 99363204
Technical data
Depth 5 mm
Preliminary actions
Remove the crankshaft drive pulley. ( Page 57)
P2D32N029E0115
Main action
.540442. Removal
1. Apply specific tool (4) to rear crankshaft tang (2) and perforate
the internal seal ring (1) using a drill bit ( 3,5 mm) through
the template holes of the tool at a depth of:
Technical data
Depth 5 mm

code
2. Fasten the tool (4) to the inner seal ring (1) by screwing the
6 provided screws (5). Proceed with the removal of the inner
seal ring (1) by tightening the screw (3).
227348 Figure 111
P2D32N029E0115
3. Use a tie rod (3) for the specific tool and a lever (4) to remove
the external seal ring (2) from the front cover (1).
code
225918 Figure 112
.540442. Refitting
4. Apply the part (1) of the special tool to the front crankshaft
tang (7) securing it with the screws (6) and keying it onto the
new sealing ring (5).
code
5. Position part (2) on part (1), tighten the nut (3) on the screw
(4) until the crankshaft sealing ring is completely installed (5) in
the front cover .
227351 Figure 113
Next actions
Refit the crankshaft drive pulley. ( Page 57)
P2D32N029E0115
Removal - refitting of the engine flywheel
.540850. Removal - refitting of the engine flywheel
Work material
Tool for retaining the flywheel 99360351
Torque wrench
Tightening torques
Engine flywheel (8 M12x1.25 screws) 1. Step 1 - Tightening with 30 4 Nm
Main action
.540850. Removal of engine flywheel
1. Apply the specific tool to the flywheel housing to stop the fly-
wheel (3) rotation.
code
Note Use the tool with the screw in the central position with
wheelbase M8
2. Unscrew two opposite screws (2) fastening the engine flywheel
(3) to the crankshaft (4). Insert two extraction pins of an ap-
propriate length in the holes of the crankshaft (see the following
figure).
3. Loosen the remaining screws (1) fastening the engine flywheel 225921 Figure 114
(3) to the crankshaft (4) and remove the specific flywheel
locking tool.
Threaded parts
Engine flywheel (8 M12x1.25 1. Step 1 - Tightening with torque
screws) (1, 2) wrench to torque
P2D32N029E0115
Removal - refitting of the engine flywheel
4. Tighten two lifting eyelets (1, 2) of an appropriate length in

the holes of the engine flywheel (5) in order to sling it with the
lifting device.
5. Control the extraction of the engine flywheel (5) through the
two guide pins (4) that were previously screwed into the holes
of the crankshaft (3).
225922 Figure 115
.540850. Refitting engine flywheel

lifting device.
7. Screw two guide pins (4) of a suitable length into the crankshaft
holes (3) and fit the engine flywheel (5) using the designated
sling and lifting device.
225922 Figure 116
8. Tighten the screws (1) fastening the engine flywheel (3) to the
crankshaft (4).
9. Remove the guide pins and the lifting eyelet from the engine fly-
wheel (3) (see the previous figure). Tighten the missing fasten-
ing screws (2) to the crankshaft (4).
10. Apply the specific tool to the flywheel housing to stop the en-
gine flywheel (3) rotation.
code
wheelbase M8
225921 Figure 117
11. Tighten the screws (1, 2) retaining the flywheel (3) in two
steps:
P2D32N029E0115
Removal - refitting of the crankshaft rear seal ring
tightening torque
30 4 Nm
60
Tool / Material
Torque wrench
Note Tightening to angle is performed using tool 99395216.

Before each assembly operation, check that the thread
dirt.
.540462. Removal - refitting of the crankshaft rear seal ring
Work material
Extraction tool for crankshaft rear gasket 99340056
Key to fit crankshaft rear gasket 99346253
Preliminary actions
Remove the engine flywheel. ( Page 61)
P2D32N029E0115
Main action
.540462. Removal
1. Apply specific tool (3) to the rear crankshaft tang (5) and per-
forate the internal seal ring (1) using a drill bit ( 3,5 mm) at
a depth of 5 mm through the template holes of the tool.
code
227349 Figure 118
P2D32N029E0115
the external seal ring (2) from the flywheel housing (4).
code
225924 Figure 119
.540462. Refitting
4. Apply the part (2) of the special tool to the rear crankshaft tang
(3) securing it with two screws (5) and fit the new sealing ring
(4).
code
5. Position part (7) on part (2) tighten the nut (1) on screw (6)
until the sealing ring (4) is completely installed in the flywheel
housing .
227350 Figure 120
Next actions
Refit the engine flywheel. ( Page 62)
P2D32N029E0115
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV General mechanical overhaul
Contents 1
Contents
General mechanical overhaul . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
Contents
Contents
General mechanical overhaul of the engine on the

bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
P2D32N029E0115
4 General mechanical overhaul
P2D32N029E0115
General mechanical overhaul of the engine on the bench
General mechanical overhaul

.540110. General mechanical overhaul of the engine on the bench
Consumables
Vaseline
LOCTITE 5205 SEALANT
LOCTITE 5970
Work material
Equipment for checking spring load 99305047
Assembly rotating stand for overhaul (load bearing capa- 99322205
city 1000 daN, torque 120 daNm)
Dual-actuated bridge 99341001
Bracket torque 99341009
Clamp 99341015
Pliers for piston rings removal/refitting (65-110 mm) 99360183
Pinion (use with 99360221) 99360222
Tool to take down and fit back engine valves 99360268
Drift tool for removing/fitting camshaft bush (to be used 99360362
with 99370006)
Crankshaft lifting tool 99360500
Clamp for fitting piston into cylinder liner (60 - 125 mm) 99360605
Brackets for fastening engine to 99322205 rotary stand 99361037
Manual pump for measuring pressure and vacuum 99367121
Grip for inter-changeable drifts 99370006
Dial gauge base to adjust lay shaft bearings (use with 99370415
99395603)
Torque screwdriver (1-6 Nm) for adjusting the locking 99389834
nut of the injector solenoid valve connectors
- 1/2" and 3/4"
Dial gauge (0-5 mm) 99395603
P2D32N029E0115
Bore gauge
Reamer
Drift
Feeler gauge
Allen key
Torque wrench
Box wrench
Dial gauge
Magnetic dial gauge
Centesimal dial gauge
Micrometer
Grinder
Ruler
Metal brush
Tightening torques
Starter motor 1. (3 M10x1.5 nuts) 43 6 Nm
2. (3 M10x1.5x50 studs) 25 5 Nm
Bracket retaining the electric actuator coolant return 1. (1 M12x1.75x25 screw) 48 5 Nm
pipe 2. (1 M6x1x16 screw) 9.5 1 Nm
Alternator and fastening bracket 1. (1 M10x1.5x30 screw) 43 6 Nm
2. (1 M10x1.5x20 screw) 43 6 Nm
3. (1 M10x1.5x110 screw) 43 6 Nm
Automatic belt tensioner mount (2 M8x1.25x30 screws) 24 4 Nm
Lower part of the electric actuator coolant return 1. (1 M10x1 fitting) 20 Nm
Electric actuator coolant return pipe joint (2 screws M8x1.25x20) 23 2 Nm
Bracket retaining the electric actuator coolant return (1 M10 nut) 20 Nm
pipe
Coolant delivery pipe to the electric actuator 1. (1 M10x1 fitting) 20 Nm
2. (1 M12x1.5 nut) 45 Nm
Turbocharger on the exhaust manifold 1. (4 M8x1.25 nuts) 24 4 Nm
2. (4 M8x1.25x40 studs) 11 3 Nm
P2D32N029E0115
Power-take off seat cover (2 M12x1.75x25 screws) 80 5 Nm
Camshaft timing sensor (1 M6x1 nut) 10 2 Nm
High pressure fuel injection pump 1. (3 M8 nuts) 24 4 Nm
2. (3 M8x1.25x50 studs) 11 3 Nm
Crankcase cover (2 M8x1.25x20 screws) 24 4 Nm
Intake manifold 1. (1 M8x1.25x70 screw) 24 4 Nm
2. (6 screw M8x1.25x25) 24 4 Nm
Coolant temperature sensor (1 M14x1.5x12 union) 24 4 Nm
Fan drive pulley (4 M10x1.5x25 screws) 68 7 Nm
Fan drive pulley mount (4 M8x1.25x45 screws) 24 4 Nm
Alternator support and engine coolant inlet pipe 1. (1 M10x1.5x70 screw) 43 6 Nm
2. (2 screws M10x1.5x130) 43 6 Nm
Guide pulley (1 M10x1.5 screw) 43 6 Nm
Crankshaft speed sensor (1 M6x1x20 screw) 10 2 Nm
Crankshaft pulley (6 M12x1.25x78.5 screws) 1. Step 1 - Tightening with 50 5 Nm
Dual threaded shank screws fastening the tappet cover (4 M8x1.25 dual threaded shank 11 3 Nm
screws)
Electro-injector wiring support 1. (3 screws M8x1.25x70) 24 4 Nm
2. (2 screws M8x1.25x50) 24 4 Nm
Electro-injector brackets (8 M6x1x35 screws) 1. Step 1 - Tightening with 3.5 0.35 Nm
Fuel manifolds for electro-injectors on the cylinder head (4 M22x1.5x9.5 nuts) 55 5 Nm
Cylinder head 1. Step 1 - (8 M12x1.75x130 35 5 Nm
screws )
P2D32N029E0115
Cylinder head 2. Step 1 - (10 55 5 Nm

M12x1.75x150 screws )
Engine oil sump 1. (22 screws) 24 4 Nm
2. (2 screws) 24 4 Nm
Bracket retaining the suction strainer in the sump (1 M10x1.5x25 screw) 43 5 Nm
Oil intake suction strainer in the sump (2 M8x1.25x20 screws) 24 4 Nm
Additional masses (8 M10x1.5 screws) 48 8 Nm
Front cover 1. (5 screws M8x1.25x45) 24 4 Nm
2. (8 screws M8x1.25x30) 24 4 Nm
Oil pump (4 M8x1.25 screws) 1. Step 1 - pretightening with 8 1 Nm
the torque wrench
2. Step 2 - Tightening with 24 4 Nm
Engine flywheel (8 M12x1.25 screws) 1. Step 1 - Tightening with 30 4 Nm
Flywheel housing 1. (8 M12x1.75 screws) 85 10 Nm
2. (12 M10x1.5 screws) 49 5 Nm
Timing gear (6 M8x1.25 screws) 36 2 Nm
Rear gear case 1. (1 M12x1.75 screw) 77 12 Nm
2. (4 M8x1.25 screws) 24 4 Nm
3. (5 M10x1.5 screws) 47 5 Nm
Crankshaft connecting rod caps(8 M10x1.25x52 1. Step 1 - Tightening with 50 5 Nm
screws) torque wrench to torque
Crankshaft main bearing caps (10 M12x1.5 screws) 1. Step 1 - Tightening with 80 6 Nm
Oil sprayers for piston cooling (4 M8x1 25x20 unions) 15 3 Nm
Camshaft longitudinal retaining plate (2 M8x1.25 screws) 24 4 Nm
High pressure pump gear (1 M18x1.5 nut) 105 5 Nm
Pressure sensor on RDS4 rail (1 M18x1.5 screw) 70 5 Nm
Pressure relief valve on rail DBV4 (1 M20x1.5 screw) 100 5 Nm
Technical data
Planarity error 0.075 mm
Cylinder head maximum deformation 0.20 mm
Thickness B maximum allowance 0.13 mm
Nominal thickness A 105 0.25 mm
P2D32N029E0115
Maximum valve centring error 0.03 mm

Assembly clearance 0.032 mm to0.072 mm
Valve stem measurement 6.990 mm to7.010 mm
Connecting rod axial clearance 0.10 mm to0.33 mm
Inside diameter of roller 0.250 mm to0.500 mm
Difference between A and B 0.08 mm
Maximum difference between point C and D 0.08 mm
Split ring opening discrepancy 120
Piston protrusion 0.28 mm to0.52 mm
Intake cam lift 7.582 mm
Exhaust cam lift 6.045 mm
Alignment error 0.04 mm
Camshaft axial clearance 0.23 0.13 mm
Water pressure 2 bar to3 bar
Gear heating temperature 180
Ring gear heating temperature 150
Main action
.540110. DISASSEMBLING THE ENGINE
.542010. Fuel filter removal
1. To apply to the engine block the brackets for fastening the
engine to the overhaul stand, proceed as follows working from
the left side of the engine:
code
2. Position a suitable container to collect any fuel which may leak

out.
3. Use a specific tool to remove the fuel filter (3) from the mount
(1), recovering the relative gasket (2).
Threaded parts
225876 Figure 1

code
P2D32N029E0115
.542014. Removal of the fuel filter mount

4. Disconnect the low pressure fuel pipes (1,3,4,6) from the fuel
filter mount (5).
5. Disconnect the electrical connections of the fuel temperature
Threaded parts
Fuel temperature sensor (1 M14x1.5x12 union) (8)
6. Unscrew the fastening screws (7) and remove the fuel filter
cover (5) from the crankcase.
Threaded parts
Fuel filter mount (2 M12x1.75x30 screws) (7)
225877 Figure 2

116237 Figure 3
.760810. Removal of the electric starter motor

8. Make sure that the electric starter motor (2) is sufficiently sup-
ported. Unscrew the fastening nuts (4) and remove the electric
starter motor (2). Unscrew the studs (1) from the flywheel
housing (3).
Threaded parts
2. (3 M10x1.5x50 studs)
225878 Figure 4
P2D32N029E0115
.543740. Removal of the throttle valve cooling pipe re-

taining bracket
9. Unscrew the fastening screws (1, 3) and remove the throttle
valve cooling pipe retaining bracket (2).
Threaded parts
Bracket retaining the elec- 1. (1 M12x1.75x25 screw)
tric actuator coolant return
2. (1 M6x1x16 screw)
pipe (1, 3)
225879 Figure 5
P2D32N029E0115
225718 Figure 6
.769140. Engine cable removal

10. Remove the engine cable by disconnecting the connectors from the control unit (7), from the motorised throttle valve actu-
ator connector (2) and from all sensors and transmitters with which it is connected.
11. To remove the engine cable (6) open the clips (2,4) fastening
the engine cable to the crankcase, to the intake manifold and to
the tappet cover, unscrewing the relative nuts (3,5).
225881 Figure 7
P2D32N029E0115
.540110. Assembly on the stand and draining of the engine lubricant

Caution!
Engine lifting Lift the engine only by using the specific tool for engine removal and refitting and the specific lifting eye-
lets.
The only method recommended for lifting the engine consists in using the specific tool for engine removal and re-
fitting and the specific lifting eyelets provided together with it. As the tool is adjustable, make sure that the lifting
points keep the engine balanced, as shown in the figure. Use a hoist to lift the engine slowly with a longitudinal load,
as an angular load considerably reduces the lifting capacity.
Handle all the parts with great care. Never place hands or fingers between parts. Wear suitable personal protective
equipment such as a visor, gloves and safety shoes.
225880 Figure 8
12. Fit the brackets to the crankcase (1,5) and use these to secure the engine to the rotating stand (3).
P2D32N029E0115
225880 Figure 8

Assembly rotating stand for overhaul (load bearing capacity 1000 daN, torque 120 daNm) 99322205
13. Drain the lubricant from the engine by removing the plug (4) from the oil sump.
Threaded parts
Lubricant drain plug on the sump (1 M22x1.5 plug) (4)
P2D32N029E0115
.766161. Removal of the EDC17CV41 control unit

14. Remove the screws (2) and disconnect the electronic control
unit (1) together with the heat exchanger.
Threaded parts
Control unit with fuel heat exchanger (3 M8x1.25x45 screws) (2)
225882 Figure 9
.543411. Water pump drive belt/alternator disassembly

Caution!
Spring belt Precaution during disassembly
The flexible belt must be replaced with a new one every time it is removed from the vehicle.
15. Using the appropriate tool (4), act on the automatic belt ten-
sioner (1) and remove the water pump drive belt (3), altern-
ator and fan pulley.
16. Unscrew the fastening screw (2) and remove the automatic
belt tensioner (1).
225883 Figure 10
.760310. Alternator removal

17. Remove the fastening screws (1,4,5) and disconnect the altern-
ator (6) with the relative support bracket.
Threaded parts
bracket (1, 4, 5) 2. (1 M10x1.5x20 screw)
3. (1 M10x1.5x110 screw)
18. Unscrew the fastening screws (2) and remove the automatic
belt tensioner mount (3).
Threaded parts
Automatic belt tensioner mount (2 M8x1.25x30 screws) (2)
225884 Figure 11
P2D32N029E0115
.543070. Oil filter removal

19. Use a specific tool to remove the oil filter (3) from the mount
(1), recovering the relative gasket (2).
Threaded parts

code
225885 Figure 12
.542430. Removal of the turbocharger oil pipes

20. Unscrew the unions (1,3) and remove the lubricant delivery
pipe (2) to the turbocharger.
Threaded parts
Lubricant delivery pipe to turbocharger (2 11/16-16 M16 unions) (1, 3)
225886 Figure 13
P2D32N029E0115
21. Unscrew the screws (1) fastening the lubricant oil return pipe
(2) from the turbocharger.
Threaded parts
Turbocharger lubricant return pipe (2 M8x1.25x25 screws) (1)
22. Unscrew the screw (3) and the nut (5) and disconnect the
bracket (4) retaining the turbocharger oil return pipe (2).
23. Remove the union (6) from the crankcase and remove the
lubricant return pipe (2) from the turbocharger.
225887 Figure 14
P2D32N029E0115
.543760. Removal of the motorised throttle valve (Ex-

haust flap)
24. Position a suitable container to collect the coolant.
25. Unscrew the fastening nut (11) and the union (2) and remove
the upper part of the electric actuator coolant return pipe (4).
Threaded parts
2. (1 M12x1.5 nut)
joint (2, 11)
the lower part of the electric actuator coolant return pipe (7).
Threaded parts
Lower part of the electric 1. (1 M10x1 fitting)
2. (1 M12x1.5 nut)
joint (6, 8)
27. Unscrew the fastening screws (5, 10) and remove the joint (9)
of the electric actuator coolant return pipe.
Threaded parts
Electric actuator coolant return pipe (2 screws M8x1.25x20)
joint (5, 10)
28. Unscrew the fastening nut (12) and remove the bracket retain-
ing the electric actuator coolant return pipe .
Threaded parts
Bracket retaining the electric actu- (1 M10 nut)
225888 Figure 15
ator coolant return pipe (12)
the electric actuator coolant delivery pipe (3).
Threaded parts
Coolant delivery pipe to the 1. (1 M10x1 fitting)
electric actuator (1, 13) 2. (1 M12x1.5 nut)
30. The electric connector of the throttle valve was removed previ-
ously together with the engine cable.
31. Unscrew the screw (4) and loosen the V collar (3) fastening
the motorised throttle valve (5).
Threaded parts
screw) (4)
32. Remove the throttle body (5) together with the electric actu-
ator (1) from the turbocharger exhaust (2).
225889 Figure 16
P2D32N029E0115
.542410. Turbocharger removal

33. Unscrew the nuts (1) from the studs (5) and remove the tur-
bocharger (2) from the exhaust manifold (4), recovering the
gasket (3).
34. If necessary, remove the studs (5) from the exhaust manifold
(4) and replace them.
Threaded parts
manifold (1, 5) 2. (4 M8x1.25x40 studs)
225890 Figure 17
.542032. Removal of the fuel delivery and return pipes

from the rail
35. Disconnect the low pressure unions (2,3) from the rail and
from the cylinder head, as shown in the following figure, and
remove the return fuel pipe (4) from the rail and the electro-
injectors.
36. Unscrew the fastening screws (6,8) and remove the brackets
Threaded parts
2. (1 M8x1.25x20 screw)
the rail (6, 8)
37. Unscrew the unions (1,5) and remove the delivery fuel pipe 225891 Figure 18
(7) from the high pressure pump to the rail.
Threaded parts
116237 Figure 19
P2D32N029E0115
.790510. Removal of the air compressor for services and

the timing sensor
39. Remove the screws (1) and disconnect the cover (2) of the
power take-off seat (for example, the air compressor) recover-
ing the relative gasket(3) from the gear case (4).
Threaded parts
Power-take off seat cover (2 M12x1.75x25 screws) (1)
40. Unscrew the nut (5) and remove the timing sensor(6) from
the gear case (4).
Threaded parts
Camshaft timing sensor (1 M6x1 nut) (5)
225892 Figure 20
.771010. Removal of the high pressure fuel pump

41. Unscrew the nuts (1) from the studs (5) and disconnect the
high pressure pump (6) together with the mechanical supply
pump.
Threaded parts
pump (1, 5) 2. (3 M8x1.25x50 studs)

code
Note Place the specific tool on the flywheel housing to block

the flywheel rotation to facilitate the removal of the 225893 Figure 21
high pressure pump. Use the tool with the screw in the
central position with an M8 pitch.
42. Unscrew the retaining screws (3) and remove the cover (2).
Threaded parts
Crankcase cover (2 M8x1.25x20 screws) (3)
.542025. Fuel delivery pipe to injectors removal

43. Disconnect the high pressure fuel delivery pipes (1) acting on
the rail side (3) unions (4) and on the manifold side unions (2)
for electro-injectors.
Threaded parts
225894 Figure 22
P2D32N029E0115
.774510. Removal of the common rail

44. Unscrew the screws (2) and remove the common rail (1) from
the intake manifold (3).
Threaded parts
Common Rail (3 M8x1.25x125 screws) (2)
225895 Figure 23
.761910. Removal of the air heater (Grid heater)

45. Remove the fastening screws (3) and disconnect the air
heater(2) for cold ignition from the intake manifold, recovering
the relative gasket (1).
Threaded parts
Heater for cold ignition (6 M6x1x16 screws) (3)
225896 Figure 24
.540710. Intake manifold removal

46. Remove the screw (2) and disassemble the air pressure and
temperature sensor (3) housed in the intake manifold (4).
Threaded parts
Air temperature and pressure sensor (1 M6x1x20 screw) (2)
47. Remove the screws (1, 5) and disconnect the intake manifold
(4) from the cylinder head.
Threaded parts
2. (6 screw M8x1.25x25)
225897 Figure 25
P2D32N029E0115
.540720. Exhaust manifold removal

48. Remove the screws (3, 4) recovering the spacers (2) and dis-
connect the exhaust manifold (5) together with the relative
gaskets (6) from the cylinder head (1).
Threaded parts
Exhaust manifold (8 screws M10x1.5x65) (3, 4)
225898 Figure 26
.540480. Removal of the blow-by filter and oil vapour re-

circulation pipes
49. Position a suitable container to collect the oil. Unscrew the
fastening screw (1), loosen the clips (4) and remove the
breather pipe (3). Unscrew the unions (2, 6) and remove the
oil vapour recirculation pipe (5).
Threaded parts
Oil vapour recirculation pipe (2 M12x1.5 screws) (2, 6)
50. Unscrew the fastening screws (8) and remove the blow-by
filter (7) from the flywheel housing.
Threaded parts
Blow-by filter (3 screws M6x1) (8)
225899 Figure 27
.543250. Thermostat removal

51. Remove the fastening screws (1) and remove the engine
coolant outlet/thermostat cover(2) and remove the underlying
thermostat (5) together with the gasket from the cylinder head
(4).
Threaded parts
Thermostat cover (3 M6x1x12 screws) (1)
52. Remove the coolant temperature sensor (3) housed in the

cylinder head (4).
Threaded parts
Coolant temperature sensor (1 M14x1.5x12 union) (3)
225900 Figure 28
P2D32N029E0115
.543416. Removal of the fan drive pulley

53. Unscrew the fastening screws (3) and remove the fan drive
pulley (2) from its mount.
Threaded parts
Fan drive pulley (4 M10x1.5x25 screws) (3)
54. Unscrew the fastening screws (1) and remove the fan pulley
mount (4) from the cylinder head.
Threaded parts
Fan drive pulley mount (4 M8x1.25x45 screws) (1)
225901 Figure 29
.544011. Alternator support removal

55. Remove the screws (4) and disconnect the engine coolant in-
let/alternator mount (1) recovering the gasket (2). Pay atten-
tion to the protrusion due to the reference dowels (3).
Threaded parts
Alternator support and en- 1. (1 M10x1.5x70 screw)
gine coolant inlet pipe (4) 2. (2 screws M10x1.5x130)
225902 Figure 30
.543415. Removal of the guide pulley

56. Unscrew the fastening screw (1) and remove the guide pulley
(6).
Threaded parts
Guide pulley (1 M10x1.5 screw) (1)
57. Remove the fastening screw(3) and disassemble the crankshaft

speed sensor (2).
Threaded parts
Crankshaft speed sensor (1 M6x1x20 screw) (3)
58. Unscrew the fastening screw (5) and disconnect the oil level
control/filler cover (4).
225903 Figure 31
P2D32N029E0115
.543210. Water pump removal

59. Remove screws (3) and remove the water pump (2), recover-
ing the gasket (1).
Threaded parts
Water pump (2 screws M8x1.25x35) (3)
225904 Figure 32
.540821. Removal of the crankshaft pulley

60. Unscrew the fastening screws (3), recover the spacer (4) and
remove the crankshaft pulley (2) from the crankshaft (1).
Threaded parts
225905 Figure 33
.540630. Tappet cover removal

61. Unscrew the flanged nuts (2), recover the elastic inserts (1)
and remove the tappet cover (5) together with the engine
lubricant filler cap (6) from the mount for the electro-injector
wiring, recovering the relative gasket (3).
Threaded parts
Tappet cover (4 M8x1.25 flanged nuts) (2)
62. Unscrew the screws with a dual threaded shank (4) from the
electro-injector wiring mount.
Threaded parts
Dual threaded shank screws fastening the tappet cover (4 M8x1.25 dual
threaded shank screws) (4)
225906 Figure 34
P2D32N029E0115
.540634. Electro-injector wiring support removal

63. Unscrew the nuts (6) and disconnect the electrical cables from
Threaded parts
Electro-injector wiring (8 M4 nuts) (6)
64. Remove screws (1, 2) and disconnect the electro-injector wir-

ing mount (3) including the gasket (4).
Threaded parts
port (1, 2) 2. (2 screws M8x1.25x50)
225907 Figure 35
.541230. Disassembly of rocker arms assembly

65. Loosen the tappet adjustment nuts(3) and unscrew the relative
adjustment screws.
66. Remove the screws (4), disassemble the rocker arm unit con-
sisting of: mount (2), rocker arms (1) and spindles (5).
Threaded parts
Rocker arm unit (8 M8x1.25 screws) (4)
225908 Figure 36
67. Remove the push rods (2) from the cylinder head (3) and
remove the valve control bridges (1).
225909 Figure 37
P2D32N029E0115
.775021. Fuel manifold removal

68. Remove the screws (1) and disconnect the mount (2) fastening
Threaded parts
69. Remove the nuts (5) and extract the fuel manifolds (6) from
the cylinder head.
Threaded parts
225910 Figure 38
Fuel manifolds for electro-injectors on the cylinder head (4 M22x1.5x9.5
nuts) (5)

To make it easier to disassemble the fuel manifolds (6)
unscrew the screws (4) and remove the lifting eyelet
(3). When removal is complete, refit the removed
lifting eyelet needed for hoisting the cylinder head.
.775010. Removal of electronic injectors

70. After removing the brackets fastening the electro-injectors
using the specific tool (1) remove the electro-injectors (2)
from the cylinder head (3).
code
225911 Figure 39
.540610. Cylinder head removal

71. Remove the cylinder head (3) fastening screws (1, 2).
Threaded parts
)
2. Step 1 - (10 M12x1.75x150 screws
)
225912 Figure 40
P2D32N029E0115
72. Hook the lifting eyelets (1, 3) with metal cables or by means
of the specific tool (2) and use the lifting device to detach the
cylinder head (6) from the crankcase (5).
code
73. Recover the cylinder head gasket (4) from the crankcase (5).
225913 Figure 41
.543110. Removal of the engine lubricant heat exchanger

74. Remove the screws (6) and remove the engine oil pressure and
temperature sensor.(5).
Threaded parts
Engine oil temperature and pressure sensor (2 M6x1x20 screws) (6)
75. Remove the screws (7) and disassemble the heat exchanger:
oil filter mount (1), intermediate plate (3) and corresponding
gaskets (2, 4).
Threaded parts
Heat exchanger and oil filter mount (15 M8x1.25x35 screws) (7)
225914 Figure 42
.540430. Oil sump removal

76. Overturn the engine.
77. Remove the screws (1), disconnect the oil sump (2) and re-
cover the gasket (3).
Threaded parts
2. (2 screws)
225915 Figure 43
P2D32N029E0115
.543060. Removal of the oil intake suction strainer

78. Remove the screw (4) fastening the bracket (5) retaining the
oil intake suction strainer (1) and recover the spacer (3).
Threaded parts
Bracket retaining the suction strainer in the sump (1 M10x1.5x25
screw) (4)
79. Remove the screws (2) and disassemble the oil suction strainer
(1) and recover the relative gasket.
Threaded parts
Oil intake suction strainer in the sump (2 M8x1.25x20 screws) (2)
225916 Figure 44
.540813. Removal of the additional masses

80. Use the pin (1) to temporarily block the rotation of the addi-
tional masses (3) at the TDC.
81. Unscrew the fastening screws (2, 5) and remove the additional
masses (3) from the crankcase (4).
Threaded parts
Additional masses (8 M10x1.5 screws) (2, 5)
225917 Figure 45
P2D32N029E0115
.540442. Crankshaft front gasket removal

82. To remove the seal ring of the crankshaft from the front cover
(6) apply the specific tool (4) on the front tang (2) of the
crankshaft.
code
83. Pierce the inner seal ring (1) through the guide holes of the
tool, using a drill bit ( 3.5 mm) to a depth of 5 mm.
227348 Figure 46
the external seal ring (2) from the front cover (1).
code
225918 Figure 47
P2D32N029E0115
.540440. Front cover removal

86. Remove the screws (1, 2) and disconnect the front cover (3).
Threaded parts
Front cover (1, 2) 1. (5 screws M8x1.25x45)
2. (8 screws M8x1.25x30)
Note Note the assembly position of the screws (1, 2) since

they are of different lengths.
225919 Figure 48
.543010. Disassembling the oil pump

87. Remove the screws (1) and disconnect the oil pump (2).
Threaded parts
Oil pump (4 M8x1.25 1. Step 1 - pretightening with the
screws) (1) torque wrench
2. Step 2 - Tightening with torque
wrench to torque
Note The oil (2) pump cannot be overhauled.
225920 Figure 49
.540850. Engine flywheel removal

88. Apply the specific tool to the flywheel housing to stop the fly-
wheel (3) rotation.
code
wheelbase M8
89. Unscrew two opposite screws (2) fastening the engine flywheel
(3) to the crankshaft (4). Insert two extraction pins of an ap-
propriate length in the holes of the crankshaft (see the following
figure). 225921 Figure 50
90. Loosen the remaining screws (1) fastening the engine flywheel
(3) to the crankshaft (4) and remove the specific flywheel
locking tool.
Threaded parts
P2D32N029E0115

lifting device.
92. Control the extraction of the engine flywheel (5) through the
two guide pins (4) that were previously screwed into the holes
of the crankshaft (3).
225922 Figure 51
.540462. Crankshaft rear gasket removal

93. To remove the seal ring of the crankshaft from the flywheel
housing apply the specific tool (3) on the rear tang (5) of the
crankshaft.
code
94. Pierce the inner seal ring (1) through the guide holes of the
tool, using a drill bit ( 3.5 mm) to a depth of 5 mm.
227349 Figure 52
P2D32N029E0115
the external seal ring (2) from the flywheel housing (1).
code
225924 Figure 53
.540463. Flywheel housing removal

97. Remove the screws (1, 2, 3, 4) and detach the flywheel hous-
ing.
Threaded parts
Flywheel housing (1, 2, 3, 4) 1. (8 M12x1.75 screws)
2. (12 M10x1.5 screws)
Note Take note of screw assembling positions since they

have different sizes.
225925 Figure 54
P2D32N029E0115
.541251. Removal of the timing gear

98. Unscrew the screws (2) and remove the timing gear (1) from
the camshaft (3).
Threaded parts
Timing gear (6 M8x1.25 screws) (2)
225927 Figure 55
.540445. Removal of the gear housing

99. Remove the screws (2, 4, 5, 6) and disconnect the timing gear
case (1) from the crankcase (3).
Threaded parts
Rear gear case (2, 4, 5, 6) 1. (1 M12x1.75 screw)
2. (4 M8x1.25 screws)
3. (5 M10x1.5 screws)
Note Take note of screw assembling positions since they

have different sizes.
225929 Figure 56
.540840. Piston removal

100. Remove the fastening screws (1) from the connecting rod caps
(2) and remove them.
Threaded parts
Crankshaft connecting 1. Step 1 - Tightening with torque
rod caps(8 M10x1.25x52 wrench to torque
screws) (1) 2. Step 2 - Angle tightening
101. Withdraw the pistons including the connecting rods from the
top of the engine block.
Note Keep the half-bearings in their housings since in case of
use they shall be fitted in the same position found at
removal. 70158 Figure 57
P2D32N029E0115
.540830. Connecting rod removal

Threaded parts
.540831. Connecting rod bearings removal

Threaded parts
.540810. Crankshaft removal

106. Remove the screws (1) and disassemble the main bearing caps
(2).
Threaded parts
Crankshaft main bearing caps 1. Step 1 - Tightening with torque
(10 M12x1.5 screws) (1) wrench to torque
70159 Figure 60
P2D32N029E0115
107. The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
Note Take note of lower and upper half-bearing assembling
positions since in case of reuse they shall be fitted in the
same position found at removal.
70160 Figure 61
108. With the specific tool (1) and hoist, remove the crankshaft (2)
from the crankcase.
code
Crankshaft lifting tool 99360500
70161 Figure 62
.540816. Main bearings removal

109. Disassemble the main half-bearings(1).
70162 Figure 63
P2D32N029E0115
.540414. Sprayer removal

110. Remove the screws (2) and disassemble the oil injectors (3).
Threaded parts
Oil sprayers for piston cooling (4 M8x1 25x20 unions) (2)
70162 Figure 64
.541210. Camshaft of distribution removal

111. Remove the screws (1) and disassemble the camshaft (3) re-
taining plate (2).
Threaded parts
Camshaft longitudinal retaining plate (2 M8x1.25 screws) (1)
Note Take note of the plate assembly position (2).
70163 Figure 65
112. Carefully withdraw the camshaft (1) from the crankcase.
70164 Figure 66
P2D32N029E0115
.541224. Tappet removal

113. Remove the tappets (1) from the crankcase.
70165 Figure 67
.540410. ENGINE BLOCK MEASUREMENTS AND CHECKS

.540420. Cylinder liner measurement
114. Once the engine is disassembled, thoroughly clean the cylinder-
crankcase assembly.
115. Use the proper rings to handle the cylinder block.
116. Carefully inspect the crankcase for cracks.
117. Check cast hole plugs conditions and replace them in case of
uncertain seal or if rusted.
118. Examine the surfaces of the cylinder liners; they should not be
scored, seized, ovalized, conical or worn to excess.
119. The internal diameter of the cylinder liners is checked to ascer-
tain the extent of ovalization, taper and wear, using the bore
meter (1) fitted with a dial gauge previously reset on the ring
gauge (2) of the diameter of the cylinder liner.
Note Should the ring gauge be not available, use a micro- 70166 Figure 68
meter for zero-setting.
P2D32N029E0115
70167 Figure 69
120. Measurements should be carried out for every single cylinder liner at three different heights and on two perpendicular plane
levels: the one parallel to the longitudinal axis of the engine (A) and the other perpendicular to it (B); the area of maximum
wear is normally found on this surface in correspondence of the first measurement.
121. If any ovalization, taper or wear is found, proceed with boring and grinding the cylinder liners. The cylinder liners must be
reground based on the diameter of the pistons supplied as spare parts increasing the nominal value and the specified assembly
clearance by 0.5 mm.
Note In case of regrinding, all cylinders shall have the same oversize (0.5 mm).
P2D32N029E0115
196428 Figure 70
122. Check main bearing housings as follows:
123. fit the main bearing caps on the supports without bearings.
124. Tighten the fastening screws to the specified torque.
tightening torque
Crankshaft main bearing caps (10 M12x1.5 screws) 1. Step 1 - Tightening with torque wrench to torque
80 6 Nm
90
125. Use the proper internal gauge to check whether the housing diameter is falling within the specified value.
126. Replace if higher value is found.
P2D32N029E0115
.540410. Checking cylinder block head contact surface

127. Check absence of distortions on the head supporting surface on
the cylinder block.
128. This check can be carried out, after having removed the dowel
pins (4) with a calibrated rule (2) and feeler gauge (3).
129. After ascertaining the areas of deformation, correct the contact
surface with a grinding machine.
Tool / Material
Grinder
130. Planarity error shall not exceed:

Technical data
Planarity error 0.075 mm
70170 Figure 71
Note Block levelling shall be performed only after checking
that piston protrusion from the cylinder is not exceed-
ing the specified value.
131. Check the condition of the casting hole plugs (1) of the cylinder
unit and replace them if rusted or if there is any doubt about
their seal.
132. When levelling is completed, reset cylinders top chamfer as
shown in the figure.
.5412. TIMING SYSTEM
70169 Figure 72
.541210. Camshaft of distribution measurement
133. The values shown refer to pin regular diameter.
134. The surfaces of shaft journals and of cams must be very smooth; if, on the contrary, they show traces of seizing and scoring,
the shaft and relating bushing have to be replaced.
P2D32N029E0115
135. Check camshaft (2) journals diameter using micrometer (1) on

two perpendicular axes.
Tool / Material
Micrometer
70171 Figure 73
.541211. Checking cam lift and journals alignment

136. Place the shaft onto tailshocks and, using a centesimal comparator positioned beneath the central support, check alignment
offset.
Technical data
Alignment error 0.04 mm
Tool / Material
Centesimal dial gauge
137. Otherwise replace the shaft.

138. Check the cam lift:
Technical data
Exhaust cam lift 6.045 mm
Intake cam lift 7.582 mm
139. If it is any different, replace the shaft.
.541213. Check and measurement of camshaft bushes

140. The bush (2) for the camshaft must be forced into the relevant
seat.
141. Internal surfaces must not show seizing or wear.
142. By bore gauge (3), measure the diameter of bushing (2) and
intermediate seat (1) for camshaft.
Tool / Material
Bore gauge
143. Measurements shall be performed on two perpendicular axes.
70172 Figure 74
P2D32N029E0115
107399 Figure 75
* Dimension to be obtained after driving the bushing.
144. Check the bushing fitting dimensions.
.541213. Camshaft bushes replacement

145. To replace bushing (1), use driver (2) and handgrip (3) for
dismounting and mounting.
code
Drift tool for removing/fitting camshaft bush (to be used 99360362
with 99370006)
Grip for inter-changeable drifts 99370006
Note Upon assembly, bushing (1) must be oriented so that

the lubrication holes (2) match holes in crankcase seat.
70174 Figure 76
P2D32N029E0115
.541224. Tappet measurement

146. Perform tappet measurements and make sure these corres-
pond with their main data and with the data of the crankcase
seats as in the figure.
116253 Figure 77
.541224. Tappet assembly

147. Lubricate the tappets (1) and fit them into the relevant crank-
case housing.
70176 Figure 78
.541210. Fitting camshaft

148. Lubricate bushing and other camshaft support housings and
assemble camshaft (1) making sure not to damage support
bushing and housings.
70164 Figure 79
P2D32N029E0115
149. Position the camshaft (1) retaining plate (3) with the slot facing
the upper surface of the crankcase and the punch marks facing
the operator, tighten the screws (2) to a torque of:
tightening torque
Camshaft longitudinal retaining plate 24 4 Nm
(2 M8x1.25 screws) (2)
70238 Figure 80
150. Check the axial clearance between the camshaft (1) and the
retainer plate using a feeler gauge or dial gauge.
151. The axial clearance of the camshaft (1) must be:
Technical data
Camshaft axial clearance 0.23 0.13 mm
Note To measure the axial clearance, move the camshaft in

the longitudinal direction indicated by the arrows () in
the figure.
152. If the camshaft has excessive axial clearance replace the worn
parts.
70179 Figure 81
.540414. Oil sprayer assembly

153. Install the oil sprayers (2) and tighten the fastening screws (1)
to the specified torque.
tightening torque
Oil sprayers for piston cooling (4 15 3 Nm
M8x1 25x20 unions) (1)
70180 Figure 82
P2D32N029E0115
.540810. Crankshaft measurement

154. If signs of seizure, scoring or excessive ovalization on main
journals and crankpins are identified, it is necessary to regrind
the pins.
155. Before grinding the journals (2), measure them with a micro-
meter (1) to decide the final diameter to which the pins are to
be ground.
70182 Figure 83
201711 Figure 84
* Nominal value
156. It is advisable to enter readings in a table.

157. See previous figure.
158. The main journals and crankpins must always be ground to the same undersize class.
159. Journals and crankpins undersize shall be marked on the side of the crank arm No.1.
Note For undersized crankpins, letter M.
Letter B for undersized main journals.
For undersized crankpins and main journals, letter MB.
P2D32N029E0115
70183 Figure 85
* measured on radius greater than 45.5 mm ** 0.50 between adjacent journals
160. Check that the values indicated in the figure are strictly observed and that the surfaces show no signs of any damage or imper-
fections.
MAIN CRANKSHAFT TOLERANCES
TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL
Circularity
SHAPE
Cylindricity //
Alignment
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
CLASS OF IMPORTANCE
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
P2D32N029E0115
70237 Figure 86
161. Check that the fittings of the main journals comply with the angles prescribed in the figure.
.540815. Oil pump drive gear replacement

162. Check that gear toothing (1) is not damaged or worn, other-
wise remove using the proper puller (3).
163. When fitting the new gear, heat it to specified temperature for
10 minutes in an oven and then key it to the crankshaft.
Technical data
Gear heating temperature 180
70184 Figure 87
.540816. Main bearings assembly

Note Refit the main bearings that have not been replaced, in the same position found at removal.
164. The main bearings (1) are supplied as spare parts undersized on
the inner diameter by:
Technical data
Inside diameter of roller 0.250 mm to0.500 mm
Note Do not modify the bearings in any way.

165. Thoroughly clean the main half bearings (1) with the lubricating
hole and fit them into their housings.
166. The second last main half bearing (1) is fitted with shoulder half
rings.
70185 Figure 88
P2D32N029E0115
.540810. Crankshaft assembly

167. Install crankshaft (2).
168. Check the clearance between the crankshaft main journals and
the corresponding bearings as described in the procedure Main
journal clearance measurement ( Page 48).
70161 Figure 89
.540811. Main journal clearance measurement

169. Check the clearance between the crankshaft journals and their
bearings as follows:
170. clean accurately the parts and remove any trace of oil.
171. Lay down pieces of calibrated wire (3) on the pins (4) of the
crankshaft, parallel to the longitudinal axis.
172. fit caps (1), including the half bearings (2) on the relevant sup-
ports.
70186 Figure 90
Conditions
In case of re-use of the main journals fastening screws.
Perform two measurements of the diameter of the fasten-

ing screws of the main bearing caps as shown in the
figure, measuring diameters D1 and D2: if D1-D2 <0.1
mm the screw can be reused; if D1-D2 >0.1 mm the
screw must be replaced.
75703 Figure 91
P2D32N029E0115
173. Screw in the pre-lubricated screws (1) and tighten them in two
successive stages.
tightening torque
Crankshaft main bearing caps 1. Step 1 - Tightening with torque
(10 M12x1.5 screws) (1) wrench to torque
80 6 Nm
90
Tool / Material
Torque wrench
70187 Figure 92
174. With the specific tool (1) positioned as shown in the figure,
tighten the screws further (2).
code
1/2" and 3/4"
70188 Figure 93
175. Remove caps from supports.

176. The clearance between the main bearings and their pins is
measured by comparing the width of the calibrated wire (2),
at the point subjected to the greatest crushing forces, with the
graduated scale on the casing (1) containing the calibrated wire.
177. Numbers shown on the scale specify the clearance of coupling
in millimetres.
178. If clearance is detected that is different than what is specified,
replace the half-bearings and repeat the control; on obtaining
the prescribed clearance, lubricate the main bearings and fit
the supports permanently by tightening the fastening screws as
described above.
70189 Figure 94
P2D32N029E0115
.540810. Checking crankshaft end float

179. Thrust clearance is checked by placing a magnetic dial gauge
(2) on the crankshaft(3), as shown in the figure, the normal
assembly clearance is:
Technical data
Tool / Material
Dial gauge
180. If the clearance is found to be greater than required, replace

the main half- bearings of the last but one rear support (1)
carrying the thrust bearing and repeat the clearance check
between the crankshaft pins and the main half-bearings.
70190 Figure 95
.540830. PISTON - CONNECTING ROD ASSEMBLY OVERHAUL
70191 Figure 96
1 Retaining rings 5 Screws
2 Pin 6 Half-bearings
3 Piston 7 Connecting rod
4 Piston rings 8 Bushing
181. Connecting rod/piston assembly overhaul.

Note Pistons are supplied spare with 0.5 mm oversize.
P2D32N029E0115
.540842. Piston rings removal

182. Use pliers (3) to remove the circlips (1) from the piston (2).
code
32613 Figure 97
183. Disassembly of the pin (1) retaining circlips (2) for the piston is
carried out using a scriber (3).
32614 Figure 98
P2D32N029E0115
196434 Figure 99
A Pin axis * The dimension should be taken 1.5 mm from the
B Piston axis outer diameter
X 0.6 0.15 ** The measurement is taken on the diameter of 99 mm
184. MAIN DATA FOR THE PISTON, PINS AND CIRCLIPS.
.540840. Measuring the piston diameter

185. Using a micrometer (2) measure the piston diameter (1) to
determine the assembly clearance.
Tool / Material
Micrometer
Note The diameter shall be measured at 60.5 mm from the

piston skirt end.
32615 Figure 100
186. The clearance between the piston and the cylinder liner can be
also checked with a feeler gauge (1) as shown in the figure.
Tool / Material
Feeler gauge
70192 Figure 101
P2D32N029E0115
.540841. Piston pin measurement

187. Measuring the diameter of the piston pin (1) using a micro-
meter (2).
Tool / Material
Micrometer
18857 Figure 102
.540840. Conditions for correct pin / piston coupling

188. Use engine oil to lubricate the pin (1) and the relative seat in
the piston hubs; the pin must insert in the piston with slight
manual pressure and must not slip out due to gravity.
32619 Figure 103
.540842. Measuring seal rings

189. Check the sealing ring (2) thickness using a micrometer (1).
Tool / Material
Micrometer
16552A Figure 104
P2D32N029E0115
190. Check the clearance between the sealing rings (3) of the 2nd
and 3rd slots and the relevant housings on the piston (2) with a
feeler gauge (1).
Tool / Material
Feeler gauge
32620 Figure 105
191. Due to the particular shape of the first tapered seal ring, the
clearance between the slot and the ring itself must be measured
as follows: make the piston (1) protrude from the crankcase
so that the ring (2) in question exits about half way out of the
cylinder liner (3).
192. In this position, use a feeler gauge to check the clearance (X)
between the ring and the slot: this clearance must be the spe-
cified value.
41104 Figure 106
193. Measuring the clearance between the ends of the circlips (2)
fitted into the cylinder liner (3) using a feeler gauge (1).
70194 Figure 107
.540830. Connecting rod measurement

Note The connecting rod - connecting rod cap mating surfaces are knurled for a better coupling.It is therefore recommended to
not remove the knurling.
P2D32N029E0115
194. During checks make sure that the main data of the connecting
rod, bushing, piston pin and half-bearings is that shown in the
figure.
196435 Figure 108

* Inner diameter to be ** Value not measurable
obtained after driving in released condition.
in the small end and
regrinding with borer.
P2D32N029E0115
196436 Figure 109

A Identification code stamped on the connecting rod * Identification colour of connecting rod weight
B Identification code stamped on the connecting rod cap
195. Check the identification data of each connecting rod noting the code stamped in areas (A) and (B).
Connecting rod identification code
Connecting rod cap (B) Connecting rod (A)
No. of connecting No. of connecting
Production year Production day Weight
rods rods
1234 H 123 1234 W
0001 H = 2007 001 0001 V (Yellow) = 1731-1770 g
I = 2008 W (Green) = 1771-1810 g

J = 2009 X (Blue) = 1811-1851 g
9999 K = 2010 366 9999
Note Spare connecting rods are of the W class and are marked in green.
Removal of material is not allowed.
P2D32N029E0115
.540834. Small end bushing check

196. Check the bushing in the small end has not come loose and shows no sign of scoring or seizure. Replace it if it does.
197. Removal and refitting shall be performed using the proper driver.
Tool / Material
Drift
198. When refitting take care to make the oil holes on the bush coincide with those on the connecting rod small end.
199. Ream the bush to obtain the specified diameter.
Tool / Material
Reamer
.540830. Connecting rod check

.540830. Connecting rod axes parallelism check
200. Check the parallelism of the connecting rod axis (1) using a
device (5) proceed as follows:
201. Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
202. Set the spindle (3) on the V prisms, resting the connecting rod
(1) on the stop bar (2).
61696 Figure 110
.540830. Torsion check

203. Check the bend of the connecting rod (5) by comparing two
points (A e B) and of the pin (3) on the horizontal plane of
the connecting rod axis.
204. Position the support (1) of the dial gauge (2) so that it pre-
loads ~ 0.5 mm on the pin (3) in point (A) and reset the dial
gauge (2). Move the spindle (4) with the connecting rod (5)
and compare with the opposite side (B) of the pin (3) for any
deviation; the difference between A and B must not exceed:
Technical data
Difference between A and B 0.08 mm
61694 Figure 111
P2D32N029E0115
.540830. Bending check

205. Check the bend of the connecting rod (5) by comparing two
points C and D of the pin (3) on the vertical plane of the con-
necting rod axis.
206. Position the vertical support (1) of the dial gauge (2) so that
this rests on the pin (3) at point C.
207. Swing the connecting rod to and fro, establishing the highest
position of the pin and reset the dial gauge in this condition (2).
208. Move the spindle with connecting rod (5) and repeat the con-
trol of the highest point on the opposite side D of the pin (3).
The difference between point C and point D must not exceed:
Technical data
Maximum difference between point C and 0.08 mm
D
61695 Figure 112
.540840. Piston assembly

209. Before assembly of the piston with the connecting rod, identify
the arrow (2) on the piston crown.
196437 Figure 113

1 Part code 3 Production date
2 Arrow indicating the 4 Marking showing 1st
assembly orientation slot insert testing;
of the connecting 5 Supplier code
rod - piston assembly
(facing the front of the
crankcase)
P2D32N029E0115
210. With the pin (3), connect the piston (2) to the connecting rod
(4) so that the piston (2) assembly reference arrow (1)in the
cylinder liners and the numbers (5) printed on the connecting
rod (4) appear as shown in the figure.
102596 Figure 114
211. Position the piston (1) on the connecting rod according to the
diagram shown in the figure, fit the pin (3) and stop it by the
Seeger rings (2).
32614 Figure 115
.540842. Fitting piston rings

212. Use the specified calliper (3) to fit the piston rings (1) on the
piston (2).
code
213. The rings need to be mounted with the word "TOP" facing
upwards, direct the ring openings so they are staggered 120
apart.
Note Spare piston rings are supplied in the sizes below.
Standard.
Increased by 0.5 mm.
32613 Figure 116
P2D32N029E0115
.540831. Connecting rod bearings assembly

214. Mount the half bearings (1) both on the connector rod and the
cap.
Note Not finding it necessary to replace the connecting rod
bearings, you need to fit them back in exactly the same
sequence and position as in removal.
Do not make any adjustment on the half-bearings.
70200 Figure 117
.540840. Fitting the connecting rod-piston assembly into the cylinder liners
Caution!
Possible damage to the vehicle! Indications of rod movement.
Please ensure that the connecting rod not to strike the cylinder walls.
215. Lubricate the pistons well, including the piston rings and the
inside of the cylinder liners.
216. Using the band (2), install the connecting rod-piston assemblies
(1) in the cylinder linings checking that:
code
Clamp for fitting piston into cylinder liner (60 - 125 mm) 99360605
217. the number of each connecting rod corresponds to the cap

coupling number.
70201 Figure 118
P2D32N029E0115
70202 Figure 119

218. The openings of the circlips are staggered:
Technical data
Split ring opening discrepancy 120
219. connecting rod-piston assemblies shall have the same weight.

220. the arrow stamped on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston
skirt shall be corresponding to the oil nozzle position.
.540812. Main journal assembly clearance measurement

221. Carry out the following operations to measure the clearance:
222. carefully clean the parts and remove any trace of oil.
223. set a piece of calibrated wire (2) on the crankshaft pins (1).
224. fit the connecting rod caps (3) with the relevant half bearings
(4).
70203 Figure 120
225. Screw in the screws (1) previously lubricated with engine oil
and tighten them in two successive steps.
226. Step 1: tighten the screws (1) with a torque wrench (2) to a
torque of:
tightening torque
screws) (1) 50 5 Nm
60
Tool / Material
70204 Figure 121
Torque wrench
P2D32N029E0115
Caution!
Screw diameter check Indications for checks of screws fixing connecting rod cap
Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the centre
of the thread length is not 0.1 mm less than the diameter measured at approx. 10 mm from screw end.
227. Step 2: place the specific tool (1) on the socket wrench and
tighten the screws (2) further with an angle of:
tightening torque
screws) (2) 50 5 Nm
60

code
1/2" and 3/4"
70205 Figure 122
228. Remove the cap and find the existing clearance by comparing
the calibrated wire width (1) with the scale indicated on the
envelope (2) which contained the wire.
70206 Figure 123
229. If the clearance is not as prescribed, change the half bearings

and repeat the check.
230. On obtaining the prescribed clearance, lubricate the connecting
rod half bearings and fit them permanently by tightening the
screws securing the connecting rod caps as described.
231. Check manually that the connecting rods (1) are sliding axially
on the crankshaft pins and that their axial clearance, measured
with feeler gauge (2) is:
Technical data
Connecting rod axial clearance 0.10 mm to0.33 mm
Tool / Material
Feeler gauge
70207 Figure 124
P2D32N029E0115
.540840. Piston protrusion check

232. When assembly of the connecting rod-piston assembly is com-
plete, using a dial gauge (1) together with a base (2) check the
protrusion of the pistons (3) at T.D.C. compared to the upper
surface of the crankcase.
code
Dial gauge (0-5 mm) 99395603
99395603)
233. It must be:

Technical data
Piston protrusion 0.28 mm to0.52 mm
70208 Figure 125
.771013. High pressure pump drive gear replacement

.771013. Disassembly
234. Lock rotation of the high-pressure pump (1) drive shaft (2).
235. Remove the nut (3), and washer (4) using a dual-actuated
bridge, brackets and clamps, detach the gear (5) from the shaft
(2).
Threaded parts
High pressure pump gear (1 M18x1.5 nut) (3)

code
Dual-actuated bridge 99341001
Bracket torque 99341009
Clamp 99341015 158823 Figure 126
.771013. assembly
236. For reassembly, reverse the order of the removal operations, and tighten nut (3) to a torque of:
tightening torque
High pressure pump gear (1 M18x1.5 nut) (3) 105 5 Nm
.774511. Replacement of the pressure sensor on the rail

237. Loosen the pressure sensor using the wrench or unscrew the rail by hand.
238. If present, remove the O-ring gasket.
239. Clean the sensor thread and the contact surface of the rail.
240. Plug the seat of the sensor on the rail using a plastic cap to prevent contamination.
.774511. assembly
241. Remove the plastic cap from the sensor seat on the rail.
242. Inspect the thread and the contact surfaces of the pressure sensor and the rail.
243. If there is any damage or wear, replace the concerned parts.
244. If present, install a new O-ring gasket.
245. Prior to assembly, lubricate the sensor thread and mordant.
246. Manually tighten the pressure sensor on the rail to a torque of:
P2D32N029E0115
tightening torque
.774513. Replacement of the pressure relief valve on the rail

247. Loosen the pressure relief valve using a wrench and screw it manually off the rail.
248. If present, remove the O-ring gasket.
249. Clean the valve thread and the contact surface of the rail.
250. Plug the seat of the valve on the rail using a plastic cap to prevent contamination.
.774513. assembly
251. Remove the plastic cap from the valve seat on the rail.
252. Inspect the thread and the contact surfaces of the pressure relief valve and the rail.
253. If there is any damage or wear, replace the concerned parts.
254. If present, install a new O-ring gasket.
255. Prior to assembly, lubricate the valve thread and mordant.
256. Manually tighten the pressure relief valve on the rail to a torque of:
tightening torque
Pressure relief valve on rail DBV4 (1 M20x1.5 screw) 100 5 Nm
.540610. CYLINDER HEAD OVERHAUL

.540662. Valve removal
257. The intake (1) and exhaust (2) valves have the same diameter
mushroom.
258. The central cavity () of the exhaust valve mushroom (2)
distinguishes it from the intake valve.
Note Before removing the valves from the cylinder head,
number them so that they can be re-installed in the
same positions they were removed from if they are to
be re-used.
A = intake side S = exhaust side
070319a Figure 127
259. The removal of the valve is carried out with a specific tool (1)
exerting pressure on the plate (3) so that when compressing
the springs (4), it is possible to remove the cotters (2).
code
260. Then remove: the plate (3), the springs (4).

261. Repeat this operation for all the valves.
262. Turn the cylinder head upside down and remove the valves (5).
70321 Figure 128
P2D32N029E0115
263. Remove the sealing rings (1 e 2) from the relative valve guides.
Note The seal rings (1) for intake valves are yellow: the seal
rings (2) for exhaust valves are green.
70322 Figure 129
.540610. Cylinder head hydraulic seal check

264. Check the hydraulic head using a suitable tool. Use a pump to
introduce water heated to ~ 90C and pressurised to:
Technical data
Water pressure 2 bar to3 bar
265. Replace the casting hole plugs (1) if they are found to leak,
using a suitable drift for their disassembly - assembly.
Tool / Material
Drift
Note Before refitting, smear the plug surfaces with water-

repellent sealant. 70323 Figure 130
266. Replace the cylinder head if leaks are found.
.540610. Cylinder head contact surface check

267. The contact surface of the cylinder head (1) with the cylinder
block is checked using a rule (2) and a feeler gauge (3).
Tool / Material
Ruler
Feeler gauge
268. Distortion found along the whole cylinder head shall not ex-
ceed:
Technical data
Cylinder head maximum deformation 0.20 mm
269. If higher values are found grind the cylinder head according to
values and indications shown in the following figure.
70324 Figure 131
P2D32N029E0115
270. The nominal thickness A of the cylinder head is:

Technical data
Nominal thickness A 105 0.25 mm
271. Max. metal removal must not exceed thickness B by:

Technical data
Thickness B maximum allowance 0.13 mm
Note After regrinding, check the valve recessing and if ne-

cessary regrind the valve seats to meet the prescribed
valve recess.
70325 Figure 132
.540662. Cleaning and testing valves

272. Remove all carbon deposits from the valves using a wire brush.
Tool / Material
Metal brush
273. Check that the valves show no signs of seizing, scoring or crack-
ing.
274. Regrind the valve seats, if required, using a grinding machine and
removing as less material as possible.
Tool / Material
Grinder
18625 Figure 133
.540662. Measuring valves

275. Use micrometer (2) to measure the valve (1) stem: it must be:
Technical data
Valve stem measurement 6.990 mm to7.010 mm
Tool / Material
Micrometer
18882 Figure 134
P2D32N029E0115
.540660. Checking clearance between valve stem and

valve guide and centring valves
276. Insert the valve (2 )in its seat and let the head protrude about 1
ten millimetres.
2
277. Position the dial gauge (1) equipped with a flat end with the
magnetic dial gauge base in a radial position with respect to the
head and measure the assembly clearance in two perpendicular
directions:
Technical data
278. Making the valve (2 ) rotate in its seat, make sure that the cent-
ring error does not exceed:
Technical data
70327 Figure 135
Maximum valve centring error 0.03 mm
279. If there is an excessive radial clearance or centring error,

recheck the valve dimensions and replace the worn parts.
.540667. Measuring valve guides

280. Using a bore gauge, measure the inside diameter of the valve
guides; it must be equal to the value shown in the figure.
Tool / Material
Bore gauge
79457 Figure 136
.540661. Regrinding - replacing the valve seats

281. Check the valve seats (2). If slight scoring or burns are found,
regrind using the tool according to the angle values shown in the
following Figure.
70330 Figure 137
P2D32N029E0115
A B
122618 Figure 138

A Exhaust B Intake
282. If valve seats cannot be restored just by regrinding, it is possible to assemble the spare inserts provided.
A B
125570 Figure 139

A Exhaust B Intake
283. Using a specific tool and taking care not to nick the cylinder head, remove as much material as possible from the valve seats
until they can be removed from the cylinder head with a punch.
284. To mount the valve seats in the cylinder head, heat cylinder head to 80 - 100 C and, using a suitable drift, fit the new valve
seats (2), previously cooled.
Tool / Material
Drift
285. Then use the specific tool to grind the valve seats to the values shown in the following Figure.
P2D32N029E0115
.540661. Checking valve recessing

286. After the grinding operation, with the base (2) and the feeler
gauge (1), check that the recess value of the valves (3) is the
specified one.
code
99395603)
Dial gauge (0-5 mm) 99395603
70333 Figure 140
.540665. Valve spring check

287. Prior to assembling, check the valve spring flexibility using the
specific tool.
code
Equipment for checking spring load 99305047
288. Compare the elastic deformation and load data with those of
the new springs shown in the following table.

Height Under a load of 50676 Figure 141
Millimetre [mm] Newton [N]
H
Spare
47.75
H1 P1
35.33 339.8 19
H2 P2
25.2 741 39
.540660. Valve assembly

289. Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked during removal.
290. Fit the sealing rings (2 e 3) on the valve guide.
Note The seal rings (2) for intake valves are yellow: the seal
rings (3) for exhaust valves are green.
70334 Figure 142
P2D32N029E0115
291. Position the following on the cylinder head: the spring (4) and
the upper plate (3): using the specific tool (1) compress the
spring (4) and bind the parts to the valve (5) using the cotters
(2).
code
770321 Figure 143
.541221. Rod check

292. the rocker arm control rods must not be deformed; the spher-
ical seats in contact with the rocker arm adjustment screws
and with the tappet (frecce) must not show signs of seizing
or wear; otherwise replace them. The rods that control the
intake and exhaust valves are identical and therefore can be in-
terchanged.
32655 Figure 144
.541230. Rocker assembly check

293. Check that shaft / rocker arm surfaces are not excessively worn
or damaged.
70344 Figure 145
P2D32N029E0115
.542410. Turbocharger checks

.542418. Checking and adjusting the actuator
294. Cover air, exhaust gas and lubricant inlets and outlets.
295. Thoroughly clean the outside of the turbocharger using anticor-
rosive and antioxidant fluid and check the actuator (3).
296. Clamp the turbocharger in a vice.
297. Disconnect the actuator pipe (4) and fit the pump pipe to the
actuator pipe (5) filler.
code
Manual pump for measuring pressure and vacuum 99367121
298. Apply the magnetic stand gauge to exhaust gas inlet flange in the
turbine.
Tool / Material 158832 Figure 146
Magnetic dial gauge
299. Set gauge feeler pin (1) on the end of the tie rod (3) and set
gauge to zero (1).
300. Use the pump (5) to blow compressed air into the actuator
(4) at the specified pressure, making sure that this value stays
constant for the entire duration of the check, if not replace the
actuator (4).
301. In this set-up, the tie rod must have travelled by the specified
distance.
Note During the operation, beat the actuator (6) slightly
in order to eliminate possible sticking of the actuator
internal spring.
302. If a different value is found, loosen the nut (5) and act on the
knurled ring nut (4).
.540110. ENGINE ASSEMBLING

.540445. Gear case assembly
303. The figure indicates the "GEAR CASE SEALANT APPLICA-
TION DIAGRAM".
304. Carefully clean the timing gear case and the crankcase (2).
to seal.
306. Apply the specified sealant on the timing gear case in order to
Tool / Material

308. Any flaws must be corrected in as short a time as possible. 225930 Figure 147
310. Excessive sealant could come out from joint sides and cause
lubricant passage clogging.
P2D32N029E0115
312. The figure shows the "DIAGRAM FOR TIGHTENING THE

REAR TIMING GEAR CASING FASTENING SCREWS".
313. Reattach the timing gear case(1) to the crankcase (3).
314. Tighten the fastening screws (2, 4, 5, 6) in the position found
upon removal and tighten the screws to the tightening torque
indicated below in the order shown in the figure.
tightening torque
Rear gear case (2, 4, 5, 6) 1. (1 M12x1.75 screw)
77 12 Nm
2. (4 M8x1.25 screws)
24 4 Nm
3. (5 M10x1.5 screws)
47 5 Nm 225929 Figure 148

dirt.
.541251. Assembly of the timing gear

315. Use a felt-tip pen to highlight the drive gear tooth (1) on crank-
shaft (2) with a chamfer on its side for timing.
70211 Figure 149
316. During the assembly of the timing gear (4) on the camshaft(2),
make sure to align the reference pin (1) with the seat of the
key (5).
317. Orient the crankshaft (3) and the camshaft (2) so that when
the driven gear (4) is fit on the latter, the mark stamped on
the gear of the camshaft (4) coincides with the rounded tooth
located on the gear wheel of the crankshaft (3).
225928 Figure 150
P2D32N029E0115
318. Tighten the screws (2) fastening the timing gear (1) to the
camshaft(3) to a torque of:
tightening torque
Timing gear (6 M8x1.25 36 2 Nm
screws) (2)
225927 Figure 151
.540463. Flywheel housing assembly

319. The figure shows the "FLYWHEEL HOUSING SEALANT AP-
PLICATION DIAGRAM".
320. Carefully clean the attachment surfaces of the flywheel housing
(1) and the distribution gear case.
to seal.
322. Apply the specified sealant on the flywheel housing (1) in order
to form a seam with a diameter of a few mm.
Tool / Material

bubbles, thin areas or gaps. 225926 Figure 152
328. The figure shows the "SEQUENCE FOR TIGHTENING THE

FLYWHEEL HOUSING FASTENING SCREWS".
329. Reconnect the flywheel housing to the crankcase, tighten the
fastening screws (1, 2, 3, 4) in the position found upon re-
moval and tighten them to the torque indicated below in the
order shown in the figure.
tightening torque
Flywheel housing (1, 2, 3, 4) 1. (8 M12x1.75 screws)
85 10 Nm
2. (12 M10x1.5 screws)
49 5 Nm
Note Before each assembly operation, check that the thread 225925 Figure 153
dirt.
P2D32N029E0115
.540462. Crankshaft rear gasket assembly

330. Apply the part (2) of the special tool to the rear crankshaft tang
(3) securing it with two screws (5) and fit the new sealing ring
(4).
code
331. Position part (7) on part (2) tighten the nut (1) on screw (6)
until the sealing ring (4) is completely installed in the flywheel
housing .
227350 Figure 154
.540850. Engine flywheel check

332. Check the clutch plate working surface (1) of the engine fly-
wheel and turn it if scored.
333. Check the condition of the ring gear teeth (2). If breakage or
excessive wear is found remove the ring gear from the flywheel
using a generic beater and fit the new one, previously heated
to specific temperature for 15' to 20'; the chamfer made along
the inner diameter of the crown wheel must face the engine
flywheel.
Technical data
Ring gear heating temperature 150
Tool / Material
Drift 225923 Figure 155
.540850. Engine flywheel assembly

lifting device.
335. Screw two guide pins (4) of a suitable length into the crankshaft
holes (3) and fit the engine flywheel (5) using the designated
sling and lifting device.
225922 Figure 156
P2D32N029E0115
336. Tighten the screws (1) fastening the engine flywheel (3) to the
crankshaft (4).
337. Remove the guide pins and the lifting eyelet from the engine fly-
wheel (3) (see the previous figure). Tighten the missing fasten-
ing screws (2) to the crankshaft (4).
338. Apply the specific tool to the flywheel housing to stop the en-
gine flywheel (3) rotation.
code
wheelbase M8
225921 Figure 157
339. Tighten the screws (1, 2) retaining the flywheel (3) in two
steps:
tightening torque
30 4 Nm
60
Tool / Material
Torque wrench
Note Tightening to angle is performed using tool 99395216.

Before each assembly operation, check that the thread
dirt.
.543010. Installing the oil pump

340. Fit the oil pump (2).
tightening torque
Oil pump (4 M8x1.25 1. Step 1 - pretightening with the
screws) (1) torque wrench
8 1 Nm
2. Step 2 - Tightening with torque
wrench to torque
24 4 Nm
225920 Figure 158
P2D32N029E0115
.540440. Assembling the front cover

342. The figure shows the "FRONT COVER SEALANT APPLICA-
TION DIAGRAM".
343. Thoroughly clean the engine crankcase (1).
to seal.
345. Apply the specified sealant on the crankcase (1) in order to
form a seam with a diameter of a few mm.
Tool / Material

347. Any flaws must be corrected in as short a time as possible. 227352 Figure 159
350. After applying the sealant, the joints must be assembled imme-
diately (max 10 minutes). After applying the sealant, the joints
must be assembled immediately (max. 10 minutes).
351. Fit the front cover (3) and tighten the screws (1, 2) to a
torque of:
tightening torque
Front cover (1, 2) 1. (5 screws M8x1.25x45)
24 4 Nm
2. (8 screws M8x1.25x30)
24 4 Nm
225919 Figure 160
.540442. Crankshaft front gasket installation

352. Apply the part (1) of the special tool to the front crankshaft
tang (7) securing it with the screws (6) and keying it onto the
new sealing ring (5).
code
353. Position part (2) on part (1), tighten the nut (3) on the screw
(4) until the crankshaft sealing ring is completely installed (5) in
the front cover .
227351 Figure 161
P2D32N029E0115
.540813. Assembly of the additional masses

354. Overturn the engine.
355. Align the stamped marks (A, B, C) on the gears of the addi-
tional masses (3) for timing.
356. Use the pin (1) to temporarily block the rotation of the addi-
tional masses (3) at the TDC.
357. Fit the additional masses (3) and tighten the fastening screws(2,
5) on the crankcase (4) to the specified torque.
tightening torque
Additional masses (8 M10x1.5 48 8 Nm
screws) (2, 5)
358. Remove the locking pin (1) from the additional masses (3).
225917 Figure 162
.543060. Oil intake suction strainer assembly

359. Fit the oil intake suction strainer (1) after inserting the relative
gasket and tighten the fastening screws (2) to a torque of:
tightening torque
Oil intake suction strainer in the 24 4 Nm
sump (2 M8x1.25x20 screws) (2)
360. Fasten the bracket (5) retaining the oil intake suction strainer
(1) , tighten the screw (4) completely fastening the spacer (3)
and tighten it to a torque of.
tightening torque
Bracket retaining the suction 43 5 Nm
strainer in the sump (1 M10x1.5x25
screw) (4) 225916 Figure 163
.540430. Oil sump assembly

361. Position the gasket (3) on the crankcase, aligning the fastening
holes.
Note If not faulty the gasket can be reused.
362. Position the oil sump (2), screw on the screws (1) and tighten
them to a torque of:.
tightening torque
24 4 Nm
2. (2 screws)
24 4 Nm
225915 Figure 164
P2D32N029E0115
.543110. Assembly of the engine lubricant heat

exchanger
363. Fit the heat exchanger in the crankcase: a new gasket (2), the
intermediate plate (3), a new gasket (4) and the oil filter mount
(1).
tightening torque
Heat exchanger and oil filter mount 26 4 Nm
(15 M8x1.25x35 screws) (7)
365. Install the engine oil pressure and temperature sensor (5) and
tighten the screws (6) to the specified torque.
tightening torque
Engine oil temperature and pressure 10 2 Nm
225914 Figure 165
sensor (2 M6x1x20 screws) (6)
.540610. Cylinder head assembly

366. Check that the mating surfaces of the cylinder head and crank-
case are clean.
367. There are two types of cylinder head gaskets (2):

Type A is 1.25 mm thick
Type B is 1.15 mm thick
368. Check the average protrusion S of the pistons as indicated in

the relative procedure. If S > 0.40 mm use the type A gasket. If
S 0.40 mm use the type B gasket.
369. Keep the cylinder head gasket (2) clean.
370. Fit the cylinder head gasket (2) with the marking ALTO facing
the head itself. 227353 Figure 166
371. Pay attention to the cable reference dowels (1, 3) present on
the surface of the crankcase.
372. The thickness of the cylinder head gasket (2) is indicated on the
tab (4).
373. After correctly positioning the cylinder head gasket (4) on the
crankcase (5) hook the lifting eyelets (1, 3) using metal ropes
or by means of the specific tool (2) and use the lifting device to
place the cylinder head (6) on the crankcase (5).
code
Note If the valves were removed from the cylinder head,

refit them before installing the cylinder head on the
crankcase.
225913 Figure 167
P2D32N029E0115
Conditions
In case of re-use of the cylinder head fastening screws:
perform two measurements of the diameter of the fasten-

ing screws as shown in the figure, measuring diameters D1
and D2: if D1-D2 <0.1 mm the screw can be reused; if
D1-D2 >0.1 mm the screw must be replaced.
75703 Figure 168
374. After fitting the cylinder head (4), screw in the fixing screws
(1, 3) and tighten them in three stages, following the order and
methods shown in the following figure.
code
1/2" and 3/4"
Note The screws (1, 3) must be lubricated prior to the as-

sembly of the cylinder head (4).
Note Use specific tool (2) for angle tightening.
Note Before each assembly operation, check that the thread 227354 Figure 169
dirt.
375. Diagram of the tightening sequence for the cylinder head fixing
screws:
tightening torque
)
35 5 Nm
203452 Figure 170
2. Step 1 - (10 M12x1.75x150 screws
)
55 5 Nm
90
90
Tool / Material
Torque wrench
Note The screws must be tightened following a "spiral" se-

quence, starting from the centre and proceeding out-
ward.
P2D32N029E0115
.775010. Assembling electro-injectors

376. Fit both a new sealing ring (2) lubricated with Vaseline and a
new sealing washer (3) on the electro-injector (1).
Tool / Material
Vaseline
70338 Figure 171
377. Fit the electro-injectors (1) on the cylinder head seats, directed
so that the fuel inlet hole (2) is facing the fuel manifold seat (3)
side.
378. Position the electro-injector fastening brackets (1) and screw in
the screws without tightening them.
227355 Figure 172
.775021. Fuel manifold installation

379. Fit a new sealing ring (4) lubricated with Vaseline on the fuel
manifold (5) and fit it into the cylinder head seat so that the
positioning balls (3) coincide with the relevant housing (2).
227356 Figure 173
380. During the operation position the electro-injector (1) so that

the fuel manifold is inserted correctly in its fuel inlet hole (2).
70338 Figure 174
P2D32N029E0115
381. Tighten the nuts (5) fastening the fuel manifolds (6) without
locking them.
382. Use a torque wrench to gradually and alternatively tighten the
screws (1) of the brackets fastening(2) the electro-injectors
(7) to the tightening torque and angle specified in the relative
table.
tightening torque
3.5 0.35 Nm
25
25
25
Tool / Material
Torque wrench

To make it easier to refit the fuel manifolds (6) un-
screw the screws (4) and remove the lifting eyelet (3).
When refitting is complete, refit the removed lifting
eyelet needed for hoisting the engine.
383. Tighten the nuts (5) securing the fuel manifolds (6) to a torque
of:
tightening torque
Fuel manifolds for electro-injectors 55 5 Nm
on the cylinder head (4
M22x1.5x9.5 nuts) (5)
.541230. Rocker assembly installation

384. Insert the push rods(2) in the cylinder head (3).
385. Position the control bridges (1) on valves with marks () facing
the exhaust manifold.
225909 Figure 176
P2D32N029E0115
386. Check that the tappet adjustment nuts (3) and the relative
adjustment screws are loosened to prevent their sticking on
the push rods when refitting the rocker arm unit.
387. On the cylinder head, fit the rocker arm units consisting of:
mount (2), rocker arms (1) and spindles (5).
388. Tighten the screws(4) fastening the rocker arm units to the
cylinder head to a torque of:
tightening torque
Rocker arm unit (8 M8x1.25 36 5 Nm
screws) (4)
225908 Figure 177
70520 Figure 178

Technical data
very carefully.
P2D32N029E0115
Tool / Material
Box wrench
Tool / Material
Feeler gauge
Tool / Material
Allen key
Tool / Material
Feeler gauge
tightening torque
direction no.
1 and 4 at T.D.C. 4 1
180 2 3
180 1 4
180 3 2
below:

intake * *
exhaust * *
below:

intake * *
exhaust * *
P2D32N029E0115
Conditions
143281 Figure 179

(1).
Pinion (use with 99360221) 99360222
.540634. Assembly of the electro-injector wiring mount

400. Check the conditions of the electric cables (5), and if dam-
aged replace them by cutting the clips that retain them to the
mount (2) and removing the screws (4) that fasten the con-
nectors to it (3). Once replaced, fasten the electric cables (5)
to the mount (2) using new clips and tighten the screws (4) to
a torque of:
tightening torque
Electro-injector wiring connectors 10 2 Nm
(2 M6x1x16 screws) (4)
401. Assemble a new gasket (1) on the electro-injector wiring

mount (2).
70352 Figure 180
P2D32N029E0115
402. Fit the electro-injector wiring mount (3), together with a new
gasket (4), screw on the screws (1, 2) and tighten them to a
torque of:
tightening torque
port (1, 2) 24 4 Nm
2. (2 screws M8x1.25x50)
24 4 Nm
225907 Figure 181
403. Connect the electrical wiring (1) to the electro-injectors (3)

and using a torque wrench (4) tighten the securing nuts (2) to
a torque of:
tightening torque
Electro-injector wiring (8 M4 1.5 0.25 Nm
nuts) (2)

code
Torque screwdriver (1-6 Nm) for adjusting the locking nut 99389834
of the injector solenoid valve connectors
99228 Figure 182
.540630. Tappet cover assembly

404. Screw the dual threaded shank screws (4) onto the electro-
injector wiring mount.
tightening torque
Dual threaded shank screws fasten- 11 3 Nm
ing the tappet cover (4 M8x1.25
dual threaded shank screws) (4)
405. Place a new gasket (3) on the tappet cover (5).

406. Restore the engine lubricant filler cap (6).
407. Fit the tappet cover (5) on the electro-injector wiring mount,
position the elastic inserts (1), tighten the flanged nuts (2) and
tighten them to a torque of:
tightening torque 225906 Figure 183
Tappet cover (4 M8x1.25 flanged 24 4 Nm
nuts) (2)
P2D32N029E0115
.540821. Assembly of the crankshaft pulley

408. Fit the spacer(4) and the crankshaft pulley (2) on the crank-
shaft (1), screw on the fastening screws (3) and tighten them in
two steps:
tightening torque
50 5 Nm
90

code
225905 Figure 184
1/2" and 3/4"
Torque wrench
Note Use specific tool for angle tightening.
Note The flywheel clamping tool can make it easier to install

the crankshaft pulley.
.543210. Water pump assembly

409. Fit a new sealing ring (1) to the water pump (2).
70221 Figure 185
410. Fit the water pump (2) together with the gasket (1).
tightening torque
Water pump (2 screws 24 4 Nm
M8x1.25x35) (3)
225904 Figure 186
P2D32N029E0115
.543415. Assembly of the guide pulley

412. Fit the guide pulley(6), screw on the fastening screw (1) and
tighten it to the specified torque.
tightening torque
Guide pulley (1 M10x1.5 screw) (1) 43 6 Nm
413. Fit the oil level control/filler cover (4) in the front cover, screw
on the fastening screw (5) and tighten it to the specified torque.
414. Fit a new sealing ring on the rpm sensor (2).
415. Fit the speed sensor(2) of the crankshaft in the front cover and
tighten the fastening screw (3) to a torque of:
tightening torque
Crankshaft speed sensor (1 10 2 Nm
225903 Figure 187
M6x1x20 screw) (3)
.544011. Alternator support assembly

416. Fit a new gasket (2) on the engine coolant inlet/alternator
mount (1).
417. Position the engine coolant inlet/alternator mount (1) so that
the reference dowels (3) are up against the crankcase.
418. Fasten the screws (4) and tighten them to a torque of:
tightening torque
Alternator support and en- 1. (1 M10x1.5x70 screw)
gine coolant inlet pipe (4) 43 6 Nm
2. (2 screws M10x1.5x130)
43 6 Nm
225902 Figure 188
.543416. Assembly of the fan drive pulley

419. Fit the fan pulley mount (4) on the cylinder head and tighten
the fastening screws (1) to the specified torque.
tightening torque
Fan drive pulley mount (4 24 4 Nm
M8x1.25x45 screws) (1)
420. Fit the fan drive pulley (2) on the relative mount and fasten it
by tighten the fastening screws (3) to a torque of:
tightening torque
Fan drive pulley (4 M10x1.5x25 68 7 Nm
screws) (3)
225901 Figure 189
P2D32N029E0115
.543250. Thermostat assembly

421. Install the thermostat (5) together with the gasket in the seat
on the cylinder head (4).
422. Fit the engine coolant outlet/thermostat cover(2) and tighten
the fastening screws(1) to the specified torque.
tightening torque
Thermostat cover (3 M6x1x12 13.5 1.5 Nm
screws) (1)
423. Fit the coolant temperature sensor (3) housed in the cylinder
head (4) and tighten it to the specified torque.
tightening torque
Coolant temperature sensor (1 24 4 Nm
M14x1.5x12 union) (3)
225900 Figure 190
.540480. Assembly of the blow-by filter and oil vapour

recirculation pipes
424. Fit the blow-by filter (7) in position on the flywheel housing and
tighten the fastening screws (8) to the specified torque.
tightening torque
Blow-by filter (3 screws M6x1) (8) 10 2 Nm
425. Install the oil vapour recirculation pipe (5) and tighten the uni-
ons (2, 6) to the specified torque.
tightening torque
Oil vapour recirculation pipe (2 20 4 Nm
M12x1.5 screws) (2, 6)
426. Insert the vapour breather pipe (3) in the union located on 225899 Figure 191
the timing gear case and fasten it with the clips (4). Tighten the
screw (1) fastening the tappet cover to a torque of:
tightening torque
Oil vapour breather pipe (1 M6x1 10 2 Nm
screw) (1)
.540720. Exhaust manifold assembly

427. Fit the exhaust manifold (5) in position together with the new
gaskets (6) on the cylinder head (1) and tighten the fastening
screws (3, 4) together with the spacers (2) to the specified
torque, following the tightening order and methods shown in
tightening torque
Exhaust manifold (8 screws 55 3 Nm
M10x1.5x65) (3, 4)
Note Always replace the gaskets (6) with new spare parts.
Check the thread of the fastening screws: it must not
show signs of wear or deposits of dirt.
225898 Figure 192
P2D32N029E0115
428. Diagram of tightening sequence for exhaust manifold fastening

screws.
Note A = Front side
200095 Figure 193
.540710. Intake manifold assembly

429. The figure indicates the "INTAKE MANIFOLD SEALANT AP-
PLICATION DIAGRAM".
430. Carefully clean the intake manifold and the cylinder head (2).
to seal.
432. Apply the specified sealant on the intake manifold in order to
Tool / Material
LOCTITE 5970

227358 Figure 194
436. Excess sealant will come out on both sides of the joint with the
risk of clogging.
438. Fit the intake manifold (4) on the cylinder head and tighten the
fastening screws (1, 5) to the specified torque:
tightening torque
24 4 Nm
2. (6 screw M8x1.25x25)
24 4 Nm
439. Fit the air pressure and temperature sensor (3) housed in the
intake manifold (4) and tighten the screw (2) to the specified
torque.
tightening torque
Air temperature and pressure 10 2 Nm 225897 Figure 195
sensor (1 M6x1x20 screw) (2)
P2D32N029E0115
.761910. Assembly of the air heater (Grid heater)

440. Fit the cover (2) or air heater for cold ignition (if present), to-
gether with a new gasket (1), in the seat of the intake manifold
and tighten the fastening screws (3) to a torque of:
tightening torque
Heater for cold ignition (6 10 2 Nm
M6x1x16 screws) (3)
225896 Figure 196
.774510. Installation of the common rail

441. Fit the common rail (1) on the intake manifold (3).
442. Manually screw on (without tightening) the fastening screws (2),
then tighten the central screw to a torque of 0.1 Nm.
443. Proceed with the assembly of the fuel delivery pipes to the
electro-injectors, as described in the relative procedure.
444. Tighten the fastening screws (2) to a torque of:
tightening torque
Common Rail (3 M8x1.25x125 36 5 Nm
screws) (2)
225895 Figure 197
.542025. Fuel delivery pipe to injectors installation

445. Fit the high pressure fuel delivery pipes (1) by first manually
positioning the nuts (4) on the common rail side (3) and then
the nuts (2) on the manifold side for the electro-injectors.
446. First tighten the nuts (2) on the manifold side for the electro-
injectors to a torque of 10 Nm and then the nuts (4) on the
common rail side (3).
447. After tightening the screws fastening the common rail to the
intake manifold, first tighten the nuts (4) on the common rail
side (3) and then the nuts (2) on the manifolds side for the
electro-injectors in two steps to a torque of:
tightening torque
225894 Figure 198
55

code
P2D32N029E0115
Note The high pressure fuel delivery pipes must be replaced

each time they are disconnected.
.771010. Assembly of the high pressure fuel pump

448. Tighten the studs (5) on the gear case for fastening the high
pressure pump (6).
449. Refit the high pressure pump (6) together with the mechanical
supply pump and tighten the nuts (1) on the studs (5) to a
torque of:
tightening torque
pump (1, 5) 24 4 Nm
2. (3 M8x1.25x50 studs)
11 3 Nm
Tool / Material Product 225893 Figure 199

code
Note Place the specific tool on the flywheel housing to block

the flywheel rotation to facilitate the refitting of the
high pressure pump. Use the tool with the screw in the
central position with an M8 pitch.
450. Fit the cover (2) and tighten the fastening screws (3) to a
torque of:
tightening torque
Crankcase cover (2 M8x1.25x20 24 4 Nm
screws) (3)
.790510. Assembly of the air compressor for services and

the timing sensor
451. Refit the cover (2) for the power-take off seat (for example,
the air compressor) together with the relative gasket (3) on the
gear case (4) and tighten the screws (1) to a torque of:
tightening torque
Power-take off seat cover (2 80 5 Nm
M12x1.75x25 screws) (1)
452. Fit the timing sensor (6) on the gear case (4) with the relative
mount and the new seal rings and tighten the relative fastening
nut (5) to a torque of:
tightening torque
Camshaft timing sensor (1 M6x1 10 2 Nm 225892 Figure 200
nut) (5)
P2D32N029E0115
.542032. Assembly of the fuel delivery and return pipes

from the rail
453. Fit the fuel delivery pipe (7) from the high pressure pump to
the rail and tighten the nuts (1, 5) to a torque of:
tightening torque
55

code
225891 Figure 201
Note The high pressure fuel delivery pipes must always be

replaced each time they are removed.
454. Install the brackets retaining the fuel pipe (7) and tighten the
fastening screws (6, 8) to the specified torque.
tightening torque
the rail (6, 8)
2. (1 M8x1.25x20 screw)
25 Nm
455. Fit the fuel return pipe (4) from the rail and electro-injectors
and connect the low pressure unions (2, 3) to the rail and the
cylinder head, as shown in the following figure.

116237 Figure 202
P2D32N029E0115
.542410. Turbocharger assembly

457. If removed, screw the nuts (5) onto the exhaust manifold (4)
and tighten them to the specified torque.
458. Refit the turbocharger (2) on the exhaust manifold (4), to-
gether with a new gasket (3) and tighten the fastening nuts (1)
on the studs (5) to a torque of:
tightening torque
manifold (1, 5) 24 4 Nm
2. (4 M8x1.25x40 studs)
11 3 Nm
225890 Figure 203
.543760. Assembly of the motorised throttle valve (Ex-

haust flap)
459. Fit the throttle body (5) together with the electric actuator (1)
on the turbocharger exhaust (2).
460. Turn the screw (4) and tighten the V collar (3) to the specified
torque.
tightening torque
screw) (4)
225889 Figure 204
P2D32N029E0115
461. Fit the coolant delivery pipe (3) of the electric actuator and
tighten the fastening nut (13) and the union (1) to a torque of:
tightening torque
Coolant delivery pipe to the 1. (1 M10x1 fitting)
electric actuator (1, 13) 20 Nm
2. (1 M12x1.5 nut)
45 Nm
462. Fit the lower part of the coolant return pipe (7) of the electric
actuator and tighten the fastening nut (8) and the union (6) to
a torque of:
tightening torque
Lower part of the electric 1. (1 M10x1 fitting)
joint (6, 8)
2. (1 M12x1.5 nut)
45 Nm
463. Fit the upper part of the coolant return pipe (4) of the electric
actuator and tighten the fastening nut (11) and the union (2) to
a torque of:
tightening torque
joint (2, 11)
2. (1 M12x1.5 nut)
45 Nm
225888 Figure 205
464. Fit the coolant return pipe joint(9) of the electric actuator and
tighten the fastening screws (5, 10) to a torque of:
tightening torque
Electric actuator coolant return pipe (2 screws M8x1.25x20)
joint (5, 10) 23 2 Nm
465. Fit the bracket retaining the electric actuator coolant return
pipe and tighten the fastening nut (12) to a torque of:
tightening torque
Bracket retaining the electric actu- (1 M10 nut)
ator coolant return pipe (12) 20 Nm
466. The electric connector for the throttle valve actuator will be
connected later when assembling the engine cable.
P2D32N029E0115
.542430. Assembly of the turbocharger oil pipes

467. Insert the lubricant return pipe (2) from the turbocharger in
the crankcase together with a new seal ring on the union (6).
468. Tighten the screws (1) fastening the lubricant oil return pipe
(2) from the turbocharger to a torque of:
tightening torque
Turbocharger lubricant return pipe 23 2 Nm
(2 M8x1.25x25 screws) (1)
469. Fit the bracket (4) retaining the lubricant return pipe (2) from
the turbocharger and tighten the screw (3) and the nut (5) to
the specified torque.
225887 Figure 206
470. Fit the lubricant delivery pipe (2) to the turbocharger and
tighten the unions (1,3) to a torque of:
tightening torque
unions) (1, 3)
225886 Figure 207
P2D32N029E0115
.543070. Oil filter assembly

471. Fit a new gasket (2) onto the oil filter (3).
472. Fit the oil filter (3) on the mount (1) and tighten it using the
specific tool to a torque of:
tightening torque

code
225885 Figure 208
.760310. Alternator assembly

473. Fit the alternator (6) with the relative support bracket and
tighten the fastening screws(1, 4, 5) to a torque of:
tightening torque
bracket (1, 4, 5) 43 6 Nm
2. (1 M10x1.5x20 screw)
43 6 Nm
3. (1 M10x1.5x110 screw)
43 6 Nm
474. Install the automatic belt tensioner mount (3) and tighten the
fastening screws (2) to a torque of: 225884 Figure 209
tightening torque
Automatic belt tensioner mount (2 24 4 Nm
M8x1.25x30 screws) (2)
.543411. Assembly of the alternator / water pump drive

belt
475. Fit the automatic belt tensioner (1) and tighten the fastening
screw (2) to a torque of:
tightening torque
Automatic belt tensioner (1 screw 43 6 Nm
M10x1.5x70) (2)
Caution!
Spring belt Precaution during disassembly
The flexible belt must be replaced with a new one
every time it is removed from the vehicle. 225883 Figure 210
476. Using the appropriate tool (4), act on the automatic belt ten-
sioner (1) and fit the new water pump, alternator and fan pul-
ley drive belt (3).
P2D32N029E0115
.766161. Assembly of the EDC17CV41 control unit

477. Refit the control unit (1) including the heat exchanger to the
crankcase and tighten the screws (2) to a torque of:
tightening torque
Control unit with fuel heat ex- 14 Nm
changer (3 M8x1.25x45 screws) (2)
Note It is recommended that the supporting elastic parts are

replaced (2).
225882 Figure 211
P2D32N029E0115
225880 Figure 212

.540110. Removal from the rotating stand
478. Apply the lifting beam to the engine hooks, anchor the beam to the hoist and detach the engine from the rotating stand. Re-
move the brackets from the crankcase.
Assembly rotating stand for overhaul (load bearing capacity 1000 daN, torque 120 daNm) 99322205
479. Tighten the lubricant drain plug (4) housed in the lower part of the oil sump and tighten it to a torque of:
tightening torque
Lubricant drain plug on the sump (1 M22x1.5 plug) (4) 50 5 Nm
480. Continue the operation of filling the engine lubricant in the quantity and quality specified in the REFILLING table through the
oil filler hole located in the tappet cover.
P2D32N029E0115
.769140. Fitting the engine cable

481. Correctly position the engine cable (6) and close the clips (2,4)
retaining the engine cable to the crankcase, to the intake mani-
fold and to the tappet cover, tightening the relative nuts (3,5).
225881 Figure 213
P2D32N029E0115
225718 Figure 214

482. Connect the engine cable to the connector from the control unit (7), to the motorised throttle valve actuator connector (2)
and to all the sensors and transmitters indicated.
.543740. Assembly of the throttle valve cooling pipe re-

taining bracket
483. Fit the throttle valve cooling pipe retaining bracket (2) and
tighten the fastening screws (1, 3) to a torque of:
tightening torque
Bracket retaining the elec- 1. (1 M12x1.75x25 screw)
tric actuator coolant return 48 5 Nm
pipe (1, 3)
9.5 1 Nm
225879 Figure 215
P2D32N029E0115
.760810. Mounting the electric starter motor

484. Tighten the studs (1) on the flywheel housing (3).
485. Refit the electric starter motor (2) on the flywheel housing (3)
and tighten the fastening nuts (4) to a torque of:
tightening torque
43 6 Nm
2. (3 M10x1.5x50 studs)
25 5 Nm
225878 Figure 216
.542014. Assembly of the fuel filter mount

486. Fit the fuel filter mount (5) on the crankcase and tighten the
fastening screws (7) to the specified torque:
tightening torque
Fuel filter mount (2 M12x1.75x30 80 8 Nm
screws) (7)
487. Connect the low pressure fuel pipes (1,3,4,6) to the fuel filter
mount (5).
488. Fit the fuel temperature sensor (8) housed in the fuel filter
mount (5) and tighten it to a torque of:
tightening torque
Fuel temperature sensor (1 24 4 Nm
M14x1.5x12 union) (8)
225877 Figure 217
489. Connect the electrical connections of the fuel temperature

116237 Figure 218
P2D32N029E0115
.542010. Fuel filter assembly

491. After removing the brackets for fastening the engine to the
overhaul stand from the crankcase, proceed as follows working
from the left side of the engine:
code
492. Fit a new gasket (2).

493. Manually screw the fuel filter (3) until flush on the mount (1).
494. Using the specific tool, tighten the fuel filter (3) on the mount
(1) to a torque of:
tightening torque
225876 Figure 219

code
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV technical specifications
Contents 1
Contents
technical specifications . . . . . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
Contents
Contents
DATA - INSTALLATION CLEARANCES . . . . . . . . . 5

Assembly clearances and data . . . . . . . . . . . . . . . 5
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . 9
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 9
P2D32N029E0115
4 technical specifications
P2D32N029E0115
DATA - INSTALLATION CLEARANCES
Assembly clearances and data
CYLINDER ASSEMBLY AND CRANK GEARS mm
Cylinder liners 1 104.000 104.024
1 0.4 - 0.8
Pistons type:
Measuring point X 49.5 49.5
Outer diameter 1 103.739 103.757 103.739 103.757
Pin housing 2 40.010 40.016 40.010 40.016
Piston - cylinder liners 0.243 0.285 0.243 0.285
Piston diameter 1 0.4 - 0.8
Piston position from

X 0.28 0.52
crankcase
Piston pin 3 39.994 40.000
Piston pin - pin seat 0.010 0.022 0.010 0.022
X 1* 2.705 2.735 2.705 2.735

Piston ring slots X2 2.420 2.440 2.420 2.440
X3 4.030 4.050 4.030 4.050
* measured on of 101 mm
S 1** 2.563 2.597
Piston rings S2 2.350 2.380
S3 3.970 3.990
* measured at 1.5 mm from at the outside
1 0.108 0.172 0.108 0.172
Piston rings - slots 2 0.040 0.090 0.040 0.090
3 0.040 0.080 0.040 0.080
Piston rings 0.4 - 0.8
P2D32N029E0115

Piston ring end gap in cylinder
liner:
X1 0.30 0.40
X2 0.60 0.80
X3 0.30 0.55
Connecting rod small end bush
seat
1 42.987 43.013
Big-end bearing seat
2 73.987 74.013
Connecting rod small end bush
diameter
External 4 43.082 43.112

Internal 3 40.019 40.033
Connecting rod bearing

shells supplied as spare S 1.958 1.968
parts
Connecting rod small end bush -
0.069 0.125
housing
Piston pin - bushing 0.019 0.039
Connecting rod half-bearings 0,25 - 0,50
Main journals 1 82.990 83.010
Crankpins 2 69.987 70.013
Main half-bearings S1 2.464 2.472
Connecting rod half-

S2 1.958 1.968
bearings
*provided as spare part
Main bearings
No. 1 5 3 87.982 88.008
No. 2 3 4 3 87.977 88.013

Half-bearings - main journals
No. 1 5 0.028 0.090
No. 2 3 4 0.023 0.095
Half-bearings - crankpins 0.038 0.110
Main half-bearings
0,25 - 0,50
Connecting rod half-bearings
P2D32N029E0115
Thrust main journal X1 37.475 37.545
Thrust main bearing X2 32.180 32.280
Thrust half rings X3 2.470 2.530
Crankshaft thrust 0.135 0.425
CYLINDER HEAD - TIMING SYSTEM mm
Valve guide housing on

1 7.042 7.062
cylinder head
Valves:
4 6.990 7.010
60 0 15'
4 6.990 7.010
45 0 15'
Valve stem and related guide 0.032 0.072
Housing on head for valve seat
1 34.837 34.863
1 34.837 34.863
Valve seat outside diameter;

valve seat angle on cylinder
head:
2 34.917 34.931
60
2 34.917 34.931
45
P2D32N029E0115

0.59 1.11
Sinking X
0.96 1.48
0.054 0.094
Between valve seat and
cylinder head
0.054 0.094
Valve seats
Valve spring height:

free spring H 47.75
under a load of:
339.8 19 N H1 35.33
741 39 N H2 25.2
Injector protrusion X Not adjustable
Seat for camshaft bushing no. 1

59.222 59.248
(flywheel side)
Camshaft seats no. 2-3-4-5 54.089 54.139
Camshaft journals:

15 53.995 54.045
1-2-3
Bushing inside diameter

54.083 54.147
after drive-in
Bushing and seat in crankcase 0.113 0.165
Bushing and support pins 0.038 0.152
Useful cam height:
H 6.045
H 7.582
Tappet housing on
1 16.000 16.030
crankcase
P2D32N029E0115
TIGHTENING TORQUES

Tappet outside diameter:
2 15.924 15.954
3 15.960 15.975
Between tappets and seats 0.025 0.070
Tappets
Rocker-arm shaft 1 21.965 21.977
Rocker arms 2 22.001 22.027
Between rockers and shaft 0.024 0.062
TIGHTENING TORQUES
540110 TIGHTENING TORQUES
Torques
tightening torque
Oil sprayers for piston cooling (4 M8x1 25x20 unions) 15 3 Nm
Crankshaft main bearing caps (10 M12x1.5 screws) 1. Step 1 - Tightening with torque wrench to torque
80 6 Nm
90
Crankshaft connecting rod caps(8 M10x1.25x52 screws) 1. Step 1 - Tightening with torque wrench to torque
50 5 Nm
60
Camshaft longitudinal retaining plate (2 M8x1.25 screws) 24 4 Nm
Rear gear case 1. (1 M12x1.75 screw)
77 12 Nm
2. (4 M8x1.25 screws)
24 4 Nm
3. (5 M10x1.5 screws)
47 5 Nm
Timing gear (6 M8x1.25 screws) 36 2 Nm
Flywheel housing 1. (8 M12x1.75 screws)
P2D32N029E0115
TIGHTENING TORQUES
tightening torque
Flywheel housing 1. 85 10 Nm
2. (12 M10x1.5 screws)
49 5 Nm
Engine flywheel (8 M12x1.25 screws) 1. Step 1 - Tightening with torque wrench to torque
30 4 Nm
60
Oil pump (4 M8x1.25 screws) 1. Step 1 - pretightening with the torque wrench
8 1 Nm
2. Step 2 - Tightening with torque wrench to torque
24 4 Nm
Front cover 1. (5 screws M8x1.25x45)
24 4 Nm
2. (8 screws M8x1.25x30)
24 4 Nm
Additional masses (8 M10x1.5 screws) 48 8 Nm
Oil intake suction strainer in the sump (2 M8x1.25x20 screws) 24 4 Nm
Bracket retaining the suction strainer in the sump (1 M10x1.5x25 screw) 43 5 Nm
Engine oil sump 1. (22 screws)
24 4 Nm
2. (2 screws)
24 4 Nm
Cylinder head 1. Step 1 - (8 M12x1.75x130 screws )
35 5 Nm
2. Step 1 - (10 M12x1.75x150 screws )
55 5 Nm
90
90
Electro-injector brackets (8 M6x1x35 screws) 1. Step 1 - Tightening with torque wrench to torque
3.5 0.35 Nm
25
25
25
Fuel manifolds for electro-injectors on the cylinder head (4 M22x1.5x9.5 55 5 Nm
nuts)
P2D32N029E0115
TIGHTENING TORQUES
tightening torque
Electro-injector wiring support 1. (3 screws M8x1.25x70)
24 4 Nm
2. (2 screws M8x1.25x50)
24 4 Nm
Dual threaded shank screws fastening the tappet cover (4 M8x1.25 dual 11 3 Nm
threaded shank screws)
Intake manifold 1. (1 M8x1.25x70 screw)
24 4 Nm
2. (6 screw M8x1.25x25)
24 4 Nm
Pipes delivering fuel to the electro-injectors (8 M14x1.5 unions) 1. Step 1 - Tightening with torque wrench to torque
10 Nm
55
Pipe delivering fuel from the pump to the rail (2 M14x1.5 uni- 1. Step 1 - Tightening with torque wrench to torque
ons) 10 Nm
55
Bracket retaining the delivery fuel pipe from the pump to the 1. (1 M8x1.25x16 screw)
rail 25 Nm
2. (1 M8x1.25x20 screw)
25 Nm
Power-take off seat cover (2 M12x1.75x25 screws) 80 5 Nm
High pressure pump gear (1 M18x1.5 nut) 105 5 Nm
High pressure fuel injection pump 1. (3 M8 nuts)
24 4 Nm
2. (3 M8x1.25x50 studs)
11 3 Nm
Crankcase cover (2 M8x1.25x20 screws) 24 4 Nm
Turbocharger on the exhaust manifold 1. (4 M8x1.25 nuts)
24 4 Nm
2. (4 M8x1.25x40 studs)
11 3 Nm
P2D32N029E0115
TIGHTENING TORQUES
tightening torque
Coolant delivery pipe to the electric actuator 1. (1 M10x1 fitting)
20 Nm
2. (1 M12x1.5 nut)
45 Nm
Lower part of the electric actuator coolant return pipe joint 1. (1 M10x1 fitting)
20 Nm
2. (1 M12x1.5 nut)
45 Nm
Upper part of the electric actuator coolant return pipe joint 1. (1 M10x1 fitting)
20 Nm
2. (1 M12x1.5 nut)
45 Nm
Electric actuator coolant return pipe joint (2 screws M8x1.25x20)
23 2 Nm
Bracket retaining the electric actuator coolant return pipe (1 M10 nut)
20 Nm
Bracket retaining the electric actuator coolant return pipe 1. (1 M12x1.75x25 screw)
48 5 Nm
9.5 1 Nm
Crankshaft pulley (6 M12x1.25x78.5 screws) 1. Step 1 - Tightening with torque wrench to torque
50 5 Nm
90
Fan drive pulley mount (4 M8x1.25x45 screws) 24 4 Nm
Fan drive pulley (4 M10x1.5x25 screws) 68 7 Nm
Guide pulley (1 M10x1.5 screw) 43 6 Nm
Automatic belt tensioner mount (2 M8x1.25x30 screws) 24 4 Nm
Alternator support and engine coolant inlet pipe 1. (1 M10x1.5x70 screw)
43 6 Nm
2. (2 screws M10x1.5x130)
43 6 Nm
Alternator and fastening bracket 1. (1 M10x1.5x30 screw)
43 6 Nm
2. (1 M10x1.5x20 screw)
43 6 Nm
3. (1 M10x1.5x110 screw)
43 6 Nm
P2D32N029E0115
TIGHTENING TORQUES
tightening torque
Starter motor 1. (3 M10x1.5 nuts)
43 6 Nm
2. (3 M10x1.5x50 studs)
25 5 Nm
Crankshaft speed sensor (1 M6x1x20 screw) 10 2 Nm
Camshaft timing sensor (1 M6x1 nut) 10 2 Nm
Coolant temperature sensor (1 M14x1.5x12 union) 24 4 Nm
P2D32N029E0115
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV Equipment
Contents 1
Contents
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
TOOLS 3
Contents
Contents
P2D32N029E0115
4 TOOLS
P2D32N029E0115
TOOLS 5
TOOLS
Tool for verifying the diesel supply circuit and the common rail injection system
(99305453)
Set of 5 insert wrenches 9x12 (14-15-17-18-19 mm) (99317915)
Assembly rotating stand for overhaul (load bearing capacity 1000 daN, torque 120 daNm)
(99322205)
Extraction tool for crankshaft front ring seal (99340055)
P2D32N029E0115
6 TOOLS
Extraction tool for crankshaft rear gasket (99340056)
Dual-actuated bridge (99341001)
Bracket torque (99341009)
Clamp (99341015)
Extraction tool for injectors (99342101)
P2D32N029E0115
TOOLS 7
Key to fit crankshaft front gasket (99346252)
Key to fit crankshaft rear gasket (99346253)
Extraction tool for cartridge filters (99360076)
Pliers for piston rings removal/refitting (65-110 mm) (99360183)
Tool to rotate flywheel (use with 99360222) (99360221)
P2D32N029E0115
8 TOOLS
Pinion (use with 99360221) (99360222)
Tool to take down and fit back engine valves (99360268)
Tool for retaining the flywheel (99360351)
Drift tool for removing/fitting camshaft bush (to be used with 99370006) (99360362)
Crankshaft lifting tool (99360500)
P2D32N029E0115
TOOLS 9
Arm for engine removal and refitting (99360595)
Clamp for fitting piston into cylinder liner (60 - 125 mm) (99360605)
Brackets for fastening engine to 99322205 rotary stand (99361037)
Extraction tool for gaskets (99363204)
Manual pump for measuring pressure and vacuum (99367121)
P2D32N029E0115
10 TOOLS
Grip for inter-changeable drifts (99370006)
Dial gauge base to adjust lay shaft bearings (use with 99395603) (99370415)
Coupling torque wrench 9X12 (5-60 Nm) (99389829)
Torque screwdriver (1-6 Nm) for adjusting the locking nut of the injector solenoid valve
connectors (99389834)
Set of gauges for angle tightening with square connection - 1/2" and 3/4" (99395216)
P2D32N029E0115
TOOLS 11
Dial gauge (0-5 mm) (99395603)
P2D32N029E0115
12 TOOLS
P2D32N029E0115
NEF 45 TIER 4B/STAGE IV safety regulations
Contents 1
Contents
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . 3
P2D32N029E0115
2 Contents
P2D32N029E0115
SAFETY REGULATIONS 3
Contents
Contents
Standard safety precautions . . . . . . . . . . . . . . . . . . 5
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . 5
During maintenance . . . . . . . . . . . . . . . . . . . . . . . 5
Protection of the environment . . . . . . . . . . . . . . . . 6
P2D32N029E0115
4 SAFETY REGULATIONS
P2D32N029E0115
SAFETY REGULATIONS 5
Standard safety precautions
SAFETY REGULATIONS
Standard safety precautions
We direct your attention on some precautions that must be necessarily followed in a regular work environment and, in case of
non-compliance, any other precaution will not be sufficient to protect the safety of the staff in charge of maintenance.
Please obtain information and inform the staff on applicable laws on safety, making the informative material available for con-
sultation.
Please keep the rooms as clean as possible and properly ventilated.
Equip the rooms with specific, well-visible first-aid boxes, always stocked up with suitable medical aids.
Be equipped with suitable fire extinguishing devices, properly signalled and never obstructed. Check their operation on a regu-
lar basis and train the staff on the intervention priorities and methods.
Arrange gathering points for the evacuation of the rooms, properly signalling the exit routes.
Absolutely prohibit smoking in the areas where the works subject to fire hazard are carried out.
Draw the attention on prohibitions and indications with suitable signs, which are immediately comprehensible always in case of
emergency.
Accident prevention
Do not wear cloths with loose edges, rings and chains, while working near engines and moving organs.
Use protective gloves and glasses when: - filling up inhibitors or antifreeze; - replacing or filling up lubricant; - using air or li-
quids under pressure (permitted pressure 2 bar).
Wear a protective helmet if working in an area with suspended loads or overhead systems.
Always wear safety shoes and cloths fitted to the body, better if equipped with rubber bands at the edges.
Use protective creams for hands.
Change wet clothes as soon as possible.
In the presence of voltage higher than 48-60V, check the efficacy of the ground electric connections. Make sure your hands
and feet are dry and perform the work standing on insulating platforms. Do not proceed if not qualified!
Do not smoke or spark free flames near batteries and any combustible material.
Return oily rags or solvents to fire-proof containers.
Do not perform operations without the necessary instructions.
Do not use equipment to perform works other than those for which they have been designed, you may sustain accidents,
even of serious type.
In case of checks or calibrations that require the engine to be on, make sure that the room is properly ventilated and use
proper fans to remove exhaust gases: intoxication and death hazard.
During maintenance
Never open the filling cap of the cooling circuit when the engine is hot. The operating pressure will spill the high temperature
liquid with serious risk of burns. Wait until the temperature drops below 50 C.
Never add coolant to an overheated engine and only use appropriate fluids.
Always operate with engine off: in case particular circumstances require maintenance with the engine on, consider all the risks
involved in these operations.
Use adequate and safe containers for draining the engine fluids and exhaust oil.
Preserve the engine clean from oil, gas oil stains and/or chemical solvents.
The use of solvents or detergents during maintenance may develop toxic vapours. Always ventilate the work rooms. Use
safety masks when required.
Do not leave cloths soaked with flammable substances near the engine.
When starting up the engine after a repair operation, foresee suitable measures to stop air suction in case of over-revving.
Do not use quick screwers.
Do not disconnect the batteries whilst the engine is running.
P2D32N029E0115
6 SAFETY REGULATIONS
Protection of the environment
Before any interventions involving the electrical circuits, disconnect the batteries.
Disconnect the batteries from the on-board network while charging.
After each intervention, make sure the polarity of the battery's terminals is respected and the latter are well tightened and
protected against accidental short circuits and oxidation phenomena.
Do not disconnect and connect the electric connections when power is on.
Before carrying out removal operations on pipes (pneumatic, hydraulic or fuel pipes), check the possible presence of fluid or
air under pressure. Adopt the necessary precautions, exhausting the residual pressures or closing the shut-off valves. Always
wear suitable masks or protective glasses. Serious accidents and intoxications may occur if not respecting these rules.
Avoid improper tightening operations or out of torque. The engine's components may be damaged also seriously, thus preju-
dicing their life cycle.
Avoid draughts from fuel tanks in copper alloy and/or pipes without filters.
Do not apply changes to the cabling, their length must not be modified.
Do not connect any utility to the engine's electric equipment, unless specifically approved.
Do not modify the fuel or hydraulic systems without authorization. Any unforeseen change will void the warranty and may
prejudice the engine's duration and life cycle.
For engines equipped with electronic units:
Do not carry out any arch welding without previously removing the electronic units.
Remove the electronic control units in case of interventions in which the temperatures will exceed 80 C.
Do not paint the electronic components and connections.
Do not modify or alter the data contained in the engine management electronic control unit. Any manipulation or alteration of
the electronic components will invalidate the service warranty of the engine and may also affect its operation and duration.
Protection of the environment

Allows prioritise protection of the environment implementing all necessary precautions to protect the safety and health of
staff.
Make sure you and all staff are fully aware of current standards for the treatment and disposal of fluids and engine oils. Set up
adequate signage and specific courses to ensure a full understanding of the rules and the basic prevention measures.
Collect used oil in suitable containers with water tight seals also providing storage in areas which are adequately
marked,ventilated, away from sources of heat and present no fire hazard.
Handle batteries with care in well ventilated areas and in antacid containers. Beware of fumes coming from the batteries: they
may pose a serious risk of poisoning and contamination of the environment.
P2D32N029E0115

F4HFE413K

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NEF 45 TIER 4B/STAGE IV

Technical repair manual

FPT Industrial S.p.A.

Figures and words: FPT Industrial S.p.A. 2015

Technical repair manual 1

SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . . 6

GENERAL WARNINGS REGARDING THE

Grounding and screening . . . . . . . . . . . . . . . . . . . . 9

Optional electrical and mechanical parts

Conversions between the main units of measurement

Danger for persons

Risk of serious damage to the assembly

NOTE Indicates an additional explanation for a piece of information.

SYMBOLS - SERVICE OPERATIONS

Tighten to the specified torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

Grounding and screening

Optional electrical and mechanical parts installations

Revolutions per time unit

CORRESPONDENCE BETWEEN TECHNICAL

CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES

Technical codes Commercial Codes

F4HFE413K*B010 - ENGINE FAMILY IDENTIFICATION

F4HFE413K*B010 - Non structural crankcase - Application OFF-ROAD

F4HFE413K*B010 - ENGINE WITH HW DESIGNED FOR TIER4/EURO6

F4HFE413K*B010 - CYLINDER CONFIGURATION (E = 4-stroke vertical with post-treatment device)

F4HFE413K*B010 - NUMBER OF CYLINDERS

F4HFE413K*B010 - MAIN ENGINE CHARACTERISTICS (1 = Direct injection turbodiesel with aftercooler)

F4HFE413K*B010 - APPLICATION (3 = Industrial/agricultural)

F4HFE413K*B010 - Engine torque or power level

F4HFE413K*B 010 - Level of emissions (B = Tier 4 full / Stage IV)

N45ENTHW20.50 ENGINE FAMILY IDENTIFICATION (N = NEF)

N45E NTHW20.50 - FUEL SUPPLY: E = ELECTRONICALLY CONTROLLED INJECTION

N45ENTHW20.50 - CRANKCASE: N = NOT STRUCTURAL (NORMAL DISTRIBUTION)

N45ENTHW20.50 - AIR INTAKE: T = INTERCOOLED TURBOCHARGED

N45ENTHW20.50 - EMISSION LEVEL: H = Tier 4 full / Stage IV

N45ENTHW20.50 - ENGINE CONTROL UNIT: W = EDC17CV41

N45ENTHW20.50- Progressive engine variants

Right side view

Type F4HFE413K*B010 F4HFE413T*B005

Cycle Diesel 4-stroke

Power supply Turbocharged with intercooler

Number and arrangement of

Type F4HFE413K*B010 F4HFE413T*B005

Total displacement cm3 4.485

Max. power (CV) (170) (121)

r.p.m 2.200 2.200

Maximum torque (kgm) (72,38) (54,94)

r.p.m 1.500 1.250

Idle speed with no load r.p.m 750 100

Maximum engine idle

TURBOCHARGING Turbocharger with intercooler

Turbocharger type HONEYWELL GARRETT GT2556N

Type F4HFE413K*B010 F4HFE413T*B005

start before T.D.C. A 8.5

end after B.D.C. B 8.5

start before B.D.C. D 51

End after T.D.C. C 12.5

For timing check

High pressure fuel supply controlled by BOSCH EDC17CV41

Electro-injectors type CRIN2 CRIN2-16

Type F4HFE413K*B010 F4HFE413T*B005

Type F4HFE413KB010 F4HFE413TB005

Type F4HFE413KB010 F4HFE413TB005

Type F4HFE413KB010 F4HFE413TB005

Type F4HFE413KB010 F4HFE413TB005