Motor Iveco F5C PDF
Motor Iveco F5C PDF
Motor Iveco F5C PDF
F5AE9454D / F5AE9454J /
F5AE9454L / F5AE9484A /
F5AE9484B / F5AE9484G /
F5AE9484K / F5CE5454B*A005 /
F5CE5454B / F5CE5454C*A003 /
F5CE5454G*A001 / F5CE9454C /
F5CE9454E / F5CE9454G /
F5CE9484C / F5CE9484E
Engine
SERVICE MANUAL
INTRODUCTION
ENGINE AND PTO IN ................................................................... B
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A
ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A
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Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
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INTRODUCTION
Foreword
This publication contains data, features instructions and methods for performing repair operations on the assembly
and its components and is addressed to qualified, specialized personnel.
Check to make sure you have the right publication related to the component you are about to work on before you start.
Make sure that you have all the necessary safety equipment: safety glasses, helmet, gloves, footwear, etc. Check
that the working lifting and transport equipment is available and in working order. Make sure that vehicle is secured.
Proceed by carefully observing the instructions contained in this publication and use the indicated specific tools to
ensure correct repair procedures and safety of operators.
NOTE: This manual applies to multiple applications, therefore images may not all be accurate.
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INTRODUCTION
Safety rules
Standard safety precautions
Be informed and notify personnel of the laws in force regulating safety, and provide documentation available for
consultation.
• Keep working areas as clean as possible.
• Ensure that working areas are provided with emergency boxes. They must be clearly visible and always contain
adequate sanitary equipment.
• Fire extinguishers must be properly identified and always be clear of obstructions. Their efficiency must be checked
on a regular basis and personnel must be trained on proper interventions and priorities.
• Keep all emergency exits free of obstructions and clearly marked.
• Smoking in working areas subject to fire danger must be strictly prohibited.
Prevention of injury
• Wear suitable work attire and safety glasses with no jewelry such as rings and chains when working close to
engines and equipment in motion.
• Wear safety gloves and goggles when performing the following operations:
• Topping off or changing lubrication oils.
• Using compressed air or liquids at a pressure greater than 2 bar (29 psi).
• Wear a safety helmet when working close to hanging loads or equipment working at head level.
• Always wear safety shoes and fitting clothes.
• Use protection cream for hands.
• Change wet clothes as soon as possible.
• In the presence of voltages exceeding 48 - 60 V, verify the efficiency of the ground and mass electrical connections.
Ensure that hands and feet are dry and use isolating foot boards. Workers should be properly trained to work with
electricity.
• Do not smoke or start an open flame close to batteries and any fuel material.
• Place soiled rags with oil, diesel fuel or solvents in specially provided anti-fire containers.
• Do not use any tool or equipment for any use other than what it was originally intended for. Serious injury may
occur.
• If running an engine indoors, make sure there is a sufficient exhaust fan in use to eliminate exhaust fumes.
During maintenance
• Never open the filler cap of the cooling system when the engine is hot. High temperature liquid at operating
pressure could result in serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122
°F).
• Never add coolant to an overheated engine and use only appropriate liquids.
• Always work when the engine is turned off. Certain circumstances require maintenance on a running engine. Be
aware of all the risks involved with such an operation.
• Always use adequate and safe containers for engine fluids and used oil.
• Keep engine clean of any spilled fluids such as oil, diesel fuel, and or chemical solvents.
• Use of solvents or detergents during maintenance may emit toxic vapors. Always keep working areas aerated.
Wear a safety mask if necessary.
• Do not leave soiled rags that may contain any flammable substances close to the engine.
• Always use caution when starting an engine after any work has been performed. Be prepared to cut off intake air
in case of engine runaway.
• Never disconnect the batteries while the engine is running.
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INTRODUCTION
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INTRODUCTION
Torque
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Oil Pan
Threaded cap with O-ring 45 - 55 N·m (33 - 41 lb ft)
Oil pan spacer M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
- Angle torque 85 - 95 °
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Conical thread cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Conical thread cap 1/8" 10 - 20 N·m (7 - 15 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
Cylinder head M15x1.5
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
Cylinder head M12x1.5
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
Exhaust Manifold
Exhaust manifold 10 - 20 N·m (7 - 15 lb ft)
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INTRODUCTION
Torque
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Oil Pan
Side cap M6 35 - 45 N·m (26 - 33 lb ft)
Side caps M22 45 - 55 N·m (33 - 41 lb ft)
Front cap M35 35 - 45 N·m (26 - 33 lb ft)
Fixing of sump 65 - 75 N·m (48 - 55 lb ft)
Engine Block
Crankshaft caps
- Pre torque 45 - 55 N·m (33 - 41 lb ft)
- Torque 75 - 85 N·m (55 - 63 lb ft)
- Angle torque 85 - 95 °
Piston cooling nozzle 16 - 20 N·m (12 - 15 lb ft)
Conical thread cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Conical thread cap 1/8" 10 - 20 N·m (7 - 15 lb ft)
Water drainage cap 20 - 30 N·m (15 - 22 lb ft)
Oil turbo supply pipe fitting 35 - 45 N·m (26 - 33 lb ft)
Timing gearcase
Conical thread cap 10 - 20 N·m (7 - 15 lb ft)
Gear cooling nozzle 10 - 20 N·m (7 - 15 lb ft)
Cover M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Ignition pump screw stud 3 - 5 N·m (27 - 44 lb in)
Timing pin seat cap 20 - 30 N·m (15 - 22 lb ft)
Gearcase M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Inspection cover 20 - 30 N·m (15 - 22 lb ft)
Flywheel housing
Housing M8x1.25 30 - 40 N·m (22 - 30 lb ft)
M12x1.75 115 - 125 N·m (85 - 92 lb ft)
Cylinder head
Cylinder head M15x1.5
- Stage 1 120 - 140 N·m (89 - 103 lb ft)
- Stage 2 85 - 95 °
- Stage 3 85 - 95 °
Cylinder head M12x1.5
- Stage 1 60 - 70 N·m (44 - 52 lb ft)
- Stage 2 85 - 95 °
- Stage 3 55 - 65 °
Threaded cap 35 - 45 N·m (26 - 33 lb ft)
Overhead
Rocker arm dowel 20 - 30 N·m (15 - 22 lb ft)
Overhead M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Valve adjusting nut 15 - 25 N·m (11 - 18 lb ft)
Intake Manifold
Intake manifold M8x1.25 20 - 30 N·m (15 - 22 lb ft)
Throw fastening to intake manifold 20 - 30 N·m (15 - 22 lb ft)
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INTRODUCTION
Exhaust Manifold
Exhaust manifold 30 - 40 N·m (22 - 30 lb ft)
Turbocharger mounting stud 10 - 20 N·m (7 - 15 lb ft)
Pulley
Engine crankshaft pulley 335 - 365 N·m (247 - 269 lb ft)
Connecting Rod
Connecting rod cap
- Pre-torque 45 - 55 N·m (33 - 41 lb ft)
- Angle torque 65 - 75 °
Flywheel
Flywheel
- Pre-torque 25 - 35 N·m (18 - 26 lb ft)
- Angle torque 85 - 95 °
Timing
Phonic wheel 12 - 18 N·m (9 - 13 lb ft)
Thrust block 20 - 30 N·m (15 - 22 lb ft)
Gear 31 - 41 N·m (23 - 30 lb ft)
Injector
Injector stud screw 21 - 29 N·m (15 - 21 lb ft)
Injector fastening nut
- Pre-torque 10 - 20 N·m (7 - 15 lb ft)
- Angle torque 25 - 35 N·m (18 - 26 lb ft)
LDA
Manifold side 15 - 25 N·m (11 - 18 lb ft)
Pump side 15 - 25 N·m (11 - 18 lb ft)
Sensors
Crankshaft speed sensor 5 - 15 N·m (4 - 11 lb ft)
Camshaft speed sesnor 5 - 15 N·m (4 - 11 lb ft)
Water temperature sensor 31 - 41 N·m (23 - 30 lb ft)
Oil temperature sensor 20 - 30 N·m (15 - 22 lb ft)
Air pressure sensor 5 - 15 N·m (4 - 11 lb ft)
Fuel filter
Union fixing to support 20 - 30 N·m (15 - 22 lb ft)
Fuel filter 20 - 30 N·m (15 - 22 lb ft)
Supply Pump
Supply pump 20 - 30 N·m (15 - 22 lb ft)
Inlet 20 - 30 N·m (15 - 22 lb ft)
Fast clutch 20 - 30 N·m (15 - 22 lb ft)
Turbocharger
Collector fastening screw nuts 20 - 30 N·m (15 - 22 lb ft)
Oil delivery inlet 20 - 30 N·m (15 - 22 lb ft)
Delivery pipe fastening screw 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Drain pipe to turbo 10 - 20 N·m (7 - 15 lb ft)
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INTRODUCTION
Cooling pipe
Water pipe to heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Water pipe to the support 20 - 30 N·m (15 - 22 lb ft)
Conical threaded cap 3/8" 35 - 45 N·m (26 - 33 lb ft)
Oil
Oil pressure control valve 40 - 50 N·m (30 - 37 lb ft)
Oil dipstick 20 - 30 N·m (15 - 22 lb ft)
Oil inlet pipe 10 - 20 N·m (7 - 15 lb ft)
Pickup tube to block 8 - 12 N·m (6 - 9 lb ft)
Pickup tube support 30 - 40 N·m (22 - 30 lb ft)
Oil filter cartridge union 40 - 50 N·m (30 - 37 lb ft)
Oil filter 20 - 30 N·m (15 - 22 lb ft)
Oil filter cartridge 16 - 20 N·m (12 - 15 lb ft)
Oil pump
- Stage 1 10 - 20 N·m (7 - 15 lb ft)
- Stage 2 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger
Threaded caps 40 - 50 N·m (30 - 37 lb ft)
Exchanger unit 20 - 30 N·m (15 - 22 lb ft)
Heat exchanger 20 - 30 N·m (15 - 22 lb ft)
Thermostat
Thermostat unit 20 - 30 N·m (15 - 22 lb ft)
Bleed vent 35 - 45 N·m (26 - 33 lb ft)
Fan support
Water pump 20 - 30 N·m (15 - 22 lb ft)
Bearing 35 - 45 N·m (26 - 33 lb ft)
Fan support 20 - 30 N·m (15 - 22 lb ft)
Pulley 35 - 45 N·m (26 - 33 lb ft)
Alternator
Alternator support 45 - 55 N·m (33 - 41 lb ft)
Alternator 45 - 55 N·m (33 - 41 lb ft)
Lifting
Front hook 45 - 55 N·m (33 - 41 lb ft)
Rear hook 65 - 75 N·m (48 - 55 lb ft)
Injection Pump
Pump gear
- Pre-torque 16 - 20 N·m (12 - 15 lb ft)
- Torque 85 - 95 N·m (63 - 70 lb ft)
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Special tools
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
380000134 1
380000150 2
380000219 3
380000220 4
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INTRODUCTION
380000221 5
380000222 6
380000228 7
380000229 8
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INTRODUCTION
380000302_3A 9
380000304 10
380000364_3A 11
380000667 12
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INTRODUCTION
380000670 13
380000301 14
380000999_3-2 15
380001006_3 16
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INTRODUCTION
380002385_3A 17
380100072_3A 18
380100074_3-2 19
380100075_3-2 20
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INTRODUCTION
380100076_3-2 21
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INTRODUCTION
Special tools
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
380000134 1
380000150 2
380000219 3
380000220 4
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INTRODUCTION
380000221 5
380000222 6
380000228 7
380000229 8
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INTRODUCTION
380000302_3A 9
380000304 10
380000364_3A 11
380000667 12
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INTRODUCTION
380000670 13
380000301 14
380002385_3A 15
380000999_3-2 16
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INTRODUCTION
380001006_3 17
380100072_3A 18
380100073 19
380100074_3-2 20
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INTRODUCTION
380100076_3-2 21
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INTRODUCTION
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SERVICE MANUAL
ENGINE AND PTO IN
84465357 28/02/2011
B
Contents
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A
F5AE5484A , F5AE9454A , F5AE9454D , F5AE9454J , F5AE9454L , F5AE9484A , F5AE9484B , F5AE9484G , F5AE9484K ,
F5CE5454B*A005 , F5CE5454B , F5CE5454C*A003 , F5CE5454G*A001 , F5CE9454C , F5CE9454E , F5CE9454G , F5CE9484C
, F5CE9484E
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ENGINE AND PTO IN - B
ENGINE - 10.A
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Contents
ENGINE - 10.A
TECHNICAL DATA
ENGINE
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454C
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454G
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454E
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5CE9484E
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5CE9484C
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE9454A
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE9484A
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE9454D
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE9484B
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5AE9484G
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5CE5454G*A001
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5CE5454B*A005
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5AE5484A
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5AE9454J
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5AE9454L
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5AE9484K
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
FUNCTIONAL DATA
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ENGINE
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Wiring harness
Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B,
F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K
Electronic control
Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
Sensing system
Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SERVICE
ENGINE
Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A,
F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Valve drive
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Crankshaft
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Timing gear
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
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Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Cylinder block
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Valve cover
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Front cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Rear cover
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Wiring harness
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
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ENGINE AND PTO IN - ENGINE
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ENGINE AND PTO IN - ENGINE
Timing
Intake
- Start before T.D.C. 19 °
- End after B.D.C. 37 °
Exhaust
- Start before B.D.C. 61 °
- End after T.D.C. 21 °
Valve Clearance (hot)
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
Valve Clearance (cold)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Injection Type Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2
Cylinder and Crankshaft Unit
Cylinder bore 99.000 - 99.020 mm (3.8976 - 3.8984 in)
Pistons
- Outside diameter 98.908 - 98.918 mm (3.8940 - 3.8944 in)
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Clearance between cylinder bore and piston 0.082 - 0.112 mm (0.0032 - 0.0044 in)
Piston protrusion -0.22 - 0.07 mm (-0.0087 - 0.0028 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
Clearance between piston pin and housing 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Piston ring landings
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
Clearance between Rings and Landings
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Small end bearing housing 39.460 - 39.490 mm (1.5535 - 1.5547 in)
- Big end bearing housing 67.833 - 67.841 mm (2.6706 - 2.6709 in)
- Small end bearing inside diameter 39.570 - 39.595 mm (1.5579 - 1.5589 in)
- Small end bearing inside diameter (installed) 36.010 - 36.020 mm (1.4177 - 1.4181 in)
Connecting rod big end bearing thickness
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
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Clearance between cam bearings and journals 0.038 - 0.162 mm (0.0015 - 0.0064 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
- Tappet (Upper and Lower) 15.924 - 15.954 mm (0.6269 - 0.6281 in)
- Tappet (Middle) 15.960 - 15.975 mm (0.6283 - 0.6289 in)
Clearance between tappets and housing 0.03 - 0.068 mm (0.0012 - 0.0027 in)
Rocker Assembly
- Rocker Shaft Outside diameter 18.979 - 19.000 mm (0.7472 - 0.7480 in)
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
Clearance between rockers and shaft 0.020 - 0.054 mm (0.0008 - 0.0021 in)
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Timing
Intake
- Start before T.D.C. 19 °
- End after B.D.C. 37 °
Exhaust
- Start before B.D.C. 61 °
- End after T.D.C. 21 °
Valve Clearance (hot)
- Intake 0.25 mm (0.010 in)
- Exhaust 0.50 mm (0.020 in)
Valve Clearance (cold)
- Intake 0.20 mm (0.008 in)
- Exhaust 0.45 mm (0.018 in)
Fuel Feed
Injection Type Bosch VE 4/12F
Nozzle type BOSCH DSLA138PV 33
Injection sequence 1-3-4-2
Cylinder and Crankshaft Unit
Cylinder bore 99.000 - 99.020 mm (3.8976 - 3.8984 in)
Pistons
- Outside diameter 98.908 - 98.918 mm (3.8940 - 3.8944 in)
- Pin housing 36.003 - 36.009 mm (1.4174 - 1.4177 in)
Clearance between cylinder bore and piston 0.082 - 0.112 mm (0.0032 - 0.0044 in)
Piston protrusion -0.22 - 0.07 mm (-0.0087 - 0.0028 in)
Piston pin 35.990 - 35.996 mm (1.4169 - 1.4172 in)
Clearance between piston pin and housing 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Piston ring landings
- Top 2.21 mm (0.0870 in)
- Middle 2.050 - 2.070 mm (0.0807 - 0.0815 in)
- Bottom 2.540 - 2.560 mm (0.1000 - 0.1008 in)
Piston rings
- Top 2.068 - 2.097 mm (0.0814 - 0.0826 in)
- Middle 1.970 - 1.990 mm (0.0776 - 0.0783 in)
- Bottom 2.470 - 2.490 mm (0.0972 - 0.0980 in)
Clearance between Rings and Landings
- Top -
- Middle 0.06 - 0.100 mm (0.0024 - 0.0039 in)
- Bottom 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Piston ring end gap
- Top 0.20 - 0.35 mm (0.0079 - 0.0138 in)
- Middle 0.60 - 0.80 mm (0.0236 - 0.0315 in)
- Bottom 0.30 - 0.60 mm (0.0118 - 0.0236 in)
Connecting Rod
- Small end bearing housing 39.460 - 39.490 mm (1.5535 - 1.5547 in)
- Big end bearing housing 67.833 - 67.841 mm (2.6706 - 2.6709 in)
- Small end bearing inside diameter 39.570 - 39.595 mm (1.5579 - 1.5589 in)
- Small end bearing inside diameter (installed) 36.010 - 36.020 mm (1.4177 - 1.4181 in)
Connecting rod big end bearing thickness
- Red 1.875 - 1.884 mm (0.0738 - 0.0742 in)
- Blue 1.883 - 1.892 mm (0.0741 - 0.0745 in)
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Clearance between cam bearings and journals 0.038 - 0.162 mm (0.0015 - 0.0064 in)
Cam lift
- Intake 6.213 mm (0.2446 in)
- Exhaust 5.5105 mm (0.2169 in)
Tappets
- Housing 15.000 - 15.018 mm (0.5906 - 0.5913 in)
- Tappet (Upper and Lower) 15.924 - 15.954 mm (0.6269 - 0.6281 in)
- Tappet (Middle) 15.960 - 15.975 mm (0.6283 - 0.6289 in)
Clearance between tappets and housing 0.03 - 0.068 mm (0.0012 - 0.0027 in)
Rocker Assembly
- Rocker Shaft Outside diameter 18.979 - 19.000 mm (0.7472 - 0.7480 in)
- Rockers 19.020 - 19.033 mm (0.7488 - 0.7493 in)
Clearance between rockers and shaft 0.020 - 0.054 mm (0.0008 - 0.0021 in)
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ENGINE - Overview
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
73092733 1
ENGINE FRONT VIEW
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73092734 2
ENGINE RIGHT SIDE VIEW
73092735 3
ENGINE LEFT SIDE VIEW
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73092736 4
ENGINE REAR VIEW
73092737 5
ENGINE TOP VIEW
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ENGINE - Overview
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
73092883 1
ENGINE FRONT VIEW
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73092885 2
ENGINE RIGHT SIDE VIEW
73092884 3
ENGINE LEFT SIDE VIEW
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73092886 4
ENGINE REAR VIEW
73092887 5
ENGINE TOP VIEW
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ENGINE - Overview
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
93111631 1
ENGINE FRONT VIEW
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93111630 2
ENGINE RIGHT SIDE VIEW
93111629 3
ENGINE LEFT SIDE VIEW
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93111632 4
ENGINE REAR VIEW
93111628A 5
ENGINE TOP VIEW
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73092848A 1
CONNECTING ROD AND PISTON UNIT COMPONENTS
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Balancer - Overview
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
73092889 1
Dynamic Balancer
(1) Reference notches for alignment and timing (4) Balancing masses
(2) Thrust washers (5) Shaft
(3) Bushings (6) Case
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73092804 1
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73092807 1
ELECTRIC CABLE TO CONNECT KSB WITH CERA
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73092805 1
Electrical Layout
20000 - Starter battery 58105 - Engine high water temperature warning light
25201 - Remote control for pre-heating switch 58484 - Diagnosis warning light
48035 - Engine rev. no. sensor 47034 - Engine water temperature sensor for EGR
52502 - Key commutator for services with start 78029 - EGR solenoid valve
61121 - Resistor for engine pre-heating 86020 - EGR E.C.U.
58101 - Pre--heating (on) warning light 85156 - Air pressure temperature sensor
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73092806 1
Technical specifications
Manufacturer Bitron
Rated Voltage 13.5 V
Actual Voltage 10 - 16 V
Working temperature -30 - 100 °C (-22 - 212 °F)
Maximum current input Less than 5 A
EGR valve control signal PWM 133 - 147 Hz
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Ref. Description
1 PWM output signal for EGR solenoid valve
2 -
3 ECU Mass
4 Mass for pre--heating (on) warning light
5 ECU supply (+ 15)
6 K line signal
7 Intake manifold temperature and pressure sensor supply
8 EGR solenoid valve feed (potentiometer)
9 K line mass
10 EGR solenoid valve mass (potentiometer)
11 Cooling liquid temperature sensor mass, on thermostat unit
12 Air pressure and temperature sensor mass
13 Engine RPM Signal
14 E.C.U. supply (+30)
15 Pre--heating remote control switch
16 Engine high temperature warning light
17 Diagnosis warning light
18 Start
19 EGR solenoid valve position signal
20 Cooling liquid temperature sensor, on thermostat unit
21 Air temperature sensor signal
22 Pressure sensor signal, on intake manifold
23 Negative from engine drive shaft impulse transmitter
24 Engine drive shaft transmitter mass
25 Positive from engine drive shaft impulse transmitter
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1. Fit the tool 380000150 (1) through the case and into
the port on the flywheel, as shown.
2. Using the tool 380000150 (1) rotate the flywheel un-
til the notch (2) is visible in the inspection hole and
cylinder one is at T.D.C..
73092764 1
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1. Fit the tool 380000150 through the case and into the
port (1) on the flywheel.
93111650 1
93111626 2
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73092771 1
Next operation:
Rocker assembly Housing - Install (B.10.A)
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73092775 1
Next operation:
Camshaft Push rod - Inspect (B.10.A)
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73092779 1
73092780 2
Next operation:
Rocker assembly Rocker arm - Install (B.10.A)
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73092794 1
Next operation:
Camshaft Push rod - Install (B.10.A)
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73092775 1
Next operation:
Rocker assembly Housing - Install (B.10.A)
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73092780 1
Next operation:
Rocker assembly Housing - Install (B.10.A)
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73092771 1
Next operation:
Valve cover - Install (B.10.A)
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73092822A 1
73092823A 2
Next operation:
Valve drive Camshaft - Install (B.10.A)
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73092829 2
Next operation:
Valve drive Camshaft - Install (B.10.A)
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73092830 1
73092831 2
MAIN DATA OF THE CAMSHAFT BUSHING AND RELEVANT SEAT
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73092832 1
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ENGINE AND PTO IN - ENGINE
1. Lubricate the tappets (1) and fit them into the relevant
seats within the crankcase.
73092834 1
Next operation:
Valve drive Camshaft - Install (B.10.A)
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73092823A 1
73092835 2
Next operation:
Valve drive Camshaft - End play (B.10.A)
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Next operation:
Valve assembly Valve - Measure (B.10.A)
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Next operation:
Cylinder head - Assemble (B.10.A)
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73092880 1
Height Load
(H) 44.6 mm (1.756 in) 0 N (0 lb)
(H1) 34 mm (1.339 in) 256 - 284 N (58 - 64 lb)
(H2) 23.8 mm (0.937 in) 502 - 554 N (113 - 125 lb)
Next operation:
Cylinder head - Assemble (B.10.A)
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73092782 1
Next operation:
Flywheel - Install (B.10.A)
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73092818 1
73092819 2
73092821 3
Next operation:
Crankshaft Main bearing - Install (B.10.A)
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Crankshaft - Remove
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Prior operation:
Oil pan - Remove (B.60.A)
73092820 1
Next operation:
Crankshaft - Install (B.10.A)
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Crankshaft - Measure
Prior operation:
Crankshaft - Remove (B.10.A)
73092838 1
73092839 2
PROSPECT REPORTING MEASUREMENT VALUES OF THE ENGINE DRIVE SHAFT MAIN JOURNALS AND
CRANKSHAFT BEARING PINS
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73092840 3
ENGINE DRIVE SHAFT MAIN TOLERANCES
73092841 4
Next operation:
Crankshaft - Install (B.10.A)
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73092842 1
Next operation:
Crankshaft - Install (B.10.A)
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Crankshaft - Install
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Prior operation:
Crankshaft Main bearing - Install (B.10.A)
73092820 1
Next operation:
Crankshaft - End play (B.10.A)
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73092843 1
73092844A 2
73092845A 3
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Next operation:
Crankshaft - Install (B.10.A)
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1. Fit the specific tool (5) to the rear shank (6) of the
engine drive shaft, fix it with the screws (4) and install
the new seal (3).
2. Position part (1) on part (5), tighten the screw nut
(2) until the seal has been fitted (3) into the flywheel
casing (7).
73092904 1
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73092909 1
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Crankshaft - Remove
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
73092920 1
Next operation:
Crankshaft - Install (B.10.A)
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Crankshaft - Install
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Prior operation:
Crankshaft - Remove (B.10.A)
73092920 1
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73092907 1
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73092907 1
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73092774 1
Next operation:
Timing gear housing - Install (B.10.A)
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Prior operation:
Timing gear housing - Remove (B.10.A)
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73092900 1
Next operation:
Timing gear housing - Install (B.10.A)
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Prior operation:
Timing gear housing - Remove (B.10.A)
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73092817 1
Next operation:
Connecting rod and piston - Install (B.10.A)
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1. Make sure that the piston does not show any signs
of seizing, scoring or cracking. Replace if necessary.
2. Remove the piston rings (2) using the tool
380000324 (1).
73092849 1
3. Remove the snap rings (1) that hold the piston pin in
place using round tipped pliers.
73092863 2
73092862 3
Next operation:
Connecting rod and piston - Assemble (B.10.A)
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73092850 1
73092852 2
MAIN DATA OF THE PISTON, PINS AND SNAP RINGS
Next operation:
Connecting rod and piston - Assemble (B.10.A)
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73092853 1
2. Lubricate the pin (1) and the pin housing in the piston
with engine oil.
3. Insert the pin into the piston. It must be inserted with
slight finger pressure and it should not come out by
gravity.
73092854 2
Next operation:
Connecting rod and piston - Assemble (B.10.A)
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73092855 1
73092856 2
3. The ring (2) of the first landing has a "V" shape. The
clearance (X) between the ring and landing is mea-
sured by setting the piston (1) with the ring in the
cylinder liner (3) so that the ring is exposed half way
out of the cylinder liner.
73092857 3
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73092858 4
Next operation:
Connecting rod and piston - Assemble (B.10.A)
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73092862 1
2. Install the snap rings (1) using the round tipped pliers
to hold to the assembly together.
73092863 2
73092849 3
Next operation:
Connecting rod and piston - Install (B.10.A)
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73092864 1
73092865 2
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73092866 3
Journal Clearance
4. Carefully clean the parts eliminating any oil residuals.
5. Place a piece of calibrated wire (2) on the engine
crankshaft pins (1).
6. Fit the connecting rod caps (3) and the relevant half
bearings (4).
NOTICE: Always use new screws in phase of assembly.
73092867 4
73092868 5
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73092869 6
73092870 7
Next operation:
Oil pan - Install (B.60.A)
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Flywheel - Remove
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
73092772 1
73092773 2
Next operation:
Flywheel - Install (B.10.A)
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Flywheel - Install
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Prior operation:
Flywheel - Remove (B.10.A)
73092783 2
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Flywheel - Remove
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
73092772 1
73092899 2
Next operation:
Flywheel - Install (B.10.A)
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Flywheel - Install
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Prior operation:
Flywheel - Remove (B.10.A)
73092905 2
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Flywheel - Remove
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
73092772 1
93111650 2
Next operation:
Flywheel - Install (B.10.A)
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ENGINE AND PTO IN - ENGINE
Flywheel - Install
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Prior operation:
Flywheel - Remove (B.10.A)
93111650 1
93111650 2
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Balancer - Remove
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Prior operation:
Oil pan - Remove (B.60.A)
73092902 1
Next operation:
Balancer - Install (B.10.A)
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Balancer - Install
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Prior operation:
Balancer - Remove (B.10.A)
76092914 1
Next operation:
Oil pan - Install (B.60.A)
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73092775 1
Next operation:
Cylinder head - Install (B.10.A)
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73092790 1
73092791 2
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73092775 3
Next operation:
Rocker assembly Housing - Install (B.10.A)
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73092871 1
73092872 2
6. Remove the seals (1) and (2) from their valve guides.
73092873 3
Next operation:
Cylinder head - Install (B.10.A)
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73092874 1
Next operation:
Cylinder head - Assemble (B.10.A)
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73092878 1
Next operation:
Cylinder head - Assemble (B.10.A)
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Next operation:
Cylinder head - Assemble (B.10.A)
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1. Lubricate the valve stems (1) and fit them in the rel-
evant valve guides in the same position they were
before disassembly.
2. Fit the grommets (2)and (3) to the valve guide using
tool 380000134.
73092881 1
3. Place the spring (4) and the upper plate (3) on the
cylinder head.
4. Using tool 380000302 (1), compress the spring (4)
and constrain the parts to the valve (5) using the
keepers (2).
73092872 2
Next operation:
Cylinder head - Install (B.10.A)
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1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing’s cover using the centring pins (1) to
correctly position it and then tighten the fastening
screws to the prescribed torque.
73092787A 1
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1. Fit the new gasket using the centring pins (1) on the
casing for its correct positioning.
2. Fit the casing’s cover using the centring pins (1) to
correctly position it and then tighten the fastening
screws to the prescribed torque.
73092908 1
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93111626 1
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Index
ENGINE - 10.A
Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Balancer - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connecting rod and piston Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Crankshaft Journal - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Crankshaft Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Crankshaft Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cylinder head Valve guide - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Cylinder head Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Electronic control Control module - Electrical schema EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
Electronic control Control module - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454C
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454G
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE9454E
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5CE9484E
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5CE9484C
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE9454A
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE9484A
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE9454D
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE9484B
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5AE9484G
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5CE5454G*A001
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5CE5454B*A005
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454C*A003
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5AE5484A
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5AE9454J
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5AE9454L
ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5AE9484K
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
ENGINE - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
ENGINE - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A,
F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
ENGINE - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
ENGINE - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
ENGINE - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
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Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Rocker assembly Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Rocker assembly Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Timing gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Valve assembly Spring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Valve drive Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Valve drive Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Valve drive Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring harness - Overview EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
Wiring harness - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B,
F5AE9484G, F5AE9454J, F5AE9454L, F5AE9484K
Wiring harness - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
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Contents
FUNCTIONAL DATA
SERVICE
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel filter system
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
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Fuel injector
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Priming pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Fuel line
Low pressure - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
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73092749 1
SUPPLY SYSTEM DIAGRAM
(1) Injectors (2) Fuel filter (3) Tank (4) Supply pump (5) Ignition pump
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73092750 2
PIPE LAYOUT
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73092751 3
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73092753 1
(1) Fuel supply pipe (4) Compression chamber (7) End of delivery port
(2) Solenoid valve (5) Fuel delivery pipe from pump to (8) Cursor
injectors
(3) Axial groove (6) Distributor piston (9) Injector
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Delivery phase
The distributor piston (5) driven by the cam disk, goes up to the T.D.C. and simultaneously rotates on its own axle. The
combination of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within
the chamber (2). The distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to
the injectors (6).
73092754 2
(1) Fuel feed pipe (3) Distributor piston inner pipe (5) Distributor piston
(2) Compression chamber (4) Fuel delivery pipe from pump to (6) Injector
injector
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73092755 3
(1) Fuel feed pipe (3) Fuel delivery pipe (5) Cursor
(2) Compression chamber (4) End of delivery pipe (6) Distributor piston
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Engine stop
Engine stop is provoked cutting out the starter contact. The electric flux to the solenoid valve (4) is cut out. The
solenoid valve, throughout its spring (3), drives the mobile cap to the end of stroke (2) and the mobile cap obstructs
the fuel feed pipe (1).
73092756 4
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73092757 5
Section of the LDA device
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73092752 1
Ref. Description
(1) Membrane
(2) Setting ring
(3) Feeler pin
(4) Drive lever
(5) Speed regulator
(6) Transfer pump
(7) Drive shaft
(8) Cam disk
(9) Spark lead adjuster
(10) Distributor piston
(11) Supply pipe fitting
(12) Hydraulic head
(13) Control plate
(14) Adjusting pin
(15) Counter spring
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73092759 1
(1) Fuel filter support (2) Cartridge filter (3) Water drainage device (not
available on all versions)
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73092758 1
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It consists of an NTC temperature sensor and a pressure sensor, both integrated in a single device.
73092811 1
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73092801 1
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Next operation:
Fuel injection pump - Install (B.20.A)
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Prior operation:
Fuel injection pump - Remove (B.20.A)
73092787A 1
Next operation:
Fuel injection pump - Timing adjust (B.20.A)
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Prior operation:
Fuel injection pump - Remove (B.20.A)
73092908 1
Next operation:
Fuel injection pump - Timing adjust (B.20.A)
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Prior operation:
Fuel injection pump - Remove (B.20.A)
20111651A 2
21. Install the timing adaptor (2) and the dial indicator (3)
into the hole where you removed the plunger access
plug.
22. If needed, loosen and reposition the bottom two in-
jector lines to allow room for the dial indicator.
23. Tighten the timing adapter.
24. Preload the dial indicator needle to 2.5 mm (0.10 in).
25. Pull outward on the end of the dial indicator stem and
release it to ensure the stem moves freely and does
not bind. If the stem does not move freely, reposition
the dial indicator until the stem moves freely.
20111652 3
26. Slide out the TDC timing pin from the flywheel to un-
lock the flywheel.
27. Rotate the engine counter-clockwise until the dial in-
dicator needle drops to a minimum reading and stops
moving. You are now positioned between cam lobes
of the injection pump.
28. Position the dial indicator needle at the zero position.
29. Rotate the engine clockwise until the TDC timing pin
reengages the flywheel and locks it at TDC.
30. Check the injection pump timing.
• Specification is 0.75 mm (0.030 in)
• Timing between 0.65 - 0.85 mm (0.026 - 0.033
in)
31. If only a slight timing adjustment is required, loosen
the pump mounting bolts and rotate the injection
pump.
NOTE: The holes for the mounting bolts are not elongated. Only a slight adjustment can be made by rotating the
injection pump.
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73092765 1
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1. Install the fuel filter support (1) and the fuel filter (2).
73092765 1
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73092894 1
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1. Install the fuel filter support (1) and the fuel filter (2).
73092894 1
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73092766 1
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73092796 1
73092795 2
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73092765 1
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73092765 1
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73092894 1
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM
73092762 1
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Index
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ENGINE AND PTO IN - B
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Contents
FUNCTIONAL DATA
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
SERVICE
Turbocharger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
73092748 1
BOOSTING
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
73092891 1
BOOSTING
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Turbocharger - Remove
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
73092760 1
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Turbocharger - Install
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
73092760 1
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Turbocharger - Remove
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
73092892 1
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Turbocharger - Install
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
73092892 1
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Turbocharger - Remove
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
93111630 1
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ENGINE AND PTO IN - AIR INTAKE SYSTEM
Turbocharger - Install
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
93111630 1
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Index
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ENGINE AND PTO IN - B
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Contents
FUNCTIONAL DATA
EXHAUST SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sensing system
Overview EGR valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
SERVICE
EXHAUST SYSTEM
Remove EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454B, F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003, F5AE5484A
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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ENGINE AND PTO IN - EXHAUST SYSTEM
INTERNAL EGR
The specific design of intake cams of the internal EGR system allows part of exhaust gas to be recycled to engine
cylinders. This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always
active. Its configuration requires no additional parts such as control valves, pipelines or heat exchangers therefore
engine profile remains unchanged. Besides main lobe, intake cam has an additional lobe as to configuration without
EGR. During concerned cylinder exhaust phase, this lobe allows a shaft advanced opening of intake valve. In this
way, part of the exhaust gas is trapped in the suction duct and later, during cylinder suction phase, this gas is recycled
to cylinder inlet for combustion phase.
73092746 1
Aspiration cam profile
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ENGINE AND PTO IN - EXHAUST SYSTEM
EXTERNAL E.G.R.
The external EGR system is a device fitted between the exhaust manifold and the intake manifold. Allows partial
exhaust gas recovery into the engine cylinders after having been cooled throughout a heat exchanger. This way the
combustion temperature maximum values, responsible of the formation of Nitrogen oxides (NOx) can be reduced.
Hence, reducing the aforesaid temperatures by decreasing the concentration of oxygen in the combustion chamber,
the EGR system efficiently controls NOx emissions. The exhaust gases through the conduit (4) and only after re-
ceiving the consent by the electronic control unit EGR, cross the valve (1) and reach the heat exchanger (2) where,
thanks to the engine coolant recycle, are cooled to be then entered into the intake manifold (5).
73092747 1
EXTERNAL E.G.R.
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ENGINE AND PTO IN - EXHAUST SYSTEM
73092813 1
(A) Exhaust gas input - (B) Exhaust gas output
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ENGINE AND PTO IN - EXHAUST SYSTEM
1. Using pliers, remove the clips (1) and the water deliv-
ery pipe connected to the valve support and the ex-
changer (2). Loosen the clip (3) and detach the pipe
(4), from the EGR valve housing. Unscrew the EGR
fastening screws on the front side (5), and those on
the valve support side (6), then remove the EGR unit.
73092761 1
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ENGINE AND PTO IN - EXHAUST SYSTEM
73092761 1
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ENGINE AND PTO IN - EXHAUST SYSTEM
73092766 1
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ENGINE AND PTO IN - EXHAUST SYSTEM
73092793 1
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Index
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ENGINE AND PTO IN - B
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Contents
FUNCTIONAL DATA
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Thermostat
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Water pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sensing system
Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Coolant temperature - Overview KSB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE
Thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Coolant line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
The closed circuit forced circulation engine cooling system is composed of the following parts:
• expansion tank: position, form and dimensions may vary depending on the engine fitting
• radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions
may vary depending on the application
• fan increasing the radiator’s cooling power. This component may vary depending on the application
• heat exchanger cooling the lubricant oil. This component may vary depending on the application
• centrifugal water pump positioned in the front part of the engine block
• thermostat controlling cooling liquid circulation
73092742 1
ENGINE COOLING SYSTEM DIAGRAM
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
The closed circuit forced circulation engine cooling system is composed of the following parts:
• expansion tank: position, form and dimensions may vary depending on the engine fitting
• radiator dissipating the heat absorbed by the engine cooling liquid. This component’s position and dimensions
may vary depending on the application
• fan increasing the radiator’s cooling power. This component may vary depending on the application
• heat exchanger cooling the lubricant oil. This component may vary depending on the application
• centrifugal water pump positioned in the front part of the engine block
• thermostat controlling cooling liquid circulation
73092890 1
ENGINE COOLING SYSTEM DIAGRAM
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Thermostat - Overview
When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermo-
stat, which cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-engine
circuit, allowing engine heat up quickly. The thermostat valve starts opening at nearly 80 °C (176 °F), allowing water
circulation into the radiator and also obstructing direct return towards the engine. Check the thermostat efficiency and
replace it in case of doubtful functioning.
73092744 1
THERMOSTAT DIAGRAM
(1) Stroke starts at 77 - 81 °C (171 - 178 °F). (2) 7 mm (0.28 in) stroke at 92 - 96 °C (198 - 205 °F).
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092743 1
WATER PUMP SECTION
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092808 1
Characteristics
Working temperature range
- Connector’s side -40 - 130 °C (-40 - 266 °F) ; 150 °C (302 °F) for less
than 10 min.
- Bulb’s side on engine -40 - 140 °C (-40 - 284 °F)
Voltage 6 - 28 V
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092810 1
Characteristics
Contact closing temperature 60 - 70 °C (140 - 158 °F)
Maximum load on contacts 15 A
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Thermostat - Remove
1. Remove the thermostat unit (1).
73092766 1
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive Belt - Remove (B.50.A)
73092770 1
Next operation:
Water pump - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092789 1
Next operation:
Fan and drive - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive Belt - Remove (B.50.A)
73092898A 1
Next operation:
Water pump - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092760 1
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
93111630 1
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092767 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive Belt - Remove (B.50.A)
73092767 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive Belt - Remove (B.50.A)
73092770 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive - Remove (B.50.A)
73092792 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092767 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
1. Fit the drive belt (1) on the pulley and the guide
rollers.
2. Tension the drive belt by tightening the screw (2).
73092767 1
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
73092896 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive Belt - Remove (B.50.A)
73092896 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive Belt - Remove (B.50.A)
73092898A 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM
Prior operation:
Fan and drive - Remove (B.50.A)
73092910 1
Next operation:
Fan and drive Belt - Install (B.50.A)
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Index
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Contents
TECHNICAL DATA
Oil pump
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil filter
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
LUBRICATION SYSTEM
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Oil pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F5C, F5A
Oil filter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5C, F5A
SERVICE
Oil pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil pan
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
84465357 28/02/2011
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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Oil filter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Piston lubrication
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Oil cooler
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Oil line
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
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ENGINE AND PTO IN - LUBRICATION SYSTEM
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ENGINE AND PTO IN - LUBRICATION SYSTEM
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ENGINE AND PTO IN - LUBRICATION SYSTEM
Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is dis-
tributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat
exchanger, the centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed
air system is also fitted.
73092738 1
LUBRICATION SYSTEM DIAGRAM
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ENGINE AND PTO IN - LUBRICATION SYSTEM
Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine drive shaft. From the oil pan, the lubrication oil is dis-
tributed to the engine drive shaft, the camshaft and the valve control. The lubrication system also comprises the heat
exchanger, the centrifugal blower for the versions with turbocharger and eventually the compressor if the compressed
air system is also fitted.
73092888 1
LUBRICATION SYSTEM LAYOUT
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092739 1
Oil pump
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092740 1
Engine oil filter
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092741 1
ENGINE OIL VAPOR RECIRCULATION
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092745 1
OIL COOLER
The oil cooler within the engine cooling system has the duty to control the engine oil temperature, reducing it by
absorbing heat throughout the engine cooling liquid.
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092809 1
Characteristics
Voltage 12 - 24 V
Contact closure with decreasing pressure 0.2 bar (3 psi)
Contact opening with increasing pressure 0.9 bar (13 psi)
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092919 1
Characteristics
Voltage 12 - 24 V
Calibration 0.6 - 0.9 bar (9 - 13 psi)
Tightening torque 35 N·m (26 lb ft)
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092778 1
Next operation:
Oil pump - Install (B.60.A)
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092784 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092776 1
73092777 2
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092777 1
73092800 2
3. Assemble the oil pan (1) and fit the plate thereon (3).
Tighten the fastening screws (2) to the prescribed
torque setting.
73092776 3
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092901 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092916 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
1. Remove the oil filter (1) and the oil filter base (2).
73092765 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
1. Install the oil filter support (1) and the oil filter (2).
73092765 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
1. Remove the oil filter (1) and the oil filter base (2).
73092894 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
1. Install the oil filter support (1) and the oil filter (2).
73092894 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
1. Remove the oil filter (1) and the oil filter base (2).
93111635 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
1. Install the oil filter support (1) and the oil filter (2).
93111635 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092821 1
Next operation:
Piston lubrication Spray nozzle - Install (B.60.A)
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092837 1
Next operation:
Oil pan - Install (B.60.A)
84465357 28/02/2011
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092769 1
84465357 28/02/2011
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092769 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092760 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092760 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092892 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
73092892 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
93111630 1
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ENGINE AND PTO IN - LUBRICATION SYSTEM
93111630 1
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Index
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Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
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ENGINE AND PTO IN - B
84465357 28/02/2011
B.80.A / 1
Contents
TECHNICAL DATA
FUNCTIONAL DATA
Engine starter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
SERVICE
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F5CE5454G*A001, F5CE5454B*A005, F5CE5454C*A003
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F5CE5454B, F5CE9454C, F5CE9454E, F5CE9454G, F5CE9484C, F5CE9484E, F5CE5454G*A001, F5CE5454B*A005,
F5CE5454C*A003
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F5AE9454A, F5AE9454D, F5AE9484A, F5AE9484B, F5AE9484G, F5AE5484A, F5AE9454J, F5AE9454L, F5AE9484K
84465357 28/02/2011
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ENGINE AND PTO IN - STARTING SYSTEM
84465357 28/02/2011
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ENGINE AND PTO IN - STARTING SYSTEM
93111647 1
A glow plug typically comprises a heating coil in a metal tube closed at one end and filled with electrically insulating
ceramic powder. The closed end of the metal tube with the heating coil protrudes through a hole in the cylinder head
into the combustion chamber. When the glow plug is electrically energized, its heated portion reaches a surface
temperature of more than 1000°C within a few seconds. The air-fuel spray generated by the injection ignites close to
the glow plug and initiates combustion.
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ENGINE AND PTO IN - STARTING SYSTEM
73092815 1
Manufacturer BOSCH
Electrical system 12 V
Rated output 3 kW (4 Hp)
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ENGINE AND PTO IN - STARTING SYSTEM
NOTE: Three glow plugs (1) have direct access and are easily removed.
NOTE: The fourth glow plug (2) requires removal of the turbo intake (3).
1. Disconnect electrical connections (A) and (B) and
move out of the way.
93111637 1
93111637 2
93111637 3
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ENGINE AND PTO IN - STARTING SYSTEM
93111638 4
93111638 5
6. Remove the four bolts (8) from the top of the intake.
93111638 6
7. Loosen the two hose clamps (C) from the elbow hose
(9) and remove hose.
93111639 7
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ENGINE AND PTO IN - STARTING SYSTEM
93111639 8
93111640 9
NOTE: Now you have free access to remove the fourth glow plug.
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ENGINE AND PTO IN - STARTING SYSTEM
93111639 1
3. Install the four bolts (3) through the top of the air
intake.
93111638 2
93111638 3
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ENGINE AND PTO IN - STARTING SYSTEM
5. Install the elbow hose (5) and tighten the two hose
clamps (A) securing it from the turbo to the air intake.
93111637 4
93111637 5
93111637 6
93111637 7
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ENGINE AND PTO IN - STARTING SYSTEM
73092761 1
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ENGINE AND PTO IN - STARTING SYSTEM
73092761 1
84465357 28/02/2011
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ENGINE AND PTO IN - STARTING SYSTEM
73092892 1
84465357 28/02/2011
B.80.A / 13
ENGINE AND PTO IN - STARTING SYSTEM
73092892 1
84465357 28/02/2011
B.80.A / 14
Index
84465357 28/02/2011
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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557
PRINTED IN U.S.A.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CNH Dealer.
84465357 28/02/2011
SPECIAL TOOL INDEX
Genuine IU PAGE
380000134 [Valve Guide Seal Special tools 12
Installer - for use with 7.8L &
9.0L Cursor Engines]
380000150 [Top Dead Center Special tools 12
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000219 [Valve Guide Special tools 12
Remover/Installer - used on
4.5L & 6.7L NEF Engines -
Same as 291046]
380000220 [Piston Ring Special tools 12
Clamp (60 - 125 mm)]
380000221 [Piston Ring Pliers Special tools 13
(65 - 110 mm)]
380000222 [Valve Guide Special tools 13
Reemer - used on 4.5L & 6.7L
NEF Engines]
380000228 [Dial Gauge (0 - 5 Special tools 13
mm)]
380000302 [Cylinder Head Special tools 14
Valve Spring Compressor]
380000304 [Torque Tightening Special tools 14
Angle Gauges (1/2 Inch And
3/4 Inch)]
380000364 [Piston Protrusion Special tools 14
Check, Gauge Base]
380000667 [Camshaft Special tools 14
Bushing Remover And
Installer]
380000670 [Oil Filter Removal Special tools 15
Tool (NH F5C)]
380000978 [Motore NEF - Special tools 15
Vedi Allegato]
380000999 [Adaptor 7/16 Special tools 15
UNF Male]
380001006 [Cylinder Special tools 15
Compression Tester]
380000732 [Engine Turning Special tools 16
Tool]
380100072 [Special Tool] Special tools 16
380100074 [Special Tool] Special tools 16
380100075 [Special Tool] Special tools 16
380100076 [Special Tool] Special tools 17
380000134 [Valve Guide Seal Special tools 18
Installer - for use with 7.8L &
9.0L Cursor Engines]
380000150 [Top Dead Center Special tools 18
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000219 [Valve Guide Special tools 18
Remover/Installer - used on
4.5L & 6.7L NEF Engines -
Same as 291046]
380000220 [Piston Ring Special tools 18
Clamp (60 - 125 mm)]
28/02/2011
17
Genuine IU PAGE
380000221 [Piston Ring Pliers Special tools 19
(65 - 110 mm)]
380000222 [Valve Guide Special tools 19
Reemer - used on 4.5L & 6.7L
NEF Engines]
380000228 [Dial Gauge (0 - 5 Special tools 19
mm)]
380000302 [Cylinder Head Special tools 20
Valve Spring Compressor]
380000304 [Torque Tightening Special tools 20
Angle Gauges (1/2 Inch And
3/4 Inch)]
380000364 [Piston Protrusion Special tools 20
Check, Gauge Base]
380000667 [Camshaft Special tools 20
Bushing Remover And
Installer]
380000670 [Oil Filter Removal Special tools 21
Tool (NH F5C)]
380000978 [Motore NEF - Special tools 21
Vedi Allegato]
380000732 [Engine Turning Special tools 21
Tool]
380000999 [Adaptor 7/16 Special tools 21
UNF Male]
380001006 [Cylinder Special tools 22
Compression Tester]
380100072 [Special Tool] Special tools 22
380100073 [Special Tool] Special tools 22
380100074 [Special Tool] Special tools 22
380100076 [Special Tool] Special tools 23
380000150 [Top Dead Center ENGINE - Service instruction - Finding Top Dead Center B.10.A / 35
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000150 [Top Dead Center ENGINE - Service instruction - Finding Top Dead Center B.10.A / 35
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000150 [Top Dead Center ENGINE - Service instruction - Finding Top Dead Center B.10.A / 36
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000150 [Top Dead Center ENGINE - Service instruction - Finding Top Dead Center B.10.A / 36
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000667 [Camshaft Camshaft Bushing - Replace B.10.A / 48
Bushing Remover And
Installer]
380000999 [Adaptor 7/16 Camshaft Bushing - Replace B.10.A / 48
UNF Male]
380100076 [Special Tool] Crankshaft Rear seal - Install B.10.A / 55
380000362 [Crankshaft Lifting Crankshaft - Remove B.10.A / 58
Hook]
380000304 [Torque Tightening Crankshaft Journal - Measure B.10.A / 63
Angle Gauges (1/2 Inch And
3/4 Inch)]
380000362 [Crankshaft Lifting Crankshaft - Remove B.10.A / 68
Hook]
28/02/2011
18
Genuine IU PAGE
380000324 [110-150 Diameter Connecting rod and piston - Disassemble B.10.A / 77
Piston Ring Pliers]
380000221 [Piston Ring Pliers Connecting rod and piston - Assemble B.10.A / 82
(65 - 110 mm)]
380000220 [Piston Ring Connecting rod and piston - Install B.10.A / 83
Clamp (60 - 125 mm)]
380000304 [Torque Tightening Connecting rod and piston - Install B.10.A / 85
Angle Gauges (1/2 Inch And
3/4 Inch)]
380002385 [Flywheel Crank Flywheel - Remove B.10.A / 86
Handle]
380002385 [Flywheel Crank Flywheel - Install B.10.A / 87
Handle]
380000304 [Torque Tightening Flywheel - Install B.10.A / 87
Angle Gauges (1/2 Inch And
3/4 Inch)]
380002385 [Flywheel Crank Flywheel - Remove B.10.A / 88
Handle]
380002385 [Flywheel Crank Flywheel - Install B.10.A / 89
Handle]
380000304 [Torque Tightening Flywheel - Install B.10.A / 89
Angle Gauges (1/2 Inch And
3/4 Inch)]
380002385 [Flywheel Crank Flywheel - Remove B.10.A / 90
Handle]
380002385 [Flywheel Crank Flywheel - Install B.10.A / 91
Handle]
380000304 [Torque Tightening Flywheel - Install B.10.A / 91
Angle Gauges (1/2 Inch And
3/4 Inch)]
380000302 [Cylinder Head Cylinder head - Disassemble B.10.A / 99
Valve Spring Compressor]
380000134 [Valve Guide Seal Cylinder head - Assemble B.10.A / 103
Installer - for use with 7.8L &
9.0L Cursor Engines]
380000302 [Cylinder Head Cylinder head - Assemble B.10.A / 103
Valve Spring Compressor]
380000150 [Top Dead Center Fuel injection pump - Remove B.20.A / 18
Setting Tool for use on 7.8L,
10.3L & 12.9L (13L) Cursor
Engines]
380000228 [Dial Gauge (0 - 5 Fuel injection pump - Timing adjust B.20.A / 21
mm)]
Kit IU PAGE
380000229 [Measuring Special tools 13
Adapter used with 380000228]
380000229 [Measuring Special tools 19
Adapter used with 380000228]
28/02/2011
19
New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557
PRINTED IN U.S.A.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CNH Dealer.
84465357 28/02/2011