16. 14 SECTION 10 -- ENGINE -- CHAPTER 1
SPECIAL TOOLS
No. TOOL NAME
380000979 Puller for engine injection pump union gear
380000665 Tool to extract crankshaft front seal
380000663 Tool to extract crankshaft rear seal
380001099 Injector extractor
380000666 Splining tool for fitting front seals on crankshaft
380000664 Splining tool for fitting rear seal on crankshaft
380000988 Plate for engine flywheel rotation tool with flywheel timing pin (use with 380000732)
380000732 Tool for engine flywheel rotation (use with 380000988)
380000667 Drift for camshaft bushing disassembly and reassembly
380000158 Torque screwdriver for injector solenoid valve connector nut setting
380001003 Complete square to check for connecting rod distortion
380000301 Engine stand (revolving)
380001298 Engine stand to Cylinder block brackets
380001073 Engine lifting brackets
17. SECTION 10 -- ENGINE -- CHAPTER 1 15
DESCRIPTION OF OPERATION
COOLING
The forced circulation, closed--circuit engine cooling system is composed of the following components:
-- Expansion tank: its location, shape and size may change depending on the engine version.
-- Radiator, whose job is to dissipate the heat taken by the coolant from the engine. This component, too, is
a feature of the version as regards both positioning and engine.
-- Viscostatic fan, with the task of increasing the radiator’s dissipating capacity: this, too, belongs to the specific
engine version.
-- A lubricating oil cooler: this, too, belongs to the specific engine version.
-- A centrifugal coolant pump housed at the front of the crankcase.
-- A thermostat governing coolant circulation.
-- The circuit may also extend to the compressor if the version includes it.
80369
A = TO THE RADIATOR
B = FROM THE RADIATOR
8
COOLING SYSTEM DIAGRAM
18. 16 SECTION 10 -- ENGINE -- CHAPTER 1
LUBRICATION
Forced--circulation lubrication is accomplished by the oil pump, housed at the front of the crankcase.
The lubricating oil is sent from the oil sump to the crankshaft, camshaft and valve control.
Lubrication also includes the cooler, turbo--blower and compressor for the compressed air system if there is one.
All these components often change according to use and will therefore be covered under the specific heading.
80370
Pressurized oil
Oil under gravity
9
19. SECTION 10 -- ENGINE -- CHAPTER 1 17
LUBRICATION SYSTEM COMPONENTS
80371
10
1. Crankshaft – 2. Balancing weight – 3. Oil sump with suction rose – 4. Suction rose in oil sump –
5. Oil pump – 6. Relief valve.
20. 18 SECTION 10 -- ENGINE -- CHAPTER 1
ENGINE OVERHAUL
INTRODUCTION
Removal
To remove engine from tractor see Section 01
“Separating the Tractor.”
DISASSEMBLY
Some of the operations described in this section can
be carried out directly with the engine fitted on the
vehicle, depending on access to the engine bay and
on the version.
CAUTION
The operations for removing the engine, as those for
overhaul, must be performed by skilled personnel us-
ing specific tools.
Fuel System/Preparing Engine to Mount on
Rotating Stand
To be able to fit the brackets 380001298 (for fixing the
engine to the overhaul stand, 380000301) to the
crankcase, it is necessary to work from the left--hand
side of the engine:
1. Remove the fuel filters (6) from the mounting
(1);
2. Disconnect the electrical connection (2) from
the mounting (1) and the one to the heater
(again located on the filter mounting);
3. Disconnect the fuel pipes (3 -- 4 -- 5) from the
mounting (1);
4. Remove the bracket supporting the mounting
(1) from the crankcase.
CAUTION
To disconnect the fuel pipes (3 – 4 – 5, Figure 11)
from the relevant fittings, you need to press the clip
(1) as shown in Figure 12, B.
After disconnecting the piping, put the clip (1) back in
its locking position (Figure 12, A) to prevent it getting
buckled.
80372
11
5. Disconnect the high--pressure fuel pipe (7, Fig-
ure 1) from the rail choke tube and from the
high--pressure pump (8) and remove it from the
crankcase by taking out the bracket.
6. Disconnect the pipe 9 from the high--pressure
pump (8).
CAUTION
Depending on the high pressure in the piping from
the high--pressure pump to the rail and from here to
the electro--injectors, never:
-- disconnect the pipes with the engine running,
-- reuse disconnected pipes.
80628
12
21. SECTION 10 -- ENGINE -- CHAPTER 1 19
7. Remove the oil filler pipe (3).
8. Unscrew the fixing screws (1) and remove the
starter motor (2) from its seat.
80374
13
9. Working from the right--hand side of the engine,
disconnect the lubricating pipe (1) from the top
of the cooler to the turbo--blower (2).
10. Remove the thermostat body (3) together with
the seal.
80373
14
11. Fit brackets 380001298 into the holes (1) and
(2) in the crankcase on both sides and, using
these brackets, secure the engine to the rotat-
ing stand 380000301. Drain off the engine oil by
removing the plug from the sump.
80401
15
22. 20 SECTION 10 -- ENGINE -- CHAPTER 1
80375
16
REMOVING COMPONENTS OF THE APPLICATION
1. Connection for electro--injectors -- 2. Engine coolant temperature sensor --
3. Fuel pressure sensor cable -- 4. Engine oil pressure and temperature sensor -- 5. Crankshaft sensor --
6. Electro--injector -- 7. Air pressure temperature sensor -- 8. Timing system phase sensor --
9. Fuel temperature sensor -- 10. Pressure regulator wiring -- 11. EDC7C control unit
Electrical Connections
12. Disconnect the engine cable from the connec-
tors: (1) electro-injector wiring (6); (7) air
pressure/temperature sensor; (3) fuel pressure
sensor; (11) EDC control unit; (10 high-pres-
sure pump sensor; (8) timing system phase
sensor; (2) engine coolant temperature sensor
on thermostat; (5) crankshaft speed sensor.
23. SECTION 10 -- ENGINE -- CHAPTER 1 21
Fuel Rail
13. Take off the clamps fastening it to the crankcase
and remove it completely.
14. Disconnect the fuel pipes (5) from the rail (2)
and from the manifolds (6) for the electro--injec-
tors.
CAUTION
When locking the fittings (4) securing the pipes (6) to
the rail (2), using an appropriate wrench, you must
prevent the flow limiters, if fitted, (3) from turning.
15. Remove the screws (1) and detach the rail (2).
80376
17
Cylinder Head
16. Disconnect the piping from the fuel return pres-
sure limiter (1).
17. Undo the nuts (2) and take off the tappet cover
(3).
80377
18
18. Remove the nuts (7) and disconnect the electric
cables from the electro--injectors (8).
19. Take out the screws (1) and remove the elec-
tro--injector wiring mounting (2) together with its
seal.
20. Take out the screws (5), remove the air temper-
ature/pressure sensor (6).
21. Remove the nuts (3) and extract the fuel man-
ifolds (4).
CAUTION
Once removed, the fuel manifolds (4) must not be re-
used; they must be replaced with new ones.
80591
19
24. 22 SECTION 10 -- ENGINE -- CHAPTER 1
22. Loosen the tappet adjuster fixing nuts (1) and
unscrew the adjusters.
23. Take out the screws (2), remove the rocker--arm
assembly (3) comprising the mounting (6),
rocker arms (4) and spindles (5) then remove
the bridges (7) from the valves.
24. Remove the rods (8).
80640
20
25. Take out the screws securing the electro--injec-
tors and, using tool 380001099 (1), extract the
electro--injectors (2) from the cylinder head.
80686
21
26. Working on the tightener (1), extract the belt
(12) from the pulleys of the alternator, coolant
pump and snub pulleys.
27. Unscrew the bolt (2) and remove the tightener;
28. Remove the snub pulley (6), unscrew the bolts
(7) and remove the pulley (8) from the mounting
beneath.
29. Unscrew the bolts (10) and remove the tighten-
er mounting.
30. Unscrew the bolts (11) and remove the mount-
ing (9) from the crankcase.
31. Unscrew the bolts (3) and remove the coolant
pump (4).
32. Unscrew the bolt and remove the engine speed
sensor (5)
80378
22
25. SECTION 10 -- ENGINE -- CHAPTER 1 23
Proceed to remove the turbocharger:
33. Unscrew the ring nut (1) and remove the lu-
brication piping of the turbo--blower.
34. Unscrew the nuts (2) securing the turbo--blower
on the exhaust manifold (4).
35. Support the turbo--blower (5) and, lifting it, re-
move the seal.
36. Unscrew the retaining nuts (3) and remove the
exhaust manifold (4).
80315
23
37. From the opposite side, unscrew the bolts se-
curing the intake manifold (1) and remove it to-
gether with the air heater (2) for cold starts.
80379
24
38. Hook up the brackets, 380001073 (1) with a
suitable sling and, using a hoist, remove the cyl-
inder head (2) from the crankcase.
80687
25
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27. 24 SECTION 10 -- ENGINE -- CHAPTER 1
Crankcase -- External Components
39. Remove the oil filter (1).
40. Unscrew the retaining bolts and remove the al-
ternator (2).
80380
26
41. Unscrew the retaining bolts (1) and remove the
pipe fitting (2).
80326
27
42. Disconnect the connector (1) from the oil pres-
sure--temperature sensor.
43. Unscrew the bolts (2) and remove the oil pres-
sure--temperature sensor (3).
44. Unscrew the bolts (4) and remove the oil filter
mounting (5) from the crankcase together with
its seals.
45. Remove the cooler from its seat.
80400
28
28. SECTION 10 -- ENGINE -- CHAPTER 1 25
46. Remove the nuts (1) and detach the high--pres-
sure pump (2) together with the feed pump (3).
80381
29
Crank Shaft Seals
47. Install the engine turning / locking tool,
380000988, (1) and 380000732, (2).
48. Loosen the screws fixing the flywheel to the
crankshaft.
2
30
49. Unscrew the bolts (1), remove the pulley (2),
spacer (3) and pulley (4).
50. The engine flywheel locking tool can help with
disassembly of the damper flywheel (2) fitted on
the pulley (4).
80382
31
29. 26 SECTION 10 -- ENGINE -- CHAPTER 1
51. Extract the front cover shaft seal.
52. Apply tool 380000665 (4) on the front tang (2)
of the crankshaft.
53. Perforate the inner seal (1) with a drill bit
(∅ 3.5 mm (0.1378 in.)) through the tool’s guide
holes, for a depth of 5 mm (0.1969 in.).
54. Secure the tool to the seal by screwing down the
6 screws supplied. Extract the seal (1) by
screwing down the screw (3).
80595
32
55. Use a suitable hooked device (3) with the aid
of the lever (4) extract the outer seal (2) from the
front cover (1).
80596
33
56. Take out the screws (1) and remove the oil
pump (2).
CAUTION
Note down the assembly position of the screws (1) as
they have different lengths.
80330
34