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1
General information
2
Technical information
3
Safety information
4
Storage information
5
Information regarding discharge of liquids
6
Information for replacing the functional units
7
Information for disassembly
8
Information about overhauling
9
Assembly information
10
Fluids filling information
11
Information about optional components
12
Information on adjustments
13
Tools information
14
Information about failures
15
Glossary
Tightening torques and the use of sealants
Tab. 9.4 - *Alternatively to the capscrew replacements, with "Dri-loc"
| BASE CONFIGURATION |
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| SHORT BLOCK | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Oil sprays fastening capscrew | M6x1 | 10 | |
| Lower crankcase fastening capscrew | M14x1.25 | 3 Torque cycles | |
| 1st Cycle | 60 | ||
| 2nd Cycle | +45° | ||
| 3rd Cycle | +45° | ||
| Lower crankcase fastening capscrew | M10x1.25 | 30 | |
| Connecting rod screw | M11x1 | 3 Torque cycles | |
| 1st Cycle | 28 | ||
| 2nd Cycle |
+30° |
||
| 3rd Cycle | +30° | ||
| Coolant drain hole closing cap | M16x1.5 | 50 | |
| Main oil delivery line closing plate | M6x1 | 15 | |
| Intermediate idle gear cap fastening screw | M8x1 | 25 | |
| OIL SUMP ASSEMBLY | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Oil suction hose fastening capscrew | M6x1 | 10 | Loctite 2701* |
| Oil return pipe fastening screw | M6x1 | 10 | Loctite 2701* |
| Oil sump fastening capscrew | M8x1 | 25 | |
| Oil drain cap | M18x1.5 | 30 | |
| FLANGE ASSEMBLY (1st PTO) | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Flange bell fastening capscrew | M12x1,75 | 75 | |
| Flywheel fastening capscrew | M12x1,25 | 3 Torque cycles | |
| 1st Cycle | 60 | ||
| 2nd Cycle |
130 |
||
| 3rd Cycle | 130 | ||
| ENGINE CYLINDER HEAD ASSEMBLY | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Air bleeding cap (Rev. 00) | M6x1 | 6 | |
| Air bleeding cap (Rev. 01) | M14x1,5 | 50 | |
| Lifting brace fastening capscrew | M8x1.25 | 80 | |
| Injector manifold | M12x1 | 30 | |
| Cylinder head fastening capscrew | M12x1.25 | 4 Torque cycles | |
| 1st Cycle | 75 | ||
| 2nd Cycle | +90° | ||
| 3rd Cycle | +90° | ||
| 4th Cycle | +90° | ||
| Rocker arm gudgeon fastening capscrew | M8x1,25 | 40 | |
| Rocker arm cover fastening capscrew | M6x1 | 10 | |
| INJECTION SYSTEM | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Fuel filter fastening capscrew | M8x1.25 | 25 | |
| Fuel cartridge fastening | ... | 17 | |
| Common rail fastening capscrew | M8x1.25 | 25 | |
| Electronic injector brace fastening capscrew | M8x1.25 | 20 | |
| Distributor fastening capscrew | M8x1.25 | 25 | |
| Waste line fastening drilled capscrew on common rail | M10x1 | 30 | |
| Injector side injection tube nuts | M12x1.5 | 25 | |
| Injection pump side injection tubes nuts | M12x1.5 | 25 | |
| Common Rail side injection tubes nuts | M14x1.5 | 30 | |
| Injection pump fastening capscrew | M8x1.25 | 25 | Loctite 2701* |
| Gear fastening nut on high-pressure fuel injection pump | M14X1.5 | 140 | |
| Screw for cover over injection pump shaft nut (on bell housing) | M6x1 | 10 | |
| INTAKE MANIFOLD | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Internal semi-manifold fastening capscrew (on cylinder head) | M8x1.25 | 25 | |
| External semi-manifold fastening capscrew | TG8 | 22 | |
| Intake flange fastening capscrew | TG8 | 22 | |
| EXHAUST MANIFOLD | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Exhaust manifold fastening screw | M10x1.5 | 50 | |
| Exhaust manifold fastening nut | M10x1.5 | 50 | |
| Exhaust manifold fastening stud | M10x1.5 | 2 Torque Cycles | |
| 1st Cycle | 40 | ||
| 2nd Cycle | 80 | ||
| LUBRICATION CIRCUIT | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
|
Oil vapour separator support plate fastening capscrew |
TG8 | 22 | |
| Oil vapour separator support fastening capscrew (on crankcase) | M6x1 | 12 | |
| Oil steam separator return tube drilled fastening screw (on cranckase) | M16x1.5 | ||
| Oil filter fastening union | M20x1.5 | 15 | Loctite 2701* |
| Oil cooler fastening capscrew | M6x1 | 10 | |
| Cartridge-holder cover | ... | 25 | |
| Oil pump fastening screw | M6x1 | 10 | |
| CRANKSHAFT AND TARGET WHEEL PULLEY ASSEMBLY (2nd PTO) | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Phonic wheel fastening capscrew (on crankshaft pulley) | M6x1 | 10 | |
| Crankshaft pulley fastening capscrew | M12x1.75 | 100 | Molyslip |
| COOLANT CIRCUIT |
|||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Coolant tube clamp fastening capscrew (Oil Cooler return) | TG8 | 22 | |
| Thermostatic valve cover fastening capscrew | M6x1 | 10 | |
| Coolant pump fastening capscrew | M8x1.25 | 25 | |
| Blower fastening capscrew | M8x1.25 | 25 | |
| TURBOCHARGER | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Oil return tube fastening capscrew | M6x1 | 10 | |
| Oil supply tube fastening capscrew | M10x1 | 15 | |
| Turbine fastening stud (on manifold) | M10x1.5 | 25 | |
| Exhaust flange fastening stud (on turbine) | M8x1.25 | 25 | |
| Turbine fastening stud | M10x1.5 | 30 | |
| Exhaust flange fastening nut (on turbine) | M8x1.25 | 25 | |
| ELECTRICAL COMPONENTS | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| MAP sensor fastening capscrew | M6x1 | 10 | |
| Coolant temperature sensor | M12x1.5 | 20 max. | |
| Oil pressure switch | M12x1.5 | 35 | |
| Phase sensor fastening capscrew | M6x1 | 10 | |
| Speed sensor fastening capscrew | M6x1 | 10 | |
| Sensor for water presence in fuel | 5 | ||
| Alternator fastening capscrew | M10x1.5 | 45 | |
| Alternator fastening capscrew | M8x1.25 | 25 | |
| Alternator brace fastening capscrew | M12x1.75 | 75 | |
| Starter motor fastening capscrew | M10x1.5 | 45 | |
| Supply cable fastening nut (starter motor) | M10x1.5 | 15 | |
| EGR CIRCUIT | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Flange EGR valve fastening capscrew | M8x1.25 | 25 | |
| EGR valve fastening capscrew | M6x1 | 10 | |
| EGR Cooler tube fastening capscrew (on flange EGR valve) | TG8 | 22 | |
| EGR Cooler fastening capscrew | TG8 | 22 | |
| Tube fastening capscrew on EGR Cooler | M8x1.25 | 25 | |
| Tube fastening capscrew on intake manifold | TG8 | 22 | |
* Alternatively to the capscrew replacements, with "Dri-loc"
| OPTIONAL COMPONENTS (Chap. 11) | |||
| HEATER | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Flange intake with heater fastening capscrew | M8x1.25 | 25 | |
| IDLE GEAR (FOR 3rd) | |||
| Component | Thread (mm) | Torque (Nm) | Sealer |
| Gear fastening capscrew | M8x1 | 25 | |
* Alternatively to the capscrew replacements, with "Dri-loc"
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