KDI 1903TCR / KDI 1903TCRE5

KDI 2504TCR / KDI 2504TCRE5

WORKSHOP MANUAL
(Rev. 14)
 INDEX

1 General information ............................................................................................................... 7

1.1 Identification of the external components of the engine (BASE CONFIGURATION) ............... 7
1.2 Identification of the main internal components of the engine and operating reference
(BASE CONFIGURATION) ............................................................................................................................. 10
1.3 Homologation labels ...................................................................................................................... 13
1.4 Manufacturer and engine identification ..................................................................................... 16
1.5 Useful information ......................................................................................................................... 17
1.6 ATS (After Treatment System) ..................................................................................................... 18
2 Technical information.......................................................................................................... 19
2.1 Engine specifications .................................................................................................................... 19
2.2 Engine dimensions (mm) .............................................................................................................. 22
2.3 Performance ................................................................................................................................... 23
2.4 Oil .................................................................................................................................................... 25
2.5 Fuel .................................................................................................................................................. 27
2.6 Coolant recommendation ............................................................................................................. 30
2.7 Battery recommendation .............................................................................................................. 31
2.8 Periodic maintenance ................................................................................................................... 32
2.9 Fuel system .................................................................................................................................... 34
2.10 Lubrication circuit.......................................................................................................................... 42
2.11 Cooling circuit ................................................................................................................................ 46
2.12 Intake and exhaust circuit ............................................................................................................ 49
2.13 Electric system............................................................................................................................... 56
2.14 Sensors and switches ................................................................................................................... 63
2.15 Electrical components .................................................................................................................. 69
2.16 Timing system and tappets .......................................................................................................... 73
2.17 Components handling ................................................................................................................... 77
2.18 Turbocharger ................................................................................................................................. 79
2.19 Balancer device (optional) ............................................................................................................ 83
3 Safety information ............................................................................................................... 84
3.1 Before start-up .............................................................................................................................. 84
3.2 Safety precautions ........................................................................................................................ 85
3.3 General remarks ............................................................................................................................ 86
3.4 Safety signal description .............................................................................................................. 89
3.5 Information and safety signals ..................................................................................................... 91
3.6 Safety and environmental impact ................................................................................................ 93
3.7 Location of safety signals on engine ........................................................................................... 94
4 Storage information ............................................................................................................. 95
4.1 Product preservation ..................................................................................................................... 95

EN
 INDEX

4.2 Engine storage (up to 6 months) .................................................................................................. 96

4.3 Engine storage (over 6 months) ................................................................................................... 97
4.4 Engine starting after storage ....................................................................................................... 98
5 Information regarding discharge of liquids ....................................................................... 99
5.1 Coolant ........................................................................................................................................... 99
5.2 Engine oil ...................................................................................................................................... 101
6 Information for replacing the functional units ................................................................. 102
6.1 Electronic injector replacement ................................................................................................. 102
6.2 High-pressure fuel injection pump replacement ..................................................................... 107
6.3 Unit EGR Cooler replacement .................................................................................................... 112
6.4 EGR valve replacement ............................................................................................................... 114
6.5 Coolant pump replacement ........................................................................................................ 116
6.6 Target wheel replacement .......................................................................................................... 118
6.7 Oil pump replacement ................................................................................................................. 120
6.8 Oil pressure valve replacement.................................................................................................. 123
6.9 Oil vapour separator replacement ............................................................................................. 124
6.10 Oil cooler unit and oil filter replacement................................................................................... 126
6.11 Fuel filter replacement ................................................................................................................ 128
6.12 Replacement of SCV valve ......................................................................................................... 129
7 Information for disassembly ............................................................................................. 131
7.1 Recommendations for disassembly .......................................................................................... 131
7.2 EGR circuit disassembly ............................................................................................................. 132
7.3 Electric components disassembly ............................................................................................. 134
7.4 Turbocharger disassembly ......................................................................................................... 138
7.5 Exhaust manifold disassembly ................................................................................................... 139
7.6 Coolant recirculation components disassembly ...................................................................... 140
7.7 Crankshaft and target wheel pulley disassembly .................................................................... 142
7.8 Lubrication circuit disassembly ................................................................................................. 143
7.9 Intake manifold disassembly ...................................................................................................... 146
7.10 Fuel system disassembly ............................................................................................................ 147
7.11 Timing system gear disassembly ............................................................................................... 150
7.12 Flange unit disassembly ............................................................................................................. 151
7.13 Cylinder head unit disassembly ................................................................................................. 152
7.14 Oil sump unit disassembly .......................................................................................................... 155
7.15 Engine block disassembly .......................................................................................................... 155
8 Information about overhauling ......................................................................................... 161
8.1 Recommendations for overhauls and tuning ........................................................................... 161
8.2 Crankcase..................................................................................................................................... 162
8.3 Tappets and tappet housings..................................................................................................... 166

[Titolo] EN
 INDEX

8.4 Crankshaft .................................................................................................................................... 167

8.5 Connecting rod - piston assembly ............................................................................................. 169
8.6 Cylinder head ............................................................................................................................... 172
8.7 Oil pump check ............................................................................................................................ 176
9 Assembly information ....................................................................................................... 178
9.1 Information on engine configuration ......................................................................................... 178
9.2 Assembly recommendations ...................................................................................................... 179
9.3 Engine block assembly ............................................................................................................... 180
9.4 Oil sump unit assembly ............................................................................................................... 188
9.5 Flange unit assembly .................................................................................................................. 190
9.6 Timing system gear assembly and injection pump.................................................................. 191
9.7 Cylinder head unit assembly ...................................................................................................... 193
9.8 Fuel system assembly ................................................................................................................. 199
9.9 Intake manifold assembly ........................................................................................................... 203
9.10 Exhaust manifold assembly ........................................................................................................ 204
9.11 Assembly lubrication circuit ....................................................................................................... 205
9.12 Crankshaft and phonic wheel pulley unit assembly ................................................................ 209
9.13 Coolant circuit assembly ............................................................................................................ 210
9.14 Turbocharger Assembly .............................................................................................................. 211
9.15 Electric component assembly .................................................................................................... 213
9.16 EGR Circuit Assembly ................................................................................................................. 218
9.17 Tightening torques and the use of sealants ............................................................................. 220
10 Fluids filling information ................................................................................................... 226
10.1 Engine oil ...................................................................................................................................... 226
10.2 Coolant ......................................................................................................................................... 227
11 Information about optional components .......................................................................... 230
11.1 Oil dipstick in cylinder head ....................................................................................................... 230
11.2 Heater (replacement) .................................................................................................................. 232
11.3 Poly-V alternator belt (replacement and adjustment) ............................................................. 233
11.4 Tightening pulley and alternator for Poly-V belt ...................................................................... 235
11.5 Idler gear (for 3rd / 4th PTO) ...................................................................................................... 237
11.6 3rd PTO (replacement) ................................................................................................................ 239
11.7 4th PTO (replacement) ................................................................................................................ 242
11.8 3rd + 4th PTO (configurations) ................................................................................................... 246
11.9 Balancer device (replacement)................................................................................................... 247
11.10 Air filter (cartridge replacement) ................................................................................................ 250
11.11 Remote oil filter (disassembly and assembly) .......................................................................... 251
11.12 Oil sump with supporting structure........................................................................................... 253
11.13 ETB (replacement) ....................................................................................................................... 256

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 INDEX

11.14 ACACT (replacement) .................................................................................................................. 257

11.15 EGTS (Black | Yellow - replacement) ......................................................................................... 258
11.16 DPF filter (replacement) .............................................................................................................. 259
12 Information on adjustments .............................................................................................. 262
12.1 'Waste Gate' opening valve regulation ..................................................................................... 262
12.2 Air filter check .............................................................................................................................. 264
12.3 Oil steam separator check .......................................................................................................... 265
12.4 Rubber hoses and manifolds check .......................................................................................... 266
12.5 Oil leak check ............................................................................................................................... 267
12.6 Oil pressure check ....................................................................................................................... 268
13 Tools information............................................................................................................... 269
13.1 Information regarding specific tools ......................................................................................... 269
14 Information about failures ................................................................................................. 272
14.1 Possible causes and trouble shooting ...................................................................................... 272
15 Glossary ............................................................................................................................. 274
15.1 Glossary ........................................................................................................................................ 274

[Titolo] EN
 1 GENERAL INFORMATION

EN 6
 GENERAL INFORMATION 1

1 GENERAL INFORMATION
1.1 Identification of the external components of the engine (BASE CONFIGURATION)

VIEW OF TIMING SYSTEM SIDE - EXHAUST

Fig 1.1

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 1 GENERAL INFORMATION

VIEW OF FLYWHEEL SIDE

Fig 1.2

This paragraph illustrates all external components NOTE: The illustrated components may differ from
that are present in the base configuration of the those illustrated; the illustration is only as an
engine. example.
For components present on engines that differ from
those represented in these illustrations, refer to
Chap. 11 .

Tab 1.3
POS. DESCRIPTION
POS. DESCRIPTION 18 Oil Cooler
1 Oil filler cap 19 Lub. oil filter
2 Wiring 20 Oil dipstick
3 ECU 21 Fuel filter
4 Turbocharger 22 EGR valve
5 Oil pressure switch 23 Crankshaft pulley (2 nd PTO)
6 Starter motor 24 Flywheel (1 st PTO)
7 Oil steam separator
25 Intake manifold
8 Oil drain plug
26 Waste Gate valve control actuator
9 Engine identification name plate 27 Exhaust manifold
10 Alternator 28 Flange bell
11 Coolant pump
29 Electronic injectors

EN 8
 GENERAL INFORMATION 1

12 Coolant temperature sensor 30 Common Rail

13 Oil filler cap side 31 Air intake hose
14 Thermostatic valve
15 Catalyst
16 EGR Cooler
17 High-pressure fuel injection pump

UPPER VIEW

Fig 1.3

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 1 GENERAL INFORMATION

1.2 Identification of the main internal components of the engine and operating reference
(BASE CONFIGURATION)
WIEW OF EXHAUST SIDE

Fig 1.5

Tab 1.2

The following chapters contain operating references in order to REF. DESCRIPTION

clearly understand the engine. This paragraph illustrates these
references that may be recognised by means of some main internal A View of timing system
components. side (2 nd PTO)
B View of flywheel side
Should you need to execute complex operations, always consult
(1 nd PTO)
this paragraph
C View of exhaust side

D View of intake side

1 Cylinder/Piston N. 1
(KDI 1903 - KDI 2504)
2 Cylinder/Piston N. 2
(KDI 1903 - KDI 2504)
3 Cylinder/Piston N. 3
(KDI 1903 - KDI 2504)
4 Cylinder/Piston N. 4
(KDI 2504)
POS. DESCRIPTION
5 Crankshaft pulley (2 nd
PTO)

EN 10
 GENERAL INFORMATION 1

6 Gear timing system

7 Thermostatic valve
8 Oil pump
9 Oil suction hose
10 Crankshaft
11 Exhaust manifold
12 Intake manifold
13 Camshaft
14 Gears adaptor for 3 th
/4 th PTO (optional)
15 Flywheel (1 st PTO)

WIEW OF FLYWHEEL SIDE

Fig 1.6

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 1 GENERAL INFORMATION

WIEW OF TIMING SYSTEM SIDE

Fig 1.7

EN 12
 GENERAL INFORMATION 1

1.3 Homologation labels

1.8.1 Label for EPA rules (compilation example)

Tab 1.1
POS. DESCRIPTION
1 Model year in compliance with the rules
2 Power category (kW)
3 Engine displacement (L)
4 Particulate emission limit (g/kWh)
5 Engine family ID
6 Emission Control System = ECS
7 Fuel with low sulphur content
8 Injection timing
9 Electronic injector opening pressure (bar)
10 Production date (example: 2013.JAN)

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 1 GENERAL INFORMATION

1.8.2 Label for China Standards (compilation example)

Tab 1.2
POS DESCRIPTION
1 Manufacturer
2 Engine model
3 Manufactoring date
4 Certificate N°
5 Power range (kW)
6 Emission level
7 Rated power
8 Aftertreat system

EN 14
 GENERAL INFORMATION 1

1.8.3 Label for Korea Standards (compilation example)

Tab 1.3
POS DESCRIPTION
1 Tier 4 Final
2 Engine model
3 Manufactoring date and manufacturer code
4 N° Korea emission certificate

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 1 GENERAL INFORMATION

1.4 Manufacturer and engine identification

The engine identification name plate is situated in the lower part of the crankcase; it is visible from the
intake or exhaust side.

Fig 1.1 - Fig 1.2

Fig 1.3

EN 16
 GENERAL INFORMATION 1

1.5 Useful information

• This manual contains the instructions needed to carry out proper use and maintenance of the
engine, therefore it must always be available, for future reference when required.
• Information, descriptions and pictures contained in this manual reflect the basic configuration of the
engines ( Par. 1.4 and Par. 1.5 ).
• However, the development of engines is continuous. Therefore, the information in this manual is
subject to change without notice.
• KOHLER reserves the right to make, at any time, changes on the engines for technical or
commercial reasons.
• These changes do not require KOHLER to intervene on the production marketed up to that time
and nor to consider this manual as inappropriate.
• The paragraphs, tables and figures are numbered by chapter and followed by the progressive
paragraph, table and/or figure number.
Es: Par. 1.3 - chapter 1 paragraph 3 .
Tab. 2.4 - chapter 2 table 4 .
Fig. 4.5 - chapter 4 figure 5 .

NOTE: The paragraphs may contain sub-paragraphs.

• All technical terms, specific components and symbols ( Tab. 15.1 ) that are in the manual are listed
and described inside the glossary, which can be consulted in ( Chap. 15 ).
• The references of the objects described in the text and in the figure are indicated by letters and
numbers, which are always and only related to the paragraph you are reading unless there are
specific references to other figures or paragraphs.
• Reference to values are indicated by letters or numbers.
•
The mark ( ) after the title of a paragraph, indicates that the procedure is not required in order to
disassemble the engine, however the procedures are featured in order to illustrate the disassembly
of components.
• Any additional section that KOHLER will deem necessary to supply at a later stage must be kept
with the manual and considered as an integral part of it.
• The information contained in this manual is the sole property of KOHLER , therefore no partial or
total reproduction or replication is allowed without the express permission of KOHLER .

1.1.1 Useful Information - accident prevention - environmental impact

• Before proceeding repair - handling the motor , read the entire chapter 3, which contains important
information about the procedures to be followed for safety and environment .

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 1 GENERAL INFORMATION

1.6 ATS (After Treatment System)

1.6.1 ATS with DOC filter Tab 1.4

POS. DESCRIZIONE
NOTE: The ATS system can be installed in a different way than shown.
1 Turbocharger
2 Gas exhaust
flange
3 DOC
4 Flexible exhaust
tube

Fig 1.10

1.6.2 ATS with DOC+DPF filter Tab 1.5

POS. DESCRIZIONE
NOTE: the ATS system with DPF filter is only present for versions
1 Turbocharger
compliant with "Stage V" emission regulations.
The ATS system can be installed in a different way than shown. 2 Turbine exhaust
pipe
3 DOC
4 DPF
5 ETB

Fig 1.11

EN 18
 TECHNICAL INFORMATION 2

2 TECHNICAL INFORMATION
2.1 Engine specifications
MANUFACTURER SPECIFICATIONS AND OPERATION
GENERAL INFORMATION UNIT OF KDI 1903 TCR KDI 2504 TCR
MEASURE
Operating cycle diesel - 4 stroke
Cylinders N° 3 4
Bore x stroke mm 88x102
Displacement cm 3
1861 2482
Compression ratio 17.4:1
Intake Supercharged with Turbocharger
Cooling Liquid
Crankshaft rotation (view from flywheel side) Counterclockwise
Combustion sequence 1-3-2 1-3-4-2
Timing System
Valves per cylinder N° 4
Timing System Rods and rocker arms - Camshaft in
the crankcase
Tappets Hydraulic
Injection Direct - Common Rail
Engine dry weight Kg 233 267
MAX inclination 30' continuous operation α 25°
MAX inclination 1' continuous operation α 35°
Volume of aspirated air (2600 rpm) m /h 3
2.4 2.8
POWER AND TORQUE
GENERAL INFORMATION UNIT OF KDI 1903 TCR KDI 2504 TCR
MEASURE
MAX operating speed Rpm 2600
MAX operating power (ISO TR 14396 - SAE kW 42 55.4
J1995 - CE 97/68)
Maximum torque (at 1500 rpm) Nm 225 300
Admissible axial load on crankshaft Kg 300
CONSUMPTIONS
GENERAL INFORMATION UNIT OF KDI 1903 TCR KDI 2504 TCR
MEASURE
Specific fuel consumption (best point) g/kWh 210
Oil consumption %Fuel < 0.05
FUEL SUPPLY SYSTEM
GENERAL INFORMATION UNIT OF KDI 1903 TCR KDI 2504 TCR
MEASURE

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 2 TECHNICAL INFORMATION

Type of fuel Diesel UNI-EN590 - ASTM D975

High-pressure fuel injection pump DENSO HP3
Fuel supply Low pressure electric pump (if
necessary)
Fuel filter
Filtering surface cm 2 2300
Degree of filtration µm 5
Maximum pressure at injection pump inlet bar 0,2
LUBRICATION CIRCUIT
GENERAL INFORMATION UNIT OF KDI 1903 TCR KDI 2504 TCR
MEASURE
Lubrication
Recommended oil See Par. 2.4
Circuit forced Lobe pump
Oil sump capacity ( MAX ) Lt. 8,9 11,5
Oil pressure switch
Intervention pressure ( MIN ) bar 0.8±0.1
Oil filter

Maximum operating pressure bar 4.0

Degree of filtration µm 17±2
Filtering surface cm 2
1744
COOLING CIRCUIT
GENERAL INFORMATION UNIT OF KDI 1903 TCR KDI 2504 TCR
MEASURE
Coolant % See Par. 2.6
Coolant pump Lt./min 75
Thermostatic valve
Opening temperature °C +79
Stroke at 91°C mm 7.50
Liquid recirculation Lt./h 9
ELECTRICAL SYSTEM - ELECTRIC FAN
GENERAL INFORMATION UNIT OF KDI 1903 TCR KDI 2504 TCR
MEASURE
Circuit rated voltage V 12
External alternator (rated current) A 80
Starter motor power kW 2
System electrical consumption, excluding: W 25
heater, electric pump, electric fan, starter
motor
Coolant temperature indicator light
Indicator light operating temperature °C +100/+110

EN 20
TECHNICAL INFORMATION 2

21 EN
 2 TECHNICAL INFORMATION

2.2 Engine dimensions (mm)

NOTE : Dimensions vary according to engine configuration.

TCR 1903

TCR 2504

Fig 2.1

EN 22
 TECHNICAL INFORMATION 2

2.3 Performance

TCR 1903

23 EN
 2 TECHNICAL INFORMATION

TCR 2504

Fig. 2.3

N = Automotive rating curve

MN = Torque curve
C = Specific fuel consumption curve

NOTE: Refer to KOHLER for power curves, torque curves and specific consumptions at speeds
other than those given above.

Key

 N ( ISO TR 14396 - SAE J1995 - CE 97/68 ) AUTOMOTIVE RATING CURVE : Intermittent duty at
variable speed and load.
Engine capacity at intermittent conditions with variable speed and load.

 MN: = TORQUE RATING CURVE : Also called twisting moment, it is the push generated by the
engine through transmission.
The highest engine performance is obtained at the maximum torque.

EN 24
 TECHNICAL INFORMATION 2

 C = SPECIFIC CONSUMPTION CURVE : Engine fuel consumption in a given time at a certain

revolution value.
Expressed in g/kW (grams/kilowatt), it expresses fuel yield.

* The above curves express indicative values, in that the overall performance depends on the type
of application and the ECU control uni.
o The ratings reported in the diagram regard the run-in engine, fitted with air and exhaust
filters, at the atmospheric pressure of 1 Bar and at a room temperature of +20°C
o Maximum rating is guaranteed with a 5% tolerance.

Warning
• Non approval by KOHLER for any modification releases the company from liability for damage
incurred on the engine.

2.4 Oil

Important
• The engine may be damaged if operated with improper oil level.
• Do not exceed the MAX level because a sudden increase in engine rpm could be caused by its
combustion.
• Use only the recommended oil to ensure adequate protection, efficiency and service life of the
engine.
• The use of lubricants other than recommended may shorten the engine life.
• Viscosity must be appropriate to the ambient temperature to which the engine is to be exposed.

Danger
• Prolonged skin contact with the exhausted engine oil can cause cancer of the skin.
• If contact with oil cannot be avoided, thoroughly wash your hands with soap and water as soon as
possible.
• For the exhausted oil disposal, refer to the Par. DISPOSAL and SCRAPPING .

2.4.1 SAE oil classification

• In the SAE classification, oils are identified according to viscosity without considering any other
qualitative characteristic.
• The code is composed of two numbers, which indicate, and must correspond to, the ambient
temperature in which the engine operates, the first number refers to the viscosity when cold, for use
during winter (" W "), while the second number is for viscosity at high temperatures.

2.2
RECCOMENDED OIL
VISCOSITY SAE 15W-40 (-15°C ÷ +50°C)
10w-30 (-25°C ÷ +40°C)
10w-40 (-25°C ÷ +50°C)
5w-30 (-30°C ÷ +40°C)
0w-40 (-40°C ÷ +50°C)

25 EN
 2 TECHNICAL INFORMATION

TCR TIER IV FINAL - STAGE V TCR/D TIER III or UNCERTIFIED

(1) (2)

WITH API CJ-4 Low S.A.P.S CI-4 Plus

SPECIFICATIONS CI-4
CH-4
ACEA E9 Mid S.A.P.S. E7
E6 Low S.A.P.S. E5

• Low S.A.P.S. technology (fuel with low Sulfated Ash, Phosphorus, Sulfur content) keeps catalyst in
good working conditions. The presence of sulfated ash, phosphorus and sulfur causes with time
the catalyst clogging and its consequent inefficiency.
• For Mid S.A.P.S oil sequence the sulfated ash level is the same as API CJ-4 ≤ 1.0% but as per
ACEA standardization those oils are referenced as mid SAPS.
• Filtration of oils is critical to proper operation and lubrication; always change filters regularly as
specified in this manual.

(1) NOTE : Do NOT use fuel with sulphur content above 15ppm.

(2) NOTE : Do NOT use fuel with sulphur content above 500ppm.
Low S.A.P.S. oils, sulfate ashes <1% may not be used with fuels with a sulfur content >50ppm.

EN 26
 TECHNICAL INFORMATION 2

2.5 Fuel

Important
o Use of other types of fuel could damage the engine. Do not use dirty diesel fuel or mixtures
of diesel fuel and water since this will cause serious engine faults.
o Any failures resulting from the use of fuels other than recommended will not be
warranted.

Warning
• Clean fuel prevents the fuel injectors from clogging. Immediately clean up any spillage during
refuelling.
• Never store diesel fuel in galvanized containers (i.e. coated with zinc). Diesel fuel and the galvanized
coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel
pump and/or injector failure.
2.3
FUEL COMPATIBILITY
EN 590 (biodiesel content max. 7% (V/V))
ASTM D 975 Grade 1-D S15
ASTM D 975 Grade 2-D S15
NATO F-54, equivalent to diesel fuel in accordance with EN 590
EN 590 or ASTM D 975 Grade 1, 2 -D S15 Arctic Diesel
JIS K 2204 No. 1, No. 2
NOTE : In a warranty case the customer must prove by a certificate from the fuel supplier that an allowed
fuel was used.

KDI Electronic Injection Tier 4 final – Stage IIIB – Stage IV- Stage V certified Engines
• Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane
number of at least 45. Since those engines are equipped with exhaust gas after-treatment such as
Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR),
they may only be operated with sulfur-free diesel fuels (EN 590, DIN 5168, ASTM D975 Grade 2-D
S15, ASTM D975 Grade 1-D S15). Otherwise, compliance with the emission requirements and
durability are not guaranteed.
Insufficient lubricating capacity can lead to serious wear problems above all in common rail
injection systems. Too low a lubricating capacity is particularly a problem in fuels with a low sulfur
content (and in this respect sulfur contents ‹500 mg/kg can already be considered low). An
adequate lubricating capacity is guaranteed by the appropriate additives in low-sulfur (‹50 mg/kg) or
sulfur-free (‹10 mg/kg or ‹15 mg/kg) diesel fuels according to EN 590 and ASTM D 975. In low-
sulpur and sulfur-free diesel fuels which do not comply with this standard, the lubricating capacity
may have to be guaranteed by additives. The parameter for sufficient lubricating capacity is a
maximum wear spot of 460 micrometers in the HFRR test (EN ISO 12156-1).

KDI Electronic Injection Tier 3 – Stage IIIA emission equivalent certified Engines (EGR engines)
• Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane
number of at least 45. Since those engines are not equipped with exhaust gas after-treatment, they
can be operated with diesel fuels with sulfur content up to 500 mg/kg (ppm). Compliance with the
emission requirements is guaranteed only with sulfur content up to 350 mg/kg (ppm).
Fuels with a sulfur content > 50 mg/kg demand a shorter lubricating oil change interval. This is set
at 250hrs. However, the engine oil must be changed when the Total Base Number TBN is reduced
to 6.0 mgKOH/g test method ASTM D4739. Do not use low SAPS engine oils.

KDI Electronic Injection uncertified Engines (no EGR engines)

27 EN
 2 TECHNICAL INFORMATION

• Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane
number of at least 45. Since those engines are not equipped with exhaust gas after-treatment, they
can be operated with diesel fuels with sulfur content up to 2000 mg/kg (ppm). Fuels with a sulfur
content > 15 mg/kg demand a shorter lubricating oil change interval. This is set at 250hrs. However,
the engine oil must be changed when the Total Base Number TBN is reduced to 6.0 mgKOH/g test
method ASTM D4739.

2.5.1 Fuel for low temperatures

•
When operating the engine in ambient temperatures lower than 0 degrees C, use suitable low
temperature fuel normally available from fuel distributors and corresponding to the specifications of
Tab. 2.3 .
• These fuels reduce the formation of paraffin in diesel at low temperatures.
• When paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.

2.5.2 Biodiesel fuel

• Fuels containing 10% methyl ester or B10, are suitable for use in this engine provided that they
meet the specifications listed in the Tab. 2.3.
• DO NOT USE vegetable oil as a biofuel for this engine.
2.4
BIODIESEL COMPATIBILITY
Biodiesel according to EN 14214 (only permissible for mixture with diesel fuel at max. 10% (V/V))
US biodiesel according to ASTM D6751 – 09a (B100) (only permissible for mixtures with diesel fuel at
10% (V/V))

2.5.3 Synthetic fuels: GTL, CTL, BTL, HV

It is a well-known fact that engines which are operated for longer periods with conventional diesel fuel and
then converted to synthetic fuels suffer shrinkage of polymer seals in the injection system and thus fuel
leaks. The reason for this behavior is that the aromatic-free synthetic fuels can lead to a change in the
selling behavior of polymer seals.
Therefore, conversion from diesel fuel to synthetic fuel may only be done after changing the critical seals.
The problem of shrinkage does not occur when an engine was operated with synthetic fuel from the start.

2.5.4 Non-Road Fuels

Only for KDI De- Contented Electronic Injection Tier 3 – Stage IIIA emission equivalent certified Engines
(EGR engines) and KDI De- Contented Electronic Injection Uncertified Engines (no EGR engines).
Other non-road fuels may be used if they comply with all the limit values of EN 590 except for the fuel
density, the cetane number and the sulfur content.
The following limits apply for these parameters:
2.5
FUEL PARAMETER UNIT LIMIT VALUE
Cetane number Min. 49
Fuel density at 15°C Kg/m 3
820 - 860
Sulfur content mg/kg or ppm max. 500

2.5.5 Jet Fuels

Only for KDI De- Contented Electronic Injection Uncertified Engines (no EGR engines).
The following jet fuels can be used but only adopting an additional fuel filter with lubricity doser:

EN 28
 TECHNICAL INFORMATION 2

2.6
FUEL
F-34/F-35 (kerosene, NATO designation) JP-8 (kerosene, US military
designation)
F-44 (kerosene, NATO designation JP-5 (kerosene, US military
designation)
F-63 (kerosene, NATO designation, equivalent to F-34/F-35 with Jet A (kerosene for civil aviation)
additives)
F-65 (kerosene, NATO designation, 1:1 mixture of F-54 and F- Jet A1 (kerosene for civil aviation)
34/F-35)

2.5.6 Emission-Related Installation Instructions

Failing to follow the instructions in the applications guidebook when installing a certified engine in a piece of
nonroad equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as
described in the Clean Air Act.
OEM must apply a separate label with the following statement: “ULTRA LOW SULFUR FUEL ONLY” near
the fuel inlet.
Ensure you are installing an engine appropriately certified for your application. Constant speed engines may
only be installed on constant speed equipment for constant speed operation.
If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40
CFR 1068.105.

29 EN
 2 TECHNICAL INFORMATION

2.6 Coolant recommendation

A mixture of 50% demineralized water and 50% low silicate ethylene glycol based coolant liquid must be
used.
Use a Long Life or Extended Life Heavy Duty OAT coolant free of: silicates, phosphates, borates, nitrites
and amines.
The following ethylene-glycol based engine coolant for all models within KDI engine family may be used:

• OAT (Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210

• HOAT (Hybrid Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210

The above coolants in concentrated formulation must be mixed with distilled, deionized, or demineralized
water. A pre-mixed formulation (40-60% or 50-50%) can be used directly when available.

Important
• Do not mix ethylene glycol and propylene glycol based coolants. Do not mix OAT and HOAT
based coolant. OAT performance life can be drastically reduced if contaminated with nitrite-
containing coolants.
• Never use automotive-type coolants. These coolants do not contain the correct additives to
protect heavy – duty diesel engines.

OAT coolants are maintenance free up to 6 years or 6000hrs of operation , provided that the cooling
system is topped up using the same type of coolant. Do not mix different coolant types. Test the coolant
condition annually with coolant test strips.
HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives)
added at the first maintenance interval.

EN 30
 TECHNICAL INFORMATION 2

2.7 Battery recommendation

Battery not supplied by Kohler

Tab. 2.7
RECOMMENDED BATTERIES
AMBIENT TEMPERATURE BATTERY TYPE
≥ - 15°C 100 Ah - 800 CCA/SAE
< -15°C 120 Ah - 1000 CCA/SAE

31 EN
 2 TECHNICAL INFORMATION

2.8 Periodic maintenance

The intervals of preventive maintenance in Tab. 2.8, Tab. 2.9, Tab. 2.10 and Tab. 2.11 refer to the engine
operating under normal operating conditions with fuel and oil meeting the recommended specifications.

2.8
CLEANING AND CHECKING
OPERATION DESCRIPTION PERIOD (HOURS)
100 250 500 5000
Engine oil level (8)
Coolant level (8) (9)
Cartridge dry-type air filter (2)
Radiator heat-exchange surface and Intercooler (2) (8)
Standard alternator belt (8)
Poly-V alternator belt (8)
Rubber hose (intake air / coolant)
Fuel hose
Starter Motor

Alternator

2.9
REPLACEMENT
OPERATION DESCRIPTION PERIOD (HOURS)
500 2000 5000 5000
Cartridge dry-type air filter (2)

Intake manifold hose (air filter - intake manifold) (7)

Coolant hoses (7)
Fuel line hose (7)
Alternator belt Standard alternator belt (trapezoidal) (3)

Poly-V belt heavy environmental condition

Poly-V belt standard condition
Coolant OAT
HOAT (10)

2.10
ENGINE OIL AND OIL FILTER CARTRIDGE REPLACEMENT
ENGINE VERSION PERIOD (HOURS)
250 500
KDI TCR Tier 4 final – Stage IIIB – Stage IV- Stage V (1)
KDI TCR/D Tier 3 – Stage IIIA (1) (11)

EN 32
 TECHNICAL INFORMATION 2

KDI TCR/D uncertified (1)

2.11
FUEL FILTER AND PREFILTER CARTRIDGE REPLACEMENT
ENGINE VERSION PERIOD (HOURS)
250 500
KDI TCR Tier 4 final – Stage IIIB – Stage IV- Stage V (1)

KDI TCR/D Tier 3 – Stage IIIA (1)

KDI TCR/D uncertified (1)

(1) - In case of low use: 12 months.

(2) - The period of time that must elapse before checking the filter element depends on the environment in
which the engine operates. The air filter must be cleaned and replaced more frequently under very dusty
conditions.
(3) - In case of low use: 36 months.
(7) - The replacement interval is only an indication, it strongly depends from environmental condition and
hose status detected during regular visual inspection.
(8) - The first check must be done after 10 hours.
(9) - Test the coolant condition annually with coolant test strips.
(10) - It is recommended to have SCA (Supplemental Coolant Additives) added at the first maintenance
interval.
(11) - Read Cap. 2.5, "KDI De- Contented Electronic Injection Tier 3 – Stage IIIA emission equivalent
certified Engines (EGR engines)" and "KDI De- Contented Electronic Injection Uncertified Engines (no EGR
engines)".

33 EN
 2 TECHNICAL INFORMATION

2.9 Fuel system

2.9.1 Injection circuit (pressure 2000 bar) (Fig 2.4)

The materials of the fuel system components (pipes, tank, filters, etc.) and any surface treatments must be
free from chemical elements that, transported in the fuel, compromise the operation of the injectors over
time (hole clogging).
The most critical chemical element is Zinc (Zn), therefore it is forbidden to use galvanised components.
Other damaging elements are indicated in the table below.

Tab 2.12
POLLUTANTS LIMIT VALUES OF PRESENCE IN FUEL LIMIT
VALUE
Zn (Zinc) • Zinc (Zn) is eluted from the rubber (NBR) in the fuel line. Thus, Zn ≤
the growing carboxylate (Zn) was adhered on the parts in the 0.3ppm
injection system for reacting carboxylic acid in the fuel.
• In case that the changed injection quantity, nozzle coking
occurs the fuel contents Zn≥1ppm.
• Zinc (Zn) is ≤ 0.3ppm is the limited value to avoid occur
coking.
Pb (Lead) • Lead (Pb)is eluted from Pd coading in the fuel tank. Thus, the Pd ≤
growing carboxylate (Pd) was adhered on the injection system 0.3ppm
for reacting carboxylic acid in the fuel.
• In case that the changed injection quantity and nozzle coking
occurs the fuel contents Pd.
• As interim, the identical level is the limited value with Zn.
Na (Sodium) • The growing carboxylate (Na) was adhered on the parts in the Na + K ≤
K (Potassium) injection system for reacting carboxylic acid in the fuel with 0.3ppm
fuel contents Na ≥ 0.5ppm. Thus, sliding malfunction was
occurred.
• In case that the changed injection quantity and nozzle coking
occurs the fuel contents Na.
• Especially concerns of occurring defects, NaOH is residue for
using production process of bio fuel.
• ≤ 0.3ppm is the limited value to avoid occur nozzle coking and
carboxylate. Combine K with Na equivalent alkali metal that
are less than 0.3ppm.
Ca (Calcium) • In case that carboxylate (Ca) was adhered the injection system Ca + Mg
Mg (Magnesium) inside. ≤ 0.3ppm
• Under study on the results in the moment.
• Maximum value is 0.3ppm when using fuel that is B100 fuel
with regulation EN14214 of contents 7%.
Cu (Copper) • Copper (Cu) on the fuel that can be acted wear and catalyst Cu ≤
for making decline. 0.3ppm
• In case that the changed injector quantity and nozzle coking
occurs in the fuel contents Cu.
• As interim, the identical level is the limited value with Zn.
Ba (Barium) • In case that changed injection quantity and nozzle coking Ba ≤
occurs in the fuel contents Barium (Ba). 0.3ppm
• As interim, the identical level is the limited value with Zn.

EN 34
 TECHNICAL INFORMATION 2

P (Phosphorus) • Phosphorus (P) in the fuel can poison catalyst. P≤

• No failure case is in the injection system in the moment. 0.3ppm
• Maximum value is 0.3ppm when using a B100 fuel with
regulation EN 14214 of contents 7%.
Na - K - Ca - Mg These metals are regulated in EN14214
-P

Important
• The high pressure supply injection system is highly susceptible to damage if the fuel is
contaminated.
• It is crucial that all components of the injection circuit are thoroughly cleaned before the
components are removed.
• Thoroughly wash and clean the engine before maintenance.
• Contamination in the injection system may cause a reduction in in performance or engine faults.
• If the engine is cleaned with high pressure washer, then the nozzle must be kept at a minimum
distance of 200mm from the surface, and not directed at electrical components and connectors.

The fuel supply system is under low pressure from

fuel tank 1 to the high-pressure fuel injection pump
5.

NOTE : The representation of fuel tank is

purely indicative. Component not necessarily
supplied by KOHLER .

Tab 2.13
POS. DESCRIPTION
1 Fuel tank
2 Fuel pipe under low pressure from the
tank to the fuel filter
3 Fuel filter
4 Low-pressure fuel tube from the fuel filter
to the high-pressure injection pump
Fig 2.4
5 High-pressure fuel injection pump
6 High-pressure fuel tube from the high-
pressure fuel injection pump to the
Common Rail
7 Common Rail
8 Fuel pipes under high pressure from the
Common Rail to the electronic injectors
9 Electronic injectors

35 EN
 2 TECHNICAL INFORMATION

2.9.2 Fuel return circuit

The fuel return circuit is under low pressure.

NOTE : The representation of fuel tank is

purely indicative. Component not necessarily
supplied by KOHLER .

Tab 2.14
POS. DESCRIPTION
1 Electronic injectors
2 Common Rail
3 Low-pressure fuel return tube from the
Common Rail to the fuel return distributor
4 Low-pressure fuel return tube from the
electronic injectors to the fuel return
distributor
5 Low-pressure fuel return distributor Fig 2.5
6 Low-pressure fuel return tube from the
return distributor to the fuel tank
7 High-pressure fuel injection pump
8 Low-pressure fuel return tube from the
injection pump to the fuel return
distributor
9 Fuel tank

2.9.3 High-pressure injection pump (2000 bar)

Important

• DO NOT use the cylinder connecting pipe (item 5) to

carry the pump during movement as this may cause
damage resulting in fuel leakag; to handle the injection
pump, refer Par. 2.17.1.
• The injection pump CANNOT be repaired.
Fig 2.6
• DO NOT attempt to remove the temperature sensor 7
from the pump. Should the sensor 7 be defective,
replace the injection pump.
• It is NOT possible to perform any maintenance on the
fuel intake regulating valve 6 as it is an integral part of
the injection pump.
• DO NOT attempt to remove the fuel intake regulating
valve 6 from the injection pump. Should the valve be
defective, replace the injection pump.

Fig 2.7

EN 36
 TECHNICAL INFORMATION 2

NOTE: In the event of leakage from the high pressure circuit do

not intervene when the engine is running, but turn it off and
wait 5 - 10 minutes before checking the leakage.

The inlet pressure to the high pressure pump must be between

300 mbar (suction pump without electric supply) and 200 mbar
(with electric pump power) to the high pressure rail.
The high pressure pump is operated via the pump control gear
and sends high pressure fuel to the common rail.

NOTE: The supply tube (on union 8) and fuel return (on union
9), have different diameters.

Tab 2.15
POS. COMPONENTS DESCRIPTION
1 High-pressure fuel injection pump
2 Name plate with QR code
3 Fitting for high pressure outlet to Common Rail
4 Plunger housing
5 Connection pipe plunger housing
6 Fuel intake regulating valve
7 Fuel temperature sensor
8 Fuel inlet fitting
9 Fuel return fitting
10 Shaft key positioning on the pump control gear
11 Pump control shaft
12 Gasket

37 EN
 2 TECHNICAL INFORMATION

2.9.4 Electronic injector

The electronic injector is equipped with an integral

solenoid valve which, when excited electronically,
manages a valve controlled from
inside the electronic injector to commence fuel
injection.

The ECU output signal is digital.

Important

• The electronic injector is NOT repairable.

• The electronic injectors are calibrated
individually.
• They are NOT interchangeable with the
other cylinders of the same - or other -
engines.
• It is assembled on the engine; the new
calibration code (QR code) must be
inserted in the ECU by means of a Fig 2.8
diagnostics instrument (ST_01).
Tab 2.16
• Do NOT fit new or different electronic
injectors without the instruments required POS. COMPONENTS DESCRIPTION
to enter the injector calibration code. 1 Connector for solenoid control
• Fuel containing impurities causes serious 2 Solenoid and valve closure ring
damage to the electronic injectors.
3 High pressure pipe inlet fitting
• The electronic injector for Stage V engines
is different and it is not interchangeable 4 Electronic injectors body
with other engine 5 Nozzle closure ring nut
6 Nozzle
7 QR code (Visual reading)
8 QR code (Electronic reading)
9 Return pipe fitting
10 Electronic injector identification code

2.9.5 Common Rail

Fuel is injected under pressure into the Common Rail ( Pos.3 ), from the high-pressure fuel injection
pump.
• The internal volume of the Common Rail is optimised to obtain the best compromise in order to
minimise pressure peaks due to the cyclical flow of the injection pump;
• Opening the electronic injectors;
• The high speed response of the system to the requests of the ECU control unit.
The pressure sensor 5 measures the pressure of the fuel in the Common Rail.
Safety valve 2 , only opens if internal pressure of the Common Rail exceeds the maximum value of 2400
bar. Pressure inside the Common Rail is regulated by the highpressure fuel injection pump by means of
the fuel intake regulation valve ( Pos. 6 Fig. 2.6 ).
The fuel ejected from the safety valve is introduced in the circuit of rejection returning to the tank.

EN 38
 TECHNICAL INFORMATION 2

Important

• Common Rail is NOT reparaible.

• It is NOT possible to perform any maintenance on the fuel pressure sensor 5 , as it is an integral
part of the Common Rail unit.
• Do NOT remove the pressure sensor or the fuel pressure limit valve from the Common Rail.
• If the pressure sensor or the pressure limit valve are not working, replace the entire Common Rail
unit.

Fig 2.9

Tab 2.17
POS. DESCRIPTION
1 Common Rail
2 Pressure limit valve (return due to overpressure)
3 Tube inlet union from high-pressure fuel injection pump
4 Outlet fittings for supply pipes to electronic injectors
5 Fuel pressure sensor

39 EN
 2 TECHNICAL INFORMATION

2.9.6 Fuel filter

The fuel filter is situated on the crankcase of the

engine or it may be assembled on the frame of the
vehicle.

Tab 2.18
POS. COMPONENTS DESCRIPTION
1 Fuel filter support
2 Fuel system filling button
3 Cartridge
4 Water in fuel sensor
5 Wing nut, filter drainage

Tab 2.19

DESCRIPTION VALUE
Filtering surface 2.300 cm 2
Degree of filtration 5 µm
Max operating pressure 2.0 Bar
Max flow rate 190 litres/hour Fig 2.10

2.9.7 Electric fuel pump (optional)

When the electric fuel pump is installed in a diesel engine, one
must:
1. Remove any filters installed on the inlet of the electric
injection pump;
2. Insert a pre-filter between the tank and the electric
pump;
3. The electric pump may be assembled on application at
a maximum height of 500 mm from the position of the
fuel tank.
Fig 2.11
4. Insert a shut-off valve to prevent dry operation due to
the emptying of the intake manifold;
5. The supply pressure given from the electric pump must
not exceed the pressure of 0.2 bar to the input of
highpressure injection pump.

Tab 2.20
POS. DESCRIPTION
1 Arrival pipe from the tank
2 Electric pump
3 Flow pipe to the fuel filter
4 Fuel filter

EN 40
 TECHNICAL INFORMATION 2

2.9.8 Guards for fuel injection circuit components

High-pressure injection circuit components are particularly

sensitive to impurities.
To prevent impurities, even microscopic ones, from accessing
the fuel input or output unions, you are required to close these
accesses by means of specific caps as soon as the various
tubes are disassembled and disconnected.

Disassembly of any component of the injection circuit must not Fig 2.13
occur in dusty environments.

Cap protections must remain closed in their housing (ST_40)

until the moment they are to be used.

Pay special attention when using the caps and avoid any
contamination of dust or dirt of any kind.

Even after using the caps illustrated in this paragraph, all

components of the injection circuit must be placed with care in
environments that are free of any type of impurity.

Fig 2.14
Fig. 2.13, 2.14 and 2.15 illustrate the caps that must be used
on components of the injection circuit.

Cap protections must be accurately washed after use and

placed back in their housing (ST_40).

Important

• It is highly recommended to have this page visible

during disassembly operations of the components of
the fuel injection circuit.
Fig 2.15

41 EN
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2.10 Lubrication circuit

2.10.1 Lubrication circuit diagram

The oil pump is driven by the crankshaft on the

timing system side.
On the parts of the systems shown in green on
In the parts in green, the oil is in intake, in the
parts in red, the oil is under pressure and
in those in yellow the oil is returning towards the
oil sump 2 (not under pressure).

Tab 2.21
COLOUR DESCRIPTION
Oil in intake
Oil under pressure Fig 2.16
Oil returning to the oil sump

Tab 2.22

POS. DESCRIPTION
1 Oil pump rotors
2 Oil sump
3 Crankshaft
4 Camshaft
5 Turbocharger
6 Rocker arm pin
7 Hydraulic tappets
Fig 2.17
8 Rocker arm cover
9 Cylinder head
10 Upper crankcase
11 Lower crankcase
12 Oil filter
13 Oil Cooler
14 Housing

NOTE : Click by side to play the procedure. https://www.youtube.com/embed/Ig3XosQ8h0s?rel=0

EN 42
 TECHNICAL INFORMATION 2

2.10.2 Oil pump

The oil pump rotors are trochoidal (with lobes)
and are activated from the crankshaft by means
of the key.
The pump body is situated inside the
distribution guard.
It is imperative to assemble the rotors with
reference A visible by the operator.

Tab 2.23
POS. DESCRIPTION
1 Internal rotor
2 External rotor
3 Oil pump crankcase
4 Pump control key
5 Timing system crankcase
6 Crankshaft

Fig 2.18

43 EN
 2 TECHNICAL INFORMATION

2.10.3 Oil filter and Oil Cooler

Fig 2.1 9

NOTE : unscrewing the cartridge

holder cover makes the oil in support
7 flow towards the oil sump by means
of the drain duct 4.

Tab 2.24
POS. DESCRIPTION
1 Oil arriving from the pump
2 Oil cooling
3 Oil filtering
4 Oil drain duct (oil sump return)
5 Oil returning into the circuit
6 Outgoing fitting from filter
7 Oil filter support
8 Cartridge holder cover
9 Oil filter cartridge
10 Oil Cooler
11 Crankcase
12 Oil directly from the cartridge
13 Coolant
14 Oil drain duct closure gasket Fig 2.20

15 Oil filtering chamber closure gasket

16 Cartridge holder cover gasket

Tab 2.25 Cartridge characteristics.

DESCRIPTION VALORE
Filtering surface 2.300 cm 2
Degree of filtration 2 µm
Max operating pressure 4.0 Bar
Max flow rate 190 litres/hour

EN 44
TECHNICAL INFORMATION 2

45 EN
 2 TECHNICAL INFORMATION

2.11 Cooling circuit

2.11.1 Cooling circuit diagram

Tab 2.26

POS. DESCRIPTION
1 Coolant pump
2 Coolant intake
3 Coolant, cylinder
4 Coolant, cylinder head
5 EGR gas coolant
6 Coolant to radiator
7 Coolant into radiator
8 EGR valve coolant
9 Coolant in the Oil Cooler
10 Coolant input into the Oil Cooler
11 Coolant output from the Oil Cooler
12 Vent line from radiator (to 15)
Fig 2.21
13 Vent line to expansion vase (to 15)
14 Return from compensation tank
15 Compensation tank
16 Thermostatic valve

Fig 2.22

EN 46
 TECHNICAL INFORMATION 2

2.11.2 Water pump

Tab 2.27

POS. DESCRIPTION
1 Coolant pump control pulley
2 Coolant intake fitting
3 Coolant return hose from the Oil Cooler
Fig 2.23

2.11.3 Radiator with Intercooler (optional)

Tab 2.28

POS. DESCRIPTION
1 Radiator with intercooler
2 Coolant refill cap
3 Radiator coolant vent tube or return
4 Air hose (from Intercooler to manifold) Fig 2.24
5 Intercooler air delivery hose
6 Coolant flow manifold
7 Coolant intake manifold
8 EGR Cooler coolant vent tube or return

2.11.4 Thermostatic valve

Tab 2.29

POS. DESCRIPTION
1 Cylinder head
2 Coolant outlet cover
3 Thermostatic valve
4 Gaskets Fig 2.25
5 Air bleeding hole

Starting opening temperature of +79° ± 2°C.

47 EN
 2 TECHNICAL INFORMATION

2.11.5 EGR gas circuit cooling (EGR Cooler)

Device that cools exhaust gas

Tab 2.30
POS. DESCRIPTION
1 EGR valve
2 EGR gas passage tubes Fig 2.26
3 Coolant outlet hose
4 EGR Cooler
5 Coolant draining union
6 Coolant delivery hose
7 Intake manifold

EN 48
 TECHNICAL INFORMATION 2

2.12 Intake and exhaust circuit

2.12.1 Turbocharger
The turbocharger is controlled by means of exhaust gas that
activates the turbine.

Important

• See Par 2.18 .

Tab 2.31

POS. DESCRIPTION
1 Air intake hose
2 Air compression volute
Fig 2.27
3 Turbo charger central body
4 Turbine housing with Waste Gate valve
5 Gas exhaust flange
6 Waste Gate control valve hose
7 Waste Gate valve control actuator
8 Waste Gate control valve linkage
9 Engine crankcase breather
10 Air compressed flow hose to intercooler
11 Oil drain pipe
12 Turbo charger lubrication pipe

2.12.2 ATS device

2.12.2.1 DOC

The DOC is a device to filter exhaust gas by means of its

oxidation.
Internally, it is composed of hundreds of small ducts that
enable the passage of exhaust gas.
It contains precious metals (platinum, palladium, iridium).

NOTE: The image is indicative only. The installation of the

catalyst must be approved by KOHLER, for each application.
In order to prevent breakage on the connection flange, the
catalyst is normally connected via a hose.

Important Fig 2.28

• In order to prevent breakage on the connection flange,

the catalyst must be connected via a flexible exhaust
tube.

49 EN
 2 TECHNICAL INFORMATION

Tab 2.32a

POS. DESCRIPTION
4 Turbocharger
5 Gas exhaust flange
13 DOC
14 Flexible exhaust tube

2.12.2.2 Intake and exhaust circuit diagram with DOC

Air in intake Gas in recycle Gas in exhaust

Fig 2.29

Fig 2.30

EN 50
 TECHNICAL INFORMATION 2

Important Tab 2.32b

POS. DESCRIPTION
• The diagrams in Fig. 2.29 and Fig. 2.30 do not have an air
filter, which must always be present and connected by means 1 Air in intake from air
of an intake hose to the turbocharger. filter
• The air temperature inside the intake manifold must never 2 Air in compression
exceed that of the environment by 10°C. 3 Air in intercooler
flow
Filtered air is sucked by the turbocharger, which compresses and
4 Air cooling
sends it to the intercooler (as a consequence of compression, the air
increases the temperature - the Intercooler cools it - this process 5 Air in intake manifold
enables better performance during combustion inside the cylinders). flow
From the Intercooler, it is sent to the 6 Air in head intake
intake manifold and, via ducts in the cylinder head, enters the cylinders. 7 Air in cylinder intake
Compressed air inside the cylinders and mixed with the fuel transforms
into Gas after combustion. The gas is expelled from the cylinders and 8 Gas in cylinder
outlet
sent to the exhaust manifold. The exhaust manifold sends the Gases to
2 ducts: 9 Gas in head outlet
10 Gas in outlet
• 1st duct : to the turbocharger body (the expelled Gases towards DOC
activate the turbine), the Gases then proceed towards the
11 Gas in oxidation
catalyst, which break down the pollutants contained in them
before being definitely expelled. 12 Gas in recycle
towards EGR valve
• 2nd duct : to the EGR circuit, which takes care of recovering a
part of the Gases that return to intake 13 Gas in EGR valve
(this process burns less oxygen when power is not requested, outlet
thus breaking down pollutants further). 14 Gas cooling (in EGR
The EGR circuit is managed by ECU, which controls the EGR valve Cooler)
that provides for the recovery of Gases when the engine does not
15 Exhaust gas
require power.
recirculation into
The EGR circuit is furnished with a heat exchanger (EGR Cooler), which
intake manifold
cools the recovered Gases (this process enables better performance
during combustion inside the cylinders). A Intake manifold
B Exhaust manifold
C Upper crankcase
D Lower crankcase
E Oil sump
F Catalyst
G Radiator/intercooler

51 EN
 2 TECHNICAL INFORMATION

2.12.2.3 DOC+DPF

The DOC+DPF system reduces emissions because the DPF eliminates the particulate generated by Diesel fuel
combustion. The system triggers automatic DPF regeneration cycles depending on the degree of clogging.
The smell of the gases out of the exhaust line is different than the traditional one of gases from Diesel engines.
Moreover, during regeneration stages, the exhaust gases could temporarily be white.

NOTE: During regeneration, engine idling will increase.

Fig
2.30a

Tab 2.32c
POS. DESCRIPTION
1 turbocharger
2 exhaust pipe from turbine
3 DOC
4 DPF
5 ETB
6 EGTS (Black)
7 EGTS (Yellow)
8 Delta-P (Delta Pressure)

EN 52
 TECHNICAL INFORMATION 2

2.12.2.4 DPF regeneration strategy

You can intervene on the machine control panel for the DPF regeneration operations "only if requested
by means of specific warning lights or messages on the control panel".

Tab. 2.32d describes the level of particulate accumulation, the relationship with the warning lights that
will light up on the panel, the performance limitations of the engine and the operator’s options
intervention.

Forced regeneration must be executed in accordance with the machine instructions.

Tab 2.32d
SOOT WARNING ENGINE DE- OPERATOR POSSIBLE OPERATING
LEVEL LAMPS *1 RATE ACTIONS CONDITIONS
Level 0 • No condition
Level 1
Level 2
Level 3 Forced Regeneration is • Coolant
Necessary temperature at
55°C
Fixed • Do not switch
the engine off
• Stationary
vehicle
• No load
applied to the
engine *2
Level 4 Engine de- Forced Regeneration is • Coolant
rate Necessary temperature at
55°C
Flashing • Do not switch
the engine off
• Stationary
vehicle
• No load
applied to the
engine *2
Level 5 Strong Engine Contact an authorized REGENERATION via
de-rate KOHLER workshop. KOHLER software
Service Regeneration
Flashing Required

*1: The warning lights be different – consult the machine manual.

*2: Unless stated otherwise in the machine manual.

53 EN
 2 TECHNICAL INFORMATION

Warning

• Forced regenerations must only be executed if required by the ECU when the "HIGH SOOT"
warning light goes on (due to a Level 3 - 5 particulate accumulation).
• Do NOT execute the forced regenerations if not required by the ECU (due to a Level 0 - 2
particulate accumulation).
• Repeated forced regenerations cause significant engine oil contamination by the fuel.
• The operations described in Par. 5.3 or 5.4 must be executed after every forced regeneration.
• If the regeneration inhibition function is misused, the particulate accumulation level will increase
within a short time.
• The engine oil filter and oil must be changed after a Service Regeneration is completed via
KOHLER software
• (Level 5 Particulate accumulation).
• Fuel contamination allowed in the engine oil is 3% MAX.
• Any engine load must be eliminated during forced regeneration so as to prevent damaging the
ATS *2 system.
• Do not switch the engine off during level 3, 4 and 5 regeneration so as to prevent damaging the
ATS system.

2.12.2.5 Intake and exhaust circuit diagram with DOC+DPF

EN 54
 TECHNICAL INFORMATION 2

Tab 2.32e
POS. DESCRIPTION (pos. For DPF components only)
1 Air in intake from air filter
2 Air in compression
10 Gas in outlet towards DOC
11 Gas in oxidation
12 Gas in recycle towards EGR valve
16 DPF
F DOC
G Radiator/intercooler
H ATS

2.12.3 Air filter Tab 2.33

POS. DESCRIPTION
NOTE: Component not necessarily supplied by KOHLER .
H Air filter cartridge

Important L Air filter safety

cartridge
M Filter cover
• The air filter is a dry type of filter with a paper filtering element;
N Filter support
element s H and L are replaceable (refer to Tab. 2.8 and
Tab.2.9 for procedure frequency on components). Q Dust exhaust valve
• Filter suction must be positioned in a cool place. R Filter cover hook
• Should a hose be used, the length must not exceed 400 mm
and is to be as straight as possible.

Fig 2.31

55 EN
 2 TECHNICAL INFORMATION

2.13 Electric system

2.13.1 ECU input and output signals diagram

ECU DEVICES (OUTPUT)

SENSOR/SWITCH (INPUT)

Power relay Electronic injector 1

Engine Revolution Sensor Electronic injector 2

Engine phase sensor Electronic injector 3

Coolant temperature sensor Electronic injector 4

Common Rail pressure sensor EGR valve control

Oil pressure switch Fuel intake adjustment valve

EGR valve position Revolution indicator

Fuel temperature sensor Heater relay

T-MAP sensor Diagnosis indicator lights

Sensore ACACT Regolazione Corpo farfallato

Main accelerator pedal (double track) Electric fan control (1-2 speeds or variable speed)

Secondary accelerator pedal (optional) CAN 1 (ISO15765 diagnostics)

Hydraulic oil pressure sensor (optional) CAN 2 (Vehicle SAE J1939)

Fuel level sensor (optional)

Air filter clogging sensor (optional)

Sensor to detect water in the fuel

Posizione Corpo farfallato

Sensore EGTS (black)

Sensore EGTS (yellow)

Sensore Delta-P

EN 56
 TECHNICAL INFORMATION 2

2.13.2 Control unit (ECU) 2.13.2.1 Technical features

• Operating temperature: -
The ECU is a central processor, which monitors and controls 40°C - +100°C.
engine operation. • Storage temperature: -40°C
The electronic control unit is responsible for engine management. - +100°C.
It is fitted on the frame of the vehicle, or in the cab (refer to the
technical documentation of the vehicle).

Important

• The ECU must only be used with the configuration defined

by KOHLER , for each individual engine.
• To look up ECU errors, refer to the Help File manual

Fig 2.32 - Fig 2.33

57 EN
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Tab. 2.35
ECU AND ENGINE IDENTIFICATION PLATES
POS. DESCRIPTION
1 Engine model
2 Validation code
3 Engine specifications
4 Bar Code of the engine chassis number
5 Engine chassis number
6 ECU identification code
A Connector A (ECU A)
B Connector B (ECU B)
C Barometric capsule
D Fastening points

• Do NOT mount or replace the control unit with that of another engine.
• Although externally each ECU seems to be identical, internally they are specifically configured
only for use on the engine that they are supplied with.
• To install a new control unit, is required to recharge on it's the original configuration relating to
that specific engine .
• The control units are not interchangeable nor modifiable.
• Each control unit is accompanied by its adhesive identification plate.

EN 58
 TECHNICAL INFORMATION 2

2.13.3 Engine electrical wiring

Fig 2.34

59 EN
 2 TECHNICAL INFORMATION

Tab. 2.36
RIF. DESCRIZIONE
1 Vehicle interface connector (Fig. 2.34a)
2 ECU Connector A (Fig. 2.34b)
3 ECU Connector B (Fig. 2.34b)
4 Fuel pressure regulating valve connector
5 Fuel temperature sensor connector
6 T-MAP sensor connector Fig 2.34a
7 Common Rail pressure sensor connector
8 Injectors connectors
9 EGR valve connector
10 Engine speed sensor connector
11 Engine phase sensor connector
12 Oil pressure switch connector
13 Coolant temperature sensor connector
14 D+ Connector Alternator
15 Starter motor connector (50)
Fig 2.34b
16 Starter motor connector 3,2kW (50)
17 Wiring support
18 ETB connector (Stage V versions only)
19 ACACT connector (Stage V versions only)
20 Ground
21 CAN resistor
22 ATS wiring connector (Stage V versions only)
23 ATS interface wiring (Stage V versions only)
24 Engine wiring connector
25 DPF temperature connector (yellow)
26 DPF temperature connector (black)
27 Delta-P sensor connector

NOTE: Click by side to play the procedure. https://www.youtube.com/embed/6-

0TbYG2EkY?rel=0

EN 60
 TECHNICAL INFORMATION 2

2.13.3.1 Wiring disconnection

All sensor connectors and electronic control devices are

sealed.
The connectors must be disconnected by means of
pressure on tabs A or unblock the retainers B , as illustrated
from Fig. 2.34c to Fig. 2.34r.

Fig 2.34c

Fig 2.34d Fig 2.34e

Fig 2.34f Fig 2.34g

Fig 2.34h Fig 2.34i

61 EN
 2 TECHNICAL INFORMATION

Fig 2.34l Fig 2.34m

Fig 2.34n Fig 2.34o

Fig 2.34p Fig 2.34q

Fig 2.34r

EN 62
 TECHNICAL INFORMATION 2

2.14 Sensors and switches

2.14.1 Revolution sensor on target wheel

Speed sensor A is situated on the timing system carter.

The sensor detects the signal from the target wheel B (60 -
2teeth) situated on the crankshaft pulley. It sends it to the
ECU as an analogical signal.

The sensor sends and analogue signal to the ECU.

The sensor produces a 5V square wave signal having a Hall Fig 2.35
effect while the crankshaft in rotation detects its position and
speed.
The data sent by this sensor enables the ECU to pilot fuel
anticipation injection for each piston.

For gap adjusting see Par. 9.15.1.5 .

2.14.2 Camshaft sensor

Camshaft sensor C is situated on the timing system carter.

The purpose of the camshaft sensor C is to identify the

position of the camshaft control gear E with respect to the
engine shaft and consequently the position of the pistons with
respect to the T.D.C..
The sensor produces a 5V square wave signal having a Hall
effect while the camshaft in rotation detects the phases of the Fig 2.36
4 strokes of the 1st cylinder. As a consequence, ECU by
means of internal calculations, also recognises the phases of
the other cylinders.
The data sent by this sensor enables the ECU to pilot fuel
anticipation injection for each piston.

For gap adjusting see Par. 9.15.1.4 .

63 EN
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2.14.3 T-MAP sensor

The T-MAP F sensor is situated on the intake manifold.

It detects the input pressure in the intake manifold by means
of electrical voltage variation and the air temperature by
means of an electrical resistor.
The sensor sends signals to the ECU, which determines the
values and modifies the injection strokes.
Tab. 2.36 reports the electrical resistor values according to
Fig 2.37
the intake air temperature.

NOTE : R indicates the pin where it is possible to measure

electrical resistance.

Tab 2.37
°C (°F) R(Ω)
-30 (-22) 23475 - 25945
0 (32) 5370 - 5935
25 (77) 1900 - 2100
50 (122) 772 - 854
100 (212) 177 - 195
120 (248) 107 - 119

2.14.4 ACACT sensor (versions with DPF filter only)

The ACACT sensor J is located on the intake manifold, before

the T-Map sensor, and it measures the temperature of the air
coming from the turbocharger.
Tab. 2.37b shows the electric resistance values based on the
intake air temperature.

Tab 2.37b
°C (°F) R (k Ω ) Fig 2.37a
-40 (-40) 130.3
0 (32) 33.87
25 (77) 17.17
50 (122) 9.603
100 (212) 3.739
150 (302) 1.796
200 (392) 1.000

EN 64
 TECHNICAL INFORMATION 2

2.14.5 EGTS sensor (yellow - black)

The EGTS sensors K1 and K2 are placed on the ATS system,

K1 with black wire before the DOC, K2 with yellow wire after
the DOC.
They are both needed for the DPF filter regeneration
strategies.
Tab. 2.37b shows the electric resistance values based on the
intake air temperature.
Fig 2.37b
Tab 2.37c
°C (°F) R (k Ω )
-40 (-40) 133,8
0 (32) 34,49
50 (122) 9,749
100 (212) 3,771
150 (302) 1,803
200 (392) 1,002
250 (482) 0,6173
300 (572) 0,4127
350 (662) 0,2934
400 (752) 0,2186
450 (842) 0,1690
500 (932) 0,1345
550 (1022) 0,1097
600 (1112) 0,0912
650 (1202) 0,0771
700 (1292) 0,0661
750 (1382) 0,0574
800 (1472) 0,0503
850 (1562) 0,0445

65 EN
 2 TECHNICAL INFORMATION

2.14.6 Delta-P sensor

The Delta-P sensor J detects the clogging level of the DPF

filter.

Operating temperature: -30°C - +120°C.

Fig 2.37c

Important

• Connect the J1 and J2 pipes to the Delta-P sensor

exclusively as shown in Fig. 2.37d .
Fig 2.37d

2.14.7 Common Rail pressure sensor

Fuel pressure sensor G assembled on the Common Rail,

detects the fuel pressure inside it by means of electrical
voltage variation.
Depending on the signal sent, ECU manages the fuel intake
valve on the injection pump and, if necessary, modifies the
injection strokes.

Important Fig 2.38

• Refer to Par. 2.9.5

2.14.8 Fuel filter water detection sensor

The water presence sensor H is situated in the fuel filter,

which is there to indicate the presence of water in the fuel.

Water, if present in the fuel, because of its greater specific

weight separates and settles in the lower part of the filter
where there is a specific sensor that, by means of the ECU
activates an alarm signal on the dashboard.
The butterfly valve nut M situated in the lower part of the body Fig 2.39
sensor enables the elimination of any water present in the fuel
and prevent malfunctions on components of the injection
circuit.

EN 66
 TECHNICAL INFORMATION 2

2.14.9 Fuel temperature sensor on the fuel injection pump

The fuel temperature sensor L is situated on the high-

pressure fuel injection pump.
The fuel temperature sensor L , measures the temperature of
the fuel entering the pump at high pressure.
The signal sent to the ECU is analogue.
The resistance detected by the ECU is proportional to the fuel
temperature.
Fig 2.40
Important

• Refer to Par. 2.9.3

2.14.10 Oil pressure switch

Oil pressure switch N is assembled on the crankcase.

It is a N/C sensor, calibrated at 0.8 bar ± 0.1 bar.

With oil low pressure the sensor closes the electrical circuit
and the warning lamp in the panel board switches on.

Fig 2.41

2.14.11 Coolant temperature sensor

The P coolant temperature sensor of the coolant circuit is

applied to the cylinder head on the side of the thermostatic
valve.
It is used by the ECU to obtain information regarding the
coolant temperature (via PIN R ) and control the warning light
high-temperature signal and control the electric fan of the
coolant radiator.
Indicator light operation temperature +106°C / +108°C. Fig 2.42

NOTE : R indicates the pin where it is possible to measure

electrical resistance.

Tab 2.38
CHARACTERISTICS
Temperature °C R min Ω R max Ω
-40 38.313 52.926
0 5.227 6.623
+140 0.067 0.076

67 EN
 2 TECHNICAL INFORMATION

2.14.12 Air cleaner clogging switch

NOTE: Component not necessarily supplied by KOHLER.

The switch is assembled on the air cleaner. When the filter is

clogged, it sends a signal to the panel.
Fig. 2.42 a
Features :
• Operating temperature: - 30 °C / +100°C
• Contact usually open.
• Contact closed by vacuum: -50 mbar.

EN 68
 TECHNICAL INFORMATION 2

2.15 Electrical components

2.15.1 Alternator (A)

Externally controlled by the crankshaft by means of a belt.

• Ampere 80 A
• Volt 12V

Fig 2.43

2.15.2 Alternator for Poly-V belt (optional) (B)

Externally controlled by the crankshaft by means of a belt.

• Ampere 80 A
• Volt 12V

Fig 2.44

2.15.3 Starter Motor (C)

•

Type Bosch 12 V
• Power 2 kW
• Anticlockwise rotation (seen from timing system side)

Fig 2.45a

• Type Mahle 12 V
• Power 3.2 kW
• Anticlockwise rotation (seen from timing system side)

Fig 2.45b

69 EN
 2 TECHNICAL INFORMATION

2.15.4 EGR Valve (D)

A device that provides for exhaust gas recovery that is

controlled by ECU, which, according to acceleration
parameters, RPM and power requested, varies the opening and
closing of the valve.
The device has an integrated ECU, which, on each start-up of
the control panel, executes an operation self-check.
In the event of a malfunction, it sends a signal to ECU, which,
in turn, signals the anomaly on the control panel. Fig 2.46

Characteristics:
• Type Dell'Orto EGV A16
• Operating/storage temperature: -30°C / +130°C.

2.15.5 Cold starting device (Heater)

The cold starting device consists of a resistance, managed by

the ECU, which is activated when the ambient temperature is ≤
-16° C.
The intake air is heated through the resistance and facilitates
starting.

Characteristics:
• Type Hidria AET 12 V Fig 2.47
• Power 550 W

2.15.6 Fuel intake regulating valve (SCV)

Valve E is situated on the high-pressure fuel injection pump.

It is managed by ECU, which regulates fuel intake by means of

fuel pressure values inside the Common Rail, choking the input
entrance of fuel in the injection pump. The digital signal varies
the opening of the valve in proportion to the quantity of fuel
required for the Common Rail.
Fig 2.47 a
Important

• Refer to Par 2.9.3

2.15.7 Electric fuel pump (optional)

NOTE: Component not necessarily supplied by KOHLER.

The electric pump is located before the fuel filter. One of the
following pumps can be assembled A1 - A2 - A3 - A4.

Tab. 2.39 (a-d) indicates pump features.

Fig 2.48

EN 70
 TECHNICAL INFORMATION 2

Tab. 2.39
POS. Description
B Electrical connection
C Prefilter pump
IN Ingoing fitting (IN) from tank
OUT Outgoing fitting (out) to fuel filter

Tab. 2.39a
A1 Value
Voltage 12 V - 24 V
Delivery 100 L/h @ 0.44 - 0.56 bar

Fig 2.48a

Tab. 2.39b
A2 Value
Voltage 12 V
Delivery 60.56 L/h @ 0.41 bar

Fig 2.48b

Tab. 2.39c
A3 Value
Voltage 12 V
Delivery 24 L/h @ 0.1 bar

Fig 2.48c

Tab. 2.39d
A4 Value
Voltage 12 V
Delivery 30 L/h @ 0.4 bar

Fig 2.48d

71 EN
 2 TECHNICAL INFORMATION

2.15.8 ETB (versions with DOC+DPF device - Stage V only)

The ETB valve F is controlled by the ECU during the DPF filter
regeneration strategies.

Fig 2.48e

EN 72
 TECHNICAL INFORMATION 2

2.16 Timing system and tappets

The timing system is equipped with hydraulic tappets that automatically recover the operation of the
rocker rods assembly.
No registration is therefore required.

2.16.1 Components identification

Fig 2.49

Tab 2.40

POS. DESCRIPTION
1 Crankshaft
2 Camshaft
3 Camshaft tappets
4 Rocker arm control rod
5 Rocker arms
6 Valves Fig 2.50
7 High-pressure fuel injection gear pump control
8 Camshaft control gear
9 Intermediate gear
10 Intermediate gear pin
11 Crankshaft gear
12 Target wheel positioning reference pin on
camshaft
13 Camshaft target wheel
14 Valve control bridge
15 Articulation control valves Fig 2.51
16 Hydraulic tappets

73 EN
 2 TECHNICAL INFORMATION

2.16.2 Timing system phasing angles

Important

• For information purposes, Tab. 2.41 reports the

timing system diagram phasing angle values.
• It should be noted that the said values may be
verified by rotating the crankshaft (Pos. 1 of Fig.
2.49) , by means of handling the rocker arm control
rod (Pos. 4 of Fig. 2.49) .
NOTE: Detecting the value by means of handling the rocker
arm/valves may not be correct due to the hydraulic tappets,
which may compress and create clearances that alters the
actual value.

Tab 2.41
ENGINE INTAKE EXHAUST
1903 TCR opens 20° opens 32°
before TDC before BDC
closes 32° closes 16° Fig 2.52
after BDC after TDC
2504 TCR opens 10° opens 20°
before TDC before BDC
closes 14° closes 4°
after BDC after TDC

2.16.3 Rocker arm pin

Tab 2.42

POS. DESCRIPTION
1 Rocker arm pin
2 Rocker arm distancing spring
3 Rocker arm pin support
4 Exhaust rocker arm Fig 2.53
5 Intake rocker arm

2.16.4 Rocker arms

Tab 2.43
POS. DESCRIPTION
1 Rocker arm body
2 Hydraulic tappet oil refill line
3 Valve tappet lubrication line
4 Valve tappet
5 Hydraulic tappet Fig 2.54
6 Oil flow line

EN 74
 TECHNICAL INFORMATION 2

2.16.5 Hydraulic tappets

Tab 2.44

POS. DESCRIPTION
A Hydraulic tappets
B Hight pressure chamber
1 Hydraulic tappets oil refill pipe
2 Retaining ring
3 Piston
4 Unidirectional valve
Fig 2.55
5 Tappet body
6 Spring

2.16.5.1 Hydraulic tappet operation

The operating principle of the hydraulic tappet is based on

the incompressibility of the liquids and on controlled
leakage.
The oil under pressure enters the tappet chamber A ,
providing a constant supply of oil in the low-pressure
chamber.
Through the non-return valve, 4 the oil can only access the
high-pressure chamber B and exit via the clearance
between the piston 3 and the tappet body 5 (controlled
leakage).
The chamber B is filled when the rocker arm is on the base
radius of the cam and the spring 6 keeps the piston 3
against the valve stem, thus eliminating any system play.
Thanks to the spring extension, the tappet "extends",
creating a small depression in the chamber B , making the
non-return
valve 4 open, and allowing the oil in the chamber A to pass
to chamber B , restoring the proper amount of oil required
to eliminate any play in the valves.

75 EN
 2 TECHNICAL INFORMATION

2.16.5.2 Difficult operating conditions

For proper operation on the hydraulic tappets it is essential that the low pressure chamber of the piston 3
is always full of oil.
In some conditions this may not occur (due to the fact that the oil leaks away when the engine is
switched off, which can also partially drain the tappets). This situation will be the cause of clearances that
will result in a characteristic noise similar toa ticking sound.

1. When the engine is cold, the tappet filling time could be very long if the oil used is not suitable for
the specific environmental conditions ( Tab. 2.2 )
2. If the engine is very hot: at idle speed, oil pressure may be low, and small air bubbles could form
in the circuit. Because of this, this compressing the tappet slightly and producing valve play
which is responsible for the ticking sound. On account of this, the tappet compresses slightly
giving rise to a valve clearance, thus generating a slight ticking sound, which however disappears
rapidly ( MAX 10 seconds) once normal operating conditions have been restored.

Anyway the duration of ticking Anyway the duration of ticking sound must be MAX 30 seconds. If not, the
problem is surely due to the poor quality of the oil, wear or impurities that, transported by the oil, can
infiltrate between the ball valve and its seat inside the piston, compromising the operation of the tappet
itself; In these cases, the only solution is to replace the oil or hydraulic tappets.

The prolonged persistence of the ticking sound or abnormal noise must be investigating in order to
prevent any malfunctions; if necessary, replace the hydraulic tappets and engine oil.

EN 76
 TECHNICAL INFORMATION 2

2.17 Components handling

2.17.1 High-pressure fuel injection pump

- Only handle by means of the points marked by Y .

- It is forbidden to handle using the points marked by N .

Fig 2.56

2.17.2 Electronic injector

- Only handle by means of the points marked by Y .

-It is forbidden to handle using the points marked by N .

Fig 2.57

2.17.3 Common Rail

- Only handle by means of the points marked by Y .

- It is forbidden to handle using the points marked by N .

Fig 2.58

2.17.4 Turbocharger

- Only handle by means of the points marked by Y .

- It is forbidden to handle using the points marked by N .

Important

• Refer to Par. 2.18 .

Fig 2.59

77 EN
 2 TECHNICAL INFORMATION

2.17.5 ACACT (versions with DOC+DPF device - Stage V

only)

- Only handle by means of the points marked by Y .

- It is forbidden to handle using the points marked by N .

NOTE: The sensor includes ceramic material.

- Do not install sensors which suffered impacts or falls.

- Do not install sensors in case of external contamination Fig 2.59a
- Do not install visibly damaged sensors
- Use exclusively the socket wrench to install the sensor

2.17.6 EGTS ( versions with DOC+DPF device - Stage V

only )

- Only handle by means of the points marked by Y .

- It is forbidden to handle using the points marked by N .

NOTE: The sensor includes ceramic material.

- Do not install sensors which suffered impacts or falls.

- Do not install visibly damaged sensors Fig 2.59b
- Do not install sensors in case of external contamination
- Do not apply any force on the cable or the metal elbow

Fig 2.59c

EN 78
 TECHNICAL INFORMATION 2

2.18 Turbocharger

2.18.1 What to do and what not to do

What to do: What not to do:

• Before assembling the turbocharger, make • Do not store turbocharges in damp,
sure that the protection caps are fitted on all wet places if they are not in their
openings of the turbo. original packaging.
• Ensure pre-lubrication of the turbocharger. • Do not expose the turbocharger to
• Periodically check that the joints are sealed dust and dirt if it is not in its original
against oil and air. packaging.
• Use lubricating oil according to the • Do not lift of hold the turbocharger
specifications described in Par. 2.4 . from the actuator rod if it is not in its
• Check the engine oil level. original packaging.
• Before switching it off after it has been used, • Do not apply additives to the
make the engine run idle, or without a load, for lubricating oil and fuel, unless
approximately 1 minute. instructed to do so by Kohler.
• Ensure that controls and maintenance intervals • Do not increase engine speed, or apply
of the engine are observed as specified in Tab. loads, immediately after start-up.
2.8 and 2.9 . • Do not intervene on the actuator
• Make sure that the engine and equipment are settings A (Fig. 2.61) .
used correctly so as not to compromise the life • Do not let the vehicle / engine run at
of the turbocharger. idle speed for more than 20-30
minutes at a time.

2.18.2 Practical operating rules

Users can help to maximise the duration of their

turbocharger by following the rules described below.
1. Start-up
Start the engine at idle speed, or without a
load, for approximately one minute. Oil
operating pressure is reached within a few
seconds and enables the moving parts to warm
up and be lubricated. Fig 2.60
Immediately increasing the engine speed upon
start-up means making the turbocharger run at
high speed with suboptimal lubrication, which
may compromise the life of the turbocharger.
2. After maintenance or a new installation
Proceed with pre-lubrication by filling new oil
into the oil supply duct B until filling it
completely. Start the engine at idle speed, or
without a load, for a few minutes in order to
ensure that the oil and bearings system
operate satisfactorily.
3. Low temperature air or engine inactivity
Fig 2.61
If the engine has been inactive for some time,
or the air temperature is very low, start the
engine at idle speed or without a load for a few
minutes.

79 EN
 2 TECHNICAL INFORMATION

4. Engine shutdown
Before switching the engine off after intense
activity, one must allow the turbocharger to
cool down. One must therefore let the engine
run at idle speed or without a load for at least 2
minutes, thus allowing the turbocharger to
cool.
5. Engine at idle speed
Avoid using the engine at idle speed or without
a load for long periods (more than 20-30
minutes). When operating at idle speed or
without a load, the turbocharger is at low
pressure in the exhaust chamber C and air
supply D ; this may cause oil leaks from seals E
to the extremity of the shaft. Even if this does
not cause damage, it can cause blue smoke
from the exhaust when the engine speed and
load are increased.

2.18.3 Before installing a new turbocharger

Important

• Do not lift the turbocharger with one hand from

the box.
• Do not lift turbocharger from Comp hsg side.
• Lift the turbocharger with both hands from box.
• Make sure to use clean gloves. Fig 2.62
• Handle the turbocharger as indicated in Par.
2.17.4.

1. Avoid lifting from the intake side G .

2. Remove cap guard F and check that there is no
excessive shaft axial and radial clearances.

Fig 2.63

EN 80
 TECHNICAL INFORMATION 2

1. Check for any signs of friction of the turbine on

the turbocharger body.
2. Check for any traces of oil leaks on the
turbocharger body.
3. After having check everything, reapply cap F
on intake opening H of the turbocharger and
do not remove it until assembly has been
completed.

Fig 2.64

1. Check the correct assembly of the capscrews

and the presence of paint on them.

Fig 2.65

2.18.4 Installation instructions

1. Remove the cap guards with care only when

assembling.
Handle carefully avoiding erratic movements.

Fig 2.66

2.18.5 Replacement instructions

Always understand the cause of the breakage of the turbocharger before replacing it.
Correct the cause of the breakage before replacing it with a new turbocharger.
If in doubt, contact KOHLER service department.
Important

• Failure to comply with these instructions can cause damage to the turbocharger and void the
warranty.
• Modifying the calibration of the turbocharger damages the turbocharger/engine.
• Always use the correct gaskets, and fit carefully to avoid blocking holes when mounting.
• Refer to the manual of the engine / vehicle, for: the correct type and quantity of oil, the correct
tightening of components, instructions and installation.
• It is forbidden to use liquid gaskets or sealants, particularly for the oil inlet/outlet.
• Avoid dirt / debris while installing the turbocharger.

81 EN
 2 TECHNICAL INFORMATION

• Before mounting the turbocharger, check that the code of the component is correct for the type
of engine, as mounting the wrong turbocharger can damage the turbo / engine and void the
warranty.

EN 82
 TECHNICAL INFORMATION 2

2.19 Balancer device (optional)

The balancer device is composed of a special crankshaft that

activates 2 additional shafts (balancers).
Rotation of the balancers, which have counterweights that oppose
the movement of alternating weights (crankshaft - connecting rods -
pistons), reduces vibrations caused by them.
The device is developed under the crankshaft, fixed on the
crankcase, closed by the oil sump.

Tab 2.43
POS. DESCRIPTION
1 Crankshaft
2 Balancer shaft control gear Fig 2.67
3 Balancer shaft support box
4 Conductor balance shaft
5 Conducted balance shaft

83 EN
 3 SAFETY INFORMATION

3 SAFETY INFORMATION
3.1 Before start-up

• Read the manual carefully and carry out the operations described below in compliance with the
instructions specified.
• Periodic inspection and maintenance operations must be carried out as indicated in this manual
and under the user's responsibility.

Important
• Only use original spare parts and accessories.
• The use of non-original parts, as well as voiding the warranty, affects the life and performance of
the engine, and may be dangerous.
• Non compliance with the operations described in the following pages may result damage to the
engine and vehicle on which it is installed, as well as to people and/or property.

EN 84
 SAFETY INFORMATION 3

3.2 Safety precautions

• The intended use of the engine is in conformity with the machine on which it is mounted.
• Any use of the machine other than that described cannot be considered as complying with its
intended purpose as specified by KOHLER .
• KOHLER declines all responsibility for any change to the engine not described in this manual
made by unauthorized KOHLER personnel.
• A proper use of the engine, a strict observance of the rules listed below and the rigorous
application of all these precautions will avoid the risk of accidents or injuries.
• Those who carry out the use and maintenance on the engine must wear the safety equipment
and the accident-prevention guards (Par 3.4.3) .
• KOHLER declines all direct and indirect liability for failure to comply with the standards of
conduct contained in this manual.
• KOHLER cannot consider every reasonably unforeseeable misuse that may cause a potential
danger.

85 EN
 3 SAFETY INFORMATION

3.3 General remarks

3.3.1 Note for OEM
• When installing the KDI engines, always bear in mind that any variation to the functional systems
may involve serious failures to the engine.
• Any improvement must be verified at KOHLER testing laboratories before application of the engine.
• In the event KOHLER does not approve the type of modification, KOHLER shall not be held
responsible for any consequential operation anomalies that the engine may undergo and any
damage the engine may cause to persons and things.
• The engine may only be assembled on a machine by personnel specifically trained by KOHLER and
who work in compliance with the existing documentation.
• The engine has been built to the specifications of a machine manufacturer, and it is his
responsibility to ensure that all necessary action is taken to meet the essential and legally
prescribed health and safety requirements. Any use of the machine other than that described
cannot be considered as complying with its intended purpose as specified by KOHLER , which
therefore declines all responsibility for accidents
caused by such operations.

3.3.2 Note for end user

• The following indications are dedicated to the user of the machine in order to reduce or eliminate
risks concerning engine operation and the relative routine maintenance work.
• The user must read these instructions carefully. Failure to do this could lead to serious danger for
his personal safety and health and that of any persons who may be in the vicinity of the machine.
• On starting, make sure that the engine is as horizontal as possible, unless the machine
specifications differ.
• Make sure that the machine is stable to prevent the risk of overturning.
• The engine must not operate in places containing inflammable materials, in explosive atmospheres,
where there is dust that can easily catch fire unless specific, adequate and clearly indicated
precautions have been taken and have been certified for the machine.
• To prevent fire hazards, always keep the machine at least one meter from buildings or from other
machinery.
• Children and animals must be kept at a due distance from operating machines in order to prevent
hazards deriving from their operation.
• Thoroughly wash and clean all the external parts of the engine before performing any operation, in
order to avoid the accidental introduction of impurities/foreign bodies. Use only water and/or
appropriate products to clean the engine. If cleaning engine with a pressure washer or steam
cleaner, it is important to maintain a minimum distance of at least 200mm between the surface to
be washed and the nozzle. Avoid directing the nozzle on electrical components, cable connections
and sealed rings (oil seals etc). Thoroughly wash and clean the area surrounding the engine
following the instructions provided by machine manufacturer.
• Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.
• Make sure that no soundproofing panels and the ground or floor on which the machine is standing
have not soaked up any fuel.
• The engine may only be assembled on a machine by personnel specifically trained by KOHLER and
who work in compliance with the existing documentation.
• The engine has been built to the specifications of a machine manufacturer, and it is his
responsibility to ensure that all necessary action is taken to meet the essential and legally
prescribed health and safety requirements. Any use of the machine other than that described
cannot be considered as complying with its intended purpose as specified by KOHLER , which
therefore declines all responsibility for accidents
caused by such operations.
• Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place.
• Do not smoke or use open flames when refuelling.
• During operation, the surface of the engine can become dangerously hot. Avoid touching the
exhaust system in particular.
• Before proceeding with any operation on the engine, stop it and allow it to cool.

EN 86
 SAFETY INFORMATION 3

• Always open the radiator plug or expansion chamber with the utmost caution, wearing protective
garments and goggles.
• The coolant fluid is under pressure. Never carry out any inspections until the engine has cooled.
• If there is an electric fan, do not approach the engine when it is still hot as the fan could also start
operating when the engine is at a standstill.
• The oil must be drained whilst the engine is hot. Particular care is required to prevent burns. Do not
allow oil to come into contact with the skin because of the health hazards involved. It is
recommended to use an oil intake pump.
• During operations that involve access to moving parts of the engine and/or removal of rotating
guards, disconnect and insulate the negative wire (-) of the battery to prevent accidental short-
circuits and to stop the starter motor from being energized.
• Check belt tension only when the engine is off.
• Fully tighten the tank cap each time after refuelling. Do not fill the tank right to the top but leave an
adequate space for the fuel to expand.
• To start the engine follow the specific instructions provided in the engine and/or machine operating
manual. Do not use auxiliary starting devices not originally installed on the machine (e.g. Startpilot).
• Before starting, remove any tools that were used to service the engine and/or machine. Make sure
that all guards have been refitted.
• Do not mix fuel with elements such as oil or kerosene. Failure to comply with this prohibition will
cause the non-operation of the catalyst and non-observance of the emissions declared by
KOHLER .
• Pay attention to the temperature of the oil filter when the filter itself is replaced.
• Only check, top up and change the coolant fluid when the engine is off and reached the ambient
temperature. Coolant fluid is polluting, it must therefore be disposed of in the correct way.
• Do not use jets of air and water at high pressure on the cables, connectors and electronic injectors.
• For engines equipped with ATS device, it is necessary to inhibit regeneration if using the engine in
environments featuring risk of fire (e.g.: woods, areas containing flammable materials, areas
containing flammable gas or liquids and any type of combustible material - if this function is
available).

87 EN
 3 SAFETY INFORMATION

Important
• Only use the eyebolts A installed by KOHLER to move the engine (Fig. 3.1).
•
The angle between each lifting chain and the eyebolts shall not exceed 15° inwards.
• The correct tightening of the lifting brace capscrews is 25 Nm .
• Do not interpose spacers or washers between the eyebolts and engine head.

Fig 3.1

EN 88
 SAFETY INFORMATION 3

3.4 Safety signal description

o To ensure safe operation please read the following statements and understand their
meaning.
o Also refer to your equipment manufacturer's manual for other important safety information.
o This manual contains safety precautions which are explained below.
o Please read them carefully.

3.4.1 Adhesive safety plates

The following is a list of the adhesive safety plates that may be found on the engine, which indicate
potential points of danger to the operator.

Read the Operation and Maintenance handbook before performing any operation on the
engine.

Hot Parts.
Danger of burns.

Presence of rotating parts.

Danger of jamming or cutting.

Presence of explosive fuel.

Danger of fire or explosion.

Presence of steam and pressurized coolant.

Danger of burns.

89 EN
 3 SAFETY INFORMATION

3.4.2 Warnings
Hereunder is a list of safety warnings that may be found in the manual, which advise you to pay attention
when carrying out particular procedures that may be potentially dangerous to the operator or things.

Danger
This indicates situations of grave danger which, if ignored, may seriously threaten the health
and safety of individuals.

Important
This indicates particularly important technical information that should not be ignored.

Warning
This indicates that failure to comply with it can cause minor damage or injury.

3.4.3 Safety guards

Hereunder is a list of safety guards that must be worn prior to carrying out any type of operation and to
avoid potential
harm to the operator.

Use suitable protective gloves before carrying out any type of operation.

Use protective goggles before carrying out any type of operation.

Use earmuffs before carrying out any type of operation.

EN 90
 SAFETY INFORMATION 3

3.5 Information and safety signals

ACCIDENTAL START HIGH PRESSURE FLUID RISK OF PUNCTURE

High Pressure Fluids can puncture

Accidental Starts can cause skin and cause severe injury or death.
severe injury or death.
Work on the injection system must be carried out by
suitably trained staff wearing protection equipment.
Injuries caused by fluid penetration are highly toxic
and dangerous.
Before working on the engine or equipment, If an injury occurs, seek immediate medical
disconnect the battery negative (-) wire. attention.

HOT PARTS EXPLOSIVE FUEL

Hot Parts can cause severe Explosive fuel can cause fires and
burns. severe burns.

Engine components can get extremely hot Fuel is flammable and its vapours can ignite. Store
from operation. fuel only in approved containers, in well ventilated,
Do not touch engine while operating or just unoccupied buildings. Do not fill the fuel tank while
after stopping. the engine is hot or running, since spilled fuel could
Never operate the engine with heat shields ignite if it comes in contact with hot parts or sparks
or guards removed. from ignition. Do not start the engine near spilled
fuel. Never use fuel as a cleaning agent.

ROTATING PARTS
EXPLOSIVE GAS
Rotating Parts can cause
severe injury. Explosive Gas can cause fires and
severe acid burns.
Stay away while engine is in operation. Keep
hands, feet, hair, and clothing away from all Charge battery only in a well ventilated area. Keep
moving parts to prevent injury. Never
sparks, open flames, and other sources of ignition
operate the engine with covers, shrouds, or
guards removed. away from the battery at all times. Batteries produce
explosive hydrogen gas while being charged.
Keep batteries out of the reach of children. Remove
all jewelry when servicing batteries. Before
disconnecting the negative (-) ground cable, make
LETHAL EXHAUST GASES
sure all switches are OFF. If ON, a spark will occur
at the ground cable terminal which could cause an
Carbon Monoxide can cause explosion.
severe nausea, fainting or
death.

91 EN
 3 SAFETY INFORMATION

Avoid inhaling exhaust fumes and never run

the engine in a closed building or confined
area. CALIFORNIA WARNING - DECLARATION 65
Carbon monoxide is toxic, odorless,
colorless, and can cause death if inhaled.
Engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

ELECTRICAL SHOCK

Electrical Shock can cause

injury.

Do not touch wires while engine is running.

EN 92
 SAFETY INFORMATION 3

3.6 Safety and environmental impact

Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its
own activities (products, services, etc.) on the environment. Procedures for identifying the extent of the
impact on the environment must consider the following factors:
- Disposal of liquids.
- Waste management.
- Soil contamination.
- Atmospheric emissions.
- Use of raw materials and natural resources.
- Regulations and directives regarding environmental impact.

In order to minimise the impact on the environment, KOHLER provides some indications to be followed by
all those handling the engine, for any reason, during its expected lifetime.
- All components and fluids must be disposed of in accordance with the laws of the country in which
disposal is taking place.
- Keep the injection system as well as engine management and exhaust pipes in efficient working order to
limit environmental and noise pollution.
- When decommissioning the engine, select all components according to their chemical characteristics and
dispose of them separately.

93 EN
 3 SAFETY INFORMATION

3.7 Location of safety signals on engine

EN 94
 STORAGE INFORMATION 4

4 STORAGE INFORMATION
4.1 Product preservation

Important
• If the engines are not to be used for 6 months, they must be protected by carrying out the
operations described in Engine storage (up to 6 months) (Par. 4.2) .
• If the engine is still not in use after the first 6 months, it is necessary to carry out a further procedure
to extend the protection period (more than 6 months) (Par. 4.3) .
• If the engine is not to be used for an extended period, the protective treatment procedure must be
repeated within 24 months of the previous one.

95 EN
 4 STORAGE INFORMATION

4.2 Engine storage (up to 6 months)

Before storing the engine check that:
• The environments are not humid or exposed to bad weather. Cover the engine with a proper
protective sheet against dampness and atmospheric contaminants.
• The place is not near electric panel.
• Avoid storing the engine in direct contact with the ground.

EN 96
 STORAGE INFORMATION 4

4.3 Engine storage (over 6 months)

Follow the steps described in Par. 4.2.
1. Pour protective oil in the carter up to the MAX level.
2. Refuel with fuel additives for long storage.The following additives are recommended:
DEFA Fluid Plus (Pakelo Lubricants),
Diesel Treatment (Green Star),
Top Diesel (Bardhal),
STP® Diesel Fuel Injector Treatment.
3. With expansion tank:
make sure that the coolant is up to the maximum level.
4. Without expansion tank:
Top liquid up until the pipes inside the radiator are covered by about 5 mm.
Do not overfill the radiator, but leave room for the fuel to expand.
5. Start the engine and run it at idle speed for around 2 minutes.
6. Bring the engine to 75% of maximum rated speed for 5 to 10 minutes.
7. Turn off the engine.
8. Empty out completely the fuel tank.
9. Spray SAE 10W-40 on the exhaust and intake manifolds.
10. Seal the exhaust and intake ducts to prevent foreign bodies from entering.
11. When cleaning the engine, if using a pressure washer or steam cleaning device, avoid directing the
nozzle on electrical components, cable connections and sealed rings (oil seals etc).
If cleaning engine with a pressure washer or steam cleaner, it is important to maintain a minimum
distance of at least 200mm between the surface to be washed and the nozzle - avoiding absolutely
electrical components such as alternators, starter motors and engine control units (ECU).
12. Treat non-painted parts with protective products.
13. Loosen the alternator belt Par. 7.3 point 1 and 2
NOTA: For Poly-V belt Par. 11.3 from points 1 to 3 .

If the engine protection is performed according to the suggestions indicated no corrosion damage will be
found.

97 EN
 4 STORAGE INFORMATION

4.4 Engine starting after storage

1. Remove the protective sheet.
2. Use a cloth soaked in degreasing product to remove the protective treatment from the external
parts.
3. Inject lubricating oil (no more than 2 cm3) into the intake ducts.
4. Adjust the alternator belt tension ( Par. 9.15.2 from points 7 to 10 ) - for a Poly-V belt ( Par. 11.3
from point 5 to 8 )or replace if there are signs of deterioration.

5. Refill the tank with fresh fuel.

Warning

• Over time, lubricants and filters lose their properties, so itis important to consider whether they
need replacing, also based on the criteria described in Tab. 2.9 .

1. Make sure that the oil and the coolant are up to the maximum level.
2. Start the engine and run it at idle speed for around 2 minutes.
3. Bring the engine to 75% of maximum rated speed for 5 to 10 minutes.
4. Stop the engine and while the oil still hot, perform the operation in Par. 5.2 .
5. Replace the filters (air, oil, fuel) with original spare parts.
6. Perform the operations described in Par. 10.1 .
7. Perform the operations described in Par. 5.1 and Par. 10.2 .

EN 98
 INFORMATION REGARDING DISCHARGE OF 5
LIQUIDS

5 INFORMATION REGARDING DISCHARGE OF

LIQUIDS
5.1 Coolant

Important
• Before proceeding with operation,
read Par. 3.3.2 .

NOTE: Component not necessarily supplied

by KOHLER .
The representation of the radiator is purely
indicative.
Warning
Fig 5.1

• Presence of steam pressurized

coolant danger of burns.
1. Undo the cap A carefully (circuit under
pressure).

2. Loosen clamp G and remove cap B

from exhaust pipe C , draining the
liquid into an appropriate container
and refer to ( Par. 3.6 ). Fig 5.2

3. Undo cap F to drain all liquid from the

system contained in the engine
crankcase ducts into an appropriate
container and refer to ( Par. 3.6 ).

Fig 5.3

Fig 5.4

99 EN
 5 INFORMATION REGARDING DISCHARGE OF
LIQUIDS

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EN 100
 INFORMATION REGARDING DISCHARGE OF 5
LIQUIDS
5.2 Engine oil

Important

• Before proceeding with operation,

read Par. 3.3.2 .
• This operation should be carried out
with vacuum pump. The oil must be
drained whilst the engine is hot,
which requires particular care to
prevent burns. Do not allow oil to Fig 5.5
come into contact with the skin
because of the health hazards
involved. It is recommended to use an
oil intake pump via the oil dipstick
hole B.
• Electric/pneumatic screwdrivers are
forbidden.
1. Undo the cartridge holder cover C by
performing three complete turns and
wait 1 minute.
NOTE : this operation will allow to oil Fig 5.6
contained in the support G to flow into the oil
sump in the correct way.

1. Unscrew cartridge holder cover C and

check that the oil in the lub. oil filter
bracket G has flowed towards the oil
sump (refer to NOTE in Par. 2.10.3 ).
2. Undo the oil filler cap A (Fig. 5.5) .
3. Remove the oil dipstick B .
4. Remove the oil drain plug D and the
gasket E (the oil drain plug is on both
sides of the oil sump).
5. Drain oil in to an appropriate
container.
(For used oil disposal refer to the Par.
3.6 ).
6. Replace gasket E .
7. Tighten the drain oil plug D (tightening
torque at 35 Nm ).
8. Perform the operations described in
Par. 6.10.2 and the operation 5 Par.
6.10.3.

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101 EN
 6 INFORMATION FOR REPLACING THE
FUNCTIONAL UNITS

6 INFORMATION FOR REPLACING THE

FUNCTIONAL UNITS
6.1 Electronic injector replacement

Important

• Before proceeding with operation,

read Par. 3.3.2 .
• In the event of the electronic injectors
being disassembled (not necessarily
replaced) their position with respect to
individual cylinders must not be
changed when re-assembled. Refer to
Fig 6.1
the reference between each injector
and respective cylinder number.
• Seal all injection component unions as
illustrated in Par. 2.9.8 during
disassembly.
• Handle the components as described
in Par. 2.17 .
• Replace all seal gaskets after each
assembly for all components on which
they are provided.
• The high pressure pipes must be
replaced every time they are
disassembled.
• Before disassembling the electronic
injectors, make sure the new high
pressure pipes are available.
• If a new (or different) electronic injector
is fitted on the engine, the new
calibration data must be entered in the
ECU through a specific instrument (
ST_01 ) .
• Electronic injectors are not repairable.
• This procedure may be performed on
one or more electronic injectors.

NOTE: In the event of a leak upon

replacement (oil - coolant - fuel - air),
do not intervene with the engine
running, but stop it and wait for 5/10
minutes before checking and solving
the problem.

EN 102
 INFORMATION FOR REPLACING THE 6
FUNCTIONAL UNITS

6.1.1 Fuel return pipes disassembly

(Common Rail/electronic injectors)
1. Disconnect the connector C .

Fig 6.2

1. Remove clips E from the electronic

injector F .
2. Disconnect the junction G from the
electronic injector F .
Warning

• After removing the fittings, the clips E

must automatically return to their initial
position; otherwise they must be
Fig 6.3
replaced.

1. Seal all injection component unions as

illustrated in Par. 2.9.8 .

6.1.2 High pressure fuel pipes disassembly

(Common Rail/electronic injectors)
Danger

• The fuel injection circuit is under high

pressure, use safety protections as
described in Par 3.4.3 .
• Ensure that the Common Rail is not
under pressure by slowly and carefully
Fig 6.4
unscrewing one of the nuts H .
1. Undo the nut H on the Common Rail L
and then the nut M on the electronic
injector F and remove the pipe N .

Important

• In the event that the electronic injectors

are disassembled (not necessarily
replaced), mark them with the relevant
cylinder number from which they
originate so as not to confuse them
during re-assembly.
• Seal all injection component unions as
illustrated in Par. 2.9.8 .

103 EN
 6 INFORMATION FOR REPLACING THE
FUNCTIONAL UNITS

6.1.3 Electronic injectors disassembly

1. Undo and remove the screw P with the

washer R e and then the bracket Q .

Important
• Be careful not to damage the gaskets
X. Fig 6.5
• Replace rings X , if damaged.
2. Pull out the electronic injector F .

NOTE: Should you be unable to remove the

electronic injector (acting only on point BC ),
use an open-ended spanner (Ø 34 mm), by
applying small rotations to unblock the
component.

3. Seal all injection component unions as

illustrated in Par. 2.9.8 .
4. Ensure that gasket S has remained in the Fig 6.6
correct position (Fig. 6.6) . Otherwise, recover
the gasket from inside the electronic injector T
manifold.

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6.1.4 Electronic injector assembly

Important

• Always replace and lubricate the

gaskets AA and S of the electronic
injectors F with fuel, every time they
are replaced.
• Reposition the electronic injectors (not
replaced) by following the references
made for disassembly, as indicated in Fig 6.7
Par. 6.1.2.
1. Insert the gasket S on the electronic
injectors F (Fig. 6.7) .
2. Insert electronic injector F into manifold
T , being extra careful not to damage
gasket AB and direct it as indicated in
Fig. 6.7 .

EN 104
 INFORMATION FOR REPLACING THE 6
FUNCTIONAL UNITS

6.1.5 High pressure fuel pipes assembly

Important

• Always replace the pipes N after each

assembly.

1. Position tube N in the Common Rail

seat of the electronic injector; correct
Fig 6.8
the position of the electronic injector by
means of the entrance of the electronic
injector unions F and Common Rail L .
2. Apply the nuts H and M by hand
without tightening them.
3. Position the fastening brace of
electronic injectors Q on capscrew
surface AD , insert capscrews P in
brace Q inserting washer R .

Important

• Ensure that brace S is perfectly

positioned onto the electronic injector.

4. Tighten the fixing screws P of the electronic

injector bracket (tightening torque at 20 Nm ).
5. Tighten the nut M (tightening torque at 25
Nm ). Fig 6.9
6. Tighten the nut H (tightening torque at 30
Nm ).

6.1.6 Fuel return pipes assembly

1. Check the condition of the gaskets AE

.

Fig 6.10

105 EN
 6 INFORMATION FOR REPLACING THE
FUNCTIONAL UNITS

1. Insert unions AF onto electronic

injectors F and block them with clips E
.
2. Mount the connectors C on the
electronic injectors F .

Warning
Fig 6.11

• Slightly move the wiring support to

check that the electrical wire of
connector C is not strained in
correspondence with the outlet
hole AF .

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EN 106
 INFORMATION FOR REPLACING THE 6
FUNCTIONAL UNITS
6.2 High-pressure fuel injection pump replacement

Danger

• The fuel injection circuit undergoes

high pressure, use safety protections
as described in Par 3.4.3 .
• Ensure that the Common Rail is not
under pressure by slowly and carefully
unscrewing nut A .
Fig 6.12

Important
• Before proceeding with operation,
read Par. 3.3.2 .
• Always replace the high pressure pipes
after each disassembly.
• Before disassembling the injection
pump, make sure the new high-
pressure pipe is available.
• The injection pump is not repairable.
• Should the fuel feeding pump need to
be replaced, after assembly, it is
necessary to perform the Pump
Learning procedure by means of
instrument ST_01 .
• Seal all injection component unions as
illustrated in Par. 2.9.8.
• To handling components refer to Par.
2.17.
• Always replace the gaskets (where are
provided) after each disassembly.

6.2.1 High-pressure fuel line disassembly

(from the injection pump to the Common
Rail).

1. Undo the nut A .

Fig 6.13

107 EN
 6 INFORMATION FOR REPLACING THE
FUNCTIONAL UNITS

1. Undo nut D from Common Rail E .

Fig 6.14

1. Undo the nut B on the intake manifold

C and remove the pipe F .

Fig 6.15

6.2.2 Timing system carter oil filling flange

disassembly

1. Remove starter motor ( Par. 7.3.2 ) and

assemble special tool ST_34 ( Par. 7.7
point 2 ) .
2. Undo the screws G ( ST_06 ) ,remove
the clamp E and the flange H .

Fig 6.16

6.2.3 High-pressure fuel injection pump

disassembly

1. Undo and remove nut L fixing the fuel

feeding pump control
gear M .

Important
• Be careful that the nut L does not fall Fig 6.17
into the timing cover.

1. Tighten tool ST_04 on the gear M .

EN 108
 INFORMATION FOR REPLACING THE 6
FUNCTIONAL UNITS

Important

• Do NOT use the cylinder connection

pipe W as a handle, to prevent
damage or fuel leaks.
• Before disassembling, carefully read
Par. 2.17 .
• Seal all injection component unions as
illustrated in Par. 2.9.8. Fig 6.18
1. Release the clamps N on the return
pipe P and on the fuel inlet pipe Q .
2. Disconnect tubes P and Q from fuel
feeding pump R .
3. Disconnect connectors S and T .
4. Loosen the screws U .
5. Redo the capscrew of tool ST_04 to
disconnect injection
pump R from gear M .
6. Undo capscrews U and extract
injection pump R with the relevant
gasket V . Fig 6.19
7. Undo and remove the tool ST_04 .

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6.2.4 High-pressure fuel injection pump

assembly

Important

• Before assembling, carefully read Par.

2.17
• Always replace the gasket V after each
assembly. The gasket V can only be Fig 6.20
fitted in one direction.
• Remove the tool ST_04 from the pump
control gear ( Ref. M of Par. 6.2.3 ) if
applicable.
• Do NOT use the cylinder connection
pipe W as a handle, to prevent damage
or fuel leaks.
• Remove the protection caps only when
reconnecting the hoses.

109 EN
 6 INFORMATION FOR REPLACING THE
FUNCTIONAL UNITS

1. Check that the contact surfaces AA

are free from impurities.
2. Insert the reference key K in the seat of
the shaft Z .
3. Assemble the new gasket V on
injection pump R . Insert injection
pump R in its housing on crankcase
AA making key K coincide with key
seat AH of gear M .
Fig 6.21

1. Fully tighten the nut L on the shaft Z of

the injection pump.

Important
• Apply nut L by hand, but do not
tighten.
Fig 6.22

Important

• It is mandatory to replace the screws U

or apply a few drops of Loctite 270 .
1. Clamp the screws U on the crankcase
AB (tightening torque at 25 Nm ).
2. Clamp the nut L (Fig. 6.22) (tightening
torque at 65 Nm ).
Fig 6.23

1. Fit the connector T on the sensor J .

2. Fit the connector S on the sensor Y .
3. Remove the protection caps.
4. Fit the pipe Q on the fitting AA .
5. Fit the pipe P on the fitting AB .
6. Hook the clamps N on the hoses Q
and P .

Fig 6.24

EN 110
 INFORMATION FOR REPLACING THE 6
FUNCTIONAL UNITS

6.2.5 High-pressure line assembly (injection

pump /
Common Rail)

1. Remove the protection cap.

2. Position the pipe F .

Fig 6.25
Important
• Manually tighten the nut A .

1. Manually tighten the nut D .

2. Fix clamp AC by means of capscrew B
on intake manifold C (tightening torque
10 Nm - ST_06 ).
3. Clamp nut D (tightening torque at 30
Nm ) and A (tightening
torque at 25 Nm ) in sequence.

Fig 6.26

6.2.6 Timing system carter oil filling flange

assembly

NOTE: Always replace the gasket AE after

each assembly.

1. Position the gasket AE in the set on

the flange H .
2. Fix the flange H on the crankcase AF
with the screws AG (tightening torque Fig 6.27
at 10 Nm - ST_06 ).
3. Fit the clamp E on the flange H .
4. Disassemble the special tool ST_34
and assemble the starter motor
(tightening torque 45 Nm ).

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111 EN
 6 INFORMATION FOR REPLACING THE
FUNCTIONAL UNITS
6.3 Unit EGR Cooler replacement

6.3.1 Disassembly

Important

• Before proceeding with operation, read Par.

3.3.2 .
• To handling components refer to Par. 2.17.
• Always replace the gaskets (where are
provided) after each disassembly.
Fig 6.28

NOTE: Perform the operations described in Par. 5.1 .

1. Undo the screws B of pipe C .

1. Undo screws D and E .

2. Remove pipe F and the relevant metal
gaskets.
3. Release the clamps G and remove the sleeve
M.

Fig 6.29

1. Undo the screws H and remove the EGR

Cooler L from the sleeve N ( ST_05 ).
2. Should the passage ducts of the gas exhaust
be clogged by soot or carbon, replace EGR
Cooler L .

Fig 6.30

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V1YY?rel=0

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6.3.2 Assembly
1. Insert the fitting U in the manifold M of the
EGR valve unit.
2. Fit the EGR Cooler L with the screws H on the
intake manifold S (tightening torque at 22 Nm
- ST_05 )
3. Insert the hose G on the fitting V .
4. Secure the clamps F .

Fig 6.31

1. Insert the gasket N between the hose B and

the EGR Cooler L and fix the screws A
(tightening torque at 25 Nm )

Fig 6.32

1. Insert the hose E in its housing on the

manifold S inserting the gasket R .
2. Insert the gasket T between the hose E and
the EGR Cooler L and fit the screws C
(tightening torque at 25 Nm ).
3. Fit the screws D (tightening torque at 22 Nm -
ST_05 ).

NOTE: Perform the operations described in Par. 10.2 Fig 6.33

.

NOTE: Click by side to play the procedure. https://www.youtube.com/embed/XSTfzyJa-

9Q?rel=0

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6.4 EGR valve replacement

6.4.1 Disassembly

Important
• Before proceeding with operation,
read Par. 3.3.2 .

NOTE: Perform the operations described in

Par. 5.1 .
Fig 6.34
1. Disconnect the connector A from the
valve C .
2. Undo the screws B and remove the
EGR valve C with the relevant gasket.

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6.4.2 Assembly

Important

• Always replace gasket D after each

assembly.
• The EGR valve is not a serviceable
item, and if faulty / worn out, should
be replaced with a new one.
Fig 6.35
• Movimentare i componenti come
descritto nel Par. 2.17 .
1. Mount the new gasket D on the valve
C.
2. Fit the valve C on the flange E with
screws B (tightening torque at 10 Nm
).

1. Fit the connector A on the valve C .

NOTE: Perform the operations described in

Par. 10.2

Fig 6.36

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115 EN
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6.5 Coolant pump replacement

6.5.1 Disassembly

NOTE: Perform the operations described in

Par. 5.1 .

Important
• Before proceeding with operation,
read Par. 3.3.2 . Fig 6.37
• If the engine is fitted with the Poly-V
belt, perform the operations described
in Par. 11.3 .

1. Loosen the screws A and B .

2. Push the alternator C in the direction
of the arrow D and remove the belt E .
3. Release clamp F and disconnect tube
G from the coolant pump N .

NOTE : If union R , is disassembled, replace it

or alternatively apply Loctite 2701 on the Fig 6.38
thread when assembling on pump G
(tightening torque of 20 Nm ).

1. Release the clamp M from the coolant

pump N .
2. Undo the screws H and remove the
pump N with the relevant gasket L .

Fig 6.39

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6.5.2 Assembly

Important

• Always replace the gaskets L , after

each disassembly.
• Always replace the belt E after each
assembly.

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FUNCTIONAL UNITS

• If the engine is fitted with the Poly-V Fig 6.40

belt, perform the operations described
in Par. 11.3 .
• To handling components refer to Par.
2.17.
• Always replace the gaskets (where are
provided) after each disassembly

1. Fit the coolant pump N with the

screws H interposing the new gasket
L (tightening torque at 25 Nm ).

1. Reinsert the pipe G and hook the

clamp F ( Fig. 6.38 ).
2. Rehook the clamp M on the pump N
(Fig. 6.39) .
3. Push the alternator C in the direction
of the arrow D .
4. Insert the belt E on the pulleys P .

Fig 6.41

1. Pull the alternator C in the direction of

the arrow Q .
2. While tensioning the alternator C , first
clamp screw A (tightening torque at
25 Nm ) and then screw B (tightening
torque at 69 Nm ).
3. Check the tension of the belt E with
the instrument ( DENSO BTG-2 ),
positioning it in point P (the tension
must be between 350 and 450 Nm ). Fig 6.42
4. If the tension values do not
correspond, tighten screws A and B ,
then repeat operations 6, 7 and 8 .

NOTE: Click by side to play the procedure. https://www.youtube.com/embed/GbvNS15R9SQ?rel=0

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6.6 Target wheel replacement

6.6.1 Disassembly

Important
• Before proceeding with operation, read Par. 3.3.2 .

1. Position the crankshaft with the 1st cylinder in TDC,

reference A upwards.
2. Remove the alternator belt following steps 1 and 2 (
Par. 6.5.1 ) . Fig 6.43

1. Disassemble the starting motor.

2. Mount the tool ST_34 in the seat of the starter motor C
and fit it with the two starter motor fixing screws.

Fig 6.44

1. Disconnect the connector L .

2. Undo the screw M and remove the revolution sensor N
and its respective spacer.

Fig 6.45

1. Undo the screw P (clockwise) and remove the

pulley/targetwheel unit Q .

Fig 6.46

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1. Undo the screws R and remove the target wheel S with

the relevant sound-absorption disk T .

Fig 6.47

6.6.2 Assembly

1. Check that the pin U is mounted properly on the pulley

V.
2. Insert the disk T on the pulley V respecting the
reference of the pin U .
3. Position the target wheel S on the pulley V respecting
the reference of the pin U .
4. Fit the target wheel S with the screws W (tightening
torque 10 Nm ). Fig 6.48
5. Perform the operations described in Par. 6.7.7 and
then the operations between point 2 and 9 of Par.
6.5.2 .

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6.7 Oil pump replacement

Important
• Before proceeding with operations, read Par. 3.3.2 .
• The oil pump is not repairable.

6.7.1 Refrigerant pump disassembly

1. Perform the operations described in Par 6.5.1 .

6.7.2 Crankshaft and target wheel pulley disassembly

1. Perform the operations described in Par 6.6.1 .

2. Disconnect the connector AE from the sensor S .
Fig 6.49

6.7.3 Timing system crankcase disassembly

Important

• Perform the operations described in Par. 5.2 .

1. Make sure that the reference pin A is facing upwards.

2. Undo the screw H ( ST_06 ) and remove the sensor S .
3. Undo the screws B and remove the timing system Fig 6.50
crankcase C .

6.7.4 Oil pump disassembly

1. Undo the screws D ( ST_06 ) and remove the group

pump E from the timing system crankcase C .
2. Remove the rotors F and G from the oil pump
crankcase E .

Fig 6.51

Fig 6.52

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6.7.5 Oil pump assembly

NOTE: Carry out the checks described in Par. 8.7 prior to

assembly.

1. Check that all surfaces in contact between F, G, H, E

and C are free from impurities - scratches - dents.
2. When assembling, do not use any type of gasket
between E and C .
3. Thoroughly lubricate the seat of the rotors H on the oil Fig 6.53
pump crankcase E and the two rotors F and G .
4. Within housing H insert the 2 rotors (in sequence) G
and F , observing the references BP as described in
figure (or refer to Par. 2.10.2 ).
5. Check that the 2 pins L are inserted properly in the
timing system crankcase C .
6. Position the oil pump carter E using the reference pins
L.
7. Clamp the oil pump carter E with the screws D
(tightening torque 10 Nm - ( ST_06 ) ).

Fig 6.54

6.7.6 Timing system crankcase assembly

Important

• Always replace the oil seal J after each assembly.

• Always replace the gasket P after each assembly.
1. Lubricate the lip of the oil seal J .
2. Apply a coating of Loctite 5188 around 1mm thick on
the surfaces K of the crankcase C . Fig 6.55
3. Make sure that the key M (Fig. 6.56) is inserted
properly on the crankshaft and that it is facing
upwards.
4. Check that the 2 pins N are inserted properly in the
timing system crankcase C .

1. Lubricate and insert the gasket P in the seat of the oil

pump Q .
2. Tighten the tool ST_10 on the crankshaft.
3. Position the crankcase C on the base, using the
reference pins N , inserting the oil pump Q on the
crankshaft.

Fig 6.56

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1. Fit the timing system crankcase C with the screws R

observing the indicated clamping sequence (tightening
torque at 25 Nm ).

Fig 6.57

1. Assemble sensor S by means of capscrew T on carter

C inserting gasket U (tightening torque at 10 Nm ST_06
).

Fig 6.58

6.7.7 Crankshaft and target wheel pulley assembly

1. Leave the tool ST_34 mounted ( Fig. 6.44 ) .

2. Check that the pin A is mounted properly on the
crankshaft Z .
3. Position the pulley unit W on the crankshaft Z
respecting the reference with the pin A .
4. Apply Molyslip grease on the screw thread Y .
5. Clamp the pulley unit W with the screw Y (tightening Fig 6.59
torque at 360 Nm ).
6. Remove the special tool ST_34 ( Fig. 6.44 ) .

1. Mount the bracket Z with the screws AA (tightening

torque at 10 Nm ).
2. Perform the operations described in Par. 9.12 .
3. Insert the shim AB on the sensor AC .
4. Clamp the sensor AC on the bracket Z with the screw
AD (tightening torque at 10 Nm ).

Fig 6.60

6.7.8 Coolant pump assembly

1. Perform the operations described in Par 6.5.2 .

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6.8 Oil pressure valve replacement

6.8.1 Disassembly

Important
• Before proceeding with operation, read Par. 3.3.2 .

1. Undo cap A .
2. Remove spring B , check its condition and replace it if
broken.
3. Remove the valve piston C using a magnet. Fig 6.61

6.8.2 Assembly

1. Lubricate the piston C and fully insert it in the seat E .

2. Insert the spring B in the piston.

NOTE: Always replace the gasket F after each

assembly.
3. Mount the gasket F on cap A .
4. Clamp the cap A on the crankcase D (tightening torque
at 50 Nm ). Fig 6.62

123 EN
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6.9 Oil vapour separator replacement

6.9.1 Disassembly

Important
• Before proceeding with operation, read Par. 3.3.2 .

1. Release the clamp AA and remove the pipe D .

2. Release the clamps F .
3. Remove the clamp P cutting it in the point indicated
and remove the separator body C removing it from the Fig 6.63
hose AG and G .

1. Release the clamp F .

2. Remove the pipes G and AG .
3. Remove the clamp J .
4. Undo the screws B .
5. Release the clamp S from the sleeve K .
6. Pull the flange H out of the manifold K and remove the
relevant gasket, being careful not to bend the pipe E .

Fig 6.64

6.9.2 Assembly

Warning

• Always carefully inspect the condition of the tubes, and

replace them if there is any doubt regarding their
integrity.
• Always replace the gasket M after each assembly.
1. Check that the contact surface L is free from Fig 6.65
impurities.
2. Position flange H inserting hose K onto the flange
union H , being careful not to bend tube E .
3. Insert the gasket M between the flange H and the
crankcase N .
4. Secure the flange H using the screws B on the
crankcase N (tightening torque at 10 Nm ).
5. Secure the clamp S on the manifold K .
6. Fit the pipes G and AG on the flange H .
7. Fit the breather body C on the pipes G and D and fit
the pipe G with the clamps F and the pipe D with the
clamp AA . Fig 6.66
8. Fit the breather body C on the support flange H with
the new clamp P .

EN 124
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125 EN
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6.10 Oil cooler unit and oil filter replacement

6.10.1 Oil Cooler unit disassembly

Important

• Before proceeding with operation, read Par. 3.3.2 .

• Perform the operations described in Par 5.1 and Par
5.2 .
• Oil Cooler unit E is not repairable.
Fig 6.67

1. Release the clamps A .

2. Remove the pipes B out of the Oil Cooler unit E .

Warning

• Electric/pneumatic screwdrivers are forbidden.

• Use a suitable container to recover any residue oil.

1. Unscrew cartridge holder cover H by performing

three complete turns and wait 1 minute.
NOTE this operation allows to oil contained in the support E
:
to flow into the oil sump in the correct way.
Fig 6.68
1. Unscrew cartridge holder cover H and check that the
oil in the lub. oil filter support E has flowed towards
the oil sump.
2. Undo the screws C and D and remove the Oil Cooler
unit E .

1. Remove the gaskets F and G from the Oil Cooler unit

E.

Fig 6.69

EN 126
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6.10.2 Oil filter cartridge replacement

1. Remove gaskets L, M and N from element holder

cover H .
2. Remove cartridge P from element holder cover H .

Fig 6.70

1. Lubricate and insert gaskets L, M and N in the L1,

M1 and N1 seats of element holder cover H .
2. Insert element P into element holder cover H .

Fig 6.71

6.10.3 Oil Cooler unit assembly

Important

• In the event of assembly of union U on crankcase S ,

manual tightening torque with Loctite 2701 on the
thread).

1. Check that the surface Q on the support E and on the Fig 6.72
crankcase S are free from impurities.
2. Lubricate and insert the gasket T on the fitting U .
3. Lubricate and insert the gaskets on the support E :
F in seat F1 ;
G in seat G1 .
4. Fit the support R with the screws C and D (tightening
torque at 10 Nm ).
5. Insert and tighten the cartridge support H on the filter
support E (tightening torque at 25 Nm ).
6. Fit the pipes B on the support E and secure the pipes
B with the clamps A .
Fig 6.73

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6.11 Fuel filter replacement

6.11.1 Disassembly

Important
• Before proceeding with operation, read Par. 3.3.2 .

Warning Fig 6.74

• The fuel filter is not always mounted in the engine.

• When disassembling the sensor E , use a suitable
container to recover the fuel contained in the cartridge
F.

1. Release the clamps A and pull the pipes B out of the

support H .
2. Unscrew the sensor E from the cartridge F .
3. Unscrew the cartridge F from the support H .
4. Undo the screws C and remove the support H .
Fig 6.75

6.11.2 Assembly
1. Clamp the fuel filter support H with the screws C on the
crankcase M (tightening torque at 25 Nm ).
2. Fit the pipes B on the support H .
3. Secure the pipes B with the clamps A .

Fig 6.76

1. Lubricate the gasket N with fuel.

2. Tighten the cartridge F on the support H (tightening
torque at 17 Nm ).
3. Assemble gasket J onto sensor E and lubricate with
fuel.
4. Tighten the sensor E on the cartridge F (tightening
torque at 5 Nm ).

Fig 6.77

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6.12 Replacement of SCV valve

Warning
• Before starting any replacement operations, make sure
the work area is free from dust (part X of valve B is
extremely sensitive to micro-dust).
• Pay the utmost attention to cleaning in order to prevent
any type of contamination during replacement
operations
• - Before proceeding with the replacement, clean the
outer part of pump A thoroughly - Avoid any type of
contact with part X of the valve during replacement. Fig. 6.78
• Lubricate part X of valve B with oil spray.
• Before starting any replacement operations, make sure
that the key on the vehicle’s panel is OFF .
• Assemble the new valve in the same position as the
previous one.

6.13.1 Disassembly

1 - Disconnect connector C from valve B .

2 - Loosen screws D .

3 - Remove valve B from pump A .

Fig. 6.79

129 EN
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6.13.2 Assembly

1 - Insert studs E supplied with valve B in the fastening holes of

pump A and insert gasket F in the seat of pump A .

2 - Assemble valve B on pump A using studs E as positioning

guides.

3 - Remove studs E and secure valve B with screws D

(tightening torque of 6 Nm). Fig. 6.80

4 - Fasten valve B by means of screws D (tightening torque of

10 Nm).

Fig. 6.81 Fig. 6.82

EN 130
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7 INFORMATION FOR DISASSEMBLY

7.1 Recommendations for disassembly

Important
• The mark ( ) after the title of a paragraph, indicates that the procedure is not required in order to
disassemble the engine, however the procedures are featured in order to illustrate the disassembly
of components.
• The operator should prepare all equipment and tools in order to enable him to carry out the
operations correctly and safely.
• Before disassembly, perform the operation described in Chap. 5 .
• Before proceeding with operation, carefully read Chap. 3 .
• In order to operate safely and easily, we recommend positioning the engine on a rotating stand for
engine overhauling.
• Seal all injection component unions as illustrated in Par. 2.9.8 during assembly.
• Protect all disassembled components and coupling surfaces subject to oxidation with lubricant.
• Where necessary, reference to special tools to use during disassembly operations is indicated (es.
ST_05 ), identified in Tab. 13.1 - 13.2 - 13.3 .

131 EN
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7.2 EGR circuit disassembly

7.2.1 EGR cooler unit

1. Undo the screws A ( ST_06 ) and B and remove the

pipe C with the relative gaskets.

Fig 7.1

1. Undo the screws D, E ( ST_06 ) and remove pipe F and

the relevant gaskets.

Fig 7.2

1. Release the clamp M and remove pipe N .

2. Release the clamp L .
3. Undo capscrews G and remove EGR Cooler H from
hose X ( ST_05 ) .

Fig 7.3

7.2.2 EGR Valve

1. Disconnect the connector P .
2. Undo the screws Q and remove the EGR valve R with
the relevant gasket.

NOTE: The EGR valve is not a serviceable item, and if

damaged/worn, it should be replaced with a new one.

Fig 7.4

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 INFORMATION FOR DISASSEMBLY 7

1. Undo capscrews S and remove flange T with the

relative gasket.

Fig 7.5

133 EN
 7 INFORMATION FOR DISASSEMBLY

7.3 Electric components disassembly

7.3.1 Electric wiring

Important
• Refer to Par. 2.13 prior to proceeding with
disassembly.

1. Disconnect the connectors A, B and C .

Fig 7.6
2. Release the clamp D .

1. Disconnect the connectors E, F and G .

2. Release the clamps J and H .

Fig 7.7

1. Disconnect the connectors K and L .

Fig 7.8

1. Disconnect the connectors M and P .

2. Release the clamp Q .

Fig 7.9

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 INFORMATION FOR DISASSEMBLY 7

1. Disconnect the connectors R .

2. Undo the screws S and remove the wiring support T (
ST_06 ) .

Fig 7.10

7.3.2 Starter motor

Important
• The motor is not repairable.

1. Undo the screws U and remove the starter motor V .

Fig 7.11

7.3.3 Belt and alternator

1. Loosen the screws Z and W .
2. Push the alternator AA in the direction of the arrow AB
.
3. Remove the belt AC from the pulleys AR .
4. Undo the screws Z and W and remove the alternator
AA .

Important Fig 7.12

• The belt must always be replaced every time it is

disassembled, even if it has not reached the
scheduled hours for replacement.

7.3.4 Sensors and switches

Important
• After disassembly, protect the sensors suitably
against knocks, dampness and any high temperature
sources.
• The sensors and switches cannot be repaired,
Fig 7.13
therefore they must be replaced in the event of
anomalies.

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 7 INFORMATION FOR DISASSEMBLY

7.3.4.1 Oil pressure switch ( )

1. Unscrew and remove the oil pressure switch AD .

7.3.4.2 Coolant temperature sensor ( )

1. Unscrew and remove the coolant temperature sensor
AE .

Fig 7.14

7.3.4.3 Speed sensor ( )

1. Undo the screw AF and remove the sensor AG with
the relative spacer ( ST_06 ) .
2. Undo the screws AH and remove the sensor ( ST_06 )
.

Fig 7.15

7.3.4.4 Camshaft phase sensor

1. Undo the screw AM and remove the sensor AN with
the relative spacer ( ST_06 ).

Fig 7.16

7.3.4.5 T-MAP Sensor ( )

1. Undo the screw AP and remove the sensor AQ (

ST_06 ).

Fig 7.17

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7.3.4.6 Fuel filter water detection sensor ( )

Warning
• The fuel filter is not always mounted on the engine.
• When disassembling the sensor A , use a suitable
container to recover the fuel contained in the cartridge
B.
Fig 7.18
1. Unscrew the sensor A from the cartridge B .

137 EN
 7 INFORMATION FOR DISASSEMBLY

7.4 Turbocharger disassembly

1. Release the clamps A and B and remove the manifold

C.

Fig 7.19

1. Unscrew the fittings D and remove the pipe E with the

relative gaskets G .
2. Undo the screws F .
3. Release clamp M .

Fig 7.20

1. Undo the nuts L .

2. Remove tube N .

Fig 7.21

EN 138
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7.5 Exhaust manifold disassembly

1. Undo the nuts A and remove the manifold B and the

gaskets C .
2. Close the openings and manifolds to prevent foreign
bodies from entering.

Fig 7.22

139 EN
 7 INFORMATION FOR DISASSEMBLY

7.6 Coolant recirculation components disassembly

7.6.1 Oil Cooler manifold

1. Release the clamps Z .

2. Undo the screw W and remove hoses J ( ST_05 ) .

Fig 7.23

1. Release the clamp K and remove hoses AA .

Fig 7.24

7.6.2 Coolant pump

Important

• The pump B is not repairable.

1. Undo the screws A and remove the water pump unit B

with its gasket C .
Fig 7.25

7.6.3 Thermostatic valve

1.

Undo the screws A and remove the thermostatic valve

cover B .
2. Remove the thermostatic valve C and its gasket.

Important
Fig 7.26
• Always replace the gasket D every time it is
disassembled.

1. Check that the air bleeding hole is not clogged or

blocked ( Par. 2.11.4 ).

EN 140
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141 EN
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7.7 Crankshaft and target wheel pulley disassembly

1. Position the crankshaft with the 1st cylinder at

TDC,reference H .
2. Undo the screw C clockwise.
3. Remove the drive pulley unit and the target wheel D .

Fig 7.27

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7.8 Lubrication circuit disassembly

7.8.1 Oil pressure valve( )

1. Undo the cap A .

2. Remove the spring B , check its condition and replace
it if broken.
3. Remove the valve piston C using a magnet.

Fig 7.28

7.8.2 Timing system carter oil filling flange ( )

1. Undo the screws D and remove the oil filling flange E (

ST_06 ) .
2. Remove the gasket F .

Fig 7.29

7.8.3 Timing system carter

1. Ensure that the crankshaft with the 1st cylinder is at the

TDC (taper pin W must be facing upwards).
2. Undo the screws G .
3. Remove the timing system semi-crankcase H .

Fig 7.30

7.8.4 Oil pump

Important
• The oil pump is not repairable.
1. Undo the screws L and remove the pump unit M from
the timing system carter H ( ST_06 ) .
Fig 7.31

143 EN
 7 INFORMATION FOR DISASSEMBLY

1. Remove the rotors N and P from oil pump carter M .

Fig 7.32

7.8.5 Oil Cooler unit and lub. oil filter

1. Screw the lid cartridge holder V .
2. Undo the screws Q, R and remove Oil Cooler group S .

Warning
• Use a suitable container to recover any residue oil.
• Oil Cooler unit S is not repairable.
Fig 7.33

1. Remove the gaskets T and U .

NOTE: To replace the oil cartridge, refer to Par. 6.10.2 .

Fig 7.34

7.8.6 Oil vapour separator unit

1. Release the clamps AA .

2. Remove the manifolds AB, AC and AD .
3. Remove the clamp AE by carefully cutting it at the
point indicated and remove the oil separator AF .

Fig 7.35

EN 144
 INFORMATION FOR DISASSEMBLY 7

1. Undo the screws AG .

2. Remove la flangia di supportoRemove flange support
AH and the gasket seal AL .

Fig 7.36

145 EN
 7 INFORMATION FOR DISASSEMBLY

7.9 Intake manifold disassembly

1. Undo the screws A and remove the semi-manifold B (

ST_05 ) .
2. Remove the separation plate C and the gaskets H .

Fig 7.37

1. Undo the screws D ( ST_06 ) and E .

2. Remove the semi-manifold F and the gasket G .

Fig 7.38

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7.10 Fuel system disassembly

7.10.1 Fuel return pipes

1. Release the clip A .

Warning

• After removing the union, the clip A must automatically

return to its initial position; otherwise it must be
replaced.
Fig 7.39
1. Undo the B distributor return fixing capscrew.
2. Release the clamp D .
3. Disconnect the pipe E from the fuel return fitting.
4. Undo and remove the screw G with the relative gaskets
and put the cap on the Common Rail pressure relief
valve AA .
5. Disconnect unions M from electronic injectors N .
6. Remove the fuel return pipes.

Fig 7.40

7.10.2 Fuel flow pipes

Important

• Seal all openings of the inlet and return unions on the

injection pump D with the relevant caps, in order to
prevent impurities from entering.

1. Loosen the clamps P .

Fig 7.41
2. Remove the pipes Q and R .

7.10.3 High pressure fuel pipes

Danger

• The fuel injection circuit undergoes high pressure, use

safety protections as described in Par 3.4.3 .
• Ensure that the Common Rail is not under pressure by
slowly and carefully unscrewing one of the nuts S .
Fig 7.42
1. Loosen the nuts S and T in sequence.
2. Fully undo the nuts S and T in sequence, and remove
the high pressure pipes U and V .

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 7 INFORMATION FOR DISASSEMBLY

7.10.4 Common Rail

1. Undo the screws AB and remove the Common Rail AC

NOTE: Take care to protect te sensor AD from knocks,

moisture and any high temperature source. The internal parts of
the rail cannot be repaired.

Important
Fig 7.43
• Seal all injection component unions as illustrated in
Par. 2.9.8 .
• Common rail cannot be repaired.

7.10.5 Electronic injectors

Important

• In the event that the electronic injectors are

disassembled (not necessarily replaced), mark them
with the relevant cylinder number from which they
originate so as not to confuse them during re-assembly
(Fig. 7.45) .
Fig 7.44
• The electronic injectors cannot be repaired.
• If one or more electronic injectors are to be replaced,
the new calibration data must be inserted in the ECU
via a specific instrument ( ST_01 ).
• Be careful not to damage the gaskets X .

1. Undo capscrews AE and remove them together with

the relative washers AF and then brace AG .
2. Pull out the electronic injector AH .

NOTE: Should you be unable to remove the electronic

injector (acting only on point BC ), use an open-ended
spanner (Ø 34 mm), by applying small rotations to Fig 7.45
unblock the component.

3. Seal all injection component unions as illustrated in

Par. 2.9.8 .
4. Ensure that gasket AL has remained in the correct
position (Fig. 7.46) .
Otherwise, recover the gasket from inside the
electronic injector AM .

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 INFORMATION FOR DISASSEMBLY 7

7.10.6 Fuel filter ( )

1. Undo the fuel cartridge AW from support AP .
2. Undo the screws AN and remove the filter support AP .

Fig 7.46

7.10.7 High-pressure fuel injection pump

Important

• Before disassembling, carefully read Par. 2.17 .

• The injection pump is not repairable
• Should the fuel feeding pump need to be replaced,
after assembly, it is necessary to perform the Pump
Learning procedure by means of instrument ST_01. Fig 7.47

1. Undo the nut AQ .

2. Loosen the screws AR of the injection pump.
3. Screw the tool ST_04 on the thread of the gear AS .
4. Tighten the screw AT on the puller to disconnect the
gear AS from the injection pump and remove the
injection pump control gear AS .
5. Undo the screws AR .
6. Remove injection pump AU and the relative gasket
AV.
7. Seal all injection component unions as illustrated in
Par. 2.9.8 . Fig 7.48

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 7 INFORMATION FOR DISASSEMBLY

7.11 Timing system gear disassembly

1. Unscrew screws H and remove target wheel G .

2. Unscrew screws D and remove camshaft gear E .
3. Remove retainer ring A and the shoulder ring B .
4. Remove the intermediate gear C .

Fig 7.49

5. Remove the shoulder ring F .

6. Unscrew the screws L and remove the intermediate
gear support M .

Fig 7.50

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 INFORMATION FOR DISASSEMBLY 7

7.12 Flange unit disassembly

7.12.1 Flywheel

Important

• Leave the special tool ST_34 for blocking the flywheel (

Par. 7.7 ) .

1. Only undo the screw C located uppermost.

2. Insert the tool ST_09 in the seat of the screw C
Fig 7.51
tightening it all the way.
3. Undo the remaining screws D .

Danger

• The flywheel E is very heavy. Pay the utmost attention

while removing it in order to prevent it dropping or
falling, as this may have serious consequences for the
operative.

4. Remove the flywheel E .

5. Remove the tool ST_09 .
6. Remove the tool ST_34 shown in Fig. 7.11 .

7.12.2 Flange housing

1. Undo the screws A and remove the engine housing B .

Danger

• The flange housing is very heavy. Pay the utmost

attention while removing it in order to prevent it
dropping or falling, as this may have serious
Fig 7.52
consequences for the operative.

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 7 INFORMATION FOR DISASSEMBLY

7.13 Cylinder head unit disassembly

7.13.1 Rocker arms cover

1. Undo the screws A .
2. Remove the rocker arms cover B .
3. Remove the gasket C .

Fig 7.53

7.13.2 Rocker arm pin

1. Undo the screws D .
2. Remove the rocker arm pin unit E .

Fig 7.54

7.13.2.1 Rocker arm ( )

1. Remove the retainer ring F .
2. Remove the shoulder rings G .
3. Remove the rocker arms H .

Fig 7.55

7.13.3 Valve rods and bridges

1. Remove the valve control U-bolts M .
2. Remove the rocker arm control rods N .

Fig 7.57

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 INFORMATION FOR DISASSEMBLY 7

7.13.4 Cylinder head

Important

• The cylinder head fastening bolts P must be replaced

every time they are disassembled.

1. Undo the bolts P .

Fig 7.58
Important

• To lift cylinder head Q , only use both eyebolts AE

provided by KOHLER (refer to Fig. 7.66 ).
• When removing the cylinder head Q and subsequent
disassembly, control, and assembly operations, it is
necessary to protect the contact surface W of cylinder
head Q and crankcase J against impacts.

2. Remove the cylinder head Q .

3. Remove the head gasket R . Fig 7.59

7.13.4.1 Valves ( )

1. Mount the tool ST_07 on the head AF fixing it on one of

the holes for fixing the rocker arm cover.

NOTE: Change the fixing hole according to the position

of the valves to be removed.

2. Position the tool ST_07 on the valve as shown in the

figure. Fig 7.60

3. Push the lever of the tool ST_07 downwards, in order

to lower the valve plates S in the direction of the arrow
T , remove cotters U using a magnet.

NOTE: Repeat all the operations for all the valves concerned.

Fig 7.61

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 7 INFORMATION FOR DISASSEMBLY

Important

• Before removing the valves, make some marks to

record their original position, in order to avoid
confusing them when reassembling (if they are not
replaced).

4. Remove the valves V .

Fig 7.62

7.13.4.2 Electronic injector sleeves ( )

1. Unscrew and remove the sleeves Z from the head Q .
2. Remove the gaskets AA and AB .

Fig 7.63

7.13.4.3 Valve stem gasket ( )

1. Remove the gaskets AC .

Fig 7.64

7.13.4.4 Lifting eyebolts ( )

1. Undo the screws AD and remove the eyebolts AE .
2. Thoroughly wash the cylinder head Q .

Fig 7.65

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 INFORMATION FOR DISASSEMBLY 7

7.14 Oil sump unit disassembly

7.14.1 Oil sump

1. Undo the screws A .
2. Remove the oil sump B by inserting a plate in the areas
indicated by the arrow AA .

Fig 7.66

7.14.2 Oil suction pipe

1. Undo the screws C and remove the oil pipe D .

Fig 7.67

7.14.3 Oil vapour pipes ( )

1. Unscrew and remove the pipes E .

Fig 7.68

7.15 Engine block disassembly

7.15.1 Crankshaft gasket flange

1. Undo the screws A .
2. Remove the flange B and the gasket C .

Fig 7.69

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 7 INFORMATION FOR DISASSEMBLY

7.15.2 Piston unit/connecting rod

Important

• Mark some numerical references (cylinder n°) on the

connecting rods, connecting rod caps F1 , pistons
and gudgeon pins to prevent unintentionally confusing
the components not replaced during assembly. Failure
to do this may result in engine malfunctions. Fig 7.70
• References on connecting rod M and cap F1 must
only be carried out on a side in correspondence with
K1 and K2 , as illustrated in Fig. 7.70a .

1. Screw the bolt AM temporarily.

2. Unsrew bolts E1 and remove the connecting rod caps
F1 .

NOTE : coupling cap F1 on the connecting rod can be carried

out with centring taper pins (Fig. 7.70b) or broken ( Fig. 7.70c
- without centring taper pins).

Fig. 7.70b

Fig 7.70a

Fig. 7.70c

EN 156
 INFORMATION FOR DISASSEMBLY 7

3. Pull out the connecting rod - piston assembly from

position 2 and 3 by manually applying pressure on the
connecting rod big end L in the direction of arrow AK.
4. Couple the connecting rod big end caps L with the
relevant piston and connecting rod unit M .
5. Turn capscrew AM and rotate the crankshaft by 180°.
6. Repeat points 2 to 5 to disassemble the connecting
rod-piston assembly to position 1 and 4 .
Fig 7.71

Warning

• The connecting rod half-bearings Z are made of

special material. Therefore, they must be replaced
every time they are removed to prevent seizures.

Fig 7.72

7.15.3 Lower semi-crankcase 3 Cylinders

3 CYLINDERS
1. Undo capscrews E and F by following the order
indicated in the figure.
2. Remove the lower semi-crankcase D and store it in a
suitable container for washing.

Fig 7.73

157 EN
 7 INFORMATION FOR DISASSEMBLY

4 CYLINDERS 4 Cylinders
1. Undo capscrews E and F by following the order
indicated in the figure.
2. Remove the lower semi-crankcase D and store it in a
suitable container for washing.

Fig 7.74

7.15.4 Crankshaft

Remove:
1. Crankshaft G .
2. The shoulder semi-rings H .

Fig 7.75

7.15.5 7.15.5 Piston ( )

1. Remove the retainer ring N .
2. Remove the pin P to separate the piston Q from the
connecting rod R .

Important
• If they are not replaced, keep the components
Fig 7.76
together (connecting rod - piston - gudgeon pin) by
using references in order to prevent them from getting
mixed up during assembly.

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 INFORMATION FOR DISASSEMBLY 7

7.15.5.1 Rings ( )
1. Remove the rings S .

Fig 7.77

7.15.6 Oil spray nozzles ( )

1. Undo the screws T and remove the spray nozzles U
from the upper semi-crankcase AB .

Fig 7.78

7.15.7 Camshaft
1. Remove the lock ring V .
2. Extract the camshaft W from the upper semi-
crankcase AB .

Fig 7.79

7.15.8 Camshaft tappets

1. With a magnet, remove the tappets AA from the upper
semi-crankcase AB .

Fig 7.80

159 EN
 7 INFORMATION FOR DISASSEMBLY

7.15.9 Crankshaft bushings

1. Remove the crankshaft bushings AC from the upper

crankcase AB .

Important

• The crankshaft half-bearings AC are made of special

material. Therefore, they must be replaced every time
Fig 7.81
they are removed to prevent seizures.

2. Remove the crankshaft bushings AF from the lower

semicrankcase AE .

Fig 7.82

7.15.10 Cover 3 th PTO ( )

1. Undo the screws AG .
2. Remove the cover AH and the gasket AL from the
semicrankcase top.

Fig 7.83

EN 160
 INFORMATION ABOUT OVERHAULING 8

8 INFORMATION ABOUT OVERHAULING

8.1 Recommendations for overhauls and tuning
• The information is laid out in sequence, according to operational requirements, and the intervention
methods have been selected, tested and approved by the manufacturer's
technicians.
• This chapter describes procedures for checking, overhauling and tuning units and/or individual
components.

NOTE : To easily locate specific topics, the reader should refer to the analytical index or chapter index.
•
Before any intervention, the operator should lay out all equipment and tools in such a way as to
enable him to carry out operations correctly and safely.
• The operator must comply with the specific measures described in order to avoid errors that might
cause damage to the engine.
• Before carrying out any operation, clean the units and/or components thoroughly and eliminate any
deposits.
• Do not wash the components with steam or hot water. Use suitable products only.
• Do not use flammable products (petrol, diesel, etc.) to degrease or wash components. Use suitable
products only.
• Dry all washed surfaces and components thoroughly with a jet of air or special cloths before
reassembling them.
• Apply a layer of lubricant over all surfaces of all disassembled components to protect them against
oxidation.
• Check the integrity and state of wear of all disassembled components in order to ensure good
working condition of the engine.
• When indicated, some components are to be replaced in pairs or together with other parts (e.g.
crankshaft half-bearings/connecting rod, piston complete with rings and gudgeon pin, etc.).
• When indicated, some grinding operations are to be carried out in series (e.g. grinding of cylinders,
crankpins, journals, etc.).

161 EN
 8 INFORMATION ABOUT OVERHAULING

8.2 Crankcase

8.2.1 Oil line check

Use a pipe cleaner in access points A, B, C, D, E to clean the oil ducts of crankcase G .
Use compressed air to eliminate any residues.
Replace and assemble the conical cap in hole B ( B1 if present - tightening torque at 30 Nm ) and caps in
holes D , after having performed cleaning operations.

Fig 8.1

8.2.2 Cylinder check

Position crankcase G onto a workbench.
With a dial gauge, measure the diameter in correspondence to points J-M-N (Fig. 8.2) lengthwise and
diagonally with regard to axis H of the crankshaft.
If ovalisation or wear detected in a single point in J-M-N is greater than +0.05 mm with regard to the
value in Tab. 8.1a , you are required to perform grinding operations on all cylinders F.
Refer to Tab. 8.1a to establish the clearance value of cylinders subjected to grinding operations.
Important
• Grinding is prohibited before 10000 h of operation on all engines provided with an EPA name
plate (refer to Par. 1.3 ).
• The grinding involved is of +0.20, +0.50 e + 1 mm .
• Cylinder grinding operations must observe KOHLER SPECIFICATIONS - cod. ED0035612500.
• Grinding must be strictly performed on all cylinders F .
Tab. 8.1a details the dimensional values of new components only.
• (1) The increase of +0.20 mm , may already be present on the engine.

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 INFORMATION ABOUT OVERHAULING 8

Tab 8.1a Grinding values

PISTON Ø CILINDER (± 0.007 mm) Ø PISTON (± 0.007 mm) CLEARANCE VALUE (mm)
STD 88.010 87.950 0.046 - 0.074
+0.20 (1)
88.210 88.150
+0.50 88.510 88.450
+1.00 89.010 88.950

Fig 8.2

8.2.3 4-cylinder camshaft housing check Tab 8.2a Housing and camshaft gudgeon
dimensions.
The camshaft housings only contain the timing
system side bushing Q . REF. DIMENSIONS CLEARANCE
Use an internal dial gauge to measure the (mm) VALUE (mm)
diameters of housings X - W - K - Y - Z . X 44.000 - 44.025 0.040 - 0.085
With a micrometer, measure the diameters of
gudgeon pins X1 - W1 - K1 - Y1 - Z1 (Fig. 8.4) . X1 43.940 - 43.960
According to the values measured, calculate the W 43.000 - 43.025 0.060 - 0.105
clearance between the housing and gudgeon, W1 42.920 - 42.940
which is to observe the
values in Tab. 8.2a . K 42.000 - 42.025 0.060 - 0.105
The MAX value of wear allowed is 0.120 mm K1 41.920 - 41.940
Y 41.000 - 41.025 0.060 - 0.105
Important
Y1 40.920 - 40.940
Z 36.000 - 36.025 0.060 - 0.105
• Tab. 8.2a details the dimensional values of
Z1 35.920 - 35.940
new components only.

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 8 INFORMATION ABOUT OVERHAULING

Fig 8.3

8.2.3.1 Cylinder head surface check

Use a dial gauge to check if the cylinder head

surface A1 is level.
The MAX value of allowable irregularity of
surface A1 is: Fig 8.3a
• 0.10 mm on the entire area;
• 0.03 mm on an area of 100x100 mm.

Grinding of surface A1 is not permitted

8.2.4 Camshaft control for 4 cylinder engine

Tab 8.2b Camshaft dimensions.
With a micrometer, measure the maximum REF. DIMENSIONS (mm)
dimensions of intake camshaft R and exhaust
R 32.638 - 32.700
camshaft S (Tab. 8.2b) .
The MAX value of wear allowed is 0.1 mm . S 32.998 - 32.060

Important

• Tab. 8.2b details the dimensional values of

new components only.

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 INFORMATION ABOUT OVERHAULING 8

Fig 8.4

8.2.5 3 -cylinder camshaft housing check Tab 8.3a Housing and camshaft gudgeon
dimensions.
The camshaft housings only contain the timing system
side bushing Q . REF. DIMENSIONS CLEARANCE
Use an internal dial gauge to measure the diameters (mm) VALUE (mm)
of housings X - W - K - Z . X 44.000 - 44.025 0.040 - 0.085
Use an internal dial gauge to measure the diameters
of housings X1 - W1 - K1 - Z1 (Fig. 8.5) . X1 43.940 - 43.960
According to the values measured, calculate the W 43.000 - 43.025 0.060 - 0.105
clearance between the housing and gudgeon, which is W1 42.920 - 42.940
to observe the
values in Tab. 8.2a . K 42.000 - 42.025 0.060 - 0.105
The MAX value of wear allowed is 0.120 mm K1 41.920 - 41.940
Z 36.000 - 36.025 0.060 - 0.105
Important
Z1 35.920 - 35.940

• Tab. 8.3a details the dimensional values of

new components only.

Fig 8.5

8.2.6 Camshaft control for 3 cylinder engine Tab 8.3b Camshaft dimensions
REF. DIMENSIONS (mm)
With a micrometer, measure the maximum
R 32.834 - 32.896
dimensions of intake camshaft R and exhaust
camshaft S (Tab. 8.3b) . The MAX value of wear S 33.335 - 33.397
allowed is 0.1 mm .

Important

• Tab. 8.3b details the dimensional values of

new components only.

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 8 INFORMATION ABOUT OVERHAULING

Fig 8.6

8.3 Tappets and tappet housings

8.3.1 Tappets check

Use a surface plate and a dial gauge as shown in Fig. 8.7 .

Check the perpendicularity of the plate C , making the tappet D
rotate in the direction of the arrow.
The MAX value of wear allowed is 0.02 mm .

With a gauge, check the length of value A and B (Tab. 8.4) .

The MAX value of wear allowed is 0.08 mm .
Fig 8.7

8.3.2 Tappet housing check

Use an internal dial gauge to measure the diameter of the

tappet housings X .
Use value of A detected (Par. 8.3.1) to calculate the clearance
value ( Tab. 8.4 ).
If the clearance values are not observed, replace the worn
component.

Important Fig 8.8

• Tab. 8.4 details the dimensional values of new

components only.

Tab. 8.4 T appets and t appet housing size.

DIMENSIONS (mm) CLEARANCE VALUE (mm)
REF.
A 11.966 - 11.984
X 12.000 - 12.018 0.060 - 0.105

B 46.5 ± 0.2 ---

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 INFORMATION ABOUT OVERHAULING 8

8.4 Crankshaft
8.4.1 Dimensional check and overhauling

Wash the crankshaft thoroughly using suitable detergent.

Insert the pipe cleaner into all lubrication ducts B and blow compressed air to free them completely from
any dirt residues.
Check the state of wear and integrity of journals C and connecting rod D .
Perform the operations described in Par. 9.3.1 , perform the operations described in Par. 9.3.6 - except
Points 2, 4, 9 and 10 .
Measure the crank pins A1 with a micrometer, and using a dial gauge measure the internal diameter of the
connecting rod half-bearings A2 .
Measure the main journals B1 , with a micrometer, and using a dial gauge measure the internal diameter of
the crankshaft half-bearings B2 .
If the values described in Tab. 8.5 do not correspond, proceed with grinding all gudgeon pins A1 and B1 .
Gear A on the crankshaft is timed by a key, assembly of gear A on the shaft occurs after heating at a
stabilized temperature of +180° C for 5 mins.

Fig 8.9

Important Tab 8.5 Connecting rod and journal

diameter

• The crankshaft and connecting rod must be REF. DIMENSIONS CLEARANCE

replaced every time they are assembled to prevent (mm) VALUE (mm)
seizure, as they are made of special lead-free
material. A1 53.981 - 0.035 - 0.085
• The MAX allowed value of wear for A1 and A2 is 54.000
0.120 mm. A2 54.035 -
• The MAX allowed value of wear for B1 and B2 is 54.066
0.120 mm. B1 63.981 - 0.035 - 0.102
• To grind the crankshaft, a decrease in diameter of 64.000
the halfbearings and connecting rod is provided for B2 64.035 -
at 0.25 mm and 0.50 mm, to grind gudgeon pins A1 64.083
and B1 , measure the values of diameters A2 and
B2 by assembling the decreased half-bearings,

167 EN
 8 INFORMATION ABOUT OVERHAULING

define the diameter to grind of pins A1 and B1 ,

observing the clearance indicated in Tab. 8.5.
• La Tab. 8.5 riporta i valori dimensionali solo per i
componenti nuovi.

8.4.2 Checking the axial clearance of the crankshaft

Perform the operations described in Par. 9.3.5 and 9.3.6 .

Using a dial gauge, measure the axial shift of crankshaft E .

Axial shift must be a MIN of 0.18 mm and MAX 0.38 mm..
If the values measured do not correspond, replace shoulder
rings D .

Fig 8.10

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 INFORMATION ABOUT OVERHAULING 8

8.5 Connecting rod - piston assembly

8.5.1 Connecting rod dimensions check

Important
• Before assembling the connecting rod and pistons
(Par. 9.3.7 e 9.3.8 ), check that the difference in weight
between the complete connecting rod and piston units Fig 8.11
do not exceed 8 gr to prevent weight imbalances
during rotation of the crankshaft and consequent
damage.
• Mark some references on the connecting rods, caps Q
, pistons and gudgeon pins to prevent unintentionally
confusing the components during assembly. Failure to
do this may result in engine malfunctions.
• Connecting rod half-bearings S must be there with
each assembly.

Check that the contact surfaces are perfectly clean and intact.
Assemble the connecting rod cap Q to the connecting rod with Fig 8.12
the half-bearings S and tighten capscrews P (tightening torque
at 25 Nm ).
With a dial gauge, measure diameters B and D .
The MAX allowed value of wear for B and D is 0.06 mm.

Tab 8.6
REF. DIMENSIONS (mm) CLEARANCE VALUE (mm)
A 169.980 - 170.020
B 30.020 - 30.030 0.025 - 0.030
C 29.995 - 30.000
D 54.035 - 54.066 Fig 8.13
E 67.700 - 68.000
F 29.750 - 29.790

Important

• Tab. 8.6 details the dimensional values of new

components only.
• Check that the connecting rod and crankshaft half-
bearings are coupled properly.
• Refer to the warnings in Par. 8.4.1 for value D
decreased.
• If the clearance value between B and C is not
observed, you are required to replace bearing R (Fig.
8.12) .

169 EN
 8 INFORMATION ABOUT OVERHAULING

Measure value A, C, D, E and F and confront them with those

described in Tab.8.6 .
If the measured values do not follow those described in
Tab.8.6 , replace connecting rod T .

8.5.2 Checking the gudgeon pin-pin axes are parallel

Lubricate gudgeon pin A and bearing R (Fig. 8.12) .

Insert the gudgeon pin into bearing R .
Use a dial gauge to check the axis parallelism of the
connecting rod big end and small end.
Parallel deviation (value V ) measured at the tip of the
gudgeonpin, must be a MIN of 0,015 and MAX of 0,030 mm.
If the parallelism values do not comply with the specified
ones,replace the connecting rod with a new one. Fig 8.14

8.5.3 Piston rings check

Insert ring U into the cylinder, measure value H (distance

between the points of ring U ).
Repeat for all the seal rings.
If the measured value H does not correspond to the values
indicated in the table (Tab. 8.7) , replace the seal rings U .
Important

• Seal rings cannot be replaced separately.

Fig 8.15
NOTE: refer to Fig. 8.19 to locate the rings.

Tab. 8.7

RINGS H (mm)
U1 0.100 - 0.300
U2 0.250 - 0.500
U3 0.250 - 0.400

8.5.4 Piston dimension check

Clean the piston thoroughly.

Measure the diameter of the piston at 12 mm (quota L ) from
the base of the skirt in correspondence with the graphite
lubrication windows M .
Refer to Tab. 8.1b to establish the clearance value of the
pistons with a decreased diameter.
In correspondence with point W , there are:
3 digits for the STD piston; Fig 8.16
3 digits followed by R for a piston with an increased diameter
of 0.20 mm;

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 INFORMATION ABOUT OVERHAULING 8

+0.5 for a piston with an increased diameter of 0.50 mm;

+1 for a piston with an increased diameter of 1.00 mm;

If clearance between cylinder and piston is greater than 0,074

mm, the piston and seal rings must be replaced.

Important

• Tab. 8.1b details the dimensional values of new

Fig 8.17
components only.

Tab. 8.1b
PISTON Ø CYLINDERS Ø CLEARANCE
(± 0.007 mm) PISTON VALUE
(± 0.007 (mm)
mm)
STD 88.010 87.950
+0.20 88.210 88.150 0.046 + 0.074

+0.50 88.510 88.450

+1.00 89.010 88.950

Important

• With a feeler gauge, measure the clearance of the seal

ring in the respective seat (value L1, L2 e L3 ).
• If the clearance does not comply with the values shown
in the Tab. 8.8 , replace the seal rings and the piston.

Tab 8.8

SEAL RINGS CLEARANCE VALUE (mm)

U1 (L1) 0.110 - 0.150
U2 (L2) 0.070 - 0.115
U3 (L3) 0.030 - 0.065

Fig 8.18 e 8.19

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 8 INFORMATION ABOUT OVERHAULING

8.6 Cylinder head

8.6.1 Flatness check

Put the cylinder head on a surface plate and, with a dial gauge,
check the flatness of surface C .

The MAX value of allowable irregularity of surface C is 0.10mm.

If the value is not observed, you are required to grind surface
C.
The MAX removal allowed is 0.20 mm.

Important

• Grinding is to be performed with sleeves A of the

electronic injectors assembled.
• Grinding is prohibited on all engines provided with an
EPA name plate (refer to Par. 1.3 ).

Fig 8.20a -
Fig 8.20b

8.6.2 Valve seats check

Measure indentation B of each valve with regard to the cylinder

head surface C , which is to be a MIN of 0.60 mm and MAX of
0.85 mm.
The B MAX indentation allowed on worn components is 1.10
mm.

If the measured value does not correspond with the values

indicated, replace the worn component. Fig 8.21

Important

• The seats must be worked after driving to reach value

B , go to a rectification workshop for such operations.

8.6.3 Valve springs

Using a dynamometer, subject the spring to two different

forces (in Tab. 8.9) and check that the length of the spring
corresponds to the values indicated in the table.
Fig 8.22
(*1)
The code ED0057551850-S is installed from S/N
4418801760

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 INFORMATION ABOUT OVERHAULING 8

Tab 8.9
WEIGHT (kg) LENGHT (mm)
ED0057552810-S ED0057551850-S (*1)
0 0 Z 48.34
13.5 20.4 Z1 30.00
19.5 29.8 Z2 22.00

8.6.4 Valve guides check

Measure the diameters D and E of the rods and guides valve

(Tab. 8.10) .
If the diameters don't correspond to the values indicated,
replace the valves or guides.

The MAX allowed value of wear for D and E is 0.10 mm.

Observe values G from surface F when assembling guides H

(Tab. 8.10) .

Important

• Carry out the measurements in different points to

detect any ovalisation and/or concentrated wear.
• Tab. 8.10 details the dimensional values of new
components only.
Fig 8.23
Tab 8.10 Valve stem - valve guide dimensions

REF. DIMENSIONS (mm) CLEARANCE VALUE (mm)

D 5.978 - 5.990
E 6.030 - 6.042 0.040 - 0.064

G 7.000 - 7.020

173 EN
 8 INFORMATION ABOUT OVERHAULING

8.6.5 Valve guides replacement

The intake and exhaust guides are both made out of grey iron
with pearlitic phosphoric matrix and they have the same
dimensions.
The guides are press-fit assembled; assembly is possible by
cooling the guides with the aid of liquid nitrogen.

Before assembling a new guide, measure value L and M

,calculate the press-fit value, which must observe the values in
Tab. 8.11 .

Observe values G from surface F when assembling guides H

(Tab. 8.10 - Fig. 8.23) .

Important

• The guides must be worked for value E (Tab. 8.10 -

Fig.8.23) after driving. Contact a rectification workshop Fig 8.24
for such operations.

Tab 8.11 valve guides - housing dimensions

REF. DIMENSIONS (mm) PRESS-FIT VALUE (mm)

L 10.000 - 10.015
M 10.045 - 10.054 0.030 - 0.054

EN 174
 INFORMATION ABOUT OVERHAULING 8

8.6.6 Rocker arm check

Measure values W1 in correspondence with holes M located

on rocker arm gudgeon L (seen from B in Fig. 8.25 ).
Measure values W2 (Fig. 8.27).
Based on the values measured, calculate the clearance
between W1 and W2 , which is to observe the values in Tab.
8.12.
Check that all oil pipes N and M are free from impurities or
obstructions.
Fig 8.25

Tab 8. 12
REF. DIMENSIONS (mm) CLEARANCE VALUE (mm)
W1 19.985 - 20.005
W2 20.040 - 20.061 0.035 - 0.076

Fig 8.27

Fig. 8.26

175 EN
 8 INFORMATION ABOUT OVERHAULING

8.7 Oil pump check

8.7.1 Dimensional and visual check

Perform the operations described in Par.7.8.1 and

Par.7.8.4.

Measure clearance value B between the rotor teeth, the

value of allowable wear is MAX 0.28 mm.

Clean all the components thoroughly, check that the work

surfaces C of the rotors and pump body are not worn. Fig 8.28

Important

• Should the results from checks carried out not be

in accordance with the conditions described,
replace the timing system carter together with the
oil pump.

On assembly, references A must be visible.

Fig 8.29

8.7.2 R otors clearance check

Important

Replace carter R complete with its oil pump, if there are

signs of wear in area P of surface Q (Fig. 8.32 - 8.32a) .

Measure values G and H (Fig. 8.30) .

Measure values L, M and N (Fig. 8.31) .
Fig 8.30
According to the values measured, calculate the clearance
between G and H, L and M and L and N which are to
observe the values in Tab. 8. 13 .

For assembly, carry out the operations described from Par.

9.11.3 to Par. 9.11.4 .

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 INFORMATION ABOUT OVERHAULING 8

Tab 8.13
REF. DIMENSIONS CLEARANCE VALUE
(mm) (mm)
G 82.820 - 82.855
0.032 - 0.075 Fig
H 82.500 - 82.540
L 15.500 - 15.525
M 0.036 - 0.086

N 15.464 - 15.489
8.31

Fig 8.32 - Fig 8.32a

8.7.3 Oil pressure valve check

Measure the free length F of spring D , which must be

47.91 mm .
If the measured value does not correspond to the value
indicated, replace spring D .

Tab 8.14
DESCRIPTION
POS Fig 8.33
B Oil stopper
C Gasket
D Spring
E Piston

177 EN
 9 ASSEMBLY INFORMATION

9 ASSEMBLY INFORMATION
9.1 Information on engine configuration
• In this chapter, the engine is represented as "BASE CONFIGURATION" (refer to Par 1.4 - Par.
1.5).
• For the assembly of components not described in this chapter refer to Chap. 11 .
• The following are the components described in Chap. 11 .

11.1 Oil dipstick in cylinder head

11.2 Heater (replacement)
11.3 Poly-V alternator belt (replacement and adjustment)
11.4 Tightening pulley and alternator for Poly-V belt
11.5 Idler gear (for 3 rd / 4 th PTO)
11.6 3 rd PTO (replacement)
11.7 4 th PTO (replacement)
11.8 3 rd + 4 th PTO (configurations)
11.9 Balancer shafts (replacement)
11.10 Air filter (cartridge replacement)
11.11 Remote oil filter (disassembly and assembly)
11.12 Oil sump with supporting structure

EN 178
 ASSEMBLY INFORMATION 9

9.2 Assembly recommendations

• The information is laid out in sequence, the intervention methods have been selected, tested and
approved by the manufacturer's technicians.
• This chapter describes the installation procedures for the assemblies and/ or individual components
which have already been checked, overhauled or possibly replaced with original spare parts.
• Where necessary, reference to special tools during assembly operations is indicated and identified
in Tab. 13.1 , Tab. 13.2 and Tab. 13.3 hereinafter in Tab. 9.1 an example of a special tool ( ST_05 ).

Tab. 9.1
SPECIAL TOOLS
"ST" Code Picture /draw DESCRIPTION PART NUMBER

ST_05 Six nicks Key SN 8 ED0014603650-S

Important

• Before proceeding with operations, read Par. 3.3.2 .

• To easily locate specific topics, the reader should refer to the analytical index or chapter index .
• The operator must check that:
o the components, the assemblies, the coupling surfaces of the parts are washed, clean and
thoroughly dried;
o the coupling surfaces are undamaged;
o the equipment and tools are ready so that all work can be carried out correctly and safely;
o ensure that the working environment is safe.
• The operator must:
o carry out the procedures smoothly and safely. It is thus recommended to install the engine
on a special rotating stand used when servicing engines to ensure the safety of the
operator and the other individuals involved;
o tighten the assemblies and / or components in a criss-cross or alternating pattern, initially
with a value lower than that preset, and then subsequently, with the tightening torque
specified in the procedure;
o replace all seal gaskets after each assembly for all components on which they are provided.

179 EN
 9 ASSEMBLY INFORMATION

9.3 Engine block assembly

9.3.1 Crankshaft bushings

Important

• Execute the procedure in Par. 8.2.1 and

8.2.2 , before proceeding with assembly..
• The crankshaft half-bearings are made of
special material. Therefore, they must be
replaced every time they are assembled to
Fig 9.1
prevent seizures.

1. Fit the new half-bearings B onto the

crankcase upper half E adhering to the
reference notches C .

Important

• After the half-bearings are fitted, check that

the lubrication holes D correspond with the
crankcase grooves E .
• The lower and upper half bearings Fig 9.2
CANNOT be singularly replaced, and both
halves must be replaced together.

1. Fit the new half-bearings S onto the lower

crankcase F using the reference notches C .
2. Lubricate the half-bearings A and B with oil.

9.3.2 Tappets

1. Lubricate the tappets G with oil.

2. Insert the tappets G into the housings H of
the upper crankcase.

Fig 9.3

9.3.3 Camshaft

1. Check that the bushing Q is correctly fitted.

2. Lubricate the pins L , the cams M of the
camshaft N , all the housing P and the
bushing Q with oil.
3. Insert the camshaft N all the way into its
housing P .
Fig 9.4

EN 180
 ASSEMBLY INFORMATION 9

4. Fit the lock ring R on to the crankcase E to

hold the position of the camshaft N .
5. Manually rotate the camshaft N ensuring
that it is free.

9.3.4 Oil spray nozzles

1. Insert the sprayers V onto the upper

crankcase E manually screwing the screw
fittings U .
2. Direct the sprayers V as shown Z and
tighten the connecting screws U (tightening
torque of 10 Nm ).
Fig 9.5

9.3.5 Crankshaft

Important

• Carry out the checks described in Par.

8.4.1 and Par. 8.4.2 .

1. Check that the crankshaft half-bearings are

mounted correctly on the upper crankcase
Fig 9.6
E.
2. Lubricate the main journal and crankpin J ,
with oil.
3. Insert the crankshaft W into its seat on the
upper crankcase E .
4. Insert the 2 shoulder half-rings K , between
the crankshaft W and the upper crankcase
E ( AB detail).

9.3.6 Lower crankcase

1. Check that the crankshaft half-bearings are

mounted correctly on the lower crankcase F
( AC detail).
2. Assemble the 2 shoulder half-rings AD onto
the lower crankcase F applying two drops
of grease to keep them in their seat.
3. Check that the coupling surfaces AE are
free from dirt and grit. Fig 9.7

181 EN
 9 ASSEMBLY INFORMATION

4. Spread a bead of Loctite 5660 (rif. AL) of

approx 1 mm thickness on the surface AM
of the upper crankshaft half C being careful
not to block the oil feed grooves AG and
the return oil sump AH .
5. Join the two crankshaft halves E and F
observing the guide pins AN .

Fig 9.8

Important 3 Cylinders

• Failure to adhere to the bolt fixing

procedures may compromise the
functionality of the engine, and may also
cause damage to persons and property.

6. Tighten the fastening screws strictly

following the sequence and the tightening
torque indicated.
Tightening sequence for 3 cylinders
Tightening Screws Torx M12x1.25 (from
the n° 1 to the n° 8 ):
CYCLE 1 - with a torque of 40 Nm ;
CYCLE 2 - with a torque of 70 Nm ;
CYCLE 3 - with a torque of 120 Nm .

Tightening Screws M8x1.25 (from the n° 9 to

the n° 21 ):
Fig 9.9
CYCLE 4 - with a torque of 20Nm ;
CYCLE 5 - with a torque of 35 Nm ;
7. Perform the operations described in Par.
8.4.2 .
8. Check that crankshaft W rotates smoothly.

NOTE: In the next illustrations of Par. 9.1 the

coupled crankcase half will be indicated with the
letter E .

9. Tightening sequence for 3 cylinders

Tightening Screws Torx M12x1,25 (from
the n° 1 to the n° 10 ):
CYCLE 1 - with a torque of 40 Nm ;
CYCLE 2 - with a torque of 70 Nm ;
CYCLE 3 - with a torque of 120 Nm .

Tightening Screws M8x1.25 (from the n° 11

to the n° 27 ):

EN 182
 ASSEMBLY INFORMATION 9

CYCLE 4 - with a torque of 20Nm ; 4 Cylinders

CYCLE 5 - with a torque of 35 Nm ;
10. Perform the operations described in Par.
8.4.2 .
11. Check that crankshaft W rotates smoothly.

Fig 9.10

9.3.7 Piston rings

1. Perform the operations described in Par.

8.5.3 .
2. Put the scraper ring AP onto the piston AQ
.
3. Put the 2° seal ring AR on the piston AQ .
4. Put the 1° seal ring AS onto the piston AQ .

Fig 9.11

1. Perform the operations described in Par.

8.5.4 .
2. Position the segment openings with a 120°
angle between them ( Y ).

NOTE: do not use the segment opening with the

pin hole ( N )

1. Lubricate the piston skirt and piston rings

with oil. Fig 9.12

183 EN
 9 ASSEMBLY INFORMATION

9.3.8 Piston

Important

• Before proceeding to the assembly of the

piston and connecting rod, carry out the
checks described in Par. 8.5.1 .
• Always replace the bearings CE after each Fig 9.13
assembly.
• Mate components respecting references at
Par. 7.15.5 .
1. Loosen the screws AU and remove the
connecting rod cap AV .
2. Fit the new bearings CE .
3. Insert the connecting rod AZ into the piston
AQ and align the seats BA .
4. Insert the gudgeon pin BB into the seat BA
for the assembly of the connecting rod and
piston unit.
Fig 9.14 - Fig 9.15
5. Insert the lock rings BD inside the seat BE
of the piston AQ to lock the gudgeon pin
BB .

9.3.9 Piston and connecting rod assembly

Important

• Before assembling the piston and

connecting rod assemblies, execute the
controls described in Par. 8.5.5 .

1. Rotate the crankshaft W by moving the

Fig 9.16
crankpin BG to a TDC position of the
affected cylinder.

1. Lubricate the piston skirt and rings AQ .

2. Check that the half-bearing AS is mounted
correctly and lubricate it thoroughly.
3. Using the piston ring compression pliers,
insert the piston inside the cylinder BQ by
around 10mm (height BM ).

Fig 9.17
Important

EN 184
 ASSEMBLY INFORMATION 9

• Make sure you are at the stage described in

Point 1 .
• The piston AQ must be mounted with the
arrow BN (stamped on the piston crown)
facing the timing system side.

1. Rotate the piston AQ by 10° counter-

clockwise with respect to its correct
assembly position ( Fig. 9.18 - height BP ).
NOTE: Doing this prevents the impact between the Fig 9.18
connecting rod AZ and the sprayer V .

Fig 9.19

Important

• Leave the ring compressor assembled on

the piston

1. Push piston AQ downwards without

introducing the segments in the cylinder,
rotate piston AQ by 10° in a clockwise Fig 9.20
direction (value BR
– correct assembly position).

1. Push the piston AQ downwards by

centering the crankpin BG with the
connecting rod AZ .
2. Turn the crankcase on support to
assemble the con rod capp on cylinder
1 and 4.
3. Check that the half-bearing AS is
mounted correctly on the connecting
rod cap AV .
Fig 9.21

Important

185 EN
 9 ASSEMBLY INFORMATION

• Check that the break levels of

connecting rod cap AV coincide
perfectly onto connecting rod AZ
before screwing on and tightening
capscrews AU.

1. Couple the connecting rod cap AV to

the connecting rod AZ using the marks
made at disassembly ( Par. 7.15.2 and
7.15.5 ). Fig 9.22
2. Screw in the screws AU .
3. Repeat the operations from 1 to 10 for
each cylinder.

Important
• Failure to adhere to the assembly
procedures may compromise the
functionality of the engine, and also
cause damage to persons and Fig 9.23
property.

1. Tighten the screws AU , alternately,

strictly following the tightening torques
indicated.

Tightening sequence of screws Torx

M10x1 :
1° CYCLE - with a torque of 40 Nm;
2° CYCLE - with a torque of 85 Nm ;
2. Check that the connecting rods have
axial play and the crankshaft W rotates
smoothly.

NOTE: After the check carried out at point 14 ,

position the shaft W with the first cylinder to
TDC.

NOTE: Click by side to play the procedure. https://www.youtube.com/embed/Ba8qqxTx6wA?rel=0

EN 186
 ASSEMBLY INFORMATION 9

9.3.10 Crankshaft gasket flange

Important

• Check that the contact surface

between the flange and the crankcase
is free of grit and dirt.
• Always replace the gasket BS at each
Fig 9.24
assembly.
1. Check that there are bushings BT on
the crankcase E .
2. Lubricate the oil seal lip BU .
3. Position the gasket BS and flange BV
on the crankcase E in correspondence
with the bushings BT .
4. Put Loctite 243 on the 2 screws BW
matching the bushings BT .
5. Screw the fastening screws all the way
in BW without tightening them.
6. Tighten all the screws BW strictly
Fig 9.25
following the tightening sequence
indicated (tightening torque to 10 Nm ).

rd
9.3.11 Cover 3 PTO

Important

• Replace capscrews CA with each

assembly or alternatively apply Loctite
2701 on the thread.

1. Secure the cover CB with the screws Fig 9.26

CA and CC inserting the gasket CD
(tightening torque 25 Nm ).

187 EN
 9 ASSEMBLY INFORMATION

9.4 Oil sump unit assembly

9.4.1 Oil vapour pipes

1. Apply Loctite 648 on the pipe threads A .

2. Screw and tighten the pipes A (tightening torque of 15
Nm ).

Fig 9.27

9.4.2 Oil suction pipe

Important

• It is mandatory to replace the gasket B after each

assembly.
• Always replace capscrews D with new ones or
alternatively apply Loctite 2701 .
1. Insert the new gasket B in the seat of the oil suction Fig 9.28
hose flange D .
2. Secure the hose C on the crankcase E with the screws
D (tightening torque 10 Nm ).

9.4.3 Oil Sump

1. Ensure that the contact surfaces F of the oil sump G

and the crankcase E are completely clean.
2. Apply a bead of approx. 2.5 mm of sealant (Loctite
5660) on the surface F of the oil sump G .
3. Position the oil sump G on the crankcase E in line with
the fastening holes (use the aid of tool ST_18 ).

Fig 9.29
Note : alternatively apply Loctite 5699 .

Important

• Tighten the screws L , strictly following the sequence

and tightening torque indicated.
1. Tighten the screws L following the sequence indicated
(tightening torque 25 Nm ).
2. After tightening all of the screws, loosen screw n°1 and
retighten it to the torque value specified in step 4 .
3. Check that the oil drain plugs M are tight (tightening Fig 9.30
torque 35 Nm ).

EN 188
ASSEMBLY INFORMATION 9

189 EN
 9 ASSEMBLY INFORMATION

9.5 Flange unit assembly

9.5.1 Bell housing

Danger

• Bell A is very heavy; pay special attention during

assembly operations to avoid dropping and causing
serious risks to the operator.
Fig 9.31
1. Install the bell housing A in accordance with the
reference pins B on the base C .

Important

• Failure to adhere to the assembly procedures may

compromise the functionality of the engine, and also
cause damage to persons and property.

1. Tighten the fastening screws strictly following the

tightening sequence indicated (tightening torque 50
Nm ). Fig 9.32

9.5.2 Flywheel

Danger

• Flywheel F is very heavy; pay special attention during

assembly operations to avoid dropping and causing
serious risks to the operator.

1. Screw the special tool ST_09 on the crankshaft E

Fig 9.33
instead of the screws G positioned higherup (Fig. 9.33).
2. Insert the flywheel F on the crankshaft E using the tool
as a guide ST_09 and manually tighten all the screws
G, remove the tool ST_09 and install the last screw G.
3. Mount the tool ST_34 in the seat of the starter motor H
and fit it with the two starter motor fixing screws.
4. Tighten the screws G (tightening torque at 140 Nm ).

EN 190
 ASSEMBLY INFORMATION 9

9.6 Timing system gear assembly and injection pump

9.6.1 Timing system gear assembly

1. Check that the key A is correctly fitted on the camshaft

B.
2. Position the gear C on the camshaft B adhering to the
key reference A .
3. Screw capscrew D until the end.
4. Insert the reference pin E on the gear C .
5. Screw the encoder F with the screws G on the gear C
observing the plug E . Fig 9.34
6. Tighten the middle gear pin H , in the housing J of the
crankcase, with the screws K (tightening torque 25
Nm).

Important

• The fitting of the middle gear pin H has only one

position, the 4 screw holes K are not equally spaced.
• Always replace the gasket L after each assembly. Fig 9.35

1. Insert the shoulder ring M .

2. Check the integrity of the bushing N on the middle gear
P , and ensure that it is free from impurities.
3. Thoroughly lubricate the pin H and the bushing N .
4. Position the gear P on the pin H observing all the
marks W of the gears C and S , (Fig. 9.37).

Important
Fig 9.36
• Failure to comply with the marks W on the gears C, P
and S , causes engine malfunction and serious
damage.

1. Insert the shoulder ring Q and the lock ring R .

2. Tighten the gear C with the screw D ( Fig. 9.34 -
tightening torque at 100 Nm ).
3. Tighten the screws G on the gear C (tightening torque
at 5 Nm ).

Fig 9.37

191 EN
 9 ASSEMBLY INFORMATION

9.6.2 High-pressure injection pump

1. Check that the surface V is free from impurities ( Fig.

9.38 ).

Important
• Always replace gasket U with every assembly.
Fig 9.38
• The seal gasket U can only be fitted in one direction(
Fig. 9.38 ).
• Always replace capscrews T with new ones or
alternatively apply Loctite 2701 (Fig. 9.38) .

1. Fit the new gasket U on the injection pump Z (Fig.

9.38) .
2. Fix the pump Z into the housing V together with the
gasket U by the screws T ( Fig. 9. 38 - tightening
torque at 25 Nm ).
3. Check the correct fitting of the key AA on the shaft AB
Fig 9.39
of the injection pump ( Fig. 9.39 ).
4. Place the gear AC on the shaft AB of the pump
respecting the reference to the key AA and the
reference Q of the gear A E (Fig. 9.39) .
Serrare il dado AD (coppia di serraggio a 65 Nm ).
5. Remove special tool ST_34 ).

Fig 9.40

EN 192
 ASSEMBLY INFORMATION 9

9.7 Cylinder head unit assembly

9.7.1 Valve stem gasket

Important
• Carry out the checks described in Par. 8.6.4 before
proceeding with the following operations.
• Lubricate the oil seals A on the inside.
1. Fit the oil seals A on the valve guides B using the tool
Fig 9.41
ST_08 .

9.7.2 Electronic injector sleeves ( )

1. Insert the seals C in the seats of the sleeve D .

2. Insert the seal E with the convex side facing upward at
the base of the sleeve D .
3. Lubricate the gaskets C .
4. Insert and carefully screw the sleeve D into the seat of
the head F .

NOTE: The sleeve D must not protrude above the Fig 9.42
surface of the head BF .
5. Clamp the sleeve D (tightening torque at 30 Nm ).

9.7.3 Electronic injectors projection

1. Insert the electronic injector G inside the sleeve H .

2. Mount the rocker arm pin fixing screw L up to the stop.
3. Mount the electronic injector fixing bracket M and
secure it with the screw N , without performing the
calibration.
4. Check using ST_03 tool (Fig. 9.44) , the projection of
the injector, which must range between 1.68 ÷ 2.42
mm. Fig 9.43

NOTE : if the value detected does not correspond,

replace gasket Q with a different thickness.

Fig 9.44

193 EN
 9 ASSEMBLY INFORMATION

9.7.4 Valves

1. Pre-lubricate and insert the valves X into the head F

taking care to fit them in the original positions as per
the reference marks made in Par. 7.13.4.1 .
2. Position the spring Y on the seat of the head F .
3. Position the disk S on the spring Y centering the valve
X.

Fig 9.45
1. Mount the tool ST_07 on the head F fixing it on one of
the holes for securing the rocker arm cover.

NOTE: Change the fixing hole according to the position

of the valves to be fitted.
2. Position the tool ST_07 on the valve as shown in the
figure.

1. Push the lever of the tool ST_07 downwards, in order Fig 9.46
to lower the valve disks S in the direction of the arrow
AK , and insert the valve cotters AJ inside the disk S .
2. Check that the valve cotters AJ are properly mounted
on the valve seats X and release the tool ST_07 .

NOTE: repeat all the steps for the relevant valves and
remove the tool ST_07 .

Fig 9.47

9.7.5 Cylinder head

1. Fix the eyebolts AW with the screws AX onto the head

F (tightening torque of 25 Nm ).
2. Position the piston P at the TDC.
3. Position the tool ST_03 on the crankcase surface of the
head and measure the piston protrusion P from head
level K in 4 diametrically opposed points R. Repeat the
operation for all pistons P and take note of the highest Fig 9.48
average value, determining valu e S (Tab. 9.2) .

Tab. 9.2

S (mm) Hole number

1
0.030 - 0.126

EN 194
 ASSEMBLY INFORMATION 9

2
0.127 - 0.250

3
0.251 - 0.375

4. Based on the value detected at point 3 , select the

relevant gasket T as shown in the Tab. 9.2 (Fig. 9.50
detail U ).
5. Check that the crankcase surface K and the gasket T Fig 9.49
are completely free of dirt and grit.

Important
• The head gasket must be replaced for each assembly.

1. Position the gasket T on the surface K with reference

to the centering bushings J .
Fig 9.50

1. Check that the surface head W is free from impurities.

2. Position the head F on the crankcase Z with reference
to the centering bushings J .

Important
• The fastening bolts V must be replaced every time they
are assembled. Fig 9.51

1. Secure the head F by tightening the screws V strictly

following the sequence indicated in the Fig. 9.52 or
Fig. 9.53 and the tightening torque indicated in the
Tab. 9.3 .

Important 3 CYLINDERS

• Failure to adhere to the bolt fixing procedures may

compromise the functionality of the engine, and also
may cause damage to persons and property.
• Tighten capscrews V observing the cycles, tightening,
and subsequent rotation as indicated in Tab. 9.3 .
• For engine KDI 1903 TCR : 8 screws Torx M12x1,25
(Fig. 9.52) .
• For engine KDI 2504 TCR : 10 screws Torx M12x1,25 Fig 9.52
(Fig. 9.53) .

195 EN
 9 ASSEMBLY INFORMATION

Tab. 9.3 4 CYLINDERS

CYCLE TORQUE
1 40 Nm
2 70 Nm
3 100 Nm
4 90°
5 90°
6 90° Fig 9.53

9.7.6 Rods and valve bridges

1. Insert the rocker control rods AA into the niches of the

head F .
Important

• Properly centre the rods AA into the spherical housing

of the camshaft tappets AB .
1. Mount the valve bridge AC on to the pairs of discharge Fig 9.54
and suction valves.

Fig 9.55

9.7.7 Rocker arms

Important

• To correctly position the rocker arms, turn the rocker

arm pin AH with the lower height AL towards the timing
system side as in Fig.9.57 .
• The discharge rocker arm AT is shorter than the Fig 9.57
suction arm AR .
1. Fit the lock ring AM into the seat AN of the rocker arm
pin AH .
2. Position the pin AH with the screw support surface AP
facing upwards and insert the 2 shoulder rings AQ .

EN 196
 ASSEMBLY INFORMATION 9

3. Insert in sequence the suction rocker arm AR , the

holder AS and the discharge rocker arm AT in the pin
AH .
4. Insert the spring AU in the pin AH .
5. Repeat points 3, 4 for all the rocker arms.
NOTE: The holder AV must be fitted with the last pair
of rocker arms towards the flywheel.
6. Insert 2 shoulder rings AQ and the lock ring AN to lock
all the components inserted in the pin AH .
NOTE : The spring AU ensures that the supports AS Fig 9.58
and AV are kept in place.

9.7.8 Rocker arm pin assembly

Important

• Position the rocker arm pin assembly BB on a level to

align all the support surfaces.
• Check that the pistons are positioned half way between
the TDC and BDC. Rotate the crankshaft 90° Fig 9.59
counterclockwise with regard to the 1st cylinder TDC,
positioning the crankshaft pin BP as shown in Fig
9.60a . If the crankshaft pulley and the timing gear
cover have not been removed, rotate the
crankshaft positioning the reference BQ located on the
target wheel in correspondence of the speed sensor,
as shown in Fig. 9.60b .
1. Position the rocker arm pin assembly BB on the head F
, respecting the plug BC on the head using the holder
indicated AV .
2. Check the correct positioning of all the rocker arms and
the u-bolt control valves (detail BD ). House the tappet Fig 9.60
in the seat of the rocker arms control rod.
3. Secure the rocker arm pin BB tightening the screws BE
(tightening torque to 25 Nm ). Adhere to the screw
tightening sequence BE as shown in Fig. 9.60 .

Fig 9.60a
Fig 9.60b

197 EN
 9 ASSEMBLY INFORMATION

9.7.9 Assembly Rocker arm cover

Important

• Replace gasket BF, BL and BM with each assembly (

ST_11 - ST_12 ) .
• Observe the order of tightening illustrated in Fig. 9.62 -
9.63 . Fig 9.61
1. Position tool ST_17 onto the head in correspondence
with the two fastening holes 5 and 6 .
2. Position gasket BF on cylinder head F using tool ST_17
as a guide.
3. With vaseline lubricate the gaskets BL in the upper
part, and the gaskets BM in the lower part.
4. Attach the rocker arm cover BN on the head F with the
screw BG (tightening torque to 10 Nm ).

Fig 9.62 Fig 9.63

EN 198
 ASSEMBLY INFORMATION 9

9.8 Fuel system assembly

Important

• Do NOT mount new or different injectors without the

required tool ( Chap. 13 ).
• Remove the protective caps from all the components of
the fuel circuit just before assembly just before
assembly.

9.8.1 Fuel filter

Fig 9.64

1. Secure the fuel filter holder R with the screws S on the

crankcase T (tightening torque of 25 Nm ).

NOTE: For the assembly of the fuel cartridge, refer to

operations 4 and 5 of Par. 6.11.2 .

1. Insert the tube K on the fitting coming out of the filter

holder R and on the fuel inlet fitting of the injection
pump M and secure it with the clamps N .

Fig 9.65

9.8.2 Common Rail

1. Secure the rail AA on the head AB with the screws AC

(tightening torque at 25 Nm ).

Fig 9.66

1. Fit the gaskets AD and the fitting AE on the screw AF .

2. Tighten the parts so assembled on the Common Rail
AG (tightening torque at 15 Nm ) with the entrance of
union AE facing upward.

Fig 9.67

199 EN
 9 ASSEMBLY INFORMATION

9.8.3 Electronic injectors

Important

• Always replace and lubricate the gaskets AH and AL of

the electronic injectors AM with fuel, every time they
are assembled.
• Pay attention when repositioning the electronic
Fig 9.68
injectors, using the marks as described inl Par. 7.10.5 .
• If a new (or different) electronic injector is fitted on the
engine, you are required to prepare tool ST_01 .
1. Insert the gasket AL inside the injector sleeve BQ .
2. Insert the electronic injectors AM inside the rocker arm
cover AN and orientate them as per Fig. 9.68 .

9.8.4 High pressure fuel pipes

Important

• Always replace the pipes AQ and tube E after each

assembly.
1. Position the pipes AQ on the Common Rail AA and on
the electronic injectors AM , adjust the position of Fig 9.69
electronic injectors AM via the fitting inlets with the
pipes AQ.

Important
• Tighten the nuts AS and AT manually, without clamping
them.

1. Position the injector fastening brackets AV and the

screws AU , inserting the washer AJ . Fig 9.70

Important
• Replace the pipes AQ (Fig. 9.69) if the screws AU do
not rotate freely.

1. Tighten all the nuts AS (tightening torque at 30 Nm ).

2. Tighten the nuts AT (tightening torque at 25 Nm ).
Fig 9.71

EN 200
 ASSEMBLY INFORMATION 9

3. Make sure that the mounting brackets AV are

positioned correctly on electroinjectors BR and on
fixing screws of the rocker arm assembly AM.
4. Tighten the fixing screws of the injector mounting
bracket (tightening torque of 20 Nm ).
5. Position the pipe E screwing the screws BA and BB .

Important
• Screw the nuts BA and BB manually without tightening
them.

1. Tighten the nut BA (tightening torque of 30 Nm ).

2. Tighten the nut BB (tightening torque of 25 Nm ).
3. Tighten the Common Rail fastening screws BC
(tightening torque of 25 Nm ).

9.8.5 Fuel return pipes

1. Check the gaskets BD on the fittings BG .

NOTE: Do not disconnect the pipes from the distributor.

Fig 9.72

1. Position the return pipes and fitting the distributor BE

with the screw BC on the head BF ( Fig. 9.72 -
tightening torque of 10 Nm ).
2. Mount the fittings BG ( Fig. 9.74 ) on the injectors AM
and lock them with the clips BH .
3. Insert the pipe BL on the fitting BN .
4. Insert the pipe BM on the fitting BP .

Fig 9.73

Important

• Pipes of a "BASE CONFIGURATION" (refer to Par. 1.5

) engine are shown. Other return pipes can be missing
or different.
• The pipes can vary in quantity, size and dimensions
depending on the engine version.

Fig 9.74

201 EN
 9 ASSEMBLY INFORMATION

EN 202
 ASSEMBLY INFORMATION 9

9.9 Intake manifold assembly

9.9.1 Semi-collettor external

Important
• Check that the contact surfaces between the semi-
collector C and the head D are free from impurities.
1. Insert the special tool ST_18 into indicated point.
2. Insert the screws A and the gasket B on the semi- Fig 9.75
collector C .
3. Secure the semi-collector C with the screws A on the
head D (tightening torque of 25 Nm ).
4. Tighten the clamp E with the screw F on the semi-
collector C (tightening torque of 10 Nm - ST_06 ).
5. Tighten the screw G and the holder H on the semi-
collector C (tightening torque of 10 Nm - ST_06 ).

Fig 9.76

9.9.2 External half-manifold

Important
• Check that the contact surfaces between the two semi
collectors C and M are free from impurities.
1. Fit the screws L on the semi-collector M freeing the
holes Q indicated in Fig. 9.78 .
Fig 9.77
2. Mount the gaskets N on the semi-collector by
interposing the separation sheet P .
3. Fit the semi-collector M on the semi-collector C with
the screws L (tightening torque of 22 Nm - ST_05 ).

Fig 9.78

203 EN
 9 ASSEMBLY INFORMATION

9.10 Exhaust manifold assembly

Important

• Replace the self-locking nuts B and the metal gaskets

D between the manifold and the cylinder head every
time they are disassembled.
• In the event of mounting the studs C , fix ( 25 Nm
tightening torque) with Loctite 2701 on the thread.

1. Check that the contact surfaces F are free from Fig 9.79
impurities.
2. Insert the gaskets D and E on the studs C .
3. Position the manifold A on the studs C .
4. Fix the manifold A on the cylinder head by tightening
the self-locking nuts B (tightening torque of 25 Nm ).

EN 204
 ASSEMBLY INFORMATION 9

9.11 Assembly lubrication circuit

9.11.1 Assembly oil mist separator unit

Important
• Always replace the gasket B after each assembly.
• Always carefully inspect the condition of the pipes, and
replace them if there is any doubt regarding the
integrity of their seal.
Fig 9.80
1. Check that the contact surfaces A are free from
impurities.
2. Mount the gasket B on the holder C .
3. Fix the separator body holder C on the crankcase E
with the screws D (tightening torque of 12 Nm ) fitting
the gasket B .

1. Fit the pipes F and G on the holder C .

2. Insert the bleeder H attaching it to the pipes F and G.
Secure the pipe F with the clamps J .
3. Secure the bleeder H onto the holder C with the clamp
K.

Fig 9.81

9. 11 .2 Oil Cooler and oil filter Unit Assembly

1. Check that the surface L on the holder V and on the

crankcase E are free from impurities.
2. Lubricate and insert the gasket N on the fitting P .

Important
• Always replace the gaskets Q and S every time they
are disassembled.

1. Lubricate and insert the gaskets Q and S respectively

in the seats R and T of the holder V .
2. Secure the holder V with the screws AA and AB
(tightening torque of 10 Nm ).

Fig 9.83 e Fig 9.83

205 EN
 9 ASSEMBLY INFORMATION

Important
• In the event of mounting the fitting P on the crankcase
E (tightening torque of 15 Nm with Loctite 2701 on the
thread).

NOTE: To assemble the oil cartridge refer to operations 5 and

6 of Par. 6.10.2 .

Important
• Always replace the gaskets BM and BN every time
they are assembled.
1. Insert and tighten the cartridge-holder cover AC on the
filter holder V (tightening torque of 25 Nm ). Fig 9.84

9. 11 .3 Oil pump

NOTE: Carry out the checks described in Par. 8.7 before

proceeding with the following operations.
1. Check that all contact surfaces between AL, AH, AF,
AG and AN are free of impurities – scratches - dents.
2. When assembling, do not use any type of gasket
between AG and AN .
3. Thoroughly lubricate the seat of the rotors AF on the oil
pump crankcase AG and the two rotors AH and AL . Fig 9.85
4. Insert, inside the seat AF , the 2 rotors (in sequence)
AH and AL , respecting the reference BP as the picture
(or refer to Par. 2.10.2 ).
5. Check that the 2 pins AM are inserted properly in the
crankcase timing system AN .
6. Position the oil pump assembly AG using the pin marks
AM.
7. Fasten the oil pump cover AG with the screws AH
(tightening torque 10 Nm ).

Fig 9.86

EN 206
 ASSEMBLY INFORMATION 9

9. 11 .4 Timing system carter

Important

• Always replace the the gasket AP after each assembly (

ST_14 ).
• Always replace the gasket AU after each assembly.
1. Distribute a bead of Loctite 5188 , of about 1mm
Fig 9.87
thickness, on the surfaces AQ of the crankcase AN.
2. Make sure that the key AS (Fig. 9.88) is inserted
properly on the crankshaft and that it is facing
upwards.
3. Lubricate and insert the gasket AU in the seat of oil
pump AV .
4. Apply the tool ST_10 onto the crankshaft.
5. Check that the 2 pins AT ( Fig. 9.88 ) are properly
insertedin the timing system crankcase AN .
6. Lubricate oil seal AP with oil and position the carter AN
on the crankcase E , using the pins AT , inserting the
oil pump AV on the crankshaft.
Fig 9.88
7. Fasten capscrews AW observing the indicated
clamping sequence (tightening torque of 25 Nm ).

Fig 9.89

9. 11 .5 Crankcase oil filler flange Timing System

Important

• Always replace the gasket BA after each assembly.

1. Position the gasket BA in the seat on the flange BB .

2. Fasten the flange BB on the crankcase BC with the
Fig 9.90
screws BD (tightening torque of 10 Nm - ST_06 ).

207 EN
 9 ASSEMBLY INFORMATION

9. 11 .6 Oil pressure relief valve

1. Lubricate the piston BE and fully insert it in the seat BF

.
2. Insert the spring BG in the piston.

Important
Fig 9.91
• Always replace the gasket BH after each assembly.

1. Mount the gasket BH on cap BL .

2. Tighten the cap BL on the crankcase AN (tightening
torque of 50 Nm ).

EN 208
 ASSEMBLY INFORMATION 9

9.12 Crankshaft and phonic wheel pulley unit assembly

NOTE: To fit the target wheel refer to the operations in Par.

6.6.2 .

1. Check that the pin F is mounted properly on the

crankshaft G .
2. Position the pulley unit H on the crankshaft G using the
pin mark F (detail M ).
3. Apply Molyslip grease on the screw thread N .
4. Fix the pulley T with the screw Z (tightening torque of
360 Nm ) and remove special tool ST_34 ( Fig. 9.33 ). Fig 9.92

209 EN
 9 ASSEMBLY INFORMATION

9.13 Coolant circuit assembly

9.3.1 Thermostatic valve

Important

• Always replace the gasket A after each assembly.

1. Check the condition of the seal gasket A and fit it on
the thermostatic valve B .
2. Position the thermostatic valve B in the seat on the
head C (detail D ).
Fig 9.93
3. Secure the cover E with the screws F on the head C
(tightening torque of 10 Nm ).

9.13.2 Coolant pump assembly

Important

• Always replace the gasket L every time it is

assembled.
1. Fit the pump G with the screws H interposing the
gasket L (tightening torque of 25 Nm ).

Fig 9.94

9.13.3 Oil Cooler hoses

1. Assemble the Oil Cooler hose behind the injection

pump and connect to oil heat exchanger.
2. Insert hose L into clamp N .
3. Fasten hose L by means of clamp P on Oil Cooler M .

Fig 9.95

4 . Secure the sleeve Q on Oil Cooler M and to the coolant

pump T with the clamps K .
5. Fasten the clamp Y with the screw S (tightening torque of
22 Nm - ST_05 ).

Fig 9.96

EN 210
 ASSEMBLY INFORMATION 9

9.14 Turbocharger Assembly

Important

• Before proceeding, perform the operation described in

Par. 2.18 .
• Ensure that tube B is not clogged.
1. Fasten the connecting sleeve A to the pipe B with the
clamp C onto the flange fitting D .

Fig 9.97

Important
• Always replace the gasket F after each assembly.

1. Lubricate and insert the gasket F into the seat of the

pipe G .

Important Fig 9.98

• Remove the plastic or foam caps from the turbo
compressor before assembling.
• Replace nuts M with each assembly.

1. Check that the contact surfaces E are free from

impurities deformations or cracks, otherwise replace
exhaust manifold L .
2. Position the turbo-compressor H on the bolts on the
manifold L .
3. Fasten the turbo-compressor H with the nuts M
(tightening torque of 25 Nm ).
4. Fasten the pipe G with the screws N to the turbo- Fig 9.99
compressor H .

Important
• Always replace the gasket P after each assembly.
• Before assembly of the tube Q , perform the operation
described in Par. 2.19.2 - point 2 .
• Ensure that tube Q is not clogged.

1. Fasten the fuel outlet pipe Q with the fittings R on the Fig 9.100
turbocompressor H and on the crankcase S (tightening
torque of 15 Nm ).

211 EN
 9 ASSEMBLY INFORMATION

Insert the gaskets P between:

- Q and R ;
- Q and S ;
- Q and H .
2. Insert the sleeve T on the turbo-compressor H and
secure it with the clamp U .
3. Insert the pipe V onto the sleeve T and onto the relief
valve Z . Secure tube V with the clamps W .

EN 212
 ASSEMBLY INFORMATION 9

9.15 Electric component assembly

9.15.1 Sensors and switches

9.15.1.1 T-MAP Sensor

1. Fasten the sensor A with the screws B on the manifold

C (tightening torque of 10 Nm - ST_06 ).

Fig 9.101

9.15.1.2 Coolant temperature sensor

1. Secure the sensor D onto the head E (tightening torque

of 20 Nm ).

Fig 9.102

9.15.1.3 Oil Pressure Switch

1. Clamp the oil pressure switch F on the crankcase G

(tightening torque at 35 Nm ).

Fig 9.103

9.15.1.4 Camshaft phase sensor disassembly

1. Rotate the crankshaft H posizioning a tooth L of the

target wheel which is mounted on the camshaft at the
center of hole M .
2. Carry out the steps described in points 5, 6 and 7 to
insert the correct number of spacers N .
3. Fit the spacer N on the sensor P .
4. Fasten the phase sensor P on distribution guard L with
the screw Q (tightening torque of 10 Nm - ST_06 ). Fig 9.104

213 EN
 9 ASSEMBLY INFORMATION

1. Measure the distance from the coupling surface AD to

the tooth surface on the target wheel (X1) .
2. Measure the distance between the coupling surface AD
and the sensor surface R (Y1) .
3. The difference between the 2 measurements
determines the air gap value (Z1) .
The value (Z1) permitted must be a minimum of 0.2
mm and a maximum of 1.2 mm .
Insert one or two spacers N (Fig. 9.104) based on the
value (Z1) detected. Fig 9.105

NOTE: The calibrated spacers N have a thickness of 0.2 mm .

9.15.1.5 Speed sensor

1. Measure the distance from the coupling surface AE to

the external diameter of the target wheel (X2) .
2. Measure the distance between the coupling surface AE
and the sensor surface V (Y2) .
3. The difference between the 2 measurements
determines the air gap value (Z2) .
The value (Z2) permitted must be a minimum of 0.2
mm and a maximum of 1.2 mm . Fig 9.106
Insert one or two spacers N (Fig. 9.104) based on the
value (Z2) detected.
NOTE: The calibrated spacers U have a thickness of 0.2 mm .

4. Mount the bracket S with the screws T (tightening

torque at 10 Nm - ST_06 ).
5. Insert the shim U on the sensor V .
6. Clamp the sensor V on the bracket S with the screw Z
(tightening torque at 10 Nm - ST_06 ).

Fig 9.107

9.15.1.6 Fuel filter water detection sensor

1. Lubricate and insert the gasket AA on the fitting AB .

2. Tighten the sensor AB onto the cartridge AC
(tightening torque of 5 Nm ).

Fig 9.108

EN 214
 ASSEMBLY INFORMATION 9

9.15.2 Alternator

1. Insert the screw BA onto the alternator BB .

2. Insert the washer BC onto the screw BA .
3. Manually fit the screw BA all of the way onto the
crankcase BD without tightening.
4. Manually fit the screw BE all of the way onto the head
BF without tightening.

Fig 9.109

1. Pull out the dipstick BB in the direction of the arrow BG

.

Important

• The belt BH must always be replaced every time it is

assembled, even if it has not reached the scheduled
hours for replacement. Fig 9.110

1. Insert the belt BH on the pulleys BJ .

1. Pull out the dipstick BB in the direction of the arrow BK

.
2. While tensioning the alternator BB , first clamp screw
BE (tightening torque at 25 Nm ) and then screw BA
(tightening torque at 69 Nm ).

Fig 9.111

1. Check the tension of the belt BH with a Clavis type

instrument, positioning it in point (the tension must be
between 350 and 450 Nm ).
2. If the tension values do not correspond, tighten screws
BA and BE , then repeat operations 7, 8 and 9 .

Fig 9.112

215 EN
 9 ASSEMBLY INFORMATION

9.15.3 Starter Motor

Important

• Remove the ST_34 tool if it remains in position on the

engine

1. Fit the starter BQ with the screws BR on to the flange

bell BS (tightening torque of 45 Nm ).
Fig 9.113

9.15.4 Electric cabling

1. Position the cable holder BT together with the cabling

BU on the rocker cap BV .
2. Mount the connectors C1 on the electronic injectors S1
.
3. Screw the wiring holder BT on the rocker cap BV with
the screws BW (tightening torque of 10 Nm - ST_06 ).

Fig 9.114

1. Fit the connector C2 on the sensor S2 .

2. Fit the connector C3 on the sensor S3 .
3. Insert the clamp H1 on the collector DA .

Fig 9.115

1. Insert the connector C4 on the fuel intake valve S4 .

2. Insert the connector C5 on fuel temperature sensor S5
.

Fig 9.116

EN 216
 ASSEMBLY INFORMATION 9

1. Fit the connector C6 on the sensor S6 .

2. Fit the connector C7 on the sensor S7 .
3. Insert the clamps H2 on the thermostat cover DB and
H3 on the lateral oil intake flange DC .
4. Fit the connector C8 on the sensor S8 .

Fig 9.117

1. Fit the connector C9 on switch S9 .

2. Insert the terminal C10 on the engine S10 .
3. Insert the connector C11 on the alternator cable S11 .
4. Insert the clamp H4 on the vent holder DD .

Fig 9.118

217 EN
 9 ASSEMBLY INFORMATION

9.16 EGR Circuit Assembly

9.16.1 EGR valve

Important
• Check that the contact surfaces between flange B and
the head D are free from impurities.
• Always replace the gasket A after each assembly.
1. Mount the gasket A on the flange B .
Fig 9.119
2. Secure the flange B with the screws C on the head D
(tightening torque of 10 Nm ).

1. Insert the screws E into the holder F .

2. Position the gasket G in correspondence with the
screws E on the holder F .
3. Secure the EGR valve holder F with the screws E on
the flange B (tightening torque of 10 Nm ).

Fig 9.120

1. Fit the connector H on the valve L .

2. Tighten the clamp J with the screw K on the flange B .

Fig 9.121

9.16.2 EGR Cooler

1. Insert the fitting N of EGR Cooler M in the sleeve P of

the EGR valve unit.
2. Position EGR Cooler M on the intake manifold Q with
the screws R ( ST_05 ) .
3. Secure the fitting N with the clamp S to the sleeve P .

Fig 9.122

EN 218
 ASSEMBLY INFORMATION 9

1. Fasten the pipe T with the screws U on the EGR valve

unit V inserting the gasket W (tightening torque of 10
Nm - ST_06 ).
2. Fasten the pipe T with the screws AA on EGR Cooler
M inserting the gasket AB (tightening torque of 25 Nm
).

Fig 9.123

1. Fasten the pipe AC on the intake manifold AD with the

screws AE (tightening torque of 25 Nm - ST_05 )
inserting the gasket AF .
2. Fasten the pipe AC on the EGR Cooler M with the
screws AG (tightening torque of 25 Nm ) inserting the
gasket AH .
3. Fit the EGR Cooler M on the intake manifold Q with the
screws R (tightening torque of 25 Nm - ST_05 - Fig.
9.122 ).
4. Connect hose AL on EGR Cooler M . Fig 9.124

219 EN
 9 ASSEMBLY INFORMATION

9.17 Tightening torques and the use of sealants

Tab. 9.4 - *Alternatively to the capscrew replacements, with "Dri-loc"
BASE CONFIGURATION

SHORT BLOCK

Component Thread Torque (Nm) Sealer

(mm)
Oil sprays fastening capscrew M6x1 10
Lower crankcase fastening capscrew M12x1.25 3 Torque
cycles
1st Cycle 40
2nd Cycle 70
3rd Cycle 120
Lower crankcase fastening capscrew M8x1.25 2 Torque
cycles
1st Cycle 20
2nd Cycle 35
Connetting road screw M8x1 2 Torque
cycles
1st Cycle 40
2nd Cycle 85
Flange oil seal fastening capscrew M6x1 10
Closing cover fastening capscrew 3rd PTO M8x1.25 25 Loctite
2701*
Idle gear lubr. hole cap closure M14x1.5 30 Loctite
2701*
Coolant drain hole closing cap M16x1.5 50
OIL SUMP ASSEMBLY
Component Thread Torque (Nm) Sealer
(mm)
Oil fumes tube M12x1,5 15 Loctite 648
Oil suction hose fastening capscrew M6x1 10 Loctite
2701*
Oil sump fastening capscrew M8x1.25 25
Oil drain cap M18x1.5 35
FLANGE ASSEMBLY (1ST PTO)
Component Thread Torque (Nm) Sealer
(mm)
Flange bell fastening capscrew M10x1,5 50
Flywheel fastening capscrew M12x1,25 140
GEAR DISTRIBUTION
Component Thread Torque (Nm) Sealer
(mm)

EN 220
 ASSEMBLY INFORMATION 9

Intermediate gear gudgeon fastening screw M8x1.25 25

Camshaft gear control fastening capscrew M10x1 100
Gear fastening nut on high-pressure fuel injection pump M14x1.5 65
ENGINE CYLINDER HEAD ASSEMBLY
Component Thread Torque (Nm) Sealer
(mm)
Air bleeding cap M6x1 8
Lifting brace fastening capscrew M8x1.25 25
Electronic injector manifold M12x1 30
Cylinder head fastening capscrew M12x1.25 6 Torque
cycles
1st Cycle 40
2st Cycle 70
3st Cycle 100
4st Cycle 90°
5st Cycle 90°
6st Cycle 90°
Rocker arm gudgeon fastening capscrew M8x1,25 25
Rocker arm cover fastening capscrew M6x1 10
INJECTION SYSTEM
Component Thread Torque (Nm) Sealer
(mm)
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 10
Waste line fastening drilled capscrew on common rail M10x1 15
Electronic 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*
INTAKE MANIFOLD
Component Thread Torque (Nm) Sealer
(mm)
Internal semi-manifold fastening capscrew (on cylinder M8x1.25 25
head)
External semi-manifold fastening capscrew TG8 22
Intake flange fastening capscrew TG8 22
EXHAUST MANIFOLD

221 EN
 9 ASSEMBLY INFORMATION

Component Thread Torque (Nm) Sealer

(mm)
Exhaust manifold fastening stud M8x1.25 25
Exhaust manifold fastening nut M8x1.25 25
Exhaust/manifold/muffler flange fastening nut M8x1.25 25
LUBRICATION CIRCUIT
Component Thread Torque (Nm) Sealer
(mm)
Oil fumes support fastening capscrew (on crankcase) M6x1 12
Oil filter fastening union M20x1.5 15 Loctite
2701*
Oil cooler fastening capscrew M6x1 10
Cartridge-holder cover ... 25
Oil pump carter fastening capscrew TG6 10
Carter distribution fastening capscrew M8x1.25 25
Side oil load flange fastening capscrew (onto carter TG6 10
distribution)
Pressure relief valve cap M16x1.5 50
CRANKSHAFT AND TARGET WHEEL PULLEY ASSEMBLY (2 ND
PTO)
Component Thread Torque (Nm) Sealer
(mm)
Phonic wheel fastening capscrew (on crankshaft pulley) M6x1 10
Crankshaft pulley fastening capscrew M16x1.5 360 Molyslip
COOLANT CIRCUIT
Component Thread Torque (Nm) Sealer
(mm)
Coolant tube clamp fastening capscrew (Oil Cooler TG6 10
return)
Thermostatic valve cover fastening capscrew M6x1 10
Coolant pump fastening capscrew M8x1.25 25
TURBO COMPRESSOR
Component Thread Torque (Nm) Sealer
(mm)
Oil return tube fastening capscrew M6x1 10
Oil supply tube fastening capscrew M10x1 15
Turbine fastening stud (on manifold) M8x1.25 25
Exhaust flange fastening stud (on turbine) M8x1.25 25
Turbine fastening nut M8x1.25 25
Exhaust flange fastening nut (on turbine) M8x1.25 25
ELECTRICAL COMPONENTS
Component Thread Torque (Nm) Sealer
(mm)
MAP sensor fastening capscrew TG6 10

EN 222
 ASSEMBLY INFORMATION 9

Coolant temperature sensor M12x1.5 20 max.

Oil pressure switch M12x1.5 35
Phase sensor fastening capscrew TG6 10
Speed sensor fastening capscrew TG6 10
Sensor for water presence in fuel 5
Alternator bracket fastening capscrew M8x1.25 25
Alternator fastening capscrew M8x1.25 25
Alternator fastening capscrew M10x1.5 69
Starter motor fastening capscrew M10x1.5 45
Supply cable fastening nut (starter motor) M8x1.25 10
Cabling support fastening capscrew TG6 10
EGR CIRCUIT

Component Thread Torque (Nm) Sealer

(mm)
Flange EGR valve fastening capscrew M6x1 10
EGR valve fastening capscrew M6x1 10
EGR Cooler tube fastening capscrew (on flange EGR TG6 10
valve)
EGR Cooler fastening capscrew TG8 22
Tube fastening capscrew on EGR Cooler M8x1.25 25
Tube fastening capscrew on intake manifold M8x1.25 25
* Alternatively to the capscrew replacements, with "Dri-loc"
OPTIONAL COMPONENTS (CHAP. 11)
OIL DIPSTICK ON CYLINDER HEAD
Component Thread Torque (Nm) Sealer
(mm)
Oil dipstick tube fastening capscrew M6x1 10
HEATER

Component Thread Torque (Nm) Sealer

(mm)
Flange intake with heater fastening capscrew M8x1.25 22
ALTERNATOR WITH POLY-V BELT
Component Thread Torque (Nm) Sealer
(mm)
Pulley fastening capscrew M10x1.5 48
Pulley positioning blocking nut capscrew M10x1.5 45
Alternator brace fastening capscrew M8x1.25 25
Alternator fastening capscrew (upper) M8x1.25 25
Alternator fastening capscrew (lower) M8x1.25 40
Pulley sliding plate fastening capscrew M8x1.25 25

223 EN
 9 ASSEMBLY INFORMATION

IDLE GEAR (FOR 3TH /4TH PTO)

Component Thread Torque (Nm) Sealer
(mm)
Gear drilled fastening capscrew M14x1.5 Consultare il Par. Molyslip
>>
3 TH PTO
Component Thread Torque (Nm) Sealer
(mm)
Pump support fastening capscrew M8x1.25 25 Loctite
2701*
Pump fastening capscrew M8x1.25 25
4 TH
PTO
Component Thread Torque (Nm) Sealer
(mm)
Grooved crankshaft support fastening capscrew M8x1.25 25 Loctite
2701*
Cover fastening capscrew (3 rd PTO side) M8x1.25 25
Sump support fastening capscrew TG6 10
Pump fastening capscrew M8x1.25 25
BALANCE DEVICE (4 CYLINDERS)
Component Thread Torque (Nm) Sealer
(mm)
Housing closing panel fastening capscrew M6x1 8
Shafts support fastening capscrew M10x1.5 50
REMOTE OIL FILTER
Component Thread Torque (Nm) Sealer
(mm)
Head fastening and Oil Cooler union on crankcase M20x1.5 25 Loctite
2701*
Crankcase head nipple and oil filter support M14x1.5 40
Tube union on crankcase head G3/8 30
Tube union on filter support G3/8 35
Oil filter M20x1.5 20
Filter support head air bleeding cap M8x1.25 25
INTAKE CIRCUIT
Component Thread Torque (Nm) Sealer
(mm)
Air filter support plate fastening capscrew (on flange M8x1.25 25
bell)
Air filter support fastening capscrew M8x1.25 25
EXHAUST CIRCUIT
Component Thread Torque (Nm) Sealer
(mm)
Muffler brace support fastening capscrew M8x1.25 25

EN 224
 ASSEMBLY INFORMATION 9

Muffler fastening capscrew on muffler M8x1.25 25

Muffler fastening nut M8x1.25 25
COOLING CIRCUIT
Component Thread Torque (Nm) Sealer
(mm)
Blower fastening capscrew M6x1 10
Radiator support fastening capscrew M16x1.5 150
Shroud radiator fastening capscrew M6x1 10
Radiator lower brace fastening capscrew M8x1.25 25
Radiator on anti-vibrating M8x1.25 25
Anti-vibrating radiator fastening nut (on lower brace) M8x1.25 25
Anti-vibrating and brace fastening capscrew (upper) M6x1 10
Upper brace fastening capscrew (on engine cylinder M8x1.25 25
head)
Side bulkheads fastening capscrew M6x1 10
ENGINE SUPPORT
Component Thread Torque (Nm) Sealer
(mm)
Side feet fastening capscrew (on flange bell or M12x1.75 50
crankcase)
Rear feet fastening capscrew M16x1.5 200

225 EN
 10 FLUIDS FILLING INFORMATION

10 FLUIDS FILLING INFORMATION

10.1 Engine oil

Important
• Before proceeding with
operation, read Par. 3.3.2
.

1. Loosen the oil filler cap A

or the oil filler cap C if the
cap A is not accessible.
2. Add the type and amount
of oil recommended ( Tab.
2.2 ).

Fig 10.1

1. Remove the oil dipstick B

and check that the level is
up to but does not exceed
the MAX .
2. If the oil level is not at
MAX , insert more oil until
the MAX level is reached
as indicated on the
dipstick.
3. Re-tighten the cap A or C Fig 10.2
.

NOTE: See the Par. 11.1 for the

various configurations of the oil
dipstick.

NOTE : Click by side to play the https://www.youtube.com/embed/cVpoy_m253A?showinfo=0&rel=0

procedure.

EN 226
 FLUIDS FILLING INFORMATION 10

10.2 Coolant

Important
• Before proceeding with
operation, read Par.
3.3.2 .

1. Tighten the cap G ,

replacing the copper
gasket (Tightening torque
of 50 Nm ).

Fig 10.3

NOTE: A sealing plug or

connecting pipe to the expansion
tank may be present on the
junction B , both should be
secured with a strap.
1. Reinsert on the junction B
the sealing plug or a
connecting pipe to the
expansion tank.
Fig 10.4

Warning
•
Presence of steam
pressurized coolant
danger of burns.

1. Refill the radiator with

coolant (refer to Par. 2.6
for the liquid Fig 10.5
specifications).
2. Top liquid up until the
pipes inside the radiator
are covered by about 5
mm.
3. For engines equipped
with separate expansion
tank, pour in fluid until
reaching the max level
mark.
4. Loosen the screw F on
the head H , release any

227 EN
 10 FLUIDS FILLING INFORMATION

air and tighten the screw

F (Tightening torque of 8
Nm - Fig. 10.7 ).
5. Start the engine without
the radiator cap A or the
expansion tank (C) cap B.
6. Keep the engine at idle
speed or without a load
until the coolant level
goes down and becomes
steady (the waiting times
varies according to the
ambient temperature).
7. Turn off the engine and
allow it to cool. Fig 10.6
8. If there is an expansion
tank (C) top liquid up to
the mark MAX .
9. Without expansion tank
top liquid up until the
pipes inside the radiator
are covered by 5 mm. Do
not overfill the radiator,
but leave room for the
coolant to expand.
10. Tighten the radiator cap A
or the expansion tank (C)
cap B.

Warning
• Before starting make sure
that the radiator cap and
expansion tank cap, if
present, are installed
correctly to avoid loss of
liquid or vapour at high
temperatures.

1. After a few hours of

operation stop the engine
and allow it to cool.
Check and top up the
coolant.

EN 228
 FLUIDS FILLING INFORMATION 10

Fig. 10.7

NOTE : Click by side to play the https://www.youtube.com/embed/S79xPhTZMps?showinfo=0&rel=0

procedure.

229 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

11 INFORMATION ABOUT OPTIONAL

COMPONENTS
11.1 Oil dipstick in cylinder head

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.1.1 Check

1. Pull out the dipstick B in the direction of the arrow A .

2. Check that the mark left by the oil on the dipstick is
between the MIN and MAX notches.

Fig 11.1

11.1.2 Replacement

11.1.2.1 Disassembly

1. Undo the screw D .

2. Pull out the oil dipstick hose E in the direction of the
arrow F

Fig 11.2

11.1.2.2 Assembly

Important

• Always replace the gasket G every time it is

disassembled.

1. Insert the gasket G in the seat K of the hose E .

2. Insert the hose E in the crankcase H . Fig 11.3

EN 230
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS

1. Secure the oil dipstick hose E using the screw D on the

manifold L (tightening torque at 10 Nm ).

Fig 11.4

NOTE: Check the integrity of the gaskets J .

1. Insert the dipstick B inside the hose E .

Fig 11.5

231 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS
11.2 Heater (replacement)

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.2.1 Disassembly

1. Undo the screws A and the relevant washers and

remove the earth cable B .
2. Remove the flange C and the manifold D .
3. Remove the heater E and the relevant gaskets F .

Fig 11.6

11.2.2 Assembly

Important

• Always replace gaskets F , with each assembly.

1. In sequence, fit the manifold G with the gasket F , the
new heater E , the second gasket F , the flange C ,
the washers H , the screws A and the cable B .
2. Secure the flange H with the screws A (tightening Fig 11.7
torque at 22 Nm ).
3. Secure the earth cable B with the nut J and the
relevant washer on the heater E .

EN 232
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.3 Poly-V alternator belt (replacement and adjustment)

Important
• Before proceeding with operation, read Par. 3.3.2 .

1. Loosen the nut B and manually tighten the screw C

until it just touches the pulley pin D (Fig. 11.9) .

Fig 11.8

1. Untighten the screw E by around 32mm (A) .

2. Untighten the screw C .

NOTE: The belt tensioner pulley F should move towards the

arrow G . If it does not, please move it manually.

Fig 11.9

1. Remove the V-Belt H and install the new one.

NOTE: Ensure that the internal profile of belt H is properly

inserted into the grooves of the pulley A (as illustrated in D1 e
D2 ).

Fig 11.10

1. Tighten capscrew C , to shift gudgeon D fully to the

bottom of the grooved guide.
2. Tighten capscrew E (tightening torque at 45Nm ).
3. Hold the screw C still with a key, and tighten the screw
B on the plate L to secure the screw C (tightening
torque at 45Nm ).
4. Check, in point P (Fig. 11.8) ,the tension of the belt.
Check by the appropriate tool that at point p the
tension value is between 149 and 196 Hz .
Fig 11.11

233 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

NOTE: After the engine has been in operation for around 15

minutes, repeat point 8 .

EN 234
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.4 Tightening pulley and alternator for Poly-V belt

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.4.1 Disassembly

1. Perform the operations from point 1 to 3 of Par. 11.3 .

2. Remove the belt H ( Fig. 11.10 ) .
3. Undo and remove the screw A .
4. Fully undo the screw B and remove the tightening
pulley C .

Fig 11.12

1. Undo the screws D and remove the plate E and the pin
F.

Fig 11.13

1. Undo the screws G and H remove the alternator L .

Fig 11.14

1. Undo the screws M and remove the bracket N .

Fig 11.15

235 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

11.4.2 Assembly

1. Secure the bracket N using the screws M on the

cylinder head P (tightening torque at 25 Nm ).

Fig 11.16

1. Insert the screw H into the fixing hole on the alternator

L.
2. Insert the spacer R on the screw H (between the
alternator and crankcase).
3. Tighten the screw manually H onto the crankcase Q .
4. Orientate the second fixing hole of the alternator L with
the hole of the bracket N , secure the alternator L using
the screw G (tightening torque at 25 Nm ) onto the
bracket N and then the screw H (tightening torque at
25 Nm ). Fig 11.17

1. Insert the pin F in the plate slot E .

2. Orientate the pin F with the surface S (support for
screw A ) upwards.
3. Secure the plate E using the screws D on the bracket N
(tightening torque at 25 Nm ).

Fig 11.18

1. Insert the screw B in the tightening pulley C .

2. Manually tighten the screw B onto the pin F up to the
stop; Undo the screw B again by one turn.

NOTE: The screw B must protrude by about 32 mm (A)

from the surface of the tightening pulley C (see detail
X).
3. Install the new belt H (Fig. 11.10) .
4. Tighten the screw A onto the plate E up to the stop on
the pin F . Fig 11.19
5. Perform the operations from point 6 to 8 of Par. 11.3 .

EN 236
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.5 Idler gear (for 3rd / 4th PTO)

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.5.1 Disassembly

1. Undo the screw A and remove the gear unit B .

Fig 11.20

1. Remove the retainer ring C from the seat of the pin D .

2. Remove the shoulder washer E , the gear B , the
shoulder ring F and the bushing G from the pin G .

11.5.2 Assembly

1. Insert gudgeon D :
- shoulder ring F (minimum shim)
- gear B Fig 11.21
- shoulder ring E
- retainer ring C .
2. Insert the bushing G on the crankcase L .

Fig 11.22

Important

• Always replace the gasket H every time it is

disassembled.
• Check that the perforated screw A is free from
impurities inside it.
• Lubricate the thread and under the head of the screw A
with Molyslip .
1. Position the gear unit B on the hole J using the bushing Fig 11.23
G to centre.

237 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

2. Secure the gear unit B using the screw A inserting the

gasket H (tightening torque at 40 Nm ).
3. Loosen and tighten the screw A again (tightening
torque at 20 Nm + 20° ).

EN 238
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.6 3rd PTO (replacement)

Fig 11.12

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.4.1 Disassembly

1. Undo the screws A and remove the pump B .

Fig 11.13

239 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

1. Remove the centring ring C and the relative gaskets.

2. Undo the screws N .

Fig 11.14

1. Remove the flange F with the components D, E, G

and H in the direction of the arrow P .
2. Remove the gasket J .

Fig 11.15

1. Remove the retainer ring D and the shoulder washer

E.
2. Remove the gear H and the shoulder ring G from the
flange F in the direction of the arrow Q .

Fig 11.16

11.4.2 Assembly

Important

• Always replace the gasket J after each assembly.

• Lubricate the gear H with oil.

1. Insert the gear H in the flange F in the direction of

the arrow R inserting the shoulder ring G .
Fig 11.17
2. Insert the shoulder ring E on the flange F and clamp
the gear H using the retainer ring D .
3. Position flange F on the crankcase K inserting the
gasket J , and inser gear H in crankcase K .

EN 240
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS

Fig 11.18

1. Secure the flange F using the screws N (tightening

torque at 25 Nm ).

Fig 1

Important

•
Always replace rings P and Q after each assembly.

5. Insert the centring ring C in the flange F up to the stop.

6. Position the pump B on the flange F engaging the gear H .
7. Secure the pump B using the screws A on the flange F
(tightening torque at 25 Nm ). Fig 11.20

241 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS
11.7 4th PTO (replacement)

Fig 11.21

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.7.1 Disassembly

1. Undo the screws A and remove the pump B .

Fig 11.22

EN 242
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS

1. Undo the screws C and remove the flange D .

Fig 11.23

1. Undo the screws E and remove the cover F .

Fig 11.24

1. Undo the screws G and remove the flange K with the

components H, J, M, N and P .

Fig 11.25

1. Remove the retainer ring H and the shoulder ring J

from the flange K .
2. Remove the gear N and the shoulder ring M from the
flange K .

Fig 11.26

243 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

11..2 Assembly

Important

• Always replace the gasket J after each assembly.

• Lubricate the gear H with oil.

1. Insert the gear N in the flange K in the direction of the

arrow W inserting the shoulder ring M . Fig 11.27
2. Insert the shoulder ring J on the flange K and clamp
the gear N using the retainer ring H .

1. Position flange K onto crankcase Q inserting gasket

P and insert gear N in crankcase Q .

Important

• Always change capscrews G with new ones or

alternatively apply Loctite 2701 .

1. Secure the flange K using the screws G (tightening

Fig 11.28
torque at 25 Nm ).

Important

• Always replace the gasket V after each assembly.

1. Insert gasket V on cover F , insert and position the
cover F on flange K .
2. Secure the cover F using the screws E (tightening
torque at 25 Nm ) on the flange K .

Fig 11.29

Important

• Always replace the gasket T after each assembly.

1. Position and tighten flange D by means of capscrews
C on carter S (tightening torque 10 Nm - ST_06 ).

Fig 11.30

EN 244
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS

Important

• Always replace the gasket U after each assembly.

1. Position the gasket U on the flange D .
2. Secure the pump B using the screws A (tightening
torque at 25 Nm ) on the flange D .

Fig 11.31

245 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS
11.8 3rd + 4th PTO (configurations)

Fig. 11.45

11.8.1 Information

Hydraulic pumps on the 3rd and 4th PTO can be installed at

the same time.
In some configurations, there is also the centering ring C on
the 4th PTO.

Important

Fig. 11.46
• For disassembly or installation, refer to Par. 11.5 , Par.
11.6 e Par. 11.7 .
• Always replace the gasket of the rings B and C and
flanges D and K at each assembly.
• Lubricate the gear H with oil.

EN 246
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.9 Balancer device (replacement)

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.9.1 Disassembly

1. Perform the operations described in Par. 5.2 .

2. Undo the screws A and remove the oil sump B .

Fig 11.47

1. Undo the screws C and remove the hose D .

Fig 11.48

1. Undo the screws E and remove the shaft support box F

.

Fig 11.49

1. Undo the screws G and remove the plate H .

Fig 11.50

247 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

1. Remove the shafts J and K in the direction of the arrow

L from box F .

Fig 11.51

11.9.2 Assembly

1. Lubricate the bushings V with Molikote grease.

2. Insert the shafts J and K inside the box F in the
direction of the arrow M .

Fig 11.52

1. Make sure that the shafts J and K i nside the box F

observe the marks N and that the shaft J with the gear
indicated by letter " S " stamped on it is on the left with
respect to the box F .

Fig 11.53

1. Secure the plate H using the screws G on the box F

(tightening torque at 8 Nm ).

Fig 11.54

EN 248
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS

1. Manually tighten the retainer screw ST_15 on the box F

by slightly rotating the shaft K , centring the hole on it
using the ST_15 , to lock the device.

Fig 11.55

1. Rotate the crankshaft and clamp it on the TDC (Ref. P

upwards) using the tool ST_34 secured in place of the
starter motor (detail Q ).

Fig 11.56

1. Position the box F on the surface of crankcase R

observing the reference bushings.
2. Secure housing F using capscrews E and insert
washers U (tightening torque at 50 Nm ).
3. Remove the retainer screw ST_15 from the box F .

Fig 11.57

Important

• Check that the retainer capscrew ST_15 (Fig. 11.55) is

not present in point X on housing F .
• Always replace the gasket W after each assembly.
• Lubricate the gasket W with oil before assembling it.
1. Insert the gasket W in the seat on the flange of the oil
hose D .
2. Secure the oil intake hose D using the screws C . Fig 11.58
3. Perform the operations described in Par. 9.4.3 to
assemble the oil sump.

249 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS
11.10 Air filter (cartridge replacement)

1. Release the two hooks A and remove the cover B from

the body C .
2. Remove the cartridges D and E .

Important
• Before proceeding with operation, read Par. 3.3.2 .
• The safety cartridge E (if present) must always be Fig 11.59
replaced if it is dirty or damaged.

1. Insert the new cartridge E inside the new cartridge D

and both of them inside the filter body C .
2. Secure the cover B via the hooks A .

EN 250
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.11 Remote oil filter (disassembly and assembly)

Important
• Before proceeding with operation, read Par. 3.3.2 .

11.11.1 Disassembly

1. Perform the operations described in Par. 5.2 .

Important

• Before proceeding with operation, read Par. 3.3.2 .

• For the replace the cartridge, please refer to operation Fig 11.60
n° 4 (Par. 11.11.1) and operation n° 7 (Par. 11.11.2) .
• For the disassembly of the pipes B and C , lock with a
tool the fittings K, H (Fig. 11.61) and L (Fig. 11.62) in
order to prevent their lose together with the nuts A ,
with the consequent of oil leakage.

1. Undo the nuts A and remove the hoses B and C .

2. Unscrew the fittings L and remove the copper gaskets
from the support M .
3. Unscrew the cartridge N with gasket from the support
M.
Fig 11.61

1. Release the clamps D and remove the hoses E and F

from Oil Cooler G .
2. Unscrew and remove the fitting H with its copper
gasket from the oil filter head J .
3. Unscrew and remove:
- the fitting K with the copper gasket;
- Oil Cooler G and the relative gasketsi;
- the oil filter head J .

Fig 11.62

11.11.2 Assembly

Important

• Always replace the gaskets P, Q, R and U at each

assembly.
• Lubricate the gaskets P, Q and R with oil before
assembling them.
Fig 11.63
1. Insert the gasket P on the seat of the fitting K .

251 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

2. Insert flange head J on the fitting K and the gasket Q in

the seat of head J .
3. Insert the Oil Cooler G on the fitting K and the gasket R
in the seat of Oil Cooler G .
4. Onto crankcase S apply Oil Cooler G and flange J by
means of union K (tightening torque at 25 Nm +
Loctite 2701 on thread) as positioned in Fig. 11.64.
5. Clamp union H on flange J inserting gasket U
(tightening torque at 40 Nm ).

Fig 11.64

Important

• Always replace the gaskets V after each assembly.

1. Clamp unions L on support M inserting gasket V

(tightening torque at 40 Nm ).
2. Lubricate gasket W and clamp cartridge N on support
M (tightening torque at 20 Nm ).
Fig 11.65

7. Connect tube B to the central fitting of support M and

of head J .
8. Connect tube C to the side fitting of support M and of
head J .
9. Clamp the nuts A on the head J (tightening torque at
30 Nm).
10. Clamp the nuts A on support M (tightening torque at 35
Nm).

Important Fig 11.66

• Check the tightening of the fittings K, H (Fig. 11.64)

and L (Fig. 11.65) (tightening torque at 40 Nm ).

EN 252
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.12 Oil sump with supporting structure

11.12.1 Flywheel (J) disassembly

1. Execute the operations described in Par. 7.12.1 .

11.12.2 Plate/flange housing (L) disassembly

1. Loosen supplementary capscrews A and B .

2. Execute the operations described in Par. 7.12.2 .
3. Remove housing or plate L . Fig. 11.67

11.12.3 Oil sump disassembly

1. Execute the operations described in Par. 5.2 .

2. Loosen capscrews C and remove bypass tube D .
3. Loosen capscrews E and remove oil sump F .

Fig. 11.68

11.12.4 Oil sump assembly

1. Make sure contact surfaces G of oil sump F and

crankcase H have no impurities.
2. Apply a sealing bead of approximately 2.5 mm (
Loctite 5660 ) onto surface G of crankcase H .
3. Place oil sump F onto crankcase H in correspondence
with the fastening holes (use tool ST_18 ).

Fig. 11.69

253 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

Fig. 11.70

1. Apply capscrews E into the fastening holes and use

torque at 10 Nm .
2. Loosen capscrews E , leaving approximately 1 mm
leeway ( position A ) between the neck surface of
capscrews E and oil sump F .
3. Place flange housing or plate L onto crankcase H ,
complying with centring tap pins M .
4. Using 2 capscrews A , fasten housing or plate L onto
crankcase H (tightening torque at 20 Nm ).
5. Using 2 capscrews A , fasten housing or plate L onto oil Fig. 11.71
sump F (tightening torque at 20 Nm ).

Fig. 11.72

EN 254
 INFORMATION ABOUT OPTIONAL 11
COMPONENTS

1. Fasten oil sump F by tightening capscrews E and strictly

following the order shown in Fig. 11.73 (tightening
torque at 20 Nm ).
2. Loosen capscrews A and remove housing or plate L (
Fig. 11.72 ).
3. Fasten oil sump F by tightening capscrews E and strictly
following the order shown in Fig. 11.73 (tightening
torque at 47 Nm ).

Fig. 11.73

1. Insert gaskets N into seats P of bypass

tube D .
2. Fasten bypass tube D onto oil sump F
using capscrews C (tightening torque at
10 Nm ).

Fig. 11.74

11.12.5 Flange plate / housing assembly

1. Execute the operations described in point 6

of Par. 11.12.4 .
2. Fasten housing or plate L by using
capscrews A and strictly following the order
shown in Fig. 11.75 (tightening torque at 85
Nm ).
3. Fasten housing or plate L by using
capscrews B (tightening torque at 270 Nm). Fig. 11.75

11.12.6 Flywheel assembly

1. Execute the operations described in Par.

9.5.2 .

255 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS
11.13 ETB (replacement)

1. Unscrew screws A and remove the ETB valve B with its

gasket C .
Important

• Always replace the gasket C at each assembly.

Fig. 11.76

1. Fix the ETB valve B and its gasket C by means of

screws A (tightening torque 10 Nm )

Fig. 11.77

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 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.14 ACACT (replacement)

1. Unscrew sensor A and its gasket B .

Important

• Before assembling the new sensor, see Par. 2.17.5

• Always replace the gasket B at each assembly.

Fig. 11.78

1. Fix sensor A and gasket B on their support C

(tightening torque 20 Nm ).

Fig. 11.79

257 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS
11.15 EGTS (Black | Yellow - replacement)

1. Unscrew sensors A .
Important

• Before assembling the new sensor, see Par. 2.17.6

Fig. 11.80

1. Fix sensors A on the ATS B (tightening torque 30 Nm ).

Fig. 11.81

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 INFORMATION ABOUT OPTIONAL 11
COMPONENTS
11.16 DPF filter (replacement)

1. Obtain a new replacement KIT for the DPF filter or a

replacement KIT with regenerated DPF filter from your
spare parts service.

Important

• Before disassembling/assembling any sensors, see

Par. 2.17.5 and 2.17.6
• Always replace the seal P upon every assembly. Fig. 11.82

2. Perform the operations indicated in point 1 of Par.

11.15 .
3. Open the package of the DPF replacement KIT, taking
care not to damage it.
4. Unscrew screw A and loosen clamps B , then remove
the Delta-P sensor D .
5. Disconnect pipes C from their unions J and remove the
Delta-P sensor D .
6. Unscrew and remove unions J .

7. Loosen clamps E and remove manifold N .

Fig. 11.83

8. Loosen clamp G and remove the DPF filter H .

NOTE: do not remove clamp G .

9. Inspect the DPF filter to detect any visible signs of oil

contamination.
10. Put the removed DPF filter in the plastic container
supplied with the replacement KIT and send it to your
spare parts service using the replacement KIT Fig. 11.84
package.

NOTE : a residual value will be recognised depending on

whether the used DPF is intact and recyclable or damaged and
requiring a correct disposal.

259 EN
 11 INFORMATION ABOUT OPTIONAL
COMPONENTS

11. Insert gasket P on manifold M .

12. Insert the new DPF filter H inside clamp G .
13. Insert the DPF filter H on manifold M until reaching the
gasket P .

Fig. 11.85

Important

• Before fastening the DPF filter H , it must be oriented in

the same position as the previous filter.

14. Fasten the DPF filter H with clamp E (tightening torque

12 Nm ).

Fig. 11.86

15. Insert gasket P on the DPF filter H .

16. Insert manifold N on the DPF filter H until reaching the
gasket P .

Important

• Before fastening manifold N , it must be oriented in the

original position.
Fig. 11.87
17. Fasten manifold N with clamp E (tightening torque 12
Nm ).

18. Position support K in contact with support K1 and

fasten clamp G (tightening torque 12 Nm ).

Fig. 11.88

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 INFORMATION ABOUT OPTIONAL 11
COMPONENTS

1. Screw unions J on the DPF filter H and position them

about 20° away from the centre line (as in Fig. 11.90 ).

Fig. 11.89

1. Fix unions J (tightening torque 60 Nm ).

Fig. 11.90

1. Fit pipes C on unions J and fasten them with clamps B

.
2. Fix the Delta-P sensor D on its support K by means of
screw A (tightening torque 10 Nm ).
3. Provide the machine owner with the warranty certificate
of the new DPF filter KIT installed.

Fig. 11.91

261 EN
 12 INFORMATION ON ADJUSTMENTS

12 INFORMATION ON ADJUSTMENTS
12.1 'Waste Gate' opening valve regulation

Important
• Before proceeding with operation, read Par. 3.3.2 .
• Regulation must not be carried out with the engine running.
• During the procedure in point 5 , pay special attention not to bend rod H .
1. Disconnect the hose A from the turbocharger, and connect a pressure gauge B (scale from 0 to 5
bar).
2. Connect the gauge B to the network of compressed air, interposing a pressure reducer C .
3. Position dial gauge D in such a way that feeler F rests onthe Waste Gate rod control valve extremity
H (point E ).
4. By using gradually the reduction gear C send the air to the Waste Gate actuator control L in order
to move rod H forward by 1 mm (value M to check on dial gauge D). Pressure read on gauge B
must be: 1350 mbar for engine model KDI 2504 TCR and 1250 mbar for engine model KDI 1903
TCR.
5. If pressure is less or more than the indicated value, proceed as follows:
- Undo lock nut G from rod H.
- Remove the retainer cotter pin (point E ) and disconnect rod H from the Waste Gate control lever.
- Tighten (to increase) / or loosen (to decrease) pressure of the ring nut of rod H until reaching the
corrected calibration.
- Redo lock nut G .
- Reconnect rod H and assemble the cotter pin point E .

Fig 12.1

EN 262
INFORMATION ON ADJUSTMENTS 12

263 EN
 12 INFORMATION ON ADJUSTMENTS

12.2 Air filter check

Important
• Before proceeding with operation, read Par. 3.3.2 .
• When the cartridge G is dirty, do not clean it but
replace cartridges B and G .

1. All manifolds connected to the turbo must be fully

clean and not damaged.
2. Clean the inside components A and D with a damp
cloth.
3. Do not use compressed air , repeatedly tap the front
side E on a flat surface.

Fig 12.2

EN 264
 INFORMATION ON ADJUSTMENTS 12

12.3 Oil steam separator check

Important
• Before proceeding with operation, read Par. 3.3.2 .

1. Loosen clamp B and remove hose C from hose D .

2. Start the engine at idle speed or without a load; check
if air comes out of hose C .

NOTE: If what is described in Point 2 does not occur, proceed

with cleaning or replacing oil separator A and accurately clean
support flange F , all connecting
hoses, and repeat the operation from P oint 2.
Fig 12.3

265 EN
 12 INFORMATION ON ADJUSTMENTS

12.4 Rubber hoses and manifolds check

Important
• Before proceeding with operation, read Par. 3.3.2 .

The check is carried out by applying slight deflection or

bending along the tube/hose and next to the hose clamps.

Components must be replaced if they have clear signs of

cracks, tears, cuts, leaks, or do not retain a certain degree of
elasticity.
1. Check the condition of all rubber hoses A .
2. Check whether there are any leakages of air,
refrigerant, oil or fuel next to their connections.

Fig 12.4

Fig 12.5

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 INFORMATION ON ADJUSTMENTS 12

12.5 Oil leak check

Important
• Before proceeding with operation, read Par. 3.3.2 .

Check that there are no leakages next to area A .

1. Start the engine at idle speed or without a load and
check whether there are any leakages next to area A.
2. It is anyhow necessary to also check the seals of all
main components and their surface contact, such as:
- crankcase and gasket (side 1 a PTO)
- oil sump and exhaust caps
- cylinder head and its assembled components
- rocker arm cover
- Timing system carter and gasket (side 2 a PTO) Fig 12.6
- oil dipstick housing or rod support tube.

NOTE: Perform the checks described in Points 1 and 2

periodically and during maintenance procedures.
It is also necessary to check for leakages on the components
that are not listed.

If necessary, disassemble the components that have a leakage

and investigate the possible cause.
The components must be replaced otherwise they do
notguarantee their sealing.
Fig 12.7

267 EN
 12 INFORMATION ON ADJUSTMENTS

12.6 Oil pressure check

Important
• Before proceeding with operation, read Par. 3.3.2 .

1. Insert a thermocouple instead of the oil dipstick A .

2. Unscrew and remove the oil pressure switch and screw
on a 10 bar pressure gauge in its seat (Fig. 12.10) .
3. Start the engine at idle speed and without a load,
check the oil pressure value according to the oil
temperature (Fig. 12.9 ).

NOTE : The graph in Fig. 12.9 illustrates the pressure line with
speed of 1000 Rpm.
Fig. 12.8
1. If the pressure values are below the values indicated in
Fig. 12.9 , check to identify the cause of the problem.

Fig. 12.10

Fig. 12.9

EN 268
 TOOLS INFORMATION 13

13 TOOLS INFORMATION
13.1 Information regarding specific tools
In Tab 13.1 - 13.2 - 13.3 there is a list of all the specific tools that are required and approved to carry out
operations of disassembly - assembly - regulations - settings - repairs on engine series KDI , correctly and

safely.

Warning
• KOHLER declines all responsibility for any damage to the engine, persons, or things caused by the
use of different types of tools to those indicated in Tab 13.1 - 13.2 - 13.3 , where referred to them
in the manual.

Tab. 13.1
SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY
"ST" Picture/Draw DESCRIPTION PART NUMBER
ST_03 Piston protrusion - electronic injectors ED0014602980-
cylinder head surface control tool S

ST_04 High-pressure fuel injection pump puller gear ED0014603680-

S

ST_05 Spanner for capscrews Six nicks SN 8 ED0014603650-

S

ST_06 Spanner for capscrews Six nicks SN 5 ED0014603640-

S

ST_07 Tool for disassembling / reassembling valves ED0014603720-

S

ST_08 Tool for gasket valve stem ED0014603660-

S

ST_09 Tool for flywheel assembling / disassembling ED0014603610-

S

269 EN
 13 TOOLS INFORMATION

ST_10 Crankshaft gasket assembling tool ED0014603670-

S

ST_11 Rocker arm cover gasket assembling tool ED0014603620-

(electronic injector seat) S

ST_12 Rocker arm cover gasket assembling tool ED0014603630-

(rocker arm capscrew gudgeon seat - S
electronic injector fastening capscrew brace
seat)
ST_14 Buffer insertion of a crankshaft gasket onto a ED0014603750-
timing system carter S

ST_15 Locking screw balance shafts ED0097301980-

S

ST_17 Rocker arm cover mounting studs ED0014603730-

S

ST_18 Intake and oil sump manifold mounting studs ED0014603740-

S

ST_34 Crankshaft blocking tool ED0014604270-

S

Tab. 13.2
SPECIFIC EQUIPMENT TO PROTECT COMPONENTS OF THE INJECTION CIRCUIT

ST_40 Complete box with caps to close holes and ED0082051380-

unions for high-pressure injection circuit S
components.

Tab. 13.3
SPECIAL TOOLS TO TEST THE ENGINE ON THE TEST BENCH - DIAGNOSTIC PROCEDURE
ST_01 Complete instrument Kit for diagnostics ED0014603690-
"POLAR XL" S

EN 270
 TOOLS INFORMATION 13

ST_49 Complete instrument Kit for diagnostics ED0014604210-

"DIAGBOX" S

ST_50 Complete instrument Kit for engines bench ED0014604110-

test S

271 EN
 14 INFORMATION ABOUT FAILURES

14 INFORMATION ABOUT FAILURES

14.1 Possible causes and trouble shooting
IMMEDIATELY STOP THE ENGINE WHEN:
1. Engine rpm increases and decreases suddenly without being able to control them;
2. A sudden and unusual noise is heard;
3. The colour of the exhaust fumes suddenly darkens or turns white;
4. The oil pressure warning light or a Warning Lamp turns on during operation;
5. The coolant temperature warning light turns on during operation.

Tab. 14.1 contains the possible causes of some failures, which may occur during operation.

Always perform these simple checks before removing or replacing any part.

Warning
• Do not carry out any checks or operations on the engine when it is running.

Tab. 14.1

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INFORMATION ABOUT FAILURES 14

273 EN
 15 GLOSSARY

15 GLOSSARY
15.1 Glossary
A

ACACT: "EGR Temperature"

Air gap: Distance to respect between a fixed component and one in movement.

Alternator: A component that transforms mechanical energy into AC electrical energy.

Authorised workshop: KOHLER authorised service centre.

Authorised service KOHLER authorised workshop.

station:

ATS: "After Treatment System" - Post-treatment system, referred to the exhaust

gases produced by the engine.

Balancer device: A device that reduces vibrations caused by movement of the alternating weights
(Crankshaft - Connecting rods - Pistons).

Base Engine having components represented in Par. 1.4 - 1.5 .

configuration:

BDC: Bottom Dead Centre; a moment in which the piston is at the start of its stroke.

Bore: Internal diameter of the cylinder in combustion engines.

CAN: "Controller Area Network" - also known as CAN-bus, is a data communication standard
for ECUs.

Catalyst: See “DOC”

Combustion: Chemical reaction of a mixture composed of fuel and fuel (air) inside a combustion
chamber.

Common A high-pressure "Common Duct" that produces a constant supply of fuel directly to the
Rail: Electronic injectors.

Crankshaft: A component that transforms straight operation into rotary operation, and vice-versa.

EN 274
 GLOSSARY 15

DOC: Diesel Oxidation Catalyst - Catalyst for diesel engines that reduces harmful exhaust gas
emissions produced by the engine.

DPF: Diesel Particulate Filter - A filter that captures particles of carbonaceous origin emitted by diesel
engines.

EC: "European Community".

ECS: Emission Control System

ECU: Electronic Control Unit; an electronic device in charge of electronically detecting and
controlling other electronic control devices.

EGR: Exhaust Gas Recirculation, in internal combustion engines; a system that enables
recirculation of combusted gas by means of taking it in once again, which enables it to
break down
a part of the pollutants present in the exhaust gas.

EGR Cooler: Recirculated exhaust gas cooling; a system that is able to cool recirculated gas (EGR)
from the exhaust. This enables the temperature to remain constant inside the intake
manifold,
thus improving combustion inside the cylinders and breaking down pollutants further.

EGR valve: Electronically-controlled device that adjusts the entrance of exhaust gas recirculated
inside the intake manifold.

EGTS: "Exhaust Gas Temperature Sensor"

Electronic An electronically activated component able to inject jets of atomised fuel inside the
Injector: cylinders.

EPA: Environmental Protection Agency. The United States' authority that safeguards the
environment; its duty is to govern and control polluting emissions.

ETB: Electronic Throttle Body - This is controlled by the ECU upon request of the accelerator
pedal, and its function is crucial for the correct regeneration of the ATS system.

Fig.: Figure.

Functional Component, or group of main components, able to carry out specific functions on the
units: engine.

275 EN
 15 GLOSSARY

Galvanised: Material that has undergone surface protection treatment.

Grinding (valves Cleaning operation of the valves and seats carried out with an abrasive paste
and seats): (refer to an authorised service station for this type of operation).

Heater: A device that heats the intake air by means of an electrical resistor.

Heavy Type of extreme condition referred to the work environment in which the engine is used
conditions: (very dusty - dirty area, or in a contaminated environment due to various types of gas).

Idle speed Operation of a running engine with the vehicle stopped and on idle speed.
operation:

Intercooler: Air-cooling element under pressure from the turbo situated between the turbine
and intake manifold.

KDI: "Kohler Direct Injection"

Maintenance - A group of maintenance actions that have the sole objective to control and replace
periodic: elements on their expiry, without modifying or improving the functions carried out by
the system, neither increasing the value nor improving performance.

MAX: Maximum.

Methyl ester: It is a mixture of products by means of a chemical conversion of oils and animal
and/or vegetable fat, which is used to produce Biofuel.

Min.: Minutes.

MIN: Minimum.

Model: Model, engine identification plate, which indicates the engine's model.

N/C: Normally Closed, referred to switches (oil-pressure switch).

EN 276
 GLOSSARY 15

Oil Cooler: Small radiator used to cool the oil.

Par.: Paragraph.

Paraffin.: Fatty and solid substance that may form inside the diesel.

Pipe An instrument having a metal cylindrical body with bristles that jut outwards. It is similar
cleaner: to a brush and is used to clean areas that are not easily accessible manually (e.g. oil
ducts inside an engine).

Poly-V: Poly-V, the name associated with a service belt, which derives from the profile of its
section that is constructed with joined Vs.

Power Operation of the engine at high speeds.

operation:

PTO: Power Take Off - a point provided to take advantage of alternative operation
transmission.

Pump Automatic procedure carried out by ECU (by means of a diagnostics instrument - ST_01
Learning: ) to discover the operating characteristics of the fuel feeding pump (should the injection
pump or ECU be replaced).

QR: Quick Response (code) - QR Code, a two-dimensional matrix bar code composed of black
modules placed inside a squareshaped structure.

Ref.: Reference.

Rpm: Rounds per minute.

s/n: Serial number (engine identification name plate) indicating the engine identification
series/chassis number.

SCV: Suction Control Valve - it is situated on the high-pressure injection pump and is directly
controlled by the ECU adjusting the intake of fuel to send to the Common Rail .

Spec.: Specification, (engine identification name plate) indicating the engine version.

277 EN
 15 GLOSSARY

STD: (Standard), base configuration of a component, or a group of components.

Tab.: Table.

Target Wheel: A wheel that is a part of a device to control angular operation by means of teeth
placed on the circumference, which enable to determine and transmit the speed and
position of the crankshaft to a sensor.

TCR: Turbo Common Rail.

TDC: Top Dead Centre; a moment in which the piston is at the end of its stroke.

Thermostatic A valve that adjusts the flow of coolant liquid; it is able to operate by means of
valve: temperature variation.

Tightening A term indicated for installation of threaded components and which is determined by
torque: means of a unit of measurement Nm .

T-MAP: T-MAP (sensor), measures the temperature and absolute pressure inside the intake
collector.

Torque: Force applied to an object that rotates on an idler shaft.

Trochoid: Rounded toothed profile (also known as "lobes").

Turbocharger: Device that compresses air intake by sending it to the intake manifold by means of a
turbine.

Used Oil altered by operation or time, which is no longer compliant for correct lubrication of the
oil: components.

Waste-Gate A device, which is directly or automatically controlled, used to limit the pressure of
valve: exhaust gas inside the turbine.

Warning Lamp: A warning light (usually red) that indicates a serious anomaly during engine operation.

EN 278
 GLOSSARY 15

SYMBOLS AND UNITS OF MEASUREMENT

SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE
α degree Rotation/inclination angle 1°
cm 2
square centimetre Area 1 cm 2
Ø millimetre Circumference Ø 1 mm
Nm newton-metre Torque 1 Nm
mm millimetre 1 mm
µm 1/1000 of a millimetre (micron) Length 1 µm
H hour Time 1h
g/kW grammes per kilowatt per hour Specific consumption 1 g/kWh
kg/h kilogramme per hour Max. flow rate 1 kg/h
Lt./min. litres per minute Flow rate 1 Lt./min.
Lt./h litres per hour 1 Lt./h
ppm parts per million Percentage 1 ppm
N newton Force 1N
A Ampere Intensity of electrical current 1A
gr. gramme Weight 1 gr.
kg kilogramme 1 kg
W Watt Power 1 W.
kW kiloWatt 1 kW
pa pascal Pressure 1 pa
KPa Kilopascal 1 KPa
bar barometric pressure 1 bar
mbar (1/1000 barometric pressure 1 mbar
bar)
R Resistance Resistance to electrical current (referred 1Ω
to a component)
Ω ohm Resistance of electrical current 1Ω
Rpm revs per minute Rotation of an axis 1 Rpm
Ra average roughness expressed Roughness 1 Ra
in microns
°C degree centigrade Temperature 1°C
V Volt Electrical voltage 1V
millimetre Hex-head capscrew 1 mm
cm 3
cubic centimetre Volume 1 cm 3
Lt. litre 1 Lt.

279 EN