Engine lubricant oil level check
Figure 1
229366
The check must be performed when the engine is stopped and possibly cold.
The check is carried out with the flexible dipstick (2). Remove the dipstick (2) from its housing and check that the level is between the minimum and maximum ends etched on it.
If the reading is unclear, clean the dipstick (2) with a cloth with no looses threads and put it back in its seat. Take it off again and check the level.
If the level is insufficient, it is necessary to top up with lubricant oil which meets the international standards 5W-30/0W-30; ACEA C2; recommended oil is URANIA DAILY FE - URANIA DAILY LS.
Remove the lubricant oil cap (1) and pour engine lubricant oil through the hole.
Always make sure to add oil with the same characteristics as the one contained in the sump. Mixtures which do not ensure the proper lubrication of the internal parts of the engine are not permitted.
!
The engine oil is highly pollutant and toxic.
In case of contact with skin, wash thoroughly with water and detergent.
Suitably protect skin and eyes; proceed in accordance with accident prevention standards. Suitably dispose of the residuals and in accordance with regulations.
Engine coolant level check
Proceed only with engine not running and at low temperature to avoid any risk of burns.
With the engine at low temperature, make sure that the fluid level in the expansion tank is above the minimum level. Visually check that the fluid level is not more than 2/3 of the height of the tank in order to enable any increase in volume of the fluid caused by the temperature increase.
Top up the tank if necessary, using a 50% mixture of water and Paraflu HT even during the summer months. As an alternative to Paraflu HT use another product which complies with ASTM D-6210 international standard.
NOTE In the event that only the heat exchanger without the expansion tank is available on the vehicle, refill it if necessary, paying attention that the fluid does not saturate the internal volume of the exchanger in order to enable any increase in volume of the fluid caused by the temperature increase.
!
When the engine is warm, a pressure liable to cause hot liquid to be expelled with extreme violence is created within the cooling circuits. This results in a danger of burning.
Engine visual inspection
Before starting, it is recommended to carry out a series of simple checks that can significantly help avoid problems, also of a series nature, while the engine is operating. These checks are usually performed by the vehicle operators and drivers. Check the levels and check for any leaks from the fuel, cooling and lubrication circuits.
Inform maintenance personnel if any problems are found; top up if necessary.
After starting the engine and with the engine operating, perform the following checks and controls:
Check for any leaks from the fuel, cooling and lubrication circuits.
Make sure there is no unusual noise or beating during operation.
Use the vehicle instruments to check the foreseen pressure, temperature values, etc.
Visually check the smoke (colour of the exhaust gas). Visually check the level of the coolant in the expansion tank.
Air filter & housing cleanness check (supplied on demand)
Only proceed with the engine stopped. Figure 2
229365
Remove the cover (1) of the filter housing and extract the cartridge paying attention that the dust does not get into the sleeve.
Blow the filtering element by means of dry and compressed air, acting from the inside outwards (max. pressure: 200 kPa). Avoid using detergents; do not use diesel oil.
Never hit the filtering element by means of tools, and check its condition before reinstalling it.
In the event that breakages or tears take place, or it is not possible to remove the impurities, replace it.
Check that the gasket base is in good condition. Reassembly the filtering element and close the housing.
!
Take care to ensure that the parts are reassembled correctly.
Imperfect assembly might result in unfiltered air being sucked into the engine, causing serious damage.
Electrolyte level in batteries check/top up and terminals cleaning (supplied on demand).
Place the batteries on a level surface, then proceed as follows. Visually check that the fluid level is between the “Min” and “Max” limits; in the absence of references, check that the fluid covers the Lead plates inside the elements.
Top up with distilled water only those elements in which the level is below the minimum.
Contact specialised technical staff if the battery needs recharging.
On this occasion, make sure that the terminals and clamps are clean, properly locked and protected by vaseline.
!
If all the elements of the battery need refilling with a considerable quantity of distilled water, contact specialised technical personnel in order to perform a diagnostic check on the efficiency state of the recharge system and battery.
!
The batteries contain sulphuric acid, which is extremely caustic and corrosive; always wear protective gloves and goggles when topping them up. Whenever possible it is recommended that this control be carried out by specialised personnel. Do not smoke or use live flames near the batteries during the control, and make sure that the room you are working in is adequately ventilated.
Figure 3
225112
Some types of battery have a single cover for all the inspection plugs to access the elements, use a lever as shown in the figure.
Tension and conditions check of auxiliary member belt’s
Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.
Figure 4
229364
Check that the belt (1) is not torn or worn, and that there are no lubricants or fuel on it. If this is not the case, replace them. At the same time, make sure that the tensioning device is working properly.
Exhaust duct(s) condition check
Visually check that the exhaust gas system is not blocked, corroded or damaged.
In the event of any problems, perform the operations necessary to restore the exhaust duct.
Periodic maintenance
Water drainage from the fuel pre-filter (supplied on demand)
Depending on its use, some vehicles adopt a fuel pre-filter as well.
The high risk of refuelling with fuel that is polluted by foreign bodies and water makes it advisable to carry out this control every time you refuel.
Proceed with the engine stopped. Figure 5
229363
Place a container under pre-filter to collect the fluid. Unscrew the tap plug (1) in the bottom part of the filter; in some lay-outs the plug includes a sensor to detect the presence of water in the diesel.
Drain off liquid until only “diesel” can be seen. Close the plug again, tightening it completely by hand. Dispose of the drained fluids according to current requirements.
Condensed water drainage from fuel tank
Perform the drainage/suction of water, condensation and impurities from the fuel tank/s by following the instructions contained in the manual supplied by the tank manufacturer. Proceed as necessary based on the structure or location of the tank: engines that operate in adverse environments and conditions and/or that are refuelled using drums or jerry cans, require more attention when cleaning the tank.
Engine lubricant oil replacement
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent.
Adequately protect the skin and the eyes, operate in full compliance with safety regulations.
Disposal must be carried out properly, and in full compliance with the law and regulations in force. Place a suitable container to collect the oil as it drains out.
Figure 6
229361
Pull out the oil dipstick (1). Figure 7
229362
Unscrew the filler cap (2) at the top of the engine.
Unscrew the drain plug (1) and drain the oil into a container
Ref. No. Description
(1) 1 M22x1.5x10
Wait until the oil sump has completely emptied, then retighten the lubricant oil drain plug (1) under the sump at the torque indicated in the table.
Ref. No. Description Tightening
torques
(1) 1 M22x1.5x10 50 ± 5 Nm
Proceed with the refilling operation:
Add the specified quantity of lubricant oil that meets the
international standards 5W-30/0W-30; ACEA C2;
recommended oil is URANIA DAILY FE - URANIA DAILY LS.
Lubricant oil filter replacement
Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.
Only use filters with a filtration level equivalent to the ones you are replacing (see the table at the beginning of section 4).
Place a container under the filter support, to collect the used oil.
Figure 8
227800
Unscrew the filter (1) and remove it.
Ref. No. Description
(1) 1 M22x1.5
Carefully clean the surfaces of the support that are in contact with the seal.
Moisten the new filter seal with a thin layer of oil.
Manually tighten the new filter (1) on the support until it comes into contact with the seal. Additionally tighten it using a specific tool to the torque indicated in the table.
Ref. No. Description Tighteningtorques
(1) 1 M22x1.5 25 ± 2,5 Nm
Operate the engine for a few minutes and then check the level using the dipstick. If necessary, top up to compensate for the quantity of oil used to fill up the filtering cartridge.
Fuel pre-filter replacement (supplied on demand)
Only proceed with the engine stopped. Figure 9
229360
Remove the prefilter by unscrewing it.
Check that the new filter has performance levels that satisfy the needs of the engine (e.g. by comparing them with the old one). Moisten the new filter seal with diesel or engine oil.
Hand screw the new filter into place until the seal gasket touches the support, then lock by a further 3/4 of a turn. Place the water presence sensor in its seat, taking care to couple the threads correctly.
Loosen the bleeder screw (2) on the pre-filter support and activate the hand pump (1) until the supply circuit is full. Ensure that any fuel coming out is not dispersed into the environment.
Lock the bleeder screw tightly.
Start the engine and run it at idle for a few minutes to eliminate any residual air.
NOTE Should it be necessary to accelerate the bleeding phase, the hand pump can be used during start-up.
Fuel filter replacement (supplied on demand)
Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.
Only use filters with a filtration level equivalent to the ones you are replacing (see the table at the beginning of section 4). Disconnect the electrical connection and the fuel pipes. Loosen the screws and remove the support including the filter. Remove the connector from the filter housing.
Remove the filter housing from the support and remove the filtering element.
Moisten the new filter seal with diesel or engine oil.
Hand screw the new filter into place until the seal gasket touches the support, then lock by a further 3/4 of a turn. Insert the connector into its seat and refit the fuel filter in the engine compartment, reversing the operation described previously.
Do not fill up the new filter before it is fitted to the support, to avoid inserting harmful impurities into the injection system and circuit.
In the event that fuel pipings have to be disconnected, clean with the utmost care the fittings before connecting them again. Make sure that the seal is appropriate by starting the engine. If leakages occur
take adequate countermeasures against this
immediately.
!
Never loosen the high pressure common rail injection circuit fitting in any way. Do not carry out un necessary and dangerous bleeding attempt.
!
Do not smoke or use open flames during this operation.
Power steering oil replacement
Only proceed with the engine stopped.
Open the cap of the storage tank and proceed depending on the necessity related to the vehicle building.
Air filter cleaning (supplied on demand)
Refer to the instructions provided for Air filter & housing cleaness check.
Air filter replacement (supplied on demand)
Refer to the instructions provided for Air filter & housing cleaness check.
Auxiliary members’ belt replacement
Figure 10
229364
Using a suitable tool remove the A/C compressor belt (2). Using the specific wrench on the automatic belt tensioner (3), reduce the tension of the belt (1) and remove it from alternator, water pump, crankshaft pulley, compressor and fixed guide roller.
Using a specific wrench on the automatic belt tensioner (3), fit the belt (1) on the pulleys and fixed guide roller, making sure that the ribs on the belt fit properly into the grooves on the pulley.
Additional adjustments are not required. The belt (1) tension is adjusted automatically by the calibrated spring in the automatic belt tensioner (3).
Using a suitable tool fit the A/C compressor belt (2). Operate the engine for a few hours and check that the auxiliary members’ belt (1) is properly fitted.
Heat exchanger (radiator) cleaning (supplied on demand)
Figure 11
229359
Check that the air intake surfaces of the radiators are free of impurities (dust, mud, straw etc.). Clean them if necessary using compressed air or steam.
When using compressed air, it is required to use suitable personal protections for hands, face and eyes.
Extraordinary maintenance
Turbocharger visual inspection
Only proceed when the engine is not turning over. Visually check that the turbine and compressor impellers and the relative inlet and outlet ducts are not obstructed or damaged, otherwise replace them.
Engine coolant replacement.
Only proceed when the engine is not turning and is at low temperature in order not to run the risk of burns.
In the event that a mixture of PARAFLU HT and water is used, the density value is equal to 1.0675 g/cm3 (at a temperature of 15˚C ).
For replacing the coolant, observe the following procedure: Use suitable containers to ensure that the coolant is not dispersed in the environment.
Loosen the retaining elements and remove the sleeves that couple the engine circuit with the heat exchanger and wait for them to empty completely. Once emptied, restore the condition of the circuit, ensuring the perfect seal of the sleeves. Refill the circuit according to the requirements specified: Use a 50% mixture of water and Paraflu HT even during the summer months. As an alternative to PARAFLU HT use another product which complies with ASTM D-6210 international standard.
Refill the engine and the exchanger until the exchanger is completely filled.
With the filler plug open, start the engine and idle it for approx. 1 minute. This phase helps to completely bleed the air contained in the cooling circuit.
Stop the engine and then top up the incomplete quantity. When the engine is cold, make sure that the coolant level is a few centimetres below the filling hole.
In the event of an externally located level indicator as regards the heat exchangers, proceed with the top up operation by making sure that the coolant does not overfill the internal volume of the exchanger in order to allow the expansion of coolant volume during increases in temperature.
The failure to observe the aforesaid procedure does not guarantee the presence of the correct quantity of coolant in the engine.
!
When the engine is hot, pressure builds up in the cooling circuits which may eject hot liquid violently, resulting in a risk of burns.
Open the filler cap of the coolant tank only if necessary and only when the engine is cold.
Pre-heating glow plug replacement
To perform this operation correctly, proceed as described in
section 5 “PRE/HEATER GLOW PLUGS
REMOVAL/REFITTING” chapter.
Auxiliary members’ belt tensioning device replacement
Figure 12
227797
Using a suitable tool remove the air compressor belt (2). Using the specific wrench on the automatic belt tensioner (4), reduce the tension of the belt (1) and remove it.
Undo the screw (3) and remove the automatic belt tensioner (4).
Ref. No. Description
(3) 1 M10x1.5x45
Fit the automatic belt tensioner (4) and tighten the screw (3) to the torque indicated in the table.
Ref. No. Description Tightening
torques
(3) 1 M10x1.5x45 45 ± 5 Nm
Using a specific wrench on the automatic belt tensioner (4), fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley.
Using a suitable tool fit the air compressor belt (2).
Timing system chain and tensioning device replacement
To perform this operation correctly, proceed as described in section 5 “CYLINDER HEAD REMOVAL/REFITTING“ chapter.
Particulate filter replacement
The particulate filter is designed to filter particulate particles that are deposited between the ceramic structure pores. When necessary (time intervals or loss in pressure along the filter), the filter is cleaned bringing the temperature of the exhaust gases to 630ºC; to do this, an exothermic reaction must be created in the catalytic converter by injecting a small quantity of fuel after the top dead centre with a delay that allows vaporization in the combustion chamber without burning.
When the vaporised fuel reaches the catalytic converter, if the temperature is at least 230˚C, the catalysts allows the start of the combustion bringing the DPF to a temperature of 630˚C. The control unit, acting at the time of the post-injection and on the quantity of oxygen (closure of the throttle valve), maintains the optimum regeneration temperature.
During the regeneration stage, the E.G.R. is closed to prevent the intake of the vapours produced into the cylinder. The filter regeneration is not possible when it presents signs of damaging: in this case proceed to the particulate filter replacement.
The filter regeneration requires that all the parameter counters are reset, as: the quantity of particulate/ashes accumulated in the new filter is zero; in the case of simultaneous replacement of the particulate filter and the engine oil is necessary to reset the amount of post-injected fuel.
All the regeneration parameters must be reset because, to all intents and purposes, this is a new life cycle. If you do not zero: the ash counter, the frequency of the regenerations will be greater than required with an unnecessary increase in consumption, the thermal fatigue of the particulate filter and, in extreme cases, an unfounded request to change the engine oil; the Oxicat ageing function with a risk of unjustified post-injection quantities; the post-injection fuel counter, may make an early request to change the engine oil.