COPERTINA FUIF511 27D Repair Manual N45 And N67 ENT Tier3 P2D32N003E Feb06

User Manual: FUIF511-27D

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NEF TIER 3 SERIES
Industrial application

N45
N45 ENT

N67
N67 ENT

Technical and Repair manual

This publication describes the characteristics, data and correct
methods for repair operations on each component of the vehicle.
If the instructions provided are followed and the specified
equipment is used, correct repair operations in the programmed time will be ensured, safeguarding against possible
accidents.
Before starting to perform whatever type of repair, ensure that
all accident prevention equipment is available and efficient.
All protections specified by safety regulations, i.e.: goggles,
helmet, gloves, boot, etc. must be checked and worn.
All machining, lifting and conveying equipment should be inspected before use.

The data contained in this publication was correct at the time
of going to press but due to possible modifications made by
the Manufacturer for reasons of a technical or commercial nature or for adaptation to the legal requirements of the different countries, some changes may have occurred.
No part of this publication, including the pictures, may be reproduced in any form or by any means.

Publication edited by
Iveco Motors
Iveco SpA
PowerTrain
Mkt. Advertising & Promotion
Viale dell’Industria, 15/17
20010 Pregnana Milanese
Milano (Italy)
Print P2D32N003GB - 1st Ed. 02.2006

Produced by:

B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15/19
10156 Turin - Italy

NEF TIER 3 ENGINES

PRELIMINARY REMARKS
Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.

SYMBOLS - WARNINGS
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

Danger of serious damage for the assembly
Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may
sometimes cause the warranty to become null and void.

General danger
It includes the dangers of above described signals.

Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
NOTE

It indicates an additional explanation for a piece of information.

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NEF TIER 3 ENGINES

GENERAL WARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by IVECO Motors original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

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NEF TIER 3 ENGINES

GENERAL WARNINGS
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.

Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO Motors commercial and assistance
network is available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

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NEF TIER 3 ENGINES

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO Motors system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.

To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.

NOTE

Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.

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NEF TIER 3 ENGINES

Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
-

Electronic central units must be connected to system bonding when they are provided with a metallic shell.

Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.

Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

Figure 1

NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR
d. DISTANCE ! 0

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NEF TIER 3 ENGINES

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling
directives issued by IVECO Motors.
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.

It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT
INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power
1 kW
1 kW
1 metric HP
1 metric HP
1 HP
1 HP

=
=
=
=
=
=

1.36 metric HP
1.34 HP
0.736 kW
0.986 HP
0.746 kW
1.014 metric HP

Torque
1 Nm
1 kgm

=
=

0.1019 kgm
9.81 Nm

THE

Revolutions per time unit
1 rad/s
= 1 rpm x 0.1046
1 rpm
= 1 rad/s x 9.5602
Pressure
1 bar
1 kg/cm2
1 bar

=
=
=

1.02 kg/cm2
0.981 bar
105 Pa

Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm

10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2

1 bar.

Temperature
0° C = 32° F
1° C = (1 x 1.8 + 32) ° F

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F4HE engines

Part 1

G-Drive Application Engines

Part 2

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NEF TIER 3 ENGINES

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F4HE NEF ENGINES

Part 1
F4HE NEF ENGINES
Sezione
General specifications

Fuel

Duty - Industrial application

Overhaul and technical specifications

Tools

Safety prescriptions

Appendix

PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the NEF engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute
such operations.

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F4HE NEF ENGINES

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F4HE NEF ENGINES

SPECIAL REMARKS
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.

Example
∅1

Ø 1 = housing for connecting rod small end bush
α

Tighten to torque
Tighten to torque + angular value

∅ 2 Ø 2 = housing for connecting rod bearings

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F4HE NEF ENGINES

SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection

Intake

Refitting
Connection

Exhaust

Removal
Disassembly

Operation

Fitting in place
Assembly

Compression ratio

Tighten to torque

Tolerance
Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation
Adjustment

Angle
Angular value

Visual inspection
Fitting position check

Preload

Measurement
Value to find
Check

Number of revolutions

Equipment

Temperature

Surface for machining
Machine finish
Interference
Strained assembly
Thickness
Clearance
Lubrication
Damp
Grease
Sealant
Adhesive
Air bleeding

bar

Pressure
Oversized
Higher than….
Maximum, peak
Undersized
Less than….
Minimum
Selection
Classes
Oversizing
Temperature < 0 °C
Cold
Winter
Temperature > 0 °C
Hot
Summer

Replacement
Original spare parts

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F4HE NEF ENGINES

UPDATING
Section

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Description

Page

Date of revision

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F4HE NEF ENGINES

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F4AE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

SECTION 1
General specifications

Page

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CORRESPONDENCE BETWEEN TECHNICAL CODE
AND COMMERCIAL CODE . . . . . . . . . . . . .

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

- 4-cylinder engine version . . . . . . . . . . . . . . . . .

- 6-cylinder engine version . . . . . . . . . . . . . . . . .

OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .

- 4-cylinder engine version . . . . . . . . . . . . . . . . .

- 6-cylinder engine version . . . . . . . . . . . . . . . . .

AIR INDUCTION - BOOST DIAGRAM . . . . . . .

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION 1 - GENERAL SPECIFICATIONS

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F4AE NEF ENGINES

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SECTION 1 - GENERAL SPECIFICATIONS

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

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Technical Code

Commercial Code

F4HE9484A*J101
F4HE9684P*J101

N45 ENT
N67 ENT

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SECTION 1 - GENERAL SPECIFICATIONS

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F4AE NEF ENGINES

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F4AE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

LUBRICATION
Lubrication by forced circulation is achieved through oil rotary
expansion pump (1), placed in the front part of the basement,
driven by the straight-tooth gear splined to the shaft’s bar hold.

Lubrication involves the heat exchanger as well, the turboblower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in
the specific section.

From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.

4-cylinder engine version
Figure 1

(Demonstration)

Oil recover from the
turbo-blower

To the exchanger
and to the
turbo-blower

Routing of oil return by gravity to sump

108511

Routing of oil return by gravity to sump
Introduction of oil

LUBRICATION SYSTEM LAYOUT
4-cylinder engines

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SECTION 1 - GENERAL SPECIFICATIONS

F4AE NEF ENGINES

6-cylinder engine version
Even for the 6 cylinders version lubrication is obtained by
forced circulation and achieved through an oil rotary expansion pump similar to the 4 cylinders’ one.

Figure 2

Also in this case, the components such as the oil exchanger,
the turbo-blower and the eventual compressor are specifically
studied and made out to suit the equipment or the duty for
which the engine has been developed.

(Demonstration)

Oil recover from the
turbo-blower

To the
exchanger and
to the
turbo-blower

Routing of oil under pressure
108512

Routing of oil return by gravity to sump
Introduction of oil

LUBRICATION SYSTEM LAYOUT
6-cylinder engines
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F4AE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

OIL VAPOUR RECYCLING
Figure 3

70484

Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine.
The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and
condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).

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SECTION 1 - GENERAL SPECIFICATIONS

F4AE NEF ENGINES

COOLING SYSTEM
The engine cooling system, closed circuit forced circulation
type, generally incorporates the following components:
- Expansion tank; placement, shape and dimensions are
subject to change according to the engine’s equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.

- Viscous pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engine’s
development.
- Heat exchanger to cool the lubrication oil: even this
component is part of the engine’s specific equipment.
- Centrifugal water pump, placed in the front part of the
engine block.
- Thermostat regulating the circulation of the cooling liquid.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.

4-cylinder engine version
Figure 4

Expansion tank

(Demonstration)

Expansion tank

Heater
(optional)

Radiator

Water coming out from thermostat
Water recirculating in engine
Water coming into pump
74194

COOLING SYSTEM LAYOUT
4-cylinder engines
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F4AE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

6-cylinder engine version
The engine cooling system, closed circuit forced circulation
type, is of a similar design as the 4 cylinders engine.
It incorporates necessary components such as the radiator,
the heat exchanger, the expansion tank and some ancillary
components such as the heater or the compressor for the
compressed air.
Such components always vary according to the engine’s equipment and duty.

Figure 5

(Demonstration)
Expansion tank

Expansion
tank

Heater
(optional)

Radiator

Water coming out from thermostat
Water recirculating in engine
Water coming into pump
108513

COOLING SYSTEM LAYOUT
6-cylinder engines
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SECTION 1 - GENERAL SPECIFICATIONS

F4AE NEF ENGINES

AIR INDUCTION - BOOST DIAGRAM
Figure 6

4 Cylinders version

TURBOCHARGER

AIR FILTRE

EXHAUST

RADIATOR

6 Cylinders version

TURBOCHARGER

AIR FILTRE

EXHAUST

RADIATOR
74195

Description
The turbocharger is composed by the following main parts:
one turbine, one transforming valve to regulate the boost
feeding pressure , one main body and one compressor.
During engine working process, the exhaust emissions flow
through the body of the turbine, causing the turbine disk
wheel’s rotation.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air through the air filter.

The turbocharger is equipped with a transforming valve to
regulate the pressure , that is located on the exhaust collector
before the turbine and connected by piping to the induction
collector.
It’s funchon is to restrict the exhaust of the emissions , releasing
part of them directly to the exhaust tube when the boost
feeding pressure, over the compressor, reaches the
prescribed bar value.
The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.

The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.

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F4HE NEF ENGINES

SECTION 2 - FUEL

SECTION 2
Fuel

Page

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HIGH PRESSURE ELECTRONIC INJECTION
SYSTEM (COMMON RAIL) . . . . . . . . . . . . . .

EDC 7 OPERATION . . . . . . . . . . . . . . . . . . . . . .

WORKING PROCESS . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . .

MECHANICAL FEEDING PUMP . . . . . . . . . . . .

CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . .

RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOOST GAUGE VALVE . . . . . . . . . . . . . . . . . . .

ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . .

- Electro-injector . . . . . . . . . . . . . . . . . . . . . . . . .

PRESSURE LIMITER FOR FUEL RETURN . . . . . .

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HIGH PRESSURE ELECTRONIC INJECTION
SYSTEM (COMMON RAIL)
Introduction
Extremely high injection pressures are necessary in order to
reduce PARTICULATE emissions.
The common rail system makes it possible to inject fuel at
pressures of up to 1450 - 1600 bar, while the injection precision obtained by electronic control of the system serves to
optimise operation of the engine while limiting emissions and
fuel consumption.

SECTION 2 - FUEL

For engines more powerful than 152 kW, the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600
bar, whilst for engines less powerful than 152 kW, DSLA
nozzles are fitted which work a pressures up to 1450 bar.
Description of system
The injection system is composed of an electrical part and a
hydraulic part.
Electrical system
The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

Figure 1

107851

1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engine’s cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engine’s oil temperature and pressure 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and air pressure sensor 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor 10. Pressure gauge cabling - 11. EDC 7 gearbox.

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SECTION 2 - FUEL

EDC 7 OPERATION
Engine preheating element control
Pre-post heating is activated when even just one of the water,
air or fuel temperature sensors detects a temperature ≤ 5 °C.
Phase recognition
By means of signals transmitted by the camshaft and
crankshaft sensors, the cylinder into which fuel must be
injected is determined at the time of starting.
Injection control
On the basis of information transmitted by the sensors, the
control unit administrates the pressure regulator and
modifies the pre-injection and main injection mode.
On F4 engines pre-injection is activated at all engine speeds.
Injection pressure closed loop control
On the basis of the engine load, as determined by processing
of data transmitted by the various sensors, the control unit
administrates the regulator to maintain injection pressure at
constantly optimal values.
Pilot and main injection advance control
On the basis of signals transmitted by the various sensors, the
control unit determines the optimum injection point on the
basis of internal mapping.
Idle speed control
The control unit processes signals transmitted by the various
sensors and adjusts the quantity of fuel injected.
It also controls the pressure regulator and modulates
injection duration of the electro-injectors.
Within specific limits, the control unit also monitors battery
voltage.
Overheating protection
If the water temperature reaches 110 °C, the control unit
reduces engine performance.
When the temperature returns below 100 °C, the engine
resumes normal operation, (in some applications, the over
boosting temperature is the reference temperature).
Maximum engine speed limiting
Depending on the application, the control unit memory can
contain appropriate engine speed limits. When the engine
speed surpasses these limits the control unit activates power
reduction strategies by controlling energization time of the
electro-injectors. In some applications the maximum limiting
response consists in stopping the engine.
Cut Off
Fuel cut-off in release phases is managed by the control unit
with the following logical interventions:

F4HE NEF ENGINES

Smoke control under acceleration
With intense load demands, in accordance with signals
received from the air inlet meter and the engine speed
sensor, the control unit manages the pressure regulator and
modulates the activation time of the electro-injectors to
prevent the emission of smoke from the exhaust.
After Run
After the engine is stopped, the control unit microprocessor
saves various parameters to the EEPROM memory, including
the faults log so that they will be available the next time the
engine is started.
Control of working speed in normal operating
conditions
Each time work load varies, the control unit adjusts torque
so as to maintain the engine in maximum power conditions.
If the load causes a reduction in power, the control unit
increases torque i.e. it increases the amount of fuel injected
in order to restore the engine to maximum power.
Recovery strategies
Recovery strategies are characterized by certain differences
as application varies, i.e.
- Control of fuel leaks
In the case of fuel supply problems, the system controls
the engine with suitable constant power values obtained
with a low number of revs and high torque values in
order to inject the maximum quantity of fuel.
- Control of pressure in the rail
When the pressure in the rail exceeds safety values, the
engine reduces power.
- Synchronism problems
In the case of synchronism problems, faulty rev sensors,
the system controls the engine by increasing the number
of revs in order to improve interpretation of the signals.
- Power restrictions as operating temperature increases
When the temperature of the supercharging air rises
above 88 °C, power reduction is started; when a
temperature of 120 °C is reached, performance is
further reduced and is comparable to that of the same
engine if it were aspirated.
- Reduction of power as reference temperature varies
In normal operating conditions, the system knows the
supercharging air, oil and water temperatures.
If the temperature of the engine water is not available,
the system takes the temperature of the oil as reference
and when this reaches the threshold of 103 °C, it starts
to reduce the power available. On reaching 113 °C,
power is reduced to 50%.

- disactivation of the electro-injectors;
- reactivation of electro-injectors immediately prior to
arrival at idle speed;
- control of fuel pressure regulator.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 2 - FUEL

WORKING PROCESS
Figure 2

High Pressure
Low Pressure
Fuel outlet
108607

1. Electro-injector - 2. Common Rail - 3. Pressure limiting device for fuel return 4. Common rail pressure relief valve - 5. Pre-filter mounted on the frame - 6. High-pressure pump 7. Mechanical vane pump - 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

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Base - February 2006

SECTION 2 - FUEL

FUEL SYSTEM LAYOUT
This fuel system is a Common Rail injection with CP3 high
pressure pump and this layout is for 4 cylinder version.
(The 6 cylinder version is similar design as the 4 cylinder engine).
The pressure regulator, placed upstream of the high-pressure
pump, adjusts the fuel flow that is necessary on the low-pressure system. Afterwards, the high-pressure pump takes care
of supplying the rail properly. This arrangement, by pressurising the necessary fuel only, improves the energetic efficiency
and limits fuel heating in the system.
Function of the pressure relief valve (2), assembled on the
high-pressure pump, is keeping the pressure, at the pressure
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream.

F4HE NEF ENGINES

The pressure relief valve (2) intervention brings about a fuel
flow increase in the high-pressure pump cooling circuit,
through inlet and drain piping (16) from piping (8).
The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow
from injectors at a pressure of 1.3 to 2 bars.
Two by-pass valves are placed in parallel with the mechanical
supply pump.
The by-pass valve (18) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value.
The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).

Figure 3

EXHAUST
SUCTION
SUPPLY SYSTEM FOR HIGH PRESSURE PUMP
(LOW PRESSURE)
HIGH PRESSURE

108608

1. High-pressure pump. — 2. Pressure relief valve on high-pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel
return from injectors, 1.3 to 2 bars. — 4. Rail overpressure valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. —
8. Return piping. — 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. —
12. Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High-pressure pump cooling
piping. — 17. By-pass valve. — 18. By-pass valve.

Base - February 2006

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F4HE NEF ENGINES

SECTION 2 - FUEL

MECHANICAL FEEDING PUMP

Jettison condition

Gear pump, placed on rear part of the high pressure pump,
whose function is to feed the high pressure pump. It is driven
by the high pressure pump’s shaft.

Figure 6

Ordinary working condition
Figure 4

72594

72592

A- Fuel entry flowing from the tank. B- Fuel exhaust to filter,
I - 2 By-pass valves in close position.

The dump by-pass valve (2) is activated in case, when the
engine is off, it is necessary to fill the feeding system through
the priming pump. In this condition the by pass valve (I) keeps
closed while the dump by-pass valve (2) opens up due to the
pressure effect on the entry unit so the fuel flows to the
exhaust unit B.

Overpressure condition in Exhaust unit

The mechanical feeding pump cannot be replaced
separately, therefore it must not be disassembled
from the high pressure pump.

Figure 5

72593

The by-pass valve (I) is activated in case of overpressure on
B Exhaust unit. The actual pressure, overcoming the
resistance of the valve’s spring (I), connects the exhaust with
the entry through the gallery (2).

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Base - February 2006

SECTION 2 - FUEL

F4HE NEF ENGINES

CP3 HIGH PRESSURE PUMP
Pump provided with 3 radial pumping elements driven by the
timing system gear, no need of timing. The mechanical
feeding pump driven by the high pressure pump’s shaft is
assembled to the rear side of the high pressure pump.

The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.

Figure 7

72595

1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear 5. Connector to fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry
flowing from engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter 9. Mechanical feeding pump.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 2 - FUEL

High pressure pump-inside structure
Figure 8

Sec. B-B

Sec. C-C

70498

1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.

Every pumping unit is composed of:
- a piston (5) actuated by a three-lobe element (2) floating
on the pump shaft (6). The element (2), being floating on
a misaligned part of the shaft (6), when the shaft rotates,
does not rotate therewith but is only translated in a
circular movement along a wider radius, with the
resulting alternate actuation of the three pumping
elements;

Print P2D32N003GB

- cap intake valve (3);
- ball delivery valve (4).

Base - February 2006

SECTION 2 - FUEL

F4HE NEF ENGINES

Working principle
Figure 9

Sec. B-B

Sec. D-D

72597

The pumping element (3) is orientated towards the pump’s
camshaft (4). During the intake phase, the pumping element
is fed through the feeding line (5). The quantity of fuel to flow
to the pumping element is determined by the pressure
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
Base - February 2006

During compression phase of the pumping element, the fuel
achieves the level of pressure determining the opening of the
by-pass valve to common rail (2), feeding it through the
exhaust unit (I).

Print P2D32N00GB

F4HE NEF ENGINES

Figure 10

Sec. C - C

SECTION 2 - FUEL

Figure 11

72598

72601

Sec. A - A

1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve.
— 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying
fuel ducts.

1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
exhaust flowing from pump with connector to high
pressure pipe for common rail.

Figure 10 shows the fuel runs at low pressure inside the
pump; the following elements are clearly visible: the main
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).

Figure 11 shows the fuel flow under high pressure running
through the exhaust galleries of the pumping elements.

The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.

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Base - February 2006

SECTION 2 - FUEL

Operation
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on
the pumping elements (about 2 bars).

F4HE NEF ENGINES

RAIL
Figure 12

The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure
circuit.
The pumping element compresses the fuel till the top dead
center (delivery stroke) is reached. Afterwards, the pressure
decreases till the exhaust valve is closed.
The pumping element piston goes back towards the bottom
dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and
the cycle is repeated.
The delivery valves must always be free in their movements,
free from impurities and oxidation.

108609

1. Rail — 2. Fuel inlet from high-pressure pump —
3. Overpressure valve - 4. Pressure sensor.
The rail volume is comparatively small to allow a quick
pressurisation at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise system spikes
and the use of plenum chambers caused by injectors
openings and closings and by the high-pressure pump
operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
A fuel pressure sensor (4) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
value is checked and, if necessary, corrected.

The rail delivery pressure is modulated between 250 and
1600 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection — reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 2 - FUEL

BOOST GAUGE VALVE
The boost valve (1750 bars) is assembled to the rail with the purpose to protect the system’s components in case of excessive
increase of pressure within the high pressure system. Pressure limiter.
The valve can be single-stage (as the one showed in the picture) or double-stage with double working limit (1750 bars and 800
bars).
In the second case, when the pressure within the high pressure system reaches 1750 bars, the valve is activated as a single-stage
one to exhaust the fuel and consequently reduce the pressure until reaching safety parameters. Then it provides mechanically
gauging the pressure into rail to aprx. 800 bars. This way the valve enables working of the engine for extended timing at limited
performances, avoiding the fuel’s overheating and preserving the exhaust galleries.
If the above mentioned valve is activated, the engine control module excludes by isolation the pressure gauge and records the
errore code 8.4.
The pump will flow the maximum delivery to the rail.

Figure 13

70500
70502

1. Body — 2. Small piston — 3. Stop — 4. Spring — 5. Direct tank discharge — 6. Seat on rail.
A

Normally, the tapered piston end keeps closed the
discharge towards the tank.

Print P2D32N003GB

If the 1750 bar fuel pressure is exceeded in rail, the small
piston is displaced and the excess pressure is discharged
into the tank.

Base - February 2006

SECTION 2 - FUEL

F4HE NEF ENGINES

ELECTRO-INJECTOR

Injection start

The injector is similar as construction to the traditional ones,
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator — spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.

Figure 15

Injector in rest position
Figure 14

70506

When coil (4) is energised, it makes shutter (6) move
upwards. The control volume (9) fuel flows towards flow
duct (12) making a pressure drop occur in control volume
(9). Simultaneously the fuel pressure into pressure chamber
(8) makes plunger (2) lift, with following fuel injection into the
cylinder.

Injection end
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.

70505

The injector cannot be overhauled and therefore it
must not be disassembled.

1. Pressure rod — 2. Plunger — 3. Nozzle — 4. Coil — 5. Pilot
valve — 6. Ball shutter — 7. Control area — 8. Pressure
chamber — 9. Control volume — 10. Control duct —
11. Supply duct — 12. Control fuel outlet — 13. Electric
connection — 14. Spring — 15. High-pressure fuel inlet.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 2 - FUEL

Electro-injector
The injectors fitted on the NEF TIER 3 engines are the CRIN 2 - BOSCH versions. Depending on the power developed by the
engine (more than or less than 152 kW) different nozzles (1) are fitted (DLLA or DSLA).

Jet

Powers

Pressures

DLLA

Up to 152 kW

250 ÷ 1600 bar

DSLA

Lower to 152 kW

250 ÷ 1450 bar

Figure 16

108610

1. Jet.

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Base - February 2006

SECTION 2 - FUEL

F4HE NEF ENGINES

PRESSURE LIMITER FOR FUEL RETURN
It is housed on the rear of the cylinder head, and adjusts the
pressure of fuel returning from injectors at a pressure 1.3 and
2 bars. By guaranteeing this pressure to the return fuel, the
fuel vapours formation inside injectors is avoided, optimising
fuel spraying and combustion.

Figure 17

70507

To tank — B From injectors

Base - February 2006

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

SECTION 3
Duty-industrial application

Page

Print P2D32N003GB

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

- Section pictures of complete engine common rail version . . . . . . . . . . . . . . . . . . . .

- Clearance data - 4 cyl. . . . . . . . . . . . . . . . . . . .

- Clearance data - 6 cyl. . . . . . . . . . . . . . . . . . . .

PART ONE MECHANICAL COMPONENTS . . . . . . . . .

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . .

- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Engine setting operations for the assembly
on turning stand . . . . . . . . . . . . . . . . . . . . . . .

- Disassembly of application components . . . . .

- Assembly of application components . . . . . . .

- Completion of the engine . . . . . . . . . . . . . . . .

- Checks and inspections . . . . . . . . . . . . . . . . . .

PART TWO ELECTRICAL EQUIPMENT . . . . . . . . . . . . .

LOCATION OF THE MAIN ELECTRICAL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .

- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Cable on engine . . . . . . . . . . . . . . . . . . . . . . .

- Injectors connector (A) . . . . . . . . . . . . . . . . . .

- Sensors connector (C) . . . . . . . . . . . . . . . . . .

- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . .

- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . .

- Supercharging air pressure - temperature sensor

- Engine oil temperature-pressure sensor . . . . .

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Page

Page
- Fuel temperature and pressure sensor . . . . . . .

MAINTENANCE PLANNING . . . . . . . . . . . . . .

- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . .

- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Pre-post heating resistance and contactor . . . .

- Regular maintenance and inspection planning .

- Coolant temperature sensor . . . . . . . . . . . . . .

- Checks not included in maintenance
planning-daily checks . . . . . . . . . . . . . . . . . . . .

- Fuel temperature sensor . . . . . . . . . . . . . . . . .

43
MAINTENANCE PROCEDURES . . . . . . . . . . . .

- High pressure pump - pressure regulator . . . .

44
- Checks and inspections . . . . . . . . . . . . . . . . . .

PART THREE - TESTS - TROUBLESHOOTING

45
- Engine oil level check . . . . . . . . . . . . . . . .

TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47
- Combustion system inspection . . . . . . . .

CHECKING THE FUEL SYSTEM . . . . . . . . . . . . .

47
- Cooling system inspection . . . . . . . . . . . .

DESCRIPTION OF TESTS AND CHECKS
THAT CAN BE PERFORMED . . . . . . . . . . . .

- Lubricating system inspection . . . . . . . . .

- Necessary equipment . . . . . . . . . . . . . . . . . . .

- Inspection of water presence within
fuel filter or pre-filter . . . . . . . . . . . . . . . .

- Low pressure supply test . . . . . . . . . . . . . . . . .

- Inspection/replacement of blow-by filter .

- Low-Pressure Pump . . . . . . . . . . . . . . . . . . . . .

- Inspection of drive belt tensioning . . . . . .

- Test on the pressure relief valve on the rail . . .

- Inspection and setting of tappet clearance

- Oil motor and filter replacement . . . . . . .

- Fuel filter replacement . . . . . . . . . . . . . . .

- Alternator belt replacement . . . . . . . . . . .

- Test on fuel backflow from the return . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

PART FOUR MAINTENANCE PLANNING . . . . . . . . . . .

Base - February 2006

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

GENERAL SPECIFICATIONS
Section pictures of complete engine - common rail version
Figure 1

108540

The NEF F4HE engines are characterised by four-stroke diesel
cycles supercharged with 4 or 6 cylinders with 4 valves per
cylinder.
They have high pressure injection fuelling (common rail) and
are entirely electronically driven in order to optimise the
working process in accordance to the operation, limiting as
much as possible the pollution emissions and consumption.

The section herein described is composed or four sections:
- Section of mechanical overhaul prescribed in accordance
to the engine’s specific duty, illustrating all necessary
operation to remove and assembly the external
components of the engine, including cylinder heads,
gearbox of the timing system and of the front part cover;
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.

Data, features and performances are valid only if the
setter fully complies with all the installation
prescriptions provided by Iveco Motors.
Furthermore, the users assembled by the setter shall
always be in conformance to couple, power and
number of turns based on which the engine has been
designed.

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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Clearance data - 4 cyl.

F4HE9484A

Type

Compression ratio
Max. output

Max. torque

16.5 : 1
kW
(HP)

104
141

rpm
Nm
(kgm)

2200
560
56

rpm

1400

Loadless engine
idling

rpm

Loadless engine
peak

rpm

Bore x stroke

104 x 132

Displacement

4485

TURBOCHARGING

with intercooler

Turbocharger type

bar

HOLSET HX27W

Forced by gear pump, relief valve single action
oil filter

LUBRICATION

Oil pressure (warm engine)
- idling

bar

0.7

- peak rpm

bar

4.0
By liquid

COOLING

Through belt
Water pump control
Thermostat
- start of opening
FILLING

82.2
°C

engine sump

liters

5.3

engine sump + filter

liters

6.3

15W40 ACEA E3

Data, features and performances are valid only if the technician fully complies with all the installation requirements provided
by Iveco Motors.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Clearance data - 6 cyl.

F4HE9684P

Type

Compression ratio
Max. output

Max. torque

17.5 : 1
kW
(HP)

175
234

rpm
Nm
(kgm)

2300
1020
102

rpm

1500

Loadless engine
idling

rpm

Loadless engine
peak rpm

rpm

Bore x stroke

104 x 132

Displacement

6728

TURBOCHARGING

with intercooler

Turbocharger type

HOLSET HX35W

LUBRICATION
Oil pressure (warm engine)
bar

- idling

bar

- peak rpm

bar

COOLING

Forced by gear pump, relief valve single action
oil filter

2
4
By liquid
Through belt

Water pump control
Thermostat
- start of opening

81 ± 2
ºC

FILLING

15W40 ACEA E3

engine sump

liters

engine sump + filter

liters

15 + 1

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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Base - February 2006

F4HE NEF ENGINES

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

DIAGNOSI

PART ONE - MECHANICAL COMPONENTS

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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Base - February 2006

F4HE NEF ENGINES

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

ENGINE OVERHAUL
Preface

Figure 3

With regard to the engine disassembly operations
from the machine, please apply for Information
consulting the specific manual.
All operations of Engine disassembly operations as
well as overhaul operations must be executed by
qualified technicians provided with the specific
tooling and equipment required.
70126

The following information relates to the engine overhaul
operations only for what concerns the different components
customising the engine, according to its specific duties.
In section ”General overhaul”, all the operations of engine
block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the
part hereby described.

Press clamp (1), as shown in Figure B, to disconnect
the low pressure fuel pipes (3 — 4 — 5, Figure 2) from
the corresponding connections.
After disconnecting the pipe, reset the clamp (1) in
locking position (Figure A) to prevent distortions.

Engine setting operations for the assembly on
turning stand
Disconnect the high pressure fuel pipeline (10, Figure 2) from
the rail diffuser and from the high pressure pump (8) and
disassemble it from the engine block removing the fixing
clamps.

Figure 2

Disconnect the pipeline (7) feeding the mechanic pump that
is combined to the high pressure pump through the
exchanger of the engine control module.

Because of the high pressure in the pipelines running
from the high pressure pump to the rail and from this
last one to the electro-injectors, it is absolutely
required NOT to:
- disconnect the pipelines when the engine is
working;

108541

- re-use the disassembled pipelines.

In order to apply the brackets 99341009 to the engine block
to fix it on to the stand for the overhaul, it is necessary to
perform the following operations on the left hand side of the
engine:
- Using the tool 99360073 disassembly the fuel filter (6)
and remove it from the support (1);
- Disconnect the electrical connection (2) from the
support (1) and the heater’s one (placed on the filter
support as well);
- Disconnect the fuel low pressure pipelines (3-4-5) from
the support (1);
- Disconnect pipeline (9) from the support (1);
- Remove the sustaining support bracket (1) from the
block.
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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 5

On the right hand side of the engine:

Figure 4

2
74166

Disconnect the oil feed pipeline unlocking the three screws
M12x25. Remove the O-ring from the pipe.
Remove the starter (2) from the flywheel housing (1).
108542

Remove the screws and remove the oil pipe (1) from the
turbocharger pipe (2) and from the engine block.

Apply brackets 99361037 to engine block and use them to
secure the engine to the revolving stand 99322205. Remove
sump cap and drain out oil.
Remove the fan from the output shaft pulley.

Disassembly of application components
Figure 6

2
7
8

10
5

74168

1. Connections for Electro-injectors - 2. Engine cooling liquid temperature’s sensor - 2. Cable of the fuel pressure sensor 4. Sensor of engine’s oil temperature and pressure - 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature - air
pressure sensor - 8. Timing system sensor - 9. Cable of fuel heater and fuel temperature’s sensor - 10. Cable of pressure
regulating gauge - 11. EDC 7 gearbox.
Base - February 2006

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Disconnect the engine’s cable from the connectors (1.
Figure 6) wiring harness to
Electro-injectors (6); (7) air pressure/temperature sensor; (3)
fuel pressure sensor;
(11) engine control module; (10) high pressure pump sensor;
(8) timing system sensor; (2) Thermostat sensor of engine
cooling liquid’s temperature; (5) sensor of engine’s
revolutions.

Figure 8

6
2

5
4

Figure 7

74170

Disconnect the pipeline (2) from the fuel recover
pressure-limiter, working on the connections as described in
Figure 3.
Unscrew the nut and loosen the clamp tightening the oil
vapour pipe.
Remove the pipe (6).
Loosen the screws (3) and disassemble the blow-by filter (4).
Remove on the nuts and tappet cover.

108543

Figure 9

Disconnect from the rail (2): the fuel pipe (7) according to
procedures described in Figure 3. Disconnect fuel pipes (5)
from rail (2) and injector manifolds (6).

When releasing pipe (6) connections (4) to rail (2),
use the proper wrench to avoid rotation of flow
limiters (3).

Remove the screws (1) and disconnect the rail (2).

74744

Remove nuts (7) and disconnect the electrical cables from
injectors (8).
Remove screws (1) and disconnect injector wiring support
(2) including the gasket.
Remove screws (5), disconnect air pressure/temperature
sensor (6).
Remove nuts (3) and remove fuel manifolds (4).

!
Print P2D32N003GB

Disassembled fuel manifolds (4) must not be used
again, replace with new ones during reassembly.

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 10

Figure 12

70132

Loosen tappet adjustment fastening nuts (1) and unscrew the
adjusters.
Remove the screws (2), remove the rocker assembly (3),
consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves.
Remove rods (8).
Figure 11

108545

Release on the drive belt tensioner (1) and extract the belt
(2) from the belt pulleys from the water pump ones and from
the belt rebound pulleys;
Disassemble the belt tensioner;
Loosen the screws fixing the alternator to the support and
disassemble it.

Figure 13

70133

Remove injector fastening screws. Use tool 99342101 (1) to
remove injectors (2) from the cylinder head.

108546

Remove the screw (4) holding the fixing clamp of the
turbocharger’s lubricating oil pipeline.
Disconnect the oil pipeline (3) from the supports of the heat
exchanger / oil filter and from the pipe fitting (5) to the
turbine.
Remove the fixing nuts and disassemble the turbocharger (1)
from the exhaust collector (2).
Loosen the screws and disassemble the exhaust collector (2)
from the cylinder head.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 17

Figure 14

108547

On the opposite side, loosen the fixing screws of the inlet
manifold (1) and disassemble the joint to the air heater (2)
for the cold start.

108580

Remove the screws (4) and disconnect
temperature/pressure sensor (3).

the oil

Remove the screws (1) and then remove: heat exchanger/oil
filter support (2), intermediate plate (6) and relevant gaskets.
Remove the oil level sensor (5).

Figure 15
Figure 18

74174

74779

Hook brackets (1) with suitable lifting chains and remove
cylinder head (2) from block using hoist.

Remove the screws (1) and disconnect the ECU (2) including
the heat exchanger.
Figure 19

Figure 16

108549

Remove the screws (2) and disconnect the alternator
support (3).
Use tool 99360076 to remove the oil filter (1).
Print P2D32N003GB

74176

Unloose the screws (3) and remove the cap (1). Keep the
gasket (4), the power take-off (2) and the second gasket (4).
Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 23

Figure 20

108549

70145

Remove the nut (1) and disconnect the timing sensor (2).
Remove the nuts (3) and disconnect the high pressure pump
(4) including the feed pump (5).

Remove the screws (1) and disconnect the water pump (2).
Remove the screw (3) and the roller (4).
Remove the screw (3) and disconnect the engine speed
sensor (4).
Figure 24

Figure 21

00900t

70146

Fit tool 99360339 (2) to the flywheel housing (1) to stop
flywheel (3) rotation.
Loosen the screws (4).

Remove the ring sealing the engine’s driving shaft from the
front cover. Use the tool 99340055 (4) to operate on the
front bar hold of the driving shaft. Through the steering holes
of the tool, perforate the inside holding ring (1) with a straight
way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool
to the ring tightening the 6 screws provided with the
equipment. Then proceed removing the ring (2) by tightening
the screw (3).

Figure 22
Figure 25

108548

Remove the screws (3) and disassemble the damping
flywheel (2) and the pulley (1).

00904t

Using the specific tie rod (3) of the tool 99363204 and the
ancillary lever (4), remove the external holding ring (2) from
the front cover (1).
Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 26

Figure 29

70152

70149

Remove the screws (1) and take out the front cover (2).

Take note of screw (1) assembling positions since
they have different lengths.

Tighten two screws of medium length into the holes (4) to
sling the flywheel with the hoist.
Throughout the two guide pins (2) previously screw into the
driving shaft holes (3) withdraw the engine flywheel (1) after
slinging it with the hoist.
Figure 30

Figure 27

Remove the screws (1) and disconnect the oil pump (2).

00903t

Figure 28

Remove the holding ring of the flywheel cover box using the
tool 99340056 (3) to operate on the driving shaft’s back bar
hold (5).
Through the steering holes of the tool, perforate the inside
holding ring with a straight way drill (diam. 3,5mm) for the
depth of 5mm.
Fix the tool 99340056 (3) to the ring tightening the 6 screws
provided with the equipment.(4)
Then proceed removing the ring (1) by tightening the screw
(2).
Using a specific tie rod of the tool 99363204 and an ancillary
lever, remove the external holding ring (2) from the front
cover.

70151

Remove two opposite screws (1) from the area where the
withdrawal pins will be introduced (2, Figure 29).
Loosen the remaining flywheel fixing screws (3) from the
driving shaft (4).
Remove the flywheel locking tool 99360351.
Print P2D32N003GB

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 31

Figure 33

70153

Remove the screws (2) and take out the rear cover (1).

Take note of screw (2) assembling positions since
they have different sizes.

86516

Remove the screws (1 and 4) and disassemble the oil suction
tube (5). Remove the screws (2) and disassemble the
stiffening plate (3).

Figure 32

For F4HE0684 engines the stiffening plate (4) has a
single element.

Figure 34

74775

Overturn the engine.
Remove the screws (2), disassemble the plate (3) and
disconnect the oil sump (1).

The shape and the dimensions of the oil pan and of
the suction tube may vary according to the duty of
the engine. The relevant pictures of the instructions
are therefore providing an outline of the
intervention to be executed.

70156

Remove the screws (1) and remove the gear (3) from the
camshaft (2).
Figure 35

However the procedures described are still
applicable.

70157

Remove the screws (2) and disconnect the timing gear case
(1).

!
Base - February 2006

Take note of screw (2) assembling positions since
they have different sizes.

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Assembly of application components

Figure 37

Figure 36

70210
70209

LOCTITE 5205 SEALANT APPLICATION AREAS
Clean accurately the timing gear case (1) and the engine
block.

Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a bead
of few mm diameter.
It shall be uniform (no clots), without air bubbles, thin
areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 — 20 minutes).

DIAGRAM FOR TIGHTENING THE REAR TIMING
GEAR CASE FASTENING SCREWS
Refit the case (1) to the engine block.
Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in
the sequence shown in the figure:
Screws M12
65 to 89 Nm
Screws M8
20 to 28 Nm
Screws M10
42 to 52 Nm

Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.

Figure 38

70211

Use a felt pen to mark the driving gear (1) tooth fitted on the
output shaft (2) having the mark (→) for timing on the side
surface.

!
Print P2D32N003GB

Fasten screwing of the two pins to facilitate the
operation of engine driving shaft rotation.

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 39

Figure 42
108577

Rotate the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding.
Figure 40

Not available
On engines
F4AE0684H-E
F4HE0684E-F-J
70215

SEQUENCE FOR TIGHTENING THE FLYWHEEL
HOUSING FASTENING SCREWS

70213

Tighten the screws (1) fastening gear (2) to camshaft (3) to
the specified torque.

Refit the housing (1) to the engine block and screw the
fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
shown in the figure:
Screws M12
75 to 95 Nm
Screws M10
44 to 53 Nm

Figure 41

Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.

70214

LOCTITE 5205 SEALANT APPLICATION AREAS
Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 43

Figure 45

70152

0901t

Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
hoister.

Apply tool 99346252 part (6) to the rear output shaft tang
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).

Figure 46

Figure 44

Apply tool 99360339 (2) to the flywheel housing to stop
engine flywheel (3) rotation. Tighten the screws (1) fastening
the engine flywheel (3) to the output shaft.
Figure 47
α
70217

Where the engine is coupled to a mechanical clutch,
verify that the flywheel nominal thickness of 49,6 ±
0,13 mm.

Check ring gear teeth (2), if breakage or excessive wear is
found remove the ring gear from the engine flywheel (1,
Figure 43) using a suitable hammer and fit the new one,
previously heated to 150°C for 15 to 20 minutes. Chamfering
on ring gear inside diameter shall be facing the engine
flywheel.

Print P2D32N003GB

70219

Tighten engine flywheel (2) fastening screws (1) in two
stages:
- 1st stage, tightening to 30 ± 4 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 60 ± 5° angle.

Tightening to angle is performed using tool
99395216.
Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.
Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 48

Figure 51

70223

70220

Fit the oil pump (1).
Tighten the fastening screws (2) to the specified torque.

Remove the sealing ring (2) from the front cover (1), clean
accurately the coupling surfaces and smear them with
LOCTITE 5205.
Figure 52

Figure 49

70224
70221

Clean accurately the front cover (2) surface and refit it.
Tighten the screws (1) to the specified torque.

Apply a new sealing ring (2) to the water pump (1).
Figure 53
Figure 50

00902t
70222

Fit the water pump (1).
Tighten the screws (2) to the specified torque.

Base - February 2006

Apply tool 99346252 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Position part (2) on part (4), screw nut (3) until completing
sealing ring (7) fitting into front cover (1).

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 54

Figure 57

108548

108553

Fit the plate (1), the oil pick up tube (2) and tighten the
fastening screws (3) to the specified torque.

Assemble the pulley (1) and the damping flywheel (2) to the
driving shaft.
Tighten the fixing screws (3) and clamp them to the couple
68 ± 7 Nm.

Figure 55

Figure 58

70230

Fit a new sealing ring on the speed sensor (3).

Set the gasket (1) on the oil sump (2).

The pictures of the instructions relating to the oil pan
and to thesuction rose may not reflect the actual shape
and dimensions of your engine equipment. However
the procedures described are still applicable.

Fit the speed sensor (3) on the front cover (1) and tighten
the screw (2) to the specified torque.
Figure 59

Figure 56

108576
74775

Fit the oil sump (1) and apply the plate (3) to it.
Tighten the screws (2) to the specified torque.

Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.

Print P2D32N003GB

Fit on the engine block: a new gasket (1), the heat exchanger
(2) a new gasket (3) and the oil filter support (4).
Tighten the screws (5) to the specified torque.

Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.
Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 60

Figure 62

108578

108550

Refit the alternator (1).
Lubricate the sealing ring (2) with engine oil and set it on the
oil filter (3).
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3) by ¾
turn.

Tighten the screw (2) to the specified torque.
Figure 63

Apply a new sealing ring on the oil temperature/pressure
sensor (4) and fit it on the support (1).
Tighten the screws (5) to the specified torque.
Fit a new sealing ring (6) in the engine block seat.

Figure 61
108552

Refit the automatic belt tensioner (2).
Tighten the screw (3) to the specified torque using a wrench,
turn the automatic belt tensioner (2) to fit the belt (1) on
pulleys and guide rollers.
Figure 64

70234

Position the alternator support (1) so that pins (3 and 4) are
set against the engine block.
Tighten the screws (2) to the specified torque.

70145

Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.

Base - February 2006

Refit the high pressure pump (6) including the feed pump (5)
and tighten the nuts (3) to the specified torque. Fit the
support (4) with a new sealing ring, the timing sensor (2) with
a new sealing ring and tighten the relevant fastening nut (1)
to the specified torque.

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 65

Figure 68

2
74176

Insert the power take-off (2) equipped with the gasket (4),
the cover (I) and its gasket (4).
Tighten the screws (3) to the prescribed matching couple.

70336

Assemble cylinder head (1), tighten the screws (2) in three
following steps, following order and mode shown in the
figure below.

Figure 66

The angle tightening is carried out through tool
99395216 (3).

Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.

!
2

Figure 69
74174

Assemble the electronic gearbox (2) equipped with the
exchanger to the engine, fixing it with the screws (1).
In case the rubber buffers are cracked or excessively
deformed, provide replacing them.

Figure 67

6-cylinder engine
70476

Tightening order layout for cylinder head fastening screws:
- 1st step pre-tightening with dynamometric wrench:
• Screw 12x1.75x130 ( ) 35 ± 5 Nm
• Screw 12x1.75 x 150 ( ) 55 ± 5 Nm
- 2nd step tightening with a 90 ± 5° angle
- 3rd step tightening with a 90 ± 5° angle
A = Front side

74779

Direct the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding.
Print P2D32N003GB

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 70

Figure 72

4-cylinder engine

A
70337

Cylinder head fastening screws tightening sequence:
- 1st stage pre-tightening, with a torque wrench::
• Screw 12x1.75x130 ( ) 35 ± 5 Nm
• Screw12x1.75 x 150 ( ) 55 ± 5 Nm
A = Lato anteriore

70339

Fit injectors (1) on the cylinder head seats, directed so that
the fuel inlet hole (2) is facing the fuel manifold seat (3) side.

- 2nd stage tightening with angle 90 ± 5°
- 3rd stage tightening with angle 90 ± 5°

Figure 73

Figure 71

70133
70338

Use tool 99342101 (1) to fit the injector (2) into its seat.
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).

Base - February 2006

Screw injector fastening screws without tightening them.

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 74

Figure 76

70343

91572

Fit a new sealing ring (3) lubricated with petroleum jelly on
the fuel manifold (2) and fit it into the cylinder head seat so
that the positioning ball (5) is coinciding with the relevant
housing (4).

ROCKER ASSEMBLY COMPONENTS:
1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
Figure 77

Disassembled fuel manifolds (2) must not be used
again. Replace with new items.
The fuel manifolds (2) for F4HE0684 engines have
2 positioning spheres.

Screw the fastening nuts (2, Figure 75) without locking them.

During this operation, the injector (1) shall be
moved so that the manifold (2, Figure 72) is properly
inserted into the fuel inlet hole (2, Figure 74).
SHAFT-ROCKER MAIN DATA
Check that shaft/rocker coupling surfaces are not showing
excessive wear or damages.

Figure 75

Figure 78

32655
70342

Use the torque wrench to tighten gradually and alternately
the injector fastening screws (1) to 8.5 ± 0.8 Nm torque.
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm
torque.

Rocker control rods shall not be distorted; the ball seats in
touch with the rocker adjusting screw and with tappets
(arrows) shall not show seizing or wear; otherwise replace
them. Intake and exhaust valve control rods are identical and
are therefore interchangeable.

Carry out the assembly of the equalisers’ unit , after previous
check of the components.
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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Figure 79

Figure 81

70520
70345

Fit the rods (2).
Position jumpers (1) on valves with marks (→) facing the
exhaust manifold.

Adjust clearance between rockers and valves using setscrew
wrench (1), box wrench (3) and feeler gauge (2).
Clearance shall be as follows:
- intake valves 0.25 ± 0.05 mm
- exhaust valves 0.50 ± 0.05 mm.

Figure 80

On TIER 3 engines, due to the additional lobe for the
INTERNAL E.G.R., it is not possible to use the valve
clearance adjustment procedure that requires
adjusting the clearance of all the valves by positioning
the crankshaft 2 times only.
Each cylinder must be checked by taking it to the
T.D.C. (top dead centre) at the end of compression
and adjusting the clearance of both valves on the
cylinder in question.

70346

Check that tappet adjusters (1) are loose to prevent their
balking on the rods (2, Figure 79) when refitting the rocker
assembly.
Then refit the rocker assembly consisting of: bracket (5),
rockers (3), shafts (4) and secure them to the cylinder head
by tightening the fastening screws (2) to 36 Nm torque.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 82

Figure 85

108547

Apply to the coupling surface of the intake manifold (1)
equipped with heater (2) a sufficient coat of LOCTITE 5999
and provide tightening the screws to the prescribed matching
couple.

108569

!
Figure 83

Pipe (7) connections shall be tightened to 20 Nm
torque, using the proper wrench (5) and the torque
wrench 99389833 (4).
Connections (6) shall be tightened by holding the
flow limiting valve hexagon (1) with the proper
wrench.

Connect the fuel pipe (3) to the rail (2) following the
procedure shown in the following figure.
Figure 86

108567

Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut to the specified torque.
Figure 84
70126

Press the clamp (1) in arrow direction (Figure B) and connect
the pipe to the rail, reset the clamp to the initial locking
position “A”.
Check proper fuel pipe connection.

108568

Connect new fuel pipes (1) to rail (3) and injector manifolds
(2).
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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Connect the electrical cables (1) to the injectors (3) and use
the torque wrench 99389834 (4) to tighten the fastening
nuts (2) to the specified torque.

Figure 87

Figure 90

70352

Check electrical cable (5) conditions, replace if damaged by
cutting the support (2) clamps and removing the screws (4)
that secure it to connections (3).
Fit a new gasket (1) on the support (2).

70355

Fit a new gasket (2) on the tappet cover (1).
Figure 88

Place the tappet cover on, install the bolts in the correct
position and tighten.

Figure 91
108570

Fit the wiring support (2) and tighten the screws (1) to the
specified torque.

Before any assembly operation always verify that the
hole and screw threads have no evidence of wear or
dirt.

Figure 89

108572

Reconnect the exhaust manifold (2) with new gaskets. Tighten
the fastening screws (1) to the specified torque.
Sling the turbocharger (1) and place it over the manifold after
having first inserted a new gasket.
Connect the oil pipeline (3) to the support of the heat
exchanger /oil filter. Fix the pipe (3) to the pipe fitting on the
turbocharger.
108571

Base - February 2006

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Figure 92

Figure 94

6
2

5
4

74170

Insert the blow-by filter (4) tightening the screws.
Connect the pipeline (6) and fix the oil vapour recover pipe
through the clamp (5); lock up the nut fixing it to the upper
edge.
Connect the pipeline (2) to the pressure- limiter (1).

Completion of the engine

108541

Assemble the bracket and the support (1) of the fuel filter (6).
Proceed connecting in sequence the pipelines (9,3,4 and 5)
of the support (1) to the high pressure pump (8).
Connect the pipeline (7) from the high pressure pump to the
engine control module heat exchanger.
Connect the pipeline (10) from the high pressure pump to
the rail diffuser.

Properly handle the engine holding it by a lifter, remove it
from the rotating shaft, remove the brackets 99341009 and
place it on proper suitable support to carry out the
completion.

Figure 95

Proceed assembling the oil filter.
Figure 93

70126

All the fuel pipelines are fixed using the clamps shown in the
picture.

Assemble the starter (2) to the internal part of the flywheel
cover.
Assemble the oil feeding pipe using a new O-ring. Fix with
three M12x25 screws.

For the connection of the pipes, press the clamp (I) following
the arrow’s direction (Figure B) and connect the pipe to the
clamp on the high pressure pump or on the support of the
fuel filter.
Reset the clamp in the initial locking ”A” position.

In case the pipes are re-employed, they must keep
the sealing tops at the edges.
Make sure that the fuel pipeline is correctly
connected.

Reconnect the engine harness to all the sensors, the engine
control module and the rail diffuser (see Figure 6)
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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Checks and inspections

The following checking inspections must be carried
out after the engine assembly on the vehicle .

Start the engine and leave it running just above the
idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:

- that there are no water leaks from the connecting
sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- check carefully the connection between the low
pressure fuel pipes and the relevant connectors;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes (if
fitted);
- check also proper operation of the warning lights set on
the instrument panel and of the equipment
disconnected when engine was removed.
- Carefully check and bleed the engine cooling equipment
by repeated draining operations.

Base - February 2006

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

PART TWO - ELECTRICAL EQUIPMENT

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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Base - February 2006

F4HE NEF ENGINES

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

LOCATION OF THE MAIN ELECTRICAL COMPONENTS
Figure 96

108641

The NEF F4HE engines are fully driven by the electronic
engine control module, which is assembled directly to the
engine by means of a heat exchanger enabling its cooling,
utilising rubber buffers to reduce vibration originated by the
engine.

The electrical and electronic components of the engine are
listed here following:

Through the engine control module it is possible to verify the
correct working of the engine. (See part three of the hereby
user’s guide specifically dedicated to diagnostic).

3. RAIL pressure sensor.

1. Coolant temperature sensor.
2. Electro-injector.
4. Air temperature/pressure sensor.
6. Timing sensor.
7. Solenoid valve for pressure regulator.
8. Fuel temperature sensor.
9. EDC electronic control unit.
10. Crankshaft sensor.
11. Engine oil pressure/temperature sensor.
12. Heating element for pre-post heating.

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Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

EDC7 ECU
Figure 97

01525t

A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled);
C - Connector to sensors.

Base - February 2006

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F4HE NEF ENGINES

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Cable on engine
All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary
version, in other words at the approval stage.

Figure 98

0051064t

1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor 5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor 8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Rail temperature and pressure sensor 11. Pressure regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Injectors connector (A)
ECU PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

FUNCTION
Cylinder 5 injector
Cylinder 6 injector
Cylinder 4 injector
Cylinder 1 injector
Cylinder 3 injector
Cylinder 2 injector
Pressure regulator
Pressure regulator
Cylinder 2 injector
Cylinder 3 injector
Cylinder 1 injector
Cylinder 4 injector
Cylinder 6 injector
Cylinder 5 injector

F4HE NEF ENGINES

Sensors connector (C)
ECU PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Base - February 2006

ECU PIN
Timing sensor
Timing sensor
Negative for rail temperature and pressure sensor
Positive for rail temperature and pressure sensor
Signal from rail temperature and pressure sensor
Coolant temperature sensor
Signal from fuel temperature sensor
Engine rpm sensor
Engine rpm sensor
Negative for engine oil pressure and temperature
sensor
Negative for air temperature and pressure sensor
Coolant temperature sensor
Signal from engine oil pressure sensor
Signal from engine oil temperature sensor
Positive for engine oil pressure and temperature
sensor
Positive for air temperature and pressure sensor
Signal from air pressure sensor
Negative for fuel temperature sensor
Signal from air temperature sensor

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Crankshaft sensor
This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from
a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ∼900 Ω.
Figure 99

50319

Crankshaft sensor

Timing sensor
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a
magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by
the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance
is ∼900 Ω.
Figure 100

50320

Timing sensor
3

50342

50288

Connector
Ref
Ref.
1
2
3

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Wiring diagram
Description

Signal
Signal
Shield

ECU pin
Camshaft sensor
19C
23C

Timing sensor
10C
9C

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Supercharging air pressure - temperature sensor
This component incorporates a temperature sensor and a pressure sensor.
Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate
calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 25C - 36C - 33C - 34C.
The power supply is 5 volt
Voltage at the sensor output is proportional to the detected pressure or temperature.
Pin 25C - 36C
Pin 33C - 34C

Temperature
Pressure

Engine oil temperature-pressure sensor
This component is analogous to the air temperature-pressure sensor.
The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position.
This sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 24C - 28C - 32C - 27C.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative
device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.
Pin 24C - 28C
Pin 32C - 27C

Temperature
Pressure

Figure 101

50324

50344

Wiring diagram

Ref
Ref.
1
2
3
4

Base - February 2006

Description
Ground
NTC signal (temperature)
+5 V power input
Signal (pressure)

ECU Pin
Oil
24C
28C
32C
27C

Air
25C
36C
34C
34C

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Fuel temperature and pressure sensor
Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback).
The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection
command.
This sensor is connected to the control unit on pins 12C - 14C- 13C.
The power supply is 5 Volt.

Figure 102

0051065t

Fuel pressure sensor connector

Ref.
1
2
3

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Description
Ground
Signal
Power supply

ECU pin
12C
14C
13C

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

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Electro-injectors
The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The impedance of the coil of each injector is 0.56 - 0.57 Ω.

Ref.
CONNECTOR 1

CONNECTOR 2

CONNECTOR 3

Description
1
2
3
4
1
2
3
4
1
2
3
4

Cylinder 2 injector
Cylinder 2 injector
Cylinder 1 injector
Cylinder 1 injector
Cylinder 4 injector
Cylinder 4 injector
Cylinder 3 injector
Cylinder 3 injector
Cylinder 6 injector
Cylinder 6 injector
Cylinder 5 injector
Cylinder 5 injector

ECU pin
11 A
6A
13 A
4A
14 A
3A
12 A
5A
15 A
2A
1A
16 A

Figure 103

50343

Figure 104

50349

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Pre-post heating resistance and contactor
The pre-post heating resistance is located on the intake manifold.
The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor on the left hand
side of the chassis.
The resistance impedance is approximately 0.5 Ω.

Figure 105

003215t

Resistance

Figure 106

002371t

A. Control contactor

The control contactor is connected to the control unit B connector.
The contactor is tripped with water and/or fuel temperature below 5 °C.
The contactor impedance is approximately 15 Ω.

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

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Coolant temperature sensor
This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication
of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
This sensor is connected to the control unit on pins 15C - 26C.
The impedance of the coolant temperature sensor at 20 °C is approximately 2.50 Ω.

Figure 107

107471

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Fuel temperature sensor
This sensor is identical to the coolant temperature sensor.
This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.
The fuel temperature sensor is connected to the control unit on pins 35C -18C.
The sensor impedance at 20 °C is approximately 2.50 Ω.
Figure 108

0051140t

1. Fuel temperature sensor - 2. Filter heating resistance.

The ECU drives the filter heater contactor at fuel temperature ≤ 5 °C.

107799

107798

Connector

Ref
Ref.
1
2

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Description
Ground
Temperature signal

ECU Pin
Coolant
15C
26C

Fuel
35C
18C

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

High pressure pump - pressure regulator
Figure 109

000912t

A. Pressure regulator.

The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the
pressure regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 and 1450 bar by the electronic control unit by controlling the pressure
regulator solenoid valve.
- This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on pins 9A - 10A.
- The solenoid valve impedance is approximately 3.2 Ω.

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

PART THREE - TESTS - TROUBLESHOOTING

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

TESTS
CHECKING THE FUEL SYSTEM
This section analyses the tests for correctly troubleshooting and checking the fuel circuit and the common rail injection system.
The stated procedure can be used in the event of trouble with the engine injection system correlated with error codes 8.x saved
in the control unit, or not accompanied by any error code and the user notices a drop in performance. The following table gives
descriptions of error codes 8.x.

Error
8.1

Description
- Negative deviation of the fuel pressure (actual pressure higher than the objective pressure).
- Positive deviation of the fuel pressure (actual pressure lower than the objective pressure).
- Drop in fuel pressure with vehicle in motion (lack of diesel).
- Drop in fuel pressure with vehicle in motion: downhill with throttle pedal released (lack of diesel).

8.2
8.4
8.5

Drop in fuel pressure with the engine idling (lack of diesel).
Fuel pressure sensor on rail.
Backflow valve control (opening the pressure relief valve DBV).
Fuel pressure in the rail too high.

- Fuel pressure in the rail too low.

DESCRIPTION OF TESTS AND CHECKS THAT CAN BE PERFORMED
The contemplated tests are:
- Low pressure supply test
- Test on the pressure relief valve on the rail
- Test on fuel backflow from the injector return

Necessary equipment
Use the kit dwg. 99305453 described in the figure.
Figure 110

108599

1. Pressure gauge 1 (0 - 15bar) and standard couplings - 2. Pressure gauge 2 and standard couplings - 3. 2-litre container 4. Pressure gauge pipes - 5. Graduated container of 100ml - 6. Plug for rail - 7. Closed Voss coupling.

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

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Low pressure supply test
The figure shows the diagram for using the components available in the kit dwg. 99305453.
Figure 111

108600

A. Fuel tank - B. Prefilter - C. Low-pressure pump - D. Fuel delivery circuit E. Fuel filter - F. High-pressure pump CP3 - G. High-pressure circuit - H. Common rail I. Fuel recirculation circuit - L. Injectors - M1. Pressure gauge 1 fuel filter inlet M2. Pressure gauge 2 fuel filter outlet - N. External container.
Figure 112

108601

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Low-Pressure Pump
The function of the gear pump is to supply the high-pressure pump CP3. It is driven by the shaft of the high-pressure pump and
is fitted on its rear portion. Under normal operating conditions, the flow of fuel inside the pump is as shown in the figure.

Figure 113

108602

On completing the fuel supply system and with the battery charged to 24.7V, the engine must start within the 20 seconds of
activation of the starter motor, drawing fuel from the external container placed at most 1 metre lower than the engine. If the pump
is not able to draw up fuel in the stated time and therefore start the engine, replace it.
After starting the engine, check the pressure at 1500 rpm:
- On pressure gauge M1 it must be between 6 and 9 bar.
f lower than 6 bar: replace the pump,
if higher than 9 bar: replace the diesel filter.
- On pressure gauge M2 it must be greater than 5 bar:
If lower, replace the diesel filter,
if the trouble persists, check the seals of the couplings of the fuel filter support and of the high-pressure pump inlet.

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

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Test on the pressure relief valve on the rail
Fitted at one end of the rail, its function is to protect the system’s components if any malfunctioning causes an excessive increase
in the pressure of the high-pressure system.

Figure 114

108603

Disconnect the recirculation pipe (1) of the pressure relief valve and plug it with the Voss coupling of the kit dwg. 99305453. No
diesel must come out of the valve at any engine speed. If the diagnosis system signals fault code 8.4 ”Engine - backflow valve control”,
it means that the EDC control unit has recognised that the valve has opened after a significant change in the pressure of the rail
(greater than 1700bar). Since its opening is to be considered a consequence of the abnormal increase in pressure, the valve is NOT
defective even though a great amount of diesel flows out. Whereas, if the valve seeps diesel without fault code 8.4, then replace
it.
With the overpressure sensor disconnected or with a bundle of defective cables fault code 8.2 is generated and the rail pressure
is set to 710bar (measurable with the diagnosis instrument). Therefore the trouble is to be found in the wiring and it is not necessary
to replace the component.

The experience acquired to date shows that the defectiveness is RARELY due to the sensor.

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Test on fuel backflow from the return
Permits establishing the operating status of the injectors. The engine speed and power are controlled through the injectors. The
power required by the user, through the accelerator, is converted into the quantity of fuel injected per cycle. In its turn, this is
converted into microseconds of injector opening according to the rail pressure.

Figure 115

108604

Notes:
The injectors may have problems of both a mechanical and an electrical nature; before proceeding with the following analysis, it
is wise to rule out the presence of water in the tank and in the fuel prefilter.
When the EDC warning light comes on occasionally (fault code 8.1) in the phase of acceleration and/or cold start trouble, make
the following checks.
- Possible incorrect tightening of the nut (1) locking the injector duct on the cylinder head. The prescribed torque setting is 50Nm
± 5Nm.

Figure 116

108605

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- Proceed with the injector fuel backflow tests.
Remove the duct (1) from the cylinder head, plug it (2) and fit on the coupled transparent pipe (3).

Figure 117

108606

Make sure first of all that the engine idling speed is as set in the factory. Check the quantities of fuel recirculation from the cylinder
head. The conditions for measuring the quantities of injector return fuel are:
- engine idling and without air compressor or air conditioner working;
- engine at temperature (> 50 °C).
The quantity that flows out must be no greater than 80ml of diesel in one minute. Excessive recirculation (more than 80ml of diesel
a minute) could be caused by:
- incorrect coupling between one or more injectors and the related ”needles”;
- problem of internal leakage of the injector.
To identify the defective injector, follow the method described hereunder. Measure the quantity of fuel flowing out in one minute
from the coupling on the cylinder head by means of a graduated container. After checking that the recirculation is greater than
80ml a minute, plug the rail outlet of one injector (4) at a time by using the rail plug in the kit dwg. 99305453. The defective injector
is the one whose exclusion caused a significant reduction in recirculation. In addition, remember that when changing an injector
it is necessary to change the duct. After identifying the injectors / ducts with a high recirculation, check that the tightness of the
ducts is as designed (50Nm ± 5) and tighten them if they are loose and then check the recirculation values again. If on the other
hand the tightness is correct, remove the pipe and check that the spherical end towards the injector is not out of shape; replace
it if it is and then check the recirculation value again. If the duct is not out of shape either, then replace the injector and duct because
there must be a leak inside the injector. Check the recirculation value again.

Base - February 2006

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Insufficient fuel level in the tank.

RECOMMENDED TESTS OR
INTERVENTION
Check fuel level.

Possible exessive smoke.
Possible blink-code 8.1

REMARKS
The excessive smoke is due to the fact
that, in case of insufficient fuel feeding, the
engine control module tries to compensate prolonging the injectors working
time.

Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of over- is working correctly.
heating.
If the pump plunger is permanently depressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter.

Replace the air filter.

Excessive fuel blow-by from rail boost Check the O Rings and the correct convalve.
nection of the pipe fittings under the
feeding pump (the lockers must stay outside and the fittings must be well locked).
Visually check the low pressure pipeline
integrity.

F4HE NEF ENGINES

Low performance at load request.

POSSIBLE CAUSE
(*) = if available in the equipment

TROUBLESHOOTING

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ANOMALY

Solve the cause of the filter’s obstruction.
Unless the leakage is significant, no performance failures will be detected.
To verify O-rings integrity, extract from
the tank the fuel recycling pipeline, seal
the end and activate the priming pump
driving the low pressure circuit.

Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve.
there are any significant blow-by from the
boost gauge valve; in such case replace
the valve.
Replace the fuel filter.

Solve the cause of the filter’s obstruction
(empty and clean the tank and the part of
the circuit over the filter, refill with clean
fuel).

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

The engine suddenly stops (with no previ- Obstructed fuel filter.
ous problems) and does not start again.

REMARKS

Eliminate the short circuit and replace the Verify that the wire line, close to the
EDC.
pedal, is not exposed to.

EDC ”burned” by short circuit on the wiring harness of the friction clutch.
Difficult start and low performance in all Inefficient high pressure pump.
conditions.

After having excluded any other possible
cause, replace the high pressure pump.

Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recoggine running with one cylinder less.
(mechanical part) blocked open.
nisable detecting by feeling the absence of
pulsing within the relevant high pressure
pipe.

In case of low entity blow-by, inficiating
the mechanical working of the injector
but not involving flow limiter activation,
there is no error memorisation in the engine control module.
If the flow limiter is activated. Check error
code memory.

Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recogfollowed by huge white exhaust fumes, no return).
nisable detecting by feeling the absence of
and a fuel smell.
pulsing within the relevant high pressure
pipe.

Usually, whether such symptoms appear,
it is instinctive to give up engine start.
However, by insisting, it is possible to start
the engine.
As a matter of facts, by insisting, if within
the rail the pressure makes the flow limiter close up, the engine starts with one
cylinder less and gradually the grade of
fumes reduces and disappears.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

The engine disconnects or does not start. (*)

RECOMMENDED TESTS OR
INTERVENTION

Base - February 2006

POSSIBLE CAUSE
(*) = if available in the equipment

ANOMALY

Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct
pump to rail.
pipe bracket.
tightening of the anti-vibration bracket blocking, to keep the brackets in the origscrews.
inal position.
The engine works with one cylinder less, Injector blocked in closed position.
without memorising failure blink codes in
the engine control module.

Identify the injector that is not working The non-working injector is easily recogany more and the relating high pressure nisable detecting by feeling the absence of
filler.
pulsing within the relevant high pressure
pipe.

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

PART FOUR - MAINTENANCE PLANNING

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.

Regular maintenance and inspection planning

Checks and periodical inspections
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection presence of water in fuel filter or pre-filter
Inspection blow-by filter elements . . . . . . . . . . . . . . .
Inspection of belt wear status . . . . . . . . . . . . . . . . . . .
Inspection and setting of tappet clearance . . . . . . . . .
EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of engine’s oil and filter . . . . . . . . . . . . .
Replacement of pre-filter . . . . . . . . . . . . . . . . . . . . . .
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . .
Replacement of blow by filter . . . . . . . . . . . . . . . . . . .
Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency (hours)
.
.
.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.
.
.
.
.

.
.
.
.
.
.
.

Daily
Daily
4000
When anomaly occurs
500
1000
500
500
1500

The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

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SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Checks not included in maintenance planning-daily checks
It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.

MAINTENANCE PROCEDURES
Checks and inspections
Engine oil level check
The check must be executed when the engine is disconnected
and possibly cool.

Figure 119

The check can be made using the specially provided flexible
rod (1) placed on the right hand side of the EDC.

Figure 118

108540

2
74174

To provide filling, operate through the upper top (1) or
through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier”.

Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine’s components.

Base - February 2006

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.

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Combustion system inspection
The check must be executed both when the engine disconnected and when it is running.
The check operation consists in examining the fuel pipelines
running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and
to the rail diffuser and from this last one to the head.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Lubricating system inspection
The check must be executed both when the engine disconnected and when it is running.
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan of from the heat exchanger.

Special attention must be paid to the connections on the high
pressure pipelines.

!
!

Due to the high pressure within the pipelines running
from the high-pressure pump to the rail diffuser and
from this last one to the electro-injectors, special
attention must be aid also in checking presence of any
leakage or blow-by.

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.

Protect the eyes and the skin from any eventual high
pressure jet: these may deeply penetrate under the
skin surface provoking serious poisoning.

Inspection of water presence within fuel filter or pre-filter

Cooling system inspection
The check must be executed both when the engine disconnected and when it is running.
Check the pipelines from the engine to the radiator, from the
expansion tank and vice-versa. Find out any blow-by, verify the
status of the pipes specially close to the holding strips.

The components of the common rail system can be
damaged very quickly in presence of water or impurity within the fuel.
Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of
the water within the feed circuit.

Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.

Due to the high temperatures achieved by the system, do not operate immediately after the engine’s
disconnection, but wait for the time deemed necessary for the cooling.
Protect the eyes and the skin from any eventual high
pressure jet of cooling liquid.

The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any case
every two year.

In case of new filling, proceed bleeding system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to
the presence of air pockets in the engine’s head.

Print P2D32N003GB

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Inspection/replacement of blow-by filter
The filter in subject has been developed and equipped for the
collection, filtering and condense of the lubricating oil vapours.
Within the filter unit (1) two cartridge filters are included (2).
Figure 120

2
74188

The check of the filtering element is carried out by removing
the cover and drawing off the cartridges (2).

Inspection of drive belt tensioning
The drive belt tensioning control is made using an automatic
tensioning device therefore no intervention is required apart
from checking the wear status of the belt itself.

Inspection and setting of tappet clearance
Figure 121

70520

Print P2D32N00GB

F4HE NEF ENGINES

Oil motor and filter replacement

Warning: We recommend to wear proper protections because of high motor service temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves.

Due to the several applications, the pan shape and the oil
quantity can change slightly. However, the following operations are valid for all applications.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Whereas you replace the lubrication oil, it is necessary to replace the filter.
According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.
- The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the
9936076-tool.

Warning: the oil filter contains inside a quantity of oil
of about 1 kg.
Place properly a container for the liquid.

We recommend to carry out the oil drainage when the motor
is hot.

Warning: avoid the contact of skin with the motor oil:
in case of contact wash the skin with running water.

- Place a proper container for the oil collecting under the
pan connected with the drain plug.

The motor oil is very pollutant: it must be disposed
of according to the rules.

- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the lubrication oil.

The oil motor is very pollutant and harmful.

- Replace the filtering cartidge with a new one and screw
manually until when the gasket is in contact with the support.

In case of contact with the skin, wash with much water
and detergent.

- Tigthen by means of the 99360076-tool of three fourth
turn.

Protect properly skin and eyes: operate according to
safety rules.

- Operate the motor for some minutes and check the level
through the dipsick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Dispose of the residual properly following the rules.

- After the complete drainage, screw the plug and carry out
the clean oil filling.

Use only the recommended oil or oil having the requested features for the corrrect motor functioning.
In case of topping up, don’t mix oils having different
features.
If you don’t comply with theses rules, the service warranty is no more valid.

- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dipsick.

Print P2D32N003GB

Base - February 2006

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

Fuel filter replacement

F4HE NEF ENGINES

Alternator belt replacement
Due to several applications the belt run can change very much.

During this operation don’t smoke and don’t use free
flames.
Avoid to breathe the vapors coming from filter.

According to the applications the filters position and the quantity can change.

Warning: with switched off motor (but still hot) the
belt can operate without advance notice.
Wait for the motor temperature lowering to avoid
very serious accidents.

However the following operations are valid for all applications.
- Drain the fuel inside the filter by operating the water release screw. Collect the fuel in a container without impurities.
- Unscrew the cartridge by using the 99360076-tool.
- Collect the eventual fuel inside the filtering cartridge.
- Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.

For applications with automatic belt stretcher, the procedure
is the following:
Figure 122

- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 10-15 Nm torque.

108545

- Operate on the tightener (1) and withdraw the belt (2)
from the alternator and water pumps from pulleys and
from the returns pumps.
- Replace the worn belt with a new one.
- Place the belt on the pulleys and the guide rollers.
- Place the automatic tightener in order to key the belt in
the functioning position.
- Further adjustments are not required.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

SECTION 4
Overhaul and technical specifications

Page

Print P2D32N003GB

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .

4 AND 6 ENGINE OVERHAUL . . . . . . . . . . . . .

ENGINE REMOVAL AT THE BENCH . . . . . . . .

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .

CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . .

- Checks and measurements . . . . . . . . . . . . . . .

- Checking head supporting surface
on cylinder unit . . . . . . . . . . . . . . . . . . . . . . . .

TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking cam lift and pin alignment . . . . . . . .

BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Bush replacement . . . . . . . . . . . . . . . . . . . . . .

- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting tappets — camshaft . . . . . . . . . . . . . . . .

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring journals and crankpins . . . . . . . . . .

- Measuring journals and crankpins (6 cyl.) . . . .

- Replacing oil pump control gear . . . . . . . . . . .

- Fitting main bearings . . . . . . . . . . . . . . . . . . . .

- Finding journal clearance . . . . . . . . . . . . . . . . .

- Checking crankshaft shoulder clearance . . . . .

CONNECTING ROD — PISTON ASSEMBLY . .

- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

Page

- Measuring piston diameter . . . . . . . . . . . . . . . .

- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Conditions for proper pin-piston coupling . . . .

- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .

- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking connecting rods . . . . . . . . . . . . . . . .

- Checking bending . . . . . . . . . . . . . . . . . . . . . . .

- Checking torsion . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod-piston assembly . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .

- Removing the valves . . . . . . . . . . . . . . . . . . . .

- Checking cylinder head wet seal . . . . . . . . . . .

- Checking cylinder head supporting surface . . .

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing carbon deposits, checking and
grinding valves . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking clearance between valve stem and valve
guide and valve centering . . . . . . . . . . . . . . . . .
34
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rod-piston coupling . . . . . . . . . . . .

- Regrinding — replacing the valve seats . . . . . . .

- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD VALVE SEATS (6 CYL.) . . . .

- Fitting connecting rod-piston assembly
into cylinder barrels . . . . . . . . . . . . . . . . . . . . .

FITTING CYLINDER HEAD . . . . . . . . . . . . . . . .

- Finding crankpin clearance . . . . . . . . . . . . . . . .

- Refitting the cylinder head . . . . . . . . . . . . . . . .

- Checking piston protrusion . . . . . . . . . . . . . . .

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Type

4 CYLINDERS

6 CYLINDERS

Cycle

Four-stroke diesel engine

Power

Turbocharged with intercooler

Injection

Direct

Number of cylinders

∅

Bore

104

Stroke

132

+.. = Total displacement

cm3

4485

6728

TIMING
start before T.D.C.
end after B.D.C.

A
B

18.5º
29.5º

start before B.D.C.
end after T.D.C.

D
C

67º
35º

Checking timing
mm

0.20 to 0.30

0.45 to 0.55

Bosch

high pressure common rail
EDC7 ECU

X
X

Checking operation
X

FUEL FEED
Injection
Type:

Injector

CRIU 2

Nozzle type

DSLA and DLLA

Injection sequence

1-3-4-2

1-5-3-6-2 -4

250 - 1450

250 - 1600

bar

Injection pressure

Print P2D32N003GB

bar

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

CLEARANCE DATA

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS
∅1

∅1

102.009 to 102.031

∅2
L

Cylinder barrels — housings on
engine block (interference)

Cylinder barrels

∅

6 CYLINDERS

Cylinder barrels:
outside diameter
length

Outside diameter

∅2

0,5

∅3
X

∅1
X
∅2

Cylinder barrels:
inside diameter

∅2

Spare pistons
type:
Size
Outside diameter
Pin housing

X
∅1
∅2

61
103.730 to 103.748
38.010 to 38.016

Piston — cylinder barrels

0.252 to 0.294

Piston diameter

∅1

Piston protrusion

0.5

∅ 3

Piston pin
Piston pin — pin housing

Base - February 2006

0.28 to 0.52

∅3

37.994 to 38.000
0.01 to 0.022

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS
X1
X2
X3
S 1
S 2
S 3

6 CYLINDERS
mm

Split ring slots

X1*
X2
X3

2.705 to 2.735
2.440 to 2.460
4.030 to 4.050

Split rings

S 1*
S2
S3

2.560 to 2.605
2.350 to 2.380
3.977 to 3.990

* measured on 98 mm ∅ 4 cyl.
* measured on 99 mm ∅ 6 cyl.
* measured on 101 mm
∅ F4HE
Split rings - slots

1
2
3

Split rings
X1
X2

∅ 2

0.5

Split ring end opening
in cylinder barrel:

∅1

0.100 to 0.175
0.060 to 0.110
0.040 to 0.083

Small end bush
housing
Big end bearing
housing

X1
X2
X3

0.30 to 0.40
0.60 to 0.80
0.30 to 0.55

∅1

40.987 to 41.013

∅2

72.987 to 73.013

∅4
∅ 3
S

Print P2D32N003GB

Small end bush diameter
Outside
∅4
Inside
∅3
Spare big end half
bearings
S

41.279 to 41.553
38.019 to 38.033
1.955 to 1.968

Small end bush — housing

0.266 to 0.566

Piston pin — bush

0.019 to 0.039

Big end half bearings

0.250 to 0.500

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Type

F4HE NEF ENGINES

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS

6 CYLINDERS
mm

X
Size

Max. tolerance
on connecting rod
axis alignment
∅1

∅2

S 1

Journals
Crankpins

∅1
∅2

82.99 to 83.01
68.987 to 69.013

Main half bearings
Big end half bearings

S1
S2

2.456 to 2.464
1.955 to 1.968

S 2
*provided as spare part

∅ 3

Main bearings
No. 1 — 5 / 1- 7
No. 2 — 3 — 4

∅ 3
∅3

87.982 to 88.008
87.977 to 88.013

Half bearings — Journals
No. 1—5 / 1-7
No. 2—3—4 / 2-3-4-5-6

0.041 to 0.119
0.041 to 0.103

Half bearings - Crankpins

0.033 to 0.041

Main half bearings
Big end half bearings

0.250 to 0.500

Shoulder journal

37.475 to 37.545

Shoulder main bearing

25.98 to 26.48

Shoulder half-rings

37.28 to 37.38

X 1

X 2
X 3

Output shaft shoulder

Base - February 2006

0.068 to 0.41

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM
∅ 1

6 CYLINDERS
mm

Valve guide seats on
cylinder head

∅1

7.042 to 7.062

∅2

∅3

∅ 2

Valve guides
∅ 3

∅ 4

Valve guides and seats on head

Valve guides

Valves:

∅4
α

6.970 to 6.999
60o ± 0.25o

∅4
α

6.970 to 6.999
45o ± 0.25o
0.052 to 0.092

Valve stem and guide

0.052 to 0.092

Housing on head for
valve seat:

∅ 1

34.837 to 34.863

∅1

34.837 to 34.863

Valve seat outside diameter;
valve seat angle on cylinder
head:
∅2
α

∅ 2

∅2
α

Sinking
Between valve seat
and head
Valve seats

Print P2D32N003GB

∅1

34.917 to 34.931
60o
34.917 to 34.931
45o

0.59 to 1.11

0.96 to 1.48
0.054 to 0.094
0.054 to 0.094
-

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Type

F4HE NEF ENGINES

4 CYLINDERS

6 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

Valve spring height:
free spring
H

H 2 under a load equal to:
339.8 ± 9 N
741 ± 39 N
Injector protrusion

47.75

H1
H2

35.33
25.2

∅ ∅ ∅
1 23 4 5

Camshaft bush
housings No. 1-5/1-7

59.222 to 59.248

Camshaft housings
No. 2-3-4/2-3-4-5-6

54.089 to 54.139

∅ 2

∅ 1

Camshaft journals:
1⇒5

∅

1⇒7

∅

53.995 to 54.045

∅ 3
∅

Camshaft bush outside
diameter:
∅

∅

Bush inside
diameter

∅

54.083 to 54.147

Bushes and housings
on block

Bushes and journals

0.038 to 0.162

Cam lift:
H

Base - February 2006

6.045

7.582

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

6 CYLINDERS
mm

∅1
Tappet cap housing
on block
∅2
∅ 3

Tappet cap outside
diameter:

∅2

∅1

16.000 to 16.030

∅2
∅3

15.924 to 15.954
15.960 to 15.975

Between tappets and housings
Tappets

0.025 to 0.070
-

∅ 1
Rocker shaft

∅1

21.965 to 21.977

Rockers

∅2

22.001 to 22.027

∅ 2
Between rockers and shaft

Print P2D32N003GB

0.024 to 0.162

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Base - February 2006

F4HE NEF ENGINES

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

4 AND 6 ENGINE OVERHAUL
ENGINE REMOVAL AT THE BENCH

Figure 3

The following instructions assume that the engine has
previously been placed on the rotating bench and that
removal of all specific components of the Iveco Motors
equipment have been already removed as well. (See Section
3 of the manual herein).
The section illustrates therefore all the most important engine
overhaul procedures.
The following operations are relating to the 4 cylinder engine
but are similar and applicable for the 6 cylinder.
Figure 1
70160

The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).

Take note of lower and upper half-bearing assembling
positions since in case of reuse they shall be fitted in
the same position found at removal.
Figure 4

70158

Loosen the fixing screws (1) and remove the rod caps (2).
Withdraw the pistons including the connecting rods from the
top of the engine block.

Keep the half-bearings into their housings since in case
of use they shall be fitted in the same position found
at removal.

70161

Use tool 99360500 (1) and hoist to remove the crankshaft (2)
from the block.
Figure 2

Figure 5

70159

Remove the screws (1) and the main bearing caps (2).

Print P2D32N003GB

Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).

70162

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

REPAIR OPERATIONS
CYLINDER UNIT
Checks and measurements

Figure 6

Figure 9

70163

Remove the screws (1) and disconnect camshaft (3) retaining
plate (2).
70166

Once engine is disassembled, clean accurately the
cylinder-block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free from seizing,
scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation, taper
and wear shall be performed using the bore dial gauge (1)
fitted with the dial gauge previously set to zero on the ring
gauge (2) of the cylinder barrel diameter.

Take note of plate (2) assembling position.

!
Figure 7

Should the ring gauge be not available, use a
micrometer for zero-setting.

70164

Figure 10
Withdraw carefully the camshaft (1) from the engine block.

Figure 8

70167

Measurements shall be performed on each cylinder, at three
different heights in the barrel and on two planes perpendicular
with each other: one parallel to the longitudinal axis of the
engine (A), and the other perpendicular (B). Maximum wear
is usually found on plane (B) in correspondence with the first
measurement.

70165

Should ovalisation, taper or wear be found, bore and grind the
cylinder barrels. Cylinder barrel regrinding shall be performed
according to the spare piston diameter oversized by 0.5 mm
and to the specified assembling clearance.

Withdraw the tappets (1) from the engine block.
Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Check main bearing housings as follows:

Figure 11

- fit the main bearings caps on the supports without
bearings;
- tighten the fastening screws to the specified torque;
- use the proper internal gauge to check whether the
housing diameter is falling within the specified value.
Replace if higher value is found.

Checking head supporting surface on cylinder
unit
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them
in case of uncertain seal or if rusted.

107267

In case of regrinding, all barrels shall have the same
oversize (0.5 mm).

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

TIMING SYSTEM
Camshaft
Figure 12

70169

CAMSHAFT MAIN DATA (4 cyl.)
Specified data refer to pin standard diameter

Figure 13

84089

MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders)
Specified data refer to pin standard diameter

Camshaft pin and cam surfaces shall be absolutely smooth;
if they show any traces of seizing or scoring replace the
Base - February 2006

camshaft and the bushes.
Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Checking cam lift and pin alignment

BUSHES

Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.

Figure 15

Figure 14

70172

70171

Camshaft bushes (2) shall be pressed into their housings.
Internal surfaces must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft front and rear
bush (2) and intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.

Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.

Figure 16

Sec. A-A

107399

CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)
* Value to be obtained after driving the bushes.
Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

Figure 17
sec. A-A

107268

MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS
*Height to be obtained after driving the bushes.

Bush replacement

Tappets

Figure 18

Figure 19

70174

To replace front and rear bushes (1), remove and refit them
using the beater 99360362 (2) and the handgrip 99370006
(3).

70175

MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK

When refitting the bushes (1), direct them to make
the lubricating holes (2) coincide with the holes on
the block housings.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Fitting tappets — camshaft

Figure 22

Figure 20

70238

Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
70176

Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Figure 23

70179

Check camshaft end float (1).
It shall be 0.23 ± 0.13 mm.

Figure 21

Figure 24

70164
70180

Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

OUTPUT SHAFT
Measuring journals and crankpins

F4HE NEF ENGINES

Figure 25

It is recommended to insert the found values in the
proper table.
See Figure 26.
Undersize classes are:

Journals and crankpins shall always be ground to the
same undersize class.
Journals and crankpins undersize shall be marked on
the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB.

70182

Grind journals and crankpins if seizing, scoring or excessive
ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.

Figure 26

70181

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Figure 27

measured on > 45.5 mm radius
between adjacent journals

70183

OUTPUT SHAFT MAIN TOLERANCES

TOLERANCES
SHAPE
DIRECTION
POSITION
OSCILLATION

TOLERANCE CHARACTERISTIC
Roundness
Cilindricity
Parallelism
Verticality
Straightness
Concentricity or coaxiality
Circular oscillation
Total oscillation
Taper

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL
○
/○/
//

GRAPHIC SYMBOL

CRITICAL

IMPORTANT

⊕

SECONDARY

⊝

MAIN BEARING ON TIMING
SYSTEM CONTROL SIDE

INTERMEDIATE MAIN
BEARINGS

FIRST MAIN BEARING
ON FRONT SIDE

70237

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

Measuring journals and crankpins (6 cyl.)
Figure 28

107269

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value

Figure 29

*
**

Measured on a radius greater than 45.5 mm
↗ 0.500

between adjacent main journals

70577

MAIN OUTPUT SHAFT TOLERANCES

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Figure 30

MAIN BEARING ON TIMING
SYSTEM CONTROL SIDE

INTERMEDIATE MAIN
BEARINGS

FIRST MAIN BEARING ON
FRONT SIDE

70237

TOLERANCES
SHAPE
DIRECTION
POSITION
OSCILLATION

TOLERANCE CHARACTERISTIC
Roundness
Cilindricity
Parallelism
Verticality
Straightness
Concentricity or coaxiality
Circular oscillation
Total oscillation
Taper

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL
○
/○/
//

GRAPHIC SYMBOL

CRITICAL

IMPORTANT

⊕

SECONDARY

⊝

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Replacing oil pump control gear

F4HE NEF ENGINES

Finding journal clearance
Figure 33

Figure 31

70161

Refit the crankshaft (2).
70184

Check that gear toothing (1) is not damaged or worn,
otherwise remove it using the proper puller (3).

Check the backlash between crankshaf main journals and the
relevant bearings as follows:
Figure 34

When fitting the new gear, heat it to 180°C for 10 minutes
in an oven and then key it to the crankshaft.

Fitting main bearings
Figure 32

70186

- clean accurately the parts and remove any trace of oil;
- position a piece of calibrated wire (3) on the crankshaft
pins (4) so that it is parallel to the longitudinal axis;
70185

- fit caps (1), including the half bearings (2) on the relevant
supports.
Figure 35

Refit the main bearings that have not been replaced,
in the same position found at removal.

Main bearings (1) are supplied spare with 0.250 — 0.500 mm
undersize on the internal diameter.
Do not try to adapt the bearings.

!
Clean accurately the main half bearings (1) having the
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
Base - February 2006

70187

Tighten the pre-lubricated screws (1) in the following three
successive stages:
- 1st stage, with torque wrench to 50 ± 6 Nm.
- 2nd stage, with torque wrench to 80 ± 6 Nm.
Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Checking crankshaft shoulder clearance

Figure 36

Figure 38

70188

3rd

stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90 ± 5° angle.

Figure 37

70190

This check is performed by setting a magnetic-base dial gauge
(2) on the crankshaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft pins and main half bearings.

CONNECTING ROD — PISTON ASSEMBLY
Figure 39

70189

- Remove caps from supports.
The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2) at
the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
The numbers on the scale indicate the backlash in mm.
Replace the half bearings and repeat the check if a different
backlash value is found. Once the specified backlash is
obtained, lubricate the main bearings and fit the supports by
tightening the fastening screws as previously described.

70191

CONNECTING ROD — PISTON ASSEMBLY
COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.

Pistons are supplied from parts with 0.5 mm oversize.

!
Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

Pistons
Measuring piston diameter

Figure 40

Figure 43

32613

Remove split rings (1) from piston (2) using pliers 99360183
(3).

Figure 41

32615

Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.

The diameter shall be measured at 12 mm from the
piston skirt.
Figure 44

32614

Piston pin (1) split rings (2) are removed using a scriber (3).
70192

The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 42

107270

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS
* Value measured on 99 mm diameter
Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Figure 45

86497

MAIN DATA CONCERNING MONDIAL MAHLE PISTON, PINS AND SPLIT RINGS
* Value measured on 101 mm diameter

Piston pins
Figure 46
Figure 48

18857

To measure the piston pin (1) diameter use the micrometer
(2).

16552

Use a micrometer (1) to check split ring (2) thickness.

Conditions for proper pin-piston coupling
Figure 47

Figure 49

32619

Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.

Print P2D32N003GB

32620

Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

Connecting rods

Figure 50

Figure 52

41104

DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.

107271

MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
* Value for inside diameter to be obtained after driving in
connecting rod small end and grinding.
** Value not measurable in released condition

Figure 51

The surface of connecting rod and rod cap are
knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.

70194

Use feeler gauge (1) to measure the clearance between the
ends of the split rings (2) fitted into the cylinder barrel (3).

Use a micrometer (1) to check split ring (2) thickness.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Figure 53

Every connecting rod is marked as follows:

- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary
to mark the new connecting rod with the same
numbers of the replaced one.
- On body with a letter showing the weight of the
connecting rod assembled at production:

CONNECTING ROD BODY
CONNECT- CONNECTING ROD
ING ROD
BODY
BODY

V, 1820 to 1860 (yellow marking);

W, 1861 to 1900 (green marking);

X, 1901 to 1940 (blue marking);

Spare connecting rods are of the W class with green
marking *.
Material removal is not allowed.

CONNECTING ROD BODY
CONNECTING ROD
BODY

CONNECTING ROD
BODY

70196

Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Checking connecting rods

F4HE NEF ENGINES

Checking bending

Figure 54

Figure 56

61695

61696

Check that the axis of the connecting rods (1) are parallel
using tool 99395363 (5) as follows:
- fit the connecting rod (1) on tool 99395363 (5) spindle
and lock it with screw (4);
- set the spindle (3) on V-blocks by resting the connecting
rod (1) on the stop bar (2).

Checking torsion
Figure 55

Check connecting rod (5) bending by comparing two points
C and D of the pin (3) on the vertical plane of the connecting
rod axis.
Position the vertical support (1) of the dial gauge (2) to rest
the latter on pin (3), point C.
Move the connecting rod forwards and backwards to find pin
top position, then in this condition reset the dial gauge (2).
Move the spindle with the connecting rod (5) and repeat the
check of the top point on the opposite side D of the pin (3).
The difference between point C and point D shall not exceed
0.08 mm.

Fitting connecting rod-piston assembly
Connecting rod-piston coupling
Figure 57

70198
61694

Check connecting rod (5) torsion by comparing two points
(A and B) of pin (3) on the horizontal plane of the connecting
rod axis.
Position the dial gauge (2) support (1) to obtain a preload of
approx. 0.5 mm on the pin (3) in point A and then set the
dial gauge (2) to zero. Move the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A and
B shall not exceed 0.08 mm.
Base - February 2006

The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Marking showing 1st slot insert testing;
4. Manufacturing date.

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Figure 58

Split rings are supplied spare with the following sizes:

standard, yellow marking;

0.5 mm oversize, yellow/green marking;

Figure 61

108597

Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Figure 59

70200

Fit half bearings (1) on connecting rod and cap.

Refit the main bearings that have not been replaced,
in the same position found at removal.
Do not try to adapt the half bearings.

72705

Position the piston (1) on the connecting rod according to
the diagram shown in the figure, fit the pin (3) and stop it by
the split rings (2).

Fitting split rings

Fitting connecting rod-piston assembly into
cylinder barrels
Figure 62

Figure 60

70201
32613

Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
Split rings shall be fitted with the marking “TOP” facing
upwards and their openings shall be displaced with each
other by 120°.
Print P2D32N003GB

Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
Use band 99360605 (2) to fit the connecting rod-piston
assembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to
the cap coupling number.
Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Figure 63

F4HE NEF ENGINES

Figure 65

108596
70204

- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench
(2).

DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120°;
- connecting rod-piston assemblies shall have the same
weight;

Figure 66
α

- the arrow marked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.

Finding crankpin clearance
Figure 64
70205

- Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60°.

Figure 67

70203

To measure the clearance proceed as follows:
- clean the parts accurately and remove any trace of oil;
- set a piece of calibrated wire (2) on the output shaft pins
(1);
- fit the connecting rod caps (3) with the relevant half
bearings (4).

Base - February 2006

70206

- Remove the cap and find the existing clearance by
comparing the calibrated wire width (1) with the scale
on the wire envelope (2).

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Checking piston protrusion

Figure 68

Figure 69

70207

If a different clearance value is found, replace the half bearings
and repeat the check.

70208

Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.

Once connecting rod-piston assemblies refitting is over, use
dial gauge 39395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 to 0.52 mm.

Before the final fitting of the connecting rod cap
fastening screws, check that their diameter
measured at the centre of the thread length is not
< 0.1 mm than the diameter measured at approx. 10
mm from screw end.

Check manually that the connecting rods (1) are sliding
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.10 to 0.33 mm.

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

CYLINDER HEAD
Removing the valves

Figure 71

Figure 70

70321

70319

Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch (→) of the exhaust valve (2) head
distinguishes it from the intake valve.

Valve removal shall be performed using tool 99360268 (1)
and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (5).
Figure 72

Should cylinder head valves be not replaced, number
them before removing in order to refit them in the
same position.
A = intake side — S = exhaust side

70322

Remove sealing rings (1 and 2) from the valve guide.

Sealing rings (1) for intake valves are yellow.

Base - February 2006

Sealing rings (2) for exhaust valves are green.

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Checking cylinder head wet seal

Figure 74

Figure 73

70323

70325

This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90°C and 2
to 3 bar pressure.

The rated thickness A for the cylinder head is 105 ± 0.25 mm,
max. metal removal shall not exceed thickness B by 1 mm.

Replace the core plugs (1) if leaks are found, use the proper
punch for their removal/refitting.

Before refitting, smear the plug surfaces with
water-repellent sealant.

After grinding, check valve sinking. Regrind the valve
seats, if required, to obtain the specified value.

Replace the cylinder head if leaks are found.

Checking cylinder head supporting surface
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

VALVES

F4HE NEF ENGINES

Figure 77

Figure 75
EXHAUST
VALVE

INTAKE
VALVE

18882

Check the valve stem (1) using a micrometer (2), it shall be
6.970 ÷ 6.999.
70326

INTAKE AND EXHAUST VALVE MAIN DATA

Removing carbon deposits, checking and
grinding valves
Figure 76

Checking clearance between valve stem and
valve guide and valve centering
Figure 78

18625

Remove carbon deposits from valves using the proper metal
brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, using tool 99305018 and
removing as less material as possible.

Base - February 2006

70327

Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.052 ÷ 0.092 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

VALVE GUIDE

VALVE SEATS
Regrinding — replacing the valve seats

Figure 79
Figure 80

INTAKE

70330

EXHAUST
70328

Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.

Check the valve seats (2). If slight scoring or burnout is found,
regrind seats using tool 99305018 (1) according to the angle
values shown in Figure 81.

Figure 81

INTAKE

EXHAUST

70331

VALVE SEAT MAIN DATA (4 CYL.)

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

Figure 82

EXHAUST

INTAKE

70332

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD (4 CYL.)
Should valve seats be not reset just by regrinding, replace
them with the spare ones. Use tool 99305018 (Figure 80) to
remove as much material as possible from the valve seats
(take care not to damage the cylinder head) until they can
be extracted from the cylinder head using a punch.

Heat the cylinder head to 80° - 100°C and using the proper
punch, fit the new valve seats, previously cooled, into the
cylinder head.
Use tool 99305018 to regrind the valve seats according to
the values shown in Figure 81.

CYLINDER HEAD VALVE SEATS (6 CYL.)
Figure 83

EXHAUST

INTAKE
70515

MAIN DATA ABOUT ENGINE VALVE SEATS

Valve seats are installed by cooling onto the cylinder head
and machining to the correct dimension.

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Figure 84

EXHAUST

INTAKE

70332

If valve seats cannot be restored just by regrinding, it is
possible to assemble the spare inserts provided.
In this case, it is necessary to install seats into the cylinder
head sized as shown in the figure and to assemble the valve
seats.

In order to assemble the valve seats into the cylinder head,
it is necessary to heat the cylinder head to 80 to 100°C and,
through a suitable punch, to assemble the new, previously
cooled valve seats (2) into the head.
Then, with tool 99305018, adjust valve seats according to the
values shown in Figure 85.

Figure 85

INTAKE

EXHAUST

70331

VALVE SEAT MAIN DATA (6 CYL.)

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

FITTING CYLINDER HEAD

Figure 86

Figure 88

70333
70334

After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).

Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.

VALVE SPRINGS

Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.

Figure 87

50676

Figure 89

MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
Before refitting use tool 99305047 to check spring flexibility.
Compare load and elastic deformation data with those of the
new springs shown in the following table.

Height

Under a load of

47.75

35.33

Base - February 2006

25.2

Free
P
P1

339.8 ± 19 N
741 ± 39 N

770321

Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

There are two types of head seals for F4AE04.., F4AE06.. and
F4HE06.. engines, for the thickness (1.25 mm Type A and
1.15 mm Type B) take the following measures:
- for each piston detect, as indicated on NO TAG, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:

Refitting the cylinder head
Figure 90

S cil1 = S1 + S2
2
For 4 cylinder versions:
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
70335

Check cleanness of cylinder head and engine block coupling
surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking “TOP” (1)
facing the head.
The arrow shows the point where the gasket thickness is
given.

S cil1 + S cil2 + S cil3 + S cil4
4
For 6 cylinder versions:
S=

Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
the average value.

S=
Figure 91

S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6
6

If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.

Before re-utilising the fixing screws for the cylinder
head, verify there is no evidence of wear or
deformation and in that case replace them.

88775

Print P2D32N003GB

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4HE NEF ENGINES

TIGHTENING TORQUE
TORQUE

COMPONENT

Nm
8±2
12 ± 2
77 ± 12
47 ± 5
24 ± 4
10 ± 2
8±1
24 ± 4
24 ± 4
24 ± 4
36 ± 4
43 ± 5
105 ± 5
24 ± 4
24 ± 4
36 ± 5
12 ± 2
8.5 ± 0.35

Studs M6 for camshaft sensors
Studs M8 for feed pump
Screw M12 for fastening rear gear case
Screw M10 for fastening rear gear case
Screw M8 for fastening rear gear case
Nut M6 for fastening camshaft sensor
Screw M8 for fastening oil pump

1st stage
2nd stage

Screw M8 for fastening front cover
Screw M8 for fastening camshaft longitudinal retaining plate
Screw M8 for fastening camshaft gear
Screw M10 for fastening crankcase plate
Nut M18 for fastening high pressure pump gear
Nuts M8 for fastening fuel pump
½ inch plug on cylinder head
¼ inch plug on cylinder head
¾ inch plug on cylinder head
Screw M6 for fastening injectors
Nut fastening for injector feed connector
Nut M6 for flame start grille on intake manifold
Screw M8 for fastening intake manifold
Screw M12 for fastening rear brackets for engine lifting
Screws M8 for fastening Common Rail
Connectors M14 for high pressure fuel pipes
Screw M12 (12 x 1.75 x 130) for fastening cylinder head
Screw M12 (12 x 1.75 x 150) for fastening cylinder head

1st stage
2ndd stage

75º ± 5º

stage

2nd stage
3rd stage
Screw for fastening rocker bracket
Valve clearance adjusting nuts
Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail
Screw M8 for fastening high pressure pipe connector
Screw M6 for fastening wiring bulkhead
Screw M8 for fastening electric wiring support for injector feed
Nuts for fastening wiring on each injector
Screw M12 for fastening fuel filter bracket
Screw M8 for fastening fuel filter holder
Fuel filter
Screw M22 for fastening oil pressure relief valve on oil filter support
Screw M8 for radiator seal and oil filter support
Oil filter
11/8 inch connection on filter support for turbine lubrication
Nut M12 for fastening turbine lubrication pipe
Screw M10 for fastening engine coolant inlet connection
90° elbow fastening (if required) to engine coolant inlet connection
Pipe on cylinder head for compressor cooling

Base - February 2006

kgm
0.8 ± 0.2
1.2 ± 0.2
7.7 ± 1.2
4.7 ± 0.5
2.4 ± 0.4
1 ± 0.2
0.8 ± 0.1
2.4 ± 0.4
2.4 ± 0.4
2.4 ± 0.4
3.6 ± 0.4
4.3 ± 0.4
10.5 ± 0.5
2.4 ± 0.4
2.4 ± 0.4
3.6 ± 0.5
1.2 ± 0.2
0.85 ± 0.035

50 ± 5
8±2
24 ± 4
77 ± 12
24 ± 4
20 ± 2
35 ± 5
55 ± 5

5 ± 0.5
0.8 ± 0.2
2.4 ± 0.4
7.7 ± 1.2
2.4 ± 0.4
2 ± 0.2
3.5 ± 0.5
5.5 ± 0.5
90º ± 5º
90º ± 5º

36 ± 5
3.6 ± 0.5
24 ± 4
2.4 ± 0.4
20 ± 2
2 ± 0.2
24 ± 4
2.4 ± 0.4
10 ± 2
1 ± 0.2
24 ± 4
2.4 ± 0.4
1.5 ± 0.25
0.15 ± 0.025
77 ± 8
7.7 ± 0.8
24 ± 4
2.4 ± 0.4
contact + ¾ turn
80 ± 8
8 ± 0.8
24 ± 4
2.4 ± 0.4
contact + ¾ turn
24 ± 4
2.4 ± 0.4
10 ± 2
1 ± 0.2
43 ± 6
4.3 ± 0.6
24 ± 4
2.4 ± 0.4
22 ± 2
2.2 ± 0.2

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

TORQUE

COMPONENT
Screw M6 for fastening engine coolant drain connector
Pin fastening on engine block for exhaust manifold
Screw M10 for fastening exhaust manifold on cylinder head
Screw M12 for fastening damper adapter
1st stage
and damper on output shaft
2nd stage
Screw M10 for fastening pulley on output shaft
Screw M8 for fastening water pump
Screw M10 for fastening auxiliary component control belt tensioners
Screw M10 for fastening fixed pulleys for auxiliary component control belt
Screw M10 for fastening flywheel housing
Screw M12 for fastening flywheel housing
Screw M6 for fastening heat exchanger for control unit
Screw M8 for fastening heat exchanger for control unit
Connection M12 for fuel inlet-outlet on heat exchanger
Nut M8 for fastening valve cover
Screw M6 for fastening camshaft sensor
Screw M6 for fastening output shaft sensor
Screw M14 for fastening coolant temperature sensor
Screw M5 for fastening oil pressure/temperature sensor
Screw for fastening fuel pressure sensor
Screw M14 for fastening fuel temperature sensor
Screw for fastening air temperature/pressure sensor on intake manifold
Screw M12 for fastening engine oil level sensor
6-cyl.
Turbine
u b e fixingg to eexhaust
aust manifold
a od
4-cyl.

{ pins
nuts
t
pins
{ nuts

M8
M8
M8
M8

Adapter M12 on turbine for lubricant oil pipes (inlet)
Pipe fixing on adapter M10 for turbine lubrication
Oil pipe fixing on adapter M10 for turbine lubrication to block
Oil drain pipe fixing M8 on turbine
Connector fixing M6 for oil return from cylinder head to flywheel housing
Screw M12 for fastening engine flywheel
1st stage
2ndd stage
Screw M8 for fastening front bracket for engine lifting
Screw for fastening engine oil sump
Screw M8 for fastening cylinder barrel lubricating nozzles
Screw M12 for fastening output shaft caps

1st stage
2nd stage
3rdd stage

Screw M8 for fastening camshaft longitudinal retaining plate
Screw M8 for fastening camshaft gear
Screw M11 for fastening connecting rod caps
1st stage
2ndd stage
Alternator
M10 Screw, Bracket fixing on water feed pipefitting
M10 Screw, alternator locking
Starter
Starter fixing screw

Print P2D32N003GB

Nm
10 ± 2
10 ± 2
53 ± 5
50 ± 5

kgm
1 ± 0.2
1 ± 0.2
5.3 ± 0.5
5 ± 0.5
90º

68 ± 7
24 ± 4
43 ± 6
43 ± 6
85 ± 10
49 ± 5
10 ± 2
24 ± 4
12 ± 2
24 ± 4
8±2
8±2
20 ± 3
6±1
35 ± 5
20 ± 3
6±1
12 ± 2
7±1
43 ± 6
7±1
24 ± 4
35 ± 5
35 ± 5
43 ± 6
24 ± 4
10 ± 2
30 ± 4

6.8 ± 0.7
2.4 ± 0.4
4.3 ± 0.6
4.3 ± 0.6
8.5 ± 1
4.9 ± 0.5
1 ± 0.2
2.4 ± 0.4
1.2 ± 0.2
2.4 ± 0.4
0.8 ± 0.2
0.8 ± 0.2
2 ± 0.3
0.6 ± 0.1
3.5 ± 0.5
2 ± 0.3
0.6 ± 0.1
1.2 ± 0.2
0.7 ± 0.1
4 3 ± 0.6
4.3
06
00.77 ± 0.1
01
2.4 ± 0.4
3.5 ± 0.5
3.5 ± 0.5
4.3 ± 0.6
2.4 ± 0.4
1 ± 0.2
3 ± 0.4
60º ± 5º

24 ± 4
24 ± 4
15 ± 3
50 ± 6
80 ± 6

2.4 ± 0.4
2.4 ± 0.4
1.5 ± 0.3
5 ± 0.6
8 ± 0.6
90º ± 5º

24 ± 4
36 ± 4
60 ± 5

2.4 ± 0.4
3.6 ± 0.4
6 ± 0.5
60º ± 5º

43 ± 6
43 ± 6

4.3 ± 0.6
4.3 ± 0.6

43 ± 6

4.3 ± 0.6

Base - February 2006

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

Base - February 2006

F4HE NEF ENGINES

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 5 - TOOLS

SECTION 5
Tools

Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Print P2D32N003GB

Base - February 2006

SECTION 5 - TOOLS

Base - February 2006

F4HE NEF ENGINES

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 5 - TOOLS

TOOLS
TOOL NO.

DESCRIPTION

99305018

Kit for valve seat regrinding

99305047

Spring load tester

99305453

Tool to check the diesel supply circuit and the common-rail injection
system

99317915

Set of 3 pin wrenches (14 - 17 - 19 mm)

99322205

Revolving stand for overhauling units (700 daN/m capacity, 120
daN/m torque)

99331052

Adapter for measures on engine injectors (use with 99395872)

Print P2D32N003GB

Base - February 2006

SECTION 5 - TOOLS

F4HE NEF ENGINES

TOOLS
TOOL NO.

DESCRIPTION

99340055

Tool to remove output shaft front gasket

99340056

Tool to remove output shaft rear gasket

99341001

Double acting puller

99341009

Pair of brackets

99341015

Press

99342101

Tool to remove injectors

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 5 - TOOLS

TOOLS
TOOL NO.

DESCRIPTION

99346252

Tool for fitting output shaft front gasket

99346253

Tool for fitting output shaft rear gasket

99360076

Tool to remove oil filter (engine)

99360183

Pliers for removing/refitting piston rings (65 — 110 mm)

99360268

Tool for removing/refitting engine valves

99360292

Keying device for seal assembly on the valve guide

Print P2D32N003GB

Base - February 2006

SECTION 5 - TOOLS

F4HE NEF ENGINES

TOOLS
TOOL NO.

DESCRIPTION

99360339

Tool for rotating/stopping the engine flywheel

99360351

Equipment for flywheel holding

99360362

Beater for removing/refitting camshaft bushes (to be used with
993700069)

99360500

Tool for lifting the output shaft

99360595

Lifting rig for engine removal/refitting

99360605

Band for fitting piston into cylinder barrel (60 — 125 mm)

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 5 - TOOLS

TOOLS
TOOL NO.

DESCRIPTION

99361037

Brackets for fastening engine to revolving stand 99322205

99363204

Tool to remove gaskets

99367121

Manual pump for pressure and depression measures

99370006

Handgrip for interchangeable beaters

99370415

Gauge base for different measurements (to be used with 99395603)

99389829

Dog type dynamometric wrench 9x12 (5-60 Nm)

Print P2D32N003GB

Base - February 2006

SECTION 5 - TOOLS

F4HE NEF ENGINES

TOOLS
TOOL NO.

DESCRIPTION

99389834

Torque screwdriver for injector solenoid valve connector stop nut
setting

99395216

Pair of gauges with ½” and ¾” square head for angle tightening

99395220

Universal goniometer/inclinometer

99395363

Complete bush testing square

99395603

Dial gauge (0 — 5 mm)

99395872

Analog to digital multimeter for voltage, current intensity, resistance,
diodes, frequencies, capacity and registration of the minimum, average
and maximum values

Base - February 2006

Print P2D32N00GB

F4HE NEF ENGINES

SECTION 5 - TOOLS

TOOLS
TOOL NO.

DESCRIPTION

8093731

Tester PT01

Print P2D32N003GB

Base - February 2006

SECTION 5 - TOOLS

Base - February 2006

F4HE NEF ENGINES

Print P2D32N00GB

F4HE NEF ENGINES

APPENDIX

Appendix

Page

Print P2D32N003GB

SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . .

- Standard safety prescriptions . . . . . . . . . . . . . .

- Prevention of injury . . . . . . . . . . . . . . . . . . . . .

- During maintenance . . . . . . . . . . . . . . . . . . . . .

- Respect of the Environment . . . . . . . . . . . . . . .

Base - February 2006

APPENDIX

Base - February 2006

F4HE NEF ENGINES

Print P2D32N00GB

F4HE NEF ENGINES

APPENDIX

SAFETY PRESCRIPTIONS
Standard safety prescriptions

- Do not execute any intervention if not provided with
necessary instructions.

Particular attention shall be drawn on some precautions that
must be followed absolutely in a standard working area and
whose non fulfillment will make any other measure useless
or not sufficient to ensure safety to the personnel in-charge
of maintenance.
Be informed and inform personnel as well of the laws in force
regulating safety, providing information documentation
available for consultation.
- Keep working areas as clean as possible, ensuring
adequate aeration.
- Ensure that working areas are provided with emergency
boxes, that must be clearly visible and always provided
with adequate sanitary equipment.
- Provide for adequate fire extinguishing means, properly
indicated and always having free access. Their efficiency
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities.
- Organize and displace specific exit points to evacuate
the areas in case of emergency, providing for adequate
indications of the emergency exit lines.
- Smoking in working areas subject to fire danger must be
strictly prohibited.
- Provide Warnings throughout adequate boards signaling
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of
emergency.

- Do not use any tool or equipment for any different
operation from the ones they’ve been designed and
provided for: serious injury may occur.

Prevention of injury

- In case of test or calibration operations requiring engine
running, ensure that the area is sufficiently aerated or
utilize specific vacuum equipment to eliminate exhaust
gas. Danger: poisoning and death.

During maintenance
- Never open filler cap of cooling circuit when the engine
is hot. Operating pressure would provoke high
temperature with serious danger and risk of burn. Wait
unit the temperature decreases under 50 °C.
- Never top up an overheated engine with cooler and
utilize only appropriate liquids.
- Always operate when the engine is turned off: whether
particular
circumstances
require
maintenance
intervention on running engine, be aware of all risks
involved with such operation.
- Be equipped with adequate and safe containers for
drainage operation of engine liquids and exhaust oil.
- Keep the engine clean from oil tangles, diesel fuel and or
chemical solvents.
- Use of solvents or detergents during maintenance may
originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.

- Do not wear unsuitable cloths for work, with fluttering
ends, nor jewels such as rings and chains when working
close to engines and equipment in motion.

- Do not leave rags impregnated with flammable
substances close to the engine.

- Wear safety gloves and goggles when performing the
following operations:
- filling inhibitors or anti-frost
- lubrication oil topping or replacement
- utilization of compressed air or liquids under pressure
(pressure allowed: ≤ 2 bar).

- Do not utilize fast screw-tightening tools.

- Wear safety helmet when working close to hanging
loads or equipment working at head height level.
- Always wear safety shoes when and cloths adhering to
the body, better if provided with elastics at the ends.
- Use protection cream for hands.
- Change wet cloths as soon as possible
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry
out working operations if not trained for.
- Do not smoke nor light up flames close to batteries and
to any fuel material.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.

Print P2D32N003GB

- Upon engine start after maintenance, undertake proper
preventing actions to stop air suction in case of runaway
speed rate.
- Never disconnect batteries when the engine is running.
- Disconnect batteries before any intervention on the
electrical system.
- Disconnect batteries from system aboard to load them
with the battery loader.
- After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
from accidental short circuit and oxidation.
- Do not disconnect and connect electrical connections
in presence of electrical feed.
- Before proceeding with pipelines disassembly
(pneumatic, hydraulic, fuel pipes) verify presence of liquid
or air under pressure. Take all necessary precautions
bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
injury and poisoning.

Base - February 2006

APPENDIX

- Avoid incorrect tightening or out of couple. Danger:
incorrect tightening may seriously damage engine’s
components, affecting engine’s duration.
- Avoid priming from fuel tanks made out of copper alloys
and/or with ducts not being provided with filters.
- Do not modify cable wires: their length shall not be
changed.
- Do not connect any user to the engine electrical
equipment unless specifically approved by Iveco.
- Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any
unauthorized modification will compromise warranty
assistance and furthermore may affect engine correct
working and duration.
For engines equipped with electronic gearbox:
- Do not execute electric arc welding without having
priory removed electronic gearbox.
- Remove electronic gearbox in case of any intervention
requiring heating over 80 °C temperature.

F4HE NEF ENGINES

Respect of the Environment
- Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
personnel’s safety and health shall be adopted.
- Be informed and inform the personnel as well of laws in
force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate board indications and
organize specific training courses to ensure that
personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Collect exhaust oils in adequate specially provided
containers with hermetic sealing ensuring that storage is
made in specific, properly identified areas that shall be
aerated, far from heat sources and not exposed to fire
danger.
- Handle the batteries with care, storing them in aerated
environment and within anti-acid containers. Warning:
battery exhalation represent serious danger of
intoxication and environment contamination.

- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

Part 2
G-DRIVE APPLICATION ENGINES
Section 1 - General specifications

Page
CORRESPONDENCE BETWEEN TECHNICAL CODE
AND COMMERCIAL CODE . . . . . . . . . . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION - BOOST DIAGRAM . . . . . . .

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . .

Section 2 - G-Drive application

Print P2D32N003GB

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . .

REMOVING AND REFITTING ENGINE
FROM RADIATOR . . . . . . . . . . . . . . . . . . . . .

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Base - February 2006

G-DRIVE ENGINES

Part 2 describes a specific industrial application: G-Drive engines.

These engines are marketed as an assembly that is also equipped with the air/coolant and possibly air/air (intercooler)
cooling device.
The description of this application gives the differences with the industrial application (given in the preceding Parts) and
reference must be made to it for all repair and maintenance work.

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

Example
∅1

Ø 1 = housing for connecting rod small end bush
α

Tighten to torque
Tighten to torque + angular value

∅ 2 Ø 2 = housing for connecting rod bearings

Print P2D32N003GB

Base - February 2006

G-DRIVE ENGINES

SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection

Intake

Refitting
Connection

Exhaust

Removal
Disassembly

Operation

Fitting in place
Assembly

Compression ratio

Tighten to torque

Tolerance
Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation
Adjustment

Angle
Angular value

Visual inspection
Fitting position check

Preload

Measurement
Value to find
Check

Number of revolutions

Equipment

Temperature

Surface for machining
Machine finish
Interference
Strained assembly
Thickness
Clearance
Lubrication
Damp
Grease
Sealant
Adhesive
Air bleeding

bar

Pressure
Oversized
Higher than….
Maximum, peak
Undersized
Less than….
Minimum
Selection
Classes
Oversizing
Temperature < 0 °C
Cold
Winter
Temperature > 0 °C
Hot
Summer

Replacement
Original spare parts

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

UPDATING
Section

Print P2D32N003GB

Description

Page

Date of revision

Base - February 2006

G-DRIVE ENGINES

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

Print P2D32N003GB

Technical Code

Commercial Code

F4HE9685A*J100

Base - February 2006

SECTION 1 - GENERAL SPECIFICATIONS

G-DRIVE ENGINES

Figure 1

Water leaving the thermostat
Coolant recirculating in the engine
Water entering the pump

106529

DIAGRAM OF THE COOLING SYSTEM

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

AIR INDUCTION - BOOST DIAGRAM
Figure 2

106548

Intake air
Compressed air to the heat exchanger
Refrigerated compressed air to the pistons
Exhaust gas

TURBOCHARGING DIAGRAM

The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.

Print P2D32N003GB

Base - February 2006

SECTION 1 - GENERAL SPECIFICATIONS

G-DRIVE ENGINES

OIL VAPOUR RECYCLING
Figure 3

Oil condensate
Oil vapours
108729

1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine.
The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and
condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

GENERAL SPECIFICATIONS
Type

FAHE9685A

Cycle

Four-stroke diesel engine

Power

Supercharged with intercooler

Injection

Direct

Number of cylinders

∅

Bore

104

Stroke

132

cm3

6728

start before T.D.C.
end after B.D.C.

A
B

18.5º
29.5º

start before B.D.C.
end after T.D.C.

D
C

67º
35º

+.. = Total displacement
TIMING

Checking timing
mm

0.20 to 0.30

0.45 to 0.55

Bosch

high pressure common rail
EDC7 ECU

X
X

Checking operation
X

FUEL FEED
Injection
Type:

Nozzle type

Injectors

Injection sequence

1-5-3-6-2 -4

bar

Injection pressure

Print P2D32N003GB

bar

250 ÷ 1450

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

Clearance data - 6 cyl.

FAHE9685A
Type

Compression ratio
Max. output

Max. torque

17 : 1
kW
(HP)

215
292

rpm
Nm
(kgm)

1800
-

rpm
Loadless engine
idling

rpm

Loadless engine
peak rpm

rpm

Bore x stroke

104 x 132

Displacement

6728

TURBOCHARGING

with intercooler

Turbocharger type

HOLSET HX35W

LUBRICATION
Oil pressure (warm engine)
bar

- idling

bar

- peak rpm

bar

COOLING

Forced by gear pump, relief valve single action
oil filter
2
4
By liquid
Through belt

Water pump control
Thermostat
- start of opening

81 ± 2
ºC

FILLING

15W40 ACEA E3

engine sump

liters

engine sump + filter

liters

15 + 1

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

CLEARANCE DATA

6 CYLINDERS

Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
∅1
∅1

103.99 to 104.010

∅2
L

Cylinder barrels — housings on
engine block (interference)

Cylinder barrels

∅

Cylinder barrels:
outside diameter
length

Outside diameter

∅2

0.5

∅3
X

∅1
X
∅2

Cylinder barrels:
inside diameter

∅2

Spare pistons
type:
Size
Outside diameter
Pin housing

X
∅1
∅2

12
103.851 to 103.865
40.00 to 40.25

Piston — cylinder barrels

0.113 to 0.147

Piston diameter

∅1

Piston protrusion

0.5

∅ 3

Piston pin
Piston pin — pin housing

Print P2D32N003GB

0.28 to 0.52

∅3

37.994 to 38
0.0006 to 0.0202

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

6 CYLINDERS

Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
X1
X2
X3
S 1
S 2
S 3

X1*
X2
X3

Split ring slots

* measured on 99 mm ∅

X 2

S 1*
S2
S3

3
2.350 to 2.380
4.030 to 4.050

Split rings - slots

1
2
3

0.100 to 0.175
0.040 to 0.90
0.020 to 0.065

∅ 2

0.5

Split ring end opening
in cylinder barrel:

∅1

3
2.42 to 2.44
4.03 to 4.05

Split rings

Split rings
X1

Small end bush
housing
Big end bearing
housing

X1
X2
X3

0.30 to 0.40
0.60 to 0.80
0.3 to 0.55

∅1

42.987 to 43.013

∅2

72.987 to 73.013

∅4
∅ 3
S

Small end bush diameter
Outside
∅4
Inside
∅3
Spare big end half
bearings
S
Small end bush — housing
Piston pin — bush
Big end half bearings

Base - February 2006

40.987 to 41.013
38.019 to 38.033
1.955 to 1.968
0.266 to 0.566
0.0188 to 0.0372
0.250; 0.500; 0.750; 1.000

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

6 CYLINDERS

Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS

X
Size

Max. tolerance
on connecting rod
axis alignment
∅1

∅2

S 1

Journals
Crankpins

∅1
∅2

82.99 to 83.01
73.533 to 74.513

Main half bearings
Big end half bearings

S1
S2

2.456 to 2.464
1.955 to 1.968

∅3
∅3

87.982 to 88.008
87.977 to 88.013

S 2
*provided as spare part

∅ 3

Main bearings
No. 1—7
No. 2—3—4—5—6
Half bearings — Journals
No. 1—7
No. 2—3—4—5—6

0.044 to 0.106
0.039 to 0.111

Half bearings - Crankpins

0.038 to 0.116

Main half bearings
Big end half bearings

+0.250; +0.500; +0.750; +1.000

Shoulder journal

37.28 to 37.38

Shoulder main bearing

28.77 to 29.03

Shoulder half-rings

37.28 to 37.38

X 1

X 2
X 3

Output shaft shoulder

Print P2D32N003GB

0.095 to 0.265

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

6 CYLINDERS

Type
CYLINDER HEAD — TIMING SYSTEM
∅ 1

Valve guide seats on
cylinder head

∅1

7.042 to 7.062

∅2

∅3

∅ 2

Valve guides
∅ 3

∅ 4

Valve guides and seats on head

Valve guides

Valves:

∅4
α

6.970 to 6.999
60 ± 0.25°

∅4
α

6.970 to 6.999
45 ± 0.25°

Valve stem and guide

0.043 to 0.092

Housing on head for
valve seat:

∅ 1

34.837 to 34.863

∅1

34.837 to 34.863

Valve seat outside diameter;
valve seat angle on cylinder
head:
∅2
α

∅ 2

∅2
α

Sinking
Between valve seat
and head
Valve seats

Base - February 2006

∅1

34.917 to 34.931
60°
34.917 to 34.931
45°

0.59 to 1.11

0.96 to 1.48
0.054 to 0.094
0.054 to 0.094
-

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

6 CYLINDERS

Type
CYLINDER HEAD — TIMING SYSTEM

Valve spring height:
free spring
H

H 2 under a load equal to:
339.8 ± 9 N
741 ± 39 N
Injector protrusion

47.75

H1
H2

35.33
25.2

∅ ∅ ∅
1 23 4 5

Camshaft bush
housings No. 1

59.222 to 59.248

Camshaft housings
No. 2-3-4-5-6-7

54.089 to 54.139

∅ 2
Camshaft journals:
1⇒7
∅ 1

∅

54.005 to 54.035

∅ 3
∅

Camshaft bush outside
diameter:
∅

∅

Bush inside
diameter

∅

54.083 to 54.147

Bushes and housings
on block

Bushes and journals

0.038 to 0.162

Cam lift:
H

Print P2D32N003GB

6.045

7.582

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

6 CYLINDERS

Type
CYLINDER HEAD — TIMING SYSTEM

∅1
Tappet cap housing
on block
∅2
∅ 3

Tappet cap outside
diameter:

∅2

∅1

16.000 to 16.030

∅2
∅3

15.924 to 15.954
15.960 to 15.975

Between tappets and housings
Tappets

0.025 to 0.070
-

∅ 1
Rocker shaft

∅1

21.965 to 21.977

Rockers

∅2

22.001 to 22.027

∅ 2
Between rockers and shaft

Base - February 2006

0.024 to 0.162

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

REMOVING AND REFITTING ENGINE FROM RADIATOR
Figure 4

108598

Removal
Remove the fan safety grilles (5) by undoing the relevant
fasteners.
Place a container under the pipe (12) to collect the coolant.
Disconnect and remove the pipe (12) together with the
sleeves by undoing the clamps.
Disconnect the air pipes (4) and (15) from the air exchanger
and from the engine, then remove it from its seat. Disconnect
the exhaust pipe (14) from the system.
Disconnect and remove the coolant pipes (1) and (2).
Block the radiator assembly (3) appropriately, then detach it
from the crankcase by undoing the fasteners (6) on both
sides.
Remove the radiator assembly from its seat, taking care over
any interference with the fan.

Disconnect the air hose (9) from air filter (10) to the turbine
(8).
Remove the air cleaner (10) by undoing the fasteners (7) and
remove it from its seat together with the support (11).

Refitting
Proceed by reversing the operations described for removal;
restore the coolant system.

NOTE Check the state of wear of the rubber couplings.

Print P2D32N003GB

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

TOOLS
TOOL NO.

DESCRIPTION

99305018

Kit for valve seat regrinding

99305047

Spring load tester

99305453

Tool to check the diesel supply circuit and the common-rail injection
system

99317915

Set of 3 pin wrenches (14 - 17 - 19 mm)

99322205

Revolving stand for overhauling units (700 daN/m capacity, 120
daN/m torque)

99331052

Adapter for measures on engine injectors (use with 99395872)

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

TOOLS
TOOL NO.

DESCRIPTION

99340055

Tool to remove output shaft front gasket

99340056

Tool to remove output shaft rear gasket

99341001

Double acting puller

99341009

Pair of brackets

99341015

Press

99342101

Tool to remove injectors

Print P2D32N003GB

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

TOOLS
TOOL NO.

DESCRIPTION

99346252

Tool for fitting output shaft front gasket

99346253

Tool for fitting output shaft rear gasket

99360076

Tool to remove oil filter (engine)

99360183

Pliers for removing/refitting piston rings (65 — 110 mm)

99360268

Tool for removing/refitting engine valves

99360292

Keying device for seal assembly on the valve guide

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

TOOLS
TOOL NO.

DESCRIPTION

99360339

Tool for rotating/stopping the engine flywheel

99360351

Equipment for flywheel holding

99360362

Beater for removing/refitting camshaft bushes (to be used with
993700069)

99360500

Tool for lifting the output shaft

99360595

Lifting rig for engine removal/refitting

99360605

Band for fitting piston into cylinder barrel (60 — 125 mm)

Print P2D32N003GB

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

TOOLS
TOOL NO.

DESCRIPTION

99361037

Brackets for fastening engine to revolving stand 99322205

99363204

Tool to remove gaskets

99367121

Manual pump for pressure and depression measures

99370006

Handgrip for interchangeable beaters

99370415

Gauge base for different measurements (to be used with 99395603)

99389829

Dog type dynamometric wrench 9x12 (5-60 Nm)

Base - February 2006

Print P2D32N00GB

G-DRIVE ENGINES

SECTION 2 - G-DRIVE APPLICATION

TOOLS
TOOL NO.

DESCRIPTION

99389834

Torque screwdriver for injector solenoid valve connector stop nut
setting

99395216

Pair of gauges with ½” and ¾” square head for angle tightening

99395220

Universal goniometer/inclinometer

99395363

Complete bush testing square

99395603

Dial gauge (0 — 5 mm)

99395872

Analog to digital multimeter for voltage, current intensity, resistance,
diodes, frequencies, capacity and registration of the minimum,
average and maximum values

Print P2D32N003GB

Base - February 2006

SECTION 2 - G-DRIVE APPLICATION

G-DRIVE ENGINES

TOOLS
TOOL NO.

DESCRIPTION

8093731

Tester PT01

Base - February 2006

Print P2D32N00GB

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Title                           : COPERTINA
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COPERTINA FUIF511 27D Repair Manual N45 And N67 ENT Tier3 P2D32N003E Feb06

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