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

User Manual: FUIF511-27D

Open the PDF directly: View PDF .
Page Count: 186 [warning: Documents this large are best viewed by clicking the View PDF Link!]

NEF TIER 3 SERIES

NEF TIER 3 SERIES

Industrial application

N45

N45 ENT

N67

N67 ENT

Technical and Repair manual

Publication edited by

Iveco Motors

Iveco SpA

PowerTrain

Mkt. Advertising & Promotion

Viale dell’Industria, 15/17

20010 Pregnana Milanese

Milano (Italy)

Print P2D32N003GB -1

st Ed. 02.2006

This publication describes the characteristics, data and correct

methods for repair operations on each component of the ve-

hicle.

If the instructions provided are followed and the specified

equipment is used, correct repair operations in the pro-

grammed 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 in-

spected 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 na-

ture or for adaptation to the legal requirements of the differ-

ent countries, some changes may have occurred.

No part of this publication, including the pictures, may be re-

produced in any form or by any means.

B.U. TECHNICAL PUBLISHING

Iveco Technical Publications

Lungo Stura Lazio, 15/19

10156 Turin - Italy

Produced by:

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.

PRELIMINARY REMARKS

General danger

It includes the dangers of above described signals.

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.

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.

Danger for persons

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

SYMBOLS - WARNINGS

It indicates an additional explanation for a piece of information.

NOTE

NEF TIER 3 ENGINES

Print P2D32N003GB Base - February 2006

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, besidesweight,onitssizeandon

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.

4NEF TIER 3 ENGINES

Base - February 2006 Print P2D32N00GB

GENERAL

ARNINGS

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.

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.

NEF TIER 3 ENGINES

Print P2D32N003GB Base - February 2006

GENERAL

ARNINGS ON THE ELECTRIC S

STEM

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.

Ifaninterventionhastobemadeontheelectric/electronicsystem, 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.

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

side.

NOTE

6NEF TIER 3 ENGINES

Base - February 2006 Print P2D32N00GB

NEF TIER 3 ENGINES

Print P2D32N003GB Base - February 2006

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.

1. NEGATIVE CABLES “STAR“CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR

d. DISTANCE !0

88039

Figure 1

Figure 2

8NEF TIER 3 ENGINES

Base - February 2006 Print P2D32N00GB

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 OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power

1 kW = 1.36 metric HP

1 kW = 1.34 HP

1 metric HP = 0.736 kW

1 metric HP = 0.986 HP

1 HP = 0.746 kW

1 HP = 1.014 metric HP

Torque

1 Nm = 0.1019 kgm

1 kgm = 9.81 Nm

Revolutions per time unit

1 rad/s = 1 rpm x 0.1046

1 rpm = 1 rad/s x 9.5602

Pressure

1bar = 1.02kg/cm

1 kg/cm2= 0.981 bar

1 bar = 105Pa

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/cm2according to ratio 1:1

1 kg/cm2=1bar.

Temperature

0°C=32°F

1°C = (1 x 1.8 + 32) °F

F4HE engines Part 1

G-Drive Application Engines Part 2

NEF TIER 3 ENGINES

NEF TIER 3 ENGINES 1

Print P2D32N003GB Base - February 2006

2NEF TIER 3 ENGINES

Base - February 2006 Print P2D32N00GB

Sezione

General specifications 1

Fuel 2

Duty - Industrial application 3

Overhaul and technical specifications 4

Tools 5

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 sepa-

rate 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 incon-

veniences.

Sections 4 and 5 illustrate the overhaul operations of the engi-

ne overhaul on stand and the necessary equipment to execute

such operations.

Part 1

F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

2F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

Tighten to torque

Tighten to torque + angular value

∅

∅2

F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

SPECIAL REMARKS

4F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

SYMBOLS - ASSISTANCE OPERATIONS

Removal

Disconnection Intake

Refitting

Connection Exhaust

Removal

Disassembly Operation

Fitting in place

Assembly ρCompression 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 bar Pressure

Interference

Strained assembly

Oversized

Higher than….

Maximum, peak

Thickness

Clearance

Undersized

Less than….

Minimum

Lubrication

Damp

Grease

Selection

Classes

Oversizing

Sealant

Adhesive

Temperature < 0 °C

Cold

Winter

Air bleeding

Temperature > 0 °C

Hot

Summer

Replacement

Original spare parts

F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

UPDATING

Section Description Page Date of revision

6F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

SECTION 1 - GENERAL SPECIFICATIONS 1

F4AE NEF ENGINES

Print P2D32N003GB Base - February 2006

SECTION 1

General specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE 3.............

LUBRICATION 5..........................

-4-cylinder engine version 5.................

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

OIL VAPOUR RECYCLING 7................

COOLING SYSTEM 8......................

-4-cylinder engine version 8.................

-6-cylinder engine version 9.................

AIR INDUCTION - BOOST DIAGRAM 10.......

-Description 10............................

2SECTION 1 - GENERAL SPECIFICATIONS F4AE NEF ENGINES

Base - February 2006 Print P2D32N00GB

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

SECTION 1 - GENERAL SPECIFICATIONS 3

F4AE NEF ENGINES

Print P2D32N003GB Base - February 2006

Technical Code Commercial Code

F4HE9484A*J101 N45 ENT

F4HE9684P*J101 N67 ENT

4SECTION 1 - GENERAL SPECIFICATIONS F4AE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 1

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.

From the pan, the lubrication oil flows to the driving shaft, to

the camshaft and to the valve drive.

Lubrication involves the heat exchanger as well, the turbo-

blower and the eventual compressor for any eventual com-

pressed air system. All these components may often vary ac-

cording to the specific duty and will therefore be examined in

the specific section.

Oil recover from the

turbo-blower

To the exchanger

and to the

turbo-blower

LUBRICATION SYSTEM LAYOUT

4-cylinder engines

Routing of oil return by gravity to sump

Introduction of oil

(Demonstration)

4-cylinder engine version

108511

SECTION 1 - GENERAL SPECIFICATIONS 5

F4AE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 2

LUBRICATION SYSTEM LAYOUT

6-cylinder engines

Routing of oil under pressure

Routing of oil return by gravity to sump

Introduction of oil

6-cylinder engine version

Even for the 6 cylinders version lubrication is obtained by

forced circulation and achieved through an oil rotary expan-

sion pump similar to the 4 cylinders’ one.

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.

Oil recover from the

turbo-blower

To the

exchanger and

to the

turbo-blower

(Demonstration)

108512

6SECTION 1 - GENERAL SPECIFICATIONS F4AE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70484

Figure 3

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).

Oil condensate

Oil vapours

OIL VAPOUR RECYCLING

SECTION 1 - GENERAL SPECIFICATIONS 7

F4AE NEF ENGINES

Print P2D32N003GB Base - February 2006

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,ifthisisincludedintheequipment.

Figure 4 (Demonstration)

4-cylinder engine version

74194

Expansion tank

Heater

(optional)

Expansion tank

Radiator

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

COOLING SYSTEM LAYOUT

4-cylinder engines

8SECTION 1 - GENERAL SPECIFICATIONS F4AE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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 equip-

ment and duty.

Figure 5 (Demonstration)

COOLING SYSTEM LAYOUT

6-cylinder engines

108513

Expansion

tank

Heater

(optional)

Expansion tank

Radiator

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

SECTION 1 - GENERAL SPECIFICATIONS 9

F4AE NEF ENGINES

Print P2D32N003GB Base - February 2006

74195

Figure 6

AIR INDUCTION - BOOST DIAGRAM

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 above mentioned air is then cooled by the radiator and

flown through the piston induction collector.

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.

RADIATOR

AIR FILTRE TURBOCHARGER

EXHAUST

4 Cylinders version

6 Cylinders version

RADIATOR

AIR FILTRE TURBOCHARGER

EXHAUST

10 SECTION 1 - GENERAL SPECIFICATIONS F4AE NEF ENGINES

Base - February 2006 Print P2D32N00GB

SECTION 2 - FUEL 1

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

SECTION 2

Fuel

Page

HIGH PRESSURE ELECTRONIC INJECTION

SYSTEM (COMMON RAIL) 3..............

EDC 7 OPERATION 4......................

WORKING PROCESS 5.....................

FUEL SYSTEM LAYOUT 6...................

MECHANICAL FEEDING PUMP 7............

CP3 HIGH PRESSURE PUMP 8...............

RAIL 12...................................

BOOST GAUGE VALVE 13...................

ELECTRO-INJECTOR 14.....................

-Electro-injector 15.........................

PRESSURE LIMITER FOR FUEL RETURN 16......

2SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 1

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.

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 preci-

sion obtained by electronic control of the system serves to

optimise operation of the engine while limiting emissions and

fuel consumption.

For engines more powerful than 152 kW, the CRIN2 injec-

tors 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 para-

meters by means of the various sensors on the engine.

107851

SECTION 2 - FUEL 3

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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:

-disactivation of the electro-injectors;

-reactivation of electro-injectors immediately prior to

arrival at idle speed;

-control of fuel pressure regulator.

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%.

4SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 2

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.

WORKING PROCESS

High Pressure

Low Pressure

Fuel outlet

108607

SECTION 2 - FUEL 5

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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.CommonRail.—6.Pressuresensor.—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.

FUEL S

STEM LA

OUT

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 en-

gine).

The pressure regulator, placed upstream of the high-pressure

pump, adjusts the fuel flow that is necessary on the low-pres-

sure system. Afterwards, the high-pressure pump takes care

of supplying the rail properly. This arrangement, by pressuris-

ing 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.

The pressure relie

e(2)in

erven

ion brings abou

uel

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, as-

sembled 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 ex-

ceeds the allowed threshold value.

The by-pass valve (17) allows filling the supply system

through the manual priming pump (10).

108608

Figure 3

EXHAUST

SUCTION

SUPPLY SYSTEM FOR HIGH PRESSURE PUMP

(LOW PRESSURE)

HIGH PRESSURE

6SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

MECHANICAL FEEDING PUMP

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 4

72592

A- Fuel entry flowing from the tank. B- Fuel exhaust to filter,

I - 2 By-pass valves in close position.

Overpressure condition in Exhaust unit

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).

Figure 6

Jettison condition

72594

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.

The mechanical feeding pump cannot be replaced

separately, therefore it must not be disassembled

from the high pressure pump.

Ordinary working condition

SECTION 2 - FUEL 7

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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.

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.

8SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70498

Figure 8

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;

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.

Sec. B-B

Sec. C-C

-cap intake valve (3);

-ball delivery valve (4).

High pressure pump-inside structure

SECTION 2 - FUEL 9

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 9

Working principle

72597

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.

Sec. D-D

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.

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).

Sec. B-B

10 SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 10

72601

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.

Sec.C-C 72598

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).

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.

Figure 11

Sec. A - A

1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel

exhaust flowing from pump with connector to high

pressure pipe for common rail.

Figure 11 shows the fuel flow under high pressure running

through the exhaust galleries of the pumping elements.

SECTION 2 - FUEL 11

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 12

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).

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.

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.

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.

RAIL

108609

12 SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70502

Figure 13

70500

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.

A Normally, the tapered piston end keeps closed the

discharge towards the tank.

B If the 1750 bar fuel pressure is exceeded in rail, the small

piston is displaced and the excess pressure is discharged

into the tank.

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

SECTION 2 - FUEL 13

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70505

70506

Figure 14

Figure 15

ELECTRO-INJECTOR

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.

Injector in rest position

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.

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.

Injection start

The injector cannot be overhauled and therefore it

must not be disassembled.

14 SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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).

Figure 16

108610

1. Jet.

SECTION 2 - FUEL 15

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Jet Powers Pressures

DLLA Up to 152 kW 250 ÷1600 bar

DSLA Lower to 152 kW 250 ÷1450 bar

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.

70507

Figure 17

ATo tank — BFrom injectors

16 SECTION 2 - FUEL F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 1

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

SECTION 3

Duty-industrial application

Page

GENERAL SPECIFICATIONS 3...............

-Section pictures of complete engine -

common rail version 3....................

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

-Clearance data - 6 cyl. 5...................

PART ONE -

MECHANICAL COMPONENTS 7.........

ENGINE OVERHAUL 9.....................

-Preface 9..............................

-Engine setting operations for the assembly

on turning stand 9.......................

-Disassembly of application components 10.....

-Assembly of application components 17.......

-Completion of the engine 29................

-Checks and inspections 30..................

PART TWO -

ELECTRICAL EQUIPMENT 31.............

LOCATION OF THE MAIN ELECTRICAL

COMPONENTS 33.......................

-EDC7 ECU 34...........................

-Cable on engine 35.......................

-Injectors connector (A) 36..................

-Sensors connector (C) 36..................

-Crankshaft sensor 37......................

-Timing sensor 37.........................

-Supercharging air pressure - temperature sensor 38

-Engine oil temperature-pressure sensor 38.....

2SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Page

-Fuel temperature and pressure sensor 39.......

-Electro-injectors 40........................

-Pre-post heating resistance and contactor 41....

-Coolant temperature sensor 42..............

-Fuel temperature sensor 43.................

-High pressure pump - pressure regulator 44....

PART THREE - TESTS - TROUBLESHOOTING 45

TESTS 47.................................

CHECKING THE FUEL SYSTEM 47.............

DESCRIPTION OF TESTS AND CHECKS

THAT CAN BE PERFORMED 47............

-Necessary equipment 47...................

-Low pressure supply test 48.................

-Low-Pressure Pump 49.....................

-Test on the pressure relief valve on the rail 50...

-Test on fuel backflow from the return 51.......

TROUBLESHOOTING 53....................

PART FOUR -

MAINTENANCE PLANNING 55...........

Page

MAINTENANCE PLANNING 57..............

-Recovery 57.............................

-Regular maintenance and inspection planning 57.

-Checks not included in maintenance

planning-daily checks 58....................

MAINTENANCE PROCEDURES 58............

-Checks and inspections 58..................

-Engine oil level check 58................

-Combustion system inspection 59........

-Cooling system inspection 59............

-Lubricating system inspection 59.........

-Inspection of water presence within

fuel filter or pre-filter 59................

-Inspection/replacement of blow-by filter 60.

-Inspection of drive belt tensioning 60......

-Inspection and setting of tappet clearance 60

-Oil motor and filter replacement 61.......

-Fuel filter replacement 62...............

-Alternator belt replacement 62...........

Figure 1

GENERAL SPECIFICATIONS

Section pictures of complete engine - common rail version

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.

108540

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 3

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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.

4SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Clearance data - 4 cyl.

Type

ρCompression ratio 16.5 : 1

Max. output kW

(HP)

rpm

104

141

2200

Max. torque Nm

(kgm)

rpm

560

1400

Loadless en

ine

idling rpm -

Loadless engine

peak rpm -

oke

Displacement

104 x 132

4485

TURBOCHARGING

Turbocharger type

with intercooler

HOLSET HX27W

bar LUBRICATION Forced by gear pump, relief valve single action

oil filter

Oil pressure (warm engine)

- idling bar

-peakrpm bar

0.7

4.0

COOLING

Water pump control

Thermostat

-startofopening °C

By liquid

Through belt

82.2

15W40 ACEA E3

FILLING

engine sump liters

engine sump + filter liters

5.3

6.3

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.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 5

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Clearance data - 6 cyl.

Type

ρCompression ratio 17.5 : 1

Max. output kW

(HP)

rpm

175

234

2300

Max. torque Nm

(kgm)

rpm

1020

102

1500

Loadless en

ine

idling rpm -

Loadless engine

peak rpm rpm -

oke

Displacement

104 x 132

6728

TURBOCHARGING

Turbocharger type

with intercooler

HOLSET HX35W

bar

LUBRICATION

Oil pressure (warm engine)

- idling bar

Forced by gear pump, relief valve single action

oil filter

- peak rpm bar 2

COOLING

Water pump control

Thermostat

- start of opening ºC

By liquid

Through belt

81 ±2

15W40 ACEA E3

FILLING

engine sump liters

engine sump + filter liters

15 + 1

6SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

PART ONE - MECHANICAL COMPONENTS

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 7

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

DIAGNOSI

8SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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.

Disconnect the pipeline (7) feeding the mechanic pump that

is combined to the high pressure pump through the

exchanger of the engine control module.

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.

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.

Figure 2

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.

70126

Figure 3

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.

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;

-re-use the disassembled pipelines.

Engine setting operations for the assembly on

turning stand

ENGINE OVERHAUL

Preface

108541

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 9

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 4

On the right hand side of the engine:

Remove the screws and remove the oil pipe (1) from the

turbocharger pipe (2) and from the engine block.

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).

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.

74166

Figure 5

74168

Figure 6

Disassembly of application components

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.

108542

10 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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 7

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

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).

74170

Disconnectthepipeline(2)fromthefuelrecover

pressure-limiter, working on the connections as described in

Figure 3.

Unscrew the nut and loosen the clamp tightening the oil

vapour pipe.

Removethepipe(6).

Loosen the screws (3) and disassemble the blow-by filter (4).

Remove on the nuts and tappet cover.

Figure 8

Figure 9

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).

Disassembled fuel manifolds (4) must not be used

again, replace with new ones during reassembly.

108543

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 11

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 10

Figure 11

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).

70133

Remove injector fastening screws. Use tool 99342101 (1) to

remove injectors (2) from the cylinder head.

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.

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.

Figure 12

Figure 13

108545

108546

12 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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.

Figure 14

Figure 15

Remove the screws (2) and disconnect the alternator

support (3).

Use tool 99360076 to remove the oil filter (1).

Figure 16

Hook brackets (1) with suitable lifting chains and remove

cylinder head (2) from block using hoist.

Figure 17

Remove the screws (4) and disconnect the oil

temperature/pressure sensor (3).

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 18

Remove the screws (1) and disconnect the ECU (2) including

the heat exchanger.

74174

Figure 19

Unloose the screws (3) and remove the cap (1). Keep the

gasket (4), the power take-off (2) and the second gasket (4).

74176

108547

74779

108549

108580

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 13

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 20

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).

Figure 21

Remove the screws (3) and disassemble the damping

flywheel (2) and the pulley (1).

Figure 22

Figure 23

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).

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).

00900t

Figure 24

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).

70146

Fit tool 99360339 (2) to the flywheel housing (1) to stop

flywheel (3) rotation.

Loosen the screws (4).

Figure 25

108548

108549

14 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 26

70149

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

Take note of screw (1) assembling positions since

they have different lengths.

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.

Figure 27

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

Figure 28

Figure 29

70152

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.

00903t

Figure 30

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.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 15

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70153

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

Take note of screw (2) assembling positions since

they have different sizes.

74775

Figure 31

Overturn the engine.

Remove the screws (2), disassemble the plate (3) and

disconnect the oil sump (1).

Figure 32

Remove the screws (1 and 4) and disassemble the oil suction

tube (5). Remove the screws (2) and disassemble the

stiffening plate (3).

70156

Figure 33

Remove the screws (1) and remove the gear (3) from the

camshaft (2).

70157

Figure 34

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

(1).

Take note of screw (2) assembling positions since

they have different sizes.

Figure 35

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.

However the procedures described are still

applicable.

For F4HE0684 engines the stiffening plate (4) has a

single element.

86516

16 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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:

ScrewsM12 65to89Nm

Screws M8 20 to 28 Nm

ScrewsM10 42to52Nm

Figure 36

Assembly of application components

LOCTITE 5205 SEALANT APPLICATION AREAS

Clean accurately the timing gear case (1) and the engine

block.

70209

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).

70210

Figure 37

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.

Fasten screwing of the two pins to facilitate the

operation of engine driving shaft rotation.

Before any assembly operation always verify that the

hole and screw threads have no evidence of wear or

dirt.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 17

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 39

Rotate the output shaft (4) and thecamshaft (2) so that when

fitting the driven gear (1) on the camshaft the marks on the

gears (1 and 3) are coinciding.

Figure 40

70213

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

the specified torque.

Figure 41

70214

LOCTITE 5205 SEALANT APPLICATION AREAS

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).

Figure 42

70215

SEQUENCE FOR TIGHTENING THE FLYWHEEL

HOUSING FASTENING SCREWS

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

showninthefigure:

ScrewsM12 75to95Nm

ScrewsM10 44to53Nm

Not available

On engines

F4AE0684H-E

F4HE0684E-F-J

Before any assembly operation always verify that the

hole and screw threads have no evidence of wear or

dirt.

108577

18 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 43

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.

Figure 44

Figure 45

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 46

70219

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.

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).

Screw two pins (2) having suitable length into shaft holes (3)

and remove the engine flywheel (1) using proper sling and

hoister.

70152

Figure 47

0901t

Tighten engine flywheel (2) fastening screws (1) in two

stages:

-1st stage, tightening to 30 ±4Nmtorquewith

dynamometric wrench;

-2nd stage, tightening to 60 ±5°angle.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 19

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 48

70220

Fit the oil pump (1).

Tighten the fastening screws (2) to the specified torque.

Figure 49

70221

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

Figure 50

Fit the water pump (1).

Tighten the screws (2) to the specified torque.

Figure 51

70223

Remove the sealing ring (2) from the front cover (1), clean

accurately the coupling surfaces and smear them with

LOCTITE 5205.

Clean accurately the front cover (2) surface and refit it.

Tighten the screws (1) to the specified torque.

Figure 52

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).

00902t

Figure 53

70222

70224

20 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 54

Fit the plate (1), the oil pick up tube (2) and tighten the

fastening screws (3) to the specified torque.

Figure 55

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.

Figure 56

Fit the oil sump (1) and apply the plate (3) to it.

Tighten the screws (2) to the specified torque.

74775

Figure 57

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.

70230

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

Fit the speed sensor (3) on the front cover (1) and tighten

the screw (2) to the specified torque.

Figure 58

Figure 59

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. !

Before any assembly operation always verify that the

hole and screw threads have no evidence of wear or

dirt.

108553

108548

108576

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 21

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 60

Figure 61

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.

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.

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.

Refit the alternator (1).

Tighten the screw (2) to the specified torque.

Figure 62

Figure 63

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.

70145

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.

Figure 64

Before any assembly operation always verify that the

hole and screw threads have no evidence of wear or

dirt.

108578 108550

108552

22 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 65

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.

74176

Figure 66

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.

74174

Figure 67

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.

Figure 68

Assemble cylinder head (1), tighten the screws (2) in three

following steps, following order and mode shown in the

figure below.

The angle tightening is carried out through tool

99395216 (3).

70336

Tightening order layout for cylinder head fastening screws:

-1st step pre-tightening with dynamometric wrench:

•Screw 12x1.75x130 ( ) 35 ±5Nm

•Screw 12x1.75 x 150 ( ) 55 ±5Nm

-2nd step tightening with a 90 ±5°angle

-3rd step tightening with a 90 ±5°angle

A=Frontside

70476

Figure 69

74779

6-cylinder engine

Before any assembly operation always verify that the

hole and screw threads have no evidence of wear or

dirt.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 23

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 70

Figure 71

70338

Fit a new sealing ring (2) lubricated with petroleum jelly and

a new sealing washer (3) on injector (1).

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.

Figure 72

70133

Use tool 99342101 (1) to fit the injector (2) into its seat.

Screw injector fastening screws without tightening them.

Figure 73

70337

4-cylinder engine A

Cylinder head fastening screws tightening sequence:

-1st stage pre-tightening, with a torque wrench::

•Screw 12x1.75x130 ( ) 35 ±5Nm

•Screw12x1.75 x 150 ( ) 55 ±5Nm

A = Lato anteriore

-2nd stage tightening with angle 90 ±5°

-3rd stage tightening with angle 90 ±5°

24 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 74

Figure 75

Figure 76

Figure 77

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).

Disassembled fuel manifolds (2) must not be used

again. Replace with new items.

The fuel manifolds (2) for F4HE0684 engines have

2 positioning spheres.

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).

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.

Carry out the assembly of the equalisers’ unit , after previous

check of the components.

70343

ROCKER ASSEMBLY COMPONENTS:

1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.

SHAFT-ROCKER MAIN DATA

Check that shaft/rocker coupling surfaces are not showing

excessive wear or damages.

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.

32655

Figure 78

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

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 25

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 79

Figure 80

Figure 81

70345

Fit the rods (2).

Position jumpers (1) on valves with marks (→)facingthe

exhaust manifold.

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.

70520

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.

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.

26 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 82

Figure 83

Figure 84

Figure 85

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.

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.

Connect new fuel pipes (1) to rail (3) and injector manifolds

(2).

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.

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.

Figure 86

108547

108567

108568

108569

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 27

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70352

Figure 87

Figure 88

Figure 89

Figure 90

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).

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

specified torque.

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

Place the tappet cover on, install the bolts in the correct

position and tighten.

70355

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.

Before any assembly operation always verify that the

hole and screw threads have no evidence of wear or

dirt.

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 91

108570

108571

108572

28 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

74170

Figure 92

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).

Figure 93

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.

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.

Figure 94

70126

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

picture.

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)

Figure 95

108541

Completion of the engine

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.

Proceed assembling the oil filter.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 29

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

-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.

Checks and inspections

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:

The following checking inspections must be carried

out after the engine assembly on the vehicle .

30 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

PART TWO - ELECTRICAL EQUIPMENT

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 31

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

32 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 96

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.

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).

The electrical and electronic components of the engine are

listed here following:

1. Coolant temperature sensor.

2. Electro-injector.

3. RAIL pressure sensor.

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.

LOCATION OF THE MAIN ELECTRICAL COMPONENTS

108641

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 33

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 97

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

C - Connector to sensors.

01525t

EDC7 ECU

34 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 98

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).

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.

0051064t

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 35

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Injectors connector (A) Sensors connector (C)

36 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

ECU PIN FUNCTION ECU PIN ECU PIN

1Cylinder 5 injector 1 -

2Cylinder 6 injector 2 -

3Cylinder 4 injector 3 -

4Cylinder 1 injector 4 -

5Cylinder 3 injector 5 -

6Cylinder 2 injector 6 -

7 - 7 -

8 - 8 -

9Pressure regulator 9Timing sensor

10 Pressure regulator 10 Timing sensor

11 Cylinder 2 injector 11 -

12 Cylinder 3 injector 12 Negative for rail temperature and pressure sensor

13 Cylinder 1 injector 13 Positive for rail temperature and pressure sensor

14 Cylinder 4 injector 14 Signal from rail temperature and pressure sensor

15 Cylinder 6 injector 15 Coolant temperature sensor

16 Cylinder 5 injector 16 -

17 -

18 Signal from fuel temperature sensor

19 Engine rpm sensor

20 -

21 -

22 -

23 Engine rpm sensor

24 Negative for engine oil pressure and temperature

sensor

25 Negative for air temperature and pressure sensor

26 Coolant temperature sensor

27 Signal from engine oil pressure sensor

28 Signal from engine oil temperature sensor

29 -

30 -

31 -

32 Positive for engine oil pressure and temperature

sensor

33 Positive for air temperature and pressure sensor

34 Signal from air pressure sensor

35 Negative for fuel temperature sensor

36 Signal from air temperature sensor

Figure 99

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.

50319

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 areNOTinterchangeablebecauseofthe different external shape.

The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance

is ∼900 Ω.

Figure 100

5028850342

Connector Wiring diagram

50320

Timing sensor

312

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 37

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

ECU pin

esc

on Camshaft sensor Timing sensor

1Signal 19C 10C

2Signal 23C 9C

3Shield

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 Temperature

Pin 33C - 34C 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 Temperature

Pin 32C - 27C Pressure

Figure 101

5034450324

Wiring diagram

38 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

ECU Pin

esc

on Oil Air

1Ground 24C 25C

2NTC signal (temperature) 28C 36C

3+5 V power input 32C 34C

4Signal (pressure) 27C 34C

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

Fuel pressure sensor connector

0051065t

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 39

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Ref. Description ECU pin

1Ground 12C

2Signal 14C

3Power supply 13C

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.

Figure 103

50343

50349

Figure 104

40 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Ref. Description ECU pin

CONNECTOR 1

Cylinder 2 injector

Cylinder 1 injector

11 A

13 A

CONNECTOR 2

Cylinder 4 injector

Cylinder 3 injector

14 A

12 A

CONNECTOR 3

Cylinder 6 injector

Cylinder 5 injector

15 A

16 A

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

Figure 106

003215t

Resistance

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.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 41

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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

42 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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

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

0051140t

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

107798107799

Connector

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 43

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

ECU Pin

esc

on Coolant Fuel

1Ground 15C 35C

2Temperature signal 26C 18C

High pressure pump - pressure regulator

Figure 109

A. Pressure regulator.

000912t

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.

44 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

PART THREE - TESTS - TROUBLESHOOTING

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 45

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

46 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 110

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.

108599

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.

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.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 47

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Error Description

8.1 - 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).

- Drop in fuel pressure with the engine idling (lack of diesel).

8.2 - Fuel pressure sensor on rail.

8.4 - Backflow valve control (opening the pressure relief valve DBV).

8.5 - Fuel pressure in the rail too high.

- Fuel pressure in the rail too low.

Figure 111

Low pressure supply test

The figure shows the diagram for using the components available in the kit dwg. 99305453.

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

48 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 113

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.

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:

-OnpressuregaugeM1itmustbebetween6and9bar.

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.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 49

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 114

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.

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.

50 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 115

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.

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

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 51

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 117

-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).

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

ductsisasdesigned(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.

52 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 53

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

ANOMALY POSSIBLE CAUSE

(*) = if available in the equipment

RECOMMENDED TESTS OR

INTERVENTION REMARKS

Low performance at load request.

Possible exessive smoke.

Possible blink-code 8.1

Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact

that, in case of insufficient fuel feeding, the

engine control module tries to compen-

sate prolonging the injectors working

time.

Fuel tank device partially obstructed by

impurities or deformed because of over-

heating.

Check if the priming pump of the pre-filter

is working correctly.

If the pump plunger is permanently de-

pressed disassemble and check the tank

pick.-up tube. If this is in order, replace the

pre-filter.

Obstructed air filter. Replace the air filter. Solve the cause of the filter’s obstruction.

Excessive fuel blow-by from rail boost

valve.

Check the O Rings and the correct con-

nection of the pipe fittings under the

feeding pump (the lockers must stay out-

side and the fittings must be well locked).

Visually check the low pressure pipeline

integrity.

Unless the leakage is significant, no per-

formance 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

valve.

Disconnect the pipe and visually check if

there are any significant blow-by from the

boost gauge valve; in such case replace

the valve.

The engine suddenly stops (with no previ-

ous problems) and does not start again.

Obstructed fuel filter. 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).

TROUBLESHOOTING

54 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

ANOMALY POSSIBLE CAUSE

(*) = if available in the equipment

RECOMMENDED TESTS OR

INTERVENTION REMARKS

The engine disconnects or does not start. (*)

EDC ”burned” by short circuit on the wir-

ing harness of the friction clutch.

Eliminate the short circuit and replace the

EDC.

Verify that the wire line, close to the

pedal, is not exposed to.

Difficult start and low performance in all

conditions.

Inefficient high pressure pump. After having excluded any other possible

cause, replace the high pressure pump.

Difficult start, low performance and en-

gine running with one cylinder less.

Injector with obstructer or solenoid

(mechanical part) blocked open.

The non-working injector is easily recog-

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 en-

gine control module.

If the flow limiter is activated. Check error

code memory.

Starting requires in excess of ten seconds,

followed by huge white exhaust fumes,

and a fuel smell.

Injector blocked in open position (with

no return).

The non-working injector is easily recog-

nisable detecting by feeling the absence of

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 li-

miter close up, the engine starts with one

cylinder less and gradually the grade of

fumes reduces and disappears.

Breaking of high pressure pipeline from

pump to rail.

Strange vibrations provoked by slack of

pipe bracket.

Replace the pipeline ensuring the correct

tightening of the anti-vibration bracket

screws.

It is very important, in addition to correct

blocking, to keep the brackets in the orig-

inal position.

Theengineworkswithonecylinderless,

without memorising failure blink codes in

theenginecontrolmodule.

Injector blocked in closed position. Identify the injector that is not working

anymoreandtherelatinghighpressure

filler.

The non-working injector is easily recog-

nisable detecting by feeling the absence of

pulsing within the relevant high pressure

pipe.

PART FOUR - MAINTENANCE PLANNING

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 55

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

56 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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

Visualcheckofengine..............................................

Inspectionpresenceofwaterinfuelfilterorpre-filter ......................

Inspectionblow-byfilterelements .....................................

Inspectionofbeltwearstatus .........................................

Inspectionandsettingoftappetclearance ...............................

EDC ............................................................

Replacementofengine’soilandfilter ..................................

Replacementofpre-filter ............................................

Replacementoffuelfilter ............................................

Replacementofblowbyfilter........................................

Replacementofbelt ...............................................

Frequency (hours)

Daily

4000

When anomaly occurs

500

1000

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.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 57

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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.

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 inconven-

iences, 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.

MAINTENANCE PROCEDURES

Checks and inspections

Engine oil level check

The check must be executed when the engine is disconnected

and possibly cool.

Thecheckcanbemadeusingthespeciallyprovidedflexible

rod (1) placed on the right hand side of the EDC.

Figure 118

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 mini-

mum level, provide filling lubrication of the engine’s compo-

nents.

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”.

Figure 119

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.

74174

108540

58 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Combustion system inspection

The check must be executed both when the engine discon-

nected 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 spe-

cific equipment), to the filter, to the high pressure pump and

to the rail diffuser and from this last one to the head.

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.

Protect the eyes and the skin from any eventual high

pressure jet: these may deeply penetrate under the

skin surface provoking serious poisoning.

Cooling system inspection

The check must be executed both when the engine discon-

nected 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.

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 sys-

tem, do not operate immediately after the engine’s

disconnection, but wait for the time deemed necess-

ary for the cooling.

Protect the eyes and the skin from any eventual high

pressure jet of cooling liquid.

Lubricating system inspection

The check must be executed both when the engine discon-

nected and when it is running.

Verifythepresenceofanyoilleakageorblow-byfromthe

head, from the engine pan of from the heat exchanger.

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.

Inspection of water presence within fuel filter or pre-filter

The components of the common rail system can be

damaged very quickly in presence of water or impur-

ity within the fuel.

Timely proceed operating on the pre-filter (not avail-

able on the engine block) to carry out the drainage of

the water within the feed circuit.

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 in-

convenience might be caused to the engine due to

the presence of air pockets in the engine’s head.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 59

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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

Figure 121

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.

70520

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.

Inspection and setting of tappet clearance

74188

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.

60 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Oil motor and filter replacement

Due to the several applications, the pan shape and the oil

quantity can change slightly. However, the following oper-

ations are valid for all applications.

We recommend to carry out the oil drainage when the motor

is hot.

-Place a proper container for the oil collecting under the

pan connected with the drain plug.

-Unscrew the plug and then take out the control dipsick

and the inserting plug to ease the downflow of the lubrica-

tion oil.

Warning: We recommend to wear proper protec-

tions because of high motor service temperature.

The motor oil reaches very high temperature: you

must always wear protection gloves.

The oil motor is very pollutant and harmful.

In case of contact with the skin, wash with much water

and detergent.

Protect properly skin and eyes: operate according to

safety rules.

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 re-

quested 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 war-

ranty is no more valid.

-Check the level through the dipsick until when the filling

is next to the maximum level notch indicated on the dip-

sick.

Whereas you replace the lubrication oil, it is necessary to re-

place the filter.

According to the application the filter can be located in differ-

ent positions: the following procedure is a valid guide for all ap-

plications.

-The filter is composed by a support and a filtering car-

tridge. 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.

Warning: avoid the contact of skin with the motor oil:

in case of contact wash the skin with running water.

The motor oil is very pollutant: it must be disposed

of according to the rules.

-Replace the filtering cartidge with a new one and screw

manually until when the gasket is in contact with the sup-

port.

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

turn.

-Operate the motor for some minutes and check the level

through the dipsick again. If it is necessary, carry out a top-

ping up to compensate the quantity of oil used for the fill-

ing of the filtering cartridge.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION 61

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Fuel filter replacement

According to the applications the filters position and the quan-

tity can change.

However the following operations are valid for all applications.

-Drain the fuel inside the filter by operating the water re-

lease screw. Collect the fuel in a container without impu-

rities.

-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.

-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.

During this operation don’t smoke and don’t use free

flames.

Avoid to breathe the vapors coming from filter.

Alternator belt replacement

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

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.

For applications with automatic belt stretcher, the procedure

is the following:

Figure 122

-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.

108545

62 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

SECTION 4

Overhaul and technical specifications

Page

GENERAL SPECIFICATIONS 3...............

CLEARANCE DATA 4.....................

4AND6ENGINEOVERHAUL 11.............

ENGINE REMOVAL AT THE BENCH 11........

REPAIR OPERATIONS 12....................

CYLINDER UNIT 12........................

-Checks and measurements 12...............

-Checking head supporting surface

on cylinder unit 13........................

TIMING SYSTEM 14........................

-Camshaft 14.............................

-Checking cam lift and pin alignment 15........

BUSHES 15...............................

-Bush replacement 16......................

-Tappets 16..............................

-Fitting tappets — camshaft 17................

OUTPUT SHAFT 18........................

-Measuring journals and crankpins 18..........

-Measuring journals and crankpins (6 cyl.) 20....

-Replacing oil pump control gear 22...........

-Fitting main bearings 22....................

-Finding journal clearance 22.................

-Checking crankshaft shoulder clearance 23.....

CONNECTING ROD — PISTON ASSEMBLY 23..

-Pistons 24...............................

2SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Page

-Measuring piston diameter 24................

-Piston pins 25............................

-Conditions for proper pin-piston coupling 25....

-Connecting rods 26.......................

-Bushes 27...............................

-Checking connecting rods 28................

-Checking bending 28.......................

-Checking torsion 28.......................

-Fitting connecting rod-piston assembly 28......

-Connecting rod-piston coupling 28............

-Fitting split rings 29........................

-Fitting connecting rod-piston assembly

into cylinder barrels 29.....................

-Finding crankpin clearance 30................

-Checking piston protrusion 31...............

Page

CYLINDER HEAD 32........................

-Removing the valves 32....................

-Checking cylinder head wet seal 33...........

-Checking cylinder head supporting surface 33...

VALVES 34................................

-Removing carbon deposits, checking and

grinding valves 34.........................

-Checking clearance between valve stem and valve

guide and valve centering 34.................

VALVE GUIDE 35..........................

VALVE SEATS 35...........................

-Regrinding — replacing the valve seats 35.......

CYLINDER HEAD VALVE SEATS (6 CYL.) 36....

FITTING CYLINDER HEAD 38................

-Refitting the cylinder head 39................

TIGHTENING TORQUE 40..................

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 3

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

GENERAL SPECIFICATIONS

Type 4CYLINDERS 6CYLINDERS

Cycle Four-stroke diesel engine

Power Turbocharged with intercooler

Injection Direct

Number of cylinders 4 6

∅

Bore mm 104

Stroke mm 132

+++..=

Total displacement cm34485 6728

TIMING

start before T.D.C. A

end after B.D.C. B

18.5º

29.5º

start before B.D.C. D

end after T.D.C. C

67º

35º

Checking timing

Checking operation

0.20 to 0.30

0.45 to 0.55

FUEL FEED

Injection

Type: Bosch

high pressure common rail

EDC7 ECU

Injector CRIU 2

Nozzle type DSLA and DLLA

Injection sequence 1-3-4-2 1-5-3-6-2 -4

bar

Injection pressure bar 250 - 1450 250 - 1600

4SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

CLEARANCE DATA

Type 4CYLINDERS 6CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅1

Cylinder barrels ∅1102.009 to 102.031

∅Cylinder barrels:

outside diameter ∅2

length L

Cylinder barrels — housings on

engine block (interference) -

Outside diameter ∅20,5

∅3

XCylinder barrels:

inside diameter ∅2-

∅1

∅2

Spare pistons

type:

Size X

Outside diameter ∅1

Pin housing ∅2

103.730 to 103.748

38.010 to 38.016

Piston — cylinder barrels 0.252 to 0.294

Piston diameter ∅10.5

Piston protrusion X 0.28 to 0.52

∅Piston pin ∅337.994 to 38.000

Piston pin — pin housing 0.01 to 0.022

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 5

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Type 4CYLINDERS 6CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

X1*

Split ring slots X 2

2.705 to 2.735

2.440 to 2.460

4.030 to 4.050

S1*

Split rings S 2

*measuredon98mm∅4cyl.

*measuredon99mm∅6cyl.

* measured on 101 mm

∅F4HE

2.560 to 2.605

2.350 to 2.380

3.977 to 3.990

Split rings - slots 2

0.100 to 0.175

0.060 to 0.110

0.040 to 0.083

Split rings 0.5

Split ring end opening

in cylinder barrel:

0.30 to 0.40

0.60 to 0.80

0.30 to 0.55

1∅

∅2

Small end bush

housing ∅1

Big end bearing

housing ∅2

40.987 to 41.013

72.987 to 73.013

∅

∅4

3Small 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

6SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Type 4CYLINDERS 6CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

Size X

Max. tolerance

on connecting rod

axis alignment

12∅∅

S1S2

Journals ∅1

Crankpins ∅2

Main half bearings S 1

Big end half bearings S 2

*provided as spare part

82.99 to 83.01

68.987 to 69.013

2.456 to 2.464

1.955 to 1.968

∅

Main bearings

No. 1 — 5 / 1- 7 ∅3

No.2—3—4 ∅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 X 1 37.475 to 37.545

X 2

Shoulder main bearing X 2 25.98 to 26.48

X3 Shoulder half-rings X 3 37.28 to 37.38

Output shaft shoulder 0.068 to 0.41

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 7

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Type 4CYLINDERS 6CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

∅1

Valve guide seats on

cylinder head ∅17.042 to 7.062

2∅

∅3

∅2

Valve guides

∅3

Valveguidesandseatsonhead -

Valve guides -

∅

4Valves:

∅4

6.970 to 6.999

60o±0.25o

6.970 to 6.999

45o±0.25o

Valve stem and guide 0.052 to 0.092

0.052 to 0.092

∅1

Housing on head for

valve seat:

∅1

34.837 to 34.863

∅

Val

esea

side diame

;

valve seat angle on cylinder

head:

∅2

34.917 to 34.931

60o

34.917 to 34.931

45o

Sinking X

0.59 to 1.11

0.96 to 1.48

Between valve seat

and head

0.054 to 0.094

Valve seats -

8SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Type 4CYLINDERS 6CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

HH1 H2

Valve spring height:

free spring H

under a load equal to:

339.8 ±9N H1

741 ±39 N H2

47.75

35.33

25.2

Injector protrusion X -

∅

123 4 5

Camshaft bush

housings No. 1-5/1-7

Camshaft housings

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

59.222 to 59.248

54.089 to 54.139

∅

Camshaft journals:

1⇒5∅

1⇒7∅53.995 to 54.045 53.995 to 54.045

∅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:

6.045

7.582

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 9

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Type 4CYLINDERS 6CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

∅1

Tappet cap housing

on block ∅116.000 to 16.030

∅2

∅

Tappet cap outside

diameter: ∅2

∅3

15.924 to 15.954

15.960 to 15.975

Between tappets and housings 0.025 to 0.070

Tappets -

∅1

Rocker shaft ∅121.965 to 21.977

∅2

Rockers ∅222.001 to 22.027

Between rockers and shaft 0.024 to 0.162

10 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70159

70158

70160

70161

70162

Figure 1

Figure 2

Figure 3

Figure 4

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.

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

The second last main bearing cap (1) and the relevant support

are fitted with shoulder half-bearing (2).

Use tool 99360500 (1) and hoist to remove the crankshaft (2)

from the block.

Remove the main half-bearings (1).

Remove the screws (2) and remove the oil nozzles (3).

Keep the half-bearings into their housings since in case

of use they shall be fitted in the same position found

at removal.

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 5

4AND6ENGINEOVERHAUL

ENGINE REMOVAL AT THE BENCH

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.

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 11

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70163

70165

70164

70166

70167

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Remove the screws (1) and disconnect camshaft (3) retaining

plate (2).

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

Withdraw the tappets (1) from the engine block.

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.

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.

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.

Take note of plate (2) assembling position.

REPAIR OPERATIONS

CYLINDER UNIT

Checks and measurements

Should the ring gauge be not available, use a

micrometer for zero-setting.

12 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Figure 11

In case of regrinding, all barrels shall have the same

oversize (0.5 mm).

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.

Check main bearing housings as follows:

-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.

107267

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 13

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70169

Figure 12

TIMING SYSTEM

Camshaft

CAMSHAFT MAIN DATA (4 cyl.)

Specified data refer to pin standard diameter

Figure 13

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

camshaft and the bushes.

84089

14 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70171

70172

Figure 14

Figure 15

Check camshaft (2) pin diameter using micrometer (1) on

two perpendicular axes.

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.

BUSHESChecking cam lift and pin alignment

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 16

CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)

* Value to be obtained after driving the bushes.

107399

Sec. A-A

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 15

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Figure 17

Figure 18

MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS

*Height to be obtained after driving the bushes.

70174

To replace front and rear bushes (1), remove and refit them

using the beater 99360362 (2) and the handgrip 99370006

(3).

Bush replacement

When refitting the bushes (1), direct them to make

the lubricating holes (2) coincide with the holes on

the block housings.

70175

MAIN DATA CONCERNING THE TAPPETS AND THE

RELEVANT HOUSINGS ON THE ENGINE BLOCK

Tappets

Figure 19

107268

sec. A-A

16 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70176

70164

70238

Lubricate the tappets (1) and fit them into the relevant

housings on the engine block.

Lubricate the camshaft bushes and fit the camshaft (1) taking

care not to damage the bushes or the housings.

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.

Fitting tappets — camshaft

Figure 20

Figure 21

Figure 22

Figure 23

70179

70180

Check camshaft end float (1).

It shall be 0.23 ±0.13 mm.

Fit nozzles (2) and tighten the fastening screws (1) to the

specified torque.

Figure 24

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 17

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70182

70181

Figure 25

Figure 26

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.

It is recommended to insert the found values in the

proper table.

SeeFigure26.

Undersize classes are:

Journals and crankpins shall always be ground to the

same undersize class.

Journals and crankpins undersize shall be marked on

thesideofthecrankarmNo.1.

For undersized crankpins: letter M

For undersized journals: letter B

For undersized crankpins and journals: letters MB.

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

*Rated value

OUTPUT SHAFT

Measuring journals and crankpins

18 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70183

Figure 27

OUTPUT SHAFT MAIN TOLERANCES

70237

MAIN BEARING ON TIMING

SYSTEM CONTROL SIDE

INTERMEDIATE MAIN

BEARINGS

FIRST MAIN BEARING

ON FRONT SIDE

measured on > 45.5 mm radius

between adjacent journals

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 19

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness ○

Cilindricity /○/

Parallelism //

DIRECTION Verticality

Straightness

POSITION Concentricity or coaxiality

Circular oscillation

OSCILLATION Total oscillation

Taper

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ©

IMPORTANT ⊕

SECONDARY ⊝

Figure 28

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES

*Rated value

Figure 29

MAIN OUTPUT SHAFT TOLERANCES

* Measured on a radius greater than 45.5 mm

** ↗0.500 between adjacent main journals 70577

Measuring journals and crankpins (6 cyl.)

107269

20 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70237

MAIN BEARING ON TIMING

SYSTEM CONTROL SIDE

INTERMEDIATE MAIN

BEARINGS FIRST MAIN BEARING ON

FRONT SIDE

Figure 30

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 21

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness ○

Cilindricity /○/

Parallelism //

DIRECTION Verticality

Straightness

POSITION Concentricity or coaxiality

Circular oscillation

OSCILLATION Total oscillation

Taper

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ©

IMPORTANT ⊕

SECONDARY ⊝

70184

70185

70187

Figure 31

Figure 32

Figure 33

Figure 34

Refit the crankshaft (2).

Check the backlash between crankshaf main journals and the

relevant bearings as follows:

Tighten the pre-lubricated screws (1) in the following three

successive stages:

-1st stage,withtorquewrenchto50±6 Nm.

-2nd stage,withtorquewrenchto80±6 Nm.

Refit the main bearings that have not been replaced,

in the same position found at removal.

Fitting main bearings

Do not try to adapt the bearings.

Main bearings (1) are supplied spare with 0.250 — 0.500 mm

undersize on the internal diameter.

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.

Check that gear toothing (1) is not damaged or worn,

otherwiseremoveitusingtheproperpuller(3).

When fitting the new gear, heat it to 180°C for 10 minutes

in an oven and then key it to the crankshaft.

Figure 35

-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;

-fit caps (1), including the half bearings (2) on the relevant

supports.

70186

70161

Replacing oil pump control gear Finding journal clearance

22 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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.

70188

70189

70190

70191

Figure 36

Figure 37

Figure 38

Figure 39

-3rd stage, with tool 99395216 (1) set as shown in the

figure, tighten the screws (2) with 90 ±5°angle.

-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.

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.

Checking crankshaft shoulder clearance

Pistons are supplied from parts with 0.5 mm oversize.

CONNECTING ROD — PISTON ASSEMBLY

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 23

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

32615

32614

32613

70192

Figure 40

Figure 41

Figure 42

Figure 43

Figure 44

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

(3).

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

Using a micrometer (2), measure the diameter of the piston

(1) to determine the assembly clearance.

The clearance between the piston and the cylinder barrel can

be checked also with a feeler gauge (1) as shown in the figure.

The diameter shall be measured at 12 mm from the

piston skirt.

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter

Pistons

Measuring piston diameter

107270

24 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

32620

16552

32619

18857

Figure 45

Figure 46

Figure 47

Figure 48

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

(2).

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.

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

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).

Piston pins

Figure 49

86497

MAIN DATA CONCERNING MONDIAL MAHLE PISTON, PINS AND SPLIT RINGS

* Value measured on 101 mm diameter

Conditions for proper pin-piston coupling

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 25

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

41104

Figure 50

Figure 51

Figure 52

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

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.

70194

Use feeler gauge (1) to measure the clearance between the

ends of the split rings (2) fitted into the cylinder barrel (3).

MAIN DATA FOR CONNECTING ROD, BUSH, PISTON

PIN AND HALF BEARINGS

Connecting rods

* Value for inside diameter to be obtained after driving in

connecting rod small end and grinding.

** Value not measurable in released condition

The surface of connecting rod and rod cap are

knurled to ensure better coupling.

Therefore, it is recommended not to smooth the

knurls.

107271

26 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70196

Figure 53

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.

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:

SV, 1820 to 1860 (yellow marking);

SW, 1861 to 1900 (green marking);

SX, 1901 to 1940 (blue marking);

Spare connecting rods are of the W class with green

marking *.

Material removal is not allowed.

CONNECTING ROD BODY

CONNECT-

ING ROD

BODY

CONNECT-

ING ROD

BODY

CONNECT-

ING ROD

BODY

CONNECT-

ING ROD

BODY

CONNECTING ROD

BODY

CONNECTING ROD BODY

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 27

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

61696

61694

61695

70198

Figure 54

Figure 55

Figure 56

Figure 57

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).

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.

Checkconnectingrod(5)bendingbycomparingtwopoints

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

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.

Checking connecting rods Checking bending

Checking torsion

28 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

72705

32613

70200

70201

Figure 58

Figure 59

Figure 60

Figure 61

Figure 62

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.

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

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°.

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

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.

Split rings are supplied spare with the following sizes:

- standard, yellow marking;

- 0.5 mm oversize, yellow/green marking;

Fitting connecting rod-piston assembly into

cylinder barrels

Refit the main bearings that have not been replaced,

in the same position found at removal.

Do not try to adapt the half bearings.

108597

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 29

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70203

70204

70205

70206

Figure 63

Figure 64

Figure 65

Figure 66

Figure 67

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;

-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

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).

-Lubricate the screws (1) with engine oil and then tighten

them to the specified torque using the torque wrench

(2).

-Apply tool 99395216 (1) to the socket wrench and

tighten screws (2) of 60°.

-Remove the cap and find the existing clearance by

comparing the calibrated wire width (1) with the scale

onthewireenvelope(2).

108596

30 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70207

70208

Figure 68

If a different clearance value is found, replace the half bearings

and repeat the check.

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

oftheengineblock.

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.

Checking piston protrusion

Figure 69

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 31

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70319

Figure 70

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.

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

CYLINDER HEAD

Removing the valves

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).

70321

70322

Figure 71

Figure 72

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

Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

32 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70323

Figure 73

Figure 74

This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90°Cand2

to 3 bar pressure.

Replace the core plugs (1) if leaks are found, use the proper

punch for their removal/refitting.

Replace the cylinder head if leaks are found.

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.

Checking cylinder head wet seal

Before refitting, smear the plug surfaces with

water-repellent sealant.

Checking cylinder head supporting surface

70325

The rated thickness A for the cylinder head is 105 ±0.25 mm,

max. metal removal shall not exceed thickness B by 1 mm.

After grinding, check valve sinking. Regrind the valve

seats, if required, to obtain the specified value.

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 33

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70326

18625

18882

70327

Figure 75

Figure 76

Figure 77

Figure 78

VALVES

INTAKE AND EXHAUST VALVE MAIN DATA

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.

Check the valve stem (1) using a micrometer (2), it shall be

6.970 ÷6.999.

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.

Removing carbon deposits, checking and

grinding valves Checking clearance between valve stem and

valve guide and valve centering

INTAKE

VALVE

EXHAUST

VALVE

34 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

EXHAUST

70328

70330

70331

Figure 79

Figure 80

Use a bore dial gauge to measure the inside diameter of the

valve guides, the read value shall comply with the value

showninthefigure.

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.

VALVE SEATS

Regrinding — replacing the valve seats

VALVE SEAT MAIN DATA (4 CYL.)

INTAKE EXHAUST

INTAKE

Figure 81

VALVE GUIDE

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 35

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

70332

Figure 82

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.

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD (4 CYL.)

EXHAUST INTAKE

Figure 83

MAIN DATA ABOUT ENGINE VALVE SEATS

Valve seats are installed by cooling onto the cylinder head

and machining to the correct dimension.

CYLINDER HEAD VALVE SEATS (6 CYL.)

70515

EXHAUST INTAKE

36 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

70332

70331

Figure 84

Figure 85

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.

VALVE SEAT MAIN DATA (6 CYL.)

In order to assemble the valve seats into the cylinder head,

it is necessary to heat the cylinder head to 80 to 100°Cand,

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.

EXHAUST INTAKE

EXHAUSTINTAKE

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 37

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

50676

70334

770321

Figure 86

Figure 87

Figure 88

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.

FITTING CYLINDER HEAD

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.

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).

Sealing rings (2) for intake valves are yellow and

sealing rings (3) for exhaust valves are green.

VALVE SPRINGS

70333

Figure 89

After regrinding, check that valve (3) sinking value is the

specified one by using the base 99370415 (2) and the dial

gauge 99395603 (1).

38 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

Height Under a load of

mm kg

H 47.75 Free

H135.33 P 339.8 ±19 N

H225.2 P1 741 ±39 N

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.

70335

Figure 90

Refitting the cylinder head

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

Figure 91

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:

For4cylinderversions:

Repeat the operation for pistons 2, 3 and 4 and calculate the

average value.

For6cylinderversions:

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

the average value.

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

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

S=Scil1 +Scil2 +Scil3 +Scil4 +Scil5 +Scil6

Scil1 =S1 +S2

S=Scil1 +Scil2 +Scil3 +Scil4

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 39

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

40 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

TIGHTENING TORQUE

TORQUE

Nm kgm

Studs M6 for camshaft sensors 8±2 0.8 ±0.2

Studs M8 for feed pump 12 ±2 1.2 ±0.2

Screw M12 for fastening rear gear case

Screw M10 for fastening rear gear case

Screw M8 for fastening rear gear case

77 ±12

47 ±5

24 ±4

7.7 ±1.2

4.7 ±0.5

2.4 ±0.4

Nut M6 for fastening camshaft sensor 10 ±2 1 ±0.2

Screw M8 for fastening oil pump 1st stage

2nd stage

8±1

24 ±4

0.8 ±0.1

2.4 ±0.4

Screw M8 for fastening front cover 24 ±4 2.4 ±0.4

Screw M8 for fastening camshaft longitudinal retaining plate 24 ±4 2.4 ±0.4

Screw M8 for fastening camshaft gear 36 ±4 3.6 ±0.4

Screw M10 for fastening crankcase plate 43 ±5 4.3 ±0.4

Nut M18 for fastening high pressure pump gear 105 ±5 10.5 ±0.5

Nuts M8 for fastening fuel pump 24 ±4 2.4 ±0.4

½inch plug on cylinder head

¼inch plug on cylinder head

¾inch plug on cylinder head

24 ±4

36 ±5

12 ±2

2.4 ±0.4

3.6 ±0.5

1.2 ±0.2

1st s

8.5 ±0.35 0.85 ±0.035

crew

ors

2nd stage 75º ±5º

Nut fastening for injector feed connector 50 ±5 5 ±0.5

Nut M6 for flame start grille on intake manifold 8±2 0.8 ±0.2

Screw M8 for fastening intake manifold 24 ±4 2.4 ±0.4

Screw M12 for fastening rear brackets for engine lifting 77 ±12 7.7 ±1.2

Screws M8 for fastening Common Rail 24 ±4 2.4 ±0.4

Connectors M14 for high pressure fuel pipes 20 ±2 2 ±0.2

Screw M12 (12 x 1.75 x 130) for fastening cylinder head

}

35 ±5 3.5 ±0.5

Screw M12 (12 x 1.75 x 150) for fastening cylinder head 1s

age

}

55 ±55.5±0.5

2nd stage 90º ±5º

3rd stage 90º ±5º

Screw for fastening rocker bracket 36 ±5 3.6 ±0.5

Valve clearance adjusting nuts 24 ±4 2.4 ±0.4

Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 ±2 2 ±0.2

Screw M8 for fastening high pressure pipe connector 24 ±4 2.4 ±0.4

Screw M6 for fastening wiring bulkhead 10 ±2 1 ±0.2

Screw M8 for fastening electric wiring support for injector feed 24 ±4 2.4 ±0.4

Nuts for fastening wiring on each injector 1.5 ±0.25 0.15 ±0.025

Screw M12 for fastening fuel filter bracket 77 ±8 7.7 ±0.8

Screw M8 for fastening fuel filter holder 24 ±4 2.4 ±0.4

Fuel filter contact + ¾turn

Screw M22 for fastening oil pressure relief valve on oil filter support 80 ±8 8 ±0.8

Screw M8 for radiator seal and oil filter support 24 ±4 2.4 ±0.4

Oil filter contact + ¾turn

11/8inchconnectiononfiltersupport for turbine lubrication 24 ±4 2.4 ±0.4

Nut M12 for fastening turbine lubrication pipe 10 ±2 1 ±0.2

Screw M10 for fastening engine coolant inlet connection 43 ±6 4.3 ±0.6

90°elbow fastening (if required) to engine coolant inlet connection 24 ±4 2.4 ±0.4

Pipe on cylinder head for compressor cooling 22 ±2 2.2 ±0.2

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 41

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

TORQUE

Nm kgm

Screw M6 for fastening engine coolant drain connector 10 ±2 1 ±0.2

Pin fastening on engine block for exhaust manifold 10 ±2 1 ±0.2

Screw M10 for fastening exhaust manifold on cylinder head 53 ±5 5.3 ±0.5

Screw M12

enin

dam

er ada

er 1st s

e50 ±5 5 ±0.5

and damper on output shaft 2nd stage 90º

Screw M10 for fastening pulley on output shaft 68 ±7 6.8 ±0.7

Screw M8 for fastening water pump 24 ±4 2.4 ±0.4

Screw M10 for fastening auxiliary component control belt tensioners 43 ±6 4.3 ±0.6

Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 ±6 4.3 ±0.6

Screw M10 for fastening flywheel housing

Screw M12 for fastening flywheel housing

85 ±10

49 ±5

8.5 ±1

4.9 ±0.5

Screw M6 for fastening heat exchanger for control unit

Screw M8 for fastening heat exchanger for control unit

10 ±2

24 ±4

1±0.2

2.4 ±0.4

Connection M12 for fuel inlet-outlet on heat exchanger 12 ±2 1.2 ±0.2

Nut M8 for fastening valve cover 24 ±4 2.4 ±0.4

Screw M6 for fastening camshaft sensor 8±2 0.8 ±0.2

Screw M6 for fastening output shaft sensor 8±2 0.8 ±0.2

Screw M14 for fastening coolant temperature sensor 20 ±3 2 ±0.3

Screw M5 for fastening oil pressure/temperature sensor 6±1 0.6 ±0.1

Screw for fastening fuel pressure sensor 35 ±5 3.5 ±0.5

Screw M14 for fastening fuel temperature sensor 20 ±3 2 ±0.3

Screw for fastening air temperature/pressure sensor on intake manifold 6±1 0.6 ±0.1

Screw M12 for fastening engine oil level sensor 12 ±2 1.2 ±0.2

{

pins M8

7±1

0.7 ±0.1

Turbine fixing to exhaust manifold

{

sM8

{

4-cyl.

{

nuts M8

24 ±4

2.4 ±0.4

Adapter M12 on turbine for lubricant oil pipes (inlet) 35 ±5 3.5 ±0.5

Pipe fixing on adapter M10 for turbine lubrication 35 ±5 3.5 ±0.5

Oil pipe fixing on adapter M10 for turbine lubrication to block 43 ±6 4.3 ±0.6

Oil drain pipe fixing M8 on turbine 24 ±4 2.4 ±0.4

Connector fixing M6 for oil return from cylinder head to flywheel housing 10 ±2 1 ±0.2

Screw M12 for fastening engine flywheel 1st stage

30 ±4 3 ±0.4

2nd stage 60º ±5º

Screw M8 for fastening front bracket for engine lifting 24 ±4 2.4 ±0.4

Screw for fastening engine oil sump 24 ±4 2.4 ±0.4

Screw M8 for fastening cylinder barrel lubricating nozzles 15 ±3 1.5 ±0.3

Screw M12 for fastening output shaft caps 1st stage

2nd stage

50 ±6

80 ±6

5±0.6

8±0.6

3rd stage 90º ±5º

Screw M8 for fastening camshaft longitudinal retaining plate 24 ±4 2.4 ±0.4

Screw M8 for fastening camshaft gear 36 ±4 3.6 ±0.4

Screw M11 for fastening connecting rod caps 1st stage

60 ±5 6 ±0.5

2nd stage 60º ±5º

Alternator

M10 Screw, Bracket fixing on water feed pipefitting 43 ±6 4.3 ±0.6

M10 Screw, alternator locking 43 ±6 4.3 ±0.6

Starter

Starter fixing screw 43 ±6 4.3 ±0.6

42 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

SECTION 5 - TOOLS 1

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

SECTION 5

Tools

Page

TOOLS 3................................

2SECTION 5 - TOOLS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

SECTION 5 - TOOLS 3

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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)

4SECTION 5 - TOOLS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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

SECTION 5 - TOOLS 5

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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

6SECTION 5 - TOOLS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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)

SECTION 5 - TOOLS 7

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

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)

8SECTION 5 - TOOLS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

TOOLS

TOOL NO. DESCRIPTION

99389834 Torque screwdriver for injector solenoid valve connector stop nut

setting

99395216 Pair of gauges with ½”and¾” 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

SECTION 5 - TOOLS 9

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

TOOLS

TOOL NO. DESCRIPTION

8093731 Tester PT01

10 SECTION 5 - TOOLS F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

APPENDIX 1

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

Appendix

Page

SAFETY PRESCRIPTIONS 3..................

-Standard safety prescriptions 3..............

-Prevention of injury 3.....................

-During maintenance 3.....................

-Respect of the Environment 4...............

2APPENDIX F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

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 no

execu

ean

erven

ion i

pro

ided

necessary instructions.

-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.

-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.

SAFET

PRESCRIPTIONS

Standard safety prescriptions

Prevention of injury

-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.

-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).

-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.

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 leave rags impregnated with flammable

substances close to the engine.

-Upon engine start after maintenance, undertake proper

preventing actions to stop air suction in case of runaway

speed rate.

-Do not utilize fast screw-tightening tools.

-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.

APPENDIX 3

F4HE NEF ENGINES

Print P2D32N003GB Base - February 2006

-Avoid incorrec

igh

ening or ou

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.

-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.

-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.

Res

ect of the Envi

onment

4APPENDIX F4HE NEF ENGINES

Base - February 2006 Print P2D32N00GB

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

Part 2

G-DRIVE APPLICATION ENGINES

Section 1 - General specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE 7.............

COOLING SYSTEM 8......................

AIR INDUCTION - BOOST DIAGRAM 9.......

-Description 9............................

OIL VAPOUR RECYCLING 10................

Section 2 - G-Drive application

GENERAL SPECIFICATIONS 11...............

CLEARANCE DATA 13......................

REMOVING AND REFITTING ENGINE

FROM RADIATOR 19.....................

-Removal 19..............................

-Refitting 19..............................

TOOLS 20................................

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.

2G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

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

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

Tighten to torque

Tighten to torque + angular value

∅

∅2

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

SPECIAL REMARKS

4G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

SYMBOLS - ASSISTANCE OPERATIONS

Removal

Disconnection Intake

Refitting

Connection Exhaust

Removal

Disassembly Operation

Fitting in place

Assembly ρCompression 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 bar Pressure

Interference

Strained assembly

Oversized

Higher than….

Maximum, peak

Thickness

Clearance

Undersized

Less than….

Minimum

Lubrication

Damp

Grease

Selection

Classes

Oversizing

Sealant

Adhesive

Temperature < 0 °C

Cold

Winter

Air bleeding

Temperature > 0 °C

Hot

Summer

Replacement

Original spare parts

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

UPDATING

Section Description Page Date of revision

6G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

SECTION 1 - GENERAL SPECIFICATIONS 7

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

Technical Code Commercial Code

F4HE9685A*J100 -

Figure 1

106529

Water leaving the thermostat

Coolant recirculating in the engine

Water entering the pump

DIAGRAM OF THE COOLING SYSTEM

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,ifthisisincludedintheequipment.

8SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

Figure 2

AIR INDUCTION - BOOST DIAGRAM

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 above mentioned air is then cooled by the radiator and

flown through the piston induction collector.

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.

106548

Compressed air to the heat exchanger

Refrigerated compressed air to the pistons

Exhaust gas

Intake air

TURBOCHARGING DIAGRAM

SECTION 1 - GENERAL SPECIFICATIONS 9

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

Figure 3

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).

Oil condensate

Oil vapours

OIL VAPOUR RECYCLING

108729

10 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

SECTION 2 - G-DRIVE APPLICATION 11

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

GENERAL SPECIFICATIONS

Type FAHE9685A

Cycle Four-stroke diesel engine

Power Supercharged with intercooler

Injection Direct

Number of cylinders 6

∅

Bore mm 104

Stroke mm 132

+++..=

Total displacement cm36728

TIMING

start before T.D.C. A

end after B.D.C. B

18.5º

29.5º

start before B.D.C. D

end after T.D.C. C

67º

35º

Checking timing

Checking operation

0.20 to 0.30

0.45 to 0.55

FUEL FEED

Injection

Type: Bosch

high pressure common rail

EDC7 ECU

Nozzle type Injectors

Injection sequence 1-5-3-6-2 -4

bar

Injection pressure bar 250 ÷1450

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.

12 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

Clearance data - 6 cyl.

Type

ρCompression ratio 17 : 1

Max. output kW

(HP)

rpm

215

292

1800

Max. torque Nm

(kgm)

rpm

Loadless en

ine

idling rpm -

Loadless engine

peak rpm rpm -

oke

Displacement

104 x 132

6728

TURBOCHARGING

Turbocharger type

with intercooler

HOLSET HX35W

bar

LUBRICATION

Oil pressure (warm engine)

- idling bar

Forced by gear pump, relief valve single action

oil filter

-peakrpm bar 2

COOLING

Water pump control

Thermostat

-startofopening ºC

By liquid

Through belt

81 ±2

15W40 ACEA E3

FILLING

engine sump liters

engine sump + filter liters

15 + 1

SECTION 2 - G-DRIVE APPLICATION 13

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

CLEARANCE DATA

Type 6 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅1

Cylinder barrels ∅1103.99 to 104.010

∅Cylinder barrels:

outside diameter ∅2

length L

Cylinder barrels — housings on

engine block (interference) -

Outside diameter ∅20.5

∅3

XCylinder barrels:

inside diameter ∅2-

∅1

∅2

Spare pistons

type:

Size X

Outside diameter ∅1

Pin housing ∅2

103.851 to 103.865

40.00 to 40.25

Piston — cylinder barrels 0.113 to 0.147

Piston diameter ∅10.5

Piston protrusion X 0.28 to 0.52

∅Piston pin ∅337.994 to 38

Piston pin — pin housing 0.0006 to 0.0202

14 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

Type 6 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

X1*

Split ring slots X 2

*measuredon99mm∅

2.42 to 2.44

4.03 to 4.05

S1*

Split rings S 2

2.350 to 2.380

4.030 to 4.050

Split rings - slots 2

0.100 to 0.175

0.040 to 0.90

0.020 to 0.065

Split rings 0.5

Split ring end opening

in cylinder barrel:

0.30 to 0.40

0.60 to 0.80

0.3 to 0.55

1∅

∅2

Small end bush

housing ∅1

Big end bearing

housing ∅2

42.987 to 43.013

72.987 to 73.013

∅

∅4

3Small end bush diameter

Outside ∅4

Inside ∅3

Spare big end half

bearings S

40.987 to 41.013

38.019 to 38.033

1.955 to 1.968

Small end bush — housing 0.266 to 0.566

Piston pin — bush 0.0188 to 0.0372

Big end half bearings 0.250; 0.500; 0.750; 1.000

SECTION 2 - G-DRIVE APPLICATION 15

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

Type 6 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

Size X

Max. tolerance

on connecting rod

axis alignment

12∅∅

S1S2

Journals ∅1

Crankpins ∅2

Main half bearings S 1

Big end half bearings S 2

*provided as spare part

82.99 to 83.01

73.533 to 74.513

2.456 to 2.464

1.955 to 1.968

∅

Main bearings

No. 1—7 ∅3

No. 2—3—4—5—6 ∅3

87.982 to 88.008

87.977 to 88.013

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 X 1 37.28 to 37.38

X 2

Shoulder main bearing X 2 28.77 to 29.03

X3 Shoulder half-rings X 3 37.28 to 37.38

Output shaft shoulder 0.095 to 0.265

16 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

Type 6 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

∅1

Valve guide seats on

cylinder head ∅17.042 to 7.062

2∅

∅3

∅2

Valve guides

∅3

Valveguidesandseatsonhead -

Valve guides -

∅

4Valves:

∅4

6.970 to 6.999

60 ±0.25°

6.970 to 6.999

45 ±0.25°

Valve stem and guide 0.043 to 0.092

∅1

Housing on head for

valve seat:

∅1

34.837 to 34.863

∅

Val

esea

side diame

;

valve seat angle on cylinder

head:

∅2

34.917 to 34.931

60°

34.917 to 34.931

45°

Sinking X

0.59 to 1.11

0.96 to 1.48

Between valve seat

and head

0.054 to 0.094

Valve seats -

SECTION 2 - G-DRIVE APPLICATION 17

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

Type 6 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

HH1 H2

Valve spring height:

free spring H

under a load equal to:

339.8 ±9N H1

741 ±39 N H2

47.75

35.33

25.2

Injector protrusion X -

∅

123 4 5

Camshaft bush

housings No. 1

Camshaft housings

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

59.222 to 59.248

54.089 to 54.139

∅

Camshaft journals:

1⇒7∅54.005 to 54.035

∅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:

6.045

7.582

18 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

Type 6 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

∅1

Tappet cap housing

on block ∅116.000 to 16.030

∅2

∅

Tappet cap outside

diameter: ∅2

∅3

15.924 to 15.954

15.960 to 15.975

Between tappets and housings 0.025 to 0.070

Tappets -

∅1

Rocker shaft ∅121.965 to 21.977

∅2

Rockers ∅222.001 to 22.027

Between rockers and shaft 0.024 to 0.162

Figure 4

Removal

Remove the fan safety grilles (5) by undoing the relevant

fasteners.

Placeacontainerunderthepipe(12)tocollectthecoolant.

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.

108598

Check the state of wear of the rubber couplings.

REMOVING AND REFITTING ENGINE FROM RADIATOR

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

SECTION 2 - G-DRIVE APPLICATION 19

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

20 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

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)

SECTION 2 - G-DRIVE APPLICATION 21

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

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

22 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

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

SECTION 2 - G-DRIVE APPLICATION 23

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

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)

24 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

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)

SECTION 2 - G-DRIVE APPLICATION 25

G-DRIVE ENGINES

Print P2D32N003GB Base - February 2006

TOOLS

TOOL NO. DESCRIPTION

99389834 Torque screwdriver for injector solenoid valve connector stop nut

setting

99395216 Pair of gauges with ½”and¾” 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

26 SECTION 2 - G-DRIVE APPLICATION G-DRIVE ENGINES

Base - February 2006 Print P2D32N00GB

TOOLS

TOOL NO. DESCRIPTION

8093731 Tester PT01

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

Navigation menu

Versions of this User Manual:

Views

Navigation