F4AE3481-3681-3682

EURO 4 NEF SERIES Application to vehicles

N40 N40 ENT C

N60 N60 ENT C

Technical and Repair manual

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

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

Publication edited by Iveco Motors Iveco SpA PowerTrain Mkt. Advertising & Promotion Viale dell’Industria, 15/17 20010 Pregnana Milanese Milano (Italy) Print P1D32N002 E - 1st Ed. 07.2006

Produced by:

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

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PRELIMINARY REMARKS Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.). Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections of units to/from the vehicle, overhauls at the bench and relating troubleshooting. On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the electric system. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.

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

Danger of serious damage for the vehicle Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes guarantee lapse too.

!

General danger It includes the dangers of above described signals.

Environment protection It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.

NOTE

It indicates an additional explanation for a piece of information.

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1

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F4A Engines

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Part 1

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

Example ∅1

Ø 1 = housing for connecting rod small end bush α

Tighten to torque Tighten to torque + angular value

∅ 2 Ø 2 = housing for connecting rod bearings

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Graph and symbols Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly

α

!

Compression ratio

Tighten to torque

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Replacement Original spare parts

Regulation Adjustment

Rotation

Warning Note

Angle Angular value

Visual inspection Fitting position check

Preload

Measurement Value to find Check

Number of revolutions

Equipment

Temperature

Surface for machining Machine finish

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ρ

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

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Part 1 F4A ENGINES Section General specifications

1

Fuel

2

Application to vehicles

3

General overhaul and characteristics

4

Tools

5

Safety prescriptions

Appendix

PREFACE TO USER’S GUIDELINE MANUAL Section 1 describes the F4A engine illustrating its features and working in general. Section 2 describes the type of fuel feed. Section 3 relates to the specific duty and is divided in four separate parts: 1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating specific duty. 2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating specific duty. 3. Maintenance planning and specific overhaul. 4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct instructions to identify the cause of the major inconveniences. Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such operations. Installation general prescriptions are reported within the appendix. The appendix reports general safety prescriptions to be followed by all operators whether being in-charge of installation or maintenance, in order to avoid serious injury. Print P1D32N002 E

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UPDATING Section

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Description

Page

Date of revision

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GENERAL SPECIFICATIONS

SECTION 1 General specifications Page

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

3

LUBRICATION (4 CYLINDERS) . . . . . . . . . . . . .

5

LUBRICATION (6 CYLINDERS) . . . . . . . . . . . . .

6

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . .

7

- Oil pressure relief valve . . . . . . . . . . . . . . . . . .

8

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

9

COOLING SYSTEM (4 CYLINDERS) . . . . . . . . .

10

COOLING SYSTEM (6 CYLINDERS) . . . . . . . . .

12

- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

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

15

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

15

DeNOx 2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .

16

- General Information . . . . . . . . . . . . . . . . . . . . .

16

- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

- AdBlue fluid level gauge control . . . . . . . . . . . .

18

- Pump module . . . . . . . . . . . . . . . . . . . . . . . . . .

18

- Dosing module . . . . . . . . . . . . . . . . . . . . . . . . .

18

- Exhaust gas temperature sensor . . . . . . . . . . . .

19

- Humidity detecting sensor . . . . . . . . . . . . . . . .

20

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CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

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Technical Code

Commercial Code

F4AE3481 F4AE3681 F4AE3682

N40 ENT C N60 ENT C N60 ENT C

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GENERAL SPECIFICATIONS

LUBRICATION (4 CYLINDERS) 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.

5

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

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

Figure 1

Oil recover from the turbo-blower

To the exchanger and to the turbo-blower

1

Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil

LUBRICATION SYSTEM LAYOUT

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LUBRICATION (6 CYLINDERS) Even for the 6 cylinders version lubrication is obtained by forced circulation and achieved through an oil rotary expansion pump similar to the 4 cylinders’ one.

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.

Figure 2

Oil recover from the turbo-blower

To the exchanger and to the turbo-blower

Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil

LUBRICATION SYSTEM LAYOUT

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OIL PUMP

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GENERAL SPECIFICATIONS

Figure 3

NOTE Since the oil pump cannot be overhauled, it shall be replaced when damaged.

The oil pump is controlled directly by the drive shaft.

70576

HEAT EXCHANGER Figure 4 5

6 1

2

3

4 70480

1. Heat exchanger body with filter support - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.

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Oil pressure relief valve Figure 5

Pressure regulation at 100°C oil temperature: - 1.2 bar min pressure; - 3.8 bar max. pressure 107418

By-pass valve to cut out clogged oil filter. Figure 6 Figure 7

Flow

107419

MAIN DATA TO CHECK OIL PRESSURE RELIEF VALVE SPRING Base - July 2006

70482

Max blow-by: 20 cm3/1’ at 0.83 bar pressure and at 26.7°C oil temperature.

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OIL VAPOUR RECYCLING Figure 8

Oil condensate Oil vapours

109903

1. Pre-separator - 2. Bleeder on side 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. The condensed oil returns to the oil sump, whereas the residual vapour is conveyed, collected and discharged into the open air through the bleeder on the side (2). Print P1D32N002 E

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COOLING SYSTEM (4 CYLINDERS) The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment. - Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions. - Viscous pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development. - Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment. - Centrifugal water pump, placed in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.

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Figure 9

Expansion tank

Expansion tank

Heater (optional)

Radiator

Radiator

Water coming out from thermostat Water recirculating in engine Water coming into pump COOLING SYSTEM LAYOUT Print P1D32N002 E

74194

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

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Figure 10 Expansion tank

Expansion tank

Heater (optional)

Radiator

Radiator

Water coming out from thermostat Water recirculating in engine Water coming into pump COOLING SYSTEM LAYOUT

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GENERAL SPECIFICATIONS

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Water Pump

Viscous fan

Figure 11

Figure 13

70486 Sec. A-A The water pump is located in a housing obtained in the engine block and is controlled by and a poly-V belt.

An automatic tensioner keeps the belt tension.

Thermostat Figure 12

70487

Characteristics: Max control speed:

2700 rpm

Max fan speed:

2565 rpm ± 50 rpm

Operating temperature:

72°C± 4°C at 2160 rpm fan speed

79458

The thermostat (1) of the by-pass type is located in the cylinder head and doesn’t need regulations. Whenever doubts on its operation are present, replace it. On the thermostat body are fitted the thermometric transmitter/switch and water temperature sensor. A= stroke beginning: 79.0 — 83.0 °C B= stroke at 96 °C ≥ 7.5 mm Base - July 2006

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GENERAL SPECIFICATIONS

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AIR INDUCTION - BOOST DIAGRAM Figure 14

4 Cylinders version

TURBOCHARGER

AIR FILTRE

EXHAUST

RADIATOR

6 Cylinders version

TURBOCHARGER

AIR FILTRE

EXHAUST

RADIATOR 74195

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

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

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

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DeNOx 2 SYSTEM General Information To restrict the nitrogen oxide (NOx) emissions in the exhaust to within the limits prescribed by Euro 4 regulations, with low fuel consumption levels, the vehicles have been fitted with a system for post-treatment of the substances present in the exhaust gasses, basically comprising an electronically controlled oxidising catalytic converter. The system, by means of the SCR (Selective Catalytic Reduction) process, transforms the nitrogen oxides (NOx) into inert compounds: free nitrogen (N2) and water vapour (H2O). The SCR process is based on a series of chemical reactions that, by reacting the ammonia with the oxygen in the exhaust gas, results in reduction of the nitrogen oxides (NOx) present in the exhaust fumes.

Figure 15

A A A

108124

DIAGRAM OF SCR SYSTEM A. PUMP MODULE - B. DOSING MODULE 1. AdBlue solution tank - 2. Intercept solenoid valve - 3. Volumetric pump - 4. AdBlue solution temperature sensor 5. AdBlue level sensor - 6. Filter - 7. AdBlue temperature sensor - 8. AdBlue solution pressure sensor - 9. Pump Module Control unit - 10. NOx humidity detection sensor - 11. Temperature sensor - 12. Injection solenoid valve - 13. Discharged exhaust gas temperature sensor - 14. Catalytic converter - 15. Incoming exhaust gas temperature sensor - 16. Cooling solenoid valve - 17. Prefilter.

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GENERAL SPECIFICATIONS

The system essentially comprises: - a tank (9) of reagent solution (water - urea: AdBlue) with a level indicator; - a pump module (2); - a mixing and injection module (7); - a catalytic converter (4); - two temperature sensors (5 and 6) at the exhaust gas inlet and outlet to the catalytic converter (4);

17

The pump module (2) picks up the reagent solution from the tank (3) and sends it under pressure to the mixing and injection module (7) to be injected into the exhaust pipe upstream of the catalytic converter (4). The first phase of the process takes part in the first part of the catalytic converter: due to the effect of the exhaust gas temperature, the reagent solution evaporates instantly and, by hydrolysis, converts into ammonia (2NH3) and carbon dioxide (CO2).

- a humidity sensor (1) fitted on the engine air intake pipe downstream of the air filter.

Evaporation of the solution causes lowering of the exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The SCR system is electronically managed by the DCU (Dosing Control Unit) incorporated in the pump module (2), which according to the number of engine revs, the torque delivered, the exhaust temperature, the amount of nitrogen oxides and humidity in the incoming air, adjusts the flow rate of the AdBlue solution to be put into the system.

The exhaust fumes, additioned with ammonia and at the reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gasses the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

Figure 16

-

108588

LOCATION OF SCR SYSTEM COMPONENTS ON THE VEHICLES 1. Humidity sensor for incoming air - 2. Pump module - 3. Tank of reagent solution (water - urea: AdBlue) 4. Catalytic converter - 5. Temperature sensor for exhaust gas entering the catalytic converter - 6. Temperature sensor for exhaust gas leaving the catalytic converter - 7. Mixing and injection module. Print P1D32N002 E

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Tank

Pump module

Figure 17

Figure 19

108508

The tank with the level indicator command contains the reducing substance necessary for the SCR process, comprising a solution of 35% urea and water, known as AdBlue.

108128

1. AdBlue l tank return - 2. AdBlue return pipe from dosing module - 3. AdBlue solution outlet - 4. AdBlue solution infeed - 5. Electrical connection - 6. DCU control unit connector - 7. Filter - 8. Prefilter.

AdBlue fluid level gauge control

Dosing module

Figure 18

Figure 20

102296

AdBlue fluid level gauge command1. AdBlue fluid intake pipe - 2. AdBlue fluid return pipe - 3. Inlet pipe for hot engine coolant fluid - 4. NTC sensor - 5. Outlet pipe for hot engine coolant fluid - 6. Float - 7. AdBlue fluid heater coil.

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108129

1. AdBlue infeed - 2. Electrical connection 3. AdBlue outlet. Has the job of dosing the AdBlue solution to be sent into the exhaust pipe upstream of the catalytic converter.

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GENERAL SPECIFICATIONS

Exhaust gas temperature sensor Figure 21

102303

Figure 22

102304

FUNCTIONAL WIRING DIAGRAM 1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Earth cable (white) - 6. Sensor. The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to calculate the amount of urea to be injected into the system.

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Humidity detecting sensor Figure 23

102311

1. Temperature - 2. Earth - 3. Humidity percent value - 4. Power supply. This sensor is located on the air filter output conveyor, and is used to inform the control unit of the amount (percentage) of humidity found in sucked air, to determine the calculation of nitric oxide emissions.

Figure 24

102312

ELECTRIC BLOCK DIAGRAM 1. Earth - 2. Temperature - 3. Power supply unit - 4. Humidity percent value - A. Sample frequency generator B. Reference oscillator - C. NTC temperature sensor - D. Amplifier lowpass filter.

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FUEL

1

SECTION 2 Fuel Page

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COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . .

3

- General Specifications . . . . . . . . . . . . . . . . . . .

3

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . .

5

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

6

FUEL PREFILTER . . . . . . . . . . . . . . . . . . . . . . . . .

8

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

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

9

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

10

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

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

14

DOUBLE STAGE OVERPRESSURE VALVE . . . .

14

INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

- Injector in rest position . . . . . . . . . . . . . . . . . .

15

- Injection start . . . . . . . . . . . . . . . . . . . . . . . . . .

15

- Injection end . . . . . . . . . . . . . . . . . . . . . . . . . .

15

PRESSURE LIMITER FOR FUEL RETURN . . . . . .

15

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FUEL

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FUEL

COMMON RAIL General Specifications In order to reduce PARTICULATES emissions, very high injection pressures are required. The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision, obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.

System description Electric system Figure 1

108501

1. Injectors connections - 2. Fuel pressure sensor - 3. Engine coolant temperature sensor - 4. Engine oil temperature and pressure sensor - 5. Output shaft sensor - 6. EDC 7 control unit - 7. Pressure regulator - 8. Fuel heater and fuel temperature sensor - 9. Camshaft sensor - 10. Air pressure/temperature sensor - 11. Injector.

Through the sensors, present on the engine, the ECU controls the engine operation.

The outlet tension is proportional to the pressure or temperature obtained by the sensor.

Air pressure/temperature sensor

Engine oil temperature and pressure sensor

It is a component integrating a temperature sensor and a pressure sensor.

Same as air pressure/temperature sensor, it is fitted on the engine oil filter, in a horizontal position.

Fitted on the intake manifold, it measures the max. inlet air capacity to calculate precisely the fuel quantity to inject at every cycle.

It measures engine oil temperature and pressure.

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FUEL

Fuel pressure sensor Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The injection pressure value is used to control the pressure and to determine the electric injection control length. Fuel temperature sensor It is a sensor that is equal to the previous one. It measures fuel temperature to provide the control unit with an index of the diesel fuel thermal state. Coolant temperature sensor It is a variable-resistance sensor suitable to measure the coolant temperature to provide the control unit with an index of the engine thermal state. Output shaft sensor It is an inductive sensor placed on the front engine part. Signals generated through the magnetic flow that is closed on the phonic wheel, change their frequencies depending on output shaft rotation speed. Timing sensor It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape. System functionality Self-diagnosis The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data. IVECO Code recognition The EDC7 control unit communicates with the Immobilizer control unit to obtain the startup consent. Engine pre-heating resistance check The pre-post heating is activated when even only one of the water, air or fuel temperature sensors signals a temperature that is less than 5 °C. Phase recognition By means of signals coming from camshaft sensor and flywheel sensor, the cylinder on which fuel must be injected is recognised upon startup.

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Injection control The control unit, depending on information coming from sensors, controls the pressure regulator, and changes pre-injection and main injection modes. Closed-loop control for injection pressure Depending on engine load, measured by processing signals coming from various sensors, the control unit controls the regulator in order to always have the optimum pressure. Pilot and main injection spark advance control The control unit, depending on signals coming from various sensors, computes the optimum injection point according to an internal mapping. Idle speed control The control unit processes signals coming from various sensors and adjusts the amount of injected fuel. It controls the pressure regulator and changes the injection time of injectors. Within certain thresholds, it also takes into account the battery voltage. Maximum speed limiting At 2700 rpm, the controlunit limits fuel flow-rate by reducing the injectors opening time. Over 3000 rpm it deactivates the injectors. Cut Off Fuel cut off upon release is controlled by the control unit performing the following logics: - it cuts off injectors supply; - it re-activates the injectors shortly before idle speed is reached; - it controls fuel pressure regulator. Smoke control upon acceleration With strong load requests, the control unit, depending on signals received by air inlet meter and engine speed sensor, controls the pressure regulator and changes the injectors actuation time, in order to avoid exhaust smokes. Fuel temperature control When the fuel temperature exceeds 75 °C (measured by the sensor placed on fuel filter) the control unit intervenes by reducing injection pressure. If the temperature exceeds 90 °C, the power is reduced to 60%. AC compressor engagement control The control unit is able to drive engagement and disengagement of the electromagnetic compressor clutch depending on coolant temperature. If the coolant temperature reaches about 105 °C, it disengages the clutch. After Run The control unit microprocessor allows storing certain EPROM data, among which failure memory and Immobilizer information, in order to make them available upon the following startup.

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FUEL

HYDRAULIC SYSTEM Figure 2

High pressure Low pressure

108499

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

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FUEL

EURO 4 NEF ENGINES

FUEL SYSTEM LAYOUT This fuel system is a Common Rail injection with CP3 high pressure pump and this layout is for 4 cylinder version. (The 6 cylinder version is similar design as the 4 cylinder engine). The pressure regulator, placed upstream of the high-pressure pump, adjusts the fuel flow that is necessary on the low-pressure system. Afterwards, the high-pressure pump takes care of supplying the rail properly. This arrangement, by pressurising the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system. Function of the pressure relief valve (2), assembled on the high-pressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream. The pressure relief valve (2) intervention brings about a fuel flow increase in the high-pressure pump cooling circuit, through inlet and drain piping (16) from piping (8). The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 to 2 bars. Two by-pass valves are placed in parallel with the mechanical supply pump. The by-pass valve (18) allows fuel to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value. The by-pass valve (17) allows filling the supply system through the manual priming pump (10).

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

Base - July 2006

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Print P1D32N002 E

HIGH PRESSURE

HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE)

SUCTION (LOW PRESSURE)

EXHAUST

EURO 4 NEF ENGINES FUEL

7

Figure 3

114545

Base - July 2006

8

FUEL

EURO 4 NEF ENGINES

FUEL PREFILTER

FUEL FILTER

Figure 4

Figure 5

70494 99231

The fuel filter is of the high water separation type, is assembled on the right side of the vehicle chassis, and has the sensor (4) for detecting water in fuel placed on the cartridge (3) base. Manual priming pump (5) and air bleeding screw (2) from system are placed on filter support. The presence of condensate into filter is signalled by sensor (4) when a warning light on the instrument panel is lit.

1. Fuel filter support - 2. Fuel temperature sensor 3. Electric fuel heater - 4. Fuel filter - 5. Adaptor 6. Heater connector - 7. Gasket. A. Outlet connection for fuel discharge to the tank B. Outlet connection to high-pressure pump C. Discharge connection from high-pressure pump D. Inlet connection for fuel discharge from common rail E. Inlet connection from fuel pump. It is placed on engine block in the circuit between supply pump and high-pressure pump (CP3).

!

If the warning light is on, it is necessary to immediately operate to remove its cause; the common rail system components are quickly damaged by the presence of water or impurities in the fuel.

Cartridge filtering degree: 4 microns. Pressure delta 2 bars. The following are placed on the support: fuel temperature sensor and heater resistances. Fuel temperature, signalled by the related sensor to EDC7 control unit, allows a very accurate computation of the fuel flow-rate to be injected into the cylinders.

Base - July 2006

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EURO 4 NEF ENGINES

FUEL

MECHANICAL FEEDING PUMP

9

Jettison condition

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

Figure 8

Ordinary working condition Figure 6

72594

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

The by-pass valve (2) intervenes when, with the engine off, the supply system needs to be filled using the priming pump. In this situation, the by-pass valve (1) stays closed and the by-pass valve (2) opens due to the incoming pressure. The fuel flows out of outfeed B.

!

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

Figure 7

72593

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

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Base - July 2006

10

FUEL

EURO 4 NEF ENGINES

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

!

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

Figure 9

72595

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

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

FUEL

11

High pressure pump-inside structure Figure 10

Sec. B-B

Sec. C-C

70498

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

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

Print P1D32N002 E

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

Base - July 2006

12

FUEL

EURO 4 NEF ENGINES

Working principle Figure 11

Sec. B - B

Sec. D - D

72597

1. Fuel exhaust connector to rail - 2. By-pass valve to common rail - 3. Pumping element - 4. Pump’s camshaft 5. Pumping element fuel duct - 6. Fuel duct for pressure regulating gauge - 7. Pressure regulating gauge.

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

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

Print P1D32N002 E

EURO 4 NEF ENGINES

Figure 12

Sec. C - C

13

FUEL

Figure 13

72598

72601

Sec. A - A

1. Inlet to the pumping element - 2. Duct lines for the pump lubrication - 3. Inlet to the pumping element 4. Main feeding line to the pumping element 5. Pressure gauge - 6. Inlet to the pumping element 7. Pressure gauge exhaust flue - 8. Flow limiting valve to 5 bar - 9. Fuel exhaust from pressure gauge inlet.

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

Figure 12 shows the fuel runs at low pressure inside the pump; the following elements are clearly visible: the main feeding line to the pumping elements (4); the feeding lines to the pumping elements (1-3-6), the duct lines run for the pump lubrication (2), the pressure gauge (5), the flow limiting valve to 5 bar (8) and the fuel exhaust flue (7).

Figure 13 shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.

The pump shaft is lubricated by the fuel through the feeding and recovery lines (2). The pressure gauge (5) determines the quantity of fuel to feed the pumping elements: the fuel in excess flows through the exhaust gallery (9). The limiting valve to 5 bar, in addition to recovering fuel exhaust as a collector has also function to keep the pressure constant to 5 bar limit at gauge entry.

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Base - July 2006

14

FUEL

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

EURO 4 NEF ENGINES

RAIL Figure 14

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.

108500

1. Rail. — 2. Pressure sensor. — 3. Fuel inlet from high-pressure pump. — 4. Overpressure valve. The rail volume is of reduced sizes to allow a quick pressurisation at startup, at idle and in case of high flow-rates. It anyway has enough volume as to minimise 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 (2) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.

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

DOUBLE STAGE OVERPRESSURE VALVE Once the valve has been mounted at one rail end, the valve task is to protect system components in the case where a fault in either rail pressure sensor or pump pressure regulator CP3 causes pressure excessive increment in high pressure system. The valve is of a definitely mechanical type and has double operation threshold: 1750 bar and about 800 bar. When pressure in the rail reaches 1750 bar, the valve first operates as a single stage valve to cause fuel to be drained away and pressure to be consequently decreased to safety values, then it mechanically regulates pressure in the rail to about 800 bar. This valve enables to have the engine operated for long time with limited performance and inhibits fuel excessive overheating, so preserving the pipings returning from the tank.

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

FUEL

INJECTOR

15

Injection start

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

Figure 16

15

Injector in rest position Figure 15

70506

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

15

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

PRESSURE LIMITER FOR FUEL RETURN

70505

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.

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

Figure 17

70507

A Print P1D32N002 E

To tank — B From injectors Base - July 2006

16

FUEL

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

1

SECTION 3 Application to vehicles Page

Print P1D32N002 E

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

3

GENERAL PROPERTIES . . . . . . . . . . . . . . . . . . .

4

- 4 cylinder engines . . . . . . . . . . . . . . . . . . . . . .

4

GENERAL PROPERTIES . . . . . . . . . . . . . . . . . . .

5

- 6 cylinder engines . . . . . . . . . . . . . . . . . . . . . .

5

GENERAL PROPERTIES . . . . . . . . . . . . . . . . . . .

6

- 6 cylinder engines . . . . . . . . . . . . . . . . . . . . . .

6

PART ONE - MECHANICAL COMPONENTS

7

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

9

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

9

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

9

- Distribution gear box . . . . . . . . . . . . . . . . . . .

17

- Distribution timing . . . . . . . . . . . . . . . . . . . . . .

17

- Flywheel housing . . . . . . . . . . . . . . . . . . . . . . .

18

- Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . .

19

- Tappet play adjustment . . . . . . . . . . . . . . . . . .

26

- Intake manifold . . . . . . . . . . . . . . . . . . . . . . . .

27

- Wiring support . . . . . . . . . . . . . . . . . . . . . . . .

29

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

33

PART TWO - ELECTRICAL EQUIPMENT . . .

35

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

37

- Engine F4AE3481 . . . . . . . . . . . . . . . . . . . . . .

37

- Engine F4AE3681 . . . . . . . . . . . . . . . . . . . . . .

38

- Engine F4AE3682 . . . . . . . . . . . . . . . . . . . . . .

39

Base - July 2006

2

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Page

- Overview of sensors . . . . . . . . . . . . . . . . . . . .

40

ECM ELECTRONIC CONTROL UNIT (EDC 7)

41

- Electroinjectors connector “A” . . . . . . . . . . . .

42

- Sensors connector “C” . . . . . . . . . . . . . . . . . .

43

- “B” frame connector

44

...................

ECM CENTRAL UNIT COMPONENTS (EDC 7)

45

- Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . .

49

- Pressure regulator - high pressure pump . . . . .

51

- Electroinjector . . . . . . . . . . . . . . . . . . . . . . . . .

52

MAIN POWER COMPONENTS . . . . . . . . . . . .

Page PART FOUR - MAINTENANCE PLANNING .

89

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . .

91

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

91

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

91

- Inspection and/or maintenance interventions .

91

- Unscheduled and set-interval operations . . . . .

92

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

93

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

93

- Check of fuel system . . . . . . . . . . . . . . . .

93

- Lubricating system check . . . . . . . . . . . . .

93

54

- Cooling system check . . . . . . . . . . . . . . .

93

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . .

54

- Check of belt’s tear and wear status . . . .

93

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . .

55

- Changing engine oil . . . . . . . . . . . . . . . . .

94

PART THREE - TROUBLESHOOTING . . . . . .

57

- Changing engine oil filters . . . . . . . . . . . .

94

PT-01 PORTABLE TESTER . . . . . . . . . . . . . . . . .

59

- Changing fuel pre-filter . . . . . . . . . . . . . . .

94

- Main functions . . . . . . . . . . . . . . . . . . . . . . . . .

59

- Changing fuel filter . . . . . . . . . . . . . . . . . .

94

- Test parameters . . . . . . . . . . . . . . . . . . . . . . . .

59

- Changing miscellaneous drive belts . . . . .

95

- Connect - reconnect and clean AdBlue system pre-filter . . . . . . . . . . . . . . . . . . . .

95

- Checking valve clearance and adjustment if necessary . . . . . . . . . . . . . . . . . . . . . . . .

95

DTC ERROR CODES WITH EDC7 CENTRAL UNIT . . . . . . . . . . . .

61

GUIDE TO DIAGNOSIS THROUGH SYMPTOMS

85

Base - July 2006

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EURO 4 NEF ENGINES

3

SECTION 3 - APPLICATION TO VEHICLES

GENERAL SPECIFICATIONS Figure 1

108502

F4AE3681 ENGINE The NEF F4AE 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;

!

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Iveco Motors.

- Section of preventive maintenance operations, providing instructions for the execution of the main operations.

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.

Print P1D32N002 E

Base - July 2006

4

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

GENERAL PROPERTIES - 4 cylinder engines F4AE3481C (.14)

Type

ρ

F4AE3481D (.16)

Compression ratio Max. output

Max. torque

Loadless engine idling Loadless engine peak Bore x stroke Displacement

F4AE3481B (.18)

F4AE3481A (.185)

17 : 1 kW (HP)

103 (140)

118 (160)

130 (180)

134 (185)

rpm

2700

2700

2700

2700

Nm (kgm)

460 (47)

530 (54)

570 (58)

610 (62)

rpm

1200

1200

1200

1200

rpm

750

rpm

3000 102 x 120

cm3

3920

TURBOCHARGING

with intercooler

Turbocharger type

GARRETT GT 22

LUBRICATION

Forced by gear pump, relief valve single action oil filter

Oil pressure at 80° C: bar

- at 750 rpm - at 4200 rpm

bar bar

2.0 4.0 By centrifugal pump, regulating thermostat, radiator, heat exchanger, intercooler Through belt

COOLING Water pump control Thermostat - opening start - max. opening

ACEA E3/E5 Urania LD5

81 ± 2 °C 96 °C

FILLING Total capacity - engine sump

Min. level

Max. level

litres

5.3

8.3

kg

4.8

7.5

litres

6.3

9.3

kg

5.7

8.4

engine sump + filter

!

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

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

5

GENERAL PROPERTIES - 6 cylinder engines F4AE3681C F4AE3681B F4AE3681D F4AE3681E F4AE3681A (.18) (.22) (.25) (.28) (.30)

Type

ρ

Compression ratio kW (HP)

135 (185)

160 (220)

17 : 1 185 (250)

rpm

2700

2700

2700

2700

2700

Nm (kgm)

650 (66)

680 (69)

850 (87)

950 (97)

1050 (107)

1250÷2100

1250÷2100

1250÷2100

1250÷2100

Max. output

Max. torque

rpm 1200÷2100 Loadless engine idling Loadless engine peak Bore x stroke Displacement

205 (280)

220 (300)

650

rp

3000 102 x 120

rpm

cm

5900

TURBOCHARGING

with intercooler

Turbocharger type

HOLSET HX 35 W

LUBRICATION

Forced by gear pump, relief valve single action oil filter

Oil pressure at 80° C: bar

- at 750 rpm - at 4200 rpm

bar bar

COOLING Water pump control Thermostat - opening start - max. opening

81 ± 2 °C 96 °C

FILLING Total capacity ACEA E7 Urania LD7 ACEA E4 Urania FE5W30

2.0 4.0 By centrifugal pump, regulating thermostat, radiator, heat exchanger, intercooler Through belt

Min. level

Max. level

litres kg

8 7.2

10.8 9.7

litres kg

9 8.1

11.8 10.6

- engine sump

engine sump + filter

!

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.

Print P1D32N002 E

Base - July 2006

6

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

GENERAL PROPERTIES - 6 cylinder engines F4AE3682C F4AE3682F (.22) (.25)

Type

ρ

Compression ratio

F4AE3682B F4AE3682A (.26) (.30)

kW (HP)

160 (218)

185 (252)

17 : 1 194 (264)

rpm

2700

2700

2500

2500

2500

Nm (kgm)

680 (69)

850 (87)

930 (95)

1000 (102)

1050 (107)

rpm

1200

1250

1250

1300

1300

Max. output

Max. torque

F4AE3682E (.26)

Loadless engine idling Loadless engine peak Bore x stroke Displacement

rpm

650

rpm

3000 102 x 120

cm3

5900

TURBOCHARGING

194 (264)

220 (300)

with intercooler

Turbocharger type

HOLSET HX 35 W

LUBRICATION

Forced by gear pump, relief valve single action oil filter

Oil pressure at 80° C: bar

- at 750 rpm - at 4200 rpm

bar bar

COOLING Water pump control Thermostat - opening start - max. opening

81 ± 2 °C 96 °C

FILLING Total capacity ACEA E7 Urania LD7 ACEA E4 Urania FE5W30

2.0 4.0 By centrifugal pump, regulating thermostat, radiator, heat exchanger, intercooler Through belt

Min. level

Max. level

litres kg

8 7.2

10.8 9.7

litres kg

9 8.1

11.8 10.6

- engine sump

engine sump + filter

!

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

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

7

DIAGNOSI

PART ONE - MECHANICAL COMPONENTS

Print P1D32N002 E

Base - July 2006

8

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

ENGINE OVERHAUL Preface

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.

Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well.

!

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.

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.

9

Figure 4

‘

Engine setting operations for the assembly on turning stand Figure 2

70127

The pipe (3) from the union (4) and from the supercharger (8). Remove the fuel pipe (2) from the rail and from the high-pressure pump (9) and remove it from the engine block, by removing the fixing screws (4 and 6) 105163

In order to apply to the engine block the engine fixing brackets 99341009 to the stand for the overhaul, operating on the engine left side, it is necessary: - to remove the fuel filter (4) from the support (1) by means of tool 99360076; - to remove the low pressure fuel pipe (2-3-5) from the support (1) - to remove the support (1) bracket from the block

NOTE When unlocking the pipe (2) union (7), it is necessary to prevent the union (10) rotation of the high-pressure pump (9), by using the proper wrench.

On the right side Figure 5

Figure 3

108478

116237

To disconnect the low pressure fuel pipe from the relevant connecting joint, you need to hold the clasp (1) pressed, and release the quick fitting joint (2).

Remove screws (2) and detach oil pipe (3) from turbine (1) and the engine crankcase. Remove starter motor (5) from flywheel cover (4). Apply to the block the bracket 99361037 and fix by means of these latter the engine to the revolving stand 99322205. Drain the engine oil by removing the plug from the sump. Remove the fan from the engine shaft pulley.

Print P1D32N002 E

Base - July 2006

10

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 6

108501

1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Output shaft sensor - 6. EDC7 ECU - 7. Pressure limiter - 8. Fuel heater and fuel temperature sensor 9. Timing sensor - 10. Air temperature/pressure sensor - 11. Injector. Disconnect the engine cable by disconnecting the connectors: (1) from injector wiring (6); (7) air pressure/temperature sensor; (3) fuel pressure sensor; (11) ECU; (10) high pressure pump sensor; (8) timing sensor; (2) engine coolant temperature sensor on thermostat; (5) engine speed sensor;

Figure 7

108479

Disconnect from the rail (2): the fuel pipe (4) according to procedures described in Figure 3. Disconnect fuel pipes (6) from rail (2) and injector manifolds (5). Remove the screws (1) and disconnect the rail (2). Disconnect pipe (3) from compressor and engine block.

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Figure 8

11

Figure 10

70132

Loosen tappet adjustment fastening nuts (1) and unscrew the adjusters. Remove the screws (2), remove the rocker assembly (3), consisting of: bracket (6), rockers (4), shafts (5) and remove jumpers (7) from valves. Remove rods (8). Figure 11 107248

Disconnect pipe (2) from pressure limiting device (1) for fuel return, as described in Figure 3. Remove screw (7). Loosen spring strip (3) and take off oil vapours pipe (10). Remove fittings (6 and 4) and take off pipe (5). Remove nuts (9) and take off tappets cover (8) complete with gasket. Figure 9

70133

Remove injector fastening screws. Use tool 99342101 (1) to remove injectors (2) from the cylinder head. Figure 12

108476

Remove nuts (8) and disconnect the electrical cables from injectors (7). Remove screws (1) and disconnect injector wiring support (2) including the gasket. Remove screw (5) and take off air temperature/pressure sensor (6). Remove nuts (3) and remove fuel manifolds (4). NOTE Disassembled fuel manifolds (4) must not be used again, but however replaced with other new ones.

Print P1D32N002 E

108480

Remove screw (4), loosen clamp (2) and disconnect air duct (1) from turbosupercharger (3). Base - July 2006

12

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 13

Figure 15

70137

108481

Hook brackets (1) with metal ropes and remove cylinder head (2) from block using hoist.

Remove oil pipe (5) from exhaust manifold(2). Disconnect the oil pipe (5) from the heat exchanger/oil filter support (6). Remove the nuts (3) and disconnect the turbosupercharger (4) from the exhaust manifold (2).

Figure 16

Remove the screws (1) and disconnect the exhaust manifold (2) from the cylinder head.

108483

Remove cylinder head gasket (1).

Figure 14

Use the proper wrench to operate the automatic belt tensioner (3) to loosen belt (2) tension and remove it; Remove the screw (4) and the automatic belt tensioner (3). Figure 17

108482

Remove the screws (1) and disconnect the air duct (2) including the heater. Remove the screws (4), and take out the cover (3) and the thermostat set underneath. Remove the cylinder head (6) fastening screws (5). 108484

NOTE Pointed out external screws are shorter. Remove the screws (2) and disconnect the alternator (1). Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Figure 18

13

Figure 20

108485

Remove the screws (2) and disconnect the alternator support (3).

70142

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

Use tool 99360076 to remove the oil filter (1). Figure 21

70143

Use wrench 99355019 (1) to remove the screws (3) and disconnect the hydraulic power steering pump (2) including the oil tank (4) from the air compressor (5).

Figure 19

Figure 22

108486

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

the oil

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

Print P1D32N002 E

70144

Remove the screws (2) and the nuts (1-4) and disconnect the air compressor (3). Base - July 2006

14

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 23

Figure 26

70148 70145

Remove the nut (1) and remove the phase sensor (2). Remove the nuts (3) and remove the high-pressure pump (4) complete of power supply pump (5).

Remove the screws (1) and remove the water pump (2). Remove the screws (3) and remove the roller (4). Remove the screws (5) and remove the rpm sensor (6). Figure 27

Figure 24

70146

Apply the tool 99360351 (2) to the flywheel housing (1), to stop the flywheel (3) rotation. Loosen the screws (4). Figure 25

107260

Remove screws (4) and dismount pulley (2). Remove screws (3) and dismount damper flywheel (1). Unthread phonic wheel (5). Base - July 2006

78256

Apply on the front tang (2) of the driving shaft fixture 99340055 (4) and through the guiding holes of the fixture itself, drill the internal seal ring (1) with a drill (∅ 3.5 mm) to a depth of 5 mm.. Fix fixture (4) to the ring (1) by means of the 6 screws in the kit e proceed with the removal of the ring by screwing up the screw (3). Figure 28

78257

Apply the proper rod (3) of fixture 99363204 to the external seal ring (2) as shown in the figure and use lever (4), to remove it from the front cover (1). Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Figure 29

15

Figure 32

107261 70152

Remove the screws (1 and 3) and take out the front cover (2). NOTE Write down the screw (1) assembling position because they exhibit different lengths.

Screw two pins (2) exhibiting a proper length into the engine shaft holes (3). Withdraw the engine flywheel (1) in order to sling it with the hoister and position it into the container.

Figure 30

Figure 33

70150

Remove the screws (1) and remove the oil pump (2). NOTE It is not possible to overhaul the oil pump (2).

Figure 31

78258

70151

Remove tool 99360351 (2). Remove the engine (3) flywheel fixing screws (1) to the engine shaft (4). Print P1D32N002 E

Apply fixture 99340056 (3) on the rear tang (5) of the driving shaft and through the guiding holes of the fixture, drill the internal seal ring (1) with a drill (∅ 3,5 mm) to a depth of 5 mm. Fix fixture (3) to the ring (1) by means of the 6 screws (4) in the kit e proceed with the removal of the ring by tightening the screw (2). Perform the removal of the external seal ring as shown and described in Figure 28.

Base - July 2006

16

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 34

Figure 37

70153

Remove the screws (2) and remove the rear cover (1). 70156

NOTE Write down the screw (1) assembling position because they exhibit different lengths.

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

Figure 35

70154

Figure 38

Overturn the engine. Remove the screws (2), remove the plate (3) and remove the oil sump (1). Figure 36

70157

Remove the screws (2) and the timing gearcase (1).

99222

Remove the screws (1) and remove the oil suction rose (3).

NOTE Write down the screw (2) assembling position because they exhibit different lengths.

Remove the screws (2) and remove the stiffening plate (4).

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Distribution gear box

17

Figure 40

Figure 39

107272

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

!

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

70210

DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR CASE FASTENING SCREWS Refit the case (1) to the engine block. Screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 65 to 89 Nm Screws M8 20 to 28 Nm Screws M10 42 to 52 Nm NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

Distribution timing Figure 41

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.

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

Print P1D32N002 E

Base - July 2006

18

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 42

!

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 (max 10 minutes).

70212

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

Figure 45

Figure 43

70215

70213

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

Flywheel housing Figure 44

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 shown in the figure: Screws M12 75 to 95 Nm Screws M10 44 to 53 Nm

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

70214

LOCTITE 5205 SEALANT APPLICATION AREAS

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Figure 46

19

Figure 48

70152

70216

Apply on the rear tang (6) of the driving shaft part (5) of ’fixture 99346253, fix it with screws (4) and key on it the new seal ring (3).

Screw two pins (2) having suitable length into shaft holes (3) and remove the engine flywheel (1) using proper sling and hoister. Figure 49

Position part (1) on part (5) tighten nut (2) until seal ring (3) is fully assembled into the flywheel housing box (7).

Engine flywheel Figure 47

70218

Tighten the screws (4) fastening the engine flywheel (3) to the output shaft. Apply tool 99360351 (2) to the flywheel housing (1) to stop engine flywheel (3) rotation. Figure 50 α 70217

NOTE 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) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.

Print P1D32N002 E

70219

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

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

20

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 51

Figure 54

70223

70220

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

Remove the sealing ring (2) from the front cover (1), clean accurately the coupling surfaces and smear them with IVECO nr. 2992545. Figure 55

Figure 52

70224 70221

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

Apply a new sealing ring (2) to the water pump (1). Figure 56 Figure 53

70225 70222

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

Base - July 2006

Apply on the front tang (6) of the driving shaft part (5) of fixture 99346252, fix it with screws (4) and key on it the new seal ring (3). Position part (1) on part (5), tighten nut (2) till complete assembly of seal ring (3) on the front cover (7).

Print P1D32N002 E

EURO 4 NEF ENGINES

21

SECTION 3 - APPLICATION TO VEHICLES

Figure 57

Figure 60

α

99223

Fit the plate (1), the rose pipe (2) and tighten the fastening screws (3) to the specified torque.

107274

Key phonic wheel (1) on engine shaft (2). Mount damper flywheel (6), and screw securing screws (3) and tighten them in two steps:

Figure 58

- 1st stage, tightening to 50 ± 5 Nm torque with dynamometric wrench; - 2nd stage, tightening to 90° angle. NOTE Tightening to angle is performed using tool 99395216 (4).

Fit pulley (5). Tighten the fastening screws (4) to 68 ± 7 Nm torque. 70227

Set the gasket (1) on the oil sump (2). Figure 61

NOTE If not faulty the gasket can be reused. r

Figure 59

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. 70154

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

Print P1D32N002 E

Base - July 2006

22

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 62

Figure 64

70231

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.

70234

Position the alternator support (2) so that pins (3 and 4) are set against the engine block. Tighten the screws (1) to the specified torque. Figure 65

Figure 63

70232

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.

70139

Refit the alternator (1). Tighten the screw (2) to the specified torque. Figure 66

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.

70235

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

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Figure 67

23

Figure 70

107259

Refit the ECU (2) including the heat exchanger to the engine block and tighten the screws (1) to the specified torque. 70145

Refit the high pressure pump (5) including the feed pump (6) 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.

Connect cooling pipe (3) to electronic central unit (2). NOTE Replace support elastic elements (1). Figure 71

Figure 68

70137

70144

Refit the air compressor (3). Tighten the screws (2) and the nuts (1 and 4) to the specified torque.

Apply a new gasket to the engine block and then place the cylinder head (2) slung by the hanger brackets (1). Figure 72

Figure 69

α

70336

Assemble cylinder head (1), tighten the screws (2) in three following steps, following order and mode shown in the figure below. 70143

Refit the hydraulic power steering pump (2) including the oil tank (4) to the air compressor (5). Use wrench 99355019 to tighten the fastening screws (3) to the specified torque. Print P1D32N002 E

NOTE The angle tightening is carried out through tool 99395216 (3). Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Base - July 2006

24

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 73

Figure 76

α 6-cylinder engine

A 70476

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

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.

A = Front side

Figure 74 Figure 77

α

4-cylinder engine

A 70337

Cylinder head fastening screws tightening sequence: - 1st stage pre-tightening, with a torque wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm • Screw12x1.75 x 150 ( ) 55 ± 5 Nm A = Front side 70133

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

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

A = Front side

Screw injector fastening screws without tightening them.

Figure 75

70338

Fit a new sealing ring (2) lubricated with petroleum jelly and a new sealing washer (3) on injector (1).

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Figure 78

25

Figure 80

70343 91572

Assemble a new ring (3), lubricated with vaseline, on the fuel manifold (2) and insert it in the cylinder head housing so that the position ball (5) clashes with its housing (4).

ROCKER ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers. Figure 81

NOTE Disassembled fuel manifolds (2) must not be used again. Replace with new items.

Screw the fastening nuts (2, Figure 79) without locking them.

During this operation, the injector (1) shall be moved so that the manifold (2) is properly inserted into the fuel inlet hole (2, Figure 76).

70344

SHAFT-ROCKER MAIN DATA Check that shaft/rocker coupling surfaces are not showing excessive wear or damages.

Figure 79

Figure 82

32655 108492

Use the torque wrench to tighten gradually and alternately the injector fastening screws (1) to 8.5 ± 0.35 Nm torque. Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm torque.

Print P1D32N002 E

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.

Base - July 2006

26

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Tappet play adjustment

Figure 83

Figure 85

70345

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

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.

Figure 84 In order to more quickly perform the operating clearance adjustment for rocker arms — valves, proceed as follows: 6-cylinder engine Rotate the drive shaft, balance cylinder 1 valves and adjust the valves marked by the asterisk as shown in the table: cylinder n. 1 2 3 4 5 6 intake * * * exhaust * * * Rotate the drive shaft, balance cylinder 6 valves and adjust the valves marked by the asterisk as shown in the table: 70346

Check that tappet adjusters (1) are loose to prevent their balking on the rods (2, Figure 83) 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.

cylinder n. 1 2 3 4 5 6 intake * * * exhaust * * * 4-cylinder engine Rotate the drive shaft, balance cylinder 1 valves and adjust the valves marked by the asterisk as shown in the table: cylinder n. intake exhaust

1 -

2 *

3 * -

4 * *

Rotate the drive shaft, balance cylinder 4 valves and adjust the valves marked by the asterisk as shown in the table: cylinder n. intake exhaust

Base - July 2006

1 * *

2 * -

3 *

4 -

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

27

Intake manifold Figure 86

108493

In inlet manifold (4), air heater (2) for cold start-up is housed. In case of operation faults in air heater (2), the heater has to be replaced. In replacing air heater (2), you have to operate as follows: - Remove screws (1) securing heater (2) to inlet manifold (4). - Take heater (2) off inlet manifold (4) together with relating gasket (3). Fit new heater (2) into the seat of inlet manifold (4) inverting dismounting operations.

Print P1D32N002 E

Base - July 2006

28

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 87

Figure 89

108494

108496

Smear the intake manifold (1) coupling surface with IVECO n. 2992545 and fit it on the cylinder head. Tighten the screws (2) to the specified torque.

Connect the fuel pipes (1) to rail (2) and injector manifolds (4). Pipe connections shall be tightened to 20 Nm torque, by using the proper torque wrench 99389829 together with tool 99317915.

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

Figure 88

Figure 90

116237

To connect the low pressure fuel pipe to the connecting joint, insert the quick fitting joint (2) into the connecting joint, and push until the clip (3) is fastened. 108495

Fit air temperature sensor (4) and tighten securing screw (3). Fit rail (1) and tighten securing screw (2) at prescribed torque. Base - July 2006

NOTE

Check proper fuel pipe connection.

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Wiring support

29

Figure 94

Figure 91

70352

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

70355

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

Figure 95 Figure 92

99229 99227

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

Figure 93

Fit the tappet cover (1) and tighten the nuts (2) to the specified torque.

Figure 96

99228

108497

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

Reconnect the exhaust manifold (2) with new gaskets. Tighten the fastening screws (1) to the specified torque.

Print P1D32N002 E

Base - July 2006

30

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 97

Figure 99

108498

Reconnect the turbosupercharger (3) with a new gasket to the exhaust manifold (1) and tighten the fastening nuts (2) to the specified torque. Connect oil pipe (4) to heat exchanger support (5) and turbocharger (3).

107415

Connect pipe (2) to air compressor fitting (1) and cylinder head fitting (4). Fit oil vapours pipe (5) into fitting located on supply box (7) and constrain the pipe with spring strip (6). Fit new seal ring (14) on pipe (5) and fit oil vapours pipe fitting (5) into tappets cover (13). Constrain pipe (5) securing bracket (12) by screw (11). Fit new copper washers into fittings (10 and 8) and connect pipe (9) to tappets cover (13) and supply box (7). Connect fuel return pipe (3) to pressure limiting device, rail and high pressure pump as described in following figure.

Figure 100 Figure 98

116237

108480

Connect the air duct (1) to the turbosupercharger (3) and lock it by clamp (2).

To connect the low pressure fuel pipe to the connecting joint, insert the quick fitting joint (2) into the connecting joint, and push until the clip (3) is fastened.

NOTE Check proper fuel pipe connection.

Secure air conveyor (1) to alternator support with screw (4).

Base - July 2006

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SECTION 3 - APPLICATION TO VEHICLES

31

Figure 101

108501

1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Output shaft sensor - 6. EDC7 control unit - 7. Pressure regulator - 8. Fuel heater and fuel temperature sensor - 9. Timing sensor - 10. Air temperature/pressure sensor - 11. Injector.

Re-connect the engine wire by hooking up: the electroinjector wiring (11) to connections (1), the air pressure/temperature sensor (10) the rail pressure sensor (3), the EDC7 control unit (6), the pressure regulator (7), the distribution phase sensor (9), the engine coolant temperature sensor (2) and the engine revolution number sensor (5).

Print P1D32N002 E

Apply to engine lifting hooks the lifting rig 99360555, hook the latter to the hoister and remove the engine from the revolving stand. Remove the brackets 99361037.

Base - July 2006

32

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Figure 102

Figure 104

70362 70128

Refit the bracket (2) including the fuel filter support (1) to the engine block, tighten the screws (3) to the specified torque.

Complete engine refitting as follows: Form the right side: Refit the starter (5) to the flywheel housing (4) and tighten the fastening nuts to the specified torque.

Figure 105

Fit the oil pipe (3) with a new sealing ring into the engine block and secure it to the turbosupercharger (1) by the screws (2) tightened to the specified torque.

Figure 103

105163

Screw manually the fuel filter (4) to the support (1), screw the filter by 3/4 turn, connect the pipes (2-3-5) to the relevant support connections (1) as shown in the following figure. Figure 106

70127

From the left side: Connect the fuel pipe (2) to rail and to high pressure pump (9), secure it by screws (4 and 6) tightened to the specified torque. Pipe connections (2) shall be tightened to 20 Nm torque using the proper dynamometric wrench 99389834. Connection (7) shall be tightened by holding at the same time the high pressure pump hexagon (10). When removed pipe (2) shall always be replaced. Connect pipe (3) to connection (4) and air compressor (8).

Base - July 2006

116237

To connect the low pressure fuel pipe to the connecting joint, insert the quick fitting joint (2) into the connecting joint, and push until the clip (3) is fastened. When refitting is over, fill engine with the prescribed lubricating oil in the specified quantity.

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SECTION 3 - APPLICATION TO VEHICLES

33

Checks and inspections Check proper fuel pipe connection.

!

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

- that there are no water leaks from the connecting sleeves of engine cooling circuit pipes and cab internal heating pipes, tighten the clamping collars if required; - check carefully the connection between the low pressure fuel pipes and the relevant connectors as specified in paragraph “Main servicing operations to be performed on engine fitted on vehicle”; - 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; - check also proper operation of the warning lights set on the instrument panel and of the equipment disconnected when engine was removed.

Print P1D32N002 E

Base - July 2006

34

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

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EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

35

PART TWO - ELECTRICAL EQUIPMENT

Print P1D32N002 E

Base - July 2006

36

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

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SECTION 3 - APPLICATION TO VEHICLES

37

LOCATION OF THE MAIN ELECTRICAL COMPONENTS Engine F4AE3481 Figure 107

114546

ENGINE VIEW LEFT SIDE 1. Alternator - 2. Drive shaft revolution number sensor - 3. Engine Control unit - 4. Heater and fuel temperature sensor 5. Pressure regulator - 6. Power steering oil level insufficient indicator control - 7. Air pressure/temperature sensor 8. Rail pressure sensor - 9. Connections for electroinjectors - 10. Engine coolant temperature sensor. Figure 108

114547

ENGINE VIEW RIGHT SIDE 1. Alternator - 2. Engine oil pressure /temperature sensor - 3. Starter motor. Print P1D32N002 E

Base - July 2006

38

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Engine F4AE3681 Figure 109

114548

ENGINE VIEW LEFT SIDE 1. Alternator - 2. Drive shaft revolution number sensor - 3. Engine Control unit - 4. Heater and fuel temperature sensor 5. Pressure regulator - 6. Power steering oil level insufficient indicator control - 7. Rail pressure sensor - 8. Connections for electroinjectors -9. Engine coolant temperature sensor. Figure 110

114549

ENGINE VIEW RIGHT SIDE 1. Alternator - 2. Engine oil pressure /temperature sensor - 3. Starter motor. Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

39

Engine F4AE3682 Figure 111

114550

ENGINE VIEW LEFT SIDE 1. Primary alternator - 2. Secondary alternator - 3. Air conditioner compressor - 4. Drive shaft revolution number sensor 5. Engine Control unit - 6. Heater and fuel temperature sensor - 7. Pressure regulator 8. Connections for electroinjectors - 9. Engine coolant temperature sensor. Figure 112

114921

ENGINE VIEW RIGHT SIDE 1.Primary alternator - 2. Secondary Alternator - 3. Engine oil pressure /temperature sensor - 4. Starter motor. Print P1D32N002 E

Base - July 2006

40

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Overview of sensors Figure 113

114922

Key Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 Base - July 2006

Description Coolant temperature sensor Electro-injector Rail pressure sensor Air temperature/pressure sensor Power steering level sensor Timing sensor Pressure regulator solenoid valve Fuel temperature sensor EDC7 control unit Engine oil level transmitter Drive shaft revolution number sensor Engine oil pressure/temperature sensor Pre-post hearing resistance Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

41

ECM ELECTRONIC CONTROL UNIT (EDC 7) Figure 114

102373

A. Injector connector - B. Frame connector - C. Sensor connector.

Print P1D32N002 E

Base - July 2006

42

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Electroinjectors connector “A” Figure 115

12

16

11

6

1

5 50350

1 2 3 4 5 6 7 8 9

Cable Colour (4 cylinders) HN HR MB HV V

Cable Colour (6 cylinders) LR BC BL MB MV HR V

10

C

C

BL HG MN MV

HN HG VN RG

Pin

11 12 13 14 15 16 Colour legend B black R red U blue W white P purple G green N brown Y yellow O orange Base - July 2006

Function (4 cylinders) Cylinder 3 injector Cylinder 2 injector Cylinder 1 injector Cylinder 4 injector Pressure regulator solenoid valve (pin 1) Pressure regulator solenoid valve (pin 2) Cylinder 4 injector Cylinder 1 injector Cylinder 2 injector Cylinder 3 injector

Function (6 cylinders) Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Pressure regulator solenoid valve (pin 1) Pressure regulator solenoid valve (pin 2) Cylinder 2 injector Cylinder 3 injector Cylinder 1 injector Cylinder 4 injector Cylinder 6 injector Cylinder 5 injector

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

43

Sensors connector “C” Figure 116

Colour legend B black R red U blue W white P purple G green N brown Y yellow O orange

6

8

16

9

15

22

1

3

23 30

36

29

4 5

50350

Pin 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 23 24 25 26 27 28 32 33 34 35 36 Print P1D32N002 E

Cable Colour B R BN HN RV CV CN B R GV GN BG GR NS MN CL LN BL BR

Function Phase sensor PIN 2 Phase sensor PINs 1 and 3 Rail temperature / pressure sensor PIN 1 Rail temperature / pressure sensor PIN 3 Rail temperature / pressure sensor PIN 2 Water temperature sensor PIN 1 Diesel oil temperature sensor PIN 2 Rpm sensor PINs 1 and 3 Rpm sensor PIN 2 Oil temperature / pressure sensor PIN 1 Air temperature / pressure sensor PIN 1 Water temperature sensor PIN 2 Oil temperature / pressure sensor PIN 4 Oil temperature / pressure sensor PIN 2 Oil temperature / pressure sensor PIN 3 Air temperature / pressure sensor PIN 3 Air temperature / pressure sensor PIN 4 Diesel oil temperature sensor PIN 1 Air temperature / pressure sensor PIN 2 Base - July 2006

44

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

“B” frame connector Figure 117 71

89

72

54

6

11

1 7 12

53

35

18

36

17 50350

Ref. 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 32 33 34 35 40 47 55 58 68 75 89 Base - July 2006

Cable colour code 8150 8150 0000 0000 8150 8150 0000 0000 8885 5173 5174 0173 9907 5584 6109 6108 8051 9906 0043 9966 8173 0094 2298

Function Positive (+30) of central unit power supply Positive (+30) of central unit power supply Earth Earth Positive (+30) of central unit power supply Positive (+30) of central unit power supply Earth Earth Positive for thermal start-up unit relay insertion Humidity sensor Humidity sensor Humidity sensor Positive from start button from engine compartment Engine rpm’s CAN - L line CAN - H line Positive (+15) from IBC3 Positive from stop button from engine compartment Engine brake solenoid valve negative Engine brake solenoid valve positive Humidity sensor Negative for thermal start-up unit relay insertion K ECM line Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

45

ECM CENTRAL UNIT COMPONENTS (EDC 7)

Figure 118

Air temperature/pressure sensor (85156) This component combines a temperature and a pressure sensor. It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the exact amount of fuel to be injected at each cycle. This sensor is connected to the control unit via pins 25/C 36/C - 33/C - 34/C. It is powered at 5 V. The output voltage is proportional to the pressure (or temperature) measured by the sensor. Pins 25/C - 36/C Temperature 50324

Pins 33/C - 34/C Pressure

EXTERIOR VIEW OF SENSOR Oil pressure/temperature sensor This component is identical to the air temperature/ pressure sensor

Figure 119

It is mounted horizontally on the engine oil filter. It measures the engine oil temperature and pressure. It is connected to the control unit via pins 24C - 27C - 32C - 28C. The values sent are transmitted to the EDC control unit which, in its turn, controls the indicator on the dash (indicator / low pressure warning light). Pins 24/C - 28/C Temperature Pins 32/C - 27/C Pressure 50323

The engine oil temperature is used by the EDC unit only.

CONNECTION CONNECTOR Figure 120

Ref Ref.

Description

1

ECM Control unit Pin Oil

Air

Ground

24C

25C

2

Temp. signal

28C

36C

3

+5

32C

33C

4

Press. signal

27C

34C

50344

WIRING DIAGRAM Print P1D32N002 E

Base - July 2006

46

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Crankshaft sensor (48035) This inductive type sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which close through the openings of a toothed wheel force fitted to the crankshaft. The same signal is used to manage the electronic rev counter. It is connected to the control unit via pins 23C - 19C. The sensor’s resistance value is ca 900 Ω. Supplier BOSCH Tightening torque

8 ± 2 Nm

Timing system sensor (48042) This inductive sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which close through the holes situated in gears force fitted to the camshaft. The signal generated by this sensor is used by the ECU as the injection timing signal. Though it is similar to the crankshaft sensor, it is not interchangeable with the latter since its outer shape is different. It is connected to the control unit via pins 9C - 10C. The sensor’s resistance value is ca 900 Ω. Supplier BOSCH Tightening torque

8 ± 2 Nm

Figure 121

Figure 122

180 ± 15

3

2

1

8518

TECHNICAL VIEW

8519

WIRING DIAGRAM

Figure 123

8520

PERSPECTIVE VIEW Ref Ref. 1 2 3 Base - July 2006

Description Signal Signal Shielding

ECM Control unit Pin 48035 48042 19C 23C

10C 9C

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

47

Fuel pressure sensor (85157) Fitted to one end of the rail, it measures the pressure of the existing fuel in order to determine the injection pressure. The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection electronic command. It is connected to the control unit on pins 12C - 14C - 13C. It is powered at 5 V.

Figure 124

108933

Ref. 1 2 3

Print P1D32N002 E

Description Ground Signal Power

ECM Control unit pin 12C 14C 13C

Base - July 2006

48

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Coolant temperature sensor (85153) This is a variable resistance sensor that is able to measure coolant temperature and transmit a signal to the control unit reflecting the thermal conditions of the engine.

Figure 125

The same signal is used by the control unit to manage the temperature gauge on the dash. It is connected to the control unit via pins 15C - 26C. Its resistance at 20 °C = 2.50 KΩ. It is placed in the upper engine part.

1

2

50321

Fuel temperature sensor (47042) This sensor is identical to the previous one.

Figure 126

It measures the temperature of the fuel and transmits a signal to the control unit reflecting the thermal conditions of the diesel oil. It is connected to the control unit via pins 18C - 35C. Its resistance at 20 °C = 2.50 KΩ. The ECU manages the relay for the control of filter heating when the temperature of the fuel drops to ≤ 36 °C.

50322

Base - July 2006

Ref Ref.

Description

1 2

ECM Control unit Pin 85153

47042

Ground

15C

18C

Signal

26C

35C

Print P1D32N002 E

EURO 4 NEF ENGINES

49

SECTION 3 - APPLICATION TO VEHICLES

Fuel pre-filter

Figure 127

The water separation type fuel filter is mounted on the right hand side of the vehicle frame and has, on the cartridge base 3, a sensor 4 detecting the presence of water in the fuel. The filter support houses a manual priming pup 5 and a screw 2 to bleed the air from the system. The presence of condensate in the filter and the filter clogged condition are revealed by sensor 4 by turning on a single warning light in the dash.

1

2

!

5

If the warning light lights up, take action immediately to remove the cause, as common rail system components deteriorate quickly if there is water or impurities in the fuel. 3

4

000910t

Tightening torque Bleed screw 2 Filtering cartridge 3 Sensor 4

Print P1D32N002 E

6 to 8 Nm 18 ± 0.1 Nm 0.8 ± 0.1 Nm

Base - July 2006

50

SECTION 3 - APPLICATION TO VEHICLES

Pre-post heating resistance This resistance is located on the intake manifold. It is used to warm up the air in pre-post heating operations. It is powered by a remote control switch situated on the left hand side of the frame.

EURO 4 NEF ENGINES

Figure 128 B

A

Its resistance is ~ 0,5 Ω.

108909

A. - B. Connecting terminals Resistance control remote control switch The remote control switch is connected to the EDC control unit via pins 12B - 75B. It is activated when the temperature of the water or the diesel oil exceeds 5 °C.

Figure 129 C

The remote control switch coil resistance is about 15 Ω.

50325

C. Remote control switch Exhaust brake solenoid valve (78050) This is a N.C. on-off solenoid valve.

Figure 130

It is positioned on the left hand side of the frame. By controlling this solenoid valve, the ECU opens the passage for the air coming from the aux. unit tank to control the exhaust brake cylinder which, in its turn, closes the throttle valve in the exhaust manifold. It is connected to the control unit via pins 55B - 58B.

A A. Exhaust brake solenoid valve Base - July 2006

50328

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Pressure regulator - high pressure pump

51

Figure 131

Pump with 3 radial pistons controlled by the timing gears, requiring no phase adjustment, with rotor type feed pump fitted to the back. A. Connection between fuel discharge outlet and filter support B. Connection for fuel inlet from control unit heat exchanger C. Connection for fuel inlet from fuel filter D. Connection between fuel outlet from feed pump and filter E. Connection between fuel outlet and rail 1. High pressure pump 2. Feed pump 3. Pressure regulator (N.O. solenoid valve modulated by the control unit by means of PWM signal). The pressure regulator is located at the inlet of the high-pressure pump on the low-pressure circuit; its function is to modulate the quantity of fuel to feed to the high-pressure pump on the basis of commands received from the electronic control unit. It basically consists of the following parts: - trapezoidal section shutter; - valve control pin; - pre-charging spring;

A

- coils. In the absence of the control signal, the pressure regulator is normally open, and hence the high pressure pump is in its maximum delivery conditions. The control unit modulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying the fuel to the high pressure pump. This component cannot be replaced individually and hence it cannot be taken down.

1

2

B C 3 D E

The amount of fuel feeding the high pressure pump is metered by a proportional valve situated on the low pressure system - managed by the EDC 7 control unit. The delivery pressure to the rail is modulated between 250 and 1400 bar by the control unit working on the pressure regulator solenoid valve.

000912t

It is a N.O. solenoid valve Its resistance is ca 3.2 Ω. It is connected to the control unit via pins A9 - A10.

Print P1D32N002 E

Base - July 2006

52

SECTION 3 - APPLICATION TO VEHICLES

Electroinjector

EURO 4 NEF ENGINES

Figure 132

The injector features a traditional construction, save for the fact that it has no needle return springs. The electroinjector essentially consists of two parts: - actuator - atomiser consisting of a pressure rod 1, a needle 2 and nozzle 3; - control solenoid valve, consisting of a coil 4 and pilot valve 5. The solenoid valve controls the rise of the atomiser needle.

50336

Injection starts Upon being energised, coil 4 moves up the shutter 6. The fuel contained in the control volume 9 flows back towards line 12 resulting in a pressure drop in the control volume 9.

Figure 133

At the same time, the fuel pressure in the pressure chamber 8 moves up the needle 2 resulting into the fuel being injected into the cylinder.

Injection ends When coil 4 is de-energised, the shutter 6 closes again so as to re-create a balance of forces which moves the needle back into its closed position and stops the injection process.

This is a N.O. solenoid valve. Individually connected to EDC control unit on connector A. The resistance of the coil of each individual injector is 0.56 ÷ 0.57 Ω.

000933t

INJECTION IN RESTING POSITION 1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball shutter - 7. Control area - 8. Pressure chamber - 9. Control volume - 10. Control line - 11. Feed line - 12. Control fuel outlet - 13. Electrical connection 14. Spring.

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

53

SECTION 3 - APPLICATION TO VEHICLES

Connecting connectors Figure 134

1

3

2

50343

WIRING DIAGRAM OF THE CONNECTIONS Figure 135

1

2

3

4

1

5

6

3

2 FAN SIDE

50349

Ref.

CONNECTOR 1

CONNECTOR 2

CONNECTOR 3

Print P1D32N002 E

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

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

4 cylinder Control unit Pin A15 A2 A13 A4 A5 A12 A1 A16

6 cylinder Control unit Pin A11 A6 A13 A4 A14 A3 A12 A5 A15 A2 A1 A16 Base - July 2006

54

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

MAIN POWER COMPONENTS ALTERNATOR Supplier Rated voltage Current

BOSCH 28V 70A - 1800 RPM

Figure 136

B +

W L 15 S

PERSPECTIVE VIEW

7998

Figure 139

Figure 137

A 80 70 60

B 50 40

A

8003

30

WIRING DIAGRAM A. Alternator B. Voltage regulator

20 Figure 138 10 0

2 4 6 8 10 12 14 16

rpm

8002

ALTERNATOR CURRENT DELIVERY CURVE Characteristics

8000

VOLTAGE REGULATOR TEMPERATURE CHARACTERISTICS (6000 RPM)

Base - July 2006

Rated voltage 28 V Rated power 70 A Current at environment temperature 1800 RPM/35 A At 25 ºC and rated voltage 6000 RPM/70 A Direction of rotation clockwise, seen from pulley Weight 6.4 kg

Print P1D32N002 E

EURO 4 NEF ENGINES

55

SECTION 3 - APPLICATION TO VEHICLES

STARTER MOTOR Supplier Rated voltage Rated power

BOSCH 24V 4kW

Figure 140

50275

WIRING DIAGRAM 50

30

POWER RELAY

STARTER

50354

d

Print P1D32N002 E

Base - July 2006

56

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

57

PART THREE - TROUBLESHOOTING

Print P1D32N002 E

Base - July 2006

58

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Test parameters

PT-01 PORTABLE TESTER Using PT-01 with portable tester it is possibile to execute troubleshooting and test the EDC7 electronic module of NEF engines. PT-01 has been designed and developed to ensure stoutness and practicality and is particularly suitable to be used in workshop and industrial environment.

-

Engine revolutions;

-

Spark advance;

-

Battery voltage;

-

Accelerator foot pedal position;

-

Over voltage pressure;

-

Over voltage air temperature;

The tool is connected to the engine gearbox by means of one only cable providing both tester feed and communication with the electronic module.

-

Cooling liquid temperature;

-

Fuel temperature;

Main functions

-

Oil temperature;

-

Oil pressure;

-

Fuel delivery;

-

Fuel pressure;

-

Rail pressure duty cycle electro-valve.

!

Before connecting the tester to the electronic module, check the wording on the electronic module to select the correct software on the tool. 1 2 3 4 5 6 7 8 . A B C u m m k a a *

*

. v

59

a

0 In the tables at next pages there are shown failure codes. These codes can be read and interpreted by diagnosis tool.

a a a b

software 3.3_1 software 4.1_2

Easy access to different functions is available through the menu: -

ID. Reading of the electronic module;

-

Reading of failure memory and relevant environment conditions;

-

Failure memory clear;

-

Reading of working parameters;

-

Reading of status parameters;

-

Active troubleshooting (switching on heat starter, fuel pump, EDC warning led and so on)

Print P1D32N002 E

Base - July 2006

60

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

61

DTC error codes with EDC7 central unit

Print P1D32N002 E

Base - July 2006

62

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

113

Failing component

ACCELERATOR PEDAL/BRAKE PEDAL SUSPECT

Visible failures

Possible causes

Repair actions

Vehicle acceleration Accelerator pedal and Check the accelerator very slow. brake pressed pedal signal and pedal simultaneously (for mechanical movement. Engine idle speed: 500 too long); rpm. Accelerator pedal blocked or faulty; Incorrect vehicle.

use

Checks to be performed

Measuring conditions

Values to be detected

Remarks

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

of

CLUTCH SIGNAL The parameter reading Clutch switch faulty or Check clutch pedal switch SUSPECT shows that the clutch is wiring problems in and wiring. pressed. pedal.

117

BRAKE PEDAL Slight power reduction SIGNAL ERROR

Main and secondary Check the brake switch not synchronisation of both synchronised. switches (signal) and wiring. One of the two brake pedal switches may be stuck.

119

PLAUSIBILITY +15

Possible mechanical Check wiring. problem (in pawl) or electrical problem.

121

SPEED LIMITER Warning W/LIGHT permanently off.

light Short circuit defective wiring.

or Check wiring.

122

WARNING LIGHT Warning EOBD permanently off.

light Short circuit defective wiring.

or Check wiring.

123

EDC LAMP

Warning permanently off.

light Short circuit defective wiring.

or Check wiring.

124

COLD LAMP

START Warning permanently off.

light Short circuit defective wiring.

or Check wiring.

125

MAIN DEFECT

RELAY Possible problems Relay short circuit to Check wiring between during after-run. battery positive or ECM and battery. earth. Replace relay if necessary.

63

Base - July 2006

SECTION 3 - APPLICATION TO VEHICLES

116

Failing component

Visible failures

Possible causes

126

BATTERY VOLTAGE

Possible problems Alternator or battery Check wiring. during after-run. defective. Replace alternator Possible wiring regulator or battery problem. Replace the alternator if necessary.

127

ENGINE BRAKE Engine brake ELECTROVALVE operational.

128

MAIN RELAY - Possible problems Relay short circuit to Check wiring between SHORT CIRCUIT during after-run. battery positive or ECM and battery. TO BATTERY earth. Replace relay if necessary. Relay may be faulty.

129

AIR-CONDITION Possible problems Relay short circuit to Check wiring between ER COMPRESSOR during after-run. battery positive or ECM and battery. RELAY earth. Replace relay if necessary. Relay may be faulty.

12A

RELAIS ENGINE VALVE

12B

THERMOSTARTE Heater not working. R RELAY 1 (HEATER)

Relay or wiring Check wiring. short-circuited or Replace relay if necessary. interrupted.

12C

THERMOSTARTE R RELAY 2

Heater not working.

Relay or wiring Check wiring. short-circuited or Replace relay if necessary. interrupted.

12E

MANAGEMENT SYSTEM PRE/POST-HEATI NG (ACTIVE)

Grid heater Grid heater short Check wiring permanently operating. circuited to earth. component.

not Relay or wiring Check wiring. short-circuited or Replace relay if necessary. interrupted.

Measuring conditions

Values to be detected

Remarks SECTION 3 - APPLICATION TO VEHICLES

Checks to be performed

Repair actions

64

Base - July 2006

DTC

FOR Possible problems Relay short circuit to Check wiring between BRAKE during after-run. battery positive or ECM and battery. earth. Replace relay if necessary. Relay may be faulty.

and EURO 4 NEF ENGINES

Print P1D32N002 E

Failing component

Visible failures

Possible causes

Checks to be performed

Repair actions

131

COOLANT TEMPERATURE SENSOR

No reaction noticeable Sensor short-circuited Check the wiring. Replace on behalf of the driver. or value implausible sensor if necessary.

132

COOLANT TEMPERATURE SENSOR (TEST)

Slight power reduction. Operation in extreme Ensure the engine is not environmental working in extreme conditions or sensor environmental conditions. inaccurate. Check the wiring and the sensor accuracy. Replace necessary.

sensor

Measuring conditions

Values to be detected

Remarks

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

if

133

AIR Slight power reduction. Sensor short-circuited Check the wiring. Replace TEMPERATURE or value implausible sensor if necessary SENSOR BOOST AIR

134

BOOST PRESSURE No reaction perceivable Sensor short-circuited SENSOR by the driver. or difference between environmental Parameter recovery pressure and turbo value: 2700 mbar. pressure implausible

Check the wiring. Also check the environmental pressure sensor. Replace necessary.

sensor

if

FUEL TEMPERATURE SENSOR

Slight power reduction. Sensor short-circuited Check the wiring. Replace or value implausible sensor if necessary

136

RAIL PRESSURE Possible loss SENSOR OR performance. SIGNAL ERROR

of Rail sensor value Check connections and above threshold. correct operation of Rail sensor (parameter Sensor short-circuited acquisition). or faulty.

137

DBV VALVE Possible loss MANAGEMENT performance. (BOOST PRESSURE)

of Rail pressure sensor Check connections and value above threshold. correct operation of Rail pressure sensor Sensor faulty or (parameter acquisition) injection incorrect. and injection components.

65

Base - July 2006

SECTION 3 - APPLICATION TO VEHICLES

135

Visible failures

Possible causes

OIL PRESSURE No reaction perceivable Sensor short-circuited Check the wiring and oil SENSOR by the driver. or value implausible. level. Parameter recovery value: 3000 mbar.

13A

13C

141

Replace necessary.

143

sensor

if

OIL TEMPERATURE SENSOR

No reaction perceivable Sensor short-circuited Check the wiring. Replace by the driver. or value implausible. sensor if necessary.

ATMOSPHERIC TEMPERATURE SENSOR (HUMIDTIY?)

No reaction perceivable Sensor short-circuited Check the wiring. Replace by the driver. or value implausible. sensor if necessary.

CRANKSHAFT SPEED

No reaction noticeable Signal interrupted or Check wiring on behalf of the driver. wiring problem. installation.

Parameter recovery value: coolant temperature value (if intact) otherwise 120°C).

Parameter value: 40°C.

ENGINE No reaction perceivable Signal interrupted or WORKING ONLY by the driver. wiring problem. WITH CAMSHAFT Sensor installation SENSOR may not be correct. CAMSHAFT SENSOR

Measuring conditions

Values to be detected

Remarks

recovery

Sensor installation Replace may not be correct. necessary. 142

Checks to be performed

Repair actions

SECTION 3 - APPLICATION TO VEHICLES

138

Failing component

66

Base - July 2006

DTC

sensor

Check wiring installation. Replace necessary.

sensor

No reaction perceivable Signal interrupted or Check wiring by the driver. wiring problem. installation. Sensor installation Replace may not be correct. necessary.

sensor

and if and if and if

EURO 4 NEF ENGINES

Print P1D32N002 E

Failing component

Visible failures

Possible causes

Checks to be performed

Repair actions

144

FAULT BETWEEN No reaction noticeable Signal interrupted or Check wiring FLYWHEEL on behalf of the driver. wiring problem. installation of SENSOR AND sensors. Flywheel and timing CAMSHAFT sensor installation may be incorrect.

145

FAN RELAY

and both

Measuring conditions

Values to be detected

Remarks

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

No reaction perceivable Short circuit or fan Check the wiring and the by the driver. actuator faulty. fan actuator. Fan off.

Replace the actuator if necessary.

148

AIR-CONDITION Air conditioner Wiring or relay Check the wiring. Replace ER COMPRESSOR permanently off. short-circuited. relay if necessary. RELAY

149

PRE-HEATING Filter heater RELAY FUEL working. FILTER

151

HIGH PRESSURE SYSTEM

152

FAULT ON THE Possible loss FUEL PRESSURE performance. CONTROL OF THE RAIL (POSITIVE DEVIATION)

not Wiring or filter heater Check the wiring. Replace short-circuited. the filter heater if necessary.

of High pressure system: Check the possible causes listed above. - possible leaks;

- low pressure upstream of pump; - Diesel filter blocked or leak upstream of high pressure pump.

67

Base - July 2006

SECTION 3 - APPLICATION TO VEHICLES

- injectors stuck open; - High pressure pump faulty. Low pressure system:

Failing component

Visible failures

Possible causes

Repair actions

FAULT ON THE Possible loss FUEL PRESSURE performance. CONTROL OF THE RAIL (NEGATIVE DEVIATION)

of Possible pressure Check the possible causes regulator blocked or listed above. excessive pressure upstream of pump.

154

RAIL PRESSURE Possible loss ERROR: TOO performance. LOW

of High pressure system: Check the possible causes listed above. - possible leaks; - injectors stuck open; - High pressure pump faulty. Low pressure system:

Measuring conditions

Values to be detected

Remarks SECTION 3 - APPLICATION TO VEHICLES

153

Checks to be performed

68

Base - July 2006

DTC

- low pressure upstream of pump; - Diesel filter blocked or leak upstream of high pressure pump. 155

RAIL PRESSURE Possible loss ERROR: TOO performance. HIGH

of Possible pressure Check the possible causes regulator blocked or listed above. excessive pressure upstream of pump.

EURO 4 NEF ENGINES

Print P1D32N002 E

156

Failing component

Visible failures

HIGH PRESSURE Possible loss SYSTEM performance.

Possible causes

Repair actions

of High pressure system: Check the possible causes listed above. - possible leaks; - injectors stuck open; - High pressure pump faulty. Low pressure system:

Checks to be performed

Measuring conditions

Values to be detected

Remarks

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

- low pressure upstream of pump; - Diesel filter blocked or leak upstream of high pressure pump. 157

ERROR ON THE Possible loss RAIL PRESSURE performance. (EXCESSIVE DUTY CYCLE)

of High pressure system: Check the possible causes listed above. - possible leaks; - injectors stuck open; - High pressure pump faulty. Low pressure system:

69

Base - July 2006

SECTION 3 - APPLICATION TO VEHICLES

- low pressure upstream of pump; - Diesel filter blocked or leak upstream of high pressure pump.

Visible failures

HIGH PRESSURE Possible loss SYSTEM performance.

Possible causes

Repair actions

of High pressure system: Check the possible causes - rail pressure sensor listed above. defective; - high pressure pump faulty. Possible problem also in high pressure system (MPROP)

159

PRESSURE MPROP Possible loss REGULATOR performance. ERROR

of Wiring damaged or Check wiring and disconnected; pressure regulator; possible defective replace relay if necessary. relay or pressure regulator.

161

INJECTOR One or more injectors Possible short circuit Check wiring. CYLINDER 1 / (bank 1 or bank 2) not in connections. Possible internal problem SHORT CIRCUIT operating. Possible problem in also in ECM. injector coil. Replace the injector if Possible problem in necessary. control unit.

162

INJECTOR One or more injectors Possible short circuit Check wiring. CYLINDER 2 / (bank 1 or bank 2) not in connections. Possible internal problem SHORT CIRCUIT operating. Possible problem in also in ECM. injector coil. Replace the injector if Possible problem in necessary. control unit.

Checks to be performed

Measuring conditions

Values to be detected

Remarks SECTION 3 - APPLICATION TO VEHICLES

158

Failing component

70

Base - July 2006

DTC

EURO 4 NEF ENGINES

Print P1D32N002 E

163

164

165

166

Visible failures

Possible causes

Repair actions

INJECTOR One or more injectors Possible short circuit Check wiring. CYLINDER 3 / (bank 1 or bank 2) not in connections. Possible internal problem SHORT CIRCUIT operating. Possible problem in also in ECM. injector coil. Replace the injector if Possible problem in necessary. control unit. INJECTOR One or more injectors Possible short circuit Check wiring. CYLINDER 4 / (bank 1 or bank 2) not in connections. Possible internal problem SHORT CIRCUIT operating. Possible problem in also in ECM. injector coil. Replace the injector if Possible problem in necessary. control unit. INJECTOR One or more injectors Possible short circuit Check wiring. CYLINDER 5 / (bank 1 or bank 2) not in connections. Possible internal problem SHORT CIRCUIT operating. Possible problem in also in ECM. injector coil. Replace the injector if Possible problem in necessary. control unit. INJECTOR One or more injectors Possible short circuit Check wiring. CYLINDER 6 / (bank 1 or bank 2) not in connections. Possible internal problem SHORT CIRCUIT operating. Possible problem in also in ECM. injector coil. Replace the injector if Possible problem in necessary. control unit. INJECTOR One or more injectors Possible injector Check wiring. CYLINDER 1 / (bank 1 or bank 2) not connection problem Possible internal problem OPEN CIRCUIT operating. (or disconnected also in ECM. internally). Replace the injector if Possible problem in necessary. control unit (condenser).

Checks to be performed

Measuring conditions

Values to be detected

Remarks

71

Base - July 2006

SECTION 3 - APPLICATION TO VEHICLES

167

Failing component

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

Failing component

Visible failures

Possible causes

Repair actions

INJECTOR One or more injectors Possible injector Check wiring. CYLINDER 2 / (bank 1 or bank 2) not connection problem Possible internal problem OPEN CIRCUIT operating. (or disconnected also in ECM. internally). Replace the injector if Possible problem in necessary. control unit (condenser).

169

INJECTOR One or more injectors Possible injector Check wiring. CYLINDER 3 / (bank 1 or bank 2) not connection problem Possible internal problem OPEN CIRCUIT operating. (or disconnected also in ECM. internally). Replace the injector if Possible problem in necessary. control unit (condenser).

16A

INJECTOR One or more injectors Possible injector Check wiring. CYLINDER 4 / (bank 1 or bank 2) not connection problem Possible internal problem OPEN CIRCUIT operating. (or disconnected also in ECM. internally). Replace the injector if Possible problem in necessary. control unit (condenser).

16B

INJECTOR One or more injectors Possible injector Check wiring. CYLINDER 5 / (bank 1 or bank 2) not connection problem Possible internal problem OPEN CIRCUIT operating. (or disconnected also in ECM. internally). Replace the injector if Possible problem in necessary. control unit (condenser).

Measuring conditions

Values to be detected

Remarks SECTION 3 - APPLICATION TO VEHICLES

168

Checks to be performed

72

Base - July 2006

DTC

EURO 4 NEF ENGINES

Print P1D32N002 E

16C

16D

16E

171

173

189

Visible failures

Possible causes

Repair actions

INJECTOR One or more injectors Possible injector Check wiring. CYLINDER 6 / (bank 1 or bank 2) not connection problem Possible internal problem OPEN CIRCUIT operating. (or disconnected also in ECM. internally). Replace the injector if Possible problem in necessary. control unit (condenser). COMPRESSION Compression Test in After carrying out the TEST IN progress. compression test, turn the PROGRESS key OFF (after-run). THE MINIMUM More than 2 injectors See individual faults in NUMBER OF not operating. injectors. INJECTIONS WAS NOT REACHED: STOP THE ENGINE BENCH 1 CC One or more injectors Possible injector Check wiring. (bank 1 or bank 2) not connection problem. Possible internal problem operating. Injectors also in ECM. short-circuited. Replace the injector if necessary. BENCH 2 CC One or more injectors Possible injector Check wiring. (bank 1 or bank 2) not connection problem. Possible internal problem operating. Injectors also in ECM. short-circuited. Replace the injector if necessary. BENCH 1 One or more injectors Fault in control unit. Replace the engine INJECTORS (bank 1 or bank 2) may control unit. CHECK not be operating. (INTERNAL ECU) EGR POWER ST. No fault perceived by Short circuit or EGR Check wiring. SHORT TO BATT. the driver. actuator faulty. Replace the EGR actuator EGR not working. if necessary.

Checks to be performed

Measuring conditions

Values to be detected

Remarks

73

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SECTION 3 - APPLICATION TO VEHICLES

17C

Failing component

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

192

193

198

199

19A

Visible failures

TURBINE Poor performance. ACTUATOR CONTROL ELECTROVALVE TURBINE Poor performance. ACTUATOR CONTROL ELECTROVALVE SHORT CIRCUIT TO POSITIVE TURBINE WHEEL Poor performance. REVS SENSOR

FAULT ON AT Poor performance. LEAST TWO OF THE FOLLOWING SENSORS: TURBINE SPEED, BOOT PRESSURE AND EXHAUST GAS PRESSURE TURBOCHARGER Poor performance. CONTROL BOOST PRESSURE FAILURE (PCR)

Repair actions

VGT actuator wiring defective.

or Check VGT wiring and actuator.

VGT actuator wiring defective.

or Check VGT wiring and actuator.

Air filter blocked or Check the air filter and turbine rpm sensor check parameters linked signal implausible. with the turbine by performing a road test (parameter acquisition). Sensor signal Determine which turbine implausible. component caused the problem. Sensor may be faulty.

Turbo sensor or Check turbine sensors actuator may be faulty. and actuator (parameter acquisition). Air filter may be blocked. Check whether air filter is blocked. Turbo sensor or Check turbine sensors actuator may be faulty. and actuator (parameter acquisition). Air filter may be blocked. Check whether air filter is blocked.

Checks to be performed

Measuring conditions

Values to be detected

Remarks

Print P1D32N002 E

EURO 4 NEF ENGINES

TURBINE IN Poor performance. OVERSPEED (the fault is not displayed if it is caused by a low atmosperic pressure)

Possible causes

SECTION 3 - APPLICATION TO VEHICLES

191

Failing component

74

Base - July 2006

DTC

Failing component

Visible failures

19B

TURBINE SPEED Poor performance. EXCEEDING EVERY PERMITTED RANGE

19F

NOx ERROR

Possible causes

Checks to be performed

Repair actions

Air filter blocked or Check the air filter and turbine rpm sensor check parameters linked signal implausible. with the turbine by performing a road test (parameter acquisition).

SENSOR No effect perceived by Sensor the driver. implausible.

Measuring conditions

Values to be detected

Remarks

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

signal Check the Nox sensor.

Nox sensor may be faulty. 1A5

TIMEOUT OF No effect perceived by Problems in the Check wiring. CAN MESSAGE the driver. Denoxtronic (on the Check and correct any DM1DCU CAN line). faults in the Denoxtronic control unit

1A6

TIMEOUT OF No effect perceived by CAN configuration CAN MESSAGE the driver. incorrect. SCR1 CAN connections defective.

Check CAN line wiring. Check Denoxtronic control unit wiring and operation.

Terminal resistance not suitable. 1AE

HUMIDITY SENSOR

No effect perceived by Sensor short-circuited Check wiring. the driver. or faulty. Replace sensor necessary.

if

SERIOUS EOBD No effect perceived by Problems in Ad-Blue FAULT FROM the driver. dosing system. DENOXTRONIC (EOBD FLASHING LIGHT)

1B1

ERROR ON CAN No effect perceived by CAN configuration Check CAN line wiring. CONTROLLER A the driver. incorrect. Check terminal CAN connections resistances. defective.

75

Base - July 2006

Terminal resistance not suitable.

Check the faults in the Denoxtronic and consult the control unit troubleshooting guide.

SECTION 3 - APPLICATION TO VEHICLES

1AF

Visible failures

Possible causes

Repair actions

ERROR ON CAN No effect perceived by CAN configuration Check CAN line wiring. CONTROLLER B the driver. incorrect. Check terminal CAN connections resistances. defective. Terminal resistance not suitable.

1B3

ERROR ON CAN No effect perceived by CAN configuration Check CAN line wiring. CONTROLLER C the driver. incorrect. Check terminal CAN connections resistances. defective.

Checks to be performed

Measuring conditions

Values to be detected

Remarks SECTION 3 - APPLICATION TO VEHICLES

1B2

Failing component

76

Base - July 2006

DTC

Terminal resistance not suitable. 1B4

TIMEOUT MESSAGE BC2EDC1

CAN No effect perceived by CAN configuration Check CAN line wiring. the driver. incorrect. Check BC wiring and CAN connections operation. defective. Terminal resistance not suitable.

1B5

TIMEOUT MESSAGE VM2EDC

CAN No effect perceived by CAN configuration Check CAN line wiring. the driver. incorrect. Check VCM wiring and CAN connections operation. defective. Terminal resistance not suitable.

1B7

ERROR ON No effect perceived by CAN configuration Check CAN line wiring. MESSAGES CAN the driver. incorrect. Check ECM wiring and IN CAN connections operation. TRANSMISSION defective.

Print P1D32N002 E

1B9

ERROR ON THE No effect perceived by MIL/Body Controller Consult the Body EOBD LIGHT the driver. warning light Controller MANAGED BY defective. troubleshooting guide and THE CLUSTER) check the CAN line.

EURO 4 NEF ENGINES

Terminal resistance not suitable.

Failing component

Visible failures

Possible causes

Repair actions

1BA

TIMEOUT CAN No effect perceived by CAN messages from Consult the VCM MESSAGE DASH the driver. VCM inconsistent. troubleshooting guide and DISPLAY check the CAN line.

1BC

TIMEOUT CAN No effect perceived by CAN messages from Consult the VCM MESSAGE the driver. VCM inconsistent. troubleshooting guide and AMBCOND check the CAN line.

Checks to be performed

Measuring conditions

Values to be detected

Remarks

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

1BD TIMEOUT CAN No effect perceived by CAN messages from Consult the VCM/BC MESSAGE CCVS the driver. VCM or BC troubleshooting guide and inconsistent. check the CAN line. ERROR MESSAGE No effect perceived by CAN messages from Check the ETC CAN ETC1 the driver. ETC (gearbox) connection with the CAN inconsistent. line.

1C3

TIMEOUT IN No effect perceived by CAN messages from Check the TCO RECEIVING TC01 the driver. TCO inconsistent. connection with the CAN CAN MESSAGE line.

1C6

ERROR MESSAGE No effect perceived by CAN messages from Check the TCU CAN TSC1-PE the driver. TCU (Transmission connection with the CAN Control Unit) line. inconsistent.

1C8

ERROR MESSAGE No effect perceived by CAN messages from Check the TCU CAN TSC1-VE the driver. TCU (Transmission connection with the CAN Control Unit) line. inconsistent.

1D1

ECU OVERRUN No effect perceived by Electrical interference If the error persists to MONITORING the driver. or internal control unit replace ECU. ERROR problems.

1D2

ECU OVERRUN No effect perceived by Poor control unit Reprogram the central MONITORING the driver. programming/flash unit. If the error is ERROR repeated, replace the Possible internal fault central unit, if needed.

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SECTION 3 - APPLICATION TO VEHICLES

1C2

Failing component

Visible failures

Possible causes

Repair actions

ECU OVERRUN No effect perceived by Poor control unit Reprogram the central MONITORING the driver. programming/flash unit. If the error is ERROR repeated, replace the Possible internal fault central unit, if needed.

1D4

ECU OVERRUN No effect perceived by Ecu internal failure. MONITORING the driver. ERROR

If the error persists to replace ECU.

1D5

ECU OVERRUN No effect perceived by Ecu internal failure. MONITORING the driver. ERROR

If the error persists to replace ECU.

1D6

ECU INTERNAL Control ERROR (TPU) deactivation.

1D8

ECU OVERRUN No effect perceived by Ecu internal failure. MONITORING the driver. ERROR

1E2

IMMOBILIZER

unit Electronic If the error persists to interference or replace ECU. control unit faulty.

Measuring conditions

Values to be detected

Remarks SECTION 3 - APPLICATION TO VEHICLES

1D3

Checks to be performed

78

Base - July 2006

DTC

If the error persists to replace ECU.

The engine fails to start Problem in CAN line Check the Immobiliser or immobiliser control control unit is correctly unit connected. Enter the Immobiliser PIN code during the emergency procedure.

ERROR FOR ECU No effect perceived by Ecu internal failure. INTERNAL the driver. MONITORING

If the error persists to replace ECU.

1E4

ERROR FOR ECU No effect perceived by Ecu internal failure. INTERNAL the driver. MONITORING

If the error persists to replace ECU.

1E5

SENSORS POWER No effect perceived by Excessive/insufficient Check battery voltage or SUPPLY FAULT the driver. battery voltage or connections with the (12V) possible internal ECM. control unit problem. Replace the control unit if necessary.

EURO 4 NEF ENGINES

Print P1D32N002 E

1E3

Failing component

Visible failures

Possible causes

Repair actions

SENSOR POWER No effect perceived by Excessive/insufficient Check battery voltage or SUPPLY 1 the driver. battery voltage or connections with the possible internal ECM. control unit problem. Replace the control unit if necessary.

1E7

SENSOR POWER No effect perceived by Excessive/insufficient Check battery voltage or SUPPLY 2 the driver. battery voltage or connections with the possible internal ECM. control unit problem. Replace the control unit if necessary.

1E8

SENSOR POWER No effect perceived by Excessive/insufficient Check battery voltage or SUPPLY 3 the driver. battery voltage or connections with the possible internal ECM. control unit problem. Replace the control unit if necessary.

1E9

ECU OVERRUN No effect perceived by Excessive/insufficient Check battery voltage or MONITORING the driver. battery voltage or connections with the ERROR possible internal ECM. control unit problem. Replace the control unit if necessary.

1EA

ECU OVERRUN No effect perceived by Excessive/insufficient Check battery voltage or MONITORING the driver. battery voltage or connections with the ERROR possible internal ECM. control unit problem. Replace the control unit if necessary.

1EB

ATMOSPHERIC PRESSURE SENSOR

1FA

No effect perceived by Fault in sensor inside Change ECU. the driver. control unit. Environmental pressure recovery value: 700 mbar.

Values to be detected

Remarks

79

Base - July 2006

TOO HIGH No reaction perceivable Particulate filter may Check filter. NUMBER OF by the driver. be blocked. REGENERATIONS Too many filter DEMAND regenerations carried out.

Measuring conditions

SECTION 3 - APPLICATION TO VEHICLES

1E6

Checks to be performed

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

Failing component

Visible failures

Possible causes

1FB

PERMANENT No reaction perceivable Catalytic converter Check catalytic converter RIGENERATION by the driver not installed or visually. ON TRAP damaged. PARTICLE

1FC

FIRST SENSOR No reaction perceivable Temperature sensors Check information and EXAUSTED GAS by the driver damaged or condition of sensors. TEMPERATURE incorrectly fitted.

21F

TOO HIGH No reaction noticeable Actuator coil faulty or Check actuator condition. EFFICIENCY OF on behalf of the driver. not within specified CATALYST tolerance limits. SYSTEM

225

INTERRUPTED AFTER-RUN

Measuring conditions

Values to be detected

Remarks SECTION 3 - APPLICATION TO VEHICLES

Checks to be performed

Repair actions

80

Base - July 2006

DTC

Slight power reduction. The control unit is Check wiring and then turned off by the replace the main relay. general switch instead of by the key (k15). Possible problem in main relay or connections.

228

MAIN RELAY - Slight power reduction. Short circuit in main Check wiring between SHORT CIRCUIT relay or relay faulty. battery and ECM and then TO GROUND replace the main relay.

232

COOLANT TEMPERATURE SENSOR ABSOLUTE TEST

Slight power reduction. Extreme Ensure the engine is environmental working in non-critical conditions or sensor conditions. incorrectly adjusted. Check the sensor connections and accuracy. Replace necessary.

236

RAIL PRESSURE Possible loss SENSOR OFFSET performance.

sensor

if

Print P1D32N002 E

EURO 4 NEF ENGINES

of Rail pressure sensor Check connections and value above threshold. correct operation of Rail sensor (parameter acquisition). Replace sensor if necessary.

Failing component

Visible failures

Possible causes

Repair actions

238

OIL PRESSURE

LOW Slight power reduction. Sensor incorrectly Check the sensor adjusted or faults in connections and accuracy. lubrication system. Check the lubrication system.

23A

OIL TEMPERATURE ABOVE NORMAL

259

PRESSURE MPROP Possible loss REGULATOR performance. ERROR (SHORT CIRCUIT TO POSITIVE)

27C

BENCH 2 One or more injectors Fault in control unit. INJECTORS (bank 1 or bank 2) may CHECK not be operating. (INTERNAL ECU)

292

TURBINE Poor performance. ACTUATOR CONTROL ELECTROVALVE SHORT CIRCUIT TO GROUND

2A6

TIMEOUT OF No effect perceived by Problem in the Check the faults in the CAN MESSAGE the driver. Denoxtronic (on the Denoxtronic and consult SCR2 CAN line). the control unit troubleshooting guide.

Measuring conditions

Values to be detected

Remarks

Slight power reduction. Sensor incorrectly Check the sensor adjusted or faults in connections and accuracy. lubrication system. Check the lubrication system. of Wiring damaged or Check wiring and disconnected; pressure regulator; possible defective replace relay if necessary. relay or pressure regulator.

VGT actuator wiring defective.

Replace the control unit.

engine

or Check VGT wiring and actuator.

SERIOUS EOBD No effect perceived by Problems in Ad-Blue FAULT FROM the driver. dosing system. DENOXTRONIC (EOBD FLASHING LIGHT)

Check the faults in the Denoxtronic and consult the control unit troubleshooting guide.

81

Base - July 2006

SECTION 3 - APPLICATION TO VEHICLES

Check wiring. 2AF

Checks to be performed

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

TIMEOUT MESSAGE BC2EDC2

Visible failures

Possible causes

Repair actions

CAN No effect perceived by CAN configuration Check CAN line wiring. the driver. incorrect. Check BC wiring and CAN connections operation. defective. Terminal resistance not suitable.

TIMEOUT OF No effect perceived by CAN messages from Check the TCU CAN MESSAGE the driver. TCU (Transmission connection with the CAN TSC1-PE passive Control Unit) line. inconsistent.

2C8

ERROR MESSAGE No effect perceived by CAN messages from Check the TCU CAN TSC1-VR the driver. TCU (Transmission connection with the CAN Control Unit) line. inconsistent.

2C9

ERROR MESSAGE No effect perceived by CAN messages from Check the tachograph CAN TIMEDATE the driver. TC (tachograph) connection with the CAN inconsistent. line.

2D3

ECU OVERRUN No effect perceived by Poor control unit Reprogram the central MONITORING the driver. programming/flash unit. If the error is ERROR repeated, replace the Possible internal fault central unit, if needed.

2FF

ERROR CHECK Slight power reduction OF CRITICAL TIME FOR OIL DILUTION

359

SHORT CIRCUIT Possible loss TO GROUND OF performance. METERING UNIT OUTPUT

392

NO Poor performance. LOAD/EXCESSIVE TEMP.FOR BPA POWER STAGE

Oil over-diluted.

Measuring conditions

Values to be detected

Remarks

Change the engine oil.

of Wiring damaged or Check wiring and disconnected; pressure regulator; possible defective replace relay if necessary. relay or pressure regulator. Connection damaged. Check VGT connection and actuator. Battery voltage excessive (ECU overheating).

EURO 4 NEF ENGINES

Print P1D32N002 E

2C6

Checks to be performed

SECTION 3 - APPLICATION TO VEHICLES

2B4

Failing component

82

Base - July 2006

DTC

Failing component

Visible failures

Possible causes

Repair actions

3AF

DM1DCU MESSAGE

SPN3 No effect perceived by Problems in Ad-Blue Check the faults in the the driver. dosing system. Denoxtronic and consult the control unit troubleshooting guide.

3C8

TIMEOUT OF No effect perceived by CAN messages from Check the TCU CAN MESSAGE the driver. TCU (Transmission connection with the CAN TSC1-VE passive Control Unit) line. inconsistent.

3C9

TIMEOUT OF No effect perceived by CAN configuration Check CAN line wiring. CAN MESSAGE the driver. incorrect. Check BC wiring and HRDV CAN connections operation. defective.

Checks to be performed

Measuring conditions

Values to be detected

Remarks

EURO 4 NEF ENGINES

Print P1D32N002 E

DTC

Terminal resistance not suitable. 3D3

No effect perceived by Poor control unit Reprogram the central the driver. programming/flash unit. If the error is repeated, replace the Possible internal fault central unit, if needed. REGENERATION DEMAND NUMBER 2

No effect perceived by Too many Check particulate filter the driver. regenerations carried and faults in sensors. out.

4AF

DM1DCU MESSAGE

4C8

TIMEOUT OF No effect perceived by CAN messages from Check the TCU CAN MESSAGE the driver. TCU (Transmission connection with the CAN TSC1-VR passive Control Unit) line. inconsistent.

4FA

REGENERATION DEMAND NUMBER 3

5AF

DM1DCU MESSAGE

SPN4 No effect perceived by Problems in Ad-Blue Check the faults in the the driver. dosing system. Denoxtronic and consult the control unit troubleshooting guide.

No effect perceived by Too many Check particulate filter the driver. regenerations carried and faults in sensors. out.

83

Base - July 2006

SPN5 No effect perceived by Problems in Ad-Blue Check the faults in the the driver. dosing system. Denoxtronic and consult the control unit troubleshooting guide.

SECTION 3 - APPLICATION TO VEHICLES

3FA

84

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

85

GUIDE TO DIAGNOSIS THROUGH SYMPTOMS

Print P1D32N002 E

Base - July 2006

86

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

Low performance at load request.

POSSIBLE CAUSE (*) = if available in the equipment Insufficient fuel level in the tank.

RECOMMENDED TESTS OR INTERVENTION Check fuel level.

Possible exessive smoke.

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

EURO 4 NEF ENGINES

Print P1D32N002 E

ANOMALY

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

Replace the air filter.

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

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

Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if valve. there are any significant blow-by from the boost gauge valve; in such case replace the valve. The engine suddenly stops (with no previ- Obstructed fuel filter. ous problems) and does not start again.

Replace the fuel filter.

87

Base - July 2006

SECTION 3 - APPLICATION TO VEHICLES

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).

REMARKS

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

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

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

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

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

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

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

SECTION 3 - APPLICATION TO VEHICLES

The engine disconnects or does not start. (*)

RECOMMENDED TESTS OR INTERVENTION

88

Base - July 2006

POSSIBLE CAUSE (*) = if available in the equipment

ANOMALY

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

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

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

89

PART FOUR - MAINTENANCE PLANNING

Print P1D32N002 E

Base - July 2006

90

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

91

MAINTENANCE 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.

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

Inspection and/or maintenance interventions Type of intervention

Regular intervals (km)

LUBRICATION, CHANGING OIL, FILTERS AND CHECKING FLUIDS 1

Changing engine oil *

40.000

1

Changing engine oil filter *

40.000

2

Changing fuel filter **

80.000

3

Changing fuel pre-filter **

80.000

CHECKS IN THE ENGINE BAY •

Checking state of auxiliary drive belts

40.000

•

Changing auxiliary drive belts

240.000

•

Checking of valve play and adjustment, if required

240.000

DIAGNOSTICS •

Check-up of engine’s EDC system using diagnostic tools

120.000

•

AdBlue system inspection test using diagnostic tools *

120.000

(*) Value refers to heavy-duty use. Per vehicles mainly travelling on short-to-medium suburban routes: 60,000 km. For vehicles mainly travelling on long motorway routes: 80,000 km.. (**) Value refers to heavy-duty use. Per vehicles mainly travelling on short-to-medium suburban routes: 120,000 km. For vehicles mainly travelling on long motorway routes: 160,000 km..

!

The frequency of the maintenance operations is just an indication since the use of the EURO 4 NEF 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.

Print P1D32N002 E

Base - July 2006

92

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Unscheduled and set-interval operations Operations to be carried out in the course of the scheduled maintenance service.

Unscheduled - Every 150,000 km - AdBlue system inspection test using diagnostic tools - AdBlue system pre-filter and filter replacement At set intervals - Every three months - Removal, cleaning and re-fitting of Adblue pre-filter At set intervals - Annually, before the winter season - Coolant density control At set intervals - Every two years - Replacement of cartridge and cleaning of air filter container - Replacement of engine coolant

Engine oil Fulfils specifications: ACEA E7 mineral-based ACEA E4 synthetic IVECO Standard 18-1804

Base - July 2006

SAE 15W40 SAE 5W30

Urania LD 7 Urania FE5W30

Print P1D32N002 E

EURO 4 NEF ENGINES

MAINTENANCE PLANNING Engine oil level check The check must be executed when the engine is disconnected and possibly cool. The check can be made using the specially provided flexible rod. Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level. Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level. In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine’s components.

!

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.

SECTION 3 - APPLICATION TO VEHICLES

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

!

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

Print P1D32N002 E

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

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

!

Check of fuel system The check must be executed both when the engine disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the injection pump and to the injectors.

93

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

Check of belt’s tear and wear status Carefully verify the belt’s surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing; check end and surface grinding.

!

Danger: if the engine is switched off but is still hot, unexpected motion of the belt may occur. Wait for engine temperature cooling as a precaution in order to avoid serious danger injury.

Base - July 2006

94

SECTION 3 - APPLICATION TO VEHICLES

EURO 4 NEF ENGINES

Changing engine oil

Changing fuel pre-filter

Take out the oil level dipstick. Remove the plug (1) from the oil sump and drain the engine oil off into a specific container.

Figure 143

Figure 141

74341

77836

Unscrew the pre-filter (1) and replace it. Before refitting the new cartridge, moisten the seal with diesel or engine oil. Screw the cartridge on by hand until it is in contact with the mounting and then tighten by 3/4 of a turn to the required tightening torque.

Changing engine oil filters When replacing the cartridge, it must not have been pre-filled. This is to prevent impurities getting into circulation that could damage the system components, injectors/pump.

Figure 142

Changing fuel filter Figure 144

75338

Remove the oil filter (1) with tool 99360076. NOTE Before refitting the new cartridges, moisten the seal with engine oil. Screw the oil filter (1) on by hand until it is in contact with the mounting and then tighten by 3/4 of a turn to the required tightening torque. Screw the plug back on under the sump and tighten it to the required torque. Pour oil into the engine through the filling-pipe (2) of the required grade and quantity.

Base - July 2006

108503

Remove the fuel filter (1) with tool. Before refitting the new cartridge, moisten the seal with diesel or engine oil. Screw the new one on by hand, taking care to check that the rubber seal and the mating surface are clean and in a perfect state of repair. Screw the cartridge on by hand until it is in contact with the mounting and then tighten by 3/4 of a turn to the required tightening torque.

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 3 - APPLICATION TO VEHICLES

Checking valve clearance and adjustment if necessary

Changing miscellaneous drive belts Figure 145

95

To perform these operations correctly, proceed as described in the appropriate chapter under the section ”GENERAL CHARACTERISTICS AND SERVICING”.

(Demonstration)

77839

To remove and fit the belt (1) back on, you need to use an appropriate tool on the tightener (2) in the direction shown by the arrow. NOTE The tighteners are automatic, so they are not to be adjusted after assembly.

Connect - reconnect and clean AdBlue system pre-filter Figure 146

108507

Remove pre-filter (1) of AdBlue system.Clean from possible dirt and reposition pre-filter (1) in its seat.

Print P1D32N002 E

Base - July 2006

96

SECTION 3 - APPLICATION TO VEHICLES

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

1

SECTION 4 General overhaul and characteristics

Page

Print P1D32N002 E

GENERAL CHARACTERISTICS 4-CYLINDER ENGINES . . . . . . . . . . . . . . . . .

3

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

4

GENERAL CHARACTERISTICS 6-CYLINDER ENGINES . . . . . . . . . . . . . . . . .

11

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

12

GENERAL CHARACTERISTICS 6-CYLINDER ENGINES . . . . . . . . . . . . . . . . .

19

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

20

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

27

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

27

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

28

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

28

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

28

- Head face check on the cylinder group . . . . .

29

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

30

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

30

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

31

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

31

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

32

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

32

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

33

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

34

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

34

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

34

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

36

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

38

Base - July 2006

2

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

Page

Page

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

38

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

45

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

38

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

46

- Checking crankshaft shoulder clearance . . . . .

39

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

47

CONNECTING ROD — PISTON ASSEMBLY . .

39

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

47

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

41

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

48

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

41

- Checking cylinder head supporting surface . . .

48

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

41

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

49

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

41

- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

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

49

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

42

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

43

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

43

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

43

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

44

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

44

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

44

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

44

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

Base - July 2006

45

- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . . . . . . . 49 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .

50

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

50

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

50

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .

52

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

52

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

52

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

55

AUXILIARY COMPONENTS . . . . . . . . . . . . . . .

57

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

3

GENERAL CHARACTERISTICS - 4-CYLINDER ENGINES F4AE3481C (.14)

Type

F4AE3481D (.16)

F4AE3481B (.18)

Cycle

Four-stroke diesel engine

Power

Turbocharged with intercooler

Injection

F4AE3481A (.185)

Direct

Number of cylinders

4

∅

+

+

Bore

mm

102

Stroke

mm

120

cm3

3920

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

A B

8.5º 8.5º

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

D C

51º 12.5º

+.. = Total displacement TIMING

Checking timing mm

-

mm

-

mm

0.20 to 0.30

mm

0.45 to 0.55

Bosch

high pressure common rail EDC7 ECU

X X

Checking operation X

FUEL FEED Injection Type:

Nozzle type

Injectors

Injection sequence

1-3-4-2

bar

Injection pressure

Print P1D32N002 E

bar

250 - 1600

Base - July 2006

4

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

CLEARANCE DATA

F4AE3481C (.14)

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1 Cylinder barrels X ∅1 X

F4AE3481B (.18)

F4AE3481A (.185)

mm

∅1

102.009 to 102.031

∅1

0.5

X 60.5 ∅1 101.721 to 101.739 ∅2 40.010 to 40.016

60.5 101.781 to 101.799 40.008 to 40.014

Pistons Size Outside diameter Pin housing

∅2

F4AE3481D (.16)

Piston — cylinder barrels Piston diameter

∅1

Piston protrusion

X

Piston pin

∅3

0.271 to 0.309

0.211 to 0.249 0.5

X

∅ 3

Piston pin — pin housing

Base - July 2006

0.28 to 0.52

39.9938 to 40.0002 0.0098 to 0.0222

0.0078 to 0.0202

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3481C (.14)

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

F4AE3481D (.16)

F4AE3481B (.18)

5

F4AE3481A (.185)

mm

Split ring slots

X1* 2.705 to 2.735 X 2 2.430 to 2.450 X 3 4.040 to 4.060

Split rings

S 1* S2 S3

2.705 to 2.735 2.420 to 2.440 4.020 to 4.040 2.560 to 2.605 2.350 to 2.380 3.975 to 4.000

* measured on 98 mm ∅ Split rings - slots

1 2 3

Split rings X1 X2

∅ 2 ∅ 3 S

Small end bush housing Big end bearing housing

0.5

X1 X2 X3

0.30 to 0.40 0.60 to 0.80 0.25 to 0.55

∅1

42.987 to 43.013

∅2

72.987 to 73.013

Small end bush diameter Inside Spare big end half bearings Piston pin — bush Big end half bearings

Print P1D32N002 E

0.100 to 0.175 0.040 to 0.90 0.020 to 0.065

Split ring end opening in cylinder barrel:

X3

∅1

0.100 to 0.175 0.050 to 0.100 0.040 to 0.085

∅3 S

40.019 to 40.033 1.955 to 1.968 0.0188 to 0.0392 0.250; 0.500

Base - July 2006

6

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3481C (.14)

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1

∅2

S 1

EURO 4 NEF ENGINES

F4AE3481D (.16)

F4AE3481B (.18)

F4AE3481A (.185)

mm

Journals Crankpins

∅1 ∅2

82.993 to 83.013 68.987 to 69.013

Main half bearings Big end half bearings

S 1* S 2*

2.456 to 2.464 1.955 to 1.968

∅3 ∅3

87.982 to 88.008 87.977 to 88.013

S 2 *provided as spare part

∅ 3

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

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

Shoulder journal

X1

37.475 to 37.545

Shoulder main bearing

X2

32.18 to 32.28

Shoulder half-rings

X3

37.28 to 37.38

X 1

X 2 X 3

Output shaft shoulder

Base - July 2006

0.095 to 0.265

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3481C (.14)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3481D (.16)

F4AE3481B (.18)

7

F4AE3481A (.185)

mm

∅ 1 Valve guide seats on cylinder head

∅ 2

∅1

7.042 to 7.062

∅4 α

6.970 to 6.990 60o ± 0.25o

∅4 α

6.970 to 6.990 45o ± 0.25o

Valves:

α Valve stem and guide

0.052 to 0.092

Housing on head for valve seat:

∅ 1

∅1

34.837 to 34.863

∅1

34.837 to 34.863

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

∅ 2

∅2 α

α

34.917 to 34.931 60o 34.917 to 34.931 45o

X

0.36 to 0.94

X

0.73 to 1.31

Sinking X Between valve seat and head Valve seats

Print P1D32N002 E

0.054 to 0.094 0.054 to 0.094 -

Base - July 2006

8

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

F4AE3481C (.14)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3481D (.16)

F4AE3481B (.18)

F4AE3481A (.185)

mm

Valve spring height:

H

H1

H2

free spring

H

47.75

under a load equal to: 339.8 ± 19 N 741 ± 39 N

H1 H2

35.33 25.20

Injector protrusion

X

Not adjustable

X

∅ ∅ ∅ 1 23 4 5

Camshaft bush housings No. 1 (flywheel side)

59.222 to 59.248

Camshaft housings No. 2-3-4-5

54.089 to 54.139

Camshaft journals: 1⇒5 ∅1-2-3

53.995 to 54.045

Bushing inner diameter

54.083 to 54.147

∅ 2

∅ 1

∅ 3 ∅

∅

Bushing and support pins

0.038 to 0.152

Cam lift: H

Base - July 2006

H

7.582

H

6.045

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3481C (.14)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3481D (.16)

F4AE3481B (.18)

9

F4AE3481A (.185)

mm

∅1 Tappet cap housing on block ∅2 ∅ 3

Tappet cap outside diameter:

∅2

∅1

16.000 to 16.030

∅2 ∅3

15.924 to 15.954 15.960 to 15.975

Between tappets and housings Tappets

0.025 to 0.070 -

∅ 1 Rocker shaft

∅1

21.965 to 21.977

Rockers

∅2

22.001 to 22.027

∅ 2 Between rockers and shaft

Print P1D32N002 E

0.024 to 0.062

Base - July 2006

10

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

11

GENERAL CHARACTERISTICS - 6-CYLINDER ENGINES F4AE3681C (.18)

Type

F4AE3681B F4AE3681D F4AE3681E (.22) (.25) (.28)

Cycle

Four-stroke diesel engine

Power

Turbocharged with intercooler

Injection

F4AE3681A (.30)

Direct

Number of cylinders

6 in-line

∅

+

+

Bore

mm

102

Stroke

mm

120

cm3

5880

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

A B

8.5º 8.5º

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

D C

51º 12.5º

+.. = Total displacement TIMING

Checking timing mm

-

mm

-

mm

0.20 to 0.30

mm

0.45 to 0.55

Bosch

high pressure common rail EDC7 ECU

X X

Checking operation X

FUEL FEED Injection Type:

Nozzle type

Injectors

Injection sequence

1-5-3-6-2-4

bar

Injection pressure

Print P1D32N002 E

bar

250 - 1600

Base - July 2006

12

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

CLEARANCE DATA

F4AE3681C F4AE3681B F4AE3681D F4AE3681E (.18) (.22) (.25) (.28)

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1 Cylinder barrels X ∅1 X

mm

∅1

102.009 to 102.031

∅1

0.5

Pistons Size Outside diameter Pin housing

∅2

F4AE3681A (.30)

X ∅1 ∅2

Piston — cylinder barrels Piston diameter

∅1

Piston protrusion

X

Piston pin

∅3

60.5 101.721 to 101.739 40.010 to 40.016

60.5 101.781 to 101.799 40.008 to 40.014

0.271 to 0.309

0.211 to 0.249 0.5

X

∅ 3

Piston pin — pin housing

Base - July 2006

-

39.9938 to 40.0002 0.0098 to 0.0222

0.0078 to 0.0202

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3681C (.18)

Type

F4AE3681B F4AE3681D F4AE3681E (.22) (.25) (.28)

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

Split ring slots

X1* X2 X3

Split rings

S 1* S2 S3

13

F4AE3681A (.30)

mm 2.705 to 2.735 2.430 to 2.450 4.040 to 4.060

2.705 to 2.735 2.420 to 2.440 4.020 to 4.040 2.560 to 2.605 2.350 to 2.380 3.975 to 4.000

* measured on 98 mm ∅ Split rings - slots

1 2 3

Split rings X1 X2

∅ 2 ∅ 3 S

Small end bush housing Big end bearing housing

0.5

X1 X2 X3

0.30 to 0.40 0.60 to 0.80 0.25 to 0.55

∅1

42.987 to 43.013

∅2

72.987 to 73.013

Small end bush diameter Inside Spare big end half bearings Piston pin — bush Big end half bearings

Print P1D32N002 E

0.100 to 0.175 0.040 to 0.090 0.020 to 0.065

Split ring end opening in cylinder barrel:

X3

∅1

0.100 to 0.175 0.040 to 0.085 0.040 to 0.085

∅3 S

40.019 to 40.033 1.955 to 1.968 0.0188 to 0.0392 0.250 - 0.500

Base - July 2006

14

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3681C F4AE3681B F4AE3681D F4AE3681E (.18) (.22) (.25) (.28)

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1

∅2

S 1

EURO 4 NEF ENGINES

F4AE3681A (.30)

mm

Journals Crankpins

∅1 ∅2

82.993 to 83.013 68.987 to 69.013

Main half bearings Big end half bearings

S1 S2

2.456 to 2.464 1.955 to 1.968

∅3 ∅3

87.982 to 88.008 87.977 to 88.013

S 2 *provided as spare part

∅ 3

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

0.044 to 0.106 0.039 to 0.111

Half bearings - Crankpins

0.038 to 0.116

Main half bearings Big end half bearings

+ 0.250; + 0.500

Shoulder journal

X1

37.475 to 37.545

Shoulder main bearing

X2

32.18 to 32.28

Shoulder half-rings

X3

37.28 to 37.38

X 1

X 2 X 3

Output shaft shoulder

Base - July 2006

0.095 to 0.265

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3681C F4AE3681B F4AE3681D (.18) (.22) (.25)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3681E (.28)

15

F4AE3681A (.30)

mm

∅ 1 Valve guide seats on cylinder head

∅ 4

∅1

7.042 to 7.062

∅4 α

6.970 to 6.990 60o ± 0.25o

∅4 α

6.970 to 6.990 45o ± 0.25o

Valves:

α Valve stem and guide

0.052 to 0.092

Housing on head for valve seat: ∅1 ∅ 1

∅1 Valve seat outside diameter; valve seat angle on cylinder head: ∅2 α

∅ 2

∅2 α

α

X

34.837 to 34.863

34.917 to 34.931 60o 34.917 to 34.931 45o

X

0.36 to 0.94

X

0.73 to 1.31

Sinking

Between valve seat and head Valve seats

Print P1D32N002 E

34.837 to 34.863

0.054 to 0.094 0.054 to 0.094 -

Base - July 2006

16

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

F4AE3681C F4AE3681B F4AE3681D F4AE3681E (.18) (.22) (.25) (.28)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3681A (.30)

mm

Valve spring height:

H

H1

H2

free spring

H

47.75

under a load equal to: 339.8 ± 19 N 741 ± 39 N

H1 H2

35.33 25.20

Injector protrusion

X

Not adjustable

X

∅ ∅ ∅ 1 23 4 5

Camshaft bush housings No. 1 (flywheel side)

59.222 to 59.248

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

54.089 to 54.139

Camshaft journals: 1⇒7 ∅1-2-3

53.995 to 54.045

Bushing inner diameter

54.083 to 54.147

∅ 2

∅ 1

∅ 3 ∅

∅

Bushing and support pins

0.038 to 0.152

Cam lift: H

Base - July 2006

H

7.582

H

6.045

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3681C (.18)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3681B F4AE3681D F4AE3681E (.22) (.25) (.28)

17

F4AE3681A (.30)

mm

∅1 Tappet cap housing on block ∅2 ∅ 3

Tappet cap outside diameter:

∅2

∅1

16.000 to 16.030

∅2 ∅3

15.924 to 15.954 15.960 to 15.975

Between tappets and housings Tappets

0.025 to 0.070 -

∅ 1 Rocker shaft

∅1

21.965 to 21.977

Rockers

∅2

22.001 to 22.027

∅ 2 Between rockers and shaft

Print P1D32N002 E

0.024 to 0.062

Base - July 2006

18

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

19

GENERAL CHARACTERISTICS - 6-CYLINDER ENGINES F4AE3682C (.22)

Type

F4AE3682F (.25)

F4AE3682E (.26)

F4AE3682B (.26)

Cycle

Four-stroke diesel engine

Power

Turbocharged with intercooler

Injection

F4AE3682A (.30)

Direct

Number of cylinders

6

∅

+

+

Bore

mm

102

Stroke

mm

120

cm3

5880

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

A B

8.5º 8.5º

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

D C

51º 12.5º

+.. = Total displacement TIMING

Checking timing mm

-

mm

-

mm

0.20 to 0.30

mm

0.45 to 0.55

Bosch

high pressure common rail EDC7 ECU

X X

Checking operation X

FUEL FEED Injection Type:

Nozzle type

Injectors

Injection sequence

1-5-3-6-2-4

bar

Injection pressure

Print P1D32N002 E

bar 250 - 1450

250 - 1600

Base - July 2006

20

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

CLEARANCE DATA

F4AE3682C (.22)

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1 Cylinder barrels X ∅1 X

F4AE3682E (.26)

F4AE3682B (.26)

F4AE3682A (.30)

mm

∅1

102.009 to 102.031

∅1

0.5

Pistons Size Outside diameter Pin housing

∅2

F4AE3682F (.25)

X ∅1 ∅2

Piston — cylinder barrels Piston diameter

101,721to 101,739 40,010 to 40,016

60.5 107.781 to 101.799 40.008 to 40.014

0.271 to 0.309

0.211 to 0.249

∅1

0.5

X Piston protrusion

∅ 3

Piston pin Piston pin — pin housing

Base - July 2006

X

-

∅3

39.9938 to 40.0002 0.0098 to 0.0222

0.0078 to 0.0202

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3682C (.22)

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

Split ring slots

X1* X2 X3

Split rings

S 1* S2 S3

F4AE3682F (.25)

F4AE3682E (.26)

F4AE3682B (.26)

21

F4AE3682A (.30)

mm 2.705 to 2.735 2.430 to 2.450 4.040 to 4.060

2.705 to 2.735 2.420 to 2.440 4.020 to 4.040 2.560 to 2.605 2.350 to 2.380 3.975 to 4.000

* measured on 98 mm ∅ Split rings - slots

1 2 3

Split rings X1 X2

∅ 2 ∅ 3 S

Small end bush housing Big end bearing housing

0.5

X1 X2 X3

0.30 to 0.40 0.60 to 0.80 0.25 to 0.55

∅1

42.987 to 43.013

∅2

72.987 to 73.013

Small end bush diameter Inside Spare big end half bearings Piston pin — bush Big end half bearings

Print P1D32N002 E

0.100 to 0.175 0.040 to 0.90 0.020 to 0.065

Split ring end opening in cylinder barrel:

X3

∅1

0.100 to 0.175 0.050 to 0.100 0.040 to 0.085

∅3 S

40.019 to 40.033 1.955 to 1.968 0.0188 to 0.0392 0.250 - 0.500

Base - July 2006

22

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3682C (.22)

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1

∅2

S 1

EURO 4 NEF ENGINES

F4AE3682F (.25)

F4AE3682E (.26)

F4AE3682B (.26)

F4AE3682A (.30)

mm

Journals Crankpins

∅1 ∅2

82.990 to 83.010 68.987 to 69.013

Main half bearings Big end half bearings

S 1* S 2*

2.456 to 2.464 1.955 to 1.968

Main bearings No. 1-7 No. 2—3-4-5-6

∅3 ∅3

87.982 to 88.008 87.977 to 88.013

Main bearings No. 1-7 No. 2-3-4-5-6

∅3

0.044 to 0.106 0.039 to 0.111

S 2 *provided as spare part

∅ 3

Half bearings - Crankpins

0.038 to 0.116

Main half bearings Big end half bearings

+ 0.250; + 0.500

Shoulder journal

X1

37.475 to 37.545

Shoulder main bearing

X2

32.18 to 32.28

Shoulder half-rings

X3

37.28 to 37.38

X 1

X 2 X 3

Output shaft shoulder

Base - July 2006

0.095 to 0.265

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3682C (.22)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3682F (.25)

F4AE3682E (.26)

F4AE3682B (.26)

23

F4AE3682A (.30)

mm

∅ 1 Valve guide seats on cylinder head

∅ 4

∅1

7.042 to 7.062

∅4 α

6.970 to 6.999 60o ± 0.25o

∅4 α

6.970 to 6.999 45o ± 0.25o

Valves:

α Valve stem and guide

0.052 to 0.092

Housing on head for valve seat:

∅ 1

∅1

34.837 to 34.863

∅1

34.837 to 34.863

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

∅ 2

∅2 α

α

34.917 to 34.931 59.5o 34.917 to 34.931 44.5o

X

0.36 to 0.94

X

0.73 to 1.31

Sinking X Between valve seat and head Valve seats

Print P1D32N002 E

0.054 to 0.094 0.054 to 0.094 -

Base - July 2006

24

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

F4AE3682C (.22)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3682F (.25)

F4AE3682E (.26)

F4AE3682B (.26)

F4AE3682A (.30)

mm

Valve spring height:

H

H1

H2

free spring

H

47.75

under a load equal to: 339.8 ± 19 N 741 ± 39 N

H1 H2

35.33 25.20

Injector protrusion

X

Not adjustable

X

∅ ∅ ∅ 1 23 4 5

Camshaft bush housings No. 1 (flywheel side)

59.222 to 59.248

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

54.089 to 54.139

∅ 2

∅ 1

Camshaft journals: 1⇒7

∅

53.995 to 54.045

Bushing inner diameter

∅

54.083 to 54.147

∅ 3 ∅

Bushing and support pins

0.038 to 0.152

Cam lift: H

Base - July 2006

H

7.582

H

6.045

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

F4AE3682C (.22)

Type CYLINDER HEAD — TIMING SYSTEM

F4AE3682F (.25)

F4AE3682E (.26)

F4AE3682B (.26)

25

F4AE3682A (.30)

mm

∅1 Tappet cap housing on block ∅2 ∅ 3

Tappet cap outside diameter:

∅2

∅1

16.000 to 16.030

∅2 ∅3

15.924 to 15.954 15.960 to 15.975

Between tappets and housings Tappets

0.025 to 0.070 -

∅ 1 Rocker shaft

∅1

21.965 to 21.977

Rockers

∅2

22.001 to 22.027

∅ 2 Between rockers and shaft

Print P1D32N002 E

0.024 to 0.062

Base - July 2006

26

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Base - July 2006

EURO 4 NEF ENGINES

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

4 AND 6 ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH

27

Figure 3

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

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

70158

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

Figure 4

(Demonstrative)

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

70161

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

Figure 5

70159

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

Print P1D32N002 E

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

70162

Base - July 2006

28

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

zs

REPAIR OPERATIONS CYLINDER UNIT Checks and measurements

Figure 6

Figure 9

s

70163

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

NOTE

Once engine is disassembled, clean accurately the cylinder-block assembly.

Take note of plate (2) assembling position.

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.

Figure 7

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. NOTE Should the ring gauge be not available, use a micrometer for zero-setting. 70164

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

Figure 8

70167

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

70165

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

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

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

29

Head face check on the cylinder group

Figure 11

Figure 12

70170

Check that the head face, on the cylinder group, does not present deformations. This check can be carried out, after a previous grains (4) extraction by means of a calibrated ruler (2) and feeler gauge (3). After verified the deformation areas, perform the flattening of the face by means of grinding machine. The flatness error must not be higher than 0.075 mm.

α

107267

NOTE In the event of grinding operation, all the barrels must result of the same oversize (0.5 mm)

Check the bench bearing seats, proceeding as follows: - mount the bench caps on the supports without bearings; - screw the fixing screws to the torque prescribed; - by means of an adequate gauge, verify that the internal diameter of the seats correspond to the value prescribed.

!

The block flattening could be performed only after you have checked that, at finished work, the piston projection from the cylinder barrel is not higher than the value prescribed.

Check the conditions of the working plugs (1) of the cylinder groups; replace them if rusty or in case of doubt about their conditions. When flattening is finished, restore the cylinder barrel bevel as shown in Figure 11.

If you detect a higher value, replace its block

Print P1D32N002 E

Base - July 2006

30

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

TIMING SYSTEM Camshaft Figure 13

70169

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

Figure 14

79459

CAMSHAFT MAIN DATA (6 cylinders) Specified data refer to pin standard diameter

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

camshaft and the bushes. Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Checking cam lift and pin alignment

31

BUSHES

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

Figure 16

Figure 15

70172

70171

The camshaft bushing (2) must be forced into its seat. Internal surface must not show seizing or wear. Using a bore gauge (3), measure the diameter of the bushing (2) and of the intermediate seats (1) for the camshaft. Measurements shall be performed on two perpendicular axes.

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

Figure 17

sec. A--A

107399

MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT * Measurement to make after fitting the bushing. Print P1D32N002 E

Base - July 2006

32

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

Figure 18

Sec. A-A

107268

MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT * Measurement to make after fitting the bushing.

Bush replacement

Tappets

Figure 19

Figure 20

70174

To change the bushing (1), use the drift 99360362 (2) and grip 99370006 (3) for its disassembly and assembly.

70175

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

NOTE Upon assembly, the bushing (1) must be directed so that the lubrication holes coincide with the holes in the seat in the crankcase.

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Fitting tappets — camshaft

33

Figure 23

Figure 21

70238

70176

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.

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

Figure 24

Figure 22

70179

Check camshaft end float (1). It shall be 0.23 ± 0.13 mm. 70164

Lubricate the camshaft bushes and fit the camshaft (1) taking care not to damage the bushes or the housings.

Figure 25

70180

Fit nozzles (2) and tighten the fastening screws (1) to the specified torque. Print P1D32N002 E

Base - July 2006

34

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

OUTPUT SHAFT Measuring journals and crankpins

EURO 4 NEF ENGINES

NOTE It is recommended to insert the found values in the proper table. See Figure 27 and 29.

Figure 26

Undersize classes are: 0.250 - 0.500 mm

!

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

70182

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

4-cylinder engine Figure 27

108487

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

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

35

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Figure 28

measured on > 45.5 mm radius between adjacent journals

70183

OUTPUT SHAFT MAIN TOLERANCES

TOLERANCES SHAPE DIRECTION POSITION OSCILLATION

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

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL ○ /○/ //

GRAPHIC SYMBOL

CRITICAL

©

IMPORTANT

⊕

SECONDARY

⊝

MAIN BEARING ON TIMING SYSTEM CONTROL SIDE

INTERMEDIATE MAIN BEARINGS

FIRST MAIN BEARING ON FRONT SIDE

70237

Print P1D32N002 E

Base - July 2006

36

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

6-cylinder engine Figure 29

107269

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

Figure 30

* **

Measured on a radius greater than 45.5 mm ↗ 0.500

between adjacent main journals

70577

MAIN OUTPUT SHAFT TOLERANCES

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

37

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Figure 31

MAIN BEARING ON TIMING SYSTEM CONTROL SIDE

INTERMEDIATE MAIN BEARINGS

FIRST MAIN BEARING ON FRONT SIDE

70237

TOLERANCES SHAPE DIRECTION POSITION OSCILLATION

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

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL ○ /○/ //

GRAPHIC SYMBOL

CRITICAL

©

IMPORTANT

⊕

SECONDARY

⊝

Print P1D32N002 E

Base - July 2006

38

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Replacing oil pump control gear

EURO 4 NEF ENGINES

Finding journal clearance Figure 34

Figure 32

70161

Refit the output shaft (2). 70184

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

Check the backlash between output shaft main journals and the relevant bearings as follows: Figure 35

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

Fitting main bearings Figure 33

70186

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

- fit caps (1), including the half bearings (2) on the relevant supports. Figure 36

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

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

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

70187

Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, with torque wrench to 50 ± 6 Nm. - 2nd stage, with torque wrench to 80 ± 6 Nm. Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

39

Checking crankshaft shoulder clearance

Figure 37

Figure 39

α

70188

-

3rd

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

Figure 38

70190

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

CONNECTING ROD — PISTON ASSEMBLY 70189

Figure 40

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

70191

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

NOTE The pistons are fitted with a replacer in standard size, or 0.5 mm oversize.

Print P1D32N002 E

Base - July 2006

40

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

Figure 42

Figure 41

32613

32614

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

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

Figure 43

114923

ENFINES:

MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS * Value measured on 99 mm diameter F4AE3481D, F4AE3481B, F4AE3481A, F4AE3681D, F4AE3681A, F4AE3682F, F4AE3682E, F4AE3682B, F4AE3682A

Figure 44

114924

ENFINES: Base - July 2006

MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS * Value measured on 99 mm diameter F4AE3481C, F4AE3681C, F4AE3681B, F4AE3682C Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Pistons Measuring piston diameter

41

Conditions for proper pin-piston coupling

Figure 45

Figure 48

32619

32615

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

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.

NOTE The diameter shall be measured at 60.5 mm from the piston skirt.

Split rings Figure 49 Figure 46

16552

Use a micrometer (1) to check split ring (2) thickness. 70192

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

Figure 50

Piston pins Figure 47

32620 18857

To measure the piston pin (1) diameter use the micrometer (2). Print P1D32N002 E

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

42

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

Connecting rods

Figure 51

Figure 53

41104

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

107271

In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one. MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS * Value for inside diameter to be obtained after driving in connecting rod small end and grinding. ** Value not measurable in released condition

Figure 52

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

70194

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

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

43

Checking connecting rods

Figure 54

Figure 55

(Demonstration)

CONNECTING ROD BODY

CONNECTI NG ROD No.

*

WEIGHT

CONNECTING ROD CAP CONNEC. ROD No.

YEAR

DAY

61696

70196

NOTE 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.

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

Checking torsion Figure 56

(Demonstration)

- On body with a letter showing the weight of the connecting rod assembled at production:

S

V, 1820 to 1860 (yellow marking);

S

W, 1861 to 1900 (green marking);

S

X, 1901 to 1940 (blue marking);

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

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

Print P1D32N002 E

61694

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

44

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Checking bending Figure 57

EURO 4 NEF ENGINES

Figure 59

(Demonstration)

102596

61695

Check connecting rod (5) bending by comparing two points C and D of the pin (3) on the vertical plane of the connecting rod axis. Position the vertical support (1) of the dial gauge (2) to rest the latter on pin (3), point C. Swing the connecting rod back and forth looking for pin highest position and, in such condition, reset comparator (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.

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure. Figure 60

Fitting connecting rod-piston assembly Connecting rod-piston coupling

72705

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

Figure 58

Fitting split rings Figure 61

70198

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.

Base - July 2006

32613

Use pliers 99360183 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°. Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

NOTE Split rings are supplied spare with the following sizes: -

standard;

-

0.5 mm oversize.

45

Figure 64

Figure 62

70202

DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL - Split ring openings shall be displaced with each other by 120°; 70200

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

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

- 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 Figure 65

Fitting connecting rod-piston assembly into cylinder barrels Figure 63

70203

To measure the clearance proceed as follows: 70201

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. Print P1D32N002 E

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

Base - July 2006

46

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Figure 66

EURO 4 NEF ENGINES

Figure 69

α

70204

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

70207

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.

Figure 67 α

!

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.

70205

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

Checking piston protrusion Figure 70

Figure 68

70208

70206

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

Base - July 2006

Once connecting rod-piston assemblies refitting is over, use dial gauge 99395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm.

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47

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

CYLINDER HEAD Removing the valves

Figure 72

Figure 71

70321

70319

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

Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Repeat this operation for all the valves. Overturn the cylinder head and withdraw the valves (5). Figure 73

NOTE

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

70322

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

NOTE

Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.

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48

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Checking cylinder head wet seal

EURO 4 NEF ENGINES

Figure 76

Figure 74

70323

70325

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

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

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

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

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

Replace the cylinder head if leaks are found.

Checking cylinder head supporting surface Figure 75

70324

Use a rule (2) and a feeler gauge (3) to check the cylinder head (1) supporting surface. Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure.

Base - July 2006

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EURO 4 NEF ENGINES

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

VALVES

49

Figure 79

Figure 77

18882

107280

Check the valve stem (1) using a micrometer (2), it shall be 6.970 ± 6.990.

INTAKE AND EXHAUST VALVE MAIN DATA

Removing carbon deposits, checking and grinding valves Figure 78

Checking clearance between valve stem and valve guide and valve centering Figure 80

18625

Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Grind the valve seat, if necessary, using a grinding machine, removing as little material as possible.

Print P1D32N002 E

70327

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 ± 0.092 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. Base - July 2006

50

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

VALVE GUIDE

EURO 4 NEF ENGINES

VALVE SEATS Regrinding — replacing the valve seats

Figure 81 Figure 82

70330

INTAKE

EXHAUST

79457

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

Check the valve seats (2). If slight scoring or burning is detected, regrind using a valve seat regrinding tool (1) following the inclination values shown in Figure 83.

Figure 83

EXHAUST

INTAKE 107281

ENGINE VALVE SEATS MAIN DATA Valve seats are cast on cylinder head and machined.

Base - July 2006

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SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

51

Figure 84

INTAKE

EXHAUST

107282

Where valve seats cannot be recovered just regrinding them, inserts provided with spares can be mounted. In this case, the seats dimensioned as indicated in figure have to be implemented on cylinder head and valve seats have to be mounted.

In order to fit valve seats into cylinder head, the cylinder head has to be heated at 80 °C ÷ 100 °C and previously cooled new valve seats have to be mounted into cylinder head using special beater. Then, using a suitable tool, regrind the valve seats according to the values shown in Figure 85.

Figure 85

EXHAUST

INTAKE

107283

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

Figure 86

70333

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52

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

VALVE SPRINGS

EURO 4 NEF ENGINES

Figure 89

Figure 87

50676 770321

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

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).

Refitting the cylinder head Figure 90

H H1 H2

Height mm 47.75 35.33 25.2

Under a load of N Free P1 339.8 ± 19 P2 741 ± 39

FITTING CYLINDER HEAD Figure 88 70335

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

NOTE Before reusing the cylinder head fastening screws check whether they are free from damages or distortions, otherwise replace. 70334

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.

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

Base - July 2006

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SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

53

Figure 91

88775

There are two types of head seals, 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 Figure 91, 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: S cil1 = S1 + S2 2

For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value. S cil1 + S cil2 + S cil3 + S cil4 4 For 6 cylinder versions: S=

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

S=

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

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

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Base - July 2006

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SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Base - July 2006

EURO 4 NEF ENGINES

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SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

55

TIGHTENING TORQUE COMPONENT

TORQUE

Screw M8 for fastening cylinder barrel lubricating nozzles Screw M12 for fastening output shaft caps

1st stage 2nd stage 3rdd stage

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

1st stage 2nd stage

Screw M8 for fastening front cover Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M11 for fastening connecting rod caps 1st stage 2ndd stage Screw M10 for fastening crankcase plate Nut M18 for fastening high pressure pump gear Nuts M8 for fastening fuel pump 1/2 inch plug on cylinder head 1/4 inch plug on cylinder head 3/4 inch plug on cylinder head Screw M6 for fastening injectors Nut fastening for injector feed connector Nut M6 for flame start grille on intake manifold Screw M8 for fastening intake manifold Screw M12 for fastening rear brackets for engine lifting Screws M8 for fastening Common Rail Connectors M14 for high pressure fuel pipes Screw M12 (12 x 1.75 x 130) for fastening cylinder head 1st stage Screw M12 (12 x 1.75 x 150) for fastening cylinder head 2nd stage 3rd stage Screw for fastening rocker bracket Valve clearance adjusting nuts Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail Screw M8 for fastening high pressure pipe connector Screw M6 for fastening wiring bulkhead Screw M8 for fastening electric wiring support for injector feed Nuts for fastening wiring on each injector Screw M12 for fastening fuel filter bracket Screw M8 for fastening fuel filter holder Fuel filter Screw M22 for fastening oil pressure relief valve on oil filter support Screw M8 for radiator seal and oil filter support Oil filter

}

Print P1D32N002 E

Nm 15 ± 3 50 ± 6 80 ± 6

kgm 1.5 ± 0.3 5 ± 0.6 8 ± 0.6 90° ± 5°

8±2 12 ± 2 77 ± 12 47 ± 5 24 ± 4 10 ± 2 8±1 24 ± 4 24 ± 4 24 ± 4 36 ± 4 60 ± 5

0.8 ± 0.2 1.2 ± 0.2 7.7 ± 1.2 4.7 ± 0.5 2.4 ± 0.4 1 ± 0.2 0.8 ± 0.1 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60° ± 5°

43 ± 5 105 ± 5 24 ± 4 24 ± 4 36 ± 5 12 ± 2 8.5 ± 0.35 50 ± 5 8±2 24 ± 4 77 ± 12 24 ± 4 20 ± 2 35 ± 5

4.3 ± 0.4 10.5 ± 0.5 2,4 ± 0,4 2.4 ± 0.4 3.6 ± 0.5 1.2 ± 0.2 0.85 ± 0.035 5 ± 0.5 0.8 ± 0.2 2.4 ± 0.4 7.7 ± 1.2 2.4 ± 0.4 2 ± 0.2 3.5 ± 0.5

55 ± 5

5.5 ± 0.5 90° ± 5° 90° ± 5°

36 ± 5 3.6 ± 0.5 24 ± 4 2.4 ± 0.4 20 ± 2 2 ± 0.2 24 ± 4 2.4 ± 0.4 10 ± 2 1 ± 0.2 24 ± 4 2.4 ± 0.4 1,5 ± 0,25 0.15 ± 0.025 77 ± 8 7.7 ± 0.8 24 ± 4 2.4 ± 0.4 contact + 3/4 turn 80 ± 8 8 ± 0.8 24 ± 4 2.4 ± 0.4 contact + 3/4 turn

Base - July 2006

56

SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

EURO 4 NEF ENGINES

COMPONENT

TORQUE

11/8 inch connection on filter support for turbine lubrication Nut M12 for fastening turbine lubrication pipe Screw M10 for fastening engine coolant inlet connection 90° elbow fastening (if required) to engine coolant inlet connection Pipe on cylinder head for compressor cooling Screw M6 for fastening engine coolant drain connector Pin fastening on engine block for exhaust manifold Screw M10 for fastening exhaust manifold on cylinder head Screw M12 for fastening damper adapter 1st stage and damper on output shaft 2ndd stage Screw M10 for fastening pulley on output shaft Screw M8 for fastening water pump Screw M10 for fastening auxiliary component control belt tensioners Screw M10 for fastening fixed pulleys for auxiliary component control belt Screw M10 for fastening flywheel housing Screw M12 for fastening flywheel housing Screw M6 for fastening heat exchanger for control unit Screw M8 for fastening heat exchanger for control unit Connection M12 for fuel inlet-outlet on heat exchanger Nut M8 for fastening valve cover Screw M6 for fastening camshaft sensor Screw M6 for fastening output shaft sensor Screw M14 for fastening coolant temperature sensor Screw M5 for fastening oil pressure/temperature sensor Screw for fastening fuel pressure sensor Screw M14 for fastening fuel temperature sensor Screw for fastening air temperature/pressure sensor on intake manifold Screw M12 for fastening engine oil level sensor 6-cyl. Turbine fixing to exhaust manifold 4-cyl.

{ pins nuts { pins nuts

Nm 24 ± 4 10 ± 2 43 ± 6 24 ± 4 22 ± 2 10 ± 2 10 ± 2 53 ± 5 50 ± 5 90° 68 ± 7 24 ± 4 43 ± 6 43 ± 6 85 ± 10 49 ± 5 10 ± 2 24 ± 4 12 ± 2 24 ± 4 8±2 8±2 20 ± 3 6±1 35 ± 5 20 ± 3 6±1 12 ± 2

M10 M10

7±1 43 ± 6

M8 M8

7±1 24 ± 4

Adapter M12 on turbine for lubricant oil pipes (inlet) Pipe fixing on adapter M10 for turbine lubrication Oil pipe fixing on adapter M10 for turbine lubrication to block Oil drain pipe fixing M8 on turbine Connector fixing M6 for oil return from cylinder head to flywheel housing Screw M12 for fastening engine flywheel 1st stage 2ndd stage

35 ± 5 35 ± 5 43 ± 6 24 ± 4 10 ± 2 30 ± 4

Screw M8 for fastening front bracket for engine lifting Screw for fastening engine oil sump

24 ± 4 24 ± 4

Base - July 2006

kgm 2.4 ± 0.4 1 ± 0.2 4.3 ± 0.6 2.4 ± 0.4 2.2 ± 0.2 1 ± 0.2 1 ± 0.2 5.3 ± 0.5 5 ± 0.5 6.8 ± 0.7 2.4 ± 0.4 4.3 ± 0.6 4.3 ± 0.6 8.5 ± 1 4.9 ± 0.5 1 ± 0.2 2.4 ± 0.4 1.2 ± 0.2 2.4 ± 0.4 0.8 ± 0.2 0.8 ± 0.2 2 ± 0.3 0.6 ± 0.1 3.5 ± 0.5 2 ± 0.3 0.6 ± 0.1 1.2 ± 0.2 0.7 ± 0.1 4 3 ± 0.6 4.3 06 0.7 0 7 ± 0.1 01 2.4 ± 0.4 3.5 ± 0.5 3.5 ± 0.5 4.3 ± 0.6 2.4 ± 0.4 1 ± 0.2 3 ± 0.4 60º ± 5º 2.4 ± 0.4 2.4 ± 0.4

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SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

57

AUXILIARY COMPONENTS COMPONENT Air compressor: 5/8 nut for fastening control gear on compressor shaft Nut M12 for fastening to flywheel housing Alternator: Screw M10 for fastening bracket to water inlet connector Nut M10 for fastening alternator Ventilation and heating unit: Screw M10 for fastening bracket Screw M10 for fastening compressor Starter: Screw for fastening starter

Print P1D32N002 E

TORQUE Nm

kgm

125 ± 19 77 ± 12

12.5 ± 1.9 7.7 ± 1.2

43 ± 6 43 ± 6

4.3 ± 0.6 4.3 ± 0.6

43 ± 6 24 ± 4

4.3 ± 0.6 2.4 ± 0.4

43 ± 6

4.3 ± 0.6

Base - July 2006

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SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS

Base - July 2006

EURO 4 NEF ENGINES

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EURO 4 NEF ENGINES

SECTION 5 - TOOLS

1

SECTION 5 Tools Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

Base - July 2006

2

SECTION 5 - TOOLS

Base - July 2006

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SECTION 5 - TOOLS

3

TOOLS TOOL No.

DEFINITION

99305453

Device for checking the diesel supply circuit and common-rail injection system

99317915

Set of 3 9x12 pin wrenches (14 - 17 - 19 mm)

99322205

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

99340055

Tool to remove output shaft front gasket

99340056

Tool to remove output shaft rear gasket

99341001

Double acting puller

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Base - July 2006

4

SECTION 5 - TOOLS

EURO 4 NEF ENGINES

TOOLS TOOL No.

DEFINITION

99341009

Pair of brackets

99341015

Press

99342101

Tool to remove injectors

99346252

Tool for fitting output shaft front gasket

99346253

Tool for fitting output shaft rear gasket

99360076

Tool for disassembling cartridge filters

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 5 - TOOLS

5

TOOLS TOOL No.

DEFINITION

99360183

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

99360268

Tool for removing/refitting engine valves

99360330

Tool for rotating the engine flywheel

99360351

Tool for stopping the engine flywheel

99360362

Beater for removing/refitting camshaft bushes (to be used with 99370006)

99360500

Tool for lifting the output shaft

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Base - July 2006

6

SECTION 5 - TOOLS

EURO 4 NEF ENGINES

TOOLS TOOL No.

DEFINITION

99360595

Lifting rig for engine removal/refitting

99360605

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

99361037

Brackets for fastening engine to revolving stand 99322205

99363204

Tool to remove gaskets

99367121

Manual pump for pressure and vacuum measurements

99370006

Handgrip for interchangeable beaters

Base - July 2006

Print P1D32N002 E

EURO 4 NEF ENGINES

SECTION 5 - TOOLS

7

TOOLS TOOL No.

DEFINITION

99370415

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

99389829

Joint torque wrench 9x12 - (5-60 Nm)

99389834

Torque screwdriver for injector solenoid valve connector stop nut setting

99395216

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

99395603

Dial gauge (0 — 5 mm)

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Base - July 2006

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SECTION 5 - TOOLS

Base - July 2006

EURO 4 NEF ENGINES

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EURO 4 NEF ENGINES

APPENDIX

1

Appendix Page

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

3

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

3

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

3

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

3

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

4

Base - July 2006

2

APPENDIX

Base - July 2006

EURO 4 NEF ENGINES

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EURO 4 NEF ENGINES

APPENDIX

3

SAFETY PRESCRIPTIONS Standard safety prescriptions

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

Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.

- 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.

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.

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)

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

During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC. - 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.

- Wear safety helmet when working close to hanging loads or equipment working at head height level.

- Disconnect batteries from system aboard to load them with the battery loader.

- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.

- After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

- 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.

- 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.

- Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.

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Base - July 2006

4

APPENDIX

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

EURO 4 NEF ENGINES

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

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

Base - July 2006

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