F4AFE411A

NEF SERIES EURO VI On Road - Road Sweeper application (Pivot)

F4AFE411A*C005 F4AFE411C*C026 N45 ENT 6 W Technical and Repair manual

This document provides data, specifications, instructions and methods to perform repair interventions on the assembly and its components. Anyhow, this document is addressed to qualified and specialised personnel. Before performing any intervention, check that the document relating to the vehicle model on which the intervention is being performed is available and also make sure that all accident prevention devices, including but not limited to, goggles, helmet, gloves, shoes, as well as work equipment, lifting and transport equipment, etc., are available and efficient, and also make sure that the vehicle is in safety conditions for intervention. Making interventions strictly observing the indications given here, as well as using specific equipment indicated, assures a correct repair intervention, execution timing observance and operators’ safety. Each repair intervention must be finalised to the recovery of functionality, efficiency and safety conditions that are provided by FPT. Each intervention on the vehicle that is finalised to a modification, alteration or anything else which has not been authorised by FPT relieves FPT of any liability, and, in particular, where the assembly is covered by a warranty, each intervention will immediately invalidate the warranty. FPT declines any liability for repair work. FPT is available to provide any information necessary for the implementation of the interventions and to provide instructions for any cases and situations not covered in this publication. The data contained in this issue may not be up-to-date due to possible modifications made by the Manufacturer for technical or commercial reasons, or to adaptations required by laws in force in different countries. In the event of discordance between the information in this publication and the actual assembly, please contact the FPT network before performing any interventions.” The complete or partial reproduction of the text or illustrations herein is forbidden.

Publication edited by: FPT Industrial S.p.A. Via Puglia 15, 10156 Torino, Italia www.fptindustrial.com Print P1D32N021 E - 1st Edition 03.2015

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INTRODUCTION

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Introduction Page

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

3

SYMBOLS - WARNINGS . . . . . . . . . . . . . . . . . . . .

3

- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Service operations . . . . . . . . . . . . . . . . . . . . . .

3

GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . .

5

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM . . . .

7

- Grounding and screening . . . . . . . . . . . . . . . . .

8

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS . . . . . . . . . . . . . . . . .

9

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND THE MOST COMMONLY USED DERIVED SIZES . . . . . . . . . . . . . . . . . . . . . . . . .

9

PAGE HEADER AND FOOTER INTERPRETATION

10

UPDATE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

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GENERAL INFORMATION Manuals for repairs are split into Parts and Sections, each one of which is marked by a number; the contents of these sections are indicated in the general table of contents. Sections with mechanical contents include technical data, tightening torque collections, tool lists, assembly connections - disconnections, overhauls at the bench and scheduled maintenance. On sections or parts of the electric/electronic system section there are the descriptions of the electric network and the electronic systems of the assembly, wiring diagrams, electric characteristics of components. Section 1. describes the engines illustrating its features and working in general. Section 2. describes the fuel supply type and engine operation. Section 3. is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the basis of their specific use. Section 4. describes scheduled maintenance and specific overhauling. Section 5. deals with removal and refitting of the main engine components. Section 6 describes general mechanical servicing of the engine on the revolving stand. Section 7 gives engine technical characteristics such as data, installation clearances and tightening torques. Section 8 is about the tools necessary for performing these operations. The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians, must comply with to prevent any serious injury. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of symbols has been defined to classify warnings, while another set has been specified for service operations.

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

Risk of serious damage to the assembly The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify the warranty.

!

General danger Includes the dangers of both above described signals.

Environmental protection Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.

NOTE

Indicates an additional explanation for a piece of information.

Service operations Example: Ø1

Ø 1=

Housing for connecting rod small end bush. α

Ø2

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Ø 2=

Tighten to torque + angle value

Housing for connecting rod bearings Base - March 2015

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INTRODUCTION

Removal Disconnect

Intake

Refitting Connect

Exhaust

Disassembly Dismantling

Operation

Assembly Assemble

α

!

NEF SERIES EURO VI

ρ

Compression ratio

Tighten to the specified torque

Tolerance Weight difference

Tighten to the specified torque + angle value

Rolling torque

Press or caulk

Rotation

Registration Adjustment

Angle Angle value

Warning Note

Preload

Visual check Fitting position check

Revolutions per time unit

Measuring Value to be found Check

Temperature

Tools Surface for machining Finished workpiece Interference Forced assembly Clearance Shim

bar

Pressure

Oversized Oversized by no more than ..... Undersized Undersized by no more than.....

Selection of oversizing class

Lubricate Moisten Grease

Temperature < 0o C Cold Winter

Coolant Sealant

Temperature > 0o C Hot Summer

Bleeding air

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GENERAL WARNINGS

!

The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors should be contacted whenever a dangerous situation that has not been described occurs. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check the working condition and suitability of tools not subject to periodic review. The manual handling of loads must be assessed in advance since it also depends not only on weight but also on its size and on the path. Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such tools is strictly permitted by authorised personnel only. Stay at a safe distance from the load and never below it. In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out from accidentally striking workshop personnel. Shop activities performed by two technicians must always been executed with caution; avoid operations that may be dangerous for any collaborators due to lack of field of vision or incorrect position. Keep any personnel not assigned to the operations clear of working area. Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it. Scrupulously observe all safety warnings on the assembly. Do not leave the assembly in motion unattended during repair work. When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands and that the manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp. When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe all the specific safety regulations provided. Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point cards of harmful materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks, in order to prevent sudden fires/explosions. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Strictly avoid using containers for food to store harmful liquids. Avoid drilling or burning pressurised containers and discard cloths impregnated with inflammable substances into suitable containers. Worn out, damaged or consumable parts must be replaced with original spare parts. During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and stains of liquids and oils. Electric sockets and electrical equipment necessary to perform repair operations must meet safety rules.

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Wear all required P.P.E and garments when called for by the operation at issue. Contact with moving parts may cause serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc. Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside. Do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas. Wear an appropriate respirator in the presence of paint dust. Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid direct contact with liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact occurs.

Before overhauling, clean the assemblies and make sure they are integral and complete. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers. Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking nuts with nylon inserts must always be replaced. Avoid contact of rubber with diesel fuel, petrol or other incompatible substances. Before pressure washing mechanical parts, protect electrical connectors and any control units. The tightening of screws and nuts should always be carried out according to directions. FPT’s sales and assistance network is available to provide any clarifications necessary to carry out any repair work not covered by this document. Before welding: - Disconnect all electronic control units and unplug the power cable from the battery’s positive terminal (connecting it to the chassis ground) and connectors. - Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water. - Wait approximately 15 minutes before proceeding with welding. - Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable materials flow when welding. Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), remove the electronic control units.

The disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.

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GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

!

When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the chassis earth cable first of all from the negative terminal of the battery. Before connecting the batteries to the system, make sure that the system is suitably insulated. Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from the battery terminals. Do not cause sparks to verify the presence of voltage in a circuit. Do not use a test lamp to verify circuit continuity, but proper control equipment only. Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding, grounding, etc.) conform with the FPT system and that they are carefully restored after repair or maintenance work. Measurements on the ECUs, jack connections and electrical connections of components must be done only on regular test lines, with special jacks and jack bushings. Never use improvised equipment like metal wires, screwdrivers, pins or similar. This may not only cause short circuits, but also damage the jack connectors, resulting in poor contact.

Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or special truck. Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries) may lead to their destruction. Disconnect the batteries from the system during their recharging with an external apparatus. On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening torque. Isolate the circuit prior to disconnecting the junction connector from an electronic control unit. Do not directly supply current to components served by electronic control units with nominal vehicle voltage. The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body. Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.

NOTE

The connectors are shown from cable side. Connector views contained in the manual are representative of cable side.

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Grounding and screening The negative leads connected to a system grounding point must be as short as possible and connected to one another in ”star” configuration; make sure that they are tightened in an orderly and adequate manner (Figure 1 ref. M). The following precautions must be observed regarding the electronic components: -

The electronic control units must be connected to the circuit’s ground when they have metallic casing.

-

Control unit negative cables must be connected to a system ground point, such as the dashboard compartment ground (do not use ”serial” or ”chain” connections), and to the negative terminal of the battery/ies.

-

Even if not connected to the circuit ground/battery negative terminal, analog ground (sensors) should have optimal isolation. Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.

-

The metal braid of shielded circuits must be in electric contact only at the end towards the control unit where the signal enters (Figure 2).

-

In the case of junction connectors, the unshielded section d, near the connectors must be as short as possible (Figure 2).

-

The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.

Figure 1

1.

”STAR” CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT GROUND M

Figure 2

88039

2.

SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR d. DISTANCE ! 0

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OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Accessory installation, additions and changes on the assembly must be carried out in compliance with the FPT assembly directives. It is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional) sockets in order to simplify and normalise the electrical intervention by fitters.

It is strictly forbidden to carry out any modifications or connections to the electronic control unit wiring. In particular, the data line between the control units (CAN line) is to be considered untouchable.

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

Power 1 kW = 1 kW = 1 CV = 1 CV = 1 hp = 1 hp =

1.36 CV 1.34 hp 0.735 kW 0.986 hp 0.746 kW 1.014 CV

NOTE

the unit CV is converted into hp for simplicity according to a ratio of 1:1 1 hp = 1 CV

THE

Torque 1 Nm = 0.1019 kgm 1 kgm = 9.81 Nm Revolutions per time unit 1 rpm = 0.1047 rad/s 1 rad/s = 9.55 rpm Pressure 1 bar = 1.02 kg/cm2 1 kg/cm2 = 0.981 bar 1 bar = 105 Pa NOTE

Where accuracy is not particularly required: - the unit Nm is converted into kgm for simplicity according to a ratio of 10:1 1 kgm = 10 Nm; - the unit bar is converted into kg/cm2 for simplicity according to a ratio of 1:1 1 kg/cm2 = 1 bar.

Temperature 0 C = 273.15 K 0 F = 255.37 K 0 C = 32˚F (the conversion factor between Celsius and Fahrenheit is 1:1.8)

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PAGE HEADER AND FOOTER INTERPRETATION Type of engine

Number of printed copies

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Section title

Language of Publication

Basic edition with reference to the month-year closing the drafting phase

Page number

When present, a month-year update (Revi) to the basic edition

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UPDATE DATA Section

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Section name

Modification description

Page

Date of revision

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INTRODUCTION

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NEF SERIES EURO VI Section General specifications

1

Operating diagrams

2

Electrical equipment

3

Scheduled Maintenance

4

Removal-refitting of the main engine components

5

General mechanical overhaul

6

Technical specifications

7

Tools

8

Safety prescriptions

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Appendix

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INTRODUCTION

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NEF SERIES EURO VI

1

SECTION 1 - GENERAL SPECIFICATIONS

SECTION 1 General information Page

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IDENTIFICATION PLATE . . . . . . . . . . . . . . . . .

3

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

3

TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . .

4

COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . .

5

ISO VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

TORQUE AND POWER TYPICAL CURVES . .

7

- F4AFE411A*C005 . . . . . . . . . . . . . . . . . . . . . .

7

- F4AFE411C*C026 . . . . . . . . . . . . . . . . . . . . . .

7

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .

8

GENERAL CHARACTERISTICS . . . . . . . . . . . . .

11

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SECTION 1 - GENERAL SPECIFICATIONS

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SECTION 1 - GENERAL SPECIFICATIONS

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IDENTIFICATION PLATE Figure 1

221352

1. Technical code - 2. Month and year construction date - 3. Engine serial number

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

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Technical Code

Commercial Code

F4AFE411A*C005 F4AFE411C*C026

N45 ENT 6 W

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TECHNICAL CODE The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize its application and power output level. It is stamped on a side of crank-case, close to oil filter.

F4

A

F

E

4

1

1

A

*

C

005

F4

A

F

E

4

1

1

C

*

C

026

Progressive numbers showing engine variants Emissions level: A = TIER 4a B = TIER 4full/STAGE IV C = EURO 6 D = Not emissioned E = STAGE 2 Performances: 1,2,3... A,B,C...= Engine power or torque level Application: 0 = Other application 1 = Trucks 2 = Buses 3 = Industrial / Agricultural 4 = Industrial / Agricultural

5 = Genset 6 = Marine 7 = Industrial / Agricultural turbo eVGT 8 = Cars and derivatives 9 = Military

Engine main characteristics: 0 = Turbocharged CNG 1 = Turbocharged diesel i.d. aftercooled 2 = Naturally Aspirated diesel i.d 3 = Naturally Aspirated diesel i.i 4 = Naturally Aspirated petrol 5 = Naturally Aspirated CNG 6 = Turbocharged diesel i.d. 7 = Turbocharged diesel i.i. 8 = Turbocharged petrol 9 = Turbocharged diesel i.i. aftercooled No. of cylinders Cylinder configuration: A = 4 stroke vertical B = 4 stroke horizontal C = 4 stroke vertical with EGR D = 4 stroke horizontal with EGR

E = 4 stroke vertical with post-treat F = 4 stroke horizontal with post-treat G = 4 stroke horizontal with EGR + post treat L = 4 stroke vertical with EGR + post treat

F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6 Code A D H

Type of base: Not structural Structural Not structural

Application ON-ROAD OFF-ROAD OFF-ROAD

F4 = New Engine Family Base - March 2015

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SECTION 1 - GENERAL SPECIFICATIONS

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COMMERCIAL CODE The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical purpose of recognizing the engine’s components, which is served by the ”ENGINE S/N”.

N

45

E

N

T

6

W

ENGINE CONTROL UNIT: W = EDC17CV41

EMISSION LEVEL: 6 = Euro VI

AIR INTAKE: T = INTERCOOLED TURBOCHARGED

ENGINE BLOCK: N = NOT STRUCTURAL

FUEL SUPPLY: E = ELECTRONIC INJECTION DISPLACEMENT: 45 = 4.500 cc NOMINAL

ENGINE FAMILY IDENTIFIER: N = NEF

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ISO VIEW Figure 2

227538

F4AFE411 engine

The engine F4AFE411 is a 4-cylinder in-line turbocharged with intercooler with 4 valves per cylinder; it belongs to the NEF series and operates according to a four-stroke diesel cycle. The engine supply system is electronically-controlled and it’s based on the direct injection of the fuel in the combustion chamber by means of high pressure pump and common rail. The intake and exhaust valves are timed with the camshaft tappets, the push rods and the rocker arm assembly.

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SECTION 1 - GENERAL SPECIFICATIONS

7

TORQUE AND POWER TYPICAL CURVES F4AFE411A*C005 Figure 3 TORQUE (Nm) POWER (kW) 600,0

140,0

550,0

120,0 100,0 80,0

450,0

kW

Nm

500,0

60,0 400,0 40,0 350,0

300,0 600

20,0

800

1000

1200

1400

1600

1800

2000

2200

2400

2600

0,0 2800

rpm

227495

POWER max. 118 kW (158 HP) at 2.500 rpm TORQUE max. 580 Nm (59.14 kgm) at 1.250 rpm

F4AFE411C*C026 Figure 4 TORQUE (Nm) POWER (kW) 800,0

160,0

750,0

140,0

700,0 120,0 650,0

Nm

550,0

80,0

500,0

kW

100,0

600,0

60,0

450,0 40,0 400,0 20,0

350,0 300,0 600

800

1000

1200

1400

1600

1800

rpm

2000

2200

2400

2600

0,0 2800 227496

POWER max. 152 kW (204 HP) at 2500 rpm TORQUE max. 750 Nm (76.47 kgm) at 1.400 rpm Print P1D32N021 E

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SECTION 1 - GENERAL SPECIFICATIONS

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ENGINE VIEWS (F4AFE411A*C005 - F4AFE411C*C026) Figure 5

227539

INTAKE SIDE VIEW 1. Rail - 2. High pressure fuel pipe - 3. Fuel pump - 4. Fuel filter - 5. Oil sump - 6. Engine control unit EDC17CV41 7. Engine cable - 8. Intake manifold

Figure 6

EXHAUST SIDE VIEW

227540

1. Blow-by breather - 2. Oil level dipstick - 3. Thermostat cover - 4. Exhaust manifold - 5. Turbocharger oil delivery pipe 6. Alternator - 7. Coolant inlet pipe - 8. Engine oil filter - 9. Starter motor - 10. Turbocharger oil return pipe 11. Turbocharger - 12. Motorized throttle valve (engine brake) - 13. Throttle valve control actuator - 14. Tappet cover Base - March 2015

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Figure 7

227542

FRONT VIEW 1. Engine cable - 2. Fixed belt tensioner - 3. Water pump - 4. Damper pulley - 5. Auxiliary drive belt - 6. Fixed belt tensioner 7. Automatic belt tensioner - 8. Alternator - 9. Thermostat cover Figure 8

227541

REAR VIEW 1. Tappet cover - 2. Throttle valve control actuator - 3. Motorized throttle valve (engine brake) - 4. Engine flywheel 5. Fuel low pressure pipes - 6. Lifting eyelet Print P1D32N021 E

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SECTION 1 - GENERAL SPECIFICATIONS

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Figure 9

227543

TOP VIEW 1. Intake manifold - 2. Rail - 3. Oil filler cap - 4. Blow-by breather - 5. Thermostat cover 6. Alternator - 7. Turbocharger - 8. Throttle valve control actuator - 9. Exhaust manifold - 10. Tappet cover

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11

GENERAL CHARACTERISTICS Type

F4AFE411A*C005

Cycle

Four stroke - Diesel engine

Fuel system

Common Rail Injection System

Injection

Direct

Number of cylinders



+

+

F4AFE411C*C026

4 in line

Bore

mm

104

Stroke

mm

132

cm3

4485

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

A B

8º 30’ 8º 30’

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

D C

51º 00’ 12º 30’

+.. = Total displacement TIMING GEAR

For timing check mm X mm

X

INJECTION supply Type:

Bosch

Nozzle type and brand

BOSCH CRIN2.0

Injection sequence

Injection pressure

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Compression ratio

High pressure common rail EDC 17CV41

1-3-4-2

bar

1600

17 : 1

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SECTION 1 - GENERAL SPECIFICATIONS

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Type

Max. power

Maximum torque

kW (hp) rpm Nm (kgm) rpm

F4AFE411C*C026

118 (158) 2500

152 (204) 2500

580 (59.14) 1.250

750 (76.47) 1.400

Low idle speed with no load

rpm

750

Peak engine speed with no load

rpm

2.800

TURBOCHARGING Turbocharger type

With aftercooler HONEYWELL GT 25S By means of centrifugal pump, thermostat, radiator, heat exchanger, aftercooler

LUBRICATION bar

F4AFE411A*C005

Oil pressure at 80˚C - at idle speed - at max speed

bar bar

COOLING (1) Total capacity Water pump drive Thermostat - start of opening - maximum opening REFILLING (2) - Lubrication circuit total capacity (3) - engine sump at minimum level - engine sump at maximum level

litres

˚C ˚C litres kg litres kg litres kg

2.0 4.0 By means of centrifugal pump, thermostat, radiator, heat exchanger, aftercooler 8 Belt driven 79 ± 2 96 13,5 12.2 9 8.1 12 10.8

(1) The quantities indicated only relate to the engine in its standard configuration. Use a 50% mixture of water and PARAFLU HT even during the summer months. As an alternative to PARAFLU HT, use another product that complies with FPI9.COOL002 or CNH MAT 3624 or SAE J1034 specifications. (2) Only use lubricants which meet the international standards API CJ-4 / ACEA E9-E6. Recommended oil is SAE 10W-40 or 5W-30 meeting FPI9.LUBR001 or CNH MAT 3521. The oil used is considered to be acceptable until a quantity equalling 0.15% of fuel consumption is reached. (3) The quantities indicated relate to the first refill only and are relative to the engine, oil sump and filter filling.

!

!

Data, features and performances are valid only if the technician fully complies with all the installation requirements provided by FPT. Furthermore, the equipment assembled by vehicle manufacturer shall always be in compliance with torque, power and number of revs based on which the engine has been designed. Warning - Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.

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SECTION 2 - OPERATING DIAGRAMS

1

SECTION 2 Operating diagrams Page

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COMMON RAIL INJECTION SYSTEM . . . . . . .

3

- General specifications . . . . . . . . . . . . . . . . . . .

3

- Electric system . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Main sensors . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- System functions . . . . . . . . . . . . . . . . . . . . . . .

4

- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . .

5

- Fuel system diagram . . . . . . . . . . . . . . . . . . . .

6

- Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . .

8

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

8

- Mechanical supply pump . . . . . . . . . . . . . . . . .

9

- High pressure pump CP3.3 . . . . . . . . . . . . . . .

10

- Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

- Pressure relief valve . . . . . . . . . . . . . . . . . . . . .

15

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

15

- Quick coupler for fuel return . . . . . . . . . . . . .

16

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

17

- General specifications . . . . . . . . . . . . . . . . . . .

17

- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .

18

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

20

- General specifications . . . . . . . . . . . . . . . . . . .

20

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

21

- General specifications . . . . . . . . . . . . . . . . . . .

21

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

22

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

23

INTAKE AND EXHAUST SYSTEM . . . . . . . . . .

25

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

25

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Page - Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . .

27

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

- Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

- ATS system heating/cooling system . . . . . . . .

31

MAIN COMPONENTS OF ATS SYSTEM . . . . . .

32

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

32

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

32

- DeNOx 2.2 supply module (SM - Supply Module) . . . . . . . . . . . . . . . . . . .

33

- Filter removal . . . . . . . . . . . . . . . . . . . . . . . . .

34

- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . .

35

- DeNOx 2.5 dosing module (DM - Dosing Module) . . . . . . . . . . . . . . . . . .

36

- Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . .

37

- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . .

38

- Nitrogen oxide detecting sensor . . . . . . . . . .

39

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

40

- Temperature and humidity sensor . . . . . . . . .

41

- Catalytic converter . . . . . . . . . . . . . . . . . . . . .

42

- Differential pressure sensor . . . . . . . . . . . . . .

43

SCHEDULED MAINTENANCE FOR ATS SYSTEM (DRAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

REPLACING THE DPF (DIESEL PARTICULATE FILTER) CATALYTIC CONVERTER . . . . . . . . . . . . . . .

45

- Removing the DPF catalytic converter . . . . . .

45

- Refitting the DPF catalytic converter . . . . . . .

47

Base - March 2015

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3

SECTION 2 - OPERATING DIAGRAMS

COMMON RAIL INJECTION SYSTEM 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.

Electric system Figure 1

221783

1. Electro-injector connections - 2. Motorized throttle valve actuator connector (Exhaust flap) 3. Boost pressure and air temperature sensor - 4. Rail pressure sensor - 5. Timing segment speed sensor (camshaft) 6. Fuel temperature sensor - 7. Fuel high pressure pump metering unit - 8. In line connector - 9. Rpm increment speed sensor (crankshaft) - 10. Engine Control Unit EDC17CV41 - 11. Engine oil pressure and temperature sensor 12. Coolant temperature sensor

Main sensors

This information is then used to calculate the injection time.

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

The sensor is fitted on the intake manifold.

Boost pressure and air temperature sensor The boost pressure and air temperature sensor is an integrated component which has the task of detecting the pressure and temperature of the air inside the intake manifold. Both pieces of information are needed by the injection control unit to define the amount of air taken in by the engine. Print P1D32N021 E

The output voltage is proportional to the pressure (or temperature) measured by the sensor.

Engine oil temperature and pressure sensor It is fitted on the crankcase and measures the engine oil pressure and temperature.

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Rail pressure sensor

Injection control

Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure.

On the basis of the information from the sensors and the mapped values, the control unit controls the pressure regulator and changes the pre-injection and main injection mode.

The signal provided by the sensor is used by the engine management control unit to adjust the injection pressure and duration.

Coolant temperature sensor 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.

Closed loop injection pressure management 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 advance control

This sensor is identical to the previous one.

The control unit, depending on signals coming from various sensors, computes the optimum injection point according to an internal mapping.

It detects the temperature of the fuel to give the control unit information about the fuel oil temperature conditions.

Idle speed control

Fuel temperature sensor

Rpm increment speed sensor It is an inductive sensor placed on the front part of the engine. Signals generated through the magnetic flow that is closed on the tone wheel, change their frequencies depending on crankshaft rotation speed. The engine management control unit uses the rpm sensor signal to determine the rotation speed and angular position of the crankshaft.

Timing segment speed sensor This inductive sensor is located in the left rear 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 engine management control unit as the injection phase signal. Although it is similar to the rpm sensor, it is NOT interchangeable as it has a different shape.

System functions

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 electro-injectors. Within certain thresholds, it also takes into account the battery voltage.

Maximum speed limiting At 2700 rpm, the control unit limits fuel flow-rate by reducing the electro-injectors opening time. Over 3000 rpm it deactivates the electro-injectors.

Cut Off Fuel cut off upon deceleration is controlled by the control unit performing the following logics: - it cuts off electro-injectors supply; - it re-activates the electro-injectors shortly before idle speed is reached; - it controls the fuel pressure regulator.

Smokiness on acceleration control

Self-diagnostics The control unit self-diagnostics system checks the signals from the sensors and compares them with the allowed limit values.

With important load requests, the control unit, depending on signals received by air inlet meter and engine speed sensor, controls the pressure regulator and changes the electro-injectors actuation time, in order to avoid exhaust smokes.

FPT Code recognition

Checking fuel temperature When the fuel temperature exceeds 75C (measured by the sensor placed on fuel filter) the control unit intervenes and reduces the injection pressure. If the temperature exceeds 90C, the power is reduced to 60%.

The engine management control unit communicates with the Immobilizer control unit to obtain the startup consent.

Engine pre-heating resistance management 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.

Synchronization search By means of signals from the sensor on the camshaft and that on the crankshaft pulley, at start-up the cylinder into which fuel is to be injected is recognised.

AC compressor engagement control The control unit is able to control the engagement and disengagement of the electromagnetic clutch of the compressor on the basis of the coolant temperature. If the coolant temperature reaches 105C, it disengages. 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.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

5

SECTION 2 - OPERATING DIAGRAMS

Hydraulic system Figure 2

227537

A. Low pressure - B. Return - C. High pressure 1. Rail pressure relief valve - 2. Quick coupler for fuel return - 3.Common Rail - 3. Fuel filter - 4. High pressure pump 5. Mechanical feed pump - 6. Fuel filter - 7. ECU - 8. Electro-injectors 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 electro-injectors. At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the ECU. 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 made up of the following pipes: - piping connecting high-pressure pump outlet to rail; - pipings supplying electro-injectors from rail. The low-pressure circuit is made up of the following pipes: - 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 return circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

Print P1D32N021 E

Base - March 2015

6

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Fuel system diagram This Common Rail injection system, with CP3.3 pump is shown in diagram form in the 4 cylinder version.

!

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 solution, only pressurising the necessary fuel, improves the energy efficiency and limits heating the fuel in the system. Function of the limiting valve (8), assembled on the highpressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bar, independently from the efficiency of the fuel filter and of the system set upstream. The intervention of the pressure relief valve (8) brings about an increase in the fuel flow in the high-pressure pump cooling circuit, through the inlet and drain pipe (19) from the pipe (10).

!

-

avoid connecting high-pressure pipe fittings with approximate tightening;

-

avoid disconnecting the high-pressure pipes when the engine is running (DO NOT make any attempt at bleeding: this is absolutely useless and dangerous!).

To ensure correct operation of the system, it is essential that the low-pressure circuit is intact. Therefore, avoid any attempt at modification or alteration and intervene immediately if a leak is identified.

The quick coupler housed on the cylinder head, fitted on the electro-injector return (11), limits the fuel return flow from the electro-injectors at a pressure of 1.3 ÷ 2bar. Two by-pass valves are placed in parallel with the mechanical supply pump.

Due to the very high pressure that builds within this hydraulic system, the following precautions must be observed for safety reasons:

!

After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level. (IT MUST NOT INCREASE).

The by-pass valve (17) 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 (18) allows filling the supply system through the manual priming pump (3).

Base - March 2015

Print P1D32N021 E

A. Outlet connection to high pressure pump - B. Inlet connection from mechanical supply pump - C. Low pressure - D. Fuel discharge - E. High pressure 1. Fuel tank - 2. Prefilter - 3. Manual pump - 4. Engine control unit - 5. Fuel filter - 6. Flow rate modulator - 7. High pressure pump 8. Limiting valve on high pressure pump, 5 bar - 9. Mechanical supply pump - 10. High pressure pump reflux pipe 11. Quick coupler for fuel return from the injectors - 12. Return pipe - 13. Common rail excess pressure valve 14. Common rail - 15. Pressure sensor 16. Injector - 17. By-pass valve - 18. By-pass valve - 19. High-pressure pump cooling piping

NEF SERIES EURO VI

Print P1D32N021 E

SECTION 2 - OPERATING DIAGRAMS

7

Figure 3

227484

Base - March 2015

8

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Fuel prefilter

Fuel filter

Figure 4

Figure 5

227475

1. Heater connector - 2. Fuel filter - 3. Electric fuel heater 4. Fuel temperature sensor - 5. Fuel filter support A. Inlet connection from mechanical supply pump B. Outlet connection to high-pressure pump

It is located on the crankcase in the circuit between the feed pump and the high pressure pump. Cartridge filtering degree: 4 microns Pressure delta: 70494

The fuel filter is of the high water separation type, it is fitted on the right side of the vehicle chassis with the sensor (4) for detecting water in fuel on the cartridge (3) base.

0.1 bar.

Fuel temperature sensor and heater resistors are located on the support. The fuel temperature, signalled by the relative sensor to the engine management control unit, allows a very accurate calculation of the fuel flow-rate to be injected into the cylinders.

Priming pump (5) and system air bleeding screw (2) located on the filter support. The presence of condensate into filter is signalled by sensor (4) when a warning light on the instrument panel is lit.

!

If the warning light comes on, it is necessary to act immediately to remove the cause; the components of the common rail system will be quickly damaged if the fuel contains water or other impurities.

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

9

Air bleeding conditions

Mechanical supply pump Gear pump, fitted on the rear side of the high pressure pump and used to supply it. It is driven by the high pressure pump shaft.

Figure 8

Normal operating conditions Figure 6

72594

72592

A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass valves in close position.

The by-pass valve (2) cuts in when, with engine off, the fuel system shall be filled through the priming pump. In this situation the by-pass valve (1) stays closed and the by-pass valve (2) opens as a result of the incoming pressure. The fuel flows out of outlet B.

!

Overpressure condition at outlet

The mechanical supply pump cannot be replaced individually, therefore it cannot be removed from the high pressure pump.

Figure 7

72593

The by-pass valve (1) intervenes in the presence of overpressure at the outlet B. The pressure of the fuel overcomes the force exerted by the spring of the valve (1), thereby placing the pump outlet in communication with the inlet by way of passage (2).

Print P1D32N021 E

Base - March 2015

10

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

High pressure pump CP3.3 Pump with three radial pistons controlled by the timing gear, without needing any setting. The mechanical supply pump controlled by the high pressure pump shaft is fitted on the rear side of the high pressure pump.

!

The high pressure pump - feed pump assembly cannot be overhauled and therefore should not be removed and the fastening screws should not be tampered with. The only operation that can be carried out is the replacement of the drive gear.

Figure 9

72595

1. Fuel outlet fitting to rail - 2. High pressure pump - 3. Pressure regulator - 4. Drive gear - 5. Fuel inlet fitting from filter 6. Fuel outlet fitting to tank - 7. Fuel inlet fitting from ECU heat exchanger - 8. Fuel outlet fitting from supply pump to filter 9. Mechanical supply pump.

Base - March 2015

Print P1D32N021 E

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SECTION 2 - OPERATING DIAGRAMS

11

High pressure pump internal structure Figure 10

Sect. B - B

Sect. C - C

70498

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

Every plunger unit is composed of: - a piston (5) actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), as it floats on a misaligned part of the shaft (6), when the shaft rotates, does not rotate with it but is only translated in a circular movement along a wider radius, with the result of alternatively activating the three pumping elements;

Print P1D32N021 E

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

Base - March 2015

12

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Operating principle Figure 11

Sect. B - B

Sect. D - D

72597

1. Connection between fuel outlet and rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply pipe 6. Pressure regulator supply pipe - 7. Pressure regulator.

Plunger (3) is oriented to pump shaft (4) cam. During intake, the plunger is supplied through supply duct (5). The fuel amount to be sent to the plunger is set by the pressure regulator (7). The pressure regulator meters fuel flow to plunger according to

Base - March 2015

the flow of fuel to the pumping element. During plunger compression stage, fuel reaches the pressure required to open the delivery valve to common rail (2) and to feed it through outlet (1).

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

Figure 12

Sect. C - C

13

Figure 13

72598

72601

Sect. A - A

1. Plunger inlet - 2. Pump lubrication pipes - 3. Plunger inlet - 4. Main plunger supply pipe - 5. Pressure regulator 6. Plunger inlet - 7. Regulator drainpipe - 8. Pressure limiting valve 5 bar - 9. Fuel drainage from regulator inlet.

1. Fuel outlet pipe - 2. Fuel outlet pipe - 3. Fuel outlet from pump with connector for high-pressure pipe for the common rail.

The figure shows the low-pressure fuel paths inside the pump; it shows the main supply pipe of the pumping elements (4), the pumping element supply pipes (1 - 3 - 6), the pipes used to lubricate the pump (2), the pressure regulator (5), the 5-bar pressure relief valve (8) and the fuel discharge (7).

The figure shows the flow of the fuel at high pressure through the outlet ducts of the pumping elements.

Pump shaft is lubricated by fuel through delivery and return ducts (2). The pressure regulator (5) establishes the quantity of fuel to be supplied to the plungers; The excess fuel flows off through the pipe (9). 5 bar pressure relief valve acts as fuel return collector and keeps 5 bar constant pressure at regulator inlet.

Print P1D32N021 E

Base - March 2015

14

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Operation

Pressure regulator description

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

The pressure regulator is fitted on the low pressure circuit of pump CP.3. The pressure regulator modulates the amount of fuel sent to the high-pressure circuit according to the commands received directly from the engine control unit. The pressure regulator is mainly composed of the following components:

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 engine management 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.

-

connector,

-

casing,

-

solenoid,

-

pre-load spring

-

shutter cylinder.

When there is no signal, the pressure regulator is normally open, therefore with the pump providing maximum delivery. The engine control unit, via the PWM (Pulse Width Modulation) signal, modulates the change in fuel flow rate in the high-pressure circuit by partially closing or opening the sections of passage of the fuel in the low-pressure circuit.

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.

Figure 14

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

185436

1. Solenoid - 2. Magnetic core - 3. Shutter cylinder 4. Fuel inlet - 5. Fuel outlet. When the engine control unit operates the pressure regulator (via PWM signal), the solenoid (1) is energized, which in turn generates the movement of the magnetic core (2). The shift of the core causes the shutter cylinder (3) to move axially, choking the flow of fuel.

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

15

Pressure relief valve

Figure 15

The function of the valve fitted at one end or rail is to protect system components against any fault which might result in overpressure in high pressure system. 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.

Electro-injector The electro-injector essentially consists 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 checks the lift of the nozzle needle. 185437

1. Solenoid - 2. Magnetic core - 3. Preload spring 4. Shutter cylinder. When the solenoid (1) is not energized, the magnetic core is pushed into the rest position by the pre-load spring (3). In this position the shutter cylinder (4) allows the greatest section of passage for the fuel flow.

Injector in resting position Figure 17

Rail Figure 16

15

108500

1. Rail - 2. Pressure sensor - 3. Fuel intake from HP pump 4. Relief 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 pulsations 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.

Print P1D32N021 E

70505

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 pipe - 11. Supply pipe - 12. Control fuel outlet - 13. Power connection 14. Spring - 15. High pressure fuel inlet.

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Beginning of injection

Quick coupler for fuel return It is housed on the rear part of the cylinder head and adjusts the pressure of fuel returning from the injectors to a pressure of between 1.3  2 bars.

Figure 18

Figure 19

15

186859

A

To tank - B From electro-injectors

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.

End of injection 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 electro-injector cannot be overhauled and therefore it must not be disassembled.

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

17

LUBRICATION General specifications The forced circulation lubrication is carried out by the lobe oil pump (5), housed in the front part of the crankcase and driven by the straight-toothed gear keyed to the crankshaft tang.

The lubricant oil is conveyed from the oil sump to the crankshaft, to the camshaft and to the valve control. Lubrication also includes the heat exchanger, the turbocharger and the compressor if there is a compressed air system. All these components often vary depending on use and are therefore dealt with in the specific part of the manual.

Figure 20

227478

LUBRICATION SYSTEM LAYOUT A. Oil under pressure - B. Oil in freefall C. To the heat exchanger and to the turbocharger - D. Recovery of oil from the turbocharger 1. Oil introduction - 2. Crankshaft - 3. Oil sump - 4. Suction strainer - 5. Oil pump

Print P1D32N021 E

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Oil pump

Figure 21

Housed in the front of the crankcase, the oil pump is a rotary pump commanded by a spur gear fitted to the stub of the crankshaft. NOTE Since the oil pump cannot be overhauled, it shall be replaced when damaged.

The oil pump is driven directly by the crankshaft. PUMP SPEED (rpm)

PRESSURE (bar)

NOMINAL FLOW (L/min)

750 4.200

2 4

12.2 75.9

70576

Heat exchanger Figure 22

200097

1. Heat exchanger body with filter bracket - 2. Oil pressure control valve - 3. By-pass valve to cut off clogged oil filter 4. Internal gasket - 5. Oil - water heat exchanger - 6. Gasket between exchanger unit and engine block

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

19

Oil pressure regulator valve Figure 23

1. Threaded plug - 2. Spring - 3. Valve 4. Oil filter body - 5. By-pass valve 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 24

Figure 25

Flow

70482

107419

MAIN DATA TO CHECK THE OIL PRESSURE CONTROL VALVE SPRING Print P1D32N021 E

Max section : 20 cm3/1’ at pressure of 0.83 bar and oil temperature of 26.7C. Opening pressure: 3.0 to 3.8 bar Base - March 2015

20

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

OIL VAPOUR RECYCLING General specifications Figure 26

201723

1. Tappet cover - 2. Oil vapour breather - 3. Oil vapour separator control valve - 4. Oil vapour filter housing

The oil vapour recirculation circuit is used to decant and burn the breather gases from the crankcase. These gases consist of a mix of air, fuel vapours and lubricant oil vapours. The gases from the crankcase rise back up to the cylinder head and are then conveyed into a separator fitted inside the tappet cover. The separator is equipped with a diaphragm valve which allows: - the condensation and recovery of the vapours; - the lower part of the crankcase to be kept at the right vacuum value. The condensed vapours fall back into the sump while the remaining vapours are conveyed to the filter via the designated pipes before being released into the atmosphere. In order for the engine to operate correctly, the lower part of the crankcase must be at a slightly lower pressure. For this reason, the diaphragm valve of the separator adjusts the vacuum to approximately 65 mbar.

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

21

COOLING SYSTEM General specifications The engine cooling system, of the closed-loop forced-circulation type, consists of the following components: - Expansion tank: the position, shape and dimensions can change depending on the engine outfitting. - Radiator, for dissipating the heat taken from the engine by the coolant. This component can also change depending on the outfitting both in terms of position and dimensions. - Heat exchanger to cool the lubricant oil: this is also part of the specific outfitting for the engine. - Centrifugal water pump set in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit extends to the compressor.

Figure 27

227479

A. Water coming out from thermostat - B. Water recirculating in engine - C. Water coming into pump 1. Thermostat - 2. Water pump - 3. Radiator - 4. Expansion tank - 5. Water/oil heat exchanger.

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Base - March 2015

22

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Water Pump Figure 28

70486

Sec. A-A The water pump is located in a hollow obtained in the cylinder block and is driven by and a poly-V belt. An automatic tensioner keeps the belt tension. Pump performances Coolant fluid temperature: 100 ± 5 ˚C Anti-freeze concentration: 50%

Pump speed [rpm] 5.000 2.500

Base - March 2015

Flow [L/min] 210 110

Pressure [bar] 2.00 to 2.45 0.50 to 0.65

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

23

Thermostat The thermostat, located in the cylinder head, is of the by-pass type and doesn’t need regulations. If there are doubts as to its proper functioning, replace it. The basic parts of a thermostat are: heat motor, which includes a valve attached to a piston that is embedded in a special wax, flange, spring and frame. The thermostat has a jiggle pin that allows trapped air in the cooling system to pass through the thermostat and be released from the system. The thermostat has two important jobs: - Accelerate engine warm-up by blocking the circulation of coolant between the engine and radiator until the engine has reached its predetermined temperature. - Regulate the engine’s operating temperature by opening and closing in response to specific changes in coolant temperature to keep the engine’s temperature within the desired operating range. Figure 29

209191

1. Flange - 2. Stem (piston) - 3. Frame - 4. Min. stroke at full opening temperature - 5. Jiggle pin - 6. Flange seal 7. Main spring - 8. Wax slug - 9. By-pass valve Thermostat performances Min. allowed working temperature: -40 ˚C Max. allowed working temperature: 135 ˚C Max. allowed peak temperature (5 minutes): 150 ˚C Max. working differential pressure: 3 bar Opening start: 79 ± 2 ˚C Full opening temperature: 96 ˚C Min. stroke at full opening temperature: 7.5 mm Print P1D32N021 E

Base - March 2015

24

SECTION 2 - OPERATING DIAGRAMS

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Operation description - When the engine is cold, the thermostat is normally closed; restricting flow to the radiator allowing the engine to warm-up; - As the engine warms, the increase in heat causes the wax to melt and expand, pushing against a piston inside a rubber boot; - This forces the piston outward, opening the thermostat so coolant can start to circulate between the engine and radiator; - As heat increases, the thermostat continues to open until engine cooling requirements are satisfied; - If the temperature of the circulating coolant begins to drop, the wax element contracts; allowing spring tension to close the thermostat, which decreases coolant flow through the radiator.

Figure 30

209198

A. Thermostat closed (coolant to water pump through by-pass port) B. Thermostat open (coolant to radiator)

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

25

INTAKE AND EXHAUST SYSTEM Figure 31

227494

1. Intake manifold - 2. Exhaust manifold - 3. Turbocharger - 4. Motorized throttle valve (Exhaust flap) A. Cooled compressed air from intercooler (compressed cold air) - B. Turbocharger compressed air outlet to intercooler (compressed hot air) - C. Turbocharger filtered air inlet from air filter (filtered air) - D. Turbocharger exhaust gas outlet from motorized throttle valve (Exhaust flap) (exhaust gas)

Description The engine intake system recalls external air through the air filter. The filtered air runs through the entry hose to the turbocharger. Exiting from the turbocharger, the filtered and compressed air passes through the intercooler. The compression causes an increase in air temperature and hence its expansion. In order to introduce a greater quantity of mixture into the combustion, the air is inter-cooled thus increasing its density at the same pressure. The cycle ends with the introduction of inter-cooled air into the intake manifold and then to the pistons to be used inside the combustion chamber. Print P1D32N021 E

After combustion, the exhaust manifold collects the fuel gases coming from the cylinders and conveys them directly to the turbocharger to activate it. The adoption of turbocharging makes it possible to increase the power developed by the engine by emitting, at each cycle, a quantity of combustive air greater than what the engine would have been able to intake naturally through the alternating motion of the pistons. A greater quantity of air emitted into the combustion chamber makes it possible to completely burn a higher quantity of fuel, so as to respect the optimal stoichiometric ratio. The exhaust gases cause rotation of the turbine splined to the centrifugal compressor by means of a connecting shaft. Rotation of the turbine involves the rotation of the compressor which compresses the air coming from the filter. Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

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Turbocharger The turbocharger is composed of the following main parts: a turbine, boost-pressure regulation valve (Waste-Gate), a central body and a compressor. During engine operation, the exhaust gases pass through the turbine body spinning the turbine rotor. The compressor rotor is connected by a shaft to the turbine rotor, which it spins and in doing so compresses the air taken in through the air filter. The air is then cooled by the intercooler and sent to the cylinders via the intake manifold. The turbocharger is fitted with a Waste-Gate valve which is driven by a pneumatic actuator allowing the passage of the exhaust gas to the turbine to be reduced depending on the pressure reached at the compressor outlet. The engine oil is used to cool and lubricate the turbocharger and the bearings. Figure 32

227480

A. Intake air - B. Compressed air - C. Exhaust gas 1. Gasket on exhaust manifold - 2. Studs - 3. Fastening nuts - 4. Exhaust gas turbine 5. Waste-gate valve - 6. Air compressor

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

27

Waste-Gate valve The function of the Waste-Gate valve is to choke the exhaust gas outlet, by conveying part of the gas directly into the exhaust pipe, when the boosting pressure downstream the turbocharger reaches the calibration value. Figure 33

Closed throttle valve

Throttle valve open

227497

DEMONSTRATIVE CROSS-SECTION OF A TURBOCHARGER WITH WASTE-GATE VALVE

Throttle valve The throttle valve is positioned at the turbocharger exhaust gas outlet, it’s controlled by an electric actuator via signals from the engine management control unit. The main new feature is an electric actuator which allows the exhaust gas outlet to be choked to increase the outlet temperature. This possibility is exploited in order to quickly bring catalytic converter up to standard thermal conditions (reduction of emissions when is cold). The throttle valve is cooled by the engine coolant. Figure 34

221358

1. Electric connection - 2. Electric actuator - 3. Studs - 4. Gasket 5. Fastening nuts - 6. Motorized throttle valve (Exhaust flap) Print P1D32N021 E

Base - March 2015

28

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS) Schematic 2-WAYS DIVERTER VALVE VERSION Figure 35

2

204274

A. AdBlue pump module supply line - B. AdBlue return line to tank - C. AdBlue system heating line - D. AdBlue delivery line to dosing module.

3-WAYS DIVERTER VALVE VERSION Figure 36

2

227498

A. AdBlue pump module supply line - B. AdBlue return line to tank - C. AdBlue system heating line - D. AdBlue delivery line to dosing module. Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

29

The ATS system consists essentially of: - a DOC oxidizing catalytic converter DOC (6); - a DPF particulate filter catalytic converter (5); - a differential pressure sensor (11) which detects the difference in pressure of the particulate filter inlet and outlet; - a tank (8) for reagent solution (water - urea: “AdBlue”) with level gauge (7); - an 2-ways/3-ways H2O diverter valve (9); - pump module (10); - an injection and dosing module 2.2/2.5 (12); - a SCR catalytic converter (2); - three exhaust gas temperature sensors (1): one at the DOC catalytic converter inlet (6), one after the DPF catalytic converter (5) and the other on the exhaust gas outlet pipe from the catalytic converter (2); - one humidity detection sensor fitted on the engine air inlet pipe downstream of the air filter; - two nitrogen oxide (NOx) detection sensors (3) fitted upstream and downstream of the catalytic converter; - one ammonia (NH3) detection sensor (4) at the exhaust gas outlet. To restrict the emissions in the exhaust to within the limits prescribed by legal regulations, an exhaust gas post-treatment system (ATS) has been adopted combining two devices: - a catalytic converter/particulate filter for the treatment of the HC (unburnt hydrocarbons), the CO (Carbon monoxide) and the particulate; - The DeNOx 2.2 device for the treatment of NOx (nitrogen oxide). The ATS system is controlled electronically by the EDC17CV41 control unit which on the basis of the engine rpm, torque delivered, the exhaust temperature, the quantity of nitrogen oxides and the intake air humidity, adjusts the flow rate of the AdBlue solution to be introduced into the system. The pump module picks up the reagent solution from the tank and sends it under pressure to the mixing and injection module to be injected into the exhaust pipe.

Print P1D32N021 E

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

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Figure 37

180401

1. NOx upstream of catalytic converter - 2. Differential pressure sensor - 3. Dosing module 2.2/2.5 - 4. NOx downstream of catalytic converter - 5. NH3 sensor - 6. SCR catalytic converter outlet temperature sensor - 7. SCR catalytic converter 8. SCR catalytic converter inlet temperature sensor - 9. DPF catalytic converter - 10. DOC catalytic converter - 11. DPF catalytic converter inlet temperature sensor. In the first stage the exhaust gases leaving the turbine encounter the catalytic converter DOC (10) in which the hydrocarbons (HC) and carbon monoxide (CO) are transformed, through oxidation reactions, into carbon dioxide (CO2) and water (H2O). Subsequently the exhaust gases pass through the DPF particulate filter (9) which holds back the carbonaceous particles forming the particulate. In order for the system to remain efficient, it needs to be regenerated and for this purpose there is a differential pressure sensor (2) which, by detecting the difference in input and outlet pressure is able to provide the control unit with an index for the clogging of the filter. The particulate filter regeneration is performed through the Exhaust Flap device to choke the outlet section of the exhaust gas from the turbine creating a dummy load to the engine. This way the exhaust gases reach the filter at a high temperature and the particles of the particulate burn keeping the filter clean. In the second phase the dosing module (3), through an injector placed in the exhaust pipe upstream of the SCR catalytic converter (7), introduces a solution of water and urea (AdBlue) into the exhaust gas. The first stage of the process takes place in the first part of the SCR catalytic converter: due to the effect of the exhaust gas temperature, the reagent solution evaporates instantly and is hydrolysed to ammonia (2NH3) and carbon dioxide (CO2); at the same time, the solution evaporates lowering the exhaust gas temperature to levels close to the optimum temperature required for the process. Exhaust gases containing ammonia at the temperature required for the reaction enter the SCR catalytic converter (7), where the second stage of the process takes place: by reacting with the oxygen in the exhaust gas the ammonia is converted into free nitrogen (N2) and water vapour (H2O). The Clean Up Catalyst (CUC) is in the end section of the catalytic converter and serves to oxidise the excess urea produced by the engine in the transient operating phases. The amount of AdBlue injected is controlled through a NH3 sensor (5) fitted on the outlet pipe of the silencer, which detects the presence of ammonia in the exhaust gas and sends a signal to the engine management control unit thereby providing a feedback signal. The engine control unit, on the basis of the engine rpm, torque, exhaust gas temperature, intake air humidity, amount of nitrogen oxide and the amount of urea present in the exhaust gas, detected by the respective sensors, regulates the flow of AdBlue to be injected into the system.

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

31

ATS system heating/cooling system The system has two functions: - continuous cooling of the dosing module; - heating the AdBlue tank, the supply module and the AdBlue pipes. 3-WAYS DIVERTER VALVE VERSION Figure 38 HEATING AND COOLING CONDITION A. ATS System cooling/heating circuit B. AdBlue C. Coolant circuit 1. 3-ways diverter valve version 2. AdBlue tank 3. Supply module filter 4. Supply Module 5. Dosing Module 2.2/2.5 6. Catalyst

227481

2-WAYS DIVERTER VALVE VERSION Figure 39 HEATING AND COOLING CONDITION A. ATS System cooling/heating circuit B. AdBlue C. Coolant circuit 1. 2-ways diverter valve version 2. AdBlue tank 3. Supply module filter 4. Supply Module 5. Dosing Module 2.2/2.5 6. Catalyst

204280

The system is equipped with a heating circuit to adjust the temperature of AdBlue and avoid incurring the risk of freezing (AdBlue freezes at -11˚C.). The diverter valve allows the passage of a part of the engine coolant in the coil inside the AdBlue tank and subsequently inside the supply module. The system heats pipes and tank when engine is started; AdBlue metering is engaged only when the system is free of ice. The dosing module, given its unfavourable assembly position from a cooling point of view and given the high temperatures reached by the exhaust gases downstream of the catalytic converter, is connected to the engine cooling circuit and continuously cooled.

Print P1D32N021 E

Base - March 2015

32

SECTION 2 - OPERATING DIAGRAMS

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MAIN COMPONENTS OF ATS SYSTEM Tank Figure 40

204272

The tank with the level indicator command (1) contains the reducing substance comprising a solution of 35% urea and water, known as AdBlue. There is a gauze filter on the filler (2).

AdBlue fluid level gauge control Figure 41

116181

1. AdBlue liquid delivery pipe - 2. AdBlue liquid return pipe - 3. Engine cooling hot liquid inlet pipe 4. AdBlue temperature sensor (NTC) - 5. Engine cooling hot liquid outlet pipe - 6. Float (level sensor) 7. AdBlue liquid heating coil - 8. AdBlue breather. The indicator control for the AdBlue liquid level is a device consisting of: - a float (level sensor); - an NTC temperature sensor; - a coil for heating the liquid in low temperatures. It informs the ECU of changes in the current due to the resistance, caused by the position of the float in relation to the level of the AdBlue liquid. Base - March 2015

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NEF SERIES EURO VI

33

SECTION 2 - OPERATING DIAGRAMS

DeNOx 2.2 supply module (SM - Supply Module) Figure 42

185025

1. Main filter - 2. Electric connector - 3. Pressure compensation diaphragm - 4. Feed pipe from tank 5. Pump module heating liquid inlet pipe - 6. AdBlue return pipe to tank - 7. Pump module heating liquid outlet pipe 8. Delivery line to dosing module The AdBlue supply module consists mainly of a diaphragm pump which takes up the AdBlue from the tank and sends it to the dosing module. It is equipped with a circuit connected to the engine cooling system which, in low temperatures, stops the AdBlue from freezing. Inside there is a pressure sensor. The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and are dependent on the operating conditions of the engine and from the signals sent by the sensors. Figure 43

185029

1. Engine coolant connector - 2. AdBlue inlet from tank - 3. AdBlue return to tank 4. AdBlue outlet to dosing module - 5. Pressure sensor - 6. Filter - 7. Diaphragm pump - 8. Valve 4/2. To prevent any damage to the pump and the dosing module, the supply module contains a filter which cleans the AdBlue of any impurities. Refer to the procedure described below to replace the filter.

Print P1D32N021 E

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Filter removal

Figure 47

Figure 44

185430 185435

- On the basis of the colour of the filter, insert the correct part of the tool (1) into the filter

NOTE During installation of the supply module, bear in mind the minimum clearance for replacing the filter. The minimum measurement is approximately 155 mm.

Figure 48

Figure 45

185431

- Insert the specific tool (1) until a click is heard indicating that the filter (2) has been completely engaged. 185428

- Unscrew and remove the filter cover (1). Figure 49 Figure 46

185432

185429

- Remove the compensation element (1).

Base - March 2015

- Remove the filter (1).

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

Filter assembly

35

Figure 53

Figure 50

185428 185433

- Thoroughly clean the contact surface (1) with water.

- Thoroughly clean the filter cover (1). - Screw on the filter cover and tighten to a torque of 20 ± 5 Nm.

Figure 51 Figure 54

185434

- Moisten the gaskets and insert the new filter (1). 185435

Figure 52 NOTE During installation of the supply module, bear in mind the minimum clearance for replacing the filter. The minimum measurement is approximately 155 mm.

185429

- Insert the new compensation element (1).

NOTE Make sure that the filter cover and the contact surface of the supply module show no signs of being cracked or damaged. If they do, replace the damaged components.

Print P1D32N021 E

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

DeNOx 2.5 dosing module (DM - Dosing Module)

Figure 55

Figure 56 2. 2 version

2.5 version

227499

193974

1. Power connection - 2. AdBlue inlet - 3. Coolant inlet/outlet.

The dosing module is controlled by the engine control unit. Its function is to dose the AdBlue to be injected into the exhaust pipe upstream of the SCR catalytic converter. It is fitted on the catalytic converter and while in operation it is subject to high temperatures. For this reason it is connected to the engine cooling circuit by means of the pipes (3). Maximum AdBlue injection pressure: 9 bar. DM 2.5 is based on DM 2.2 with improved cooling design. For DM 2.5 the limit for max. ambient temperature was increased to 140˚C with adjusted useful lifetime (DM 2.2 max. ambient temperature 120˚C). This requires the usage of components with increased temperature robustness. Benefits: - Dosing Module can be mounted closer to exhaust gas flow - High lifetime due to low thermal stress - Robustness against high exhaust gas temperatures

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

37

Diverter valve Figure 57

Figure 58

3-WAYS DIVERTER VALVE VERSION

2-WAYS DIVERTER VALVE VERSION

227483

1. Engine coolant pipe - 2. Dosing module coolant pipe 3. AdBlue tank heating fluid pipe - 4. Electrical connector

227482

1. Engine coolant pipe - 2. AdBlue tank heating fluid pipe 3. Electrical connector

The diverter is a 2-position 2-way/3-way solenoid valve heats the AdBlue tank and pipes with the engine coolant. Depending on the temperatures detected by the NTC sensor, the switch valve closes or opens the passage of the engine coolant into the AdBlue tank heating coil. The cooling circuit of the dosing module instead always stays open. The first position, in fact, allows the cooling of the Dosing Module (DM) whereas the second position allows the heating of the AdBlue tank, the Supply Module (SM) and the relevant pipes, besides cooling the DM.

Print P1D32N021 E

Base - March 2015

38

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

NH3 sensor Figure 59

185027

The NH3 sensor is connected to the engine management control unit and by detecting the amount of ammonia (NH3) present in the exhaust gas leaving the catalytic converter it allows an exact adjustment of the amount of AdBlue to be injected. Figure 60

185028

A. Vehicle side connector - B. Sensor side connector. 101. Power supply - 102. CAN LINE H - 103. CAN LINE L - 104. Ground. NH3 SENSOR CHARACTERISTICS Operating voltage Average current Peak current Operating limit values Tightening torque: 50 ± 10 Nm Base - March 2015

NOMINAL 10 to 32 V 1.2 A 4.0 A -40 to 105 ˚C

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NEF SERIES EURO VI

39

SECTION 2 - OPERATING DIAGRAMS

Nitrogen oxide detecting sensor Figure 61

102302

1. Positive - 2. Ground connection - 3. CAN LINE L - 4. CAN LINE H - 5. Spare The NOx sensor detects the amount of nitrogen oxide present in the exhaust gas entering and leaving the catalytic converter. On the basis of this information the engine control unit adjusts the amount of AdBlue to be injected and also measures the efficiency of the catalytic converters.

NOx SENSOR CHARACTERISTICS Ambient temperature: Cable temperature: Tightening torque: 50 ± 10 Nm Print P1D32N021 E

NOMINAL - 40 to +105 ˚C (+105 to +115 ˚C allowed for 10 min) 230 ˚C allowed for 100 h

Base - March 2015

40

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Exhaust gas temperature sensor Figure 62

102303

Figure 63

102304

FUNCTIONAL WIRING DIAGRAM 1. Supply voltage - 2. Variable power voltage at output - 3. Connector - 4. Grey signal cable - 5. White ground cable 6. Sensor It has the function of sending information to the control unit regarding the temperature of the exhaust gas entering and exiting the catalyst that is necessary for calculating the amount of urea to inject in the system. EXHAUST GAS TEMPERATURE SENSOR CHARACTERISTICS Power supply Voltage at a temperature -40 to 1.000 ˚C Pull-up resistance Cable resistance Tightening torque: 45 ± 4.5 Nm Base - March 2015

NOMINAL 5.00 V ± 0.1% 0.727 to 2.297 V 1,000  ± 0.1% 1

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

41

Temperature and humidity sensor Figure 64

125531

1. Power supply - 2. Percentage of humidity - 3. Ground - 4. Temperature This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to the ECU These data are used by the ECU to determine the level of nitrogen oxide emissions. Figure 65

102312

ELECTRIC BLOCK DIAGRAM 1. Power supply unit - 2. Percentage of humidity - 3. Ground - 4. Temperature - A. Sample frequency generator B. Reference oscillator - C. NTC temperature sensor - D. Low pass amplifier filter HUMIDITY SENSOR SPECIFICATIONS Supply voltage Current absorption Operating range Output impedance Insulating resistance TEMPERATURE SENSOR SPECIFICATIONS Operating range Resistance at 25 ˚C Maximum power at 25 ˚C Tightening torque: 14.5 ± 2.5 Nm Print P1D32N021 E

NOMINAL 5.00 ± 0.25 VDC 10 mA 0% RH to 100% RH 70 ohms 1 Mohm @ 500 V NOMINAL -40 to 125 ˚C NTC 2,186 kohms ± 1% 100 mW

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Catalytic converter Figure 66

204271

The catalytic converter consists of 2 main parts: - the first stage is made up of a DOC catalytic converter followed by a DPF catalytic converter in which the exhaust gas is cleaned of the HC (unburnt hydrocarbons), CO (carbon monoxide) and the particulate; - the second stage is made up of a SCR catalytic converter, upstream of which is the AdBlue dosing module; the reactions to reduce the NOx (nitrogen oxide) takes place in this catalytic converter.

Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

43

Differential pressure sensor The differential pressure sensor (1), connected downstream and upstream of the DPF particulate filter, measures the corresponding difference in pressure.

Figure 67

192083

This difference in pressure is converted into a voltage signal sent to the engine management control unit and consists of a clogging index of the DPF particulate filter.

Print P1D32N021 E

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

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SCHEDULED MAINTENANCE FOR ATS SYSTEM Below are indicated the checks, tests and adjustments which are to be carried out on the components of the ATS system at the established time interval. The frequency of the operations are indicative since the engine use and its characteristics are essential in evaluating replacements and checks. Not only it is permitted, but it is also recommended that the staff in charge of maintenance also perform those checking and maintenance operations which may not be included in the list below but which are recommended by good-practices and particular conditions of use of the engine. Furthermore, in case of clear malfunctioning of the system, prompt measures must be taken to verify the causes of the defect. Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with accident-prevention laws for the safety of the staff in charge of maintenance. Periodic maintenance Component Tank Neck Filter (300 or 100 m) Tank Breather Filter (5/10* m)

Maintenance and interval No regular service planned (Cleaning, if required) No regular service planned (Cleaning, if required)

SM Pre-Filter (100 or 70* m) SM Inlet-Filter (100 m) SM Main-Filter SM Backflow-Filter (100 m) Dosing Valve Filter (36 m)

Cleaning with water @ every oil change interval No regular service planned (Replacement, if required) Change every 3.600 hours or 2 years (whichever occurs first) No regular service planned (Replacement, if required) Not serviceable

*

for application working in dusty environment only.

Extraordinary maintenance Maintenance and interval

Component Service regeneration AdBlue change in the urea tank

150 hours (**) 6 months

DPF filter replacement

Once clogging signals require the substitution

**

to be performed every six months even if the specified operating hours interval has not been reached. Figure 68

227505

ATS SYSTEM FILTER LOCATION 1. Dosing valve filter (36 m) - 2. Dosing module - 3. Supply module main-filter - 4. Supply module backflow-filter (100 m) - 5. Supply module pre-filter (100 or 70* m) - 6. Tank breather filter (5/10* m) - 7. AdBlue tank 8. Tank neck filter (300 or 100* m) - 9. Supply module inlet-filter (100 m) - 10. Supply module * for application working in dusty environment only Base - March 2015

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

REPLACING THE DPF (DIESEL PARTICULATE FILTER) CATALYTIC CONVERTER

45

Figure 71

(Demonstrative figures)

Removing the DPF catalytic converter Figure 69

203464

- Remove the cover (1). 204283

- Unscrew the screws (1) and remove the guards that are on the catalytic converter.

!

Figure 70

The weight of the cover (1) is ~ 8.3 kg.

Figure 72

204284

- Undo the screws (1) fixing the cover (2).

204285

- Remove and scrap the cage nuts (2).

!

Print P1D32N021 E

Pay maximum attention to sharp edges (1); when removing DPF catalytic converter always wear protective gloves.

Base - March 2015

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SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Figure 73

Figure 75

204286

NOTE

Mark axial position of flat band clamp (1) on cone with marker pen (minimum 120˚ of circumference).

204287

- Loosen the screws (2) and move the flat band clamp (1) approx. 60 mm in the direction indicated by the arrow (). NOTE

Once the flat band clamp (1) has been removed it must not be reused but replaced.

NOTE

During the removal of the screws, pay close attention in order to prevent the screws removed drop inside the ATS system.

Figure 74

Figure 76

204288

- Loosen the V-Clamp (2) by turning the screws (1) and (3) at the same time and remove it. NOTE

Once the V-Clamp (2) has been removed it must not be reused but replaced.

204289

- Remove the DPF catalytic converter (1) from its seat using a suitable lifting device. NOTE

During the removal of the screws, pay close attention in order to prevent the screws removed drop inside the ATS system.

Base - March 2015

!

The weight of the cover (1) is ~ 24 kg.

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SECTION 2 - OPERATING DIAGRAMS

47

Refitting the DPF catalytic converter

Figure 77

Figure 79

204295 204290

Pay maximum attention to sharp edges; always wear protective gloves.

!

- Remove the 2 pressure rings (1) from the catalytic converter and DPF. NOTE

1. Cover - 2. Flat band clamp - 3. DPF catalytic converter 4.Rings - 5. Gasket - 6. V-Clamp.

NOTE

All screws have to be tightened first by 3 revolutions by hand to avoid damage to threads and screws of ATS.

The pressure rings may be reused when refitting after they have been cleaned. One pressure ring stays on the DOC, second ring has to be switched to the new (cleaned) DPF.

Figure 80

Figure 78

204291

204291

- Remove the metal gasket (1). NOTE

Clean the sealing surfaces and make a visual inspection of the DOC.

Print P1D32N021 E

- Fit a new metal gasket (1) by clips (6x). The one previously removed may not be reused. - Clean and install the pressure rings that were previously removed in their seats on the DOC and the second ring has to be switched to the new (cleaned) DPF. - Install 8 new cage M8 nuts.

Base - March 2015

48

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Figure 81

Figure 84

203474 204292

- Insert a new flat band clamp (1) on the DPF catalytic converter (2).

Position of flat band clamp (1) according to marking with pen on cone.

!

Rotational positioning of DPF with label (2) showing to outside.

Figure 82

Figure 83

204293

204289

- Position the new DPF catalytic converter (1) in its seat.

!

The weight of the cover (1) is ~ 24 kg.

Base - March 2015

- Push the new flat band clamp (1) in the direction indicated by the arrow () until it reaches its correct position. NOTE

Sliding of new flat band clamp into the direction of the rolled cone until clamp hits the marking done with a pen.

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NEF SERIES EURO VI

SECTION 2 - OPERATING DIAGRAMS

Figure 85

49

Figure 86

204294

- Positioning the screw joints of V-clamp by using dimple in front system baffle (see detail A); 204296

- Install a new V-Clamp (5) and tighten screws by hand first; tighten in sequence the fixing screws (1) and (2) to the required torque.

- Positioning of screw joint of flat band clamp by using dimple in rear system baffle (see detail B).

Figure 87 Ref

No.

Description

Tightening torques

(1, 2)

2

1st phase 2nd phase

11 Nm 18 ± 1 Nm

- Tighten in sequence the screws (3) and (4) by hand first and then to the required torque. Ref

No.

Description

Tightening torques

(3, 4)

2

1st phase 2nd phase 3rd phase

25 Nm 35 Nm 42.5 ± 2.5 Nm

204285

NOTE

Open V-clamp completely on one side and slide it around DPF. Close screws (6) by hand first. - Check cage nuts (2).

Ref

No.

(2)

8

NOTE

! Print P1D32N021 E

Description M8

If nuts are lost, control of DPF chamber for loose parts and when required removal of those parts and replacement at accurate position.

Pay maximum attention to sharp edges (1); when installing DPF catalytic converter always wear protective gloves. Base - March 2015

50

SECTION 2 - OPERATING DIAGRAMS

NEF SERIES EURO VI

Figure 88

Figure 90

204283

203481

- Refit the guards on the silences and tighten the fixing screws (1) to the required torque.

- Refit the cover (1). Ref

No.

(1)

12

The weight of the cover (1) is ~ 8.3 kg.

!

Description

Tightening torques 14 ± 1.4 Nm

Figure 89

204284

- Tighten the screws (1) fixing cover (2) to the required torque.

Ref

No.

(1)

8

Base - March 2015

Description M8x25

Tightening torques 15 ± 1 Nm

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NEF SERIES EURO VI

SECTION 3 - ELECTRICAL EQUIPMENT

1

SECTION 3 Electrical equipment Page

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

3

ELECTRONIC CONTROL UNIT (EDC17CV41)

5

- EDC System functions . . . . . . . . . . . . . . . . . .

5

ENGINE SIDE ELECTRICAL WIRING . . . . . . . .

8

- Topographic view . . . . . . . . . . . . . . . . . . . . . .

8

- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

- ECU connection to the injection cable on engine side (housing A) . . . . . . . . . . . . . . .

10

VEHICLE SIDE ELECTRICAL WIRING . . . . . . . .

12

- ECU connection to the injection cable on vehicle side (housing B) . . . . . . . . . . . . . . .

12

MAIN ELECTRICAL/ELECTRONIC EQUIPMENT

14

- Camshaft timing segment speed sensor . . . . .

14

- Crankshaft rpm increment speed sensor . . . . .

15

- Boost pressure and air temperature sensor . .

16

- Engine oil pressure and temperature sensor . .

17

- Rail pressure sensor . . . . . . . . . . . . . . . . . . . .

18

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

19

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

21

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

22

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

25

- Electric starter motor . . . . . . . . . . . . . . . . . . .

26

- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Base - March 2015

2

SECTION 3 - ELECTRICAL EQUIPMENT

Base - March 2015

NEF SERIES EURO VI

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NEF SERIES EURO VI

SECTION 3 - ELECTRICAL EQUIPMENT

3

LOCATION OF THE MAIN ELECTRICAL COMPONENTS Figure 1

227536

1. Fuel high pressure pump metering unit - 2. Fuel temperature sensor - 3. Engine Control Unit EDC17CV41 4. Timing segment speed sensor (camshaft) - 5. Engine coolant temperature sensor - 6. Electro-injectors (CRIN2) 7. Rail pressure sensor (RDS) - 8. Boost pressure and air temperature sensor - 9. Rpm increment speed sensor (crankshaft)

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Base - March 2015

4

SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

Figure 2

227535

1. Engine oil pressure and temperature sensor - 2. Starter electric motor 3. Motorized throttle valve actuator connector (Exhaust flap) - 4. Alternator

Base - March 2015

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NEF SERIES EURO VI

SECTION 3 - ELECTRICAL EQUIPMENT

5

ELECTRONIC CONTROL UNIT (EDC17CV41) Figure 3

201724

A. Engine side connector - B. Vehicle side connector

The control unit is a ”flash EPROM” and so it can be reprogrammed from outside without manipulating the hardware. The ECU processes the signals from the sensors by applying software algorithms and controls the actuators (especially the electro-injectors and pressure regulator). It records, in the non-volatile memory area, the information on the engine parameters originally set or acquired during engine operation. The control unit is mounted on the left-hand side of the engine and two connectors are fitted, of which:

EDC System functions The EDC 17CV41 electronic center manages the following main functions:. - Fuel injection - Motorized throttle valve Self-diagnosis - Recovery - It also enables:

- a connector for the engine cable (injector and sensor connector);

- Interfacing with other electronic systems (if any) available on the vehicle.

- a connector for the chassis cable.

- Diagnosis

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Base - March 2015

6

SECTION 3 - ELECTRICAL EQUIPMENT

Fuel dosing Fuel dosing is calculated based on: - accelerator position - engine rpm - quantity of air admitted The result can be corrected based on: - fuel temperature (DIESEL DENSITY) - water temperature or to prevent: - noise - fumes - overloads - overheating. Pressure can be adjusted in case of: - motorized throttle valve actuation - serious defects involving load reduction or engine stop - ANTI-POLLUTION devices cutting in: NOx sensor, NH3 sensor. Once the control unit has determined the mass of the introduced air and measured its pressure and temperature, it calculates the corresponding fuel load needed to inject into the cylinder (mg. per delivery). It also takes diesel temperature into account (density). The fuel load calculated in this way is converted into crank degrees i.e. injectionadvance and duration Delivery correction based on water temperature When cold, the engine encounters greater operating resis tan ce, mechanical friction is high, oil is till very viscous and operating plays are not optimized yet. Fuel injected also tends to condense on cold metal surfaces. Fuel dosing with a cold engine is therefore greater than when hot. Delivery correction to prevent noise, fumes or overloads Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center to prevent them. De-rating In the event of engine overheating, decreasing delivery propor t ionally to the temperature reached by the coolant changes injection. The control unit uses the oil temperature reading in the ev ent of a coolant temperature sensor failure.

NEF SERIES EURO VI

Injection lead electronic control Injection lead, or the start of fuel delivery expressed in deg rees , can differ from one injection to the next, even from one cylinder to another and is calculated similarly to delivery acc ording to engine load, namely, accelerator position, engine rpm and air admitted. Lead is corrected as required: - during acceleration; - according to water temperature; and to obtain: - reduced emissions, noise abatement and no overload; - better vehicle acceleration. High injection lead is set at start, based on water temperature. Delivery start feedback is given by injection electro valve impedance variation. Engine speed limiter The control unit controls the engine speed at all revranges an d in particular: - at idle; - at top speed. Engine start Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator pedal signal is ignored at start. Start delivery is set exclusively based on water temperature, via a specific map. The center enables the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn by the starter motor. Cold starting Pre-post heating is activated when just one of the three sensors (water, air or fuel) registers a temperature lower than 5 ˚C. Upon activation of the key contact, the pre-heating warning light turns on the electronic dash-board and remains on for a variable amount of time depending on the temperature (while the heating element at the intake manifold heats the air), then it flashes. It is now possible to start up the engine. When the engine is running, the warning lamp goes out but the heater element continues working for a certain (variable) period of time for post-heating. If, with the warning lamp blinking, the engine is not started within 20÷25 seconds (absence time) the operation is cancelled in order not to discharge the batteries. The pre-heating curve is also variable in relation to the battery voltage.

Base - March 2015

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NEF SERIES EURO VI

Warm starting When the ignition key is inserted and the reference temperature exceeds 10 ˚C, a warning light turns on for approximately 2 seconds as a short test, then goes out. It is now possible to start up the engine. Run Up When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run), and diagnoses the system. After Run At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the microprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom) memory to make tem available for the next start (Cf. Run Up). These data essentially consists of: - miscellaneous settings, such as engine idling and the like; - settings of some components;

SECTION 3 - ELECTRICAL EQUIPMENT

7

Cut-off It refers to the supply cut-off function during deceleration. Cylinder Balancing Individual cylinder balancing contributes to increasing comfort and operability. This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between each cylinder, to compensate for injector hydraulic tolerances. The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This information is provided by the entry of the codes for every single injector, by means of the diagnosis instrument. Synchronization Search If the camshaft sensor signal fails, the control unit can still recognize the cylinders into which fuel is to be injected. If this takes place when the engine is already running, the fuel flow is already acquired as a result of which the ECU continues with the sequence already synchronized.

- breakdown memory.

If this occurs when the engine is off, the control unit energizes a single solenoid valve.

The process lasts for some seconds, typically from 2 to 60 according to the amount of data to be stored, after which the ECU sends a command to the main relay and makes it disconnect from the battery.

At the latest by the 2nd engine shaft revolution, an injection will occur in that cylinder, for which the central unit only has to synchronize itself on the combustion sequence and start the engine.

NOTE

This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before 60 seconds at least after engine cut-out.

In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown memory and the engine operates at lower performance at next start while the EDC warning light stays on. Repeated procedure interruptions could in fact lead to center damage.

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Base - March 2015

8

SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

ENGINE SIDE ELECTRICAL WIRING Topographic view Figure 4

227493

1. Electro-injector connector (cylinder 1-2) - 2. Electro-injector connector (cylinder 3-4) - 3. Boost pressure and air temperature sensor - 4. Timing segment speed sensor (camshaft) - 5. Motorized throttle valve actuator connector (Exhaust flap) - 6. Fuel temperature sensor - 7. Fuel high pressure pump metering unit (ZME) - 8. In line connector: signal for dashboard - 9. Engine connector EDC 96 pin - 10. Rpm increment speed sensor (crankshaft) - 11. Engine oil pressure and temperature sensor - 12. Rail pressure sensor (RDS4) - 13. Engine coolant temperature sensor

Base - March 2015

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Figure 5

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1. Engine connector EDC 96 pin - 2. Fuel temperature sensor - 3. Engine coolant temperature sensor - 4. Engine oil pressure and temperature sensor - 5. Boost pressure and air temperature sensor - 6. Motorized throttle valve actuator connector (Exhaust flap) - 7. In line connector: signal for dashboard - 8. Timing segment speed sensor (camshaft) - 9. Rpm increment speed sensor (crankshaft) - 10. Fuel high pressure pump metering unit (ZME) - 11. Rail pressure sensor (RDS4) 12. Electro-injector (cylinder 4) - 13. Electro-injector (cylinder 3) - 14. Electro-injector (cylinder 2) - 15. Electro-injector (cylinder 1) - E1. Electro-injector connector (cylinder 1-2) - E2. Electro-injector connector (cylinder 3-4)

NEF SERIES EURO VI SECTION 3 - ELECTRICAL EQUIPMENT

9

Diagram

221356

Base - March 2015

10

SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

ECU connection to the injection cable on engine side (housing A) Pin ECU 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 Base - March 2015

Function Electro-injector cylinder 3 Electro-injector cylinder 2 Engine oil pressure and temperature sensor ground Boost pressure and air temperature sensor power supply

Rail pressure sensor power supply Fuel temperature sensor ground Engine oil pressure and temperature sensor NTC Motorised throttle valve actuator connector - Exhaust flap: CAN H Motorised throttle valve actuator connector - Exhaust flap: CAN L Electro-injector cylinder 3 Electro-injector cylinder 2 Engine oil pressure and temperature sensor power supply Engine oil pressure and temperature sensor pressure signal Rail pressure sensor signal Boost pressure and air temperature sensor NTC Coolant temperature sensor ground Electro-injector cylinder 1 Electro-injector cylinder 4 Print P1D32N021 E

NEF SERIES EURO VI

Pin ECU 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96

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SECTION 3 - ELECTRICAL EQUIPMENT

11

Function Fuel pressure regulator on HP pump Coolant/fuel temperature sensor NTC Rail pressure sensor ground Rpm sensor ground Rpm sensor signal Timing sensor ground Timing sensor signal Timing and rpm sensor shield Electro-injector cylinder 1 Electro-injector cylinder 4 Fuel pressure regulator on HP pump Boost pressure and air temperature sensor pressure signal Boost pressure and air temperature sensor ground -

Base - March 2015

12

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NEF SERIES EURO VI

VEHICLE SIDE ELECTRICAL WIRING ECU connection to the injection cable on vehicle side (housing B) Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Base - March 2015

Function V1 W1 W1 SCR pressure sensor SCR tank level & temperature sensor SCR downstream exhaust gas temperature sensor (T7) W4 Engine compartment stop switch Water in fuel switch Humidity sensor with ambient temperature sensor Exhaust gas temperature upstream sensor ATS Intelligent sensor auxiliary relay DEF dosing module V1 V1 Fuel filter/pre-filter heating relay W1 SCR tank level &temperature sensor SCR upstream exhaust gas temperature sensor (T6) Engine speed for speedometer Engine compartment starter switch W5 Humidity sensor with ambient temperature sensor W3 ODB Led ATS Intelligen sensor auxiliary relay Diagnostic connector CAN High Diagnostic connector CAN Low V1 V3 W1 DPF delta pressure sensor -

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NEF SERIES EURO VI

SECTION 3 - ELECTRICAL EQUIPMENT

Ref. 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96

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13

Function Fuel filter/pre-filter heating relay SCR pressure sensor K15 K-line (flash programming UDS) Controller Area Network 1 (High) SCR tank heating valve V1 V2 W1 Grid heater relay SCR pump motor SCR reverting valve SCR pump motor VS Controller Area Network 1 (Low) DEF dosing module

Base - March 2015

14

SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

MAIN ELECTRICAL/ELECTRONIC EQUIPMENT Camshaft timing segment speed sensor The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal. Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape. The timing sensor is connected to the control unit on pins 67A - 68A - 69A. The sensor impedance is 900 . Figure 6

209186

Figure 7

Figure 8

183652

Connector

CAMSHAFT TIMING SEGMENT SPEED SENSOR PIN OUT Description Ref. 1 Ground 2 NTC 3 Shield

Base - March 2015

50288

Wiring diagram

ECU Pin 67A 68A 69A

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NEF SERIES EURO VI

15

SECTION 3 - ELECTRICAL EQUIPMENT

Crankshaft rpm increment speed sensor The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft. The crankshaft sensor is connected to the control unit on pins 65A - 66A - 69A. The sensor impedance is 900 .

Figure 9

50319

Figure 10

Figure 11

183652

Connector

CRANKSHAFT RPM INCREMENT SPEED SENSOR PIN OUT Description Ref. 1 Ground 2 NTC 3 Shield

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50288

Wiring diagram

ECU Pin 65A 66A 69A

Base - March 2015

16

SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

Boost pressure and air temperature sensor This component incorporates a temperature sensor and a pressure sensor. Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle. The sensor is connected to the control unit on pins 90A - 37A - 07A - 86A. The power supply is 5 Volt Voltage at the sensor output is proportional to the detected pressure or temperature. Pin 37A Pin 86A

Temperature signal Pressure signal

Figure 12

Figure 13

213601

227491

SIGNAL EVALUATION WITH LOAD RESISTOR TO UH = 5.5 TO 16V

TECHNICAL DATA Pressure range Temperature range Supply voltage BOOST PRESSURE AND AIR TEMPERATURE SENSOR PIN OUT Description Ref. 1 Ground 2 NTC signal (temperature) 3 +5 V power input 4 Signal (pressure)

Base - March 2015

50 to 400 kPa -40 to 130 ˚C 4.75 to 5.25 V

ECU Pin 90A 37A 07A 86A

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NEF SERIES EURO VI

SECTION 3 - ELECTRICAL EQUIPMENT

17

Engine oil pressure and temperature sensor The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position. This sensor measures the engine oil temperature and pressure. The sensor is connected to the control unit on pins 06A - 13A - 31A - 35A. The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light). The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit. Pin 13A Pin 35A

Temperature signal Pressure signal

Figure 14

Figure 15

1 2 3 PRESSURE SENSOR

213602

4

190518

Wiring diagram

ENGINE OIL PRESSURE AND TEMPERATURE SENSOR PIN OUT Description Ref. 1 Ground 2 NTC signal (temperature) 3 +5 V power input 4 Signal (pressure) Print P1D32N021 E

ECU Pin 06A 13A 31A 35A Base - March 2015

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SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

Rail pressure sensor Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command. This sensor is connected to the control unit on pins 60A - 36A - 11A. The power supply is 5 Volt. Figure 16

201030

RAIL PRESSURE SENSOR PIN OUT Ref. 1 Ground 2 Signal 3 Power supply

Base - March 2015

Description

ECU pin 60A 36A 11A

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NEF SERIES EURO VI

SECTION 3 - ELECTRICAL EQUIPMENT

19

Coolant temperature sensor It is a N.T.C. sensor located on the head water output manifold on the engine left side. It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies the need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot. This sensor is connected to the control unit on pins 39A - 59A. The impedance of the coolant temperature sensor at 20 C is approximately 2.50 .

Figure 17

Figure 18

213603

COOLANT TEMPERATURE SENSOR PIN OUT Description Ref. 1 Ground 2 NTC signal (temperature)

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107798

ECU Pin 39A 59A

Base - March 2015

20

SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

Fuel temperature sensor This sensor is identical to the coolant temperature sensor. It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery. The fuel temperature sensor is connected to the control unit on pins 12A - 59A. The sensor impedance at 20 C is approximately 2.50 .

Figure 19

Figure 20

107798

213603

Connector

FUEL TEMPERATURE SENSOR PIN OUT Description Ref. 1 Ground 2 NTC signal (temperature)

Base - March 2015

ECU Pin 12A 59A

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NEF SERIES EURO VI

SECTION 3 - ELECTRICAL EQUIPMENT

Pressure regulator - high pressure pump

21

Figure 21

Pump with 3 radial pistons controlled by the timing gears, requiring no timing adjustment, with rotor type feed pump fitted to the back. A. Connection between fuel discharge outlet and filter housing 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 (NO solenoid valve regulated by the control unit by means of PWM signal).

Situated at the inlet of the high pressure pump on the low pressure system, this device adjusts the quantity of fuel reaching the high pressure pump on the basis of the commands received from the electronic control unit. It mainly consists of the following parts: - tapered shutter; - valve control pin; - pre-load spring; - coils. In the absence of a control signal, the pressure regulator is normally open, and thus the high pressure pump is in maximum delivery mode. The ECU regulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying fuel to the high pressure pump. This component cannot be replaced individually and thus should not be dismantled.

A 1

2

B C 3 D E

The amount of fuel feeding the high pressure pump is metered by a proportional valve on the low pressure system managed by the engine management control unit. The delivery pressure to the rail is regulate between 250 and 1400 bar by the ECU acting on the pressure regulator solenoid valve.

000912t

It is a N.O. solenoid valve. Its resistance is approximately 3.2 . PRESSURE REGULATOR PIN OUT ECU Pin Ref Description 1 Supply 58A 2 Signal 83A

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Base - March 2015

22

SECTION 3 - ELECTRICAL EQUIPMENT

Electro-injectors

NEF SERIES EURO VI

Figure 22

The electro-injector essentially consists of two parts: - an actuator - spray nozzle consisting of a pressure rod 1, a needle 2 and a nozzle 3; - driving solenoid valve made up of coil 4 and pilot valve 5. The solenoid valve checks the lift of the nozzle needle.

50336

Beginning of injection When the coil (4) is energised, it makes the shutter (6) move upwards. The control volume fuel 9 flows back towards the backflow duct 12 resulting in a drop in pressure in the control volume 9.

Figure 23

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

End of injection When power to the coil 4 is cut off, the shutter 6 closes again so as to re-create a balance of forces which moves the needle 2 back into its closed position and stops the injection process.

This is an N.O. solenoid valve. They are individually connected to the engine management control unit on connector A. The resistance of the coil of each individual injector is 0.56 to 0.57 .

000933t

INJECTOR 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 pipe 11. Supply pipe - 12. Control fuel outlet 13. Power connection - 14. Spring.

Base - March 2015

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NEF SERIES EURO VI

23

SECTION 3 - ELECTRICAL EQUIPMENT

Connection connectors Figure 24

171595

Wiring diagram Figure 25

171596

ELECTRO-INJECTORS PIN OUT Ref.

CONNECTOR 1

CONNECTOR 2

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1 2 3 4 1 2 3 4

Description

Control unit pin

Cylinder 2 injector Cylinder 2 injector Cylinder 1 injector Cylinder 1 injector Cylinder 4 injector Cylinder 4 injector Cylinder 3 injector Cylinder 3 injector

02 26 73 49 50 74 25 01

Base - March 2015

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SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

Motorized throttle valve actuator connector (Exhaust flap) Figure 26

221555

MOTORIZED THROTTLE VALVE ACTUATOR CONNECTOR PIN OUT Ref. 1 2 3 4

Base - March 2015

Description V Bat Ground Can low Can high

18A 17A

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NEF SERIES EURO VI

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SECTION 3 - ELECTRICAL EQUIPMENT

Fuel pre-filter 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.

Resistance control remote control switch The remote control switch is connected to the EDC control unit. It is activated when the temperature of the water or the diesel oil exceeds 5 C. The remote control switch coil resistance is about 15 .

Figure 28

C

!

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.

Figure 27

1

50325

C. Remote control switch

2

5

3

4

000910t

Tightening torque Bleed screw 2 Filtering cartridge 3 Sensor 4

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6 to 8 Nm 18 ± 0.1 Nm 0.8 ± 0.1 Nm

Base - March 2015

26

SECTION 3 - ELECTRICAL EQUIPMENT

NEF SERIES EURO VI

Electric starter motor Figure 29

227488

Figure 30

Figure 31

227489

227490

WIRING DIAGRAM EW: HW:

Pull-in winding Hold-on winding

The starter motor runs the engine, gaining its inertia and friction, and bringing it to a certain number of revolutions such as to initiate the formation of the mixture required for combustion and then the autonomous movement of the engine. The movement is transmitted by a DC electric motor, powered by the battery, via an engagement pinion which rotates the sprocket formed on the engine flywheel. Due to a free wheel engagement, the pinion turns off when the main engine rotates faster than the starter motor. A relay energized by the current of the starter motor engages the pinion by means of a fork. The starter motor included is a translation type and starts by means of the pinion, with relay housed directly above the starter motor. Ignition is usually controlled via the ignition switch on the control panel and provides a positive voltage to the relay located on the starter motor. Specifications: Type: BOSCH HX87-M Nominal voltage: 24 V Nominal rated power: 4 kW Number of poles: 4 Direction of rotation: clockwise (seen from flywheel side) Battery capacity: min. 44 Ah - Max. 110 Ah Discharge current (DIN 43539): min. 210 A - Max. 450 A

Base - March 2015

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SECTION 3 - ELECTRICAL EQUIPMENT

27

Alternator Figure 32

227492

Figure 33

215010

Figure 34

215008

It is frontally located on the right-hand side of the engine and is controlled by the auxiliary assembly belt. Specifications: Type: Nominal voltage: Nominal rated current:

BOSCH NCB2 28 V 90 A @ 6.000 rpm

Stand-by current consumption: Maximum continuous rotation velocity: Operating temperature range: Direction of rotation:

≤ 1mA ≤ 12,000 min-1 -40 ˚C to +110 ˚C clockwise

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SECTION 3 - ELECTRICAL EQUIPMENT

Base - March 2015

NEF SERIES EURO VI

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NEF SERIES EURO VI

SECTION 4 - SCHEDULED MAINTENANCE

1

SECTION 4 Scheduled Maintenance Page

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

3

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

3

- Planning of checks and periodical interventions

3

- Checks not included in maintenance planning

4

CHECKS AND PERIODICAL INTERVENTIONS

5

- Controls (when in use) . . . . . . . . . . . . . . . . . .

5

- Periodic maintenance . . . . . . . . . . . . . . . . . . .

8

- Extraordinary maintenance . . . . . . . . . . . . . . .

11

Base - March 2015

2

SECTION 4 - SCHEDULED MAINTENANCE

Base - March 2015

NEF SERIES EURO VI

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NEF SERIES EURO VI

SECTION 4 - SCHEDULED MAINTENANCE

3

MAINTENANCE PLANNING Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run. In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure, immediately intervene in order to find the causes. We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident prevention standards for the safety of maintenance personnel in charge.

Planning of checks and periodical interventions Checks (when in use) Action

Frequency 50 hours Daily Daily 150 hours (1) Defined by vehicle 600 hours 6 months 1 year Only in case of anomaly

Visual inspection of engine Check engine lubricant oil level Check engine coolant level Drain water from fuel pre-filter Check/top up electrolyte level in batteries Check auxiliary drive belt condition Check condition of the exhaust duct(s) Check coolant density Engine EDC system check-up by diagnostic tool Periodic maintenance Action Change engine lubricant oil Change oil filter Change fuel filter Change fuel pre-filter (not supplied by FPT) Change blow-by filter Change air filter and clean housing (not supplied by FPT) (**) Clean the air filter (not supplied by FPT) Change engine coolant Extraordinary maintenance Action Turbocharger visual inspection Adjustment valves/rocker arms clearance Change auxiliary drive belt

Frequency 600 hours (2)(3) 600 hours (2)(3)(4) 600 hours (1)(4)(5) 600 hours (1)(5) 1200 hours (2) 1200 hours 600 hours 2 years Frequency 1200 hours 2400 hours 2400 hours

(**)Early air filter clogging is usually due to environmental conditions. For this reason, the filter should be changed if clogging is signalled by the related sensor, regardless of the prescriptions that shall be observed if no specific indications have been provided. 1) Maximum period relative to the use of high quality fuel, (specification ASTM D975 or EN 590); this is reduced based on fuel contamination and the alarm signals due to filter clogging and/or the presence ofwater in the pre-filter. The filter clogging signal indicates that the filter must be replaced. If the signal of water present in the pre-filter does not turn off after drainage, the filter must be replaced. 2) Perform every year even if the specified operating hour interval is not reached. 3) Frequency applicable for lubricants which meet the international standards ACEA E9 API CJ-4 / SAE 10W-40 / ACEA E6 SAE 5W-30, as indicated in the REFILLING table. 4) Only use filters with the following specifications: - degree of filtering < 12 m - filtering efficiency 99.5% (ß > 200). 5) Perform every two years even if the specified operating hour interval is not reached. Print P1D32N021 E

Base - March 2015

4

SECTION 4 - SCHEDULED MAINTENANCE

NEF SERIES EURO VI

NOTE

The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by FPT. 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.

NOTE

The extraordinary maintenance operations described in the relative table are under exclusive responsibility of qualified personnel in possession of suitable technical information and equipped with suitable work tools and protective devices.

!

Checks, inspections and changes are indicative and must integrate specifications for vehicles equipped with the NEF EURO VI engine. The data are only valid if the fitter observes all the installation regulations provided by FPT.

Checks not included in maintenance planning 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.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

CHECKS AND PERIODICAL INTERVENTIONS

SECTION 4 - SCHEDULED MAINTENANCE

5

Check engine lubricant oil level Figure 1

Checks (when in use) Visual inspection of engine Before starting, it is recommended to carry out a series of simple checks that can significantly help avoid problems, also of a series nature, while the engine is operating. These checks are usually performed by the vehicle operators and drivers. - Check the levels and check for any leaks from the fuel, cooling and lubrication circuits. - Inform maintenance personnel if any problems are found; top up if necessary. After starting the engine and with the engine operating, perform the following checks and controls: - Check for any leaks from the fuel, cooling and lubrication circuits. - Make sure there is no unusual noise or beating during operation. - Use the vehicle instruments to check the foreseen pressure, temperature values, etc. - Visually check the smoke (colour of the exhaust gas). - Visually check the level of the coolant in the expansion tank.

227485

The check must be performed when the engine is stopped and possibly cold. The check is carried out with the flexible dipstick (2). Remove the dipstick (2) from its housing and check that the level is between the minimum and maximum ends etched on it. If the reading is unclear, clean the dipstick (2) with a cloth with no looses threads and put it back in its seat. Take it off again and check the level. If the level is insufficient, it is necessary to top up with lubricant oil which meets the international specifications API CJ-4 / ACEA E9-E6, as indicated in the REFILLING table: remove the lubricant oil cap (1) and pour engine lubricant oil through the hole. Always make sure to add oil with the same characteristics as the one contained in the sump. Mixtures which do not ensure the proper lubrication of the internal parts of the engine are not permitted.

!

Print P1D32N021 E

The engine oil is highly pollutant and toxic. In case of contact with skin, wash thoroughly with water and detergent. Suitably protect skin and eyes; proceed in accordance with accident prevention standards. Suitably dispose of the residuals and in accordance with regulations.

Base - March 2015

6

SECTION 4 - SCHEDULED MAINTENANCE

Check engine coolant level Proceed only with engine not running and at low temperature to avoid any risk of burns. - With the engine at low temperature, make sure that the fluid level in the expansion tank is above the minimum level.

NEF SERIES EURO VI

Drain water from fuel pre-filter (Component not supplied by FPT) The high risk of refuelling with fuel that is polluted by foreign bodies and water makes it advisable to carry out this control every time you refuel. Figure 2

- Visually check that the fluid level is not more than 2/3 of the height of the tank in order to enable any increase in volume of the fluid caused by the temperature increase. - Top up the tank if necessary, using clean water. Do not use distilled water; see the REFILLING section. NOTE

If the refill operations occur frequently a diagnosis of the cooling circuit is necessary.

In the event that only the heat exchanger without the expansion tank is available on the vehicle, refill it if necessary, paying attention that the fluid does not saturate the internal volume of the exchanger in order to enable any increase in volume of the fluid caused by the temperature increase.

!

When the engine is warm, a pressure liable to cause hot liquid to be expelled with extreme violence is created within the cooling circuits. This results in a danger of burning.

227502

- Proceed with the engine stopped. - Place a container under the filter or pre-filter (2) to collect the fluid. - Unscrew the tap plug (1) in the bottom part of the filter; in some lay-outs the plug includes a sensor to detect the presence of water in the diesel. - Drain off liquid until only “diesel” can be seen. - Close the plug again, tightening it completely by hand. - Dispose of the drained fluids according to current requirements. Check/top up electrolyte level in batteries (Component not supplied by FPT) Place the batteries on a level surface, then proceed as follows. - Visually check that the fluid level is between the “Min” and ”Max” limits; in the absence of references, check that the fluid covers the Lead plates inside the elements. - Top up with distilled water only those elements in which the level is below the minimum. - Contact specialised technical staff if the battery needs recharging. - Have the efficiency of the battery recharging system tested if a voltage of less than 22 V is detected with the engine running. - On this occasion, make sure that the terminals and clamps are clean, properly locked and protected by vaseline.

!

Base - March 2015

If all the elements of the battery need refilling with a considerable quantity of distilled water, contact specialised technical personnel in order to perform a diagnostic check on the efficiency state of the recharge system and battery.

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 4 - SCHEDULED MAINTENANCE

7

Check the condition of the exhaust duct(s)

!

The batteries contain sulphuric acid, which is extremely caustic and corrosive; always wear protective gloves and goggles when topping them up. Whenever possible it is recommended that this control be carried out by specialised personnel. Do not smoke or use live flames near the batteries during the control, and make sure that the room you are working in is adequately ventilated. Figure 3

Visually check that the exhaust system is not blocked or damaged. - Make sure that there is no risk of dangerous fumes within the machine. Contact the Manufacturer if necessary. Check coolant density Remove the cap from the expansion tank and draw off a sample of coolant using commercial densimeter for anti-freeze liquid density check..

!

When the engine is hot, pressure builds up in the cooling circuits which may eject hot liquid violently, resulting in a risk of burns. Open the filler cap of the coolant tank only when the engine is cold.

Depending on the temperature of the fluid, check the percentage of antifreeze in the fluid on the reading scale of the instrument. 225112

The percentage should be higher than 40% and must not exceed 50%.

Some types of battery have a single cover for all the inspection plugs.

If necessary, restore the percentage of antifreeze, bearing in mind that the fluid needs to be replaced every 2 years.

To access the elements, use a lever as shown in the figure.

!

Check auxiliary drive belt condition Figure 4

Coolant density must be checked every year before winter season and be replaced in any case every two years.

Engine EDC system check-up with diagnostic tool The diagnostic inspection can be carried out by using the diagnostic tool supplied by the FPT Technical Service Network to the appropriate connector. The inspection could underline that the system is operating even if some problems are present. In this case make provision to carry out an exhaustive check-up.

227501

Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning. - Check that the belt (1) is not torn or worn, and that there are no lubricants or fuel on it. If this is not the case, replace them. - The belt tension is adjusted automatically by the calibrated spring in the automatic belt tensioner (2). Refer to the figure above for the correct fitting of the belt.

Print P1D32N021 E

Base - March 2015

8

SECTION 4 - SCHEDULED MAINTENANCE

NEF SERIES EURO VI

Periodic maintenance

Ref.

No.

Description

Tightening torques

Change engine lubricant oil

(3)

1

M18x1.5

60 ± 9 Nm

Figure 5

Change oil filter Figure 7

227485 221779

Figure 6

- Place a container for collecting the spent oil under the filter support (1). - Unscrew and remove the filter (3) from its relative support (1) by 99360076 tool. - Replace the filter element and the sealing gasket (2) contained inside the filter (3). - Carefully clean the surfaces of the support (1) in contact with the sealing gasket (2). - Moisten the sealing gasket (2) of the new filter (3) with a thin layer of oil. - Manually tighten the new filter (3) on the support (1) until it comes into contact with the sealing gasket (2). 227486

- Place a suitable container for collecting the spent oil under the oil sump (4) next to the lubricant oil drain plug (3). - Unscrew the lubricant oil drain plug (3); afterwards extract the oil level dipstick (2) and remove the lubricant oil cap (1) to assist the flow of the engine lubricant oil. - Wait until the oil sump (4) has completely emptied, then retighten the lubricant oil drain plug (3). - Proceed with the refilling operation through the hole situated on the tappet cover, using lubricant oil that meets the international standards ACEA E9 API CJ-4 / SAE 10W-40 / ACEA E6 SAE 5W-30, as indicated in the REFILLING table. - Using the oil level dipstick (2), check that the engine lubricant oil level is between the ”Min” and ”Max” levels. - Whether it should be difficult to make the evaluation, proceed cleaning the oil level dipstick (2) using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level.

- Additionally tighten it using a 99360076 tool to prescribed torque. - Operate the engine for a few minutes and then check the level using the dipstick. If necessary, top up to compensate for the quantity of oil used to fill up the filtering cartridge. Ref.

No.

Description

Tightening torques

(3)

1

M27x2

20 ± 2 Nm

Given the high operating temperature of the engine, suitable protective gloves should be worn. The engine oil is highly pollutant and noxious. In case of contact with skin, wash thoroughly with water and detergent. Suitably protect skin and eyes; proceed in accordance with accident prevention standards.

- Retighten the lubricant oil cap (1). - Together with the replacement of the engine lubricant oil it is necessary to replace the oil filter (see paragraph CHANGE OIL FILTER). Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 4 - SCHEDULED MAINTENANCE

9

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

Do not smoke or use open flames during this operation. Do not inhale the vapours that exit the filter. Pay attention to the electric fuel pre-heater (if installed) and the relative electrical connection.

Figure 8 Do not fill the new fuel filter before placing it on the support in order to prevent harmful impurities from entering the fuel circuit and the injection system. Eliminate the consumables and any materials in contact with them (for example, filters) in accordance with current regulations. The FPT Technical Service Network workshops are equipped for this purpose. Change the fuel pre-filter (Component not supplied by FPT) Figure 9 227487

- Pay attention to the electrical fuel pre-heater (3) and relevant electrical connection. - Place a container for collecting the diesel under the filter support. - Remove the filter (3) by unscrewing it from its relative support by means of 99360076 tool. - Replace the filter element and the O-ring seal (2) contained inside the filter (3). - Carefully clean the surfaces of the support in contact with the O-ring seal (2). - Smear the O-ring seal (2) of the new filter (3) with oil. - Manually tighten the new filter (3) onto the support until it comes into contact with the gasket (2). Additionally tighten it using 99360076 tool to prescribed torque. Ref.

No.

Description

Tightening torques

(3)

1

M20x1.5

20 ± 2 Nm

- After the fuel filter (3) has been replaced it is possible that air bubbles get trapped inside the fuel supply circuit. - Bleed residual air from the fuel filter (3) by loosing the vent plug (1) connecting it to a suitable container by a transparent flexible hose. - With the hand pump of the fuel pre-filter pump until fuel completely free of air bubbles flows from the vent plug (1). - Tighten the vent plug (1) to prescribed torque. - Start the engine and allow it to run at minimum for a few minutes to expel any remaining air.

227503

Only proceed with the engine stopped. - Should the filter be fitted with a sensor to detect the presence of water (3), remove the whole sensor from its seat. - Remove the pre-filter by unscrewing it. - Check that the new filter has performance levels that satisfy the needs of the engine (e.g. by comparing them with the old one) - Damp the new filter seal with diesel or engine oil. - Hand screw the new filter into place until the seal gasket touches the support, then lock by a further 3/4 of a turn. - Place the water presence sensor in its seat, taking care to couple the threads correctly. - Loosen the bleeder screw (1) on the pre-filter support and activate the hand pump (2) until the supply circuit is full. Ensure that any fuel coming out is not dispersed into the environment. - Lock the bleeder screw tightly. - Start the engine and run it at idle for a few minutes to eliminate any residual air.

Print P1D32N021 E

Base - March 2015

10

SECTION 4 - SCHEDULED MAINTENANCE

NEF SERIES EURO VI

Clean the air filter (Component not supplied by FPT) NOTE

If it is necessary to speed up the residual air bleeding phase, use the hand pump also while starting.

Figure 11

Change blow-by filter Figure 10

227504

Only proceed with the engine stopped. - Remove the filter cover (3) after first unscrewing the locking handle. - Remove the external cartridge (2), after unfastening the second locking handle; during this operation, take care to ensure that no dust get into the sleeve. - Check that there is no dirt. If there is, clean the filter element as indicated below. 221781

- Unscrew the flanged nuts (1) from dual shank screws (6) and remove the tappet cover (4), recovering relevant gasket (7) and spring dowels (10). - Unscrew the ring nut (3) and remove the blow-by breather pipe, rotating it to release it from the bayonet coupling. - Unscrew the self-locking screws (8) and remove blow-by control valve (9) and filter element (5) from the inner side of the tappet cover (4). - Replace the blow-by filter element (5). - Fit the control valve (9) equipped with a new O-ring together with the new filter (5) inside the tappet cover (4) and tighten the self-locking screws (8) to a torque of 6 Nm. - Partially screw in the ring nut (3) on the filter element, insert the pipe rotating it to until the filter element engages with the bayonet connection and tighten the ring nut (3). - Refit the tappet cover (4) after having interposed a new gasket (7) and tighten the flanged nuts (1) after having interposed the spring dowels (10) on the dual shank screws (6).

- Blow dry compressed air through the filter element, from the inside outward (maximum pressure 200 kPa). Do not use detergents; do not use diesel. - Never use tools to beat the filter element, and check its condition before replacing it. - Replace the filter if any breakages or tears are found. - Check that the gasket at its base is in good condition. Some filter systems are fitted with a second filter element (1) which does not require cleaning; this must be replaced at least once every 3 changes in the main element. - Reassemble by repeating the above operations in reverse order. - Set up the mechanical blockage indicator for operation by pressing the button located on the top part of the indicator. This operation is not necessary if there is an electrical sensor. NOTE

Take care to ensure that the parts are reassembled correctly. Imperfect assembly might result in unfiltered air being sucked into the engine, causing serious damage.

Change air filter and clean housing (Component not supplied by FPT) Refer to the instructions provided for air filter cleaning.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

Change engine coolant

Extraordinary maintenance

- Only proceed when the engine is not turning, and is at low temperature, so as not to run the risk of burns.

Turbocharger visual inspection

- Place a container for collecting coolant under the heat exchanger (radiator).

11

SECTION 4 - SCHEDULED MAINTENANCE

Only proceed when the engine is not turning over.

- Remove the pressurization cap from the expansion tank.

Visually check that the turbine and compressor impellers and the relative inlet and outlet ducts are not obstructed or damaged, otherwise replace them.

- Loosen the retaining elements and remove the sleeves connecting the engine cooling circuit to the heat exchanger.

Adjustment of valves/rocker arms clearance Figure 12

- Drain the coolant from the heat exchanger (radiator) and wait until it is completely empty. - Once emptied, refit the cooling circuit making sure the sleeves are perfectly sealed. - Refill the engine and the heat exchanger until the cooling circuit has been completely refilled using a mixture of 50% water and PARAFLU HT, as contained in the REFILLING table. Do not fill the expansion tank to the brim. - With the coolant cap open, start the engine and let it idle for approx. one minute. This helps to completely bleed the air contained in the cooling circuit. - Stop the engine and top up with more coolant, if necessary. - When the engine is cold, make sure that the coolant in the expansion tank is a few centimetres below the filling hole. - In the event of an externally located level indicator as regards the heat exchangers, proceed with the top up operation by making sure that the coolant does not overfill the internal volume of the exchanger in order to allow the expansion of coolant volume during increases in temperature. The failure to observe the aforesaid procedure does not guarantee the presence of the correct quantity of coolant in the engine.

!

When the engine is hot, pressure builds up in the cooling circuits which may eject hot liquid violently, resulting in a risk of burns. Open the filler cap of the coolant tank only if necessary and only when the engine is cold.

182221

The adjustment of the clearance between the rocker arms and the intake and exhaust valve control rods must be strictly carried out using an Allen wrench (1), box-end wrench (3) and a feeler gauge (2). Clearance shall be as follows: -

intake valves 0.25  0.05 mm

-

exhaust valves 0.51  0.05 mm.

NOTE

In order to perform the rocker arm - valve clearance adjustment more quickly, proceed as follows: - Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked by the asterisk as shown in the tables below:

cylinder no. intake exhaust

1 -

2 *

3 * -

4 * *

- Rotate the crankshaft, balance the valves of cylinder no. 4 and adjust the valves marked by the asterisk as shown in the tables below: cylinder no. intake exhaust

Print P1D32N021 E

1 * *

2 * -

3 *

6 -

Base - March 2015

12

SECTION 4 - SCHEDULED MAINTENANCE

NEF SERIES EURO VI

Change auxiliary drive belt Figure 13

225129

- Pull the automatic belt tensioner (3) by using appropriate tool on the screw (2) and remove the auxiliary drive belt (1) from alternator, water pump, crankshaft pulley with damper and fixed guide rollers. - Replace the worn belt (1) with new one. - Fit the auxiliary drive belt (1) on the pulleys and fixed guide rollers. - Use the appropriate tool on the automatic belt tensioner (3) in order to fit the new belt (1) in the operating position. - Additional adjustments are not required. The belt (1) tension is adjusted automatically by the calibrated spring in the automatic belt tensioner (3). - Operate the engine for a few hours and check that the auxiliary drive belt (1) is properly fitted. Warning: with switched off motor (but still hot) the belt can operate without advance notice. Wait for the motor temperature lowering to avoid very serious accidents.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

1

SECTION 5 Removal-refitting of the main engine components Page

Print P1D32N021 E

AUXILIARY DRIVE BELT AND AUTOMATIC BELT TENSIONER REMOVAL/REFITTING . . . . . .

3

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

3

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

3

ALTERNATOR REMOVAL/REFITTING . . . . . . .

3

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

3

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

3

WATER PUMP REMOVAL/REFITTING . . . . . . .

4

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

4

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

4

THERMOSTAT REMOVAL/REFITTING . . . . . . .

5

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

5

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

5

STARTER MOTOR REMOVAL/REFITTING . . .

5

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

5

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

5

ENGINE CABLE REMOVAL/REFITTING . . . . . .

6

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

6

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

7

LOW PRESSURE FUEL PIPE REMOVAL/REFITTING . . . . . . . . . . . . . . . . .

8

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

8

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

8

FUEL PIPE FROM HIGH PRESSURE PUMP TO COMMON RAIL REMOVAL/REFITTING

9

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

9

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

10

ENGINE MANAGEMENT CONTROL UNIT REMOVAL/REFITTING . . . . . . . . . . . . . . . . .

11

Base - March 2015

2

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

NEF SERIES EURO VI

Page

Page - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

ELECTRO-INJECTOR REMOVAL/REFITTING . .

18

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

11

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

18

FUEL FILTER REMOVAL/REFITTING . . . . . . . . .

11

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

19

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

11

ENGINE BRAKE REMOVAL/REFITTING . . . . . . .

21

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

11

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

21

FUEL FILTER SUPPORT REMOVAL/REFITTING .

12

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

21

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

12

TURBOCHARGER REMOVAL/REFITTING . . . . .

22

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

12

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

22

HIGH PRESSURE PUMP REMOVAL/REFITTING

12

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

22

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

12

EXHAUST MANIFOLD REMOVAL/REFITTING .

23

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

12

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

23

COMMON RAIL REMOVAL/REFITTING . . . . . .

13

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

23

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

13

INTAKEMANIFOLD REMOVAL/REFITTING . . .

23

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

13

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

23

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

23

OIL VAPOUR RECIRCULATION SYSTEM (BLOW-BY) REMOVAL/REFITTING . . . . . . . .

14

CYLINDER HEAD REMOVAL/REFITTING . . . . .

24

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

14

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

24

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

14

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

26

TAPPETS COVER REMOVAL/REFITTING . . . . .

15

ENGINE OIL FILTER REMOVAL/REFITTING . . .

28

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

15

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

28

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

15

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

29

ELECTRO-INJECTORWIRING SUPPORT REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

15

ENGINE OIL HEAT EXCHANGER REMOVAL/REFITTING . . . . . . . . . . . . . . . . . .

29

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

15

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

29

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

15

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

29

ROCKER ARM ASSEMBLY REMOVAL/REFITTING

16

OIL SUMP REMOVAL/REFITTING . . . . . . . . . . .

30

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

16

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

30

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

17

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

30

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

3

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

AUXILIARY DRIVE BELT AND AUTOMATIC BELT TENSIONER REMOVAL/REFITTING

ALTERNATOR REMOVAL/REFITTING Removal

Removal

Disconnect the electrical connections of the alternator. Remove the auxiliary drive belt and automatic belt tensioner as described in the relevant section.

Figure 1

Figure 2

225129

Using the designated wrench on the automatic belt tensioner (3), reduce the tension of the belt (1) and remove it. Undo the screw(2) and remove the automatic belt tensioner (3). Ref. (2)

No. 1

Description M10x1.5

227449

Unscrew and remove the bolt (1). Unscrew the screw (2) and remove the alternator (3). No. 1 1

Refitting

Ref. (1) (2)

Fit the automatic belt tensioner (3) and tighten the screw (2) to the torque indicated in the table.

Refitting

Ref.

No.

(2)

1

Description M10x1.5

Tightening torques 43 ± 6 Nm

Using a specific wrench on the automatic belt tensioner (3), fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley.

Description M10x1.5 M10x1.5

Fit the alternator (3), tighten the screw (2) and the bolt (1) to the torque indicated in the table. Ref.

No.

(1) (2)

1 1

Description M10x1.5 M10x1.5

Tightening torques 43 ± 6 Nm 43 ± 6 Nm

Fit the auxiliary drive belt and automatic belt tensioner as described in the relevant section. Connect the electrical connections of the alternator.

Print P1D32N021 E

Base - March 2015

4

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

NEF SERIES EURO VI

Figure 5

WATER PUMP REMOVAL/REFITTING Removal Position a suitable container to collect any coolant which may leak out. Remove the auxiliary drive belt as described in the relevant section. Figure 3

201670

Fit the water pump (2) together with the new seal ring, tighten the fastening screws (1) and tighten them to the torque indicated in the table.

201670

Unscrew the screws (1) and remove the water pump (2) together with the seal ring. Ref. (1)

No. 2

Ref.

No.

Description

(1)

2

M8x1.25x35

Tightening torques 24 ± 4 Nm

Fit the auxiliary drive belt as described in the relevant section.

Description M8x1.25x35

Refitting Figure 4

70221

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

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

5

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

THERMOSTAT REMOVAL/REFITTING Removal

STARTER MOTOR REMOVAL/REFITTING Removal Disconnect the electrical connections of the starter motor.

Figure 6

Figure 7

227450

Unscrew the screws (1) and remove the thermostat body (2) together with the seal ring.

227451

Unscrew the nuts (1) and remove the starter motor (2).

Remove the thermostat together with the gasket. Ref. (3) (3)

No. 2 1

Ref. (1)

Description M6x1.0x20 M6x1.0x50

No. 3

Description M10x1.5

Refitting Fit the starter motor (2) and tighten the nuts (1) to the torque indicated in the table.

Refitting Fit the thermostat together with the gasket. Fit the thermostat body (2), together with a newseal ring and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(3) (3)

2 1

M6x1.0x20 M6x1.0x50

Print P1D32N021 E

Tightening torques 13.5 ± 1.5 Nm 13.5 ± 1.5 Nm

Ref.

No.

(1)

3

Description M10x1.5

Tightening torques 43 ± 6 Nm

Connect the electrical connections of the starter motor.

Base - March 2015

6

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

NEF SERIES EURO VI

ENGINE CABLE REMOVAL/REFITTING Removal Remove the engine cable by unplugging it from the relative brackets. Open the intermediate retaining clips securing the engine cable to the crankcase and remove it completely. Disconnect the following electrical connections: Figure 8

225115

1. Electro-injector connections - 2. Motorized throttle valve actuator connector (Exhaust flap) - 3. Boost pressure and air temperature sensor - 4. Rail pressure sensor - 5. Timing segment speed sensor (camshaft) - 6. Fuel high pressure pump metering unit - 7. Fuel temperature sensor - 8. In line connector - 9. Rpm increment speed sensor (crankshaft) -10. Engine Control Unit EDC17CV41 - 11. Coolant temperature sensor

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

7

Figure 9

225116

1. Coolant temperature sensor - 2. Engine oil pressure and temperature sensor 3. Motorized throttle valve actuator connector (Exhaust flap)

Refitting Fit the engine cable and close the retaining clips securing the engine cable to the crank case. Connect the engine cable to all the sensors and transmitters of the engine electrical equipment.

Print P1D32N021 E

Base - March 2015

8

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

LOW PRESSURE FUEL PIPE REMOVAL/REFITTING

NEF SERIES EURO VI

Refitting Figure 12

Removal Position a suitable container to collect any fuel which may leak out. Figure 10

227453

Fit the fuel pipe from tank to ECU (2), engage the intermediate retaining clips and connect the quick-fit coupling (3). 227452

Disconnect the quick-fit couplings and remove the fuel delivery pipe from the feed pump to the fuel filter (1). Disconnect the quick-fit coupling of the fuel return pipe from the high pressure pump outlet to tank (2) and disengage it from the intermediate retaining clips.

Fit the fuel return pipe (1), engage the intermediate retaining clips and connect the quick-fit couplings to the rail and to the cylinder head. Figure 13

Disconnect the quick-fit couplings and remove the fuel return pipe from the fuel filter to the high pressure pump inlet (3). Disconnect the quick-fit couplings, disengage the intermediate retaining clip and remove the fuel pipe from the heat exchanger on the engine control unit to the feed pump (4). Figure 11

227452

Fit the fuel pipe from the heat exchanger on the engine control unit to the feed pump (4), engage the intermediate retaining clip and connect the quick-fit couplings. Fit the return pipe from fuel filter to the high pressure pump inlet (3) and connect the quick-fit couplings.

227453

Disconnect the quick-fit couplings (rail side and cylinder head side), disengage the intermediate retaining clips and remove the complete fuel return pipe (1).

Fit the fuel return pipe from the high pressure pump outlet to tank (2), engage the intermediate retaining clips and connect the quick-fit coupling. Fit the fuel delivery pipe from the feed pump to the fuel filter (1) and connect the quick-fit couplings.

Disconnect the quick-fit coupling (3), disengage the intermediate retaining clips and remove the fuel pipe from tank to ECU (2).

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 14

9

FUEL PIPE FROM HIGH PRESSURE PUMP TO COMMON RAIL REMOVAL/REFITTING Removal 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. 116237

To disconnect the low pressure fuel pipe from the relevant connection fitting, hold the clip (1), disengage the catchs (3) and remove the quick fit coupling (2).

Position a suitable container to collect any fuel which may leak out. Figure 15

To connect the low pressure fuel pipe to the relevant connection fitting, insert the quick-fit coupling (2) into the connection fitting and push in until the catch (3) engages.

227454

Unscrew the fitting (1) and disconnect the fuel high pressure delivery pipe (2) from the rail. Unscrew the screw (3) securing the upper intermediate retaining bracket to the crankcase. Ref. (1) (3)

Print P1D32N021 E

No. 1 1

Description M14x1.5 M8x1.25x20

Base - March 2015

10

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 16

NEF SERIES EURO VI

Figure 18

α

α

227455

227454

Unscrew the screw (1) securing the lower intermediate retaining bracket to the crankcase.

Connect the fuel high pressure delivery pipe (2) to the rail, tighten the fitting (1) and the screw (3) securing the upper intermediate retaining bracket to the crankcase, to the torque indicated in the table.

Unscrew the fitting (3), disconnect the fuel high pressure delivery pipe (2) from the high pressure pump and remove it. Ref. (3) (1)

No. 1 1

NOTE

Description M14x1.5 M8x1.25x16

When unlocking the fuel delivery pipe fitting (3) to the high pressure pump, it is necessary to prevent the fitting from rotating on the pump itself by using the proper wrench.

Refitting Figure 17

Ref.

No.

(1)

1

(3)

1

NOTE

Description

Tightening torques

M14x1.5 1st phase 2nd phase M8x1.25x20

10 ± 1 Nm 55˚ 24 ± 4

The fuel pipe from the high pressure pump to the common rail must always be replaced with a new one when removed. The pipe fittings must be tightened to the torque indicated in the table using the wrench 99317915 and the torque wrench 99389829.

α

227455

Connect a new fuel high pressure delivery pipe (2) to the high pressure pump, tighten the fitting (3) and the screw (1) securing the lower intermediate retaining bracket to the crankcase, to the torque indicated in the table. Ref.

No.

(3)

1

(1)

1

Base - March 2015

Description

Tightening torques

M14x1.5 1st phase 2nd phase M8x1.25x16

10 ± 1 Nm 55˚ 24 ± 4 Print P1D32N021 E

NEF SERIES EURO VI

11

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

ENGINE MANAGEMENT CONTROL UNIT REMOVAL/REFITTING

FUEL FILTER REMOVAL/REFITTING Removal

Removal Figure 20 Figure 19

227456 221567

Disconnect the engine cable (2) fromthe ECU (3), as described in relevant procedure. Position a suitable container to catch any fuel.

Pay attention to the fuel temperature sensor and relevant electrical connection. Place a container for collecting the diesel under the filter support.

Disconnect the quick-fit coupling (1), disengage the intermediate retaining clips and remove fuel pipe from tank to ECU.

Remove the filter (2) by unscrewing it from its relative support by means of 99360076 tool.

Disconnect the quick-fit couplings (4), disengage the intermediate retaining clip and remove the fuel pipe from the heat exchanger on the engine control unit to the feed pump.

Ref. (2)

Unscrew the fastening screws (5) and remove the ECU (3), including the heat exchanger. Ref. (5)

No. 3

Description M8x1.25x45

No. 1

Description M20x1.5

Refitting Carefully clean the surfaces of the support in contact with the O-ring seal (1). Smear the O-ring seal (1) of the filter (2) with oil. Manually tighten the filter (2) onto the support until it comes into contact with the seal (1).

Refitting Fit the ECU (3) including the heat exchanger on the crankcase and tighten the fastening screws (5) to the torque indicated in the table. Fit the fuel pipe from the heat exchanger on the engine control unit to the feed pump, engage the intermediate retaining clip and connect the quick-fit coupling (4).

Additionally tighten it using 99360076 tool to the torque indicated in the table. Ref.

No.

(2)

1

Description M20x1.5

Tightening torques 20 ± 2 Nm

Fit the fuel pipe from tank to ECU, engage the intermediate retaining clips and connect the quick-fit coupling (1). Connect the engine cable (2) to the ECU (3), as described in relevant section. Ref.

No.

Description

(5)

3

M8x1.25x45

NOTE

Tightening torques 24 ± 4 Nm

It is recommended that the elastic support elements are replaced.

Print P1D32N021 E

Base - March 2015

12

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

NEF SERIES EURO VI

FUEL FILTER SUPPORT REMOVAL/REFITTING

HIGH PRESSURE PUMP REMOVAL/REFITTING

Removal

Removal

Position a suitable container to collect any fuel which may leak out.

Position a suitable container to collect any fuel which may leak out.

Remove the fuel filter as described in the relevant section.

Disconnect the low pressure fuel pipes from the mechanical feed pump and from the high pressure pump as described in the relevant section.

Disconnect the low pressure fuel pipes as described in the relevant section.

Disconnect the fuel filter support as described in the relevant section.

Figure 21

Remove the fuel pipe from the high pressure pump to the common rail as described in the relevant section. Figure 22

227457

Disconnect the electrical connection from the fuel temperature sensor (3). Unscrew the fastening screws (2) and remove the fuel filter support (1) from the crankcase. Ref. (2)

No. 2

Disconnect the electrical connection from the fuel high pressure pump metering unit (3).

Description M12x1.75x30

Unscrew the fastening nuts (2) and remove the high pressure pump (1) together with the feed pump, the adapter and the pump gear.

Refitting Fit the fuel filter support (1) and tighten the screws (2) to the torque indicated in the table. Ref.

No.

(2)

2

Description M12x1.75x30

227458

Tightening torques 80 ± 8 Nm

Connect the electrical connection to the fuel temperature sensor (3).

Ref. (2)

No. 3

Description M8x1.25

Refitting Fit the high pressure pump (1) together with the feed pump and tighten the fastening nuts (2) to the torque indicated in the table.

Connect the low pressure fuel pipes as described in the relevant section.

Ref.

No.

Fit the fuel filter as described in the relevant section.

(2)

3

Description M8x1.25

Tightening torques 24 ± 4 Nm

Connect the electrical connection to the fuel high pressure pump metering unit (3). Fit the fuel pipe fromthe high pressure pumpto the common rail as described in the relevant section. Fit the fuel filter support as described in the relevant section. Connect the low pressure fuel pipes to the mechanical feed pump and to the high pressure pump as described in the relevant section.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

COMMON RAIL REMOVAL/REFITTING Removal

13

Refitting

Position a suitable container to collect any fuel which may leak out. Disconnect the engine cable from the electro-injector wiring connectors on the electro-injector wiring support. Disconnect the rail pressure sensor electrical connection on the rail and the boost pressure/air temperature sensor electrical connection on the intake manifold. In order to facilitate the operations, disengage the engine cable and move aside. Disconnect the low pressure fuel return pipe from the common rail as described in the relevant section. Remove the fuel pipe from the high pressure pump to the common rail as described in the relevant section. Figure 23

Fit the common rail (2) on the intake manifold and tighten the fastening screws (1) to the torque indicated in the table. Ref.

No.

(1)

3

M8x1.25x125

Tightening torques 36 ± 5 Nm

Fit the new fuel pipes from the common rail to the electroinjector manifolds and tighten the relevant fittings (3, 4) to the torque indicated in the table. Ref.

No.

(3)

4

(4)

4

NOTE

α

Description

Description M14x1.5 1st phase 2nd phase M14x1.5 1st phase 2nd phase

Tightening torques 10 Nm 55˚ 10 Nm 55˚

Since the pipes are subject to high pressure, they must always be replaced at each disassembly. The pipe fittings must be tightened to the torque indicated in the table using the wrench 99317915 and the torque wrench 99389829.

Fit the fuel pipe fromthe high pressure pumpto the common rail as described in the relevant section. Connect the low pressure fuel return pipe to the common rail as described in the relevant section. 227459

Unscrew the fittings (3, 4) of the fuel pipes from the common rail to the electro-injector manifolds. Ref. (3) (4)

No. 4 4

Description M14x1.5 M14x1.5

Fit the engine cable in its seat. Connect the rail pressure sensor electrical connection on the rail and the boost pressure/air temperature sensor electrical connection on the intake manifold. Connect the engine cable to the electro-injector wiring connectors on the electro-injector wiring support.

Unscrew the intake manifold fastening screws (1) and remove the common rail (2) together with the pressure sensor. Ref. (1)

No. 3

Print P1D32N021 E

Description M8x1.25x125

Base - March 2015

14

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

OIL VAPOUR RECIRCULATION SYSTEM (BLOW-BY) REMOVAL/REFITTING

NEF SERIES EURO VI

Refitting Figure 26

Removal Remove the tappet cover as described in the relevant section. Figure 24

201691

201690

Unscrew the ring nut (1) and remove the blow-by breather (2), rotating it to release it from the bayonet coupling. Figure 25

Fit the control valve (2) equipped with a new O-ring together with the filter element (3) and tighten the new screws (1) to the torque indicated in the table. Ref.

No.

(1)

3

Description M5

Tightening torques 5 Nm

Figure 27

201691

Unscrew the self-locking screws (1) securing the control valve (2) to the tappet cover and remove it together with the filter element (3). Ref. (1)

No. 3

Description M5

201690

Partially screw in the ring nut (1) on the filter element, insert the pipe (2) rotating it to until the filter element engages with the bayonet connection. Complete the tightening of the ring nut (1). NOTE

When assembly has been completed, the breather pipe must be positioned transverse to the engine, on the exhaust side as shown in the figure.

Position and secure the tappet cover in its seat as described in the relevant section.

Base - March 2015

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NEF SERIES EURO VI

15

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

TAPPETS COVER REMOVAL/REFITTING Removal

ELECTRO-INJECTORWIRING SUPPORT REMOVAL/REFITTING Removal

Figure 28

Remove the tappet cover as described in the relevant section. Figure 29

227460

Unscrew the nuts (1) and remove the tappet cover (2) together with the gasket and the oil vapour recirculation assembly. Ref. (1)

No. 4

NOTE

Description M8x1.25

Fit a new gasket on the tappet cover. Fit the tappet cover (2), fit the fastening nuts (1) and tighten to the torque indicated in the table.

(1)

4

Ref. (4)

No. 8

Description M4

Unscrew the screws (2) and remove the electro-injector wiring support (3) together with the gasket.

Refitting

No.

Disconnect the engine cable from the electro-injector wiring connectors (1). Unscrew the nuts (4) and disconnect the cables from the electro-injectors.

To remove the oil vapour recirculation assembly act as described in the relevant section.

Ref.

227461

Description M8x1.25

Tightening torques 24 ± 4 Nm

Ref. (2) (2)

No. 2 3

Description M8x1.25x50 M8x1.25x70

Refitting Figure 30

70352

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

Print P1D32N021 E

Base - March 2015

16

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 31

NEF SERIES EURO VI

ROCKER ARM ASSEMBLY REMOVAL/REFITTING Removal Remove the tappet cover as described in the relevant section. Remove the electro-injector wiring support as described in the relevant section. Figure 32

227461

Fit the wiring support (3), screw the screws (2) and tighten them to the torque indicated in the table. Ref.

No.

Description

(2) (2)

2 3

M8x1.25x50 M8x1.25x70

Tightening torques 24 ± 4 Nm 24 ± 4 Nm 70132

NOTE

Before each assembly, always check that the thread on the holes and the screws shows no sign of wear or dirt.

Connect the cables to the electro-injectors and use the torque wrench 99389834 to tighten the fastening nuts (4) to the torque indicated in the table. Ref.

No.

(4)

8

Description M4

Tightening torques 1.5 ± 0.25 Nm

Connect the engine cable to the electro-injector wiring connectors (1).

Loosen the tappet adjustment fastening nuts (1) and unscrew the adjusters. Ref. (1)

No. 8

Description M8x1.25

Unscrew the screws (2) and remove the rocker assembly (3) consisting of: support (6), rocker arms (4), shafts (5). Ref. (2)

No. 8

Description M8x1.25

Remove the bridges (7) from the valves and remove the rods (8).

Fit the tappet cover as described in the relevant section.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

17

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

Figure 36

Figure 33

227474

The control rods of the rocker arms must show no sign of any deformation; the spherical seats for contact with the rocker arm adjusting screw and with the tappets (arrows) must show no trace of seizure or wear; if they do, replace them.

Fit the pushrods (2).

Intake and exhaust valve pushrods are identical and are therefore interchangeable.

Position bridges (1) on valves with marks () facing the exhaust manifold.

Figure 34

74765

Figure 37

70343

1. Screws - 2. Support - 3. Shafts - 4. Rocker arms 201697

Check that the tappet adjuster fastening nuts (1) are unscrewed to prevent them sticking on the rods when fitting the rocker arm assembly.

Figure 35

Then refit the rocker arm assembly consisting of the support (5), rocker arms (3) and shafts (4) and secure them to the cylinder head by tightening the fastening screws (2) to the torque indicated in the table. Ref.

No.

(2)

8

Description M8x1.25

Tightening torques 36 ± 5 Nm

70344

Check that shaft/rocker arm surfaces are not excessively worn or damaged.

Print P1D32N021 E

Base - March 2015

18

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 38

NEF SERIES EURO VI

ELECTRO-INJECTOR REMOVAL/REFITTING Removal Remove the tappet cover as described in the relevant section. Remove the electro-injector wiring support as described in the relevant section. Remove the rocker arm assembly as described in the relevant section. Position a suitable container to collect any fuel which may leak out. Figure 39 70520

Adjust the clearance between rocker arms and valves through Allen wrench (1), box wrench (3) and feeler gauge (2). The operating clearance is: - 0.25 0.05 mm for the intake valve - 0.51 0.05 mm for the exhaust valve Tighten the tappet adjuster nuts (1) to the torque indicated in the table. Ref.

No.

(1)

8

NOTE

Tightening torques 24 ± 4 Nm

Description M8x1.25

To carry out clearance adjustment of the valve rocker arm assembly more quickly, proceed as follows: - Apply tool 99360221 (with pinion 99360222) on the flywheel.

227462

Unscrew the fittings (1, 2) and remove the high pressure fuel pipes from the common rail to the electro-injectors manifolds. Ref. (1) (2)

No. 4 4

Description M14x1.5 M14x1.5

Figure 40

- Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked with an asterisk as shown in the tables below: cylinder n.

1

2

3

4

intake

-

-

*

*

exhaust

-

*

-

*

- Rotate the crankshaft, balance the valves of cylinder no. 4 and adjust the valves marked with an asterisk as shown in the tables below: cylinder n.

1

2

3

4

intake

*

*

-

-

exhaust

*

-

*

-

227463

Unscrew the nuts (1) and remove the electro-injector manifolds (2). Fit the electro-injector wiring support as described in the relevant section. Fit the tappet cover as described in the relevant section.

Ref. (1)

No. 4

Description M22x1.5

Unscrew the electro-injector fastening screws (3). Ref. (3) Base - March 2015

No. 8

Description M6x1x35 Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 41

19

Figure 44

70133

70133

Using tool 99342101 (1) take the electro-injectors (2) out of the cylinder head.

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

Refitting

Screw in the electro-injector fastening screws without tightening them.

Figure 42 Figure 45

70338

Fit a new seal ring (2) lubricated with vaseline and a new sealing washer (3) on electro-injector (1). Figure 43

91572

Fit a new seal ring (3) lubricated with vaseline on the electro-injector manifold (2). Fit the electro-injector manifold (2) in the cylinder head seat so that the positioning balls (5) coincide with the relevant housing (4). NOTE

Disassembled electro-injector manifolds (2) must not be used again, but must be replaced with new ones.

70339

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

Print P1D32N021 E

Base - March 2015

20

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Figure 46

NEF SERIES EURO VI

Figure 47

α α

70342

Screw in the fuel manifold (3) fastening nuts (2) but do not tighten them. NOTE

During the operation position the electro-injector so that the manifold inserts correctly into the fuel inlet hole of the electro-injector.

Gradually and alternately tighten the electro-injector fastening screws (1) to the torque and in the sequence indicated in the table. Ref.

(1)

No.

8

Description M6x1x35 1st phase 2nd phase 3rd phase 4th phase

Tightening torques 3.5 ± 0.35 Nm 25˚ 25˚ 25˚

Tighten the electro-injector manifold (3) fastening nuts (2) to the torque indicated in the table. Ref.

No.

(2)

4

Base - March 2015

Description M22x1.5

227462

Fit the new high pressure fuel pipes from the common rail to the electro-injector manifolds and tighten the fittings (1, 2) to the torque indicated in the table. Ref.

No.

(1)

4

(2)

4

Description M14x1.5 1st phase 2nd phase M14x1.5 1st phase 2nd phase

Tightening torques 10 ± 1 Nm 55˚ 10 ± 1 Nm 55˚

Since the pipes are subject to high pressure, they must always be replaced at each disassembly. The pipe fittings must be tightened to the torque indicated in the table using the wrench 99317915 and the torque wrench 99389829. Fit the rocker arm assembly, the electro-injector wiring support and the tappet cover as described in the relevant section.

Tightening torques 55 ± 5 Nm

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

ENGINE BRAKE REMOVAL/REFITTING Removal

21

Refitting Fit the engine brake (5) on the turbocharger after having positioned a new gasket.

Figure 48

Fit the nuts (4) and tighten them to the torque indicated in the table. Ref.

No.

(4)

4

Description M8x1.25

Tightening torques 25 ± 5 Nm

Fit the coolant delivery pipe to the engine brake and tighten the union (1) to the torque indicated in the table.

227464

Ref.

No.

(1)

1

Ref.

No.

Unscrew the union (3) and disconnect the engine coolant return pipe from the engine brake.

(3)

1

No. 1

Description M12x1.5

M12x1.5

Tightening torques 25 ± 5 Nm

Fit the coolant return pipe from the engine brake and tighten the union (3) to the torque indicated in the table.

Disconnect the electrical connection (2) from the throttle control actuator on the engine brake.

Ref. (3)

Description

Description M12x1.5

Tightening torques 25 ± 5 Nm

Connect the electrical connection (2) to the throttle control actuator on the engine brake.

Unscrew the union (3) and disconnect the engine coolant return pipe from the engine brake. Ref. (1)

No. 1

Description M12x1.5

Unscrew the nuts (4) and remove the engine brake (5) from the turbocharger. Ref. (4)

No. 4

Print P1D32N021 E

Description M8x1.25

Base - March 2015

22

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

TURBOCHARGER REMOVAL/REFITTING Removal Remove the engine brake as described in the relevant section.

NEF SERIES EURO VI

Refitting Fit the turbocharger (4) on the exhaust manifold (5) after having positioned a new gasket. Fit the fastening nuts (3) and tighten them to the torque indicated in the table.

Figure 49

Ref.

No.

(3)

4

Description M8x1.25

Tightening torques 25 ± 2.5 Nm

Fit the engine oil delivery pipe (2) to the turbocharger and tighten the fittings to the torque indicated in the table. Ref.

No.

(2)

2

Description M16

Tightening torques 25 ± 5 Nm

Fit the engine oil return pipe (1) to the crankcase together with the new gasket and tighten the screws to the torque indicated in the table. Ref.

No.

(1)

2

Description M6x1

Tightening torques 10 ± 2 Nm

Fit the engine brake as described in the relevant section. 221557

Unscrew the fastening screws and remove the oil return pipe (1) to crankcase. Ref. (1)

No. 2

Description M6x1

NOTE

Make sure all turbocharger pipes are whole, clean and free from foreign bodies. Furthermore, check that the sealing gaskets operate correctly and that the connection sleeves are fastened.

Unscrew the fittings and remove the engine oil delivery pipe (2) to the turbocharger. Ref. (2)

No. 2

Description M16

Unscrew the nuts (3) and remove the turbocharger (4) from the exhaust manifold (5). Ref. (3)

No. 4

Base - March 2015

Description M8x1.25

Print P1D32N021 E

NEF SERIES EURO VI

23

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

EXHAUST MANIFOLD REMOVAL/REFITTING

INTAKEMANIFOLD REMOVAL/REFITTING Removal

Removal

Remove the common rail as described in the relevant section.

Remove the engine brake as described in the relevant section. Remove the turbocharger as described in the relevant section. Remove the starter motor as described in the relevant section.

Disconnect the electrical connections of the boost pressure and air temperature sensor. Figure 51

Figure 50

227468

227467

Unscrew the screws (1 and 2), the fitting (3) and remove the oil level dipstick (4) from the crankcase. Ref. (1) (2) (3)

No. 1 1 1

Description M10x1.5x65 M8x1.25 M18x1.5

No. 8

Ref. (1) (1)

No. 6 1

Description M8x1.25x25 M8x1.25x70

Refitting

Unscrew the fastening screws (5) and remove the exhaust manifold (6) from the cylinder head. Ref. (5)

Unscrew the fastening screws (1) and remove the intake manifold (2) together with the boost pressure and air temperature sensor.

Apply a sufficient layer of LOCTITE 5999 on the mating surface of the intake manifold (2). Fit the intake manifold (2) together with the boost pressure and air temperature sensor and tighten the screws (1) to the torque indicated in the table.

Description M10x1.5x65

Refitting Fit the exhaust manifold (6) with new gaskets.

Ref.

No.

Description

Fit the fastening screws (5) and tighten them to the torque indicated in the table.

(1) (1)

6 1

M8x1.25x25 M8x1.25x70

Ref.

No.

Description

(5)

8

M10x1.5x65

Tightening torques 55 ± 3 Nm

Tightening torques 24 ± 4 Nm 24 ± 4 Nm

Fit the common rail as described in the relevant section. Connect the electrical connections of the boost pressure and air temperature sensor.

Fit the oil level dipstick pipe (4), tighten the fitting (3) and the screws (1 and 2) securing the retaining brackets onto the cranckase and onto the exhaust manifold, to the torque indicated in the table. Ref.

No.

Description

(1) (2) (3)

1 1 1

M10x1.5x65 M8x1.25 M18x1.5

Tightening torques 55 ± 3 Nm 24 ± 4 Nm 30 Nm

Fit the starter motor as described in the relevant section. Fit the turbocharger as described in the relevant section. Fit the engine brake as described in the relevant section. Print P1D32N021 E

Base - March 2015

24

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

NEF SERIES EURO VI

CYLINDER HEAD REMOVAL/REFITTING Removal Figure 52

227469

Remove the engine cable (3) as described in the relevant section. Remove the tappet cover (1) as described in the relevant section. Remove the common rail (4) as described in the relevant section. Remove the electro-injector wiring support (6) as described in the relevant section. Remove the rocker arm assembly (2) as described in the relevant section. Remove the electro-injectors (7) as described in the relevant section. Remove the intake manifold (5) as described in the relevant section. Remove the thermostat (8) as described in the relevant section.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

25

Figure 53

227470

Remove the engine brake (3) as described in the relevant section.

Figure 54

Remove the turbocharger (2) as described in the relevant section. Remove the starter motor (1) as described in the relevant section. Remove the exhaust manifold (4) as described in the relevant section.

70137

Unscrew the fastening screws, hook the brackets (1) to a suitable hoist and remove the cylinder heads (2) fromthe crankcase. Ref. (2) (2)

No. 8 10

Description M12x1.75x130 M12x1.75x150

Remove the cylinder head gasket from the centring bushes.

Print P1D32N021 E

Base - March 2015

26

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting

NEF SERIES EURO VI

Figure 57

Figure 55

α

74766 70335

Clean the cylinder head and crankcase contact surfaces.

Fit the cylinder head (1) fastening screws (2) and tighten them to the torque indicated in the table.

There are two types of cylinder head gaskets: -

Type A is 1.25 mm thick

-

Type B is 1.15 mm thick

Ref.

Check the average protrusion S of the pistons as indicated in Section 6 in the paragraph ”Determining gasket thickness”.

No.

(2)

8

(2)

10

If S is > 0.40 mm, use a type A gasket. If S is  0.40 mm, use a type B gasket. Fit the crankcase with a new gasket (1) for the cylinder head with the marking ”TOP” facing towards the head itself. The arrow shows the point where the gasket thickness is given.

Description M12x1.75x130 1st phase 2nd phase 3rd phase M12x1.75x150 1st phase 2nd phase 3rd phase

Tightening torques 35 ± 5 Nm 90˚ 90˚ 55 ± 5 Nm 90˚ 90˚

NOTE

The external screws are the shorter ones.

NOTE

Use tool 99395216 (3) for angle tightening.

Figure 56

The cylinder head screws must be tightened in three successive phases following the sequence and manner indicated in the following figure. Figure 58

α 74766

Position the cylinder head (2) on the new gasket using the brackets (1).

A 70337

NOTE

Before each assembly, always check that the thread on the holes and the screws shows no sign of wear or dirt.

- 1st phase of pre-tightening, with torque wrench:  Screw M12x1.75x130 (external screws) 35  5 Nm  Screw M12x1.75x150 (internal screws) 55  5 Nm - 2nd phase of tightening with angle of 90º - 3rd phase of tightening with angle of 90º A = Front side

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

27

Figure 59

227470

Fit the exhaust manifold (4) as described in the relevant section. Fit the starter motor (1) as described in the relevant section. Fit the turbocharger (2) as described in the relevant section. Fit the engine brake (3) as described in the relevant section.

Print P1D32N021 E

Base - March 2015

28

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

NEF SERIES EURO VI

Figure 60

227469

Remove the thermostat (8) as described in the relevant section.

ENGINE OIL FILTER REMOVAL/REFITTING

Remove the intake manifold (5) as described in the relevant section.

Position a suitable container to collect any engine oil which may leak out.

Remove the electro-injectors (7) as described in the relevant section.

Removal

Figure 61

Remove the rocker arm assembly (2) as described in the relevant section. Remove the electro-injector wiring support (6) as described in the relevant section. Remove the common rail (4) as described in the relevant section. Remove the tappet cover (1) as described in the relevant section. Remove the engine cable (3) as described in the relevant section. 201696

Using tool 99360076 remove the oil filter (1) from the support (2). Ref. (1)

Base - March 2015

No. 1

Description M27x2

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

Refitting Lubricate a new seal ring with engine oil and place it on the oil filter. Manually screw in the oil filter (1) on the support connection (2) and then screw in further by another 3/4 turn. Check that tightening is to the torque indicated in the table. Ref.

No.

(1)

1

Description M27x2

Tightening torques 20 ± 2 Nm

Operate the engine for a few minutes and then check the level using the dipstick: the level must come close to the MAX notch which can be seen on the dipstick. If this is not the case, top-up as necessary.

Unscrew the screws (3) and pressure/temperature sensor (4). Ref. (3)

No. 2

remove

the

29 oil

Description M6x1x20

Unscrew the screws (5) and remove the oil filter/heat exchanger support (6), the intermediate plate and the corresponding gaskets. Ref. (5)

No. 15

Description M8x1.25x35

Refitting Fit the new gaskets, the intermediate plate and oil filter/heat exchanger support (6) onto the crankcase. Tighten the screws (5) to the torque specified in the table.

ENGINE OIL HEAT EXCHANGER REMOVAL/REFITTING Removal

Ref.

No.

Description

Remove the auxiliary drive belt as described in the relevant section.

(5)

15

M8x1.25x35

Remove the alternator as described in the relevant section.

NOTE

Before each assembly, always check that the thread on the holes and the screws shows no sign of wear or dirt.

Position a suitable container to collect any engine oil which may leak out. Remove the engine oil filter as described in the relevant section. Figure 62

Tightening torques 26 ± 4 Nm

Fit the oil pressure/temperature sensor (4) together with a new seal ring onto the support (6) and tighten the screws (3) to the torque indicated in the table. Ref.

No.

(3)

2

Description M6x1x20

Tightening torques 10 ± 2 Nm

Fit the oil delivery pipe to the turbocharger (2) and tighten the fittings (1) to the torque indicated in the table. Ref.

No.

(1)

2

Description M16

Tightening torques 25 ± 5 Nm

Fit the engine oil filter as described in the relevant section. Fit the alternator as described in the relevant section. Fit the auxiliary drive belt as described in the relevant section. Check the oil level with the oil level dipstick: the level must come close to the MAX notch which can be seen on the dipstick. If this is not the case, top-up as necessary. 201696

Unscrew the fitting (1) and remove the engine oil delivery pipe (2) to the turbocharger. Ref. (1)

No. 2

Print P1D32N021 E

Description M16

Base - March 2015

30

SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS

OIL SUMP REMOVAL/REFITTING Removal

NEF SERIES EURO VI

Refitting

Place an appropriate container for the oil collection under the sump in correspondence with the drain plug. Open the oil filler inlet on the cylinder head and take out the oil level dipstick to allow the oil to flow more freely. Unscrew the drain plug and let the oil in the sump drain out completely. Figure 63

Fit a new gasket on the oil sump (1) and place them on the cranckcase; suddenly place the oil pan frame (2) on the cranckcase and tighteen the screws (3) to the torque indicated in the table. Ref.

No.

Description

(3) (3)

10 4

M8x1.25x40 M8x1.25x45

Tightening torques 24 ± 4 Nm 24 ± 4 Nm

Fit the drain plug together with the new gasket and tighten to the torque indicted in the table. Ref.

No.

(-)

1

Description M18x1.5

Tightening torques 60 ± 9 Nm

Proceed to refill with the specified oil. Operate the engine for a few minutes and then check the level using the dipstick: the level must come close to the MAX notch which can be seen on the dipstick. If this is not the case, top-up as necessary the engine lubricant oil with the specified quantity and quality of lubricant oil. 227471

Undo the screws (3) and remove the oil sump (1) with the gasket and its oil pan frame (2). Ref. (3) (3)

No. 10 4

Base - March 2015

Description M8x1.25x40 M8x1.25x45

Only use recommended oils or oils with the properties required for proper engine operation. Failure to observe these standards will invalidate the service warranties.

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

1

SECTION 6 General mechanical overhaul Page ENGINE DISASSEMBLING ON BENCH . . . . . .

5

- Removal of components hindering bracket assembly 5 - Fitting the engine on the rotating stand . . . . .

Print P1D32N021 E

9

ENGINE DISASSEMBLING (COMPONENTS ON TOP SIDE - PART 1) .

10

- Rail removal . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

- Tappet cover removal . . . . . . . . . . . . . . . . . . .

10

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

10

- Electro-injector wiring support removal . . . . .

11

- Rocker assembly removal . . . . . . . . . . . . . . . .

11

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

11

ENGINE DISASSEMBLING (SIDE VIEW OF COMPONENTS - PART 1)

12

- Engine brake removal . . . . . . . . . . . . . . . . . . .

12

- Turbocharger removal . . . . . . . . . . . . . . . . . . .

12

- Exhaust manifold removal . . . . . . . . . . . . . . . .

12

ENGINE DISASSEMBLING (COMPONENTS ON FRONT SIDE - PART 1)

13

- Auxiliary drive belt and automatic belt tensioner removal . . . . . . . . . . . . . . . . . .

13

- Alternator removal . . . . . . . . . . . . . . . . . . . . .

13

ENGINE DISASSEMBLING (COMPONENTS ON TOP SIDE - PART 2) .

13

- Cylinder head removal . . . . . . . . . . . . . . . . . .

13

- Intake and exhaust valve removal . . . . . . . . . .

13

ENGINE DISASSEMBLING (SIDE VIEW OF COMPONENTS - PART 2)

14

- Alternator support removal . . . . . . . . . . . . . .

14

- Engine oil filter housing removal . . . . . . . . . . .

14

- Engine control unit removal . . . . . . . . . . . . . .

15

Base - March 2015

2

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Page

Page

ENGINE DISASSEMBLING (COMPONENTS ON FRONT SIDE -PART 2)

15

- Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . .

33

- Damper pulley and crankshaft pulley removal

15

- Intake and exhaust valves . . . . . . . . . . . . . . . .

34

- Water pump - rpm sensor removal . . . . . . . .

16

- Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . .

35

- Crankshaft front seal ring removal . . . . . . . . .

16

- Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

- Crankshaft external gasket ring removal . . . . .

16

- Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . .

37

- Front cover removal . . . . . . . . . . . . . . . . . . . .

16

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

37

- Engine oil pump removal . . . . . . . . . . . . . . . .

17

(CRANKCASE COMPONENTS) . . . . . . . . . . . . .

37

ENGINE DISASSEMBLING (COMPONENTS ON REAR SIDE) . . . . . . . . .

- Tappets and camshaft refitting . . . . . . . . . . . .

37

17 - Piston cooling spray nozzles refitting . . . . . . .

38

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

17 - Main half-bearings and crankshaft refitting . . .

38

- Crankshaft rear seal ring removal . . . . . . . . . .

18 - Connecting rod and piston assembly . . . . . . .

39

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

18 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

41

- Camshaft gear removal . . . . . . . . . . . . . . . . . .

18

- Timing gear case removal . . . . . . . . . . . . . . . .

(COMPONENTS ON TOP SIDE - PART 1) . . . .

41

18 - Intake and exhaust valves refitting . . . . . . . . .

41

ENGINE DISASSEMBLING (COMPONENTS ON BOTTOM SIDE) . . . . .

19

- Cylinder head refitting . . . . . . . . . . . . . . . . . .

42

- Engine oil sump removal . . . . . . . . . . . . . . . . .

19

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

43

- Engine oil intake suction strainer removal . . . .

19

(COMPONENTS ON REAR SIDE) . . . . . . . . . . .

43

ENGINE DISASSEMBLING (CRANKCASE COMPONENTS) . . . . . . . . . .

19

- Timing gear case refitting . . . . . . . . . . . . . . . .

43

- Pistons and connecting rod assembly removal

19

- Camshaft timing . . . . . . . . . . . . . . . . . . . . . . .

44

- Main bearing caps removal . . . . . . . . . . . . . . .

19

- Engine flywheel housing refitting . . . . . . . . . . .

45

- Crankshaft removal . . . . . . . . . . . . . . . . . . . . .

20

- Crankshaft rear seal ring refitting . . . . . . . . . .

45

- Piston cooling spray nozzles removal . . . . . . .

20

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

46

- Camshaft and tappets removal . . . . . . . . . . . .

20

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

47

CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

(COMPONENTS ON FRONT SIDE - PART 1) .

47

- Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . .

21

- Engine oil pump refitting . . . . . . . . . . . . . . . . .

47

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

23

- Front cover refitting . . . . . . . . . . . . . . . . . . . .

47

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

23

- Water pump refitting . . . . . . . . . . . . . . . . . . .

47

- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Crankshaft pulley and damper pulley refitting .

48

- Connecting rod and piston assembly . . . . . . .

28

- Crankshaft front seal ring refitting . . . . . . . . . .

48

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Page - Refitting engine speed sensor . . . . . . . . . . . . .

48

ENGINE ASSEMBLY (SIDE VIEW OF COMPONENTS - PART 1) .

49

- Engi ne oil filter support refitting . . . . . . . . . . .

49

- Alternator support refitting . . . . . . . . . . . . . . .

50

- Alternator refitting . . . . . . . . . . . . . . . . . . . . .

50

- Engine control unit refitting . . . . . . . . . . . . . .

50

ENGINE ASSEMBLY (COMPONENTS ON TOP SIDE - PART 2) .

3

Page - Engine brake refitting . . . . . . . . . . . . . . . . . . .

57

ENGINE ASSEMBLY (COMPONENTS ON FRONT SIDE - PART 2)

58

- Auxiliary drive belt and automatic belt tensioner refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

ENGINE ASSEMBLY (COMPONENTS ON BOTTOM SIDE) . . . . .

58

- Engine oil intake suction strainer refitting . . . .

58

51

- Engine oil sump refitting . . . . . . . . . . . . . . . . .

59

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

51

REMOVING THE ENGINE FROM THE ROTATING STAND . . . . . . . . . . . . . . . .

59

- Rocker assembly refitting . . . . . . . . . . . . . . . .

52

- Electro-injector wiring support refitting . . . . .

54

- Exhaust side - oil level dipstick and engine brake water return pipe refitting . . . . . . . . . . . . . . . .

59

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

54

- Exhaust side - electric starter motor refitting .

60

- Tappet cover refitting . . . . . . . . . . . . . . . . . . .

54

- Intake side - fuel delivery pipe from high pressure pump to rail and high pressure pump refitting 60

- Rail refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

ENGINE ASSEMBLY (SIDE VIEW OF COMPONENTS -PART 2) . .

- Intake side - fuel filter support refitting . . . . . .

61

56

- Engine cable refitting . . . . . . . . . . . . . . . . . . . .

62

- Exhaust manifold refitting . . . . . . . . . . . . . . . .

56

CHECKS AND INSPECTIONS . . . . . . . . . . . . . .

64

- Checking and adjusting the Waste-Gate . . . . .

56

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

64

- Turbocharger refitting . . . . . . . . . . . . . . . . . . .

57

- Checking the mechanical feed pump . . . . . . .

65

Print P1D32N021 E

Base - March 2015

4

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Base - March 2015

NEF SERIES EURO VI

Print P1D32N021 E

NEF SERIES EURO VI

ENGINE DISASSEMBLING ON BENCH In order to apply the brackets 99341009 to the engine block to fix it on to the stand 99322205 for the overhaul, it is necessary to perform the following operations.

5

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Removal of components hindering bracket assembly Engine cable removal Remove the engine cable by unplugging it from the relative brackets. Open the intermediate retaining clips securing the engine cable to the crankcase and remove it completely. Disconnect the following electrical connections:

Figure 1

225115

1. Electro-injector connections - 2. Motorized throttle valve actuator connector (Exhaust flap) - 3. Boost pressure and air temperature sensor - 4. Rail pressure sensor - 5. Timing segment speed sensor (camshaft) - 6. Fuel high pressure pump metering unit - 7. Fuel temperature sensor - 8. In line connector - 9. Rpm increment speed sensor (crankshaft) 10. Engine Control Unit EDC17CV41 - 11. Coolant temperature sensor

Print P1D32N021 E

Base - March 2015

6

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Figure 2

225116

1. Coolant temperature sensor - 2. Engine oil pressure and temperature sensor 3. Motorized throttle valve actuator connector (Exhaust flap)

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

7

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Intake side - fuel filter support removal

Intake side - fuel delivery pipe from high pressure pump to rail and high pressure pump removal

Figure 3 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. Position a suitable container to collect any fuel which may leak out. Figure 5 225117

Using tool 99360076, remove the fuel filter (3) from the support (4). Ref. (3)

No. 1

Description M20x1.5

Disconnect the quick-fit couplings and remove the fuel delivery pipe from the feed pump to the fuel filter (1). Disconnect the quick-fit couplings and remove the fuel return pipe from the fuel filter to the high pressure pump inlet (2). Unscrew the screws and remove the support (4) from the crankcase. Ref. (4)

No. 2

225118

Description M12x1.75x30

Unscrew the fitting (1) and disconnect the fuel high pressure delivery pipe (2) from the rail. Unscrew the screw (3) securing the upper intermediate retaining bracket to the crankcase.

Figure 4

Ref. (1) (3)

No. 1 1

Description M14x1.5 M8x1.25x20

116237

To disconnect the low pressure fuel pipe from the relevant connection fitting, hold the clip (1), disengage the catchs (3) and remove the quick fit coupling (2).

Print P1D32N021 E

Base - March 2015

8

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Figure 6

Ref. (1)

No. 2

Description M6x1

Unscrew the nuts (3) and remove the starter motor (4) from the flywheel cover. Ref. (3)

No. 3

Description M10x1.5

Exhaust side - oil level dipstick and engine brake water return pipe removal Figure 8 225119

Unscrew the screw (1) securing the lower intermediate retaining bracket to the crankcase. Unscrew the fitting (6), disconnect the fuel high pressure delivery pipe (2) from the high pressure pump and remove it. Disconnect the quick-fit coupling of the fuel return pipe from the high pressure pump outlet to tank (3) and disengage it from the intermediate retaining clips. Disconnect the quick-fit couplings, disengage the intermediate retaining clip and remove the fuel pipe from the heat exchanger on the engine control unit to the feed pump (7). Unscrew the fastening nuts (4) and remove the high pressure pump (5) together with the feed pump, the adapter and the pump gear. Ref. (1) (6) (4)

No. 1 3 3

Description M8x1.25x16 M14x1.5 M8x1.25

225121

Unscrew the screws (1 and 3), the fitting (6) and remove the oil level dipstick (2) from the crankcase. Unscrew the union (8) (engine brake side), the union (4) (alternator support side), the screws (5) securing the intermediate retaining brackets and remove the engine brake water return pipe (7). Ref. (1) (3) (4)

Exhaust side - starter motor removal

(5)

Figure 7

(8) (6)

No. 1 1 1 2 1 1 1

Description M10x1.5x65 M8x1.25 M12x1.5 M8x16 M10x20 M12x1.5 M18x1.5

225120

Unscrew the screws (1) and remove the oil outlet pipe (2) from the turbocharger and the crankcase.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

9

Fitting the engine on the rotating stand Figure 9

227448

Fit brackets 99361037 onto the crankcase and the engine onto rotating stand 99322205.

Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water.

Place a suitable container, remove the oil sump drain plug from the oil sump and drain the engine oil. Ref. (-)

No. 1

Print P1D32N021 E

Description M18x1.5

Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.

Base - March 2015

10

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

1

ENGINE DISASSEMBLING (COMPONENTS ON TOP SIDE - PART 1)

Tappet cover removal Figure 11

Rail removal Figure 10

225123

Unscrew the nuts (1) and remove the tappet cover (2) together with the oil vapour separator and gasket. 225122

Disconnect the fuel return pipe (4) from the rail (5) and from cylinder head (3).

Ref. (1)

Unscrew the fittings and remove the fuel pipes (1) from the rail (5) and from the electro-injector manifolds (2).

Unscrew the screws (3) and remove the thermostat body (4) together with the O-ring.

Ref. (1)

Ref. (3) (3)

No. 8

Description M14x1.5

Unscrew the screws (6) and remove the rail (5). Ref. (6)

No. 3

Description M8x1.25x125

Disengange the fuel return pipe (4) from the intermediate retaining clips and remove it.

No. 4

No. 2 1

Description M8x1.25

Description M6x1.0x20 M6x1.0x50

Intake manifold removal Figure 12

225124

Unscrew the screws (1) and remove the intake manifold (2) complete with the boost pressure and air temperature sensor. Ref. (1) (1)

Base - March 2015

No. 6 1

Description M8x1.25x25 M8x1.25x70

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Electro-injector removal

Electro-injector wiring support removal

Figure 15

Figure 13

225125

227472

Remove the nuts (2) and disconnect the cables (1) from the electro-injectors. Ref. (2)

No. 8

No. 2 3

Unscrewthe nuts (1) and remove the fuelmanifolds (2) together with the O-rings. Ref. (1)

Description M4

Unscrew the screws (4) and remove the electro-injector wiring support (3) complete with gasket. Ref. (4) (4)

11

Description M8x1.25x50 M8x1.25x70

NOTE

No. 4

Description M22x1.5

Disassembled fuel manifolds (2) must not be used again, but however replaced with other new ones.

Unscrew the electro-injector fastening screws (3).

Rocker assembly removal

Ref. (3)

Figure 14

No. 8

Description M6x1x35

Figure 16

70132

Loosen the tappet adjustment fastening nuts (1) and unscrew the adjusters. Unscrew the screws (2), remove the rocker assembly (3) made up of a support (6), rocker arms (4), shafts (5) and recover the bridge (7). Ref. (1) (2)

No. 8 8

Description M8x1.25 M8x1.25

70133

Using tool 99342101 (1) remove the electro-injectors (2) from the cylinder head.

Remove the rods (8).

Print P1D32N021 E

Base - March 2015

12

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

ENGINE DISASSEMBLING (SIDE VIEW OF COMPONENTS - PART 1)

Turbocharger removal Figure 19

Engine brake removal Figure 17

225127

225126

Unscrew the union (4) and disconnect the engine brake water delivery pipe (3) from engine brake. Unscrew the nuts (1) and remove the engine brake (2) from the turbocharger. Ref. (4) (1)

No. 1 4

Description M12x1.5 M8x1.25

Unscrew the fittings and remove the oil delivery pipe to the turbocharger (1). Ref. (1)

No. 2

Description M16

Unscrew the nuts (3) and remove the turbocharger (2) from the exhaust manifold. Ref. (3)

No. 4

Description M8x1.25

Exhaust manifold removal Figure 18

Figure 20

225128

Unscrew the fitting (1) and remove the engine brake water delivery pipe (2) from crankcase. Ref. (1)

No. 1

Base - March 2015

Description M14x1.5

227465

Unscrew the screws (1) and remove the exhaust manifold (2) from the cylinder head. Ref. (1)

No. 8

Description M10x1.5x65

Print P1D32N021 E

NEF SERIES EURO VI

13

SECTION 6 - GENERAL MECHANICAL OVERHAUL

ENGINE DISASSEMBLING (COMPONENTS ON FRONT SIDE - PART 1)

ENGINE DISASSEMBLING (COMPONENTS ON TOP SIDE - PART 2)

Auxiliary drive belt and automatic belt tensioner removal

Cylinder head removal Figure 23

Figure 21

70137

225129

Using the designated wrench on the automatic belt tensioner (3), reduce the tension of the belt (1) and remove it. Undo the screw(2) and remove the automatic belt tensioner (3). Ref. (2)

No. 1

Unscrew the screws (1) hook the brackets to a suitable hoist and remove the cylinder heads (2) from the crankcase. Ref. (2) (2)

No. 8 10

Description M12x1.75x130 M12x1.75x150

Remove the cylinder head gasket from the centring bushes.

Description M10x1.5

Intake and exhaust valve removal

Alternator removal

Figure 24

Figure 22

70319

The intake (1) and exhaust (2) valves have the same diameter mushroom. 225130

Unscrew and remove the bolt (1).

The central notch distinguishes the exhaust valve (2) from the intake valve.

Unscrew the screw (2) and remove the alternator (3). Ref. (1) (2)

No. 1 1

Description M10x1.5 M10x1.5

NOTE

Mark the valves before removing them from the cylinder heads so that they can be refitted in the same position as when they were removed.

A = intake side S = exhaust side

Print P1D32N021 E

Base - March 2015

14

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Figure 25

ENGINE DISASSEMBLING (SIDE VIEW OF COMPONENTS - PART 2) Alternator support removal Figure 27

70321

Using tool 99360268 (1), apply pressure to the plate (3), compress the springs (4) and remove the cotters (2). Remove the plate (3) and springs (4). Repeat this operation for all the valves.

225131

Unscrew the screws (1 and 2) and remove the alternator support (3).

Overturn the cylinder head and remove the valves (5). Figure 26

Ref. (2) (2)

No. 1 2

Description M10x1.5x80 M10x1.5x130

Using tool 99360076, remove the engine oil filter (4). Ref. (4)

No. 1

Description M27x2

Engine oil filter housing removal Figure 28

70322

Remove the sealing rings (1 and 2) from the relevant valve guides. NOTE

The sealing rings (1) for the intake valve are yellow. The sealing rings (2) for the exhaust valve are green.

201706

Unscrew the screws (2) and remove the engine oil temperature/pressure sensor (3). Ref. (2)

No. 2

Description M6x1x20

Unscrew the screws (4) and remove the engine oil filter housing (1), the heat exchanger plate (5) and the gaskets. Ref. (4)

Base - March 2015

No. 15

Description M8x1.25x35

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Engine control unit removal

15

ENGINE DISASSEMBLING (COMPONENTS ON FRONT SIDE -PART 2)

Figure 29

Fit flywheel locking tool 99360351.

Damper pulley and crankshaft pulley removal Figure 31

225132

Disconnect the quick-fit coupling (1), disengage the intermediate retaining clips and remove fuel pipe from tank to ECU (2). 227473

Unscrew the screws (4) and remove the engine control unit (3) together with the heat exchanger. Ref. (4)

No. 3

Description M8x1.25x45

Unscrew the screws (1), remove the damper pulley (3) and the pulley (2). Ref. (1)

No. 6

Description M10x1.25x40

Unscrew the screws (4) and remove crankshaft pulley (6) together with the spacer-shaft flange (5).

Figure 30

Ref. (4)

No. 6

Description M12x1.25x78.5

Remove the crankshaft pulley (6) from the crankshaft.

225133

Unscrew the screw (1) and remove the timing sensor (2) complete of support. Ref. (1)

No. 1

Print P1D32N021 E

Description M6x1

Base - March 2015

16

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Crankshaft external gasket ring removal

Water pump - rpm sensor removal

Figure 34

Figure 32

78257 70148

Unscrew the screws (1) and remove the water pump (2). Ref. (1)

No. 2

Description M8x1.25x35

Front cover removal

Unscrew the screw (3) and remove the guide pulley (4). Ref. (3)

No. 1

Fit the tie rod (3) of tool 99363204 onto the external gasket (2) and remove it from the front cover (1) by means of the lever (4).

Figure 35

Description M10x1.5

Unscrew the screw (5) and remove the rpm sensor (6). Ref. (5)

No. 1

Description M6x1x20

Crankshaft front seal ring removal Figure 33

225138

Unscrew the screws (1), the screws (2) and remove the front cover (3). Ref. (1) (1) (2) NOTE

No. 5 8 2

Description M8x1.25x45 M8x1.25x30 M8x1.25x45

The screws securing the front cover are of different lengths. It is recommended that the operator makes a note of the assembly position.

78256

Fit tool 99340055 (4) on the front shank (2) of the crankshaft and perforate the internal seal ring (1) using a drill bit ( 3.5 mm) to a depth of 5 mm. Secure the tool (4) to the front seal ring (1) with the 6 screws (5) provided and then extract the ring by screwing in the screw (3).

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Engine oil pump removal

17

ENGINE DISASSEMBLING (COMPONENTS ON REAR SIDE)

Figure 36

Engine flywheel removal Figure 37

70150

Unscrew the screws (1) and remove the engine oil pump (2). Ref. (1) NOTE

No. 4

Description M8x1.25x30

The engine oil pump (2) cannot be overhauled.

225134

Apply tool 99360351 on the flywheel housing in order to block the engine flywheel (3) rotation. Screw out two opposite screws (2) fixing the engine flywheel (3) to the crankshaft (4). Introduce two withdrawal pins in the ports (see the following picture). Loosen remaining screws (1) fixing the engine flywheel (3) to the crankshaft (4) and remove flywheel blocking tool 99360351. Ref. No. (1, 2) 8

Description M12x1.25

Figure 38

227500

Screw up two medium length screws in the ports (2) to sling the engine flywheel (3). Throughout the two guide pins (4) previously screwed up into the crankshaft ports (1) control the engine flywheel (3) withdrawal by means of a hoist with tool 99360595.

Print P1D32N021 E

Base - March 2015

18

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Camshaft gear removal

Crankshaft rear seal ring removal

Figure 41

Figure 39

225135

78258

Fit tool 99340056 (3) on the rear shank (5) of the crankshaft and perforate the internal seal ring (1) using a drill bit (3.5 mm) to a depth of 5 mm. Secure the tool (3) to the rear seal ring (1) with the 6 screws (4) provided and then extract the ring by screwing in the screw (2). Remove the external seal ring in the same way as described for the removal of the front seal ring of the crankshaft.

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

No. 6

Description M8x1.25x25

Timing gear case removal Figure 42

Flywheel housing removal Figure 40

225136

Unscrew the screws (1) and remove the timing gear case (2). Ref. (1) (1) (1)

No. 1 4 5

Description M12x1.75 M8x1.25 M10x1.5

221788

Unscrew the fastening screws (1, 2, 3, 4 and 5) and remove the flywheel housing. Ref. (1) (2) (3) (4) NOTE

No. 10 2 2 6

NOTE

The screws (2) securing the timing gear case are of different lengths. It is recommended that the operator makes a note of the assembly position.

Description M10x1.5 M12x1.75 M10x1.5 M12x1.75

Note down the installation positions of the screws since they are of different sizes.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

19

SECTION 6 - GENERAL MECHANICAL OVERHAUL

ENGINE DISASSEMBLING (COMPONENTS ON BOTTOM SIDE)

ENGINE DISASSEMBLING (CRANKCASE COMPONENTS)

Engine oil sump removal

Pistons and connecting rod assembly removal

Rotate the engine through 180˚ on the overhaul stand.

Figure 45

Figure 43

70158

Unscrew the screws (1) and remove the connecting rod caps (2). 225137

Undo the screws (3) and remove the oil sump (1) with the gasket and its oil pan frame (2). Ref. (3) (3)

No. 10 4

Ref. (1)

No. 8

Description M10x1.25x52

Remove the pistons together with the connecting rods.

Description M8x1.25x40 M8x1.25x45

NOTE

Engine oil intake suction strainer removal Figure 44

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

Main bearing caps removal Figure 46

225139

Unscrew the screws and remove the engine oil intake suction strainer (1) with the relative gasket. Ref. (1) (1)

No. 2 1

Description M8x1.25 M10x1.5

70159

Unscrew the screws (1) and remove the connecting rod caps (2). Ref. (1)

No. 10

Description M12x1.75

Unscrew the screws (2) and remove the lower crankcase stiffening plate (3). Ref. (2)

No. 4

Print P1D32N021 E

Description M10x1.5x25

Base - March 2015

20

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Piston cooling spray nozzles removal

Figure 47

Figure 50

70160

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

Mark the upper and lower half-bearings so that they can be refitted in the same position noted during removal.

70180

Unscrew the screws (1) and remove the piston cooling spray nozzles (2). Ref. (1)

No. 4

Description M8x1.25x20

Camshaft and tappets removal Crankshaft removal

Figure 51

Figure 48

70163

70161

Using tool 99360500 (1) and a suitable hoist, remove the crankshaft (2) from the crankcase.

Unscrew the screws (1) and remove the camshaft (3) retaining plate (2). Ref. (1)

No. 2

Description M8x1.25x16

Figure 49 NOTE

Take note of plate (2) assembling position.

201709

Remove the main half-bearings (1). Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 52

21

CHECKS Cylinder block Checking cylinder liners Figure 54

70164

s

Remove the camshaft (1) from the crankcase. Figure 53 70166

After disassembling the engine, thoroughly clean the cylinder assembly. Use the suitable rings to handle the cylinder assembly. Carefully inspect the crankcase for cracks. Check the condition of the machining plugs. If they are worn, replace them.

70165

Remove the tappets (1) from the crankcase.

Check the condition of the surfaces of the cylinder liners which should show no signs being scored, seized, ovalised, tapered or excessively worn. To check the ovalisation, taper and wear of the cylinder liners, check the internal diameter using the bore gauge (1) together with the dial gauge which has been previously reset on the ring gauge (2). NOTE

Print P1D32N021 E

Use a micrometer to rest the bore gauge if a ring gauge is not available.

Base - March 2015

22

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Figure 55

Figure 56 S S

70167

Measurements shall be performed on each cylinder, at three different heights in the bore and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A) and the other perpendicular to it (B); the greatest wear is usually found to be on this surface and during the first measurement. Should ovalisation, taper or wear be found, bore and grind the cylinder liners. The regrinding of the cylinder liners should be carried out in relation to the diameter of the pistons supplied as spare parts, which are oversized by 0.4 mm of the nominal value and to the prescribed assembly clearance.

201710

NOTE

In case of regrinding, all cylinders should have the same oversize (0.4 mm).

Check the main bearing seats as follows: - fit the main bearings caps on the supports without bearings; - tighten the fastening screws to the torque specified in the table; Ref.

No.

Description

Tightening torques

(-)

10

M12x1.75 1st phase 2nd phase

80 ± 6 Nm 90˚

- using a suitable internal dial gauge, check that the seat diameter falls within the specified value. If the diameter of the seats is not within the prescribed value but exceeds this value, replace the crankcase.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

23

Checking cylinder block head contact surface Figure 57

70170

Check that the contact surface of the head, on the cylinder assembly is not deformed, then remove the dowels (4) and carry out the check using a calibrated rule (2) and a feeler gauge (3). If there are any areas of deformation, correct the contact surface with a grinding machine. Planarity error shall not exceed 0.075 mm. NOTE

Flatten the crankcase after having checked that the piston protrudes from the cylinder liner by no more than the prescribed value.

Check the state of the cylinder assembly machining plugs (1); if worn, replace them.

TIMING SYSTEM Camshaft Figure 58

70169

MAIN CAMSHAFT DATA The data given refer to the normal diameter of the pins The surfaces of the supporting pins of the shaft and those of the cams must be filed; It is recommended that the shaft and relative bushes are replaced if there are any signs of in seizing or scoring. Print P1D32N021 E

Base - March 2015

24

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Checking lift and pin alignment Set the shaft on tailstocks and, using a centesimal dial gauge on the middle support, check that the alignment error is no greater than 0.04 mm: change the shaft if it is any greater.

Checking the timing gear shaft seat and bushes Figure 60

Check that the cam lift is 6.045 mm for the exhaust and 7.582 for the intake; change the shaft if it is any greater.

Figure 59

70172

The bushing for the camshaft (2) must be forced into its seat. The internal surfaces must show no signs of seizure or wear. Measure the diameter of the bushing (2) and of the intermediate seats of the camshaft (1) with a bore gauge (3). 70171

Check the diameter of the camshaft (2) support pins using the micrometer (1) on two perpendicular axes.

Measurements should be performed on two perpendicular axes.

Figure 61 Sec. A-A

107399

MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT * Measurement to obtain after driving in the bushing. Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Replacing camshaft bushing

25

Checking camshaft end clearance

Figure 62

Figure 64

70176 70174

To disassemble and reassemble the camshaft bushing, use drift 99360362 (2) and handgrip 99370006 (3).

Lubricate the tappets (1) and fit them into the relevant housings on the crankcase. Figure 65

NOTE

During assembly, the bushing (1) must be positioned so that the lubrication holes are in line with the holes in the seat of the crankcase.

Checking the washers for the tappets Figure 63

70164

Lubricate the camshaft support bushing and mount the camshaft (1). Make sure that the bushing or support seats are not damaged.

112890

MAIN DATA CONCERNING THE TAPPET WASHERS AND THE RELEVANT HOUSINGS ON CRANKCASE

Print P1D32N021 E

Base - March 2015

26

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Crankshaft

Figure 66

Checking main journals and crankpins Figure 68

70238

Position the camshaft (3) retaining plate (1) with the slot facing the top side of the crankcase and the marking facing the operator, tighten the screws (2) to the torque indicated in the table. Ref.

No.

Description

(2)

2

M8x1.25x16

Tightening torques 24 ± 4 Nm

70182

If signs of seizure, scoring or excessive ovalisation on main journals and crankpins are identified, they must be refaced by means of grinding. Before grinding the journals (2) measure them with a micrometer (1) to decide the final end diameter to which they are to be ground. NOTE

Figure 67

Note down the values in a table. See figure below.

Undersize classes are of: 0.250 - 0.500 mm.

!

The main journals and crankpins must always be ground to the same undersize class. The undersizing of the journals and crankpins must always be marked on the side of crank arm n. 1. For undersized crankpins, letter M. Letter B for undersized main journals.

70179

Check that the camshaft end play (1) falls within 0.23 ± 0.13 mm.

Base - March 2015

For undersized crankpins and main journals, letter MB.

Print P1D32N021 E

NEF SERIES EURO VI

27

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 69

201711

TABLE IN WHICH THE MEASURED VALUES FOR THE MAIN JOURNALS AND CRANKPINS ARE TO BE NOTED DOWN Nominal value

0.007

C B--C

0.007

0.03

+

+ 0.007 0.007

0.150 B--C +

F

0.007

+ +

+ +

0.150 B--C +

**

0.007 0.007

+ +

0.150 B--C

**

B

C

0.05 B--C

0.06 B--C

0.01 B--C

+ 0.03 B--C

C 0.03 B--C

C 0.03 B--C

0.003 B--C

+

Figure 70

0.007

*

A

+

0.03 B--C

+

0.022 B--C 201714

MAIN CRANKSHAFT TOLERANCES

Print P1D32N021 E

Base - March 2015

28

SECTION 6 - GENERAL MECHANICAL OVERHAUL

TOLERANCES SHAPE

ORIENTATION POSITION OSCILLATION

NEF SERIES EURO VI

CHARACTERISTIC SUBJECT OF TOLERANCE Circularity Cylindricity Alignment Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS CRITICAL

GRAPHIC SYMBOL O /O/ // ┴ -

GRAPHIC SYMBOL 

IMPORTANT SECONDARY

Figure 71 MAIN JOURNAL ON TIMING SYSTEM DRIVE SIDE

INTERMEDIATE MAIN JOURNALS

FIRST MAIN JOURNAL ON FRONT SIDE

70237

Checking/replace oil pump drive gear

Connecting rod and piston assembly

Figure 72

Figure 73

70184

Check that oil pump drive gear toothing (1) is not damaged or worn, otherwise remove it using an appropriate puller (3). When fitting the new oil pump drive gear, heat it for 10 minutes at a temperature of 180˚C and key it onto the crankshaft with the key (2) in between.

70191

COMPONENT PARTS OF THE CONNECTING ROD PISTON ASSEMBLY 1. Retaining rings - 2. Pin - 3. Piston - 4. Circlips - 5. Screws - 6. Half-bearings - 7. Connecting rod - 8. Bushing

NOTE

Base - March 2015

Pistons are supplied as spare parts with standard size or 0.4 mm oversize. Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

29

Disassembly of connecting rod and piston Figure 74

Figure 75

32613

32614

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

The retaining circlips (1) and piston pin seeger rings (2) are removed using a scriber (3).

Main data of piston assembly Figure 76 1.5

*

*

220’

201712

PISTON, PIN AND CIRCLIP DATA * The measurement is made on the diameter of 101 mm Checking piston diameter Using a micrometer (2), measure the piston diameter (1) to determine the assembly clearance.

Figure 77

NOTE

The diameter is to be measured at 49.5 mm from the piston skirt end.

32615

Print P1D32N021 E

Base - March 2015

30

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Checking the piston pins

Figure 81

Figure 78

18857

Measuring the piston pin diameter (1) with a micrometer (2).

32620

Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relative seats on the piston (2), using a feeler gauge (1).

Figure 79

Figure 82

32619

Use engine oil to lubricate the pin (1) and the corresponding seat on the piston hubs. Pin must be inserted in the piston with a light finger pressure and it should not come out by gravity.

41104

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

Checking the circlips

In this position and using a feeler gauge, check that the clearance (X) between the ring and the slot falls within the prescribed values.

Figure 80

Figure 83

16552 70194

Check the thickness of the piston rings (2) with a micrometer (1). Base - March 2015

Use a feeler gauge (1) to measure the clearance between the ends of the circlips (2) fitted into the cylinder liner (3). Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Checking the connecting rod and bushes

31

Connecting rod cap (B) Production year Production day N = 2013 O = 2014 P = 2015 0001 ÷ 9999 001 ÷ 366 Q = 2016 R = 2017 Rod No.

Figure 84

**

2D Data Matrix (C) 1 = Supplier’s code V = Weight class 365 = Day of production 13 = Year of production

*

Characters code (D) 1 = Supplier’s code V = Weight class 365 = Day of production 13 = Year of production *

Identification colour of connecting rod weight

NOTE 201713

MAIN DATA OF CONNECTING ROD, PISTON PIN BUSHING AND HALF-BEARINGS *

Inner diameter to be obtained after driving in the small end and regrinding with borer.

** Dimension cannot be measured in free state

NOTE

The connecting rods have a determined fracture point and are supplied already fractured together with the screws fastening the caps; the connecting rod caps are not interchangeable because the profile of the fracture varies from component to component.

Every connecting rod is marked as follows: - On the body and cap with a number showing their coupling and the corresponding cylinder into which it is to be fitted. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers as the one being replaced. - On the body with a letter showing the weight class of the connecting rod fitted during production: - V, 1734  1774 (marked with yellow); - W, 1775  1814 (marked with green); - X, 1815  1854 (marked with blue); Spare connecting rods are of the W class and marked with green*. Removal of material is not allowed.

Check that the bushing in the small end has not come loose and shows no sign of seizure or scoring. Otherwise replace it.

Figure 85

Remove and fit the bushing using a suitable drift. When refitting make sure that the holes for the oil on the bushing coincide with those on the connecting rod small end. Ream the bushing to obtain the specified diameter using a bore gauge.

225140

Rod No. 0001 ÷ 9999

Print P1D32N021 E

Connecting rod (A) Weight V (Yellow) = 1734 ÷ 1774 g W (Green) = 1775 ÷ 1814 g X (Blue) = 1815 ÷ 1854 g Base - March 2015

32

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Checking connecting rod deflection

Checking connecting rod alignment

Figure 88

Figure 86

61695 61696

Check the alignment of the connecting rod axes (1) using the tool (5) as follows: - fit the connecting rod (1) on the tool (5) spindle and secure it with the screw (4); - set the spindle (3) on the V-prisms, resting the connecting rod () on the stop bar (2).

Check the deflection of the connecting rod (5) comparing two points (C and D) of pin (3) on the vertical plane of the connecting axis. Position the vertical mount (1) of the dial gauge (2) so that this rests on the pin (3) at point (C). Swing the connecting rod backwards and forwards seeking the highest position of the pin and zero the dial gauge (2). Shift the spindle with the connecting rod (5) and repeat the check on the highest point on the opposite side (D) of the pin (3). The difference between points (C) and (D) must not exceed 0.08 mm.

Checking connecting rod torsion Figure 87

Connecting rod and piston assembly Figure 89

70198 61694

Check the torsion of the connecting rod (5) by comparing two points (A and B) of the pin (3) on the horizontal plane of the connecting axis. Position the dial gauge (2) support (1) to obtain a preload of 0.5 mm on the pin (3) in point A and then set the dial gauge (2) to zero. Shift 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) must not exceed 0.08 mm. Base - March 2015

The piston crown is marked as follows: 1.

Spare part number and design modification number.

2.

Arrow showing piston cylinder liner assembling direction into cylinder liners. This arrow is to face the front side of the crankcase.

3.

Marking showing 1st slot insert testing.

4.

Manufacturing date Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 90

NOTE

33

Circlips are supplied as spares in following sizes: - standard; - increased by 0.4 mm.

Figure 93

102596

Connect the piston (2) to the connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder lining and the numbers (5) stamped on the connecting rod (4) are as shown in the figure. Figure 91

70200

Mount the half bearings (1) on both the connecting rod and the cap. NOTE

If the same big-end bearings are to be reused, refit them in the same order and position as when they were removed. Do not make any adjustment on the half-bearings.

Cylinder head Cylinder head hydraulic seal check Figure 94 72705

Fit pin (1) seeger rings (2).

Figure 92

70323

Check the hydraulic tightness using a suitable tool. Pump in water heated to approximately 90˚C at a pressure of 2  3 bar. Replace the washer plugs (1) if leaks are found using a suitable drift for their removal/refitting. 32613

Use pliers 99360183 (3) to fit the circlips (1) on the piston (2). The rings need to be mounted with the word ”TOP” facing upwards and with the ring openings staggered 120˚ apart. Print P1D32N021 E

NOTE

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

Replace if there are any leaks from the cylinder head. Base - March 2015

34

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Cylinder head contact surface check

Intake and exhaust valves

Figure 95

Figure 97

70324

The contact surface of the cylinder head (1) with the crankcase is checked using a rule (2) and a feeler gauge (3). Any deformation found on the entire length of the cylinder head must be no greater than 0.20 mm. If values greater than this are detected, regrind the cylinder head observing the values and warnings indicated in the figure below.

EXHAUST

INTAKE

107280

INTAKE AND EXHAUST VALVE MAIN DATA Descaling, checking and grinding valves Figure 98

Figure 96

204301

Remove all carbon deposits from the valves using a wire brush. Check that the valves show no signs of seizing, cracks or burns. 70325

Rated thickness A of the cylinder head is 105 ± 0.25 mm; max. metal removal must not exceed thickness B by 0.13 mm.

NOTE

If necessary, regrind the valve seats using a grinding machine and removing as little material as possible. Figure 99

After regrinding, check that the valve recessing is within the prescribed values. Otherwise, regrind the valve seats.

18882

Using the micrometer (2), measure the valve stem (1) and check that it falls between the values 6.970  6.990 mm. Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Valve guides

35

Valve seats Regrinding and replacing the valve seats

Figure 100

Figure 101

70330

EXHAUST

INTAKE

79457

Check the valve seats (2). If they are scored or burnt, regrind using the tool (1) observing the inclination values provided in the following figure.

Using a bore gauge, measure the internal diameter of the valve guides and make sure that they fall within the values indicated in the figure.

Figure 102

EXHAUST

INTAKE

217971

VALVE SEAT MAIN DATA The valve seats are cast into the cylinder head and processed.

Print P1D32N021 E

Base - March 2015

36

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Figure 103

EXHAUST

INTAKE

107282

If it is not possible to restore the valves simply by regrinding, inserts supplied as spare parts can be fitted. In this case, using the suitable tool, regrind the valve seats to the values shown in the figure and fit the valve seats. Heat the cylinder head to 80˚ -100 ˚C and, using a drift, fit in the new valve seats (2), chilled beforehand. Then, using a suitable tool, regrind the valve seats to the values shown in the following figure. Figure 104

INTAKE

EXHAUST 221791

VALVE SEAT MAIN DATA Figure 105

After regrinding, check that the valve recessing (3) falls within the prescribed values using the stand 99370415 (2) and the dial gauge 99395603 (1).

70333

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

37

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Valve springs

Figure 108

Figure 106

70164

50676

KEY DATA FOR CHECKING INTAKE AND EXHAUST VALVE SPRINGS Before assembling, check the valve spring flexibility. Compare the elastic deformation and load data with those of the new springs shown in the following table.

H H1 H2

Height mm 47.75 35.33 25.2

P1 P2

Under a load of N Spare 339.8 ± 19 741 ± 39

Mount the camshaft (1) and lubricate the support bushing. Make sure that the bushing and the relative seat are not damaged in the process.

Figure 109

70238

ENGINE ASSEMBLY (CRANKCASE COMPONENTS) Tappets and camshaft refitting

Position the camshaft (3) retaining plate (1) with the slot facing the top side of the crankcase and the marking facing the operator, tighten the screws (2) to the torque indicated in the table.

Figure 107

Ref. (2)

No. 2

Description M8x1.25x16

Tightening torques 24 ± 4 Nm

70176

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

Print P1D32N021 E

Base - March 2015

38

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Piston cooling spray nozzles refitting

Figure 112

Figure 110

70161

Using tool 99360500 (1) and a suitable lift, fit the crankshaft (2) into the crankcase. 70180

Fit the nozzles (2) and tighten the screws (1) to the torque indicated in the table. Ref. (1)

No. 4

Description M8x1.25x20

Figure 113

Tightening torques 15 ± 3 Nm

Main half-bearings and crankshaft refitting Figure 111

70186

Check the clearance between the crankshaft main journals and their respective bearings, working as follows: - clean accurately the parts and remove any trace of oil; - position a piece of calibrated wire (3) on the output shaft pins (4) so that it is parallel to the longitudinal axis; - fit caps (1), including the half bearings (2) on the relevant supports. 70185

NOTE

If refitting the same main bearings, refit them in the same order and position as when they were removed.

The main bearings (1) are supplied as spare parts undersized on the inner diameter by 0.250 - 0.500 mm. NOTE

Figure 114

α

Do not modify the bearings in any way.

Thoroughly clean the main half bearings (1) with the lubricating hole and fit them into their seats. The second last main half bearing (1) is fitted with shoulder half rings. Base - March 2015

70188

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Screw in the pre-lubricated screws (2) and tighten them in two successive stages as indicated in the table.

39

Connecting rod and piston assembly Figure 117

Use tool 99395216 (1) for the angle tightening. Ref.

No.

Description

(2)

10

M12x1.75

1st phase 2nd phase

Tightening torques 80 ± 6 Nm 90˚

Figure 115

70201

Carefully lubricate the pistons, the circlips and the inside of the cylinder liners. Using clamp 99360605 (2), fit the connecting rod-piston assemblies (1) in the cylinder liners making sure that: - The number of each connecting rod corresponds to the cap coupling number. 70189

Figure 118

- remove the caps from the supports. The clearance between the main bearings and the related pins can be found by comparing the width of the calibrated wire (2) at the greatest squeezing point, with the graduation of the scale shown on the casing (1) which holds the calibrated wire. The numbers shown on the scale indicate the clearance in millimetres of the coupling. If the clearance is not as prescribed, change the bearing shells and repeat the check; on obtaining the prescribed clearance, lubricate the main bearings and fit the supports permanently by tightening the fastening screws as described above. Checking crankshaft end float

70202

Figure 116

DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY - split ring openings shall be displaced each other by 120; - the connecting rod -piston assemblies are all of the same weight; - the arrow stamped on the piston crown faces the front side of the crankcase, or the slot obtained on the piston skirt, and is in line with position of the oil nozzle.

70190

The end float is checked by placing a magnetic mounted dial gauge (2) on the crankshaft (3), as shown in the figure; the normal assembly clearance is 0.095 - 0.265 mm. If higher value is found, replace the main half-bearings of the second last rear support (1) and repeat the clearance check between the crankshaft pins and main half bearings.

Print P1D32N021 E

Base - March 2015

40

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Crank pin fitting clearance check

Figure 121

Figure 119 α

70205 70203

Carry out the following operations to measure the crankpin fitting clearance:

- apply tool 99395216 (1) to the socket wrench and tighten the screws (2) by a further 60˚.

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

Figure 122

Figure 120

α

70204

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

No.

(1)

8

Base - March 2015

Description M10x1.25 x52

1st phase 2nd phase

70206

- remove the cap and find the existing clearance by comparing the width of the calibrated wire (1) with the scale shown on the envelope (2) which contained the wire.

Tightening torques 50 ± 5 Nm 60˚ Print P1D32N021 E

NEF SERIES EURO VI

41

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Checking the crankshaft - connecting rod end float

ENGINE ASSEMBLY (COMPONENTS ON TOP SIDE - PART 1) Intake and exhaust valves refitting

Figure 123

Figure 125

70207

If the clearance is not as prescribed, change the half bearings and repeat the check; 70334

On obtaining the prescribed clearance, lubricate the connecting rod half bearings and fit them permanently by tightening the screws securing the connecting rod caps as described. NOTE

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

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

The sealing rings (2) for the intake valves are yellow; sealing rings (3) for exhaust valves are green.

Manually check that the connecting rods (1) slide axially on the crankshaft pins and that their end float, measured with a feeler gauge (2), is 0.10 - 0.30 mm.

Piston protrusion check Figure 126

Figure 124

70208

After fitting the connecting rod - piston assemblies, use the dial gauge 99395603 (1) fitted with base 99370415 (2) to check the protrusion of the pistons (3) at T.D.C. in relation to the top crankcase surface verifying that it falls within the value of 0.28 - 0.52 mm. Print P1D32N021 E

770321

Fit the spring (4) and upper plate (3) on the cylinder head. Using tool 99360268 (1), compress the spring (4) and secure the parts to the valve (5) with the cotters (2).

Base - March 2015

42

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Checking clearance between valve stem and valve guide and centring valves

Figure 129

Figure 127

88775

70327

Carry out the checks using a magnetic mounted dial gauge (1), positioned as shown. the assembly clearance is 0.052 0.092 mm. Turn the valve (2) and check that the run out error is no greater than 0.03 mm.

When choosing the cylinder head gaskets to be fitted, two types of gasket with different thicknesses are available: Type A 1.25 mm and Type B 1.15 mm), proceed to take the following measurements: - for each piston, measuring at a distance of 45 mm from the centre, measure protrusion S1 and S2 in relation to the crankcase and then calculate the average: S cil1 = S1 + S2 2 Repeat the operation for pistons 2, 3 and 4 and calculate the average: S=

S cil1 + S cil2 + S cil3 + S cil4 4

If S is > 0.40 mm, use a type A gasket

Cylinder head refitting

If S is < 0.40 mm, use a type B gasket.

Determining the gasket thickness Figure 128

Cylinder head assembly Figure 130

70335

Check that the cylinder head and crankcase contact surfaces are clean. Make sure that the cylinder head gaskets are not damaged or dirtied in the process. Fit the cylinder head gasket (1) with the marking ”TOP” facing towards the head itself.

70137

Put a new gasket on the crankcase and fit the cylinder head (2) using the brackets (1).

The arrow shows the point where the gasket thickness is given. Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

43

ENGINE ASSEMBLY (COMPONENTS ON REAR SIDE) Timing gear case refitting

Figure 131

Figure 133

α

70336

Fit the cylinder head (1), fit the screws (2) and tighten them in three stages as indicated in the table following the order and manner shown in the following figure. 107272

Ref.

No.

(2)

8

M12x1.75x130

(2)

10

M12x1.75x150

NOTE

Description 1st phase 2nd phase 3rd phase 1st phase 2nd phase 3rdphase

Tightening torques 35 ± 5 Nm 90˚ 90˚ 55 ± 5 Nm 90˚ 90˚

DIAGRAM OF AREA FOR APPLYING LOCTITE 5205 SEALANT ON THE GEAR CASE Carefully clean the timing gear case box (1) and the crankcase.

!

Perfect seal is only obtained by cleaning accurately the surface to seal.

Use tool 99395216 (3) for the angle tightening.

Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter.

Before assembly, check that the thread on the holes and the screws shows no sign of wear or dirt.

Application must be uniform (no lumps), without any air bubbles, thin areas or gaps. Any flaws must be corrected in as short a time as possible. Avoid using too much material to seal the sealant joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging.

Figure 132

After applying the sealant, the joint shall be assembled immediately (max 10 minutes). α

A 70337

Diagram of the tightening sequence of the cylinder head fastening screws. The external screws marked by a light hexagon are 130 mm long. The inner screws marked by a dark hexagon are 150 mm long. A = Exhaust side

Print P1D32N021 E

Base - March 2015

44

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Figure 134

Figure 136

70210

DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR CASE FASTENING SCREWS Fit the timing gear case (1) on the crankcase, fit the screws in the positions noted during removal and tighten them to the torque indicated in the table and following the order shown in the figure. Ref. (1) (1) (1) NOTE

No. 1 4 5

Description M12x1.75 M8x1.25 M10x1.5

70212

Position the crankshaft (4) and the camshaft (2) so that the marks stamped on the gears (1 and 3) coincide.

Figure 137

Tightening torques 77 ± 12 Nm 24 ± 4 Nm 47 ± 5 Nm

Before assembly, check that the thread on the holes and on the screws shows no sign of wear or dirt.

Camshaft timing

225144

Tighten the screws (1) securing the gear (2) to the camshaft (3) to the torque indicated in the table.

Figure 135

Ref. (1)

No. 6

Description M8x1.25x25

Tightening torques 36 ± 2 Nm

70211

Highlight the drive gear (1) tooth fitted on the crankshaft (2) and on which the mark for timing is stamped on the side.

NOTE

Screw in the two pins to facilitate crankshaft rotation.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

45

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Engine flywheel housing refitting

Figure 139

Figure 138

221784 221561

DIAGRAM OF AREA FOR APPLYING LOCTITE 5205 SEALANT

!

Perfect seal is only obtained by cleaning accurately the surface to seal.

DIAGRAM FOR TIGHTENING THE FLYWHEEL HOUSING FASTENING SCREWS Fit the flywheel housing on the crankcase, fit the screws (1, 2, 3 and 4) in the position noted during removal and tighten them to the torque indicated in the table and following the order shown in the figure.

Application must be uniform (no lumps), without any air bubbles, thin areas or gaps.

Ref. (1) (2) (3) (4)

Any flaws must be corrected in as short a time as possible.

NOTE

Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter.

Avoid using too much material to seal the sealant 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).

No. 10 2 2 6

Description M10x1.5 M12x1.75 M10x1.5 M12x1.75

Tightening torques 49 ± 5 Nm 85 ± 10 Nm 49 ± 5 Nm 85 ± 10 Nm

Before assembly, check that the thread on the holes and the screws shows no sign of wear or dirt.

Crankshaft rear seal ring refitting Figure 140

70216

Apply tool 99346253 part (5) to the rear crankshaft tang (6), secure it using the screws (4) and fit the new seal ring (3). Position part (1) on part (5), fit the nut (2) until the seal ring (3) has fitted completely into flywheel housing (7). Print P1D32N021 E

Base - March 2015

46

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Engine flywheel refitting

Figure 143

Figure 141

α

225145

225141

Check the condition of the ring gear teeth (1).

Apply tool 99360351 on the flywheel housing in order to block the engine flywheel (3) rotation.

If breakage or excessive wear is found, remove the ring gear from the flywheel (2) using a suitable drift and fit the new one, previously heated to 150˚C for 15 - 20 minutes

Remove the two withdrawal pins in the ports (see the previous picture).

Chamfering on the internal diameter of the ring gear must be facing the flywheel.

Tighten the screws (1 and 2) fixing the engine flywheel (3) to the crankshaft (4) in two phases.

Figure 142

Ref.

No.

(1,2)

8

NOTE

Description M12x1.25

1st phase 2nd phase

Tightening torques 30 ± 4 Nm 60˚

Use tool 99395216 for the angle tightening. Before assembly, check that the thread on the holes and the screws shows no sign of wear or dirt.

227500

Screw up two medium length screws in the ports (2) to sling the engine flywheel (3). Screw up two guide pins (4) having suitable length into the crankshaft holes (1) and assemble the engine flywheel (3) by means of a hoist with tool 99360595.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

47

SECTION 6 - GENERAL MECHANICAL OVERHAUL

ENGINE ASSEMBLY (COMPONENTS ON FRONT SIDE - PART 1) Engine oil pump refitting

Figure 146

Figure 144

70222

Fit the water pump (1) and tighten the screws (2) to the torque indicated in the table.

70220

Ref. (2)

No. 2

Description M8x1.25x35

Tightening torques 24 ± 4 Nm

Fit the oil pump (1) and tighten the screws (2) to the torque indicated in the table. Ref. (2)

No. 4

Description M8x1.25x30

Tightening torques 24 ± 4 Nm

Water pump refitting

Front cover refitting

Figure 145

Figure 147

70221 70223

Fit a new seal ring (2) to the water pump (1).

Print P1D32N021 E

Fit the new seal ring (2) on the front cover (1), carefully clean the coupling surfaces and smear them with LOCTITE 5999.

Base - March 2015

48

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Crankshaft pulley and damper pulley refitting

Figure 148

Figure 150

α

70224

Carefully clean the crankcase contact surface and fit the front cover (2). Tighten the screws (1) to the torque specified in the table.

Ref.

No.

Description

(1) (1)

5 8

M8x1.25x45 M8x1.25x30

Tightening torques 24 ± 4 Nm 24 ± 4 Nm

Fit the fixed belt tensioner and tighten the screw to the torque indicated in the table. Ref. (-)

No. 1

Description M10x1.5

Tightening torques 43 ± 6 Nm

227473

Fit the crankshaft pulley (6) and the spacer-shaft flange (5) on the crankshaft. Tighten the fastening screws (4) to the torque indicated in the table. Ref.

No.

(4)

6

NOTE

M12x1.25 x78.5

1st phase 2nd phase

50 ± 5 Nm 90˚

Use tool 99395216 for the angle tightening of the fastening screws (4).

Fit the damper pulley (3), the pulley (2) and then tighten the screws (1) to the torque indicated in the table. Ref. (1)

Crankshaft front seal ring refitting

Tightening torques

Description

No. 6

Description M10x1.25x40

Tightening torques 68 ± 7 Nm

Refitting engine speed sensor

Figure 149

Figure 151

70225

225142

Apply tool 99346252 part (5) to the front crankshaft tang (6), secure it using the screws (4) and fit the new seal ring (3).

Fit the engine speed sensor (1) with a new seal ring, on the front cover (3) and tighten the screw (2) to the torque indicated in the table.

Position part (1) on part (5); screw down the nut (2) to fit the seal (3) fully inside the front cover (7).

Ref. (2) Base - March 2015

No. 1

Description M6x1x20

Tightening torques 10 ± 2 Nm Print P1D32N021 E

NEF SERIES EURO VI

49

SECTION 6 - GENERAL MECHANICAL OVERHAUL

ENGINE ASSEMBLY (SIDE VIEW OF COMPONENTS - PART 1)

Figure 153

Engi ne oil filter support refitting Figure 152

70232

Lubricate the seal ring (2) with engine oil and set it on the oil filter (3). 70231

Fit a new gasket (1) onto the crankcase.

Check that tightening is to the torque indicated in the table.

Fit the heat exchanger plate (2) and the engine oil filter mount (4) together with a new gasket (3). Tighten the screws (5) to the torque specified in the table. Ref.

No.

Description

(5)

15

M8x1.25x35

Manually screw in the oil filter (3) on the support connection (1) and then screw in further by another 3/4 turn.

Tightening torques 26 ± 4 Nm

Ref.

No.

(3)

1

Description M27x2

Tightening torques 2 0 ± 2 Nm

Fit a new seal ring on the engine oil temperature / pressure sensor (4). Fit the engine oil temperature/ pressure sensor (4) on the support (1) and tighten the screws (5) to the torque indicated in the table. Ref.

No.

(5)

2

Description M6x1x20

Tightening torques 10 ± 2 Nm

Fit a new seal ring (6) in the crankcase seat.

Print P1D32N021 E

Base - March 2015

50

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Alternator support refitting

Engine control unit refitting

Figure 154

Figure 156

225143

225133

Position the alternator support (3) and tighten the screws (1 and 2) to the torque specified in the table.

Fit the timing sensor (2) together with the new seal ring and tighten the screw (1) to the torque indicated in the table.

Ref.

No.

(2) (1)

2 1

Description M10x1.5x130 M10x1.5x80

Tightening torques 43 ± 6 Nm 43 ± 6 Nm

Ref.

No.

(1)

1

Description M6x1

Tightening torques 10 ± 2 Nm

Figure 157

Alternator refitting Figure 155

225146

225130

Fit the alternator (3), tighten the screw (2) and the bolt (1) to the torque indicated in the table. Ref.

No.

(1) (2)

1 1

Base - March 2015

Description M10x1.5 M10x1.5

Tightening torques 43 ± 6 Nm 43 ± 6 Nm

Fit the engine management control unit (3) together with the heat exchanger and tighten the screws (4) to the torque indicated in the table. Ref.

No.

Description

(4)

3

M8x1.25x45

Tightening torques 24 ± 4 Nm

Fit the fuel pipe from tank to ECU (2), engage the intermediate retaining clips and connect the quick-fit coupling (1).

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

ENGINE ASSEMBLY (COMPONENTS ON TOP SIDE - PART 2)

51

Figure 161

Electro-injectors refitting Figure 158

70338

Fit a new seal ring (2) lubricated with vaseline and a new sealing washer (3) on the electro-injector (1). Figure 159

91572

Fit a new seal ring (3) lubricated with vaseline on the fuel manifold (2). Fit the fuel manifold (2) so that the positioning balls (5) coincide with the relevant housing (4). NOTE

Do not re-use the fuel manifolds (2), but replace them with new ones.

Screw in but do not tighten the nuts (2) securing the manifolds (3) shown in the figure. It is recommended that the electro-injectors are positioned in such a way that the manifold terminal inserts correctly into the designated holes on the electro-injector. 70339

Fit the electro-injectors (1) so that the fuel inlet hole (2) faces the fuel manifold terminal (3). Figure 160

70133

Using tool 99342101 (1) fit the electro-injector (2) into its seat. Screw injector fastening screws without tightening them. Print P1D32N021 E

Base - March 2015

52

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Figure 162

Figure 164

α

108492

Using a torque wrench, gradually and alternately tighten the electro-injector fastening screws (1) to the torque indicated in the table. Ref.

(1)

No.

8

Description M6x1x35 1st phase 2nd phase 3rd phase 4th phase

Tightening torques

70344

SHAFT-ROCKER MAIN DATA Check that shaft-rocker arm coupling surfaces are not excessively worn or damaged. Figure 165

3.5 ± 0.35 Nm 25˚ 25˚ 25˚

Tighten the fuel manifold (3) fastening nuts (2) to the torque indicated in the table. Ref.

No.

(2)

4

Description M22x1.5

227474

Tightening torques 55 ± 5 Nm Figure 166

Rocker assembly refitting Figure 163

70345

Fit the pushrods (2). 70343

ROCKER ASSEMBLY COMPONENTS:

Position bridges (1) on valves with marks () facing the exhaust manifold.

1. Screw - 2. Support - 3. Shafts - 4. Rocker arms

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

53

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 167

Tappet clearance adjustment Figure 168

70520 70346

Check that the tappet adjuster fastening nuts (1) are unscrewed to prevent them sticking on the rods when fitting the rocker arm assembly. Then refit the rocker arm assembly consisting of the support (5), rocker arms (3) and shafts (4) and secure them to the cylinder head by tightening the fastening screws (2) to the torque indicated in the table. Ref.

No.

(2)

8

Description M8x1.25

Tightening torques 36 ± 5 Nm

Adjust the clearance between rocker arms and valves through Allen wrench (1), box wrench (3) and feeler gauge (2). The operating clearance is: - 0.25 ± 0.05 mm for the intake valve - 0.51 ± 0.05 mm for the exhaust valve Tighten the tappet adjuster nuts (1) to the torque indicated in the table. Ref.

No.

(1)

8

Tightening torques 24 ± 4 Nm

Description M8x1.25

To carry out rocker arm - valve clearance adjustment more quickly, proceed as follows: Apply tool 99360221 (with pinion 99360222) on the flywheel. Turn the crankshaft, balance the cylinder 1 valves and adjust the valves marked by the asterisk as shown in the table: cylinder n. intake exhaust

1 -

2 *

3 * -

4 * *

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

Print P1D32N021 E

1 * *

2 * -

3 *

4 -

Base - March 2015

54

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Electro-injector wiring support refitting

Intake manifold refitting

Figure 169

Figure 171

70352

Check the condition of the cables (5) and replace them if they are damaged. Cut the clips (5) securing the cables to the support (2) and unscrew the screws (4) securing the connectors (3). Fit a new gasket (1) on the support (3). Figure 170

225124

Apply a bead of LOCTITE 5999 sealant on the contact surface of the intake manifold (2), fit it onto the cylinder head and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1) (1)

6 1

M8x1.25x25 M8x1.25x70

Tightening torques 24 ± 4 24 ± 4

Tappet cover refitting Figure 172

225147

Fit the electro-injector wiring support (3) and tighten the screws (4) to the torque indicated in the table. Ref. (4) (4)

No. 2 3

Description M8x1.25x50 M8x1.25x70

Tightening torques 24 ± 4 Nm 24 ± 4 Nm

Connect the cables (1) to the electro-injectors and use the torque wrench 99389834 to tighten the nuts (2) to the torque indicated in the table. Ref.

No.

(2)

8

Base - March 2015

Description M4

Tightening torques 1.5 ± 0.5 Nm

225123

Fit the tappet cover (2) together with the oil vapour separator and the new gasket and tighten the nuts (1) to the torque indicated in the table. Ref.

No.

(1)

4

Description M8x1.25

Tightening torques 24 ± 4

Fit the thermostat body (4) together with the new O-ring and tighten the screws (3) to the torque indicated in the table. Ref.

No.

Description

(3) (3)

2 1

M6x1.0x20 M6x1.0x50

Tightening torques 13.5 ± 1.5 Nm 13.5 ± 1.5 Nm Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

55

Figure 174

Rail refitting Figure 173

α

116237

225148

Fit the rail (5) and tighten the screws (6) to the torque indicated in the table. Ref.

No.

(6)

3

Description M8x1.25x125

To connect the low pressure fuel pipe to the relative connection fitting, insert the quick-fit coupling (2) into the connection fitting and push in until the catchs (3) engages. NOTE

Check proper fuel pipe connection.

Tightening torques 36 ± 5 Nm

Fit the fuel pipes (1) and tighten the fittings (5) rail side and (2) the electro-injector manifolds side to the torque indicated in the table. Ref. (1)

No. 8

Description

Tightening torques

M14x1.5 1st phase 2nd phase

10 ± 1 Nm 55˚

Engage the intermediate retaining clips and connect the fuel return pipe (4) to the rail (5) and to the cylinder head (3). As the pipes are subject to high pressure, they must always be replaced with each disassembly. The pipe fittings must be tightened to the specified torque using the wrench 99317915 and the torque wrench 99389829. Connect the fuel return pipe (4) to the rail (5) following the procedures shown in the following figure.

Print P1D32N021 E

Base - March 2015

56

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

ENGINE ASSEMBLY (SIDE VIEW OF COMPONENTS -PART 2) Exhaust manifold refitting Figure 175

Checking and adjusting the Waste-Gate The turbocharger is fitted with a pressure regulation valve, mounted on the exhaust manifold before the turbine and controlled by a pneumatic actuator, connected via a pipe to the intake manifold. Its job is to limit the quantity of exhaust gas acting on the turbine by sending part of it directly into the exhaust pipe when the boost pressure downstream of the compressor reaches the maximum value set. Figure 176

227466

Fit the exhaust manifold (2) together with the new gaskets and tighten the screws (1) to the torque indicated in the table. Ref.

No.

Description

(1)

8

M10x1.5x65

Tightening torques 55± 3 Nm

221447

Cover the air, exhaust gas and lubrication oil inlets and outlets. Carry out an accurate external cleaning of the turbocharger, using the anticorrosive and antioxidant solution and perform the check on the actuator (4). Clamp the turbocharger in a vice. Disconnect the pipe of the actuator (4) and apply to the actuator union, the pipe of pump 99367121 (1). Apply the magnetic-base dial gauge (2) on the exhaust gas inlet flange in the turbine. Position the tracer point of the gauge (2) on the tie rod (3) end and set to zero the gauge (2). Through the pump (1) let in compressed air, in the actuator (4), at the prescribed pressure and make sure that such value is kept constant for the whole check time. In the above-mentioned conditions, the tie rod must have carried out the prescribe stroke. Stroke (mm) 1 4

Base - March 2015

Pressure (bar) 1.85 ± 0.03 2.18 ± 0.006

NOTE

During the operation, beat slightly the actuator (4) in order to eliminate possible sticking of the actuator internal spring.

NOTE

Is not allowed any replacement, or adjustment of the actuator because the calibration of this component is performed and guaranteed by the manufacturer for each turbocharger. Print P1D32N021 E

NEF SERIES EURO VI

NOTE

57

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Before refitting the turbocharger on engine, fill the central body with

Engine brake refitting Figure 178

Turbocharger refitting Figure 177

225128

Connect the engine brake water delivery pipe (2) on the crankcase and tighten the fitting (1) to the torque indicated in the table. 227443

Fit the turbocharger (2) together with the new gasket onto the exhaust manifold and tighten the nuts (3) to the torque indicated in the table. Ref.

No.

(3)

4

Description M8x1.25

Tightening torques 25 ± 2.5 Nm

Ref.

No.

(1)

1

Description M14x1.5

Tightening torques 45 ± 4.5

Figure 179

Connect the engine oil delivery pipe (1) to the heat exchanger support and to the turbocharger (2) and tighten the fittings to the torque indicated in the table. Ref.

No.

(1)

2

Description M16

Tightening torques 25 ± 5 Nm

227444

Fit the engine brake (2) and tighten the nuts (1) securing it to the turbocharger to the torque indicated in the table. Ref.

No.

(1)

4

Description M8x1.25

Tightening torques 25 ± 5

Connect engine brake water delivery pipe (3) to the engine brake and tighten the union (4) to the torque indicated in the table.

Print P1D32N021 E

Ref.

No.

(4)

1

Description M12x1.5

Tightening torques 25 ± 2.5

Base - March 2015

58

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

ENGINE ASSEMBLY (COMPONENTS ON FRONT SIDE - PART 2)

ENGINE ASSEMBLY (COMPONENTS ON BOTTOM SIDE)

Auxiliary drive belt and automatic belt tensioner refitting

Engine oil intake suction strainer refitting Figure 181

Figure 180

227445 227447

Fit the automatic belt tensioner (3) and tighten the screw (2) to the torque indicated in the table. Ref.

No.

(2)

1

Description M10x1.5

Tightening torques 43 ± 6 Nm

Using a specific wrench on the automatic belt tensioner (3), fit the belt (1), making sure that the ribs on the belt fit properly into the grooves on the pulley.

Base - March 2015

Fit the sub-crankcase stiffening plate (3) and tighten the screws (2) to the torque indicated in the table. Ref.

No.

Description

(2)

4

M10x1.5x25

Tightening torques 43 ± 5 Nm

Fit the engine oil intake suction strainer (1) and tighten the screws to the torque indicated in the table. Ref.

No.

(1) (1)

2 1

Description M8x1.25 M10x1.5

Tightening torques 24 ± 4 Nm 43 ± 5 Nm

Print P1D32N021 E

NEF SERIES EURO VI

59

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Engine oil sump refitting

REMOVING THE ENGINE ROTATING STAND

Figure 182

FROM

THE

Apply the arm 99360595 to engine lifting hooks, hook the arm to a suitable hoist and remove the engine from the rotating stand. Remove the brackets 99361037.

Exhaust side - oil level dipstick and engine brake water return pipe refitting Figure 183

227446

Fit a new gasket on the oil sump (1) and place them on the cranckcase; suddenly place the oil pan frame (2) on the cranckcase and tighteen the screws (3) to the torque indicated in the table. Ref. (3) (3)

No. 10 4

Description M8x1.25x40 M8x1.25x45

Tightening torques 24 ± 4 Nm 24 ± 4 Nm

Place the oil sump drain plug (4) with a new gasket and tighten it to the torque indicated in the table.

225121

Fit the engine brake water return pipe (7), tighten the union (8) on the engine brake, the union (4) on the alternator support and the screws (5) securing the intermediate retaining brackets, to the torque indicated in the table. Ref.

No.

Tightening torques 60 ± 9 Nm

(8) (4)

Rotate the engine through 180˚ on the overhaul stand.

(5)

1 1 2

M12x1.5 M12x1.5 M8x16

Tightening torques 25 ± 2.5 Nm 35 ± 3.5 Nm 25 ± 2.5 Nm

1

M10x20

36 ± 3.6 Nm

Ref.

No.

(4)

1

Description M18x1.5

Description

Fit the oil level dipstick pipe (2), tighten the fitting (6) and the screws (1 and 3) securing the retaining brackets onto the cranckase and onto the exhaust manifold, to the torque indicated in the table.

Print P1D32N021 E

Ref.

No.

Description

(1) (3) (6)

1 1 1

M10x1.5x65 M8x1.25 M18x1.5

Tightening torques 55 ± 3 Nm 24 ± 4 Nm 30 Nm

Base - March 2015

60

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Exhaust side - electric starter motor refitting Figure 184

Intake side - fuel delivery pipe from high pressure pump to rail and high pressure pump refitting Figure 185

α

225120

Fit the starter motor (4) to the flywheel cover and tighten the nuts (3) to the torque indicated in the table. Ref.

No.

(3)

3

Description M10x1.5

Tightening torques 43 ± 6 Nm

Fit the oil outlet pipe (2) together with the new gasket, connect it to the turbocharger and to the crankcase and then tighten the screws (1) to the torque indicated in the table. Ref.

No.

(1)

2

Description M6x1

Tightening torques 10 ± 2 Nm

225119

Fit the high pressure pump (5) together with the feed pump, the adapter and the pump gear, on the timing gear case and tighten the fastening nuts (4) to the torque indicated in the table Ref.

No.

(4)

3

Description M8x1.25

Tightening torques 24 ± 4 Nm

Fit the fuel pipe from the heat exchanger on the engine control unit to the feed pump (7), engage the intermediate retaining clip and connect the quick-fit couplings. Fit the fuel return pipe from the high pressure pump outlet to tank (3), engage the intermediate retaining clips and connect the quick-fit coupling. Connect a new fuel high pressure delivery pipe (2) to the high pressure pump, tighten the fitting (6) and the screw (1) securing the lower intermediate retaining bracket to the crankcase, to the torque indicated in the table.

Base - March 2015

Ref.

No.

(1)

1

(6)

1

Description M8x1.25x16 M14x1.5 1st phase 2nd phase

Tightening torques 24 ± 4 10 ± 1 55˚

Print P1D32N021 E

NEF SERIES EURO VI

61

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Figure 186

Ref.

No.

(4)

2

Description M12x1.75x30

Tightening torques 80 ± 8 Nm

Manually screw the fuel filter (3) until flush on the support (4); tighten by another ¾ of a turn and check that the tightening torque is the same as that indicated in the table. α

Ref.

No.

(3)

1

Description M20x1.5

Tightening torques 20 ± 2 Nm

Fit the fuel return pipe from fuel filter to the high pressure pump inlet (2) and connect the quick-fit couplings. 225118

Connect the fuel high pressure delivery pipe (2) to the rail, tighten the fitting (1) and the screw (3) securing the upper intermediate retaining bracket to the crankcase, to the torque indicated in the table. Ref.

No.

(3)

1

(1)

1

Description M8x1.25x20 M14x1.5 1st phase 2nd phase

Fit the fuel delivery pipe from the feed pump to the fuel filter (1) and connect the quick-fit couplings. Figure 188

Tightening torques 24 ± 4 10 ± 1 55˚

Use the torque wrench 99389829 together with the tool 99317915 for the angle tightening of the fuel delivery pipe fittings (2). If removed, the fuel delivery pipe (2) must be replaced with new ones.

116237

Toconnect the lowpressure fuel pipe to the relative connection fitting, insert the quick-fit coupling (2) into the connection fitting and push in until the catchs (3) engages. When fitting is completed, top-up the engine lubricant oil with the specified quantity and quality.

Intake side - fuel filter support refitting Figure 187

Only use recommended oils or oils with the properties required for proper engine operation. Failure to observe these standards will invalidate the service warranties. Check the oil level with the oil level dipstick: the level must come close to the MAX notch which can be seen on the dipstick.

225117

Fit the fuel filter support (4) on the crankcase and tighten the screws to the torque indicated in the table.

Print P1D32N021 E

Base - March 2015

62

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

Engine cable refitting Fit the engine cable and close the retaining clips securing the engine cable to the crankcase. Connect the following electrical connections: Figure 189

225115

1. Electro-injector connections - 2. Motorized throttle valve actuator connector (Exhaust flap) - 3. Boost pressure and air temperature sensor - 4. Rail pressure sensor - 5. Timing segment speed sensor (camshaft) - 6. Fuel high pressure pump metering unit - 7. Fuel temperature sensor - 8. In line connector - 9. Rpm increment speed sensor (crankshaft) -10. Engine Control Unit EDC17CV41 - 11. Coolant temperature sensor

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

63

Figure 190

225116

1. Coolant temperature sensor - 2. Engine oil pressure and temperature sensor 3. Motorized throttle valve actuator connector (Exhaust flap)

Print P1D32N021 E

Base - March 2015

64

SECTION 6 - GENERAL MECHANICAL OVERHAUL

NEF SERIES EURO VI

CHECKS AND INSPECTIONS

Test on the pressure relief valve on the rail

The following tests shall be made after engine assembly to the vehicle.

The function of the valve fitted at one end of rail is to protect system components against any fault which might result in overpressure in high pressure system.

Preventively check that the liquid levels have been correctly restored. 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: - There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings. - Carefully check the fuel connection pipes to the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting covers. - Cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings. - There is no fuel leakage from fuel pipelines. - There is no blow-by from pneumatic pipes (if provided). - Verify correct working of the lighting leds of the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection. - Check and blow by with care the engine cooling system, carrying out frequent drainage.

Figure 191

227476

Disconnect the recirculation pipe (2) of the overpressure valve (1) and plug the pipe using the Voss coupling (3) provided with 99305453 tool. No diesel fuel leaks shall be detected from valves at any engine rpm. If the diagnostic system indicates the fault code Rail overpressure relief valve management, this means that the control unit has identified the valve opening due to a significant change in the pressure of the rail (greater than 1800 bar). Since the valve opening is due to an abnormal pressure increase, the valve is not faulty even if a significant quantity of diesel oil is overflowing. If diesel oil leaks are detected from the valve (1) and the fault code is not emitted, replace valve.

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 6 - GENERAL MECHANICAL OVERHAUL

65

Checking the mechanical feed pump Figure 192

5

227477

1. High pressure pump (CP3.3) - 2. Mechanical feed pump - 3. External container - 4. Fuel filter support 5. Filter inlet pipe pressure gauge - 6. Filter outlet pipe pressure gauge The mechanical pump (2) feeds the high pressure pump CP3.3 (1). It is controlled by the shaft of the high pressure pump and is fitted on its rear part. Keeping the instruments of 99305453 kit fitted as in the previous figure with batteries charged ad 24.7 V, the engine must start within 20 seconds after the starter motor activation, drawing the diesel fuel from an external container (3) placed not more than 1 metre lower than the engine. If the pump does not suck the diesel fuel within the time specified, therefore the engine does not start, replace pump. NOTE

If the test was performed with a new mechanical feed pump from Spare Parts, before doing the test, a fist start is necessary in order to restore normal operation conditions.

After starting the engine, at 1500 rpm check the pressure on the pressure gauge (5). Pressure gauge pressure values

Print P1D32N021 E

6 to 9 bar (87 to 130.5 psi)

If the value measured is below 6 bar, replace pump; if the value is above 9 bar, replace the diesel fuel filter. The pressure gauge (6) must show a pressure above 5 bar; if the pressure is lower, replace the diesel fuel filter. If the problem is not cleared, check the seals of the hich pressure pump inlet and fuel filter support unions. NOTE

A new mechanical feed pump which is interchangeable with the previous version has been included in Spare Parts. The new pump has a new seal protecting against water entering the area where the two pumps are joined, thus preventing the formation of rust which could cause breakage of the shaft connecting the high and low pressure pumps. The pump is equipped with seal, however the single seal is provided as a spare. When the low pressure pump has to be replaced, thoroughly clean the mating area with high pressure pump CP3.3. Base - March 2015

66

SECTION 6 - GENERAL MECHANICAL OVERHAUL

Base - March 2015

NEF SERIES EURO VI

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 7 - TECHNICAL SPECIFICATIONS

1

SECTION 7 Technical specifications Page

Print P1D32N021 E

DATA - INSTALLATION CLEARANCES . . . . .

3

TIGHTENING TORQUES . . . . . . . . . . . . . . . . .

9

Base - March 2015

2

SECTION 7 - TECHNICAL SPECIFICATIONS

Base - March 2015

NEF SERIES EURO VI

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 7 - TECHNICAL SPECIFICATIONS

3

DATA - INSTALLATION CLEARANCES

F4AFE411A*C005 F4AFE411C*C026

Type CRANK GEAR AND CYLINDER ASSEMBLY DATA

mm

1 Cylinder liners X

1 X

104.000 ÷ 104.024

1

0.4

X 1 2

49.5 103.739 ÷ 103.757 40.010 ÷ 40.016

Pistons Measuring point Outer diameter Pin housing

2

1

Piston - cylinder liners

X

3

Piston diameter

1

Piston position from crankcase

X

Piston pin Piston pin - pin seat

Print P1D32N021 E

0.243 ÷0.285

3

0.4

0.28 ÷ 0.52 39.994 ÷40.000 0.010 ÷ 0.022

Base - March 2015

4

SECTION 7 - TECHNICAL SPECIFICATIONS

NEF SERIES EURO VI

F4AFE411A*C005 F4AFE411C*C026

Type CRANK GEAR AND CYLINDER ASSEMBLY DATA X1 X2 X3 S 1 S 2 S 3

Circlip slots

Circlips

mm X1 X2 X3

2.705 ÷ 2.735 2.420 ÷ 2.440 4.030 ÷ 4.050

S 1* S2 S3

2.563 ÷ 2.597 2.350 ÷ 2.380 3.970 ÷ 3.990

* measured on  101 mm 1 2 3

Circlips - slots Piston rings X1 X2 X3

1

0.4

Piston ring end gap in cylinder liner: X1 X2 X3

0.30 ÷ 0.40 0.60 ÷ 0.80 0.30 ÷ 0.55

Small end bushing seat 1

42.987 ÷ 43.013

2

73.987 ÷ 74.013

Inner diameter of connecting rod small end bush 3 Connecting rod half-bearings supplied as spares S

40.019 ÷ 40.033

Big-end bearing seat

2 3 S

Piston pin - bushing Connecting rod half-bearings

Base - March 2015

0.108 ÷ 0.172 0.040 ÷ 0.090 0.040 ÷ 0.080

1.958 ÷ 1.968 0.019 ÷ 0.039 0.250; 0.500

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 7 - TECHNICAL SPECIFICATIONS

F4AFE411A*C005 F4AFE411C*C026

Type CRANK GEAR AND CYLINDER ASSEMBLY DATA

1

2

S 1

S 2

Main journals Crankpins

5

mm 1 2

Main half-bearings S1* Connecting rod half-bearings S2*

82.993 ÷ 83.013 69.987 ÷ 70.013 2.456 ÷ 2.464 1.958 ÷ 1.968

*supplied as spares

3

Main journals No. 1 - 5 No. 2 - 3 - 4

3 3

87.982 ÷ 88.008 87.977 ÷ 88.013

Half-bearings - main journals nº 1 - 5 nº 2 - 3 - 4

0.044 ÷ 0.106 0.039 ÷ 0.111

Half bearings - crankpins

0.038 ÷ 0.110

Main half-bearings Connecting rod half-bearings

+ 0.250 ; + 0.500

Thrust main journal

X1

37.475 ÷ 37.545

Main journal support for thrust

X2

32.18 ÷ 32.28

Thrust half rings

X3

36.57 ÷ 37.09

X 1

X 2 X 3

Crankshaft end play

Print P1D32N021 E

0.385 ÷ 0.975

Base - March 2015

6

SECTION 7 - TECHNICAL SPECIFICATIONS

NEF SERIES EURO VI

F4AFE411A*C005 F4AFE411C*C026

Type CYLINDER HEAD - TIMING SYSTEM

mm

1 Valve guide housing on cylinder head

2

1

7.042 ÷ 7.062

2 

6.970 ÷ 6.990 60˚  0.25˚

2 

6.970 ÷ 6.990 45˚  0.25˚

Valve stem and related guide

0.052 ÷ 0.092

Valves:

 Housing on head for valve seat:

1

1

34.837 ÷ 34.863

1

34.837 ÷ 34.863

Valve seat outside diameter; valve seat angle on cylinder head: 2 

 2

2 



Between valve seat and cylinder head Valve seats

Base - March 2015

34.917 ÷ 34.931 45˚

X

0.74 ÷ 1.26

X

0.41 ÷ 0.93

Recessing X

34.917 ÷ 34.931 60˚

0.054 ÷ 0.094 0.054 ÷ 0.094 -

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 7 - TECHNICAL SPECIFICATIONS

7

F4AFE411A*C005 F4AFE411C*C026

Type CYLINDER HEAD - TIMING SYSTEM

mm

Valve spring height: H

47.75

H1 H2

35.33 25.20

X

Not adjustable

free spring H

H1

H2

under a load of: 339.8  19 N 741  39 N Injector protrusion

X Seat for camshaft bushing no. 1 (flywheel side) Camshaft seats nº 2-3-4-5

59.222 ÷ 59.248 54.089 ÷ 54.139

 2-3-4

1

Camshaft journal diameter: 15 

53.995 ÷ 54.045

Internal bush diameter

54.083 ÷ 54.147

5 



0.038 ÷ 0.152

Bushing and support pins Useful cam height: H

Print P1D32N021 E

H

7.582

H

6.045

Base - March 2015

8

SECTION 7 - TECHNICAL SPECIFICATIONS

NEF SERIES EURO VI

F4AFE411A*C005 F4AFE411C*C026

Type CYLINDER HEAD - TIMING SYSTEM

1

2

3

2

Tappet washer seat in crankcase

mm

1

Tappet outside diameter: 2 3 Between tappets and seats Tappets

16.000 ÷ 16.030

15.924 ÷ 15.954 15.960 ÷ 15.975 0.025 ÷ 0.070 -

 1 Rocker-arm shaft

1

21.965 ÷ 21.977

Rocker arms

2

22.001÷ 22.027

2 Between rockers and shaft

Base - March 2015

0.024 ÷ 0.062

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 7 - TECHNICAL SPECIFICATIONS

9

TIGHTENING TORQUES PART

TORQUE

Piston cooling spray nozzles (4 unions M8x1.25x20) Camshaft retaining plate (2 screws M8x1.25x16) Main bearing caps (10 screws M12x1.75)

1st phase 2nd phase

Timing gear case (1 screw M12x1.75) (4 screws M8x1.25) (5 screws M10x1.5) Timing gear (6 screws M8x1.25x25) Connecting rod caps (8 screws M10x1.25x52)

1st phase 2nd phase

High-pressure pump (3 nuts M8x1.25) High pressure fuel delivery pipes (10 fittings M14x1.5)

1st

phase 2nd phase

Brackets securing delivery pipe from high pressure pump to rail (1 screw M8x1.25x20) (1 screw M8x1.25x16) Cylinder head (8 screws M12x1.75x130) (10 screws M12x1.75x150)

1st phase 2nd phase 3rd phase

Nm 15 ± 3 24 ± 4 80 ± 6

kgm 1.5 ± 0.3 2.4 ± 0.4 8.0 ± 0.6 90˚

77 ± 12 24 ± 4 47 ± 5 36 ± 2 50 ± 5

7.7 ± 1.2 2.4 ± 0.4 4.7 ± 0.5 3.6 ± 0.2 5.0 ± 0.5 60˚

24 ± 4 10

2.4 ± 0.4 1.0 55˚

24 ± 4 24 ± 4

2.4 ± 0.4 2.4 ± 0.4

35 ± 5 55 ± 5

3.5 ± 0.5 5.5 ± 0.5 90˚ 90˚

Figure 193

A

70337

Tightening sequence A = Front

Print P1D32N021 E

Base - March 2015

10

SECTION 7 - TECHNICAL SPECIFICATIONS

NEF SERIES EURO VI

PART

TORQUE Nm 36 ± 5

kgm 3.6 ± 0.5

24 ± 4 11 ± 3 1.5 ± 0.25

2.4 ± 0.4 1.1 ± 0.3 0.15 ± 0.025

24 ± 4 43 ± 5 24 ± 4 43 ± 5

2.4 ± 0.4 4.3 ± 0.5 2.4 ± 0.4 4.3 ± 0.5

24 ± 4 24 ± 4

2.4 ± 0.4 2.4 ± 0.4

Flywheel housing (8 screws M12x1.75) (12 screws M10x1.5)

85 ± 10 49 ± 5

8.5 ± 1.0 4.9 ± 0.5

Engine oil sump (10 screws M8x1.25x40) (4 screws M8x1.25x45) Engine oil drain plug (1 M18x1.5) Engine oil filter support (15 screws M8x1.25x35) Engine oil filter (M27x2) Crankshaft pulley (6 screws M12x1.25x78.5)

24 ± 4 24 ± 4 60 ± 9 26 ± 4 20 ± 2 50 ± 5

2.4 ± 0.4 2.4 ± 0.4 6.0 ± 0.9 2.6 ± 0.4 2.0 ± 0.2 5.0 ± 0.5

Rocker arm assembly (8 screws M8x1.25) Tappet cover (4 nuts M8x1.25) (4 screws M8x1.25x20) Electro-injector wiring (8 nuts M4) Engine oil suction strainer (2 screws M8x1.5) (1 screw M10x1.5) Engine oil pump (4 screws M8x1.25x30) Crankcase stiffening plate (4 screws M10x1.5x25) Front cover (5 screws M8x1.25x45) (8 screws M8x1.25x30)

Damper pulley (6 screws M10x1.25x40) Electro-injectors bracket (8 screws M6x1x35)

1st phase 2nd phase 1st phase

90˚ 68 ± 7 3.5 ± 0.35

2nd phase 3rd phase 4nd phase Electro-injector wiring support (2 screws M8x1.25x50) (3 screws M8x1.25x70) (2 screws M6x1x16) Fuel manifolds (4 nuts M22x1.5) Intake manifold (6 screws M8x1.25x25) (1 screw M8x1.25x70) Rail (3 screws M8x1.25x125) Electric starter motor (3 nuts M10x1.5) Turbocharger (4 nuts M8x1.25) (4 studs M8x1.25) Oil outlet pipe from turbocharger (2 screws M6x1) Oil deliver pipe to turbocharger (2 fittings M16) Exhaust manifold (8 screws M10x1.5x65)

Base - March 2015

6.8 ± 0.7 0.35 ± 0.035 25˚ 25˚ 25˚

24 ± 4 24 ± 4 10 ± 2 55 ± 5

2.4 ± 0.4 2.4 ± 0.4 1.0 ± 0.2 5.5 ± 0.5

24 ± 2.4 24 ± 2.4 36 ± 5 43 ± 6

2.4 ± 0.24 2.4 ± 0.24 3.6 ± 0.5 4.3 ± 0.6

25 ± 2.5 11 ± 3 10 ± 2 25 ± 5 55 ± 3

2.5 ± 0.25 1.1 ± 0.3 1.0 ± 0.2 2.5 ± 0.5 5.5 ± 0.3

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 7 - TECHNICAL SPECIFICATIONS

PART

TORQUE

Alternator support (2 screws M10x1.5x130) (1 screw M10x1.5x80) Alternator (1 screw M10x1.5) (1 bolt M10x1.5) Engine control unit (3 screws M8x1.25x45) Engine oil pressure and temperature sensor (2 screws M6x1x20) Boost pressure and air temperature sensor (1 screw M6x1x20) Engine coolant / fuel temperature sensor (1 fitting M14x1.5) Timing segment speed sensor (camshaft) (1 stud M6x1) (1 nut M6x1) Rail pressure sensor (M18x1.5) Overpressure valve DBV4 (M20x1.5) Crankcase plug (1 plug M18x1.5) Cylinder head plug (1 plug M22x1.5) Engine rpm sensor (1 screw M6x1x20) Fuel filter housing (2 screws M12x1.75x30) Fuel filter (1 fitting M20x1.5) Fixed belt tensioner (1 screw M10x1.5) Automatic belt tensioner (1 screw M10x1.5) Engine flywheel (8 screws M12x1.25) Thermostat body (2 screws M6x1.0x20) (1 screw M6x1x50) Water pump (2 screws M8x1.25x35) Oil vapour recirculation system control valve (3 screws M5) Brackets for lifting engine (4 screws M8x1.25x25) (2 screws M12x1.75x25) Fuel high pressure pump gear (1 nut M18x1.5) Fuel suction pump crankcase cover (2 screws M8x1.25x20) Oil level dipstick (1 fitting M18x1.5) (1 screws M8x1.25) (1 screw M10x1.5x65) Motorized throttle valve (Exhaust flap) (4 studs M8x1.25x12) (4 nuts M8x1.25)

Print P1D32N021 E

11

1st phase 2nd phase

Nm

kgm

43 ± 6 43 ± 6

4.3 ± 0.6 4.3 ± 0.6

43 ± 6 43 ± 6 24 ± 4 10 ± 2 10 ± 2 24 ± 4

4.3 ± 0.6 4.3 ± 0.6 2.4 ± 0.4 1.0 ± 0.2 1.0 ± 0.2 2.4 ± 0.4

4 8±2 70 ± 5 100 ± 5 24 ± 4 80 ± 5 10 ± 2 80 ± 8 20 ± 2 43 ± 6 43 ± 6 30 ± 4

0.4 0.8 ± 0.2 7.0 ± 0.5 10.0 ± 0.5 2.4 ± 0.4 8.0 ± 0.5 1.0 ± 0.2 8.0 ± 0.8 2.0 ± 0.2 4.3 ± 0.6 4.3 ± 0.6 3.0 ± 0.4 60˚

13.5 ± 1.5 13.5 ± 1.5 24 ± 4 5

1.35 ± 0.15 1.35 ± 0.15 2.4 ± 0.4 0.5

36 ± 5 77 ± 12 105 ± 5 24 ± 4

3.6 ± 0.5 7.7 ± 1.2 10.5 ± 0.5 2.4 ± 0.4

30 24 ± 4 55 ± 3

3.0 2.4 ± 0.4 5.5 ± 0.3

11 ± 3 25 ± 2.5

1.1 ± 0.3 2.5 ± 0.25

Base - March 2015

12

SECTION 7 - TECHNICAL SPECIFICATIONS

NEF SERIES EURO VI

PART

TORQUE Nm

kgm

Motorized throttle valve cooling delivery/return pipes (return pipe - 1 union M12x1.5 - alternator support side) (return pipe - 1 union M12x1.5 - engine brake side) (return pipe - 1 screw M10x20) (return pipe - 2 screws M8x16)

35 ± 3.5 25 ± 2.5 36 ± 3.6 25 ± 2.5

3.5 ± 0.35 2.5 ± 0.25 3.6 ± 0.36 2.5 ± 0.25

(delivery pipe - 1 fitting M14x1.5 - crankcase side) (delivery pipe - 1 union M12x1.5 - engine brake side)

45 ± 4.5 25 ± 2.5

4.5 ± 0.45 2.5 ± 0.25

24 ± 4 36 ± 5 12 ± 2 12 ± 2

2.4 ± 0.4 3.6 ± 0.5 1.2 ± 0.2 1.2 ± 0.2

24 ± 4 24 ± 4 24 ± 4 24 ± 4

2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4

Cylinder head plug ½ inch -14 ¾ inch -14 ½ inch ¼ inch Crankcase plug (1 plug M14x1.5x11) (1 plug M10x1x9.5) (1 plug M18x1.5x14.5) Valve clearance adjustment (8 nuts M8x1.25)

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 8 - TOOLS

1

SECTION 8 Tools

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

Print P1D32N021 E

3

Base - March 2015

2

SECTION 8 - TOOLS

Base - March 2015

NEF SERIES EURO VI

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 8 - TOOLS

3

TOOLS TOOL NO.

DESCRIPTION

99305453

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

99317915

Set of five ring spanners with insert 9x12 (14 - 15 - 17 - 18 - 19)

99322205

Revolving stand for overhauling units (1000 daN capacity, 120 daNm torque)

99340055

Tool to remove output shaft front gasket

99340056

Tool to remove output shaft rear gasket

99341001

Double acting puller

Print P1D32N021 E

Base - March 2015

4

SECTION 8 - TOOLS

NEF SERIES EURO VI

TOOLS TOOL NO.

DESCRIPTION

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 to remove filters

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 8 - TOOLS

5

TOOLS TOOL NO.

DESCRIPTION

99360183

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

99360221

Tool for rotating the engine flywheel (use with 99360222)

99360222

Pinion (use with 99360221)

99360268

Tool for removing/refitting engine valves

99360351

Tool for stopping the engine flywheel

99360362

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

Print P1D32N021 E

Base - March 2015

6

SECTION 8 - TOOLS

NEF SERIES EURO VI

TOOLS TOOL NO.

DESCRIPTION

99360500

Tool for lifting the output shaft

99360595

Lifting rig for engine removal/refitting

99360605

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

99361037

Brackets for fastening engine to revolving stand 99322205

99363204

Tool to remove gaskets

99367121

Manual pump for pressure and vacuum measurements

Base - March 2015

Print P1D32N021 E

NEF SERIES EURO VI

SECTION 8 - TOOLS

7

TOOLS TOOL NO.

DESCRIPTION

99370006

Handgrip for interchangeable beaters

99370415

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

99389829

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

99389834

Torque screwdriver for injector solenoid valve connector stop nut setting (1-6 Nm)

99395216

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

99395603

Dial gauge (0 — 5 mm)

Print P1D32N021 E

Base - March 2015

8

SECTION 8 - TOOLS

Base - March 2015

NEF SERIES EURO VI

Print P1D32N021 E

NEF SERIES EURO VI

APPENDIX

1

Appendix Page

Print P1D32N021 E

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

3

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

3

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

3

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

3

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

4

Base - March 2015

2

APPENDIX

Base - March 2015

NEF SERIES EURO VI

Print P1D32N021 E

NEF SERIES EURO VI

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 50 ºC. - 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 - March 2015

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. - Do not modify fuel systems or hydraulic system unless specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80 ºC temperature.

NEF SERIES EURO VI

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 - March 2015

Print P1D32N021 E