00b4c9b7d8f8a6f83fb05e2f15b49449.pdf

EURO 3NEF SERIESApplication to vehicles

N40N40 ENT C

N60N60 ENT C

Technical and Repair manual

Publication edited byIveco MotorsIveco SpAPowerTrainMkt. Advertising & PromotionViale dell’Industria, 15/1720010 Pregnana MilaneseMilano (Italy)Print P1D32N001 E - 2nd Ed. 04.2007

This publication describes the characteristics, data and correctmethods for repair operations on each component of the ve-hicle.

If the instructions provided are followed and the specifiedequipment is used, correct repair operations in the pro-grammed time will be ensured, safeguarding against possibleaccidents.

Before starting to performwhatever type of repair, ensure thatall accident prevention equipment is available and efficient.

All protections specified by safety regulations, i.e.: goggles,helmet, gloves, boot, etc. must be checked and worn.

All machining, lifting and conveying equipment should be in-spected before use.

The data contained in this publication was correct at the timeof going to press but due to possible modifications made bytheManufacturer for reasons of a technical or commercial na-ture or for adaptation to the legal requirements of the differ-ent countries, some changes may have occurred.

No part of this publication, including the pictures, may be re-produced in any form or by any means.

B.U. TECHNICAL PUBLISHINGIveco Technical PublicationsLungo Stura Lazio, 15/1910156 Turin - Italy

Produced by:

F4A Engines Part 1

NEF ENGINES

1NEF ENGINES

Print P1D32N001 E Base - April 2007

2 NEF ENGINES

Base - April 2007 Print P1D32N001 E

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

PRELIMINARY REMARKS

General dangerIt includes the dangers of above described signals.

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

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

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

SYMBOLS - WARNINGS

It indicates an additional explanation for a piece of information.

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NOTE

3NEF ENGINES


GENERAL WARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contactimmediate superiors where a danger situation occurs which is not described.

Use both specific and general-purpose toolings according to the prescriptions contained in respective use andmaintenance handbooks. Check use state and suitability of tools not subjected to regular check.

The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and onthe path.

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said meansis compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.

In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out fromaccidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could bedangerous for the co-operator because of lack of visibility or of his/her not correct position.

Keep personnel not authorised to operations clear of working area.

You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictlyfollow all the safety indications found on the assembly.

Do not leave the running assembly unattended when making repairs.

When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supportingstands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be liftedby means of a hoist.

When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,as well as all the specific safety standards provided for.

Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressureout.

Inflammable fuel and all inflammable fluids and liquidsmust be handledwith care, according towhat contained on harmfulmaterials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flamesor sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquidsaccording to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitablecontainers.

Worn out, damaged or consumable parts must be replaced by IVECO Motors original spares.

Duringworkshop activity, always keep thework place clean; timely clear or clean floors from accidental liquid or oil spots.Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

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4 NEF ENGINES


Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembledparts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.Self-locking nuts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

Tightening screws and nuts must always be according to prescriptions; IVECO Motors commercial and assistancenetwork is available to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding:

- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)and detach connectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materialsflow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic centralunits.

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

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contactwith moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,scarves, etc.

Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operateoutdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause seriousburns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,refer to 12-point cards for provisions to make.

5NEF ENGINES


GENERAL WARNINGS ON THE ELECTRIC SYSTEM

To start up the engine, do not use fast chargers. Start upmust only be performedwith either separate batteries or specialtruck.

A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)can cause them to be destroyed.

Disconnect the batteries from the system during their recharging with an external apparatus.

On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tighteningtorque.

Before disconnecting the junction connector from an electronic central unit, isolate the system.

Do not directly supply electronic central units servo components at nominal vehicle voltage.

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

Once the intervention on the electric system has been completed, recover connectors and wiring harnesses accordingto original arrangement.

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.

Before connecting the batteries to the system, make sure that the system is well isolated.

Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off batteryterminals.

Do not cause sparks to be generated in checking if the circuit is energised.

Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.

Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screeningbraiding, bonding, etc.) comply with IVECO Motors system and are carefully recovered after repair or maintenanceinterventions.

Measurements in drive electronic central units, plugged connections and electric connections to components can onlybe made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, whichwould later cause contact problems.

Connectors presentmust be seen from cable side. Connectors views contained in themanual are representative of cableside.

!

NOTE

6 NEF ENGINES


7NEF ENGINES


Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, tryingthen to have their centering tidily and properly made (Figure 1, re. M).

Further, following warnings are to be compulsorily observed for electronic components:

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

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

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

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

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

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

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

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

88039

Figure 1

Figure 2

8 NEF ENGINES


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

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

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

Power1 kW = 1.36 metric HP1 kW = 1.34 HP1 metric HP = 0.736 kW1 metric HP = 0.986 HP1 HP = 0.746 kW1 HP = 1.014 metric HP

Torque1 Nm = 0.1019 kgm1 kgm = 9.81 Nm

Revolutions per time unit1 rad/s = 1 rpm x 0.10461 rpm = 1 rad/s x 9.5602

Pressure1 bar = 1.02 kg/cm2

1 kg/cm2 = 0.981 bar1 bar = 105 Pa

Where accuracy is not particularly needed:

- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1

1 kgm = 10 Nm;

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

1 kg/cm2 = 1 bar.

Temperature0° C = 32° F1° C = (1 x 1.8 + 32) ° F

Section

General specifications 1

Fuel 2

Duty - Application to vehicles 3

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the F4A engine illustrating its featuresand working in general.

Section 2 describes the type of fuel feed.

Section 3 relates to the specific duty and is divided in four sepa-rate parts:

1. Mechanical part, related to the engine overhaul,limited to those components with different characteristicsbased on the relating specific duty.2. Electrical part, concerning wiring harness, electricaland electronic equipment with different characteristicsbased on the relating specific duty.3. Maintenance planning and specific overhaul.4. Troubleshooting part dedicated to the operators who,being entitled to provide technical assistance, shall have simpleand direct instructions to identify the cause of themajor incon-veniences.

Sections 4 and 5 illustrate the overhaul operations of the engi-ne overhaul on stand and the necessary equipment to executesuch operations.

Installation general prescriptions are reported within the ap-pendix.

The appendix reports general safety prescriptions to be follo-wed by all operators whether being in-charge of installation ormaintenance, in order to avoid serious injury.

Part 1F4A ENGINES

1NEF ENGINES


2 NEF ENGINES


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

Example

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

α

Tighten to torqueTighten to torque + angular value

1∅

∅ 2

3NEF ENGINES


SPECIAL REMARKS

4 NEF ENGINES


SYMBOLS - ASSISTANCE OPERATIONS

RemovalDisconnection

Intake

RefittingConnection

Exhaust

RemovalDisassembly

Operation

Fitting in placeAssembly ρ Compression ratio

Tighten to torqueToleranceWeight difference

αTighten to torque + angle value Rolling torque

Press or caulk Rotation

RegulationAdjustment

AngleAngular value

Visual inspectionFitting position check

Preload

MeasurementValue to findCheck

Number of revolutions

Equipment Temperature

Surface for machiningMachine finish bar

Pressure

InterferenceStrained assembly

OversizedHigher than….Maximum, peak

ThicknessClearance

UndersizedLess than….Minimum

LubricationDampGrease

SelectionClassesOversizing

SealantAdhesive

Temperature < 0 °CColdWinter

Air bleedingTemperature > 0 °CHotSummer

ReplacementOriginal spare parts

5NEF ENGINES


UPDATING

Section Description Page Date of revision

6 NEF ENGINES


SECTION 1 - GENERAL SPECIFICATIONS 1NEF ENGINES


SECTION 1

General specifications

Page

CORRESPONDENCE BETWEEN IVECO CODEAND IVECO MOTORS COMMERCIAL CODE 3

LUBRICATION (4 CYLINDERS) 5. . . . . . . . . . . . .

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

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

COOLING SYSTEM (4 CYLINDERS) 8. . . . . . . . .

COOLING SYSTEM (6 CYLINDERS) 10. . . . . . . . .

AIR INDUCTION - BOOST DIAGRAM 12. . . . . . .

- Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 1 - GENERAL SPECIFICATIONS NEF ENGINES


CORRESPONDENCE BETWEEN IVECO CODE AND IVECO MOTORS COMMERCIAL CODE



IVECO code IVECO MotorsCommercial code

F4AE0481A*C1.. N40 ENT CF4AE0681A*C1.. N60 ENT C



LUBRICATION (4 CYLINDERS)Lubrication by forced circulation is achieved through oil rotaryexpansion pump (1), placed in the front part of the basement,driven by the straight-tooth gear splined to the shaft’s bar hold.

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

Lubrication involves the heat exchanger as well, the turbo-blower and the eventual compressor for any eventual com-pressed air system. All these components may often vary ac-cording to the specific duty and will therefore be examined inthe specific section.

Figure 1

Oil recover from theturbo-blower

To the exchan-ger and to theturbo-blower

1

Routing of oil under pressure

Routing of oil return by gravity to sump

Introduction of oil

LUBRICATION SYSTEM LAYOUT



LUBRICATION(6 CYLINDERS)Even for the 6 cylinders version lubrication is obtained byforced circulation and achieved through an oil rotary expan-sion pump similar to the 4 cylinders’ one.

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

Figure 2

To the exchan-ger and to theturbo-blower

Oil recover from theturbo-blower

Routing of oil under pressure

Routing of oil return by gravity to sump

Introduction of oil

LUBRICATION SYSTEM LAYOUT



70484

Figure 3

OIL VAPOUR RECYCLING

1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speedand condenses a part of vapours at the same time.

Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).

In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle againthrough pipe (2).

Oil condensate

Oil vapours



COOLING SYSTEM (4 CYLINDERS)

The engine cooling system, closed circuit forced circulationtype, generally incorporates the following components:

- Expansion tank; placement, shape and dimensions aresubject to change according to the engine’s equipment.

- Radiator, which has the duty to dissipate the heatsubtracted to the engine by the cooling liquid. Also thiscomponent will have specific peculiarities based on theequipment developed, both for what concerns theplacement and the dimensions.

- Viscous pusher fan, having the duty to increase the heatdissipating power of the radiator. This component aswell will be specifically equipped based on the engine’sdevelopment.

- Heat exchanger to cool the lubrication oil: even thiscomponent is part of the engine’s specific equipment.

- Centrifugal water pump, placed in the front part of theengine block.

- Thermostat regulating the circulation of the coolingliquid.

- The circuit may eventually be extended to thecompressor, if this is included in the equipment.



Figure 4

74194COOLING SYSTEM LAYOUT

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

EXPANSION TANK

EXPANSION TANK

HEATER(Optional)

RADIATOR

RADIATOR



COOLING SYSTEM (6 CYLINDERS)

The engine cooling system, closed circuit forced circulationtype, is of a similar design as the 4 cylinders engine.

It incorporates necessary components such as the radiator,the heat exchanger, the expansion tank and some ancillarycomponents such as the heater or the compressor for thecompressed air.

Such components always vary according to the engine’sequipment and duty.



Figure 5

COOLING SYSTEM LAYOUT

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

EXPANSION TANK

EXPANSION TANK

HEATER(Optional)

RADIATOR

RADIATOR



74195

Figure 6

The turbocharger is composed by the following main parts:one turbine, one transforming valve to regulate the boostfeeding pressure , one main body and one compressor.

During engine working process, the exhaust emissions flowthrough the body of the turbine, causing the turbine diskwheel’s rotation.

The compressor rotor, being connected by shaft to theturbine disk wheel, rotates as long as this last one rotates,compressing the drawn air through the air filter.

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

The turbocharger is equipped with a transforming valve toregulate the pressure , that is located on the exhaustcollector before the turbine and connected by piping to theinduction collector.

It’s funchon is to restrict the exhaust of the emissions ,releasing part of them directly to the exhaust tube when theboost feeding pressure, over the compressor, reaches theprescribed bar value.

The cooling process and the lubrication of the turbochargerand of the bearings is made by the oil of the engine.

Description

RADIATOR

AIR FILTRE TURBOCHARGER

EXHAUST

4 Cylinders version

6 Cylinders version

RADIATOR

AIR FILTRE TURBOCHARGER

EXHAUST

AIR INDUCTION - BOOST DIAGRAM



SECTION 2 - FUEL 1NEF ENGINES


SECTION 2

Fuel

Page

SYSTEM OF INJECTION FEEDING ELECTRONICTALL PRESSURE COMMON RAIL 3. . . . . . . .

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

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

MECHANICAL FEEDING PUMP 8. . . . . . . . . . . .

CP3 HIGH PRESSURE PUMP 9. . . . . . . . . . . . . . .

RAIL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOOST GAUGE VALVE 14. . . . . . . . . . . . . . . . . . .

ELECTRO-INJECTOR 15. . . . . . . . . . . . . . . . . . . . .

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

2 SECTION 2 - FUEL NEF ENGINES


74168

Figure 1

Through the sensors, present on the engine, the ECU con-trols the engine operation.

Air pressure/temperature sensorIt is a component integrating a temperature sensor and apressure sensor.

Fitted on the intake manifold, it measures the max. inlet aircapacity to calculate precisely the fuel quantity to inject atevery cycle.

The outlet voltage is proportional to the pressure or tem-perature obtained by the sensor.

Engine oil temperature and pressure sensorSame as air pressure/temperature sensor, it is fitted on theengine oil filter, in a horizontal position.

It measures engine oil temperature and pressure.

1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engine’s cooling liquid - 3. Fuel pressure sensorcable - 4. Sensor of engine’s oil temperature and pressure - 5. Driving shaft sensor -

6. Electro-injector - 7. Temperature and air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperaturesensor - 10. Pressure gauge cable - 11. EDC 7 gearbox.

SYSTEM OF INJECTION FEEDING ELECTRONIC TALL PRESSURE COMMON RAILGeneral SpecificationsIn order to reduce PARTICULATES emissions, very high injection pressures are required.The Common Rail system allows injecting the fuel up to pressures reaching 1450 bar, at the same time, the injection precision,obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.

System description

Electric system

1

2

3

4

5

6

7

8

9

10

11



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

The injection pressure value is used to control the pressureand to determine the electric injection control length.

Fuel temperature sensorIt is a sensor that is equal to the previous one.

It measures fuel temperature to provide the control unit withan index of the diesel fuel thermal state.

Coolant temperature sensorIt is a variable-resistance sensor suitable to measure thecoolant temperature to provide the control unit with anindex of the engine thermal state.

Output shaft sensorIt is an inductive sensor placed on the front engine part.Signals generated through the magnetic flow that is closed onthe phonic wheel, change their frequencies depending onoutput shaft rotation speed.

Timing sensorIt is an inductive sensor placed on the engine rear left part.It generates signals obtained frommagnetic flow lines that areclosed through holes obtained on the keyed gear on thecamshaft. The signal generated by this sensor is used by theECU as injection phase signal.

Though being equal to the flywheel sensor, it is NOTinterchangeable since it has a different outside shape.

System functionality

Self-diagnosisThe ECU self-diagnostic system checks signals coming fromsensors by comparing them with threshold data.

IVECO Code recognitionThe EDC7 control unit communicates with the Immobilizercontrol unit (if fitted) to obtain the startup consent.

Engine pre-heating resistance checkThe pre-post heating is activated when even only one of thewater, air or fuel temperature sensors signals a temperaturethat is less than 5 °C.

Phase recognitionBy means of signals coming from camshaft sensor andflywheel sensor, the cylinder on which fuel must be injectedis recognised upon startup.

Injection controlThe control unit, depending on information coming fromsensors, controls the pressure regulator, and changespre-injection and main injection modes.

Closed-loop control for injection pressureDepending on engine load, measured by processing signalscoming from various sensors, the control unit controls theregulator in order to always have the optimum pressure.

Pilot and main injection spark advance controlThe control unit, depending on signals coming from varioussensors, computes the optimum injection point according toan internal mapping.

Idle speed controlThe control unit processes signals coming from varioussensors and adjusts the amount of injected fuel.It controls the pressure regulator and changes the injectiontime of injectors.Within certain thresholds, it also takes into account thebattery voltage.

Maximum speed limitingAt 2700 rpm, the controlunit limits fuel flow-rate by reducingthe injectors opening time.Over 3000 rpm it deactivates the injectors.

Cut OffFuel cut off upon release is controlled by the control unitperforming the following logics:- it cuts off injectors supply;- it re-activates the injectors shortly before idle speed is

reached;- it controls fuel pressure regulator.

Smoke control upon accelerationWith strong load requests, the control unit, depending onsignals received by air inlet meter and engine speed sensor,controls the pressure regulator and changes the injectorsactuation time, in order to avoid exhaust smoke.

Fuel temperature controlWhen the fuel temperature exceeds 75 °C (measured by thesensor placed on fuel filter) the control unit intervenes byreducing injection pressure.If the temperature exceeds 90 °C, the power is reduced to60%.

AC compressor engagement control(if fitted)The control unit is able to drive engagement anddisengagement of the electromagnetic compressor clutchdepending on coolant temperature.If the coolant temperature reaches about 105 °C, itdisengages the clutch.

After RunThe control unit microprocessor allows storing certainEPROM data, among which failure memory and Immobilizerinformation, in order to make them available upon thefollowing startup.



70492

Figure 2

1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled onchassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter.

The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke andcylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.

Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.

When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takesplace in the related cylinder.

The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.

The high-pressure circuit is composed of the following pipings:

- piping connecting high-pressure pump outlet to rail;

- pipings supplying injectors from rail.

The low-pressure circuit is composed of the following pipings:

- fuel suction piping from tank to prefilter;

- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;

- pipings supplying the high-pressure pump through the fuel filter.

The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

WORKING PROCESS

High Pressure

Low Pressure



FUEL SYSTEM LAYOUT

This fuel system is a Common Rail injection with CP3 highpressure pump and this layout is for 4 cylinder version.(The 6 cylinder version is similar design as the 4 cylinder en-gine).

The pressure regulator, placed upstreamof the high-pressurepump, adjusts the fuel flow that is necessary on the low-pres-sure system. Afterwards, the high-pressure pump takes careof supplying the rail properly. This arrangement, by pressuris-ing the necessary fuel only, improves the energetic efficiencyand limits fuel heating in the system.

Function of the pressure relief valve (2), assembled on thehigh-pressure pump, is keeping the pressure, at the pressureregulator inlet, constant at 5 bars, independently from theefficiency of the fuel filter and of the system set upstream.

The pressure relief valve (2) intervention brings about a fuelflow increase in the high-pressure pump cooling circuit,through inlet and drain piping (16) from piping (8).

The pressure relief valve housed on the cylinder head, as-sembled on injector return (3), limits the fuel return flowfrom injectors at a pressure of 1.3 to 2 bars.

Two by-pass valves are placed in parallel with the mechanicalsupply pump.

The by-pass valve (18) allows fuel to flow from mechanicalpump outlet to its inlet, when the fuel filter inlet pressure ex-ceeds the allowed threshold value.

The by-pass valve (17) allows filling the supply systemthrough the manual priming pump (10).

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

piping. — 17. By-pass valve. — 18. By-pass valve.



Figure 3



MECHANICAL FEEDING PUMPGear pump, placed on rear part of the high pressure pump,whose function is to feed the high pressure pump. It is drivenby the high pressure pump’s shaft.

Figure 4

72592

Figure 5

72593

Figure 6

72594

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

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

Jettison condition

The dump by-pass valve (2) is activated in case, when theengine is off, it is necessary to fill the feeding system throughthe priming pump. In this condition the by pass valve (I) keepsclosed while the dump by-pass valve (2) opens up due to thepressure effect on the entry unit so the fuel flows to theexhaust unit B.

The mechanical feeding pump cannot be replacedseparately, therefore it must not be disassembledfrom the high pressure pump.

Ordinary working condition

Overpressure condition in Exhaust unit

NOTE



Figure 7

72595

CP3 HIGH PRESSURE PUMPPumpprovidedwith 3 radial pumping elements driven by thetiming system gear, no need of timing. The mechanicalfeeding pump driven by the high pressure pump’s shaft isassembled to the rear side of the high pressure pump.

The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neitherthe fixing screws must be tampered.The only allowed interventions concern control gear and pressure regulator replacement.

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

9. Mechanical feeding pump.

NOTE



70498

Figure 8

Every pumping unit is composed of:

- a piston (5) actuated by a three-lobe element (2) floatingon the pump shaft (6). The element (2), being floating ona misaligned part of the shaft (6), when the shaft rotates,does not rotate therewith but is only translated in acircular movement along a wider radius, with theresulting alternate actuation of the three pumpingelements;

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

High pressure pump-inside structure

Sec. B-B

Sec. C-C

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



Figure 9

Working principle

72597

Sec. B - B

Sec. D - D

1. Fuel exhaust connector to rail - 2. By-pass valve to common rail - 3. Pumping element - 4. Pump’s camshaft5. Pumping element fuel duct - 6. Fuel duct for pressure regulating gauge - 7. Pressure regulating gauge.

The pumping element (3) is orientated towards the pump’scamshaft (4). During the intake phase, the pumping elementis fed through the feeding line (5). The quantity of fuel to flowto the pumping element is determined by the pressureregulating gauge (7). The pressure regulating gauge,according to the PWM command received by the enginecontrol module, stops the fuel flow to the pumping element.

During compression phase of the pumping element, the fuelachieves the level of pressure determining the opening of theby-pass valve to common rail (2), feeding it through theexhaust unit (I).



Figure 10

7260172598

Figure 11

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

The pump shaft is lubricated by the fuel through the feedingand recovery lines (2).

The pressure gauge (5) determines the quantity of fuel tofeed the pumping elements: the fuel in excess flows throughthe exhaust gallery (9).

The limiting valve to 5 bar, in addition to recovering fuelexhaust as a collector has also function to keep the pressureconstant to 5 bar limit at gauge entry.

Sec. C - C Sec. A - A

1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuelexhaust flowing from pump with connector to high

pressure pipe for common rail.

1. Inlet to the pumping element - 2. Duct lines for thepump lubrication - 3. Inlet to the pumping element4. Main feeding line to the pumping element -

5. Pressure gauge - 6. Inlet to the pumping element -7. Pressure gauge exhaust flue - 8. Flow limiting valve to 5

bar - 9. Fuel exhaust from pressure gauge inlet.Figure 11 shows the fuel flow under high pressure runningthrough the exhaust galleries of the pumping elements.



Figure 12

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

The amount of fuel supplying the high-pressure pump ismetered by the pressure regulator, placed on thelow-pressure system; the pressure regulator is controlled bythe EDC7 control unit through a PWM signal.

When fuel is sent to a pumping element, the related pistonis moving downwards (suction stroke). When the pistonstroke is reversed, the intake valve closes and the remainingfuel in the pumping element chamber, not being able to comeout, is compressed above the supply pressure value existingin the rail.

The thereby-generated pressure makes the exhaust valveopen and the compressed fuel reaches the high-pressurecircuit.

The pumping element compresses the fuel till the top deadcenter (delivery stroke) is reached. Afterwards, the pressuredecreases till the exhaust valve is closed.

The pumping element piston goes back towards the bottomdead center and the remaining fuel is decompressed.

When the pumping element chamber pressure becomes lessthan the supply pressure, the intake valve is again opened andthe cycle is repeated.

The delivery valves must always be free in their movements,free from impurities and oxidation.

The rail delivery pressure is modulated between 250 and1350 bars by the electronic control unit, through thepressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

The radialjet pump disconnection — reconnection time onthe engine is highly reduced in comparison with traditionalinjection pumps, because it does not require setting.

If the pipe between fuel filter and high-pressure pump is tobe removed-refitted, be sure that hands and components areabsolutely clean.

1. Rail — 2. Fuel inlet from high-pressure pump -3. Overpressure valve — 4. Pressure sensor.

The rail volume is comparatively small to allow a quickpressurisation at startup, at idle and in case of high flow-rates.

It anyway has enough volume as to minimise system spikesand the use of plenum chambers caused by injectorsopenings and closings and by the high-pressure pumpoperation. This function is further enabled by a calibratedhole being set downstream of the high-pressure pump.

A fuel pressure sensor (4) is screwed to the rail. The signalsent by this sensor to the electronic control unit is afeed-back information, depending on which the rail pressurevalue is checked and, if necessary, corrected.

RAIL

99232



70502

Figure 13

70500

BOOST GAUGE VALVEThe boost valve (1750 bars) is assembled to the rail with the purpose to protect the system’s components in case of excessiveincrease of pressure within the high pressure system. Pressure limiter.

The valve can be single-stage (as the one showed in the picture) or double-stage with double working limit (1750 bars and 800bars).In the second case, when the pressure within the high pressure system reaches 1750 bars, the valve is activated as a single-stageone to exhaust the fuel and consequently reduce the pressure until reaching safety parameters. Then it provides mechanicallygauging the pressure into rail to aprx. 800 bars. This way the valve enables working of the engine for extended timing at limitedperformances, avoiding the fuel’s overheating and preserving the exhaust galleries.

If the above mentioned valve is activated, the engine control module excludes by isolation the pressure gauge and records theerrore code 8.4.The pump will flow the maximum delivery to the rail.

A Normally, the tapered piston end keeps closed thedischarge towards the tank.

B If the 1750 bar fuel pressure is exceeded in rail, the smallpiston is displaced and the excess pressure is dischargedinto the tank.

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

A B



15

70505

70506

Figure 14

Figure 15

ELECTRO-INJECTORThe injector is similar as construction to the traditional ones,apart from the absence of plunger return springs.The injector can be deemed as composed of two parts:- actuator — spray nozzle composed of pressure rod (1),

plunger (2) and nozzle (3);

- control solenoid valve composed of coil (4) and pilotvalve (5).

The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

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

When coil (4) is energised, it makes shutter (6) moveupwards. The control volume (9) fuel flows towards flowduct (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 thecylinder.

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

Injection start

The injector cannot be overhauled and thereforeit must not be disassembled.

15

NOTE



PRESSURE LIMITER FOR FUEL RETURNIt is housed on the rear of the cylinder head, and adjusts thepressure of fuel returning from injectors at a pressure 1.3 and2 bars. By guaranteeing this pressure to the return fuel, thefuel vapours formation inside injectors is avoided, optimisingfuel spraying and combustion.

70507

Figure 16

A To tank — B From injectors



SECTION 3 - APPLICATION TO VEHICLES 1NEF ENGINES


SECTION 3

Duty -Application to vehicles

Page

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

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

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

PART ONE - MECHANICAL COMPONENTS 7

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

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

- Engine setting operations for the assemblyon turning stand 9. . . . . . . . . . . . . . . . . . . . . . .

- Removal of components 10. . . . . . . . . . . . . . . . .

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

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

- Checks and inspections 32. . . . . . . . . . . . . . . . . .

PART TWO - ELECTRICAL EQUIPMENT 33. . .

LOCATION OF THE MAIN ELECTRICALCOMPONENTS 35. . . . . . . . . . . . . . . . . . . . . . .

- Engine F4AE0481 35. . . . . . . . . . . . . . . . . . . . . .

- Engine F4AE0681 36. . . . . . . . . . . . . . . . . . . . . .

- Overview of sensors 37. . . . . . . . . . . . . . . . . . . .

- EDC 7 electronic control unit 38. . . . . . . . . . . . .

- Electroinjectors connector “A” 39. . . . . . . . . . . .

- Sensors connector “C” 40. . . . . . . . . . . . . . . . . .

- Connector for powering components andfor the functions envisaged in application “B” 41.

- Air temperature/pressure sensor (85156) 43. . . .

- Oil pressure/temperature sensor (42030) 43. . . .

- Crankshaft sensor (48035) 44. . . . . . . . . . . . . . .

- Timing system sensor (48042) 44. . . . . . . . . . . .

2 SECTION 3 - APPLICATION TO VEHICLES NEF ENGINES


Page

- Fuel pressure sensor (85157) 45. . . . . . . . . . . . .

- Coolant temperature sensor (47035) 46. . . . . . .

- Fuel temperature sensor (47042) 46. . . . . . . . . .

- Fuel pre-filter 47. . . . . . . . . . . . . . . . . . . . . . . . . .

- Pre-post heating resistance 48. . . . . . . . . . . . . . .

- Starter 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Pressure regulator - high pressure pump 49. . . . .

- Electroinjector 50. . . . . . . . . . . . . . . . . . . . . . . . .

PART THREE - TROUBLESHOOTING 53. . . . . .

PREFACE 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLINK-CODE - GENERAL INFORMATION 56. . .

- Anomaly warning led 56. . . . . . . . . . . . . . . . . . . .

- Detectable failures 56. . . . . . . . . . . . . . . . . . . . . .

BLINK-CODE (SOFTWARE 3.3_1 VERSION) 57. .

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

GUIDELINE FOR TROUBLESHOOTINGWITH PT-01 PORTABLE TESTER 71. . . . . . . . .

PT-01 PORTABLE TESTER 73. . . . . . . . . . . . . . . . .

- Main functions 73. . . . . . . . . . . . . . . . . . . . . . . . .

- Test parameters 73. . . . . . . . . . . . . . . . . . . . . . . .

FAILURE CODES (SOFTWARE VERSION 3.3_1) 74

FAILURE CODES (SOFTWARE VERSION 4.1_2) 77

GUIDELINE FOR TROUBLESHOOTINGWITHOUT BLINK-CODE 81. . . . . . . . . . . . . . .

Page

PART FOUR - MAINTENANCE PLANNING 85.

MAINTENANCE PLANNING 87. . . . . . . . . . . . . .

- Recovery 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Planning of controlsand periodical intervention 87. . . . . . . . . . . . . . .

- Checks not included in maintenanceplanning-daily checks 88. . . . . . . . . . . . . . . . . . . .

MAINTENANCE PROCEDURES 88. . . . . . . . . . . .

- Checks and controls 88. . . . . . . . . . . . . . . . . . . .

- Engine oil level check. 88. . . . . . . . . . . . . . .

- Check of fuel system 89. . . . . . . . . . . . . . . .

- Cooling system check 89. . . . . . . . . . . . . . .

- Lubricating system check 89. . . . . . . . . . . . .

- Check of water presence withinfuel filter or pre-filter 89. . . . . . . . . . . . . . . .

- Checking/replacing the blow-by filter 89. . . .

- Check of drive belt tensioning 90. . . . . . . . .

- Check of belt’s tear and wear status 90. . . .

- Check and setting of tappet clearance 90. . .

- Changing the engine oil and oil filter 91. . . .

- Filter replacement procedure 91. . . . . . . . . .

- Fuel filter replacement 92. . . . . . . . . . . . . . .

- Alternator belt - water pump replacement 92

Figure 1

The NEF F4AE0481 and F4AE0681 engines are characterisedby four-stroke diesel cycles superchargedwith 4 or 6 cylinderswith 4 valves per cylinder.

They have high pressure injection fuelling (common rail) andare entirely electronically driven in order to optimise theworking process in accordance to the operation, limiting asmuch as possible the pollution emissions and consumption.

The section herein described is composed or four sections:

- Section of mechanical overhaul prescribed in accordanceto the engine’s specific duty, illustrating all necessaryoperation to remove and assembly the externalcomponents of the engine, including cylinder heads,gearbox of the timing system and of the front part cover;

- Electrical section, describing the connections to thedifferent components of the engine control module andof the sensors assembled to the engine;

- Diagnosis section;

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

Data, features and performances are valid only if thesetter fully complies with all the installationprescriptions provided by IVECO.

Furthermore, the users assembled by the setter shallalways be in conformance to couple, power andnumber of turns based on which the engine has beendesigned.

101585

GENERAL SPECIFICATIONS



Data, features and performances are valid only if the technician fully complies with all the installation requirementsprovided by IVECO.

Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min forwhich the engine has been designed.

NOTE



Clearance data - 4 cyl.

F4AE0481A*C1Type

F4AE0481A*C1..

ρ Compression ratio 17 : 1

Max. output kW(HP)

rpm

125(170)

2700Max. torque Nm

(kgm)

rpm

560(56.0)

1200

Loadless engineidling rpm 750

Loadless enginepeak rpm 3000

Bore x stroke

Displacement cm3

102 x 120

3920

TURBOCHARGING

Turbocharger type

with intercooler

GARRETT GT 22

bar

LUBRICATION Forced by gear pump, relief valve single actionoil filter

Oil pressure (warm engine)

- idling bar

- peak rpm bar

1.2

3.8COOLING

Water pump control

Thermostat

- start of opening ºC

By liquid

Through belt

81 ± 2

ACEA E3/E5URANIA LD5

FILLING

engine sump liters

engine sump + filter liters

5.3 ÷ 8.3

6.3 ÷ 9.3

Data, features and performances are valid only if the technician fully complies with all the installation requirementsprovided by IVECO.

Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min forwhich the engine has been designed.

NOTE



Clearance data - 6 cyl.

F4AE0681A*C1Type

F4AE0681A*C1..

ρ Compression ratio 17 : 1

Max. output kW(HP)

rpm

202(275)

2500

Max. torque Nm(kgm)

rpm

930(93.0)

1250

Loadless engineidling rpm 600

Loadless enginepeak rpm 2850

Bore x stroke

Displacement

102 x 120

5880

TURBOCHARGING

Turbocharger type

with intercooler

HOLSET HX35W

bar

LUBRICATION

Oil pressure (warm engine)

- idling bar

Forced by gear pump, relief valve single actionoil filter

1.2

Loadless enginepeak rpm rpm 3.8

COOLING

Water pump control

Thermostat

- start of opening ºC

By liquid

Through belt

81 ± 2

ACEA E3/E5URANIA LD5

FILLING

engine sump liters

engine sump + filter liters

8 ÷ 10.8

9 ÷ 11.8



PART ONE - MECHANICAL COMPONENTS



DIAGNOSI



70125

70126

70127

70128

Figure 2

Figure 3

Figure 4

Figure 5

In order to apply to the engine block the engine fixingbrackets 99341009 to the stand for the overhaul, operatingon the engine left side, it is necessary:- to remove the fuel filter (5) from the support (1) by

means of tool 99360076;- to remove the low pressure fuel pipe (2-3-4) from the

support (1)- to remove the support (1) bracket from the block

The pipe (3) from the union (4) and from the supercharger(8).

Remove the fuel pipe (2) from the rail and from thehigh-pressure pump (9) and remove it from the engine block,by removing the fixing screws (4 and 6)

On the right side

Remove screws (2) and detach oil pipe (3) from turbine (1)and the engine crankcase.

Remove starter motor (5) from flywheel cover (4).

Apply to the block the bracket 99361037 and fix by meansof these latter the engine to the revolving stand 99322205.Drain the engine oil by removing the plug from the sump.

Remove the fan from the engine shaft pulley.

In order to remove the low-pressure fuel pipe(2-3-4, Figure 2) from the relevant connectionunions, it is necessary to press the fastener (1) asshown in figure B.After removing the pipe, position the fastener (1)into its lock position, figure A, in order to avoidpossible deformations.

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

‘

NOTE

Because of the high pressure in the pipelines runningfrom the high pressure pump to the rail and from thislast one to the electro-injectors, it is absolutelyrequired NOT to:- disconnect the pipelines when the engine is

working;- re-use the disassembled pipelines.

ENGINE OVERHAULPrefacePart of the operations illustrated within this section can bepartially executed while the engine is assembled on thevehicle, depending on the room available for access to theengine and on the equipment application as well.

The following information relates to the engine overhauloperations only for what concerns the different componentscustomising the engine, according to its specific duties.In section ”General overhaul”, all the operations of engineblock overhaul have been contemplated. Therefore theabovementioned section is to be considered as following thepart hereby described.

!With regard to the engine disassembly operations fromthe machine, please apply for Information consultingthe specific manual. All operations of Enginedisassembly operations as well as overhaul operationsmust be executed by qualified technicians providedwith the specific tooling and equipment required.

Engine setting operations for the assembly onturning stand



78670

91576

Figure 6

Figure 7

1. Connections for injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil pressure andtemperature sensor - 5. Engine shaft sensor - 6. Injector - 7. Temperature-air pressure sensor - 8. Timing phase sensor -

9. Fuel temperature sensor and fuel heater - 10. Pressure adjuster - 11. Control unit EDC7.

Disconnect the enginewire by disconnecting the connectors:(1) from the injector harness (6); (7) air temperature/pressure sensor: (3) fuel pressure sensor; (11) control unit;(10) high pressure pump sensor; (8) timing phase sensor; (2)engine coolant temperature sensor on thermostat (5) rpmsensor;

Remove from the rail: the fuel pipe (4) according to theprocedures described in Figure 3. Remove the fuel pipe (5)from the rail (2) and from the manifolds (3) for injectors.

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

Removal of components



70130

70131

70132

70133

70134

Remove the blow-by filter.

Remove from the fuel return pressure limiting device (1), thepipe (2) as described in Figure 3.

Remove the pipe (4) from the air supercharger (3) and fromthe union (5). Remove the nut (10) Loosen the elastic hoseclamp (6) and remove the oil vapor pipe (9).

Remove the unions (13-11) and remove the pipe (12).

Remove the nuts (7) and remove the tappet (8) covercomplete of gasket.

Remove the nuts (7) and disconnect the electric wires fromthe injectors (8).

Remove the screws (1) and remove the injector harnesssupport (2) complete of gasket.

Remove the screws (5) and remove the airpressure/temperature sensor (6).

Remove the nuts (3) and withdraw the fuel manifolds (4).

Loosen the tappet adjuster fixing nuts (1) and unscrew theadjuster.Remove the screws (2), remove the equalizer unit (3)composed by the support (6), equalizers (4), shafts (5) andremove the bonds (7) from the valves. Remove the rods (8).

Remove the injector fixing screws and by means of tool99342101 (1) withdraw the injectors (2) from the cylinderhead.

Remove the screw (4), loosen the clamp (2) and remove theair conveyor (1) from the turbosupercharger (3).

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

The removed fuel manifold (4) shall not be usedagain and they must be replaced by new ones.

NOTE



70135

70136

70137

70138

70139

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Remove the oil pipe (5) check clamp fixing screw (4) fromthe exhaust manifold (1).

Remove the oil pipe (5) from the oil filter/ heating exchangersupport (7).

Remove the nuts (2) and remove the turbosupercharger (3)from the exhaust manifold (1).

Remove the screws (6) and remove the exhaust manifold (1)from the cylinder head.

Remove the screws (1) and remove the air conveyor (2)complete of heater. Remove the screws (4), remove thecover (3) and the relevant thermostat.

Remove the head cylinder (6) fixing screws (5).

Hook the brackets (1) with metal ropes and remove thecylinder head (2) from the block by means of a hoister.

Remove the cylinder head gasket (1).

Loosen the stretch of the belt (2) by means of a properwrench, operating the automatic belt tightener (3) andremove the belt.

Remove the screw (4) and the automatic tightener (3).

Remove the screws (2) and disconnect the alternator (1)

The external screws pointed out are shorter.NOTE



70140

70141

70142

70143

70144

Figure 18

Figure 19

Figure 20

Figure 21

Figure 22

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

Remove the oil filter (1) by means of tool 99360076.

Remove the screws (4) and remove oiltemperature/pressure sensor.

Remove the screws (1) and remove the oil filter/heatingexchanger support (2), middle plate (6) and relevant gaskets.

Remove the oil level sensor (5)

Remove the screws (1) and the electronic control unit (2)complete of heating exchanger.

By means of wrench 99355019, remove the screws (1) and(3) and remove the hydraulic power steering pump (2)complete of oil tank (4) from the air supercharger (5)

Remove the screws (2) and the nuts (1-4) and remove theair supercharger (3)



70145

70340

70146

Figure 23

Figure 24

Figure 25

Figure 26

Figure 27

Remove the nut (1) and remove the phase sensor (2).

Remove the nuts (3) and remove the high-pressure pump (4)complete of power supply pump (5).

Apply the tool 99360351 (2) to the flywheel housing (1), tostop the flywheel (3) rotation.

Loosen the screws (4)

Remove the screws (2) and remove the pulley (3) and thebumper flywheel (1).

Remove the screws (6) and remove the hub (5) and thephonic wheel (4).

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

78256

Apply on the front tang (2) of the driving shaft fixture99340055 (4) and through the guiding holes of the fixtureitself, drill the internal seal ring (1) with a drill (∅ 3.5 mm) toa depth of 5 mm..Fix fixture (4) to the ring (1) by means of the 6 screws in thekit e proceed with the removal of the ring by screwing up thescrew (3).

Figure 28

78257

Apply the proper rod (3) of fixture 99363204 to the externalseal ring (2) as shown in the figure and use lever (4), toremove it from the front cover (1).

70148



70149

70150

Figure 29

Figure 30

Figure 31

Figure 32

Figure 33

Remove the screws (1) and remove the front cover (2).

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

Write down the screw (1) assembling positionbecause they exhibit different lengths.

It is not possible to overhaul the oil pump (2).

NOTE

NOTE

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

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

78258

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

70151

70152



70153

70154

99222

70156

Figure 34

Figure 35

Figure 36

Figure 37

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

Overturn the engine.

Remove the screws (2), remove the plate (3) and remove theoil sump (1).

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

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

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


NOTE

70157

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


NOTE

Figure 38



Figure 39

Assembly of components

LOCTITE 5205 SEALANT APPLICATION AREAS

Clean accurately the timing gear case (1) and the engineblock.

70209

Perfect seal is only obtained by cleaning accuratelythe surface to seal.

Smear the casewith LOCTITE 5205 toobtain a beadof few mm diameter.

It shall be uniform (no clots), without air bubbles, thinareas or discontinuities.

Any imperfection shall be corrected as soon aspossible.

Avoid to use excess material to seal the joint.Excessive sealant could come out from joint sidesand cause lubricant passage clogging.

After applying the sealant, the joint shall beassembled immediately (max 10 minutes).

DIAGRAM FOR TIGHTENING THE REAR TIMINGGEAR CASE FASTENING SCREWS

Refit the case (1) to the engine block.Screw the fastening screws in the same position found atremoval and tighten them to the following torque values inthe sequence shown in the figure:Screws M12 65 to 89 NmScrews M8 20 to 28 NmScrews M10 42 to 52 Nm

70210

Figure 40

Figure 41

70211

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

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

Before any assembly operation always verify thatthe hole and screw threads have no evidence ofwear or dirt.

NOTE

NOTE



Figure 42

70212

Rotate the output shaft (4) and the camshaft (2) so thatwhenfitting the driven gear (1) on the camshaft the marks on thegears (1 and 3) are coinciding.

Figure 43

70213

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

Figure 44

70214

LOCTITE 5205 SEALANT APPLICATION AREAS

Perfect seal is only obtained by cleaning accuratelythe surface to seal.

Smear the casewith LOCTITE 5205 toobtain a beadof few mm diameter.

It shall be uniform (no clots), without air bubbles, thinareas or discontinuities.

Any imperfection shall be corrected as soon aspossible.

Avoid to use excess material to seal the joint.Excessive sealant could come out from joint sidesand cause lubricant passage clogging.

After applying the sealant, the joint shall beassembled immediately (max 10 minutes).

Figure 45

70215

SEQUENCE FOR TIGHTENING THE FLYWHEELHOUSING FASTENING SCREWS

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

Not availableOn enginesF4AE0684H-EF4HE0684E-F-J

Before any assembly operation always verify thatthe hole and screw threads have no evidence ofwear or dirt.

NOTE



Figure 46

70217

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

Figure 47

Figure 48

Figure 49

70219

α

Tightening to angle is performed using tool99395216.Before any assembly operation always verify thatthe hole and screw threads have no evidence ofwear or dirt.

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

70152

Figure 50

Tighten engine flywheel (2) fastening screws (1) in twostages:- 1st stage, tightening to 30 ± 4 Nm torque with

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

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

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

70216

NOTE

Tighten the screws (4) fastening the engine flywheel (3) tothe output shaft. Apply tool 99360351 (2) to the flywheelhousing (1) to stop engine flywheel (3) rotation.

70218



Figure 51

70220

Fit the oil pump (1).

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

Figure 52

70221

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

Figure 53

Fit the water pump (1).

Tighten the screws (2) to the specified torque.

Figure 54

70223

Remove the sealing ring (2) from the front cover (1), cleanaccurately the coupling surfaces and smear them withLOCTITE 5205.

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

Figure 55

Figure 56

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

70225



99223

70154

70227

70363

70230

Figure 57

Figure 58

Figure 59

Figure 60

Figure 61

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

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

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

Fit the phonic wheel (1) and the hub (2) on the output shaft.

Tighten the fastening screws (3) in two stages:

- 1st stage, tightening to 50 ± 5 Nm torque withdynamometric wrench;

- 2nd stage, tightening to 90° angle.

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

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

r

If not faulty the gasket can be reused.

Fit the damper flywheel (5) and the pulley (6).

Tighten the fastening screws (7) to 68 ± 7 Nm torque.

Tightening to angle is performed using tool99395216 (4).

α

NOTE

NOTE



70231

70232

70234

70139

70235

Figure 62

Figure 63

Figure 64

Figure 65

Figure 66

Lubricate the sealing ring (2) with engine oil and set it on theoil filter (3).

Screw manually to seat the oil filter (3) on the supportconnection (1) and then screw again the oil filter (3) by ¾turn.

Apply a new sealing ring on the oil temperature/pressuresensor (4) and fit it on the support (1).


Fit a new sealing ring (6) in the engine block seat.

Position the alternator support (1) so that pins (3 and 4) areset against the engine block.


Refit the alternator (1).

Tighten the screw (2) to the specified torque.

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

Fit on the engine block: a new gasket (1), the heat exchanger(2) a new gasket (3) and the oil filter support (4).




Figure 67

Figure 68

Figure 69 Apply a new gasket to the engine block and then place thecylinder head (2) slung by the hanger brackets (1).

Figure 70

70137

Figure 71

70320

Refit the ECU (3) including the heat exchanger to the engineblock and tighten the screws (2) to the specified torque.

Replace support elastic elements (1).NOTE

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

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

70145

70144

Refit the hydraulic power steering pump (2) including the oiltank (4) to the air compressor (5).Use wrench 99355019 to tighten the fastening screws (3) tothe specified torque.

7014375703

D1D2

NOTE Before using the fixing screws again, measure themtwice as indicated in the picture, checking D1 andD2 diameters:if D1 - D2< 0,1mm the screw can be utilised again;if D1 - D2 > 0,1 mm the screw must be replaced.



Figure 72

Figure 73

70338

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

70339

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

Figure 74

70133

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

Screw injector fastening screws without tightening them.

Figure 75

70337

4-cylinder engine A

α

Cylinder head fastening screws tightening sequence:

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

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

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

A = Front side

Figure 76

Tightening order layout for cylinder head fastening screws:

- 1st step pre-tightening with a torque wrench:• Screw 12x1.75x130 ( ) 35± 5 NmA • Screw 12x1.75 x 150 ( ) 55± 5 Nm

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

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

A = Front side

α

A6-cylinder engine

Figure 77

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

The angle tightening is carried out through tool99395216 (3). Before any assembly operationalways verify that the hole and screw threads haveno evidence of wear or dirt.

α

70336

NOTE

70476



Figure 78

Figure 79

Figure 80

Figure 81

91572

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

Disassembled fuel manifolds (2) must not be usedagain. Replace with new items.

During this operation, the injector (1) shall bemoved so that the manifold (2) is properly insertedinto the fuel inlet hole (2, Figure 75).

70342

Use the torque wrench to tighten gradually and alternatelythe injector fastening screws (1) to 8.5 ± 0.8 Nm torque.

Tighten the fuel manifold (3) fastening nuts (2) to 50 Nmtorque.

Carry out the assembly of the equalisers’ unit , after previouscheck of the components.

70343

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

SHAFT-ROCKER MAIN DATACheck that shaft/rocker coupling surfaces are not showingexcessive wear or damages.

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

32655

Figure 82

NOTE

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

70344



Figure 83

Figure 84

Figure 85

70345

Fit the rods (2).

Position jumpers (1) on valves with marks (→) facing theexhaust manifold.

70346

Check that tappet adjusters (1) are loose to prevent theirbalking on the rods (2, Figure 83) when refitting the rockerassembly.Then refit the rocker assembly consisting of: bracket (5),rockers (3), shafts (4) and secure them to the cylinder headby tightening the fastening screws (2) to 36 Nm torque.

70520

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

In order to more quickly perform the operatingclearance adjustment for rocker arms — valves,proceed as follows:6-cylinder engineRotate the drive shaft, balance cylinder 1 valves andadjust the valves marked by the asterisk as shown inthe table:

Rotate the drive shaft, balance cylinder 6 valves andadjust the valves marked by the asterisk as shown inthe table:

4-cylinder engineRotate the drive shaft, balance cylinder 1 valves andadjust the valves marked by the asterisk as shown inthe table:

Rotate the drive shaft, balance cylinder 4 valves andadjust the valves marked by the asterisk as shown inthe table:

cylinder n.intakeexhaust

1 2 3 4- - * *

*- * -

cylinder n.intakeexhaust

1 2 3 4-

* - ** * -

-



cylinder n. 1 2 3 4 5 6intake - - * - * *exhaust - * - * - *

cylinder n. 1 2 3 4 5 6intake * * - * - -exhaust * - * - * -

70348

99225

99224

99226

70126

Figure 86

Figure 87

Figure 88

Figure 89

Figure 90

Smear the intake manifold (1) coupling surface with sealantIVECO No. 2992545 and fit it on the cylinder head.Tighten the screws (2) to the specified torque.

Fit the rail (2) and tighten the screws (1) to the specifiedtorque, connect the ground cable (3) to the intake manifold(4) and tighten the fastening nut (5) to the specified torque.

Connect the fuel pipes (1) to rail (3) and injector manifolds(2).

Press the clamp (1) in arrow direction (Figure B) and connectthe pipe to the rail (2, Figure 89), reset the clamp to the initiallocking position “A”.

Fittings of pipings (3) must be tightenedwith 20Nmtorque by using special wrench 99389829 (4)associated to tool 99317915 (4).

Connect the fuel pipe (2) to the rail (1) following theprocedure shown in the following figure.

Check proper fuel pipe connection.NOTE



70352

99228

99227

70355

99229

70357

Figure 91

Figure 92

Figure 93

Figure 94

Figure 95

Figure 96

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

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

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

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

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

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



70358

70134

70360

70126

Figure 97

Figure 98

Figure 99

Figure 100

Reconnect the turbosupercharger (3) with a new gasket tothe exhaust manifold (1) and tighten the fastening nuts (2)to the specified torque.

Connect the oil pipe (5) to the heat exchanger support (6)and secure it to the exhaust manifold (1) by screw (4).

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

Secure the air duct (1) to the alternator support by screws(4).

Fit the blow-by filter.

Connect pipe (14) to tappet cover (10) and timing case (6)with connections (13-15) and new copper washers.

Connect pipe (7) to timing case (6) connection and lock itby the elastic clamp (8).

Fit a new sealing ring on pipe (11) connection and fit it on thetappet cover (10).

Secure the pipe (11) to the tappet cover (10) with the clipand the nut (12), connect pipe (4) to connection (5) and aircompressor (3).

Connect the pipe (2) to the pressure limiter (1) as shown inthe following figure.

Press the clamp (1) in arrow direction (Figure B) and connectthe pipe.

Reset the clamp to the initial locking position A.

Check proper fuel pipe connection.

Completion of the engine

NOTE



78670

Figure 101

Reconnect the engine cable by connecting injector wiring (6)connectors (1); (7) air pressure/temperature sensor; (3) railpressure sensor; (11) control unit; (10) high pressure pumpsensor; (8) timing sensor; (2) engine coolant temperaturesensor on thermostat; (5) engine speed sensor.

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

1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature andpressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air temperature/pressure sensor - 8. Timing sensor -

9. Fuel heater and fuel temperature sensor - 10. Pressure regulator - 11. EDC7 control unit.



70128

70127

70362

70125

70126

Figure 102

Figure 103

Figure 104

Figure 105

Figure 106

Form the right side:

Refit the starter (5) to the flywheel housing (4) and tightenthe fastening nuts to the specified torque.

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

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

Screw manually the fuel filter to the support (1), screw thefilter by ¾ turn, connect the pipes (2-3-4) to the relevantsupport connections (1) as shown in the following figure.

Press the clamp (1) as shown in figure B.After disconnecting the pipe, reset the clamp (1) to the initiallocking position A, to prevent deformations.When refitting is over, fill engine with the prescribedlubricating oil in the specified quantity.

From the left side:

Connect the fuel pipe (2) to rail and to high pressure pump(9), secure it by screws (4 and 6) tightened to the specifiedtorque.

Pipe connections (2) shall be tightened to 20 Nmtorque using the proper dynamometric wrench99389834.Connection (7) shall be tightened by holding at thesame time the high pressure pump hexagon (10).When removed pipe (2) shall always be replaced.Connect pipe (3) to connection (4) and aircompressor (8).



- that there are no water leaks from the connectingsleeves of engine cooling circuit pipes and cab internalheating pipes, tighten the clamping collars if required;

- check carefully the connection between the lowpressure fuel pipes and the relevant connectors asspecified in paragraph “Main servicing operations to beperformed on engine fitted on vehicle”;

- that there are no oil leaks between the cover and thecylinder head, between oil sump and engine block,between heat exchanger oil filter and the relevanthousings and between the different pipes in thelubricating circuit;

- that there are no fuel leaks from the fuel pipes;

- that there are no air leaks from pneumatic pipes;

- check also proper operation of the warning lights set onthe instrument panel and of the equipmentdisconnected when engine was removed.

Checks and inspections

Start the engine and leave it running just above theidling speed, wait until the coolant reaches thetemperature necessary to open the thermostat andthen check:

!Check proper fuel pipe connection.



PART TWO - ELECTRICAL EQUIPMENT





Figure 107

Figure 108

101585

50277

GHIM L

A D FCB E

ABCD

ENGINE VIEW LEFT SIDEA. Coolant temperature sensor - B. Electrinic injection electro valve - C. Engine preheat resistor - D. Fuel pressure sensor- E. Oversupply air temperature/fuel pressure sensor - F. Hydraulic control low fluid level indicator - G. Distribution pulse

sensor - H. Fuel pressure adjuster electro valve - I. Fuel temperature sensor - L. EDC 7 electronic center -M. Engine rpm sensor.

ENGINE VIEW EIGHT SIDEA. Alternator - B. Oil temoerature/pressure sensor - C. Oil level transmitter - D. Starter motor.

LOCATION OF THE MAIN ELECTRICAL COMPONENTS

Engine F4AE0481



A B C D E F

GH

I

LM

ENGINE VIEW LEFT SIDEA. Coolant temperature sensor - B. Electrinic injection electro valve - C. Engine preheat resistor - D. Fuel pressure sensor- E. Oversupply air temperature/fuel pressure sensor - F. Hydraulic control low fluid level indicator - G. Distribution pulse

sensor - H. Fuel pressure adjuster electro valve - I. Fuel temperature sensor - L. EDC 7 electronic center -M. Engine rpm sensor.

ENGINE VIEW EIGHT SIDEA. Alternator - B. Oil temoerature/pressure sensor - C. Oil level transmitter - D. Starter motor.

A

B

C

D

Figure 109

Figure 110

50339

50338

Engine F4AE0681





KeyRef. Description

1 Coolant temperature sensor2 Electro-injector3 RAIL pressure sensor4 Air temperature/pressure sensor5 Power steering level sensor6 Timing sensor7 Fuel temperature sensor8 EDC7 control unit9 Crankshaft sensor10 Engine oil level transmitter11 Engine oil pressure/temperature sensor12 Pre-post hearing resistance

Figure 111

Overview of sensors

50367



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

The control unit is fitted onto the engine via a heat exchanger by means of elastic blocks which reduce the vibrations transmittedto the unit by the engine.

The main relay which is normally used to power the system is located inside the control unit itself.

AC

B

50351

Figure 112

EDC 7 electronic control unit



ECUPin

CableColour

(4 cylinders)

CableColour

(6 cylinders)Function (4 cylinders) Function (6 cylinders)

1 - - - -2 - - - -3 - RU - Cylinder 2 injector4 WP WP Cylinder 4 injector Cylinder 3 injector5 - WV - Cylinder 4 injector6 - RW - Cylinder 2 injector7 - - - -8 - - - -9 RG RG Cylinder 1 injector Cylinder 1 injector10 UN UN Cylinder 2 injector Cylinder 6 injector11 UG UG Cylinder 3 injector Cylinder 5 injector12 WR WR Cylinder 4 injector Cylinder 3 injector13 RY RY Cylinder 1 injector Cylinder 1 injector14 - W Cylinder 4 injector15 UO UO Cylinder 2 injector Cylinder 6 injector16 UY UY Cylinder 3 injector Cylinder 5 injector

Colour legendB blackR redU blueW whiteP purpleG greenN brownY yellowO orange

1612

6

1 5

11

50350

Figure 113

Electroinjectors connector “A”



ECUPin

CableColour

Function

1÷4 - -5 NW Ground for pressure regulator6 - -7 NP Control for pressure regulator8 - -9 PY Power supply for engine oil temperature pressure sensor10 NY Power supply for air pressure temperature sensor11 - -12 GY Power supply for rail pressure sensor

13÷16 - -17 YR Ground for fuel temperature sensor18 YN Ground for coolant temperature sensor19 PN Ground for engine oil temperature pressure sensor20 GN Power supply for rail pressure sensor21 N Power supply for air pressure / temperature sensor22 - -23 U Timing sensor24 U Crankshaft sensor25 R Crankshaft sensor26 - -27 GO Signal from rail pressure sensor28 NG Signal from air pressure sensor29 UO Signal from air temperature30 R Ground for timing sensor

31÷32 - -33 PO Signal from engine oil temperature sensor34 YU Signal from diesel oil temperature sensor35 PG Signal from engine oil pressure sensor36 YO Signal from coolant temperature sensor

Colour legendB blackR redU blueW whiteP purpleG greenN brownY yellowO orange

50350

Figure 114 6 8 16 9 15 22

36 29302331

45

Sensors connector “C”



ECUPin

Cable Function

1 8150 Direct positive from battery2 0087 Negative for diesel oil filter heating relay3 0000 Ground4 0094 Positive for exhaust brake solenoid valve/control relay/pre-post hearing resistance5 9068 Air-conditioning system remote-control switch drive signal6 - -7 8150 Direct positive from battery8 7777 Positive for clutch sensor/Blink Code button/exhaust brake button/brake pedal switch on the

duplex (*)9 0000 Ground10 9067 Air-conditioning system remote-control switch drive signal (*)11 9966 Negative for exhaust brake solenoid valve (*)12 8150 Direct positive from battery13 8150 Direct positive from battery14 0000 Ground15 0000 Ground16 8885 Negative to turn on thermostarter relay17-18 - -19 0150 Negative for start-up buttons/stop from engine compartment/gearlever in neutral/hand brake

ON (*)20 8037 Positive from key-operated switch at starting stage (+50)21 8159 Positive from exhaust brake switch (*)22 - Control from brake pedal position exhaust brake selector23-25 -26 - -27 5162 Positive from blink code button (*)28 5535 Positive for “BLINK CODE” LED warning light (*)29 - -30 1198 L line for 30 pin tester connector (pin 1)31 2298 Line K for 30 pin tester connector (pin 2)32 0169 PTO (*)33-35 - -36 8837 Positive for diesel oil filter heating relay37 8888 Positive for starter motor38 - -

(*) depending on the vehicle application.

35

89 72

53 18 36 17

54 6 1171

1

7

12

50350

Figure 115

Connector for powering components and for the functions envisaged in application “B”



ECUPin

Cable Function

39 8051 Positive from key-operated switch, +1540 0027 Engine brake exclusion with ABS system engaged (*)41 9907 Signal from handbrake engaged switch42 6666 Signal from cab unhooked switch (*)43 0115 Positive from gearbox on neutral switch (*)44 9905 Positive from start button from engine compartment (*)45 9906 Positive from stop button from engine compartment (*)46 - -47 - -48 5198 Engine phase signal for diagnosis connector (pin 23)49 5584 Signal for electronic rev counter50 0158 Negative from accelerator pressed switch51 - -52 6109 CAN line (white wire) L53 6108 CAN line (green wire) H54 - -55 5158 Positive for accelerator pedal position sensor56 - -57-58 - -59 - -60 - -61 - -62 5602 Clutch sensor (*)63 - -64 0535 Negative for “BLINK CODE” LED (*)65 - -66 - -67-71 - -72 0159 Signal from accelerator pressed switch73 0159 Redundant signal from accelerator pressed switch74 5155 -75 - -76 8158 Positive from secondary brake pedal switch (*)77 5502 Signal from second speed limiter switch (*)78 9071 Air-conditioning system (*)79 - -80 8153 Brake light signal81 0157 Ground for accelerator pedal position sensor82 - -83 5157 Signal from accelerator pedal position sensor87 5120 PTO (*)

(*) depending on the vehicle application.

CONNECTION CONNECTOR

EXTERIOR VIEW OF SENSOR

WIRING DIAGRAM

50324

Figure 116

50323

Figure 117

50344

Figure 118



Air temperature/pressure sensor (85156)This component combines a temperature and a pressuresensor.

It is fitted to the intake manifold so that, by measuring themaximum quantity of air taken in, it makes it possible todetermine the exact amount of fuel to be injected at eachcycle.

This sensor is connected to the control unit via pins 21/C -29/C - 10/C - 28/C.

It is powered at 5 V.

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

Pins 21/C - 29/C Temperature

Pins 10/C - 28/C Pressure

Oil pressure/temperature sensor (42030)This component is identical to the air temperature/ pressuresensor

It is mounted horizontally on the engine oil filter.

It measures the engine oil temperature and pressure.

It is connected to the control unit via pins 19C - 33C - 9C -35C.

The values sent are transmitted to the EDC control unitwhich, in its turn, controls the indicator on the dash (indicator/ low pressure warning light).

Pins 19/C - 35/C Temperature

Pins 9/C - 33/C Pressure

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

Ref DescriptionControl unit Pin

Ref. DescriptionOil Air

1 Ground 19C 21C

2 Temp. signal 35C 29C

3 +5 9C 10C

4 Press. signal 33C 28C



Crankshaft sensor (48035)This inductive type sensor is located in the left front part of the engine. It generates signals obtained frommagnetic flux lines whichclose through the openings of a toothed wheel force fitted to the crankshaft. The same signal is used to manage the electronicrev counter.

It is connected to the control unit via pins 25C - 24C.

The sensor’s resistance value is ca 900 Ω.

Supplier BOSCH

Tightening torque 8± 2 Nm

Timing system sensor (48042)This inductive sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines whichclose through the holes situated in gears force fitted to the camshaft. The signal generated by this sensor is used by the ECUas the injection timing signal.

Though it is similar to the crankshaft sensor, it is not interchangeable with the latter since its outer shape is different.


The sensor’s resistance value is ca 900 Ω.

Supplier BOSCH

Tightening torque 8± 2 Nm

Ref DescriptionControl unit Pin

Ref. Description48035 48042

1 Signal 25C 23C2 Signal 24C 30C3 Shielding

TECHNICAL VIEW WIRING DIAGRAM

PERSPECTIVE VIEW

180 ± 15

213

8518

Figure 119

8519

Figure 120

Figure 121

8520



Fuel pressure sensor (85157)Fitted to one end of the rail, it measures the pressure of the existing fuel in order to determine the injection pressure.

The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injectionelectronic command.

It is connected to the control unit on pins 20C - 27C - 12C.

It is powered at 5 V.

Ref. Description Control unit pin

1 Ground 20C2 Signal 27C3 Power 12C

A - Distribution manifold

B - Fuel pressure sensor (85157)

Figure 122

1 32

A. Fuel temperature sensor B. Filter heating resistance

A

B

1 2 50321

Figure 123

50322

Figure 124

Figure 125

50348



Coolant temperature sensor (47035)This is a variable resistance sensor that is able to measurecoolant temperature and transmit a signal to the control unitreflecting the thermal conditions of the engine.

The same signal is used by the control unit to manage thetemperature gauge on the dash.


Its resistance at 20 °C = 2.50 KΩ.

It is placed in the upper engine part.

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

It measures the temperature of the fuel and transmits a signalto the control unit reflecting the thermal conditions of thediesel oil.


Its resistance at 20 °C = 2.50 KΩ.

The ECU manages the relay for the control of filter heatingwhen the temperature of the fuel drops to ≤ 36 °C.

Ref DescriptionECU pin

Ref. Description47035 47042

1 Ground 18C 17C

2 Signal 36C 34C



Fuel pre-filterThe water separation type fuel filter is mounted on the righthand side of the vehicle frame and has, on the cartridge base3, a sensor 4 detecting the presence of water in the fuel.

The filter support houses a manual priming pup 5 and a screw2 to bleed the air from the system.

Tightening torque

Bleed screw 2 6 to 8 Nm

Filtering cartridge 3 18± 0.1 Nm

Sensor 4 0.8± 0.1 Nm

1

2

3

4

5

000910t

Figure 126

If the warning light lights up, take action immediatelyto remove the cause, as common rail systemcomponents deteriorate quickly if there is water orimpurities in the fuel.



Pre-post heating resistanceThis resistance is located on the intake manifold.

It is used to warm up the air in pre-post heating operations.It is powered by a remote control switch situated on the lefthand side of the frame.

Its resistance is ~ 0,5 Ω.

StarterThe starter is usually driven by the starting block assembledto the vehicle’s dashboard and provides positive voltage to pinB20 of the EDC.

A

A. - B. Connecting terminals

BFigure 127

Figure 128

A- Feeding relay of the starter

A

74166



Pressure regulator - high pressure pumpPump with 3 radial pistons controlled by the timing gears,requiring no phase adjustment, with rotor type feed pumpfitted to the back.

A. Connection between fuel discharge outlet and filtersupport

B. Connection for fuel inlet from control unit heatexchanger

C. Connection for fuel inlet from fuel filter

D. Connection between fuel outlet from feed pump andfilter

E. Connection between fuel outlet and rail

1. High pressure pump

2. Feed pump

3. Pressure regulator (N.O. solenoid valve modulated bythe control unit by means of PWM signal).

The pressure regulator is located at the inlet of thehigh-pressure pump on the low-pressure circuit; its functionis tomodulate the quantity of fuel to feed to the high-pressurepump on the basis of commands received from the electroniccontrol unit.

It basically consists of the following parts:

- trapezoidal section shutter;

- valve control pin;

- pre-charging spring;

- coils.

In the absence of the control signal, the pressure regulator isnormally open, and hence the high pressure pump is in itsmaximum delivery conditions.

The control unit modulates a PWM control signal whichreduces, to a greater or lesser extent, the section carrying thefuel to the high pressure pump.

This component cannot be replaced individually and hence itcannot be taken down.

The amount of fuel feeding the high pressure pump ismeteredby a proportional valve situated on the low pressure system- managed by the EDC 7 control unit.

The delivery pressure to the rail is modulated between 250and 1400 bar by the control unit working on the pressureregulator solenoid valve.

It is a N.O. solenoid valve

Its resistance is ca 3.2 Ω.

It is connected to the control unit via pins C5 - C7.

A

BC3

D

E

1

2

Figure 129

000912t



ElectroinjectorThe injector features a traditional construction, save for thefact that it has no needle return springs.

The electroinjector essentially consists of two parts:

- actuator - atomiser consisting of a pressure rod 1, aneedle 2 and nozzle 3;

- control solenoid valve, consisting of a coil 4 and pilot valve5.

The solenoid valve controls the rise of the atomiser needle.

Injection startsUpon being energised, coil 4 moves up the shutter 6.

The fuel contained in the control volume 9 flows backtowards line 12 resulting in a pressure drop in the controlvolume 9.

At the same time, the fuel pressure in the pressure chamber8moves up the needle 2 resulting into the fuel being injectedinto the cylinder.

Injection endsWhen coil 4 is de-energised, the shutter 6 closes again so asto re-create a balance of forces which moves the needle backinto its closed position and stops the injection process.

This is a N.O. solenoid valve.

Individually connected to EDC control unit on connector A.

The resistance of the coil of each individual injector is 0.56÷0.57 Ω.

INJECTION IN RESTING POSITION

1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilotvalve - 6. Ball shutter - 7. Control area - 8. Pressure

chamber - 9. Control volume - 10. Control line - 11. Feedline - 12. Control fuel outlet - 13. Electrical connection -

14. Spring - 15. High pressure fuel inlet.

50336

Figure 130

Figure 131

000933t



Ref. Description Control unit Pin

1 Cylinder 2 injector 3 A

CONNECTOR 12 Cylinder 2 injector 6 A

CONNECTOR 13 Cylinder 1 injector 13 A4 Cylinder 1 injector 9 A1 Cylinder 4 injector 5 A


CONNECTOR 23 Cylinder 3 injector 12 A4 Cylinder 3 injector 4 A1 Cylinder 6 injector 10 A


CONNECTOR 33 Cylinder 5 injector 16 A4 Cylinder 5 injector 11 A

WIRING DIAGRAM OF THE CONNECTIONS

FAN SIDE

1 2 3

1 2 3

1 2 3 4 5 6

50343

Figure 132

Figure 133

50349

Connecting connectors



PART THREE - TROUBLESHOOTING





PREFACE

A successful troubleshooting is carried out with thecompetence acquired by years of experience and attendingtraining courses.

When the user complains for bad efficiency or workinganomaly, his indications must be kept into properconsideration using them to acquire any useful information tofocus the intervention.

After the detection of the existing anomaly, it isrecommended to proceed with the operations oftroubleshooting by decoding the auto-troubleshooting dataprovided by the EDC system electronic central unit.

The continuous efficiency tests of the components connectedto, and the check of working conditions of the entire systemcarried out during working, can offer an important diagnosisindication, available through the decoding of the”failure/anomaly” codes issued by blinking of the failure led:the ”blink-code” (whether programmed).

Please consider that the interpretation of the indicationsprovided by the blink-code is not sufficient to guarantee thesolution to the existing anomalies.

Using IVECO processing instruments, it is also possible toestablish a bi-directional connection with the central unit, bywhich not only to decoding the failure codes but also input anenquiry relyingonmemory files, in order to achieve any furthernecessary information to identify the origin of the anomaly.

Every time there is a breakdown claim and this breakdown isactually detected, it is necessary to proceed inquiring theelectronic unit in one of the ways indicated and then proceedwith the diagnostic research making trials and tests in order tohave a picture of the working conditions and identify the rootcauses of the anomaly.

In case the electronic device is not providing any indication, itwill be necessary to proceed relying on the experience,adopting traditional diagnosis procedures.

In order to compensate the operators’ lack of experience inthis new system, we are hereby providing the USER’sGUIDELINE FOR TROUBLESHOOTING in the followingpages.

The GUIDELINE is composed of three different parts:- Blink Code, relating to the anomalies identified by the

gearbox, mainly of electric and electrical nature;- Troubleshooting guide using PT-01 portable tester.

Tool identified as IVECO p/n 8093731.- Guideline for troubleshooting without blink code, divided

per symptoms, describing all possible anomalies notdetected by the electronic gearbox, often of mechanicaland hydraulic nature.

Any kind of operation on the electronic center unitmust be executed by qualified personnel, dulyauthorized by IVECO.

Any unauthorized tamper will involve decay ofafter-sales service in warranty.





Detectable failuresSensors:

- Air temperature boosting

- Fuel temperature

- Pressure boosting

- Unit pressure

- Flywheel

- Camshaft

- Fuel pressure

- Quantity of air flow sucked

Engine working:

- Engine runaway speed rate

- Injectors

- Fuel pressure driving system

- Pre-post heating driving system

Electro-valves:

- Fuel pressure gauge

Relé:

- Main relé

- Fuel electro-pump

- Heated fuel filter

Feed tension

Leds:

- Pre-post heating

Gearbox:

- Non-valid data set

- Incorrect saving of files in memory

- Power control bench 1

- Power control bench 2

- Internal failure (Gate Array)

- Sensor feed

- Internal failure (re-start)

- Incorrect engine disconnection

- Defective EEPROM

Anomaly warning ledThe ECU is continuously screening, by complexauto-diagnosis routine procedures, its own workingconditions as well as the conditions of the componentsconnected to, and of the engine.The detection of the anomaly provokes the lightening up ofthe warning led on the monitor and drive board, with id.modes allowing a first selection of the problem according tothe level of importance. (Review the User’s Manual of thevehicle equipped with NEF engine to know the preciseposition of the pushbutton and of the led).Led in off position (no light): no anomalies detected or small

entity anomaly with no prejudice safeworking conditions.

Lighted Led: significant anomaly. In this condition it isrecommended to go to a diagnosis centre.

Blinking led: serious anomaly requiring immediate repairintervention.

The emission of the codes of anomaly detected byauto-troubleshooting and saved in ECU memory starts afterhaving pushed and released the pushbutton. (Review theUser’s Manual of the vehicle equipped with NEF engine toknow the precise position of the pushbutton and of the led).The led, usually aside the pushbutton, will signal the light blinkcodes by to series of emissions with different frequency,highlighting the decimal numeration digits indicating theanomaly.The slow blinking identify the unit where the anomaly occurs(engine, injectors...) the fast blinking identify the specific failure.A each push and release of the pushbutton, one only memorycode will be sorted. Therefore it is necessary to repeat theprocedure until when an identical failure data to the first onereceived will be released as indication that all the failure filememory has been analysed.In case of no filed anomalies in memory, the led will light upwhen the pushbutton is pressed and will then turn off aprx. 1second after release of the pushbutton without originatingblinking.Note: applying to the blink code troubleshooting procedure,it is possible to obtain information relating to currentlyoccurring failures as well as to other anomalies occurred in thepast and not existing any more at present status.Therefore it is absolutely necessary, at the end of every repairintervention, to clear the failure file memory in order to avoidthat any future troubleshooting operation will detect anysolved anomaly whose root cause has already been corrected.In the current equipment, clear operation is set pressing theblink code pushbutton while the key change over switch is inOFF position and keeping it pressed for 4 to 8 seconds afterturning the key change over switch in ON position.Wait at least for 10 seconds before switching off the keychange over switch.The evidence that the clearing operation has been correctlymade shall be obtained proceeding to switch OFF and ONagain the key change over switch and further require blinkcode troubleshooting, that shall terminate with no display ofblink code.

Data, features and performances are valid only if thesetter fully complies with all the installationprescriptions provided by IVECO.

Furthermore, the users assembled by the setter shallalways be in conformance to couple, power andnumber of turns based on which the engine has beendesigned.

BLINK-CODE - GENERAL INFORMATION



Blink-Code EDC Led Description of anomaly Power reduction

ENGINE

2.1 On Signal from cooling liquid temperature sensor 0

2.2 Off Signal from air temperature sensor, boosting 0

2.3 Off Signal from fuel temperature sensor 0

2.4 On Signal form sensor of pressure boosting 0

2.5 Off Signal from atmospheric pressure sensor 0

2.6 On Signal from oil pressure sensor 0

2.7 Off Signal from oil temperature sensor 0

2.8 Off Signal from heated filter driving relé 0

2.9 Off Signal from pre-post heating resistor driving relé 0

3.7 On Battery tension 0

3.8 Off Alert led pre-post heating 0

3.9 Off Pre-post heating resistor 0

INJECTORS

5.1 On Electro-valve injector of cylinder 1 0




5.5 On Electro-valve injector of cylinder 5 (*) 0

5.6 On Electro-valve injector of cylinder 6 (*) 0

5.7 On Power stage 1 (cylinders 1-4) 0

5.8 On Power stage 2 (cylinders 2-3) 0

Power reduction:

0 = no power reduction

1 = performance comparable to equivalent engine but in suction stroke

2 = 50% of couple

3 = Limited engine speed

4 = Engine disconnection

BLINK-CODE (SOFTWARE 3.3_1 VERSION)RecoveryFollowing from the detection of significant or serious anomaly,the ECU also drives the set up of specific strategies to allowsafe utilisation of the engine and to limit some injectionparameters within prescribed levels, based on the importanceof the problem.

The software applications currently in use, provide for foursafety levels characterised by the reduction of the vehicle’sduty performances.

The table relating to the blink-codes reports some values ofpower reduction, that actually indicate the limitation of dutyperformances, automatically set by the gearbox based on theanomaly occurring.

In case of anomaly identified by intermitted blinking, thatmeans detected by the ECU and not existing any more, thereduction of duty performances shall be active untildisconnection of the engine.

The normal working conditions shall be recovered only at thefollowing start-up, while the anomaly data will be ”saved” inthe failure file memory.

(*): not applicable for the 4 cylinders



Blink-Code EDC Led Description of anomaly Power reduction

ENGINE RUNNING

6.1 On Signal from engine driving shaft sensor 2

6.2 On Signal from camshaft sensor 2

6.3 On Reliability of engine speed signal 0

6.4 Blinking Engine runaway speed rate 0

6.5 Off Relé of the starter 0

ENGINE RUNNING

7.2 Off CAN Line (For vehicles equipped with electrical systemprovided with CAN Line)

0

7.6 Off Oil pressure alert led 0

FUEL PRESSURE

8.1 Blinking Control fuel pressure 3

8.2 Blinking Fuel pressure signal 3

8.3 Blinking Pressure regulating electro-valve 3

8.4 Blinking Intervention to double stage boosting valve 3

8.5 Blinking Rail Min/Max pressure failure 4

EDC

9.4 On Main relè 0

9.6 On Gearbox disconnection procedure 3

9.7 On Sensor feed 0

Power reduction:

0 = no power reduction

1 = performance comparable to equivalent engine but in suction stroke

2 = 50% of couple

3 = Limited engine speed

4 = Engine disconnection



BLINK

CODE

EDCLED

POSSIBLECAUSE

(*)=ifavailableintheequip-

ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

2.1

On

Shortcircuitofthesensorofen-

ginecoolingliquidtemperature,in

positiveorearthorinopencir-

cuit.

Verifycomponentcorrectwork-

inganditsresistor(2,5kOhm

at20ºC).Incasethecomponent

works,proceedcheckingthecon-

nectionbetweenthesensorand

thegearboxconnectortopin

C18-C36.

2.2

Off

Shortcircuitofthesensorofair

combustiontemperature,inposi-

tiveorearthorinopencircuit.

(Thesensorisintegratedwiththe

airpressuresensor).

Readoutofparameters

using

multimeter.Verifycorrectwork-

ingofthecomponentandofits

resistorbetweenpin1and2(R=

2,5kOhmat20ºC).Ifthesensor

isworking,proceedcheckingthe

connectionbetweenthesensor

andtheEDCconnectortopin

C21-C29.

2.3

Off

Shortcircuitofthesensoroffuel

temperature,inpositiveorearth

orinopencircuit.

Readoutofparametersdirectly

onthesensorusingmultimetre.

(R=2,5kOhm

at20ºC).Ifthe

sensorisworking,proceedcheck-

ingtheconnectionbetweenthe

sensorandtheEDCconnectorto

pinC17-C34.

2.4

On


combustionpressureonsuction

collector,inpositiveorearthorin

opencircuit;orfedbytensionout

ofspecification.

Readout

ofparametersusing

multimetreverifyingfeedingten-

siontothesensor.(aprx.5V).

Incaseoftensionwithinspecifica-

tion,checkthewiringharnessand

theconnectionbetweenthesen-

sorandtheEDC(PinC10-C28).



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

2.5

Off


pressure(integratedinEDC)in

positiveorearthorinopencircuit

Applyforcustomerassistancefor

theinterventionontheEDC.The

sensorisintegratedintheEDC

andisnotreplaceablesingularly.

Thepaintingoftheengine/EDC

mayinficiateonthecorrectwork-

ingofthesensor.

2.6

On


gineoilpressure,inpositiveor

earthorinopencircuit.(Thesen-

sorisintegratedwiththeoiltem-

peraturesensor).

Readoutofparameters

using

multimetreverifyingfeedingten-

siontothesensor.(aprx.5V).

Incaseoftensionwithinspecifica-

tionreplacethesensor.Incaseof

tensionoutofspecification,check

thewiringharnessandthecon-

nectionbetweenthesensorand

theEDC(PinC9-C35).

2.7

Off


gineoiltemperature.(integrated

withtheoilpressuresensor),in


cuit.

Sensor

Readout

usingmulti-

metre,betweenpin1and2.(R=

2,5kOhm

at20ºC).

Ifthesensorisworking,proceed

checking

theconnectionbe-

tweenthesensorandtheEDC

(pinC19-C33).

2.8

Off

Incorrectworkingofthefuelfilter

heatingrelé.

Verify

reléworkingstatususing

thetroubleshootingdevice.Ifthe

resultisnegative,replacetherelé

andtestagain.

Iftheanomalystillpersists,check

thewiringharnessandthecon-

nectionsbetweenreléandEDC

connector(pinB2-B36)



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

2.9

Off

Incorrectworkingofthepre-post

heatingdriverelé.

Difficultstartingwithlowexternal

temperature,exhaustfumesim-

mediatelyafterstarting.

Verifyreléworkingstatususing

the

troubleshooting

device.

Checkthecorrectworkingofthe

relé(R=aprx.15Ohm).

Incasethereléworks,checkthe

wiringharnessandtheconnec-

tionsbetweenreléandEDCcon-

nector(pinB4-B16)

3.7

On

Signalforbatterytensiontoohigh

ortoolow.

Idlingaccelerated.

Carryouttheduecontrolsonthe

batteryandontherechargesys-

tem.

Ifnoanomalyisdetectedcheck

theefficiencyoftheEarthpoints

andtheabsenceoffoulingorox-

idationonthefeedwiringcon-

nectorsoftheEDC.

Eventually,theproblemmightnot

dependonthetoohighortoo

lowtensionbutduetotheincor-

rectdetectionoftensionbythe

EDC.

3.8

Off

Defectivepre-heatingledorwir-

ingharnessshortcircuitinposi-

tiveorearthorinopencircuit.

Ledalwayson

lighteven

with

startingkeyinoffpositionoral-

waysoff.

Possibledifficultstarting(withlow

externaltemperature)andex-

haustfumesatstarting.

Verify

working

status

using

troubleshootingdevice.

Iftheresultisnegativereplacethe

ledanddrivetroubleshooting

operationagain.Ifthefailureper-

sistscheckconnectionsandwir-

ingharnessbetweenledandEDC

(pinB46)

3.9

Off

Pre-heatinghasnotbeenworking

correctly.

Possibledifficultstarting(withlow

externaltemperature)andex-

haustfumesatstarting.

Usingthemultimetre,verifyconti-

nuityofpre-heatingresistorinthe

suctioncollector(R=aprx.0,5

Ohm).

Ifthecomponent

isworking,

checkthewiringharnessandthe

connectionbetweentheresistor

andtherelevantdrivingrelé.

Pre-heatingisnotworking.



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

5.1

On

ElectricalproblemwithInjectorn.

1Enginerunningwithonecylinder

less.

Checkthecorrectcouplelock

(1,5+/-0,25Nm)ofthecables

thefixingnutstotheinjectorelec-

tro-valve.

Verifytheworkingstatusofthe

injector’sbobbin(R=aprx.0,56

-0,57Ohm)andreplacethein-

jectorifdefective.

Withnewworkingbobbin,pro-

ceedcheckingthewiringharness

andtheconnections

between

electro-valveandEDCconnector

(pinA9-A13)throughthecon-

nector1ofthepinoverhead3

and4.

Suchfailuremaygeneratepower

stageinsufficiency(intheEDC)

feedingtheelectro-injector,in-

volvingworkingofonlyhalfofthe

cylindersasaconsequence,and

memorisationoftheerror5.7.

5.2

On

Electricalproblemwithinjector

n.2.

Engineworkingwithonecylinder

less.




tro-valve.




jectorifdefective.



andtheconnections

between




and3.






memorisationoftheerror5.7

within6cylinderenginesand5.8

within4cylinderengines.



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

5.3

On


n.3.


less.




tro-valve.




jectorifdefective.



andtheconnections

between




and4.






memorisationoftheerror5.7.



5.4

On


n.4.


less.




tro-valve.




jectorifdefective.



andtheconnections

between




and2.


stageinsufficiency

(intheEDC)









BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

5.5

On

Electricalproblemwithinjectorn.

5.Engineworkingwithonecylinder

less.




tro-valve.




jectorifdefective.



andtheconnections

between




and4.









5.6

On

Electricalproblemwithinjectorn.

6.Engineworkingwithonecylinder

less.




tro-valve.




jectorifdefective.



andtheconnections

between




and2.


stageinsufficiency

(intheEDC)









BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

5.7

On

EDCoutputstagedrivingpower

toelectro-injectorcouples2and

3.

Enginerunningwithonly2(3)

workingcylinders.

Clearthefailurememoryandtest

again.

Ifthefailurepersists,andonly

afterhavingexcludedinjectorde-

fect,eventuallyreplacetheEDC

withanewonere-programmed

byIVECO.

Itcanhappeniftheexternalpart

ofthegearboxisdriventoshort

circuitwiththebatterypositive

pole(accidentalbridgemadeby

wrenchorothermetallicobject).

5.8

On

EDCoutputstagedrivingpower

toelectro-injectorcouples4-5-6.Enginerunningwithonly2(3)

workingcylinders.

Clearthefailurememoryandtest

again.

Ifthefailurepersists,andonly

afterhavingexcludedinjectorde-

fect,eventuallyreplacetheEDC

withanewonere-programmed

byIVECO.

Itcanhappeniftheexternalpart

oftheEDCisdriventoshortcir-

cuitwiththebatterypositivepole

(accidentalbridge

made

bywrenchorothermetallicobject)

6.1

On

Drivingshaftsensor:nosignalor

unreliablesignal.

Enginestartrequiresmoretime

thanusual.

Powerreductionandnoise

in-

creasesincetheEDCisnotcon-

trollingthepre-injectionandthe

timing.

Engineworkingreliesonrecovery

parameters.

Usingthemultimetre,verifythe

sensor’sresistorvalueaswellas

itsworkingstatus(R=aprx.900

Ohm).

Ifthecomponentisworking,and

theanomalypersists,checkthe

wiringharness

betweenthesensorandtheEDC

connector(pinC24-C25).

Thefailureisnotdetectedwhen

theengineisnotrunning.Ifthe

drivingshaftsignalisnotregularly

working,itisnecessarytorelyon

thespeedsignalofthecamshaft

sensor.

6.2

On

Camshaftsensor:no

signalor

unreliablesignal.

Difficultstartinginallconditions.

Powerreduction.




Ohm).Verifycorrectassemblyof

thesensor:replaceitifdefective.



wiringharnessbetweenthesen-

sorandtheEDCconnector(pin

C24-C25).



camshaftsignalisnotregularly


thephasesignalofthedriving

shaftsensor.



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

6.3

On

Unreliablesurvey

ofengine

speed.

Difficultstartinginallconditions.

Powerreduction.




Ohm).Verifycorrectassemblyof

thesensor:replaceitifdefective.



wiringharnessbetweenthesen-

sorandtheEDCconnector(pin

C24-C25).



camshaftsignalisnotregularly


thephasesignalofthedriving

shaftsensor.

6.4

Blinking

Enginerunawayspeedrate.

Verifytheroot-causesthatmight

havegeneratedasuddenloadloss

totheengine,involvingconse-

quentrunawayspeedrate.

Runawayspeedratemightalso

dependdirectlyfrom

theoper-

atoraddictedtodrivingtheve-

hicle,whichtheengineisinstalled

to.

Itisnotafailurereferredtoone

componentbutthealertforan

actualenginerunawayspeedrate.

6.5

Off

Incorrectworkingofstarterrelé.Theenginedoesnotstartordis-

connects.

Usingmultimetre,checktherelé.

Incasethecomponentworks,


connectionbetweenreléand

EDCconnector(pinB27).

6.6

Off

Signalfrom

EDCtoenginespeed

indicator.

Theenginespeedindicatordoes

notwork.

Checkthewiringharnessandthe

connection

between

engine

speedindicatorandEDCcon-

nector(pinB49).

6.8

Off

Synchronisation

signal

with


Difficultiesincommunicationbe-

tweentroubleshootingdevice

andEDC.


connectionbetweenpin23ofthe

troubleshootingtapendEDC

connectortoinB48.



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

7.2

Off

(*)

CANLineHardwaredefect.

(*)

Possibleincorrectworking

orerroralertsignaloftheelectronic

controldevicesconnectedvia

CANLine.

Checkwiringharness,connection

andlockingresistor(120Ohm)

Ontheequipmentthatisnotpro-

videdwiththeCANline,thisis

blankedbya120Ohm

resistor.

7.6

Off

Defectiveoilpressureledlamp,or

wiring

harnessshortcircuitin


cuit.

SwitchingthekeycontacttoON

position,theledisnotlightingon

orkeepslighted.

Verify

working

status

using

troubleshootingdevice.Ifthere-

sultisnegativereplacetheledand

drivetroubleshootingoperation

again.

Incaseofledcorrectworking,


connectionsandwiringharness

betweenledandEDCconnector

(pinB63)andthecorrectfeedof

thegaugewithincorporatedled.

8.1

Blinking

Fuelpressuremodulationdefect.

(thegearcasemustmodifytoo

muchthecontrolsignalatthe

pressureregulatorinorderto

modulethecalculatedpressure

intherail).

Importantpowerreduction.

Iftheinjectorremainslocked

openeverynowandthen,

suddenandtemporarydecayof

theperformances,withpossible

start-upandproperoperationat

lowrpmandloadsbutthe

troubleshowsupagainwith

highrpmandloads.

Verifyifthefuelarrivesdirectlyto

thehigh

pressure

pump(no

outletsinthesuckedline,clogged

filterorpre-filter,occludedpipes,

consistentfuelleakage).

Verifythereisnofuelleakageor

lossfrom

thehighpressureline

runningfrom

thepumpandthe

railorfrom

thecylindershead.

Incaseaflowlimiterhasbeen

activated,detectandidentifythe

injectorthatisnotworkingany

moreandreplaceittogetherwith

itsrelevanthighpressurefiller.

Furtherdetailsrelatingtochecks

andcontrolstobemadeonthe

fuel’scircuitareavailablein

Troubleshootingsection2.



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

8.2

Blinking

Railpressuresensor’ssignalshort

circuitinpositiveorearthorin

opencircuit.

Significantpowerreduction.

Readout

ofparametersusing



connectionbetweenthesensor

andtheEDCConnector(PinC12

-C20-C27).

Ifeverythingisinorder,replace

thesensor.

8.3

Blinking

Pressuregaugeshortcircuitin


cuit.


Eventuallyblinkcode8.1.


workingstatusofthepressure

gaugeelectro-valve.

Ifthecomponent

isworking,


connectionbetweenthegauge

andtheEDCconnectorpin

C4-C5.

Afterhavingexcludedanyother

possibility,applytoIVECOMo-

torsfortheeventualreplacement

ofthepumpwithitsgauge.

The

singlereplacementofthe

pressuregaugeonlyisnotposs-

ible.

8.4

Blinking

Incorrectworkingoftheboost

gaugevalve(onlyifdouble-stage

type).


Replacetherailboostvalve.

8.5

Blinking

Anomalyinrailpressure.

(Droppedtominimum

valueor

overmaximum

limit).


Possible

contemporary

blink

code

8.1-8.4.

Verifyifthefuelarrivesdirectlyto

thehigh

pressure

pump(no

outletsinthesuckedline,clogged

filterorpre-filter,occludedpipes,

consistentfuelleakage).

Verifythereisnofuelleakageor

lossfrom

thehighpressureline

runningfrom

thepumpandthe

railorfrom

thecylindershead.



BLINK

CODE

EDCLED

POSSIBLECAUSE


ment

POSSIBLEDERIVING

ANOMALIES


ment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

9.4

On

Mainreléisnotdisconnecting.

Thegearboxisalwaysfedandthe

EDCledkeepslightonevenwith

thekeyinOffposition.

Thebatterydischarges.

Tryremovingandreplacingthe

fuse(tore-settheEDC)

Iftheproblempersists,applyto

IVECOMotorsfortheeventual

replacementoftheEDC.

Themainrelèisincorporatedin

theEDCandisnotreplaceable

singularly.

9.6

On

Anomalywithintheroutinecon-

trolprocedurethatthegearbox

providestothesystem

ateach

enginedisconnection.


Runtheengine,driveittoidling

anddisconnectitcorrectly.

Thefailuremightbememorised

evenincaseofengineworkingin

differentconditionsthantheones

oftheequipment(suchasengine

runningonbench,withoutiner-

tialload).

9.7

On

Anomalywithinsensorsfeed.

Memorisationoferroronallsen-

sorsfedbytheEDCgearbox.

Theenginedoesnotstartnordis-

connects,ordifficultstartingand

badworkingoftheengine.

Verifyworkingstatusandcorrect

assemblyoftheEDCconnector

dedicatedtosensors(C).

Iftheconnectorisworkingand

correctlyassembled,

applytoIVECOMotorsforthe

eventual

replacementof

the

EDC.



GUIDELINE FOR TROUBLESHOOTINGWITH PT-01 PORTABLE TESTERIVECO P.N. 8093731





PT-01 PORTABLE TESTER

Using PT-01 with portable tester it is possibile to executetroubleshooting and test the EDC7 electronic module of NEFengines.

PT-01 has been designed and developed to ensure stoutnessand practicality and is particularly suitable to be used in work-shop and industrial environment.

The tool is connected to the engine gearbox by means of oneonly cable providing both tester feed and communicationwiththe electronic module.

Main functions

!Before connecting the tester to the electronic mod-ule, check the wording on the electronic module toselect the correct software on the tool.

1 2 3 4 5 6 7 8 . A B C

u m m k a a * * . v a 0

a a software 3.3_1a b software 4.1_2

Easy access to different functions is available through themenu:

- ID. Reading of the electronic module;

- Reading of failure memory and relevant environmentconditions;

- Failure memory clear;

- Reading of working parameters;

- Reading of status parameters;

- Active troubleshooting (switching on heat starter, fuelpump, EDC warning led and so on)

Test parameters- Engine revolutions;

- Spark advance;

- Battery voltage;

- Accelerator foot pedal position;

- Over voltage pressure;

- Over voltage air temperature;

- Cooling liquid temperature;

- Fuel temperature;

- Oil temperature;

- Oil pressure;

- Fuel delivery;

- Fuel pressure;

- Rail pressure duty cycle electro-valve.





Blink code Warning type Failure description Systemdegradation

VEHICLE

1.1 1 Vehicle Speed Signal 0

1.2 1 Multiple State Switch 0

1.3 0 Cruise Control Buttons 0

1.4 1 Accelerator Pedal Signal 2

1.5 0 Clutch signal 0

1.6 1 Service Brake signal (plaus.) 0

1.7 0 Accelerator Pedal (plaus.with brake) 0

1.8 0 Diagnostic lamp 0

1.9 0 Engine brake preselection button 0

ENGINE1

2.1 1 Coolant Temp. Signal 0

2.2 0 Boost Temp. Signal 0

2.3 0 Fuel Temp. Signal 0

2.4 1 Boost Pressure Signal 0

2.5 0 Atmospheric Pressure Signal 0

2.6 1 Oil Pressure Signal 0

2.7 1 Oil Temp. Signal 0

2.8 0 Power stage Fuel filter heater 0

2.9 1 HS Power stage cold start heater relay 0

ENGINE2

3.1 0 Adapt.cylinder balancing Cyl.1 0

3.2 0 Adapt.cylinder balancing Cyl.5 (•) 0





3.7 0 Battery voltage signal 0

3.8 0 LS Power stage cold start lamp 0

3.9 1 Cold start heater monitoring 0

System degradation:

0 = 0% derate

1 = slight derate

2 = moderate derate

3 = significant derate

4 = engine stop

Blink types:

0 = No light

1 = Continous light

2 = Blinking light

Classification of power output:

LS = slight level

HS = high level

SS = moderate signal

(•): not applicable for the 4 cylinders

FAILURE CODES (SOFTWARE VERSION 3.3_1)




VGT

4.2 1 Turbo speed signal 0

4.3 1 Fuel limitation from VGT 0

4.4 2 Boost Pressure Control 2

4.5 1 CC HS Power stage 3 VGT 2

4.6 1 HS Powerstage engine brake 0

INJECTORS

5.1 1 Injector solenoid valve Cyl.1 0

5.2 1 Injector solenoid valve Cyl.5 (•) 0





5.7 1 Injector Booster Voltage C1 0


ENGINE SPEED

6.1 1 Increment speed signal 1

6.2 1 Segment speed signal 1

6.3 1 Engine speed sensing 1

6.4 2 Engine overspeed 0

6.5 1 HS power stage 8 for Starter control 0

6.6 0 SS power stage 1 for TD-signal 0

6.8 0 SS power stage 2 for sync.-signal 0

INTERFACES

7.2 1 CAN Hardware 0

7.3 0 CAN Transmission Control 0

7.4 0 CAN Aut.Traction Control (ASR) 0

DASHBOARD

7.1 0 LS Power stage 2 vehicle limit button 0

7.5 0 LS Power stage 3 engine brake lamp 0

7.6 0 LS Power stage 4 oil pressure lamp 0

7.7 0 SS Power stage 3 oil pressure gauge 0

7.6 0 LS Power stage 5 coolant temperature lamp 0

7.9 0 SS Power stage 4 coolant temperature gauge 0

System degradation:

0 = 0% derate

1 = slight derate

2 = moderate derate


4 = engine stop

Blink types:

0 = No light

1 = Continous light

2 = Blinking light


LS = slight level

HS = high level






FUEL PRESSURE

8.1 2 Fuel pressure monitoring CP3 3

8.2 2 System degradation 3

8.3 2 CC HS Power stage 1 fuel press. Control 3

8.4 2 Monitoring of rail pressure relief valve 3

8.5 2 Rail pressure Min/Max error 4

8.6 - CC HS Power stage 2 EGR control 0

8.7 - Air Mass Signal 0

8.8 - Ambient Temp. Signal 0

ECU

9.3 2 Truck Security System (Immobil.) 0

9.4 1 Main relay defect 0

9.6 1 ECU: Self Test Shutoff Paths 3

9.7 1 Power supply for sensors 0

System degradation:

0 = 0% derate

1 = slight derate

2 = moderate derate


4 = engine stop

Blink types:

0 = No light

1 = Continous light

2 = Blinking light


LS = slight level

HS = high level





VEHICLE

1.1 1 Vehicle Speed Signal 0

1.2 1** Multiple State Switch 0

1.3 0 Cruise Control Buttons 0

1.4 1 Accelerator Pedal Signal 2

1.5 0 Clutch signal 0

1.6 1 Service Brake signal (plaus.) 0

1.7 0 Accelerator Pedal (plaus.with brake) 0

1.8 0 Diagnostic lamp 0

1.9 0 Engine Brake Preselection button 0

ENGINE1

2.1 1 Coolant Temp. Signal 0

2.2 0 Boost Temp. Signal 0

2.3 0 Fuel Temp. Signal 0

2.4 1 Boost Pressure Signal 0

2.5 0 Atmospheric Pressure Signal 0

2.6 1 Oil Pressure Signal 0

2.7 1 Oil Temp. Signal 0

2.8 0 Power stage Fuel filter heater 0

2.9 1 HS Power stage cold start heater relay 0

ENGINE2







3.7 0 Battery voltage signal 0

3.8 0 LS Power stage cold start lamp 0

3.9 1* Cold start heater monitoring 0

System degradation:

0 = 0% derate

1 = slight derate

2 = moderate derate


4 = engine stop

Blink types:

0 = No light

1 = Continous light

2 = Blinking light


LS = slight level

HS = high level



*) System degradation for STUP failure not applicable (not available in ASAP)*) Masked out**) Masked out

FAILURE CODES (SOFTWARE VERSION 4.1_2)




VGT

4.2 1 Turbo speed signal 0

4.3 1 Fuel limitation from VGT 0

4.4 2 System degradation 2

4.5 1 CC HS Power stage 3 VGT 2

4.6 1 HS Powerstage engine brake 0

INJECTORS









ENGINE SPEED

6.1 1 Increment speed signal 1

6.2 1 Segment speed signal 1

6.3 0 Engine speed sensing 0

6.4 2 Engine overspeed 0

6.5 1 HS power stage 8 for Starter control 0

6.6 0 SS power stage 1 for TD-signal 0

6.8 0 SS power stage 2 for sync.-signal 0

INTERFACES

7.2 1 CAN Hardware 0

7.3 0 CAN Transmission Control 0

7.4 0 CAN Aut.Traction Control (ASR) 0

DASHBOARD

7.1 0 LS Power stage 2 vehicle lim.button 0

7.5 0 LS Power stage 3 Engine brake lamp 0

7.6 0 LS Power stage 4 oil press. lamp 0

7.7 0 SS Power stage 3 oil press. gauge 0

7.8 0 LS Power stage 5 coolant temp. lamp 0

7.9 0 SS Power stage 4 coolant temp. Gauge 0

System degradation:

0 = 0% derate

1 = slight derate

2 = moderate derate


4 = engine stop

Blink types:

0 = No light

1 = Continous light

2 = Blinking light

*) System degradation for STUP failure not applicable (not available in ASAP)*) Masked out **) Masked out (•): not applicable for the 4 cylinders


LS = slight level

HS = high level





FUEL PRESSURE

8.1 2 Rail pressure monitoring CP3 3

8.2 2 Fuel pressure signal 3

8.3 2 CC HS Power stage 1 fuel press. control 3

8.4 2 Monitoring of Press. Relief Valve(DBV) 3

8.5 2 Rail pressure Min/Max error 4

8.6 0 CC HS Power stage 2 EGR control 0

8.7 0 Air Mass Signal 0

8.8 0 Ambient Temp. Signal 0

ECU

9.3 2 Truck Security System (Immobil.) 0

9.4 1 Main relay defect 0

9.6 1 ECU: Self Test Shutoff Paths 3

9.6 2 System startup failure *

9.7 1 Power supply for sensors 0

System degradation:

0 = 0% derate

1 = slight derate

2 = moderate derate


4 = engine stop

Blink types:

0 = No light

1 = Continous light

2 = Blinking light


LS = slight level

HS = high level


*) System degradation for STUP failure not applicable (not available in ASAP)*) Masked out**) Masked out



GUIDELINE FOR TROUBLESHOOTINGWITHOUT BLINK-CODE







ANOMALY

POSSIBLECAUSE

(*)=ifavailableintheequipment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

Lowperformanceatloadrequest.

Possibleexessivesmoke.

Possibleblink-code8.1

Insufficientfuellevelinthetank.

Checkfuellevel.

Theexcessivesmokeisduetothefact

that,incaseofinsufficientfuelfeeding,the

enginecontrolmoduletriestocompen-

sateprolonging

theinjectorsworking

time.

Fueltankdevicepartiallyobstructedby

impuritiesordeformedbecauseofover-

heating.

Checkiftheprimingpumpofthepre-filter

isworkingcorrectly.

Ifthepumpplungerispermanentlyde-

presseddisassembleandcheckthetank

pick.-uptube.Ifthisisinorder,replacethe

pre-filter.

Obstructedairfilter.

Replacetheairfilter.

Solvethecauseofthefilter’sobstruction.

Excessivefuelblow-byfrom

railboost

valve.

ChecktheORingsandthecorrectcon-

nectionofthepipefittings

underthe

feedingpump(thelockersmuststayout-

sideandthefittingsmustbewelllocked).

Visuallycheckthelowpressurepipeline

integrity.

Unlesstheleakageissignificant,noper-

formancefailureswillbedetected.

ToverifyO-ringsintegrity,extractfrom

thetankthefuelrecyclingpipeline,seal

theendandactivatetheprimingpump

drivingthelowpressurecircuit.

Excessivefuelblow-byfrom

railboost

valve.

Disconnectthepipeandvisuallycheckif

thereareanysignificantblow-byfromthe

boostgaugevalve;insuchcasereplace

thevalve.

Theenginesuddenlystops(withnoprevi-

ousproblems)anddoesnotstartagain.

Obstructedfuelfilter.

Replacethefuelfilter.

Solvethecauseofthefilter’sobstruction

(emptyandcleanthetankandthepartof

thecircuitoverthefilter,refillwithclean

fuel).



ANOMALY

POSSIBLECAUSE

(*)=ifavailableintheequipment

RECOMMENDED

TESTSOR

INTERVENTION

REMARKS

Theenginedisconnectsordoesnotstart.(*)

EDC”burned”byshortcircuitonthewir-

ingharnessofthefrictionclutch.

Eliminatetheshortcircuitandreplacethe

EDC.

Verifythatthewire

line,closetothe

pedal,isnotexposedto.

Difficultstartandlowperformanceinall

conditions.

Inefficienthighpressurepump.

Afterhavingexcludedanyotherpossible

cause,replacethehighpressurepump.

Difficultstart,lowperformanceanden-

ginerunningwithonecylinderless.

Injector

with

obstructer

orsolenoid

(mechanicalpart)blockedopen.

Thenon-workinginjectoriseasilyrecog-

nisabledetectingbyfeelingtheabsenceof

pulsingwithintherelevanthighpressure

pipe.

Incaseoflowentityblow-by,inficiating

themechanicalworkingoftheinjector

butnotinvolvingflowlimiteractivation,

thereisnoerrormemorisationintheen-

ginecontrolmodule.

Iftheflowlimiterisactivated.Checkerror

codememory.

Startingrequiresinexcessoftenseconds,

followedbyhugewhiteexhaustfumes,

andafuelsmell.

Injectorblockedinopen

position(with

noreturn).




pipe.

Usually,whethersuchsymptomsappear,

itisinstinctivetogiveupenginestart.

However,byinsisting,itispossibletostart

theengine.

Asamatteroffacts,byinsisting,ifwithin

therailthepressuremakestheflowli-

mitercloseup,theenginestartswithone

cylinderlessandgraduallythegradeof

fumesreducesanddisappears.

Breakingofhighpressurepipelinefrom

pumptorail.

Strangevibrationsprovokedbyslackof

pipebracket.

Replacethepipelineensuringthecorrect

tighteningoftheanti-vibrationbracket

screws.

Itisveryimportant,inadditiontocorrect

blocking,tokeepthebracketsintheorig-

inalposition.

Theengineworkswithonecylinderless,

withoutmemorisingfailureblinkcodesin

theenginecontrolmodule.

Injectorblockedinclosedposition.

Identifytheinjectorthatisnotworking

anymoreandtherelatinghighpressure

filler.




pipe.

PART FOUR - MAINTENANCE PLANNING





MAINTENANCE PLANNINGRecovery

To ensure optimisedworking conditions, in the following pageswe 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 determineand evaluate replacements and checks.

It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessarymaintenanceand controlling operations even if not being included in the ones listed here below but that may be suggested by common senseand by the specific conditions in which the engine is run.

Planning of controls and periodical intervention

Controls and periodical intervention

Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . .

Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency (hours)

Daily

Daily

-

4000

500

1000

500

1500

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

NOTE



Checks not included in maintenance planning-daily checksIt is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoidinconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.

- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.

- Notify the maintenance if any inconvenience is detected of if any filling is necessary.

After engine start and while engine is running, proceed with the following checks and controls:

- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.

- Verify absence of noise or unusual rattle during engine working.

- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.

- Visual check of fumes (colour of exhaust emissions)

- Visual check of cooling liquid level, in the expansion tank.

MAINTENANCE PROCEDURESChecks and controls

Engine oil level check.The checkmust be executedwhen the engine is disconnectedand possibly cool.

The check can be made using the specially provided flexiblerod (1).

Figure 134

Draw off the rod from its slot and check that the level is withinthe etched tags of minimum and maximum level.

Whether it should be difficult tomake the evaluation, proceedcleaning the rod using a clean cloth with no rag grinding andput it back in its slot. Draw it off again and check the level.

In case the level results being close to the tag showingminimum level, provide filling lubrication of the engine’scomponents.

To provide filling, operate through the upper top (1) orthrough the lateral top (2). During filling operation, the topsmust be removed as well as the rod in order to make the oilflow easier”.

Some applications are equipped with a level transmitteralerting dashboard instruments in case of insufficientlubrication oil within the pan.

Figure 135

The engine oil is highly polluting and harmful.In case of contact with the skin, rinse well with waterand detergent.Adequately protect the skin and the eyes, operate infull compliance with safety regulations.Disposal must be carried out properly, and in fullcompliance with the law and regulations in force.

87756

87757



Check of fuel systemThe check must be executed both when the enginedisconnected and when it is running.The check operation consists in examining the fuel pipelinesrunning from the tank to the pre-filter (if provided in thespecific equipment), to the filter, to the injection pump and tothe injectors.

Cooling system checkThe check must be executed both when the enginedisconnected and when it is running.

Check the pipelines from the engine to the radiator, from theexpansion tank and vice-versa. Find out any blow-by, verify thestatus of the pipes specially close to the holding strips.

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

Due to the high temperatures achieved by thesystem, do not operate immediately after the engine’sdisconnection, but wait for the time deemednecessary for the cooling.Protect the eyes and the skin from any eventual highpressure jet of cooling liquid.

Lubricating system checkThe check must be executed both when the enginedisconnected and when it is running.

Verify the presence of any oil leakage or blow-by from thehead, from the engine pan of from the heat exchanger.

The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with waterand detergent.

Adequately protect the skin and the eyes, operate infull compliance with safety regulations.Disposal must be carried out properly, and in fullcompliance with the law and regulations in force.

Check of water presence within fuel filter or pre-filter

The components of the system can be damaged veryquickly in presence of water or impurity within thefuel.

Timely proceed operating on the pre-filter (notavailable on the engine block) to carry out thedrainage of the water within the feed circuit.

The density of the cooling liquid must be checked any howevery year before winter season and be replaced in any caseevery two year.

In case of new filling, proceed bleeding system,through the bleeds on the engine.

If bleeding of the system is not carried out, seriousinconvenience might be caused to the engine due tothe presence of air pockets in the engine’s head.

Fuel filter is equipped with pump screw-valve to drain thewater eventually mixed with fuel (some applications of 6cylinders engines will be equipped with two fuel filters, bothprovided with drainage.

Place a container underneath the filter and slightly loosen thescrew. Drain the water eventually contained in the filter’sbottom.

Lock the screw (max 0.5 Nm locking couple) as soon as fuelstarts bleeding.

Figure 136

77835

Unscrew the 6 screws (1) and remove cover (2).

Remove blow-by filters (3).

Before assembling the new filters clean their housing.

Checking/replacing the blow-by filter





cylinder n. 1 2 3 4intake - - * *exhaust - * - *

cylinder n. 1 2 3 4intake * * - -exhaust * - * -

cylinder n. 1 2 3 4 5 6intake - - * - * *exhaust - * - * - *

cylinder n. 1 2 3 4 5 6intake * * - * - -exhaust * - * - * -

Check of drive belt tensioningSome applications are equipped with an automatic tensionerthat provides correcting belt tensioning.

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

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

In order to more quickly perform the operatingclearance adjustment for rocker arms — valves,proceed as follows:

Rotate the drive shaft balance the valves of cylinder4 and adjust the valves marked by the asterisk asshown in the table:

4-cylinder enginesRotate the engine drive shaft balance the valves of thecylinder no.1 and adjust the valves marked by the staras indicated in the table:

Check and setting of tappet clearance

Figure 137

87673

Danger: if the engine is switched off but is still hot,unexpected motion of the belt may occur.

Wait for engine temperature cooling as a precautionin order to avoid serious danger injury.

6-cylinder enginesRotate the engine drive shaft balance the valves of thecylinder no.1 and adjust the valves marked by the staras indicated in the table:

Rotate the drive shaft balance the valves of cylinder6 and adjust the valves marked by the asterisk asshown in the table:

NOTE

Changing the engine oil and oil filter

Due to the several applications, the pan shape and the oilquantity can change slightly. However, the following oper-ations are valid for all applications.

We recommend to carry out the oil drainagewhen themotoris hot.

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

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

Warning: We recommend to wear proper protec-tions because of high motor service temperature.

The motor oil reaches very high temperature: youmust always wear protection gloves.

The oil motor is very pollutant and harmful.

In case of contactwith the skin, washwithmuchwaterand detergent.

Protect properly skin and eyes: operate according tosafety rules.

Dispose of the residual properly following the rules.

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

Use only the recommended oil or oil having the re-quested features for the corrrect motor functioning.

In case of topping up, don’t mix oils having differentfeatures.

If you don’t comply with theses rules, the service war-ranty is no more valid.

- Check the level through the dipsick until when the fillingis next to the maximum level notch indicated on thedipsick.

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

According to the application the filter can be located in differ-ent positions: the following procedure is a valid guide for allapplications.

- The filter is composed by a support and a filteringcartridge. For the cartridge replacement use the9936076-tool.

Warning: the oil filter contains inside a quantity of oilof about 1 kg.

Place properly a container for the liquid.

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

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

- Replace the filtering cartidge with a new one and screwmanually until when the gasket is in contact with thesupport.

- Tigthen by means of the 99360076-tool of three fourthturn.

- Operate the motor for someminutes and check the levelthrough the dipsick again. If it is necessary, carry out atopping up to compensate the quantity of oil used for thefilling of the filtering cartridge.

Figure 138

Filter replacement procedure

Screw the oil filter (1) on by hand until it is in contact with themounting and then tighten by 3/4 of a turn to the requiredtightening torque.Screw the plug back on under the sump and tighten it to therequired torque.Pour oil into the engine through the filling-pipe (2) of the re-quired grade and quantity.

Before refitting the new cartridges, moisten the sealwith engine oil.

Remove the oil filter (1) with tool 99360076.

75338

NOTE



Fuel filter replacement

- Drain the fuel inside the filter by operating the waterrelease screw. Collect the fuel in a container withoutimpurities.

- Unscrew the cartridge (1) by using the 99360076-tool.

- Collect the eventual fuel inside the filtering cartridge.

- Clean the gasket seat on the support and oil slightly thegasket on the new filtering cartridge.

- Screw manually the new filtering cartdrige until when thegasket is completely on its seat.

- Tigthen through the 99360076-tool at 10-15 Nm torque.

During this operation don’t smoke and don’t use freeflames.

Avoid to breathe the vapors coming from filter.

Alternator belt - water pump replacement

Figure 139

75340

Figure 140

77839

To remove and fit the belt (1) back on, you need to use anappropriate tool on the tightener (2) in the direction shownby the arrow.

The tighteners are automatic, so they are not to beadjusted after assembly.

NOTE



SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS 1NEF ENGINES


SECTION 4

General overhaul and characteristics

Page

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

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

4 AND 6 ENGINE OVERHAUL 11. . . . . . . . . . . . .

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

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

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

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

- Head face check on the cylinder group 13. . . . .

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

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

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

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

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

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

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

- 4-cylinder engine 18. . . . . . . . . . . . . . . . . . . . . . .

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

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

- 6-cylinder engine 20. . . . . . . . . . . . . . . . . . . . . . .

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

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

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

- Checking crankshaft shoulder clearance 23. . . . .

CONNECTING ROD — PISTON ASSEMBLY 23. .

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

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

2 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS NEF ENGINES


Page

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

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

- Split rings 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

- Fitting connecting rod-piston assembly into cylinderbarrels 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Page

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

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

- Checking cylinder head supporting surface 33. . .

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

- Removing carbon deposits, checkingand grinding valves 34. . . . . . . . . . . . . . . . . . . . .

- Checking clearance between valve stem and valveguide and valve centering 34. . . . . . . . . . . . . . . .

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

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

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

VALVE SPRINGS 36. . . . . . . . . . . . . . . . . . . . . . . . . .

FITTING CYLINDER HEAD 36. . . . . . . . . . . . . . . . . .

- Refitting the cylinder head 37. . . . . . . . . . . . . . .

TIGHTENING TORQUE 38. . . . . . . . . . . . . . . . . . . .



GENERAL SPECIFICATIONS

Type 4 CYLINDERS 6 CYLINDERS

Cycle Four-stroke diesel engine

Power Turbocharged with intercooler

Injection Direct

Number of cylinders 4 in-line 6 in-line

∅Bore mm 102

Stroke mm 120

+ + +.. = Total displacement cm3 3920 5880

TIMING

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

18.5º29.5º

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

67º35º

X

Checking timingmm

Xmm

Checking operationmm

Xmm

-

-

0.20 to 0.30

0.45 to 0.55

FUEL FEED

InjectionType: Bosch

high pressure common railEDC7 ECU

Nozzle type Injectors

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

bar

Injection pressure bar 250 - 1450



CLEARANCE DATA


CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅1

X

Cylinder barrels ∅1

∅1

102.009 to 102.031

0.5

∅1X

∅2

Spare pistonstype:Size XOutside diameter ∅ 1Pin housing ∅ 2

60.5107.781 to 101.79940.008 to 40.014

Piston — cylinder barrels 0.116 to 0.134

Piston diameter ∅ 1 0.5

X

Piston protrusion X 0.28 to 0.52

3∅ Piston pin ∅ 3 39.9938 to 40.0002

Piston pin — pin housing 0.0078 to 0.0202



Type 4 CYLINDERS 6 CYLINDER


X1

32

X

X

X1*Split ring slots X 2

X 3

2.705 to 2.7352.420 to 2.4404.020 to 4.040

1

32

S

SS

S 1*Split rings S 2

S 3

* measured on 99 mm

2.560 to 2.6052.350 to 2.3803.975 to 4.000

1Split rings - slots 2

3

0.100 to 0.1750.040 to 0.9000.020 to 0.065

Split rings 0.5

X1

3

2X

X

Split ring end openingin cylinder barrel:

X 1X 2X 3

0.30 to 0.400.60 to 0.800.25 to 0.55

1∅

∅ 2

Small end bushhousing ∅ 1Big end bearinghousing ∅ 2

42.987 to 43.013

72.987 to 73.013

∅

S

∅4

3 Small end bush diameterOutside ∅ 4Inside ∅ 3Spare big end halfbearings S

43.279 to 43.55340.019 to 40.033

1.955 to 1.968

Small end bush — housing 0.266 to 0.566

Piston pin — bush 0.0188 to 0.0392

Big end half bearings 0.250 ; 0.500





X

Size X

Max. toleranceon connecting rodaxis alignment

-

-

1 2∅∅

S 1 S 2

Journals ∅ 1Crankpins ∅ 2

Main half bearings S 1*Big end half bearings S 2*

*provided as spare part

82.993 to 83.01368.987 to 69.013

2.456 to 2.4641.955 to 1.968

3∅Main bearingsNo. 1—5 / 1-7 ∅ 3No. 2—3—4/2-3-4-5-6∅ 3

87.982 to 88.00887.977 to 88.013

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

0.041 to 0.1190.041 to 0.103

Half bearings - Crankpins 0.033 to 0.041

Main half bearingsBig end half bearings

+ 0.250; + 0.500

1X

Shoulder journal X 1 37.475 to 37.545

X 2

Shoulder main bearing X 2 32.23

X 3Shoulder half-rings X 3 37.30

Output shaft shoulder 0.068 to 0.410




CYLINDER HEAD — TIMING SYSTEM mm∅ 1

Valve guide seats oncylinder head ∅ 1 7.042 to 7.062

∅

α

4 Valves:

∅ 4α

∅ 4α

6.970 to 6.99060o ± 0.25o

6.970 to 6.99045o ± 0.25o

Valve stem and guide 0.052 to 0.092

∅ 1

Housing on head forvalve seat:

∅1

∅1

34.837 to 34.863

34.837 to 34.863

α

2∅

Valve seat outside diameter;valve seat angle on cylinderhead:

∅ 2α

∅ 2α

34.917 to 34.93160º

34.917 to 34.93145º

X

Sinking X

X

0.59 to 1.11

0.96 to 1.48

Between valve seatand head

0.054 to 0.094

0.054 to 0.094

Valve seats -




CYLINDER HEAD — TIMING SYSTEM mm

H H1H 2

Valve spring height:

free spring H

under a load equal to:339.8 ± 19 N H1741 ± 39 N H2

47.75

35.3325.20

XInjector protrusion X not adjustable

∅∅∅1 2 3 4 5

Camshaft bushhousings No. 1 (flywheel side)

Camshaft housingsNo. 2-3-4-5/2-3-4-5-6-7

59.222 to 59.248

54.089 to 54.139

∅

∅

∅1

2

3

Camshaft journals:1⇒ 5 ∅1⇒ 7 ∅ 53.995 to 54.045

∅Bush insidediameter ∅ 54.083 to 54.147

Bushes and journals 0.113 to 0.165

H

Cam lift:

H

H

6.045

7.582




CYLINDER HEAD — TIMING SYSTEM mm

∅1Tappet cap housingon block ∅ 1 16.000 to 16.030

∅23

∅

∅

2

Tappet cap outsidediameter: ∅ 2

∅ 315.924 to 15.95415.960 to 15.975

Between tappets and housings 0.025 to 0.070

Tappets -

∅ 1

Rocker shaft ∅ 1 21.965 to 21.977

∅ 2

Rockers ∅ 2 22.001 to 22.027

Between rockers and shaft 0.024 to 0.0162



70159

70158

70160

70161

70162

Figure 1

Figure 2

Figure 3

Figure 4

4 AND 6 ENGINE OVERHAULENGINE REMOVAL AT THE BENCHThe following instructions assume that the engine haspreviously been placed on the rotating bench and thatremoval of all specific components of the Iveco Motorsequipment have been already removed as well. (See Section3 of the manual herein).

The section illustrates therefore all the most important engineoverhaul procedures.

The following operations are relating to the 4 cylinder enginebut are similar and applicable for the 6 cylinder.

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

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

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

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

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

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

Take note of lower and upper half-bearingassembling positions since in case of reuse they shallbe fitted in the same position found at removal.

Figure 5

(Demonstrative)

NOTE

NOTE



70163

70165

70164

70166

70167

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Remove the screws (1) and disconnect camshaft (3) retainingplate (2).

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

Withdraw the tappets (1) from the engine block.

Once engine is disassembled, clean accurately thecylinder-block assembly.

Use the proper rings to handle the cylinder unit.

The engine block shall not show cracks.

Check operating plug conditions and replace them in case ofuncertain seal or if rusted.

Inspect cylinder barrel surfaces; they shall be free from seizing,scores, ovalisation, taper or excessive wear.

Inspection of cylinder barrel bore to check ovalisation, taperand wear shall be performed using the bore dial gauge (1)fitted with the dial gauge previously set to zero on the ringgauge (2) of the cylinder barrel diameter.

Measurements shall be performed on each cylinder, at threedifferent heights in the barrel and on two planes perpendicularwith each other: one parallel to the longitudinal axis of theengine (A), and the other perpendicular (B). Maximum wearis usually found on plane (B) in correspondence with the firstmeasurement.

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

Take note of plate (2) assembling position.

REPAIR OPERATIONSCYLINDER UNITChecks and measurements

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

s

NOTE

NOTE



zs

70170

Figure 11

Figure 12

Check the bench bearing seats, proceeding as follows:

- mount the bench caps on the supports withoutbearings;

- screw the fixing screws to the torque prescribed;

- by means of an adequate gauge, verify that the internaldiameter of the seats correspond to the valueprescribed.

If you detect a higher value, replace its block

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

Check the conditions of the working plugs (1) of the cylindergroups; replace them if rusty or in case of doubt about theirconditions.

When flattening is finished, restore the cylinder barrel bevelas shown in Figure 11.

The block flattening could be performed only afteryou have checked that, at finished work, the pistonprojection from the cylinder barrel is not higher thanthe value prescribed.

In the event of grinding operation, all the barrelsmust result of the same oversize (0.5 mm).

Head face check on the cylinder group

α

NOTE

107267

75703

D1D2




70169

Figure 13

Figure 14

TIMING SYSTEMCamshaft

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

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

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

camshaft and the bushes.

79459



70171

70172

Figure 15

Figure 16

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

Camshaft bush (2) shall be pressed into its housing.Internal surface must not show seizing or wear.Use bore dial gauge (3) to measure camshaft bush (2) andintermediate housing (1) diameter.Measurements shall be performed on two perpendicularaxes.

BUSHESChecking cam lift and pin alignmentSet the camshaft on the tailstock and using a 1/100 gauge seton the central support, check whether the alignment erroris not exceeding 0.04 mm, otherwise replace the camshaft.Check cam lift; found values shall be: 6.045 mm for exhaustcams and 7.582mm for intake cams, in case of different valuesreplace the camshaft.

Figure 17

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

107399

Sec. A-A



Figure 18

Figure 19

MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING

*Height to be obtained after driving the bush.

70174

To replace bush (1), remove and refit it using the beater99360362 (2) and the handgrip 99370006 (3).

Bush replacement

When refitting the bush (1), direct it to make thelubricating holes (2) coincide with the holes on theblock housing.

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

Tappets

Figure 20

107268

sec. A-A

NOTE

112890



70164

70238

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

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

Figure 21

Figure 22

Figure 23

70176

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

Fitting tappets — camshaft

Figure 24

Figure 25

70179

70180

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

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



70182

Figure 26

Figure 27

Grind journals and crankpins if seizing, scoring or excessiveovalisation are found. Before grinding the pins (2) measurethem with a micrometer (1) to decide the final diameter towhich the pins are to be ground.

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

Undersize classes are:

Journals and crankpins shall always be ground to thesame undersize class.Journals and crankpins undersize shall be marked onthe side of the crank arm No.1.For undersized crankpins: letter MFor undersized journals: letter BFor undersized crankpins and journals: letters MB

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

*Rated value

NOTE

4-cylinder engine

OUTPUT SHAFTMeasuring journals and crankpins

108487



70183

Figure 28

OUTPUT SHAFT MAIN TOLERANCES

70237

MAIN BEARING ON TIMINGSYSTEM CONTROL SIDE

INTERMEDIATE MAINBEARINGS

FIRST MAIN BEARINGON FRONT SIDE

measured on > 45.5 mm radius

between adjacent journals



TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

SHAPERoundness

SHAPECilindricity //Parallelism //

DIRECTION VerticalityStraightness

POSITION Concentricity or coaxiality

OSCILLATIONCircular oscillation

OSCILLATIONTotal oscillation

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ©

IMPORTANT ⊕SECONDARY ⊝

Figure 29

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES

*Rated value

Figure 30

MAIN OUTPUT SHAFT TOLERANCES

* Measured on a radius greater than 45.5 mm

** 0.500 between adjacent main journals 70577

6-cylinder engine

107269



70237

MAIN BEARING ON TIMINGSYSTEM CONTROL SIDE

INTERMEDIATE MAINBEARINGS

FIRST MAIN BEARING ONFRONT SIDE

Figure 31



TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

SHAPERoundness

SHAPECilindricity //Parallelism //

DIRECTION VerticalityStraightness

POSITION Concentricity or coaxiality

OSCILLATIONCircular oscillation

OSCILLATIONTotal oscillation

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ©

IMPORTANT ⊕SECONDARY ⊝

70184

70185

Figure 32

Figure 33

Figure 34

Figure 35

Refit the crankshaft (2).Check the backlash between crankshaf main journals and therelevant bearings as follows:

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

Fitting main bearings

Do not try to adapt the bearings.

Main bearings (1) are supplied spare with 0.250 — 0.500 mmundersize on the internal diameter.

Clean accurately the main half bearings (1) having thelubricating hole and fit them into their housings.

The second last main half bearing (1) is fitted with shoulderhalf rings.

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

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

Finding journal clearance

- clean accurately the parts and remove any trace of oil;- position a piece of calibrated wire (3) on the crankshaft

pins (4) so that it is parallel to the longitudinal axis;- fit caps (1), including the half bearings (2) on the relevant

supports.

70186

70161

Replacing oil pump control gear

NOTE

NOTE

75703

D1D2




This check is performed by setting amagnetic-base dial gauge(2) on the crankshaft (3) as shown in the figure, standardvalue is 0.068 to 0.41.

If higher value is found, replace main thrust half bearings ofthe second last rear support (1) and repeat the clearancecheck between crankshaft pins and main half bearings.

70188

70189

70190

70191

Figure 36

Figure 37

Figure 38

Figure 39

- 3rd stage, with tool 99395216 (1) set as shown in thefigure, tighten the screws (2) with 90° ± 5° angle.

- Remove caps from supports.

The backlash between the main bearings and the pins is foundby comparing the width of the calibrated wire (2) at thenarrowest point with the scale on the envelope (1) containingthe calibrated wire. The numbers on the scale indicate thebacklash in mm. Replace the half bearings and repeat the checkif a different backlash value is found. Once the specified backlashis obtained, lubricate the main bearings and fit the supports bytightening the fastening screws as previously described.

CONNECTING ROD — PISTON ASSEMBLYCOMPONENTS

1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -6. Half bearings - 7. Connecting rod - 8. Bush.

α

Checking crankshaft shoulder clearance

Pistons are supplied from parts with 0.5 mmoversize.

CONNECTING ROD — PISTON ASSEMBLY

NOTE

Figure 40

70187

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



32615

32614

32613

70192

84291

Figure 41

Figure 42

Figure 43

Figure 44

Figure 45

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

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

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

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

The diameter shall be measured at 60.5 mm fromthe piston skirt.

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter

NOTE

PistonsMeasuring piston diameter



32620

16552

32619

18857

Figure 46

Figure 47

Figure 48

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

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

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

Check the clearance between the sealing rings (3) of the 2ndand 3rd slot and the relevant housings on the piston (2), usinga feeler gauge (1).

Piston pins Split rings

Figure 49

Conditions for proper pin-piston coupling



41104

Figure 50

Figure 51

Figure 52

DIAGRAM FOR MEASURING THE CLEARANCE XBETWEEN THE FIRST PISTON SLOT AND THE

TRAPEZOIDAL RING

Since the first sealing ring section is trapezoidal, the clearancebetween the slot and the ring shall be measured as follows:make the piston (1) protrude from the engine block so thatthe ring (2) protrudes half-way from the cylinder barrel (3).

In this position, use a feeler gauge to check the clearance (X)between ring and slot: found value shall be the specified one.

70194

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

79456

MAIN DATA FOR CONNECTING ROD, BUSH, PISTONPIN AND HALF BEARINGS

Connecting rods

The surface of connecting rod and rod cap areknurled to ensure better coupling.Therefore, it is recommended not to smooth theknurls.



70196

Figure 53 BushesCheck that the bush in the connecting rod small end is freefrom scoring or seizing and that it is not loosen. Otherwisereplace.

Removal and refitting shall be performed using the properbeater.

When refitting take care to make coincide the oil holes seton the bush with those set on the connecting rod small end.Grind the bush to obtain the specified diameter.

Every connecting rod is marked as follows:

- On body and cap with a number showing theircoupling and the corresponding cylinder.In case of replacement it is therefore necessarytomark the new connecting rodwith the samenumbers of the replaced one.

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

S V, 1820 to 1860 (yellow marking);

S W, 1861 to 1900 (green marking);

S X, 1901 to 1940 (blue marking);

For F4HE0684 engines:

S V, 1600 to 1640 (yellow marking);

S W, 1641 to 1680 (green marking);

S X, 1681 to 1720 (blue marking);

Spare connecting rods are of the W class withgreen marking *.

Material removal is not allowed.

*

NOTE



CONNECTING ROD BODY

1234 W

CONNECT-ING ROD No. WEIGHT

0001 V

↓ W

9999 X

CONNECTING ROD CAP

1234 A 123

CONNECTINGROD No. YEAR DAY

0001 A 1998 001

↓ B 1999 ↓

9999 C 2000 366

D 2001

61696

61694

61695

70198

Figure 54

Figure 55

Figure 56

Figure 57

Check that the axis of the connecting rods (1) are parallelusing tool 99395363 (5) as follows:

- fit the connecting rod (1) on tool 99395363 (5) spindleand lock it with screw (4);

- set the spindle (3) on V-blocks by resting the connectingrod (1) on the stop bar (2).

Check connecting rod (5) torsion by comparing two points(A and B) of pin (3) on the horizontal plane of the connectingrod axis.

Position the dial gauge (2) support (1) to obtain a preload ofapprox. 0.5 mm on the pin (3) in point A and then set thedial gauge (2) to zero. Move the spindle (4) with theconnecting rod (5) and compare any deviation on theopposite side (B) of the pin (3): the difference between A andB shall not exceed 0.08 mm.

Check connecting rod (5) bending by comparing two pointsC andD of the pin (3) on the vertical plane of the connectingrod axis.Position the vertical support (1) of the dial gauge (2) to restthe latter on pin (3), point C.Move the connecting rod forwards and backwards to find pintop position, then in this condition reset the dial gauge (2).Move the spindle with the connecting rod (5) and repeat thecheck of the top point on the opposite side D of the pin (3).The difference between point C and point D shall not exceed0.08 mm.

Fitting connecting rod-piston assemblyConnecting rod-piston coupling

The piston crown is marked as follows:1. Part number and design modification number;2. Arrow showing piston assembling direction into cylinder

barrel, this arrow shall face the front key of the engineblock;

3. Marking showing 1st slot insert testing;4. Manufacturing date.

Checking connecting rods Checking bending

Checking torsion



72705

70199

32613

70200

70201

Figure 58

Figure 59

Figure 60

Figure 61

Figure 62

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

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

Fitting split rings

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

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

Lubricate accurately the pistons, including the split rings andthe cylinder barrel inside.Use band 99360605 (2) to fit the connecting rod-pistonassembly (1) into the cylinder barrels and check the following:- the number of each connecting rod shall correspond to

the cap coupling number.

Split rings are supplied spare with the followingsizes:

- standard, yellow marking;

- 0.5 mm oversize, yellow/green marking;

Fitting connecting rod-piston assembly intocylinder barrels

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

NOTE

NOTE



70202

70203

70204

70205

Figure 63

Figure 64

Figure 65

Figure 66

DIAGRAM FOR CONNECTING ROD-PISTONASSEMBLY FITTING INTO BARREL

- Split ring openings shall be displaced with each other by120°;

- connecting rod-piston assemblies shall have the sameweight;

- the arrowmarked on the piston crown shall be facing thefront side of the engine block or the slot obtained on thepiston skirt shall be corresponding to the oil nozzleposition.

Finding crankpin clearance

To measure the clearance proceed as follows:

- clean the parts accurately and remove any trace of oil;

- set a piece of calibrated wire (2) on the output shaft pins(1);

- fit the connecting rod caps (3) with the relevant halfbearings (4).

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

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

α

α

75703

D1D2




70207

70208

Figure 67

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

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

Once connecting rod-piston assemblies refitting is over, usedial gauge 39395603 (1) fitted with base 99370415 (2) tocheck piston (3) protrusion at T.D.C. with respect to the topof the engine block.

Protrusion shall be 0.28 to 0.52 mm.

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

Checking piston protrusion

Figure 68

Figure 69

70206

- Remove the cap and find the existing clearance bycomparing the calibrated wire width (1) with the scaleon the wire envelope (2).



70319

Figure 70

Intake (1) and exhaust (2) valves have heads with the samediameter.

The central notch of the exhaust valve (2) head distinguishesit from the intake valve.

Should cylinder head valves be not replaced,number them before removing in order to refitthem in the same position.

A = intake side — S = exhaust side

CYLINDER HEADRemoving the valves

Valve removal shall be performed using tool 99360268 (1)and pressing the cap (3) so that when compressing thesprings (4) the cotters (2) can be removed. Then remove thecap (3) and the springs (4).

Repeat this operation for all the valves.

Overturn the cylinder head and withdraw the valves (5).

70321

70322

Figure 71

Figure 72

Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

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

NOTE

NOTE



70323

Figure 73

This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90°C and 2to 3 bar pressure.

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

Replace the cylinder head if leaks are found.

Checking cylinder head wet seal

Before refitting, smear the plug surfaces withwater-repellent sealant.

Checking cylinder head supporting surface

70325

Figure 74

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

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

70324

Use a rule (2) and a feeler gauge (3) to check the cylinderhead (1) supporting surface.

Distortion found along the whole cylinder head shall notexceed 0.20 mm.

If higher values are found grind the cylinder head accordingto values and indications shown in the following figure.

Figure 75

NOTE



18625

18882

70327

Figure 76

Figure 77

Figure 78

Figure 79

VALVES

INTAKE AND EXHAUST VALVE MAIN DATA

Remove carbon deposits from valves using the proper metalbrush.Check that the valves show no signs of seizing, scoring orcracking.Regrind the valve seats, if required, using tool 99305018 andremoving as less material as possible.

Check the valve stem (1) using a micrometer (2), it shall be6.970 ± 6.990.

Use a magnetic base dial gauge (1) set as shown in the figure,the assembling clearance shall be 0.052 ± 0.092 mm.

Turn the valve (2) and check that the centering error is notexceeding 0.03 mm.

Removing carbon deposits, checking andgrinding valves

Checking clearance between valve stem andvalve guide and valve centering

107280

INTAKEVALVE

EXHAUSTVALVE



EXHAUST70328

70330

85486

Figure 80 Figure 81

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

Check the valve seats (2). If slight scoring or burnout is found,regrind seats using tool 99305018 (1) according to the anglevalues shown in Figure 82.

VALVE SEATSRegrinding — replacing the valve seats

VALVE SEAT MAIN DATA (4 CYL.)

INTAKE EXHAUST

INTAKE

Figure 82

Should valve seats be not reset just by regrinding, replacethem with the spare ones. Use tool 99305018 (Figure 81) toremove as much material as possible from the valve seats(take care not to damage the cylinder head) until they canbe extracted from the cylinder head using a punch.

Heat the cylinder head to 80° - 100°C and using the properpunch, fit the new valve seats, previously cooled, into thecylinder head.

Use tool 99305018 to regrind the valve seats according tothe values shown in Figure 82.

VALVE GUIDE



50676

70334

770321

Figure 83

Figure 84

Figure 85

MAIN DATA TO CHECK INTAKE AND EXHAUSTVALVE SPRINGS

Before refitting use tool 99305047 to check spring flexibility.Compare load and elastic deformation data with those of thenew springs shown in the following table.

FITTING CYLINDER HEAD

Lubricate the valve stems (1) and fit them into the relevantvalve guides according to the position marked at removal.

Fit the sealing rings (2 and 3) on the valve guide.

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

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

VALVE SPRINGS

70333

Figure 86

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

NOTE



Height Under a load of

mm N

H 47.75 Free

H1 35.33 P 339.8 ± 19 N

H2 25.2 P1 741 ± 39 N

There are two types of head seals for F4AE04.., F4AE06.. andF4HE06.. engines, for the thickness (1.25 mm Type A and1.15 mm Type B) take the following measures:- for each piston detect, as indicated on Figure 88, at a

distance of 45 mm from the centre of the pistonoverhandings S1 and S2 in relation to the engine baseupper plane then calculate the average:

For 4 cylinder versions:

Repeat the operation for pistons 2, 3 and 4 and calculatethe average value.

For 6 cylinder versions:

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

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

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

70335

Figure 87

Refitting the cylinder head

Figure 88

88775

S= Scil1+ Scil2+ Scil3+ Scil4+ Scil5+ Scil66

Scil1= S1+ S22

S= Scil1+ Scil2+ Scil3+ Scil44

75703

D1D2






TIGHTENING TORQUE

COMPONENTTORQUE

COMPONENTNm kgm

Studs M6 for camshaft sensors 8 ± 2 0.8 ± 0.2Studs M8 for feed pump 12 ± 2 1.2 ± 0.2Screw M12 for fastening rear gear caseScrew M10 for fastening rear gear caseScrew M8 for fastening rear gear case

77 ± 1247 ± 524 ± 4

7.7 ± 1.24.7 ± 0.52.4 ± 0.4

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

Screw M8 for fastening oil pump1st stage2nd stage

8 ± 124 ± 4

0.8 ± 0.12.4 ± 0.4

Screw M8 for fastening front cover 24 ± 4 2.4 ± 0.4Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4Screw M8 for fastening camshaft gear 36 ± 4 3.6 ± 0.4Screw M10 for fastening crankcase plate 43 ± 5 4.3 ± 0.4Nut M18 for fastening high pressure pump gear 105 ± 5 10.5 ± 0.5Nuts M8 for fastening fuel pump 24 ± 4 2,4 ± 0,4½ inch plug on cylinder head¼ inch plug on cylinder head¾ inch plug on cylinder head

24 ± 436 ± 512 ± 2

2.4 ± 0.43.6 ± 0.51.2 ± 0.2

Screw M6 for fastening injectors8,5 ± 0,35 0.35 ± 0.035

Screw M6 for fastening injectors75º ± 5º

Nut fastening for injector feed connector 50 ± 5 5 ± 0.5Nut M6 for flame start grille on intake manifold 8 ± 2 0.8 ± 0.2Screw M8 for fastening intake manifold 24 ± 4 2.4 ± 0.4Screw M12 for fastening rear brackets for engine lifting 77 ± 12 7.7 ± 1.2Screws M8 for fastening Common Rail 24 ± 4 2.4 ± 0.4Connectors M14 for high pressure fuel pipes 20 ± 2 2 ± 0.2Screw M12 (12 x 1.75 x 130) for fastening cylinder head

1st stage 35 ± 5 3.5 ± 0.5

Screw M12 (12 x 1.75 x 150) for fastening cylinder head1st stage 55 ± 5 5.5 ± 0.52nd stage 90º ± 5º3rd stage 90º ± 5º

Screw for fastening rocker bracket 36 ± 5 3.6 ± 0.5Valve clearance adjusting nuts 24 ± 4 2.4 ± 0.4Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 ± 2 2 ± 0.2Screw M8 for fastening high pressure pipe connector 24 ± 4 2.4 ± 0.4Screw M6 for fastening wiring bulkhead 10 ± 2 1 ± 0.2Screw M8 for fastening electric wiring support for injector feed 24 ± 4 2.4 ± 0.4Nuts for fastening wiring on each injector 1,5 ± 0,25 0.15 ± 0.025Screw M12 for fastening fuel filter bracket 77 ± 8 7.7 ± 0.8Screw M8 for fastening fuel filter holder 24 ± 4 2.4 ± 0.4Fuel filter contact + ¾ turnScrew M22 for fastening oil pressure relief valve on oil filter support 80 ± 8 8 ± 0.8Screw M8 for radiator seal and oil filter support 24 ± 4 2.4 ± 0.4Oil filter contact + ¾ turn11/8 inch connection on filter support for turbine lubrication 24 ± 4 2.4 ± 0.4Nut M12 for fastening turbine lubrication pipe 10 ± 2 1 ± 0.2Screw M10 for fastening engine coolant inlet connection 43 ± 6 4.3 ± 0.690° elbow fastening (if required) to engine coolant inlet connection 24 ± 4 2.4 ± 0.4Pipe on cylinder head for compressor cooling 22 ± 2 2.2 ± 0.2



COMPONENTTORQUE

COMPONENTNm kgm

Screw M6 for fastening engine coolant drain connector 10 ± 2 1 ± 0.2Pin fastening on engine block for exhaust manifold 10 ± 2 1 ± 0.2Screw M10 for fastening exhaust manifold on cylinder head 53 ± 5 5.3 ± 0.5

Screw M12 for fastening damper adapter 1st stage 50 ± 5 5 ± 0.5Screw M12 for fastening damper adapter 1 stageand damper on output shaft 2nd stage 90ºScrew M10 for fastening pulley on output shaft 68 ± 7 6.8 ± 0.7Screw M8 for fastening water pump 24 ± 4 2.4 ± 0.4Screw M10 for fastening auxiliary component control belt tensioners 43 ± 6 4.3 ± 0.6Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 ± 6 4.3 ± 0.6Screw M10 for fastening flywheel housingScrew M12 for fastening flywheel housing

85 ± 1049 ± 5

8.5 ± 14.9 ± 0.5

Screw M6 for fastening heat exchanger for control unitScrew M8 for fastening heat exchanger for control unit

10 ± 224 ± 4

1 ± 0.22.4 ± 0.4

Connection M12 for fuel inlet-outlet on heat exchanger 12 ± 2 1.2 ± 0.2Nut M8 for fastening valve cover 24 ± 4 2.4 ± 0.4Screw M6 for fastening camshaft sensor 8 ± 2 0.8 ± 0.2Screw M6 for fastening output shaft sensor 8 ± 2 0.8 ± 0.2Screw M14 for fastening coolant temperature sensor 20 ± 3 2 ± 0.3Screw M5 for fastening oil pressure/temperature sensor 6 ± 1 0.6 ± 0.1Screw for fastening fuel pressure sensor 35 ± 5 3.5 ± 0.5Screw M14 for fastening fuel temperature sensor 20 ± 3 2 ± 0.3Screw for fastening air temperature/pressure sensor on intake manifold 6 ± 1 0.6 ± 0.1Screw M12 for fastening engine oil level sensor 12 ± 2 1.2 ± 0.2

pins M8nuts M86-cyl. 7 ± 1

43 6

0.7 ± 0.14 3 ± 0 6

Turbine fixing to exhaust manifoldnuts M86-cyl.

pins M8

43 ± 6

7 ± 1

4.3 ± 0.6

0 7 ± 0 14-cyl. pins M8nuts M8

7 ± 124 ± 4

0.7 ± 0.12.4 ± 0.4

Adapter M12 on turbine for lubricant oil pipes (inlet) 35 ± 5 3.5 ± 0.5Pipe fixing on adapter M10 for turbine lubrication 35 ± 5 3.5 ± 0.5Oil pipe fixing on adapter M10 for turbine lubrication to block 43 ± 6 4.3 ± 0.6Oil drain pipe fixing M8 on turbine 24 ± 4 2.4 ± 0.4Connector fixing M6 for oil return from cylinder head to flywheel housing 10 ± 2 1 ± 0.2Screw M12 for fastening engine flywheel 1st stage

d30 ± 4 3 ± 0.4Screw M12 for fastening engine flywheel 1 stage

2nd stage 60º ± 5ºScrew M8 for fastening front bracket for engine lifting 24 ± 4 2.4 ± 0.4Screw for fastening engine oil sump 24 ± 4 2.4 ± 0.4Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3

Screw M12 for fastening output shaft caps 1st stage2nd staged

50 ± 680 ± 6

5 ± 0.68 ± 0.62 stage

3rd stage 90º ± 5ºScrew M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4Screw M8 for fastening camshaft gear 36 ± 4 3.6 ± 0.4Screw M10 for fastening connecting rod caps 1st stage

d60 ± 5 6 ± 0.5Screw M10 for fastening connecting rod caps 1 stage

2nd stage 60º ± 5ºAlternator 2.4 ± 0.4M10 Screw, Bracket fixing on water feed pipefitting 43 ± 6 2.4 ± 0.4M10 Screw, alternator locking 43 ± 6 2.4 ± 0.4Starter 2.4 ± 0.4Starter fixing screw 43 ± 6 2.4 ± 0.4Air supercharger:Control gear 5/8 inch fixing nut on the supercharger shaft 125 ± 19 12.5 ± 1.9Fixing nut M12 to the flywheel housing 77 ± 12 7.7 ± 1.2



SECTION 5 - TOOLS 1NEF ENGINES


SECTION 5

Tools

Page

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

2 SECTION 5 - TOOLS NEF ENGINES




TOOLS

TOOL No. DEFINITION

99305018 Kit for valve seat regrinding

99305047 Spring load tester

99317915 Set of 3 pin wrenches (14 - 17 - 19 mm)

99322205 Revolving stand for overhauling units (700 daN/m capacity, 120daN/m torque)

99331052 Adapter for measures on engine injectors (use with 99395872)

99340055 Tool to remove output shaft front gasket



TOOLS

TOOL No. DEFINITION

99340056 Tool to remove output shaft rear gasket

99341001 Double acting puller

99341009 Pair of brackets

99341015 Press

99342101 Tool to remove injectors

99346252 Tool for fitting output shaft front gasket



TOOLS

TOOL No. DEFINITION

99346253 Tool for fitting output shaft rear gasket

99355019 Wrench (10mm) for hydraulic power steering pump check screw

99360076 Tool to remove oil filter (engine)

99360183 Pliers for removing/refitting piston rings (65 — 110 mm)

99360268 Tool for removing/refitting engine valves

99360292 Keying device for seal assembly on the valve guide



TOOLS

TOOL No. DEFINITION

99360339 Tool for rotating/stopping the engine flywheel

99360351 Equipment for flywheel holding

99360362 Beater for removing/refitting camshaft bushes (to be used with993700069)

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)



TOOLS

TOOL No. DEFINITION

99361037 Brackets for fastening engine to revolving stand 99322205

99363204 Tool to remove gaskets

99367121 Manual pump for pressure and depression measures

99370006 Handgrip for interchangeable beaters

99370415 Gauge base for different measurements (to be used with 99395603)

99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)



TOOLS

TOOL No. DEFINITION

99389834 Torque screwdriver for injector solenoid valve connector stop nutsetting

99395216 Pair of gauges with ½” and ¾” square head for angle tightening

99395220 Universal goniometer/inclinometer

99395363 Complete bush testing square

99395603 Dial gauge (0 — 5 mm)

99395687 Bore meter



TOOLS

TOOL No. DEFINITION

99395872Analog to digital multimeter for voltage, current intensity, resistance,diodes, frequencies, capacity and registration of theminimum, averageand maximum values

8093731 Tester PT01



APPENDIX 1NEF ENGINES


Appendix

Page

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

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

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

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

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

2 APPENDIX NEF ENGINES


Particular attention shall be drawn on some precautions thatmust be followed absolutely in a standard working area andwhose non fulfillment will make any other measure useless ornot sufficient to ensure safety to the personnel in-charge ofmaintenance.

Be informed and inform personnel as well of the laws in forceregulating safety, providing information documentationavailable for consultation.

- Keep working areas as clean as possible, ensuringadequate aeration.

- Ensure that working areas are provided with emergencyboxes, that must be clearly visible and always providedwith adequate sanitary equipment.

- Provide for adequate fire extinguishing means, properlyindicated and always having free access. Their efficiencymust be checked on regular basis and the personnel mustbe trained on intervention methods and priorities.

- Organize and displace specific exit points to evacuate theareas in case of emergency, providing for adequateindications of the emergency exit lines.

- Smoking in working areas subject to fire danger must bestrictly prohibited.

- Provide Warnings throughout adequate boards signalingdanger, prohibitions and indications to ensure easycomprehension of the instructions even in case ofemergency.

- Do not execute any intervention if not provided withnecessary instructions.

- Do not use any tool or equipment for any differentoperation from the ones they’ve been designed andprovided for: serious injury may occur.

- In case of test or calibration operations requiring enginerunning, ensure that the area is sufficiently aerated orutilize specific vacuum equipment to eliminate exhaustgas. Danger: poisoning and death.

SAFETY PRESCRIPTIONSStandard safety prescriptions

Prevention of injury

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

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

- Wear safety helmet when working close to hanging loadsor equipment working at head height level.

- Alwayswear safety shoeswhen and cloths adhering to thebody, better if provided with elastics at the ends.

- Use protection cream for hands.

- Change wet cloths as soon as possible

- In presence of current tension exceeding 48-60 V verifyefficiency of earth andmass electrical connections. Ensurethat hands and feet are dry and execute workingoperations utilizing isolating foot-boards. Donot carry outworking operations if not trained for.

- Do not smoke nor light up flames close to batteries andto any fuel material.

- Put the dirty rags with oil, diesel fuel or solvents in anti-firespecially provided containers.

During maintenance

- Never open filler cap of cooling circuit when the engineis hot. Operating pressure would provoke hightemperature with serious danger and risk of burn. Waitunit the temperature decreases under 50ºC.

- Never top up an overheated engine with cooler andutilize only appropriate liquids.

- Always operate when the engine is turned off: whetherparticular circumstances require maintenanceintervention on running engine, be aware of all risksinvolved with such operation.

- Be equipped with adequate and safe containers fordrainage operation of engine liquids and exhaust oil.

- Keep the engine clean from oil tangles, diesel fuel and orchemical solvents.

- Use of solvents or detergents during maintenance mayoriginate toxic vapors. Always keep working areasaerated. Whenever necessary wear safety mask.

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

- Upon engine start after maintenance, undertake properpreventing actions to stop air suction in case of runawayspeed rate.

- Do not utilize fast screw-tightening tools.

- Never disconnect batteries when the engine is running.

- Disconnect batteries before any intervention on theelectrical system.

- Disconnect batteries from system aboard to load themwith the battery loader.

- After every intervention, verify that battery clamp polarityis correct and that the clamps are tight and safe fromaccidental short circuit and oxidation.

- Do not disconnect and connect electrical connections inpresence of electrical feed.

- Before proceeding with pipelines disassembly(pneumatic, hydraulic, fuel pipes) verify presence of liquidor air under pressure. Take all necessary precautionsbleeding and draining residual pressure or closing dumpvalves. Always wear adequate safety mask or goggles.Non fulfillment of these prescriptions may cause seriousinjury and poisoning.

APPENDIX 3NEF ENGINES


- Avoid incorrect tightening or out of couple. Danger:incorrect tightening may seriously damage engine’scomponents, affecting engine’s duration.

- Avoid priming from fuel tanks made out of copper alloysand/or with ducts not being provided with filters.

- Do not modify cable wires: their length shall not bechanged.

- Do not connect any user to the engine electricalequipment unless specifically approved by Iveco.

- Do not modify fuel systems or hydraulic system unlessIveco specific approval has been released. Anyunauthorized modification will compromise warrantyassistance and furthermore may affect engine correctworking and duration.

For engines equipped with electronic gearbox:

- Donot execute electric arc weldingwithout having prioryremoved electronic gearbox.

- Remove electronic gearbox in case of any interventionrequiring heating over 80ºC temperature.

- Do not paint the components and the electronicconnections.

- Do not vary or alter any data filed in the electronicgearbox driving the engine. Any manipulation oralteration of electronic components shall totallycompromise engine assistance warranty and furthermoremay affect engine correct working and duration.

- Respect of the Environment shall be of primaryimportance: all necessary precautions to ensurepersonnel’s safety and health shall be adopted.

- Be informed and inform the personnel as well of laws inforce regulating use and exhaust of liquids and engineexhaust oil. Provide for adequate board indications andorganize specific training courses to ensure that personnelis fully aware of such law prescriptions and of basicpreventive safety measures.

- Collect exhaust oils in adequate specially providedcontainers with hermetic sealing ensuring that storage ismade in specific, properly identified areas that shall beaerated, far from heat sources and not exposed to firedanger.

- Handle the batteries with care, storing them in aeratedenvironment and within anti-acid containers. Warning:battery exhalation represent serious danger ofintoxication and environment contamination.

Respect of the Environment

4 APPENDIX NEF ENGINES


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