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CNG NEF SERIESVehicle application

N60

N60 ENT G

Technical and Repair manual

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P u b l i c a t i o n e d i t e d b y

I v e c o M o t o rs

I v e c o S p A

PowerTrain

M k t . A d v e rt i s i n g & P r o mo t i o n

V i a l e d e l l I n d u s tr i a , 1 5 / 1 7

2 0 0 1 0 P r e g na n a M i l a ne s e

M i l a no ( I t a l y)

Print P1C32N001GB - 1st E d . 0 4 . 20 0 5

T h i s p u b l i c a t i o n d e s c r i b e s t h e c h a r a c t e r i s t i c s , d a t a a n d c o r r e c tm e t h o d s f o r r e p a i r o p e r a t i o n s o n e a c h c o m p o n e n t o f t h e v e -hicle.

I f t h e i n st r uc t io n s p r ov i de d a r e f o ll o we d a n d t h e s p ec i fi e de qu ip me nt i s u se d, c or re ct r ep ai r o pe ra t io ns i n t he p ro -g r a m m ed t i m e w i l l b e e n s u re d , s a f e g u a r d in g a g a i n s t p o s s i b leaccidents.

B e fo r e s t ar t in g t o p e rf o rm w h at e v er t y pe o f r e pa i r, e n su r e t h a ta l l a c c i de n t p r e v e n t i o n e q u i p m en t i s a v a i l a bl e a n d e f f i c i e n t .

A l l p r ot e ct i on s s p ec i fi e d b y s a fe t y r e gu l at i on s , i . e. : g o gg l e s,h e lm e t, g l ov e s , b o o t , e t c . m u st b e c h ec k ed a n d w o rn .

A l l m a ch i ni n g, l i ft i ng a n d c o nv e yi n g e q ui p me n t s h ou l d b e i n -s p e c te d b e f o re u s e .

T h e d a t a c o n t a i n e d i n t h i s p u b l i c a t i o n w a s c o r r e c t a t t h e t i m eo f g o in g t o p r es s b u t d u e t o p o ss i bl e m o di f ic a t io n s m a d e b y

the Manufacturer for reasons of a technical or commercial na-ture or for adaptation to the legal requirements of the differ-

e n t c o u n t r i e s , s o m e c h a n g e s m a y h a v e o c c u r r e d .

N o p a r t o f t h i s p u b l i c a t i o n , i n c l u d i n g t h e p i c t u r e s , m a y b e r e -p r o d u c e d i n a n y f o r m o r b y a n y m e a n s .

B . U . T E C H N IC A L P U B LI S H I N G

I v e c o T e c h ni c a l P u b l ic a t i on s

L u n g o S t u r a L a z i o , 1 5 / 1 9

1 0 1 5 6 T u r i n - I t a l y

P r o d uc e d b y :

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F 4 B E n g i n e s Part 1

CNG NEF ENGINES

1C N G N E F E N G I N E S

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2 C N G N E F E N G IN E S

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Where possible, the same sequence of procedures has been followed for easy reference.D i a g r a m s a n d s y m b o l s h a v e b e e n w i d e l y u s e d t o g i v e a c l e a r e r a n d m o r e i m m e d i a t e i l l u s t r a t i o n o f t h e s u b j e c t b e i n g d e a l t w i t h , ( s e en e x t p a g e ) i n s t e a d o f g i v i n g d e s c r i p t i o n s o f s o m e o p e r a t i o n s o r p r o c e d u r e s .

Example

1 = h o u s i n g f o r c o n n e c t i n g r o d s m a l l e n d b u s h

2 = h o u s i n g f o r c o n n e c t i n g r o d b e a r i n g s

T i g h t e n t o t o r qu eT i g h t e n t o t o r q u e + a n g u l a r v a l u e

1

2


SPECIAL REMARKS

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M a n u a l s f o r r e p a i r s a r e s p l i t i n t o S e c t i o n s , e a c h o n e o f w h i c h i s m a r k e d b y a n u m e r a l ; t h e c o n t e n t s o f t h e s e s e c t i o n s a r e i n d i c a t e di n t h e g e n e r a l t a b l e o f c o n t e n t s .E a c h s e c t i o n i s g e n e r a l l y d e d i c a t e d t o a m a i n U n i t ( e . g . : e n g i n e , g e a r b o x , e l e c t r i c s y s t e m , e t c . ) .S e c t io n s w i t h m e c h an i c a l c o n t e n t s i n c l u d e t e c h n ic a l d a t a , t i g h t e n i n g t o r q ue c o l l ec t i o ns , t o o l l i s t s , c o n n ec t i o ns d i s co n n e c ti o n s o f u n i t s t o / f r om t h e v e h i c l e , o v e r h a u l s a t t h e b e n c h a n d r e l a t i n g t r o u b l e sh o o t in g .O n t h e e l e c t r i c / e l e c t r o n i c s y s t e m s e c t i o n t h e r e a r e t h e d e s c r i p t i o n s o f t h e e l e c t r i c n e t w o r k a n d v e h i c l e e l e c t r o n i c s y s t e m s , e l e c t r i cs c h e me s , c o m p o n e nt s e l e c t ri c c h a r ac t e r i st i c s , c o m p o n en t s c o d e s a n d t r o u bl e s h o ot i n g r e l a t i n g t o t h e c e n t r a l u n i t s s p e c if i c o f t h ee l e c tr i c s y s t e m.T h e m a n u a l u s e s p r o p e r s y m b o l s i n i t s d e s c r i p t i o n s ; t h e p u r p o s e o f t h e s e s y m b o l s i s t o c l a s s i f y c o n t a i n e d i n f o r m a t i o n . I n p a r t i c u l a r ,

there have been defined a set of symbols to classify warnings and a set for assistance operations.

PRELIMINARY REMARKS

General danger

I t i n c l u d e s t h e d a n g e r s o f a b o v e d e s c r i b e d s i g n a l s .

Danger of serious damage for the vehicle

P a rt i a l o r c o mp l et e n o n o b se r va n ce o f t h es e p r es c ri p ti o ns c a n c a us e s e ri o us d a ma g e s t o t h e v e h ic l e a n d s o me t im e sg u a r a n t e e l a p s e t o o .

Environment protectionI t i n di c at e s c o rr e ct b e ha v io u r i n o rd e r t h at v e hi c le u s e i s e n v ir o nm e nt a l ly f r ie n dl y a s m u ch a s p o ss i bl e .

Danger for persons

M i s s in g o r i n c o m p l e t e o b s e r v a nc e o f t h e s e p r e s cr i p t io n s c a n c a u s e s e r i o u s d a n g e r f o r p e r s o n s s a f e t y .

SYMBOLS - WARNINGS

I t i n d i ca t e s a n a d d i t io n a l e x p l a n a t io n f o r a p i e c e o f i n f o rm a t i on .

!

NOTE


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Graph and symbols

RemovalDisconnection

Intake

Refitting

Connection

Exhaust

RemovalDisassembly

Operation

F i t t i n g i n p l a c eAssembly

C o m p re s s i on r a t i o

T i g h t e n t o t o r q ue Tolerance

Weight difference

Tighte n to torque + angle value R olling torque

P r es s o r c a ul k Replacement

O r i g in a l s p a r e p a r t s

RegulationAdjustment

Rotation

!WarningNote

AngleA n g u l a r v a l u e

V i s u a l i n s p ec t i o nF i t t i ng p o s i ti o n c h e c k

Preload

MeasurementV a l u e t o f i n dCheck

N u m b er o f r e v o l ut i o n s

Equipment Te mperature

S u r f ac e f o r m a c h in i n gM a c h in e f i n i sh bar

Pressure

InterferenceS t r a i ne d a s s e m bl y

OversizedH i g h e r t h a n.M a x i m u m , p e a k

Thickness

Clearance

U ndersized

L e s s t h a n.Minimum

LubricationDampGrease

SelectionClassesOversizing

SealantAdhesive

T e mp e ra t ur e < 0 CCold

Winter

A i r b l e e di n gT e mp e ra t ur e > 0 CHotSummer

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Section

General specifications 1

Fuel 2

U se 3

G e n e r a l o v e r h a u l 4

Tools 5

Safety prescriptions Appendix

PREFACE TO USERS GUIDELINE MANUAL

S e c t i o n 1 d e s c r i b e s t h e F 4 B e n g i n e i l l u s t r a t i n g i t s f e a t u r e s

a n d w o rk i ng i n g e ne r al .

S e c t i o n 2 d e s c r i b e s t h e t y p e o f f u e l f e e d .

S e ct i on 3 r e la t e s t o t h e s p ec i fi c d u ty a n d i s d i vi d ed i n f o ur s e pa -

r a t e p a r t s :

1 . M e ch a ni c al p a rt , r e la t ed t o t h e e n g i n e o v e r ha u l,

l i m i te d t o t h o s e c o m p o n e n ts w i t h d i f fe r e n t c h a r ac t e r i st i c s

b a se d o n t h e r e la t in g s p ec i fi c d u ty .

2 . E l e c t ri c a l p a r t , c o n c er n i n g w i r i n g h a r n e ss , e l e c t ri c a l

a n d e l e c t ro n i c e q u i pm e n t w i t h d i f fe r e n t c h a r a ct e r i s ti c s

b a se d o n t h e r e la t in g s p ec i fi c d u ty .

3 . M a i n te n a n c e p l a n n i n g a n d s p e c if i c o v e r h a u l .

4 . T r ou b le s ho o ti n g p a rt d e di c at e d t o t h e o p er a to r s w h o,b e in g e n ti t le d t o p r ov i de t e ch n ic a l a s s is t a nc e , s h al l h a v e s i mp l e

a n d d i re c t i n st r uc t io n s t o i d en t if y t h e c a us e o f t h e m a jo r i n co n -

veniences.

S e ct i on s 4 a n d 5 i l lu s tr a te t h e o v er h au l o p er a ti o ns o f t h e e n g i-

n e o v er h au l o n s t an d a n d t h e n e ce s sa r y e q ui p me n t t o e x ec u te

s u c h o p e ra t i o n s.

I n s t a ll a t i o n g e n e r a l p r e s c r i pt i o n s a r e r e p or t e d w i t h i n t h e a p -

pendix.

T h e a p p e n d i x r e p o r t s g e n e r a l s a f e t y p r e s c r i p t i o n s t o b e f o l l o -

w e d b y a l l o p er a to r s w h e th e r b e in g i n -c h ar g e o f i n st a ll a t io n o r

m a i n t en a n c e , i n o r d e r t o a v o i d s e r i o u s i n j u r y.

Part 1F4B ENGINES


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UPDATING

Section Description Page Date of revision

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SECTION 1 - GENERAL SPECIFICATIONS 1CNG NEF ENGINES

SECTION 1

General specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL CODEAND COMMERCIAL CODE 3. . . . . . . . . . . . .

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

OIL VAPOUR RECIRCULATING SYSTEM 6. . . . .

COOLING SYSTEM 7. . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION BOOST DIAGRAM 8. . . . . . . .

- Description 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2 S E C T IO N 1 - G E N ER A L S P E C IF I C A TI O N S C N G N E F E N G IN E S

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CORRESPONDENCE BETWEEN TECHNICAL CODE ANDCOMMERCIAL CODE

SECTION 1 - GENERAL SPECIFICATIONS 3CNG NEF ENGINES

Technical Code Commercial Code

F4BE0641A*G102 N60 ENT G



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Figure 1

LUBRICATION

L u br i ca t i on b y f o rc e d c i rc u la t io n i s a c hi e ve d t h ro u gh o i l r o ta r y e x pa n s io n p u mp , p l ac e d i n t h e f r o n t p a rt o f t h e b a se m en t ,d r iv e n b y t h e s t ra i g ht - to o th g e a r s p l i ne d t o t h e s h af t s b a r h o ld .

F r o m t h e p a n , t h e l u b r i c a t i o n o i l f l o w s t o t h e d r i v i n g s h a f t , t othe camshaft and to the valve drive.

L ubr ica tio n in vol ve s t he h ea t e xch an ge r ( 2, 3), t heturboblower for turbocompressed versions, and for any

c o m p re s s e d a i r s y s t em .

A l l t h es e c o mp o ne n ts m a y o f te n v a ry a c co r di n g t o t h e s p ec i fi cduty.

R o u t i ng o f o i l u n d e r p r e s s ur e

R o u t i n g o f o i l r e t u r n b y g r a v i t y to sump

I n t r o d u c t i o n o f o i l

76212

L U B R I CA T I O N S Y S T EM L A Y O UT

1 . L u b r i c a t i o n o i l p i p e t o s u p e r c h a r g e r - 2 . H e a t e x c h a n g e r b o d y - 3 . H e a t e x c h a n g e r - 4 . O i l r o t a r y e x p a n s i o n p u m p -

5 . O i l f i lt e r.

(Demonstrative)

S E C T IO N 1 - G E N E RA L S P E C I FI C A TI O N S 5C N G N E F E N G I N E S

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3240t

Figure 2

OIL VAPOUR RECIRCULATING SYSTEM

1 . V a l ve - 2 . B r ea t he r p i pe - 3 . T a pp et C ap .

O n t h e t a pp e t c a p ( 3 ) t h er e i s a v a l ve ( 1 ) w h o se d u ty i s t o c o nd e ns e o i l v a po u r i n d uc i ng t h es e t o f a ll d o wn b e ca u se o f g r a v it y ,to the Tappet cap underneath.

T h e r e m a i n i n g n o n - c o n d e n s e d v a p o u r s s h a l l b e p r o p e r l y c o n v e y e d t h r o u g h t h e b r e a t h e r p i p e ( 2 ) , b y s u c t i o n a s a n e x a m p l e ( c o n -n e c t i o n t o w a r d s t h e s e v a p o u r s s h a l l b e d e s i g n e d b y t h e E n g i n e e r ) .

1

2

3


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Figure 3

COOLING SYSTEM

T h e e n gi n e c o ol i ng s y st e m , c l os e d c i rc u it f o rc e d c i rc u la t io ntype, generally incorporates the following components:

- E x pa n s io n t a nk ; p l ac e me n t, s h ap e a n d d i me n si o ns a r es u b j e ct t o c h a n g e a c c o rd i n g t o t h e e n g i n e s e q u i p m e n t .

- R ad ia to r, w hi ch h as t he d ut y t o d is si pa te t he h ea ts u bt r ac t ed t o t h e e n gi n e b y t h e c o ol i ng l i qu i d. A l so t h isc o mp o ne n t w i ll h a v e s p ec i fi c p e cu l ia r it i es b a se d o n t h ee qu ip me nt d ev e lo pe d, b ot h f or w ha t c on ce rn s t hep l a ce m e n t a n d t h e d i m e ns i o n s .

- V is c p us he r f an , h av in g t he d ut y t o i nc re a se t he h ea td i ss i pa t in g p o we r o f t h e r a di a to r . T h is c o mp o ne n t a s w e llw il l b e s pe ci fi ca ll y e qu ip pe d b as ed o n t he e ng in e sdevelopment.

- H ea t e xc ha ng e r t o c oo l t he l ub ri ca t io n o il : e v en t hi sc o m po n e n t i s p a r t o f t h e e n g i n e s s p e c i f i c e q u i p me n t .

- C e nt r if u ga l w a t er p u mp , p l ac e d i n t h e f r o n t p a r t o f t h e

e n g i n e b l o c k.- T h er m os t at r e gu l at i ng t h e c i rc u la t io n o f t h e c o ol i ng l i qu i d.

- T he ci rcu it ma y e ve nt ua ll y be e xt en de d t o t hec o m p re s s o r, i f t h i s i s i n c l u d e d i n t h e e q u i p m e n t.

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

C O O L IN G S Y S T E M L A Y O U T

F R O M R A D I A T O R

T O R A D I A T O R

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S E C T IO N 1 - G E N E RA L S P E C I FI C A TI O N S 7C N G N E F E N G I N E S

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Figure 4

T h e t u rb o ch a rg e r i s c o mp os e d b y t h e f o ll o wi n g m a in p a rt s :o n e t u rb i ne , o n e t r an s fo r mi n g v a lv e t o r e gu l at e t h e b o os tf e e d i n g p r e s s u r e , o n e m a i n b o d y a n d o n e c o m p r e s s o r .

D u ri n g e n gi n e w o rk i ng p r oc e ss , t h e e x ha u st e m is s io n f l owthrough the body of the turbine, provoking the turbine disk

w h e e l s r o t a t io n .

T he c om pr es so r r ot or , b ei ng c on ne ct ed b y s ha ft t o t heturbine disk wheel, rotates as long as this last one rotates,

c o mp r es s in g t h e s u ck e d a i r t h ro u gh t h e a i r f i lt e r.

T h e a b o v e m e n t io n ed a i r i s t h en c o ol e d b y t h e r a d i at o r a n df l o w n t h r o u g h t h e p i s t on i n d u ct i o n c o l l e c t o r.

T h e t u rb o ch a rg e r i s e q ui p pe d w i th a t r an s fo r mi n g v a l ve t or e g u l at e t h e p r e s s ur e , t h a t i s l o c a t ed o n t h e e x h a u s t c o l l ec t o r b e f o r e t h e t u r b i n e a n d c o n n e c t e d b y p i p i n g t o t h e i n d u c t i o ncollector.

I t s d ut y i s t o c ho ke t he e xh au st o f t he e mi ss io ns , r el ea si ng p ar to f t h e m d i r e c t l y t o t h e e x h a u s t t u b e w h e n t h e b o o s t f e e d i n g

p r es s ur e , o v er t h e c o mp r es s or , r e ac h es t h e p r es c ri b ed b a r value.

T h e c o ol i ng p r oc e ss a n d t h e l u br i ca t io n o f t h e t u rb o ch a rg e r a n d o f t h e b e a r i n g s i s m a d e b y t h e o i l o f t h e e n g i n e .

Description

74195RADIATOR

A I R F I L T E R TU RBOCHARGER

EXHAU ST

AIR INDUCTION BOOST DIAGRAM


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S E C T I O N 2 - F U E L 1C N G N E F E N G I N E S

SECTION 2

Fuel

Page

CHEMICAL COMPOSITIONOF NAT URAL GAS (CNG) 3. . . . . . . . . . . . . .

A D V A NT A G E S O F M E T H AN E G A S U T I L I ZA T I O NIN AUT OMOTI VE 3. . . . . . . . . . . . . . . . . . . . .

- Mo tor a dv an ta ge s o f m et ha ne g as u ti liz at io n 4. .

- D is ad va nt ag es o f m et ha ne u ti li za ti on i n e ng in es 4

- T o rq u e a n d p o w er t y p i ca l c u r v es -F4 BE0641A eng ines 5. . . . . . . . . . . . . . . . . . . . .

GAS EMI SSIONS 6. . . . . . . . . . . . . . . . . . . . . . . . .

- Main pollutants 6. . . . . . . . . . . . . . . . . . . . . . . . .

- E m is s io n s o f I v e co C N G e n g in e c o mp a re d t o E T Cc yc le em is si on s - ga s o f r ef er en ce : G 20 an d G 25 7

I G NI T IO N A ND IN JE CT I ON IN TE GR A TE D S YS TE M 8

- Characteristics 8. . . . . . . . . . . . . . . . . . . . . . . . .

- Genera l items 8. . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTR IC I NJECTORS 9. . . . . . . . . . . . . . . . . . . .

AI R SUCTION CIRCU IT 10. . . . . . . . . . . . . . . . . . .

- Debimeter (Air flow s ensor) 10. . . . . . . . . . . . . .

- T hrottle valv e body 10. . . . . . . . . . . . . . . . . . . . .

PRESSURE REDU CER 11. . . . . . . . . . . . . . . . . . . . .

STEEL HOSE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OXYGEN SENSOR 15. . . . . . . . . . . . . . . . . . . . . . .

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2 S E CT I ON 2 - F U EL C N G N E F E N G IN E S

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CHEMICAL COMPOSITION OF NATURAL GAS (CNG)

N a t u r a l g a s i s a m i x t u r e o f g a s e s , m a i n l y c o m p o s e d o f m e t h a n e g a s , t h e p e r c e n t a g e o f w h i c h , a s t h e o n e o f t h e o t h e r c o m p o n e n t s ,m a y v a r y f r om e a ch f i el d . I n g a s o f d o me s ti c p r od u ct i on a n d i m p o rt e d g a s a s w e ll , m a in c h ar a ct e ri s ti c s a r e t h ou g h i n c l ud e d i n a na l m o st l i m i te d r a n g e o f t o l e r an c e . C h e m i c a l c h a r ac t e r is t i c s o f n a t u r al g a s a r e d e t e r mi n e d t h r o u g h o u t c h r o m a t og r a p hi c a n a l y si sw h ic h e n a bl e s t o d e fi n e t h e c o mp o si t io n . N a t ur a l g a s i s a m i xt u re o f a l ip h at i c s a tu r at e d c o mp o un d s c a l l e d p a r a ff i n. I n t h e o n ed i s t r i b u t e d i n I t a l y , m e t h a n e ( C H4) i s f o u n d i n p e r c e n t a g e s i n c l u d e d i n r a n g e b e t w e e n 8 3 % a n d 9 9 % . T h e o t h e r c o m p o u n d s a r eg e ne r al l y e t ha n e, ( C2H6) , p ro pa n e ( C3H8) , b ut an e ( C4H10) , n it ro g en ( N2) , c ar bo n d io xi de ( CO2) , a nd s o on . T he ma inc h e m ic a l - ph y s ic a l c h a r a c t e ri s t i cs o f t h e d o m e s ti c n a t u r a l g a s a r e r e p o rt e d i n t h e t a b l e b e l o w .

N a tu r al g a s i s c o lo u rl e ss , o do u rl e ss a n d i s n o t t o x i c . T h e l a w p r es c ri b es t h at e l ec t ro n ic s y st e m s t o c o nt r ol i g ni t io n i n m e th a ne e n g in ea r e o f a ut o -a d ju s ti n g t y pe , w h ic h m e a ns a b le t o a u to m at i ca l l y m o d i fy i g ni t io n p a ra m e te r s i n p r es e nc e o f g a s w i th d i ff e re n t c o nt e nto f m e t h a n e.

ADVANTAGES OF METHANE GAS UTILIZATION IN AUTOMOTIVE

ECOLOGIC

- M e t h a ne i s w e l l - kn o w n a s t h e o n l y a l t e r na t i v e e c o l o g ic f u e l r e a l ly a v a i l a b l e .

- M e th a ne u t il i za t i on i s r e le n t le s sl y i n cr e a si n g a s b e in g t h e m o st r e as o na b le a n d f e a si b le a l te r na t iv e t o e l ec t ri c al a n d h y br i dvehicles.

TECHNICAL

- T h e e n g i n e l i k e s m e t h a n e.

STRATEGICAL

- W o r l dw i d e o i l a n d n a t u r a l g a s a v a i l a b i l it y i s v e r y h i g h , a n d p r o cu r e m e nt s o u r ce s a r e l e s s s u b j e c t t o g e o g r a p h i c al a n d p o l i t i ca lrisks.

ECONOMICAL


GAS Domestic Russian Dutch Algerian

Indicative composition % % % %

Me thane 99.62 9 8.07 9 1.01 8 3.28

Ethan e 0.06 0 .60 3.70 7 .68

Propa ne 0.02 0.22 0.88 2.05

Butane 0.01 0 .09 0 .28 0 .78

Pentanes - 0.01 0.07 0.21

Hex an es + 0.01 0.02 0.07 0.11

Carbon dioxide 0.02 0.11 1.11 0.19

Nitrogen 0.26 0.87 2.84 5.52

Helium - 0.01 0.04 0.18

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Motor advantages of methane gas utilization

T h e g a s e o u s s t a t u s a n d t h e h i g h a n t i k n o c k p o w e r m a k e m e t h a n e a s u i t a b l e f u e l f o r t h e f e e d o f e n g i n e s w i t h f i r i n g c o n t r o l d r i v e nb y h i g h c o m pr e s s i on v o l u me t r i c r a t i o . ( u p t o 1 3 : 1 ).

T h e h i g h o c t a n e v a l u e ( 1 2 0 - 1 3 0) c o n f er s t o m e t h a ne s i g n i fi c a n t r e s i s t a nc e t o d e t o n a t i o n, f e a t u ri n g t h e s u p e r f u e l s .

D u e t o t h e f u e l i n i t i a l p u r i t y a n d t h e a b s e n c e o f a d d i t i v e s , c o m b u s t i o n o r i g i n a t e s l i m i t e d d e p o s i t f o r m a t i o n a n d v e r y s m a l l q u a n t i t y o f s u l p hu r o u s p ro d u ct s .

M o r eo v e r , t h e a b s e n ce o f c o n d en s a t i on p h e n om e n o n a l o n g t h e c o m b u s t i on c h a m b er d u c t s e n a b l e s e a s y s t a r t .Joint to with minor deposit accumulation, there is the possibility to use lubrication oil for a higher number of working hours.

T h e t e c h n ol o g y a d o p t e d b r i n g s f o r w ar d t h e f o l l o w i n gadvantages:

- i t e l i m i n a te sparticulate e m is s i o n s f r o m o r i g i n a l s o u r c e , t y p i ca l o f d i e s e l e n g i n e s a n d a b s e n t i n c o n t r o l l ed f i r e e n g i n e s ;

- i t r e d u c e sgas e m i s s i o n s ( u n b u r n t h y d r o c a r b o n s H C , c a r b o n o x i d e C O a n d n i t r o g e n o x i d e N O x ) t o v e r y l o w l e v e l s , l o w e r than the limits prescribed for 2008. This reduction takes place into the three-way catalyser which, when the mixture is

s t o i ch i o m et r i c , e l i m i n a t es p o l l ut i o n e m i s s i o n s o f t h e e n g i n e , w i t h o v e r 9 0 % e f f i ci e n c y;

- m o re o ve r , t h er e a r e n o e m is s io n s o f s u pe r io r h y dr o ca r bo n s, s u ch a s b e nz e ne a n d d e r i v at i ve s ;

- i t r e d u c e s t h e e m i ss i o n s o f carbon dioxide, t h a n k s t o t h e u t i l i z a t i o n o f m e t h a n e w h i c h , c o m p a r e d t o d i e s e l o i l a n d g a s o l i n e ,p r o du c e s m o r e w a t e r v a p o u r a n d l e s s c a r b o n d i o x i d e ;

- i t s i g n i fi c a n t ly r e d u ce snoise, a s t h e e n g i n e h a s c o n t r o l l e d f i r i n g .

Disadvantages of methane utilization in engines

S i nc e g a s , w i t h t h e s a me e n er g et i c c o nt e n t, o c cu p ie s h i gh e r v o l u m e t h a n l i qu i d f u el s t h is i n vo l ve s t h e f o ll o wi n g:

l e ss v o lu m et r ic e f fi c ie n cy o f t h e e n g in e ( i n p r op o rt i on t o t h e v o lu m e o f t h e g a s d e li v er e d a t i n du c ti o n) ;

O v er a ll v o lu m e / c o st / c o mp l ex i t y o f f u el s t or a ge s y st e m a b o a rd t h e v e hi c le .

L o w e r e n g i n e e f f i c i en c y c o m p a r e d t o D i e s el , b u t h i g h e r t h a n g a s o l i n e f e e d e n g i n e.


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Torque and power typical curves - F4BE0641A engines

Figure 1

87772

A . P o w e r - B . T o r q u e .

Performances

(ECE 88/185/195 after 50 hours of operation - Tolerance 5%)Max pow er 147 kW (200 CV)Max pow er rpm 2500 - 2700 rpmPiston av era ge speed 10.8 m/secMax torque 650 NmMax torque rpm 1250 - 2000 rpmEff. a verage pressu re. (with max torque) 14.3 Bar Pea k idle rpm 2900 rpmMinimum idling 650 rpmEfficiency with ma x power 34%Efficiency w ith max torque 36%Oil consumption with max power 0.4 g/kWh

rpm


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GAS EMISSIONS

1 9 99 / 96 / EC E u ro p ea n R e gu l a ti o n f o r h e a vy e n gi n es i n tr o du c ed a n e w t e st c y cl e c a ll e d E T C f o r m e t ha n e g a s f e ed e n g in e s a n ds ta te s t h e l im it s f or t he e mi ss io ns , l ow er E ur o 3 a nd E u ro 4 , f or t he E EV v eh ic le s e gm en t w it h m in im um i mp ac t t o t he e nv ir on me nt .

LIMIT VALUES PRESCRIBED BY 1999/96/EC REGULATION WITH ETC TEST CYCLE

Main pollutants

Carbon monoxide (CO)

I t i s a v e ry d a ng e r ou s g a s ( i n h i g h c o nc e nt r at i on i t b e co m es d e ad l y) w h ic h i s o r ig i na t ed w h en c o mb u st i on p r oc e ss i s c a rr i ed o u tw it h l ac k o f o xy ge n. I t i s a t yp ic al e mi ss i on o f t h e E ig ht -s tr ok e e mi ss io ns , w hi le i t m ay b e f ou nd i n d ie se l e ng i ne s i n v er y l owpercentages.

Unburnt hydrocarbons (HC)

T h es e a r e v i s c ou s p a rt i cl e s, a s a c o ns e qu e nc e o f a n i n co m pl e te c o mb u st i on o f f u e l s a n d l u br i ca n t s. T h e H C a r e e m it t e d b y E i gh tc yc l e e n gi n es a n d d i es e l e n gi n es i n di s ti n ct l y, b u t t h es e l a st o n es a r e m o re c r it i ca l b e ca u se t h ey c on t r ib u te o r ig i na t i ng t h e P a rt i cu l at e .

Nitrogen oxide (NOx)

When combustion is carried out at very high temperature, the nitrogen which is a neuter element normally, chemically combinesw i th t h e o x y g e n. T h e N O x a r e e m it t e d b y E i gh t c y cl e e n g in e s a n d d i es e l e n gi n es i n di s ti n ct l y.

Sulphur composites (SOx)

O r ig i na t ed b y o x id a ti o n o f s u lp h ur p a rt i cl e s c o nt a in e d i n d i es e l o i l. F o r t h is r e as o n t h ey a r e t y pi c al o f d i es e l e n gi n es .

Particulates (PT)

I n d i es e l e n g i n es , p a rt o f t h e f u el i n je c te d i n t h e c o mb u st i on c h am b er d o es n o t b u rn n o rm a ll y b u t i t i s t r an s fo r me d i n c a rb o n p a rt i cl e sw h i c h, j o i n in g t h e H C , c o m p o s e t h e P a r t ic u l a t es .


(CO)g/kWh

(NMHC)g/kWh

(CH4)g/kWh

(NOx)g/kWh

(PT)g/kWh

Euro 3 - 2000 5.45 0.78 1.6 5.0 0.16 0.21

Euro 3 - 2005 4.0 0.55 1.1 3.5 0.03

Euro 3 - 2008 4.0 0.55 1.1 2.0 0.03

EEV 3.0 0.40 0.65 2.0 0.02

IVECO engine CNG 1.27 0.006 0.01 0.45 0.002

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Emissions of Iveco CNG engine compared to ETC cycle emissions - gas of reference: G20 and G25

Figure 2

87893

Figure 3

87894

Emission

(g/kWh)


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IGNITION AND INJECTION INTEGRATED SYSTEMCharacteristics

M e t a f u e l 3 s y s t e m b e l o n g s t o t h e c a t e g o r y o f t h e e l e c t r o n i c i g n i t i o n a n d i n j e c t i o n i n t e g r a t e d s y s t e m s o f s e q u e n t i a l a n d t i m e d t y p e .

T h e c e nt r al u n it e l ec t ro n ic a l ly c o nt r ol s a i r f l ow r a te t h ro u gh m o to r is e d t h ro t tl e ( d ri v en b y V D O E G A S 2) , c o nt r ol s t h e t u rb o bl o we r through special solenoid valve, regulates fuel injection in such a way that (air/fuel) ratio is always ranging within optimal value and

c a lc u la t es i g ni t io n l e ad . T h es e f u nc t io n s e n a bl e e n gi n e t o r u n r e gu l ar l y o n v a ri a ti o ns o f e n v ir o nm e nt a l p a ra m et e rs a n d a p pl i ed l o ad s .

I g ni t io n s y st e m i s o f s t a ti c t y pe w i th o n e c o i l p e r c y l i nd e r. P o we r m o du l es a r e c o nt a in e d i n s i de t h e c e n t ra l u n it .

E n gi n e c o nt r ol s y st e m , o f s e lf - ad a pt i ng t y pe , i s a b le t o d e te c t c h an g es ( c om p on e nt s d e te r io r at i on , e t c. ) o c cu r ri n g i n e n g in e a n dc o m p en s a t e t h e m a c c o rd i n g t o s e l f -a d a p t in g f u n c ti o n s w h i c h c o r r ec t c e n t ra l u n i t m a p p i n g s . A s e l f - ad a p t i ng f u n c ti o n a l l o w in g t od e te c t f u el q u a li t y i s a l so p r es e nt .

A s a c o n s e q u e n c e o f w h a t a b o v e , i t i s a f t e r e a c h m a i n t e n a n c e i n t e r v e n t i o n n e c e s s a r y t o d r i v e t h e v e h i c l e f o r a t l e a s t 1 5 m i n u t e si n t h e v a r i o us w o rk i ng c o nd i ti o ns i n o r de r t o h a ve c e nt r a l u n i t s t or i ng a n y c h an g e s t o s y st e m a n d t o t e rm i na t e a d a pt a ti o n.

Figure 4

87608

General items

1 . D e b i m e t e r - 2 . A i r f i l t e r - 3 . F r e s h a i r - 4 . T u r b o c h a r g e r - 5 . C a t a l y s t - 6 . E x h a u s t g a s - 7 . E x h a u s t g a s t e m p e r a t u r e s e n s o r -8 . L a m b d a s e n s o r - 9 . W A S T E - G A T E v a l v e - 1 0 . O i l t e m p e r a t u r e / p r e s s u r e s e n s o r - 1 1 . O i l s u m p -

1 2 . M e t h a n e g a s r e s e r v o i r - 1 3 . R e l a y - 1 4 . G a s c y l i n d e r p r e s s u r e s e n s o r - 1 5 . P r e s s u r e r e d u c e r -1 6 . R a i l t e m p e ra t u r e /p r e s su r e s e n s o r - 1 7 . A i r t e m p e ra t u r e /p r e s s ur e s e n s o r -

1 8 . V D O E G A S I I c o n t r o l u n i t - 1 9 . M i n i m u m b y - p a s s - 2 0 . T h r o t t l e v a l v e p o t e n t i o m e t e r - 2 1 . D a s h b o a r d -2 2 . P r e s su r e s e n s or - 2 3 . I n t e rc o ol e r - 2 4 . A c c e le r at o r - 2 5 . E n g i ne c o nt r ol u n it - 2 6 . C a m s ha f t r e v s e ns o r -

2 7 . C r a n k s h a f t r e v s e n s o r .


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ELECTRIC INJECTORS

Figure 5

87776

T h e e l e c t r i c i n j e c t o r s a r e s p e c i f i c f o r m e t h a n e e n g i n e s . T h e m e t h a n e j e t s a t 9 - b a r p r e s s u r e c o m e o u t o f t h e i n j e c t o r u p s t r e a m t h es u c t io n v a l v e s .

T h e o p e r a t i n g l o g i c i s o f p h a s e s e q u e n c e t y p e . T h e s i x i n j e c t o r s a r e c o n t r o l l e d a c c o r d i n g t o t h e s u c t i o n s e q u e n c e o f t h e e n g i n ec y li n de r , w h il e t h e f u el s u pp l y c a n b e s t ar t ed f o r e a ch c y li n de r a l re a dy a t t h e e x pa n s io n s t ag e u n ti l r e ac h in g t h e s u ct i on p h as e a l re a dy started.

T h e f u e l i s i n je c te d f r om a n i n je c to r f o r e a c h c y li n de r p o si t io n ed o n t h e m a ni f ol d i n le t b e fo r e t h e s u ct i on v a lv e s .

T h e e l e c t r i c i m p u l s e r e s u l t s f r o m t h e c o n t r o l u n i t w h i c h g e n e r a t e s a m a g n e t i c f i e l d i n t h e c o i l a t t r a c t i n g t h e c o r e b y l i f t i n g t h e p i nb y s o me t e nt h s o f m i ll i me t re o f f i t s h o us i ng .


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AIR SUCTION CIRCUIT

T h e a i r s u c t i o n c i r c u i t c o n s i s t s o f t h e f o l l o w i n g c o m p o n e n t s :

A i r f i l t e r D e b im e t e r ( a i r f l o w s e n s o r )A i r t e m p er a t u r e s e n s o r S u c t io n m a n i fo l d p r e s s ur e s e n s o r T u r b oc h a r ge r p r e s su r e s e n s or

TurbochargerT h r o tt l e v a l v e a n d p o s i t i o n s e n s o r S u c t io n m a n i fo l dE n g i n e i d l i n g s p e e d a c t u a t o r

Figure 6

87777

T h e a i r f l o w s e n s o r i s o f t h e n e w t y p e w i t h h e a t e d f i l m . T h i s s y s t e m i s f i t t e d w i t h a h e a t e d f i l m p o s i t i o n e d i n a m e a s u r i n g c h a n n e lthrough which the air coming from the engine air inlet flows in.

A h e a ti n g c oi l m a in t a in s t h e f i lm a t a c o ns t an t t e mp e ra t ur e ( 1 20

C).T h e a i r m a ss f l ow i ng t h ro u gh t h e m e a su r in g c h an n el a b so r bs h e at f r om t h e f i lm . T h er e fo r e, t o m a in t a in t h e f i lm t e mp e ra t ur ec o n s t a n t , i t i s n e c e s s a r y t o h a v e a p r e - e s t a b l i s h e d c u r r e n t f l o w i n g t h r o u g h t h e h e a t i n g c o i l .

Throttle valve body

T h e t h r o t t l e v a l v e b o d y f u n c t i o n i s t o d o s e t h e q u a n t i t y o f a i r s u p p l i e d t o t h e e n g i n e a c c o r d i n g t o t h e d r i v e r s r e q u e s t t h r o u g h t h eaccelerator.

T h e t h ro t tl e v a l ve b o dy i s f a st e n ed t o t h e s u ct i on m a ni f ol d . T h e t h ro t tl e v a lv e i s o p en e d b y m e an s o f a l e ve r in g s y st e m w i th d i ff e re n to p e n in g a n g l e s.

T h e t h r o t tl e v a l ve p o si t io n s e ns o r i s f i tt e d o n t h e t h r o t tl e v a l ve b o dy .

I t c o ns i st s o f a p o te n ti o me t er w i th a m o bi l e p a rt c o nt r ol l ed d i re c tl y b y t h e t h ro t tl e v a lv e s p in d le .

Debimeter (Air flow sensor)

1 . C o n n e c t o r - 2 . M e a s u r i n g c h a n n e l - 3 . H e a t e d f i l m s e n s o r A = A i r i n l e t .


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PRESSURE REDUCER

T h e T A R T A R I N I M E T A p r e s s u r e r e d u c e r i s i n s t a l l e d i n t h e e n g i n e c o m p a r t m e n t a n d i t s t a s k i s t o r e d u c e t h e g a s p r e s s u r e f r o mthe value on the cylinder to the injector supply value and keep it under control at any operating conditions.

T h e p r es s ur e r e d uc e r i s a l so f i tt e d w i th a n h y d ra u li c c o nn e ct i on t o t h e e n g in e w a te r c o ol i ng c i rc u it w h ic h s u p pl i es t h e r i g ht a m ou n to f h e a t t o t h e g a s . A s a r e s u l t , d u r i n g t h e e x p a n s i o n p h a s e t h e g a s t e m p e r a t u r e f a l l s d r a m a t i c a l l y .

Figure 7

004425t

T h e g a s a r r i v i n g f r o m t h e c y l i n d e r s f l o w s i n t o t h e r e d u c e r a t 2 0 0 - b a r p r e s s u r e a n d a f t e r t w o p r e s s u r e l o s t h e a d s , i t i s s e n t t h r o u g ha s t e e l h o s e t o t h e s u p p l y p i p e ( r a i l ) a t 9 - b a r p r e s s u r e .

I n t h e r e d u c e r t h e r e i s a l s o a s a f e t y v a l v e w h o s e f u n c t i o n i s t o p r e v e n t o v e r - p r e s s u r e .

T h e m a x i mu m o p e r a ti n g p r e s s u r e s a r e t h e f o l l ow i n g :

Ma ximum operating pressure 22000 kPa (220 bar)First hea d maximum pressure 1400 k Pa (14 bar)Second hea d maximum pressure 900 kPa (9 bar)Sa fet y v alve exha ust pre ssure 1800 kPa (18 bar)

6


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Installation note

Y o u a r e r e co m me n de d t o p o si t io n t h e r e du c er i n a r ea s w i th o ut d u st a n d h u mi d it y .

Actions on components

G i ve n t h e h i gh t e ch n ol o gy a n d p r e c is i on r e qu i re d a t a s se m bl y , i t i s n o t p e rm i tt e d t o c a rr y o u t o p er a ti o ns o n t h e r e du c er i n ne r parts.T h e o n l y d e v i c e s w h i c h c a n b e r e m o v e d a n d r e p l a c e d w i t h o u t c o m p r o m i s i n g t h e r e d u c e r o p e r a t i o n a r e : t h e i n p u t p i p e ( 1 ) ; t h ec o i l ( 2 ) ; t h e v a l v e u n i t ( 3 ) ; t h e f i l t e r ( 4 ) ; t h e l o w p r e s s u r e s w i t c h ( 5 ) n o t u s e d o n I V E C O a p p l i c a t i o n s ; t h e p r e s s u r e s e n s o r u n i t ( 6 ) .

Reducer main elements

Filter

O n t h e r e d u c e r i n l e t t h e r e i s a f i l t e r w h i c h p r o t e c t s t h e v a l v e s a n d t h e g a s k e t s a g a i n s t i m p u r i t i e s .I t i s t h e d e v i c e w h o s e f u n c t i o n i s t o h o l d t h e m e t h a n e i m p u r i t i e s b e f o r e i t g e t s i n s i d e t h e s o l e n o i d v a l v e a n d t h e r e f o r e i n s i d e t h ereducer.U n fo r tu n at e ly i t i s e x t re m el y d i ff i cu l t t o e s ta b li s h w h en i t i s n e ce s sa r y t o c h an g e t h e f i lt e r s i nc e i t i s i n si d e a n d i t s d e gr a da t i on d e pe n dso n l y o n t h e q u a l i t y o f m e t h a n e .

T o r e p l a c e t h e f i l t e r p r o c e e d a s f o l l o w s :

- U s e a w r en c h t o s l ac k en s l ig h tl y t h e i n le t p i pe u n io n s o t h at t h e p r e s su r e i n s id e t h e p i p e g e t s o u t i n t h e a t m o sp h er e .

- R e m o v e t h e r e d u c e r .

- U s e a w r en c h t o s l ac k e n t h e p l u g u n i t , r e m ov e t h e f i lt e r a n d r e p l ac e i t .

- T i gh t e n t h e p l ug u n it t o a t o rq u e o f 1 1 N m . B e fo r e f i t ti n g t h e r e du c er o n t h e v e hi c le , f i ll i t w i th c o mp r es s ed a i r t h r o ug h t h eg a s i n l e t p i p e u n i o n a n d p o u r i n a s o a p y s o l u t i o n t o m a k e s u r e t h e r e a r e n o l e a k s .

- F i t t h e r e du c er a n d c h e c k t i g h t ne s s w i t h a s o ap y s o lu t io n .

Intercepting solenoid valve

T h e f u nc t io n o f t h e i n te r ce p ti n g s o le n oi d v a lv e w i th e l ec t ri c -m a g ne t i c c o n t ro l i s t o c l os e o r o p en t h e m e th a ne f l ow .

First stage or high pressure phase

T h e f i r s t s t a g e h a s t h e f u n c t i o n o f r e d u c i n g t h e m e t h a n e p r e s s u r e t o 1 4 0 0 k P a (1 4 b a r ) .I t u s e s a p i s t o n w i t h c o n t r a s t s p r i n g a n d v a l v e . T h e d y n a m i c a n d s t a t i c g a s k e t s a r e m a d e o f m a t e r i a l s w h i c h e n s u r e i t s r e l i a b i l i t y .T h e c o n t r a s t s p r i n g h a s b e e n d e v i s e d t o c o v e r t h e r e d u c e r l i f e w i t h a w i d e m a r g i n .

Second stage or stabilizing phase

T h e s e c o nd s t a ge h a s t h e f u nc t io n o f r e du c in g a n d s t a b il i zi n g t h e p r es s ur e o f 1 4 00 k P a ( 1 4 b a r ) a r ri v in g f r om t h e f i r st s t ag e a ta d i f f e r e n t i a l p r e s s u r e o f 9 0 0 k P a (9 b a r ) .I t u s es a p i st o n w i t h c o nt r as t s p ri n g a n d c o un t er b al a nc i ng v a l ve .T h e s e co n d s t ag e v a lv e c o un t er b al a n ci n g m a k es i t p o ss i bl e t o o b ta i n s u bs t a nt i al v a ri a t io n s o f c a pa c it y w h il e m a in t ai n in g t h e d e li v e ry p r e s su r e w i t h i n s t r i ct t o l e ra n c e s a n d e n s u ri n g t h e s y s t e m s t a b i li t y .T h e s a m e d e s i g n c r i t e r i a a d o p t e d f o r t h e f i r s t s t a g e w e r e a p p l i e d a l s o t o t h e s e c o n d s t a g e .


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Safety valve

T h e d e vi c e i s f i tt e d w i th a s a fe t y o r o v er p re s su r e v a l v e .T h i s v a l v e m a k e s i t p o s s i b l e t o d i s c h a r g e t h e o v e r p r e s s u r e g e n e r a t e d b y f a u l t y c a p a c i t i e s o f t h e f i r s t s t a g e o u t s i d e .

Exchanger

I t i s a p i p e c o m p l e t e l y s e p a r a t e d f r o m t h e g a s c i r c u i t , w h o s e f u n c t i o n i s t o h e a t t h e m e t h a n e w h i c h t e n d s t o c o o l d o w n a f t e r t h ee x pa n si o n d u e t o t h e p r es s ur e r e du c ti o n o c cu r re d a t t h e f i rs t s t a ge .T h e h e a t i s s u p p l i e d b y t h e c o n n e c t i o n w i t h t h e e n g i n e c o o l i n g c i r c u i t .

T h e f o l l o w i n g t a b l e s h o w s t h e t i g h t e n i n g t o r q u e s o f t h e c o m p o n e n t s w h i c h c a n b e r e p l a c e d :

Complete reducer

T h e r e d u ce r h a s t h e f u nc t io n o f r e d u ci n g t h e g a s p r e s su r e f r o m t h e v a lu e o n t h e c y li n de r t o t h e i n je c to r s u p p l y v a l ue a n d k e e pi t u n d e r c o n t ro l a t a n y o p e r a t i n g c o n d i t io n s .I f t h e v e hi c le o p er a ti o n i s n o t c o rr e ct c h ec k i f t h e r e du c er c a li b ra t io n p a ra m et e rs h a v e c h a n g ed .

P r o ce e d a s f o l l ow s :

- U s e a w r en c h t o s l ac k en s l ig h tl y t h e r e du c er i n le t p i pe u n io n s o t h at t h e p r e s su r e i n s i de t h e p i p e g e t s o u t i n t h e a t m o sp h er e .

- S l ac k en t h e h o s e u n io n o n t h e R A I L s i de ( i nj e ct o r s u p p ly m a ni f ol d ) u n t i l i t b e co m es l o os e .

- C o mp l et e ly s l ac k en t h e h o s e f i xe d u n io n o n t h e r e d u ce r s i de a n d f i t a n a d a pt e r w i t h p r es s ur e i n le t .

- F i t t h e h o s e o n t h e a d ap t er .

- A p pl y p r e s s ur e g a ug e 9 9 36 0 16 3 w i th s c al e b o tt o m 1 6 0 0 k P a o n t h e p r e s su r e i n l e t.

- T ig ht e n t h e p i pe u ni on o n t h e R AI L t o a t or qu e o f 7 0 N m .

- T i gh t en t h e r e d uc e r i n l et p i pe u n io n t o a t o rq u e o f 3 6 N m .

- U s e a s o ap y s o l u ti o n t o m a k e s u r e t h e re a r e n o l e a ks f r om t h e r e d uc e r i n l et p i pe u n io n .

- S t ar t t h e e n g i ne a n d c h e ck t h e re a r e n o l e ak s o n t h e p a rt s w h er e i n t e r ve n ed .

M a k e s u r e t h e p r e s s u r e o n t h e p r e s s u r e g a u g e i s a r o u n d 9 0 0 k P a ( 9 b a r ) .

S h o u l d t h e p r e s s u r e b e f a r f r o m 9 0 0 k P a , i t i s n e c e s s a r y t o c h a n g e t h e r e d u c e r .


Pos. Description Tightening

1 I nput pipe uni on 36 Nm

2 Coil unit 13 Nm

3 Valve unit 12 Nm

4 Filter plug unit 11 Nm

5 Pressure sensor 20 Nm

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T o c h an g e t h e r e du c er p r oc e ed a s f o ll o ws :

- U s e a w r en c h t o s l ac k en s l ig h t ly t h e r e d u ce r i n le t p i pe u n io n s o t h at t h e p r e s su r e i n s i de t h e p i p e g e t s o u t i n t h e a t m o sp h er e .

- T h e n s l a c k e n c o m pl e t e l y t h e p i p e u n i o n .

- R e mo v e t h e f a st o ns f r om t h e c o i l b y t a ki n g o f f a l l t h e e l ec t ri c al c o nn e ct i on s .

- S l ac k en o r r e mo v e t h e c l am p s f a s t en i ng t h e r e d u ce r h e a ti n g p i pe s .

- S l ac k en t h e t u r ni n g u n i on o f t h e h o se o n t h e R A IL s i de .

- S l ac k en c o mp l et e l y t h e f i x e d u n i o n o f t h e h o s e o n t h e r e d u ce r s i de .

- S l ac k en t h e s c r e ws f a st e ni n g t h e r e du c er t o t h e b o d y a n d c h an g e t h e r e du c er .

- F a st e n t h e n e w r e d uc e r t o t h e b o d y.

- T ig h te n t h e u ni on o n t h e R AI L s i d e t o a t or qu e o f 7 0 N m .

- R e s t o re t h e w a t e r c i r c ui t .

- T i gh t e n t h e r e d u ce r i n l e t p i p e u n i on t o a t o rq u e o f 3 6 N m .

- R e -c o nn e ct t h e f a s t on s t o t h e c o i l w i th t h e c o r r ec t p o la r it y .

- U s e a s o ap y s o l ut i on t o m a k e s u re t h er e a r e n o l e a k s f r o m t h e p i p e u n i o n.

- S t ar t t h e e n gi n e a n d c h e c k a g a i n t h e re a r e n o l e ak s f r o m t h e p i pe u n io n w i t h a s o ap y s o l u ti o n.

STEEL HOSE

I t i s t h e h o s e w h i c h c o n n e c t s t h e r e d u c e r t o t h e R A I L .A n y f a u l ts a r is i ng a r e d u e t o p o ss i bl e l e ak s .

I f t h e l e a k s a r e f r o m t h e p i p e u n i o n s , c h e c k t h e f o l l o w i n g :C h ec k i f t h e p i p e u n io n s a r e l o os e d. I f s o , t i g h t en t h em a c co r di n g t o t h e f o l l ow i ng t i gh t en i ng t o rq u es :

- O n t h e r e d u ce r : f i xe d p i p e u n i on ( A ) = 7 0 N m

- O n t h e R AI L: t ur ni ng p ip e u n io n ( B ) = 7 0 N mI n b o t h c a s e s u s e t h e r e s p e c t i v e l o c k w r e n c h e s .

I f t he p ip e u ni on s a re t ig h te ne d b ut a l ea k i s d et ec te d a ny wa y, i t i s l ik e ly t h at a n i nn er g a sk et i s m is si ng . I n t hi s c as e s la ck en t he l ea ki ngp i p e u n i o n a n d f i t t h e g a s k e t , t h e n t i g h t e n t h e p i p e u n i o n t o t h e p r e s c r i b e d t o r q u e .

I f t h e g a s l e a k i s d e t e c t e d a l o n g t h e p i p e i t i s n e c e s s a r y t o c h a n g e t h e h o s e .

- S l ac k en t h e h o s e t u r n in g u n i o n o n t h e R A I L s i d e .

- C o mp l et e ly s l ac k en t h e f i x e d p i p e u n i o n o n t h e r e d u ce r .

- R e mo v e t h e f a u l ty h o s e a n d r e p l a ce i t w i th a n e w o n e.

- F i rs t d r iv e i n t h e f i x e d u n i o n o n t h e r e d u ce r a n d m a k e s u re t h e a l um i ni u m g a s k e t p r e v io u sl y l u br i ca t ed h a s b e e n i n se r te d a sw e l l . T i g h t e n t o a t o r q u e o f 7 0 N m .

- D r iv e i n t h e t u r n in g u n i o n o n t h e R A I L a n d m a ke s u re t h e a l u m in i um g a s ke t h a s b e en i n se r te d a s w e ll . T i g h t en t o a t o rq u eo f 7 0 N m .

S t a r t t h e e n g i n e a n d u s e a s o a p y s o l u t i o n t o m a k e s u r e t h e r e a r e n o l e a k s .


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OXYGEN SENSOR

T h e o x y g e n s e n s o r i s m a d e u p o f a z i r c o n i u m d i o x i d e - b a s e d c e r a m i c b o d y c o a t e d w i t h a t h i s l a y e r o f p l a t i n u m e n c l o s e d a t o n ee n d , p l a c e d i n t o a p r o t e c t i v e t u b e , a n d h o u s e d i n a m e t a l b o d y t h a t e n s u r e e x t r a p r o t e c t i o n a n d a l l o w s t h e c e r a m i c b o d y t o b ef i t t e d t o t h e e x h a u s t m a n i f o l d . T h e e x t e r n a l p a r t o f c e r a m i c i s e x p o s e d t o t h e e x h a u s t g a s f l o w , w h e r e a s t h e i n t e r n a l p a r t c o m e si n t o c o n t a c t w i t h a m b i e n t a i r .

T h e o p e r a t i n g p r i n c i p l e i s b a s e d o n t h e v o l t a g e t h a t i s e s t a b l i s h e d b e t w e e n t h e t w o e l e c t r o d e s i n c o n t a c t w i t h d i f f e r e n t o x y g e nconcentrations.

T h e m e a su r em e nt s , m a de b y t h e s e ns o r, o f t h e e x ha u st g a s c om p os i ti o n a l lo w t h e M F 3 e l e c t ro n ic c o nt r ol u n it t o c o nt i nu o us l y a d ju s t t h e m i xt u re ( l ea n e r- r ic h er ) r e al - ti m e, t o k e e p t h e s a me a s n e ar t h e s t oi c hi o me t ri c r a ti o a s p o ss i bl e a n d i n a v e ry s h or t i n te r va lof r a n g in g b e t w e en 0 . 9 8 0 a n d 1 . 0 2 0.

T o e n su r e t h at t h e o p er a ti n g t e mp e ra t ur e ( 300 C ) i s r e ac h ed q u ic k ly , t h e s e ns o r i s e q ui p pe d w i th a n e l ec t ri c r e si s to r t h atr e d u c e s , w h e n c u r r e n t r u n s t h r o u g h i t , t h e t i m e n e c e s s a r y f o r t h e c e r a m i c t o b e c o m e a i o n c o n d u c t o r . M o r e o v e r , t h e s e n s o r c a nb e l o c a t e d i n l e s s h o t a r e a s o f t h e e x h a u s t d u c t .


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S E C T I O N 3 - U S E 1C N G N E F E N G I N E S

SECTION 3

Use

Page

GENER AL SPECIF ICAT IONS 3. . . . . . . . . . . . . . .

GENERAL PROPER TIES 4. . . . . . . . . . . . . . . . . . .

PART ONE - MECHANICAL COMPONENTS 5.

ENGI NE OVERHAUL 7. . . . . . . . . . . . . . . . . . . . .

- Pre face 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Eng ine disassembly on the stand 7. . . . . . . . . . .

- Cylinder head remov al 10. . . . . . . . . . . . . . . . . . .

- I nst allation of components 15. . . . . . . . . . . . . . . .

- Timing 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Mounting the flywheel h ousing 16. . . . . . . . . . . . .

- Eng ine flywheel 17. . . . . . . . . . . . . . . . . . . . . . . . .

- Mounting the cylinder head 22. . . . . . . . . . . . . . .

- Completion of the eng ine 26. . . . . . . . . . . . . . . .

- Check s and inspections 29. . . . . . . . . . . . . . . . . .

PART TWO - ELECTRICAL EQUIPMENT 31. . . .

GENERAL I TEMS 33. . . . . . . . . . . . . . . . . . . . . . . . .

M F 3 I G N I T I O N A N D I N J E C T I O NINTEGRATED SY STE M 34. . . . . . . . . . . . . . . . .

- MF3 syst em characteristics 34. . . . . . . . . . . . . . . .

- I njection manag ement 34. . . . . . . . . . . . . . . . . . .

- Fuel cutoff in relea se step 35. . . . . . . . . . . . . . . . .

- Combustion control by La mbda Probe 35. . . . . .

- System se lf-adapt ation 35. . . . . . . . . . . . . . . . . . .

- Startup manag ement 36. . . . . . . . . . . . . . . . . . . .

- Eng ine rotation speed manag eme nt 36. . . . . . . . .

- I gnition manage ment 37. . . . . . . . . . . . . . . . . . . .

- Addition al loads manag ement 37. . . . . . . . . . . . .

- Turboblower regulation 37. . . . . . . . . . . . . . . . . .

- C o n n e ct i o n t o v e h i c l e t h r ou g h C A N l i n e(to ge arbox and dashboa rd central units) 38. . . .

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2 S E CT I ON 3 - U S E C N G N E F E N G IN E S

Page

- Acceleration deactiv ation (option) 38. . . . . . . . . .

V E H I C LE F U N C TI O N S A P P L I E D B Y C O N T RO LUNIT MF3 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MF3 CONTROL UNIT I NSTALLATION 40. . . . . . .

M F 3 C O N T R O L U N I T W I R I N G D I A G R A M(FI RST PART) 41. . . . . . . . . . . . . . . . . . . . . . . . . .

M F 3 C O N T R O L U N I T W I R I N G D I A G R A M(SECOND PART ) 42. . . . . . . . . . . . . . . . . . . . . . .

KEY 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PIN OUT MF 3 44. . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPONENTS 47. . . . . . . . . . . . . . . . . . . . . . . . . .

- Electric injectors 47. . . . . . . . . . . . . . . . . . . . . . . .

- Air suct ion circuit 48. . . . . . . . . . . . . . . . . . . . . . .

- Debimeter (Air flow sensor) 48. . . . . . . . . . . . . .

- Throt tle va lve body 49. . . . . . . . . . . . . . . . . . . . .

- Idling actuator 50. . . . . . . . . . . . . . . . . . . . . . . . .

- Fue l cut -off 51. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Electronic injection (Cha ra cteristics) 51. . . . . . . .

- La mbda s ensor 52. . . . . . . . . . . . . . . . . . . . . . . . .

- Connections 52. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Air tempera ture -pre ss ure sen sor 53. . . . . . . . . . .

- Engine oil tempe ratu re-pressure sensor 53. . . . . .

- Cranksha ft sensor 54. . . . . . . . . . . . . . . . . . . . . .

- Timing se nsor 54. . . . . . . . . . . . . . . . . . . . . . . . . .

- Wasteg ate solenoid valve 55. . . . . . . . . . . . . . . .

- TARTARI NI META pressure reduce r 56. . . . . . .

- Steel hose 59. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Thrott le valve set ting at idling 60. . . . . . . . . . . . .

PART THREE - TROUBLESHOOTING 61. . . . . .

PR EF ACE 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BLINK-CODE - GENERAL I NF ORMAT ION 64. . . .

- Det ecta ble failures 64. . . . . . . . . . . . . . . . . . . . . .

- Anoma ly warning led 64. . . . . . . . . . . . . . . . . . . .

Page

- Self-diag nosis 65. . . . . . . . . . . . . . . . . . . . . . . . . .

- R e c o v er y ( o p e r a t io n w i t h c o m p o n e nt ssubjected to failure) 65. . . . . . . . . . . . . . . . . . . . .

- VDO EGAS2 Diagnosis Syst em 66. . . . . . . . . . . .

- Error deleting 66. . . . . . . . . . . . . . . . . . . . . . . . . .

T R O U BL E S H OO T I N G B Y M E A N SOF BLINK-CODES 67. . . . . . . . . . . . . . . . . . . . . .

- MF3 Diagnosis 67. . . . . . . . . . . . . . . . . . . . . . . . .

VDO DI AGNOSI S 72. . . . . . . . . . . . . . . . . . . . . . . .

- Blin k-code reading 72. . . . . . . . . . . . . . . . . . . . . .

- Cle aring the error memory 72. . . . . . . . . . . . . . .

- VDO EGAS2 system diag nosis 73. . . . . . . . . . . .

TROUBLESHOOT ING BY SYMPTOMS 74. . . . . . . .

PART FOUR - MAINTENANCE PLANNING 81. .

MAINTENANCE PLANNING 83. . . . . . . . . . . . . . .

- Recov ery 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- P la n ni ng o f c on tr ol s a n d p er io di ca l i nt er v en ti on 8 3

- C h e c ks n o t i n c l u d ed i n m a i n t e n a n ceplanning-daily checks 84. . . . . . . . . . . . . . . . . . . .

MAINTENANCE PROCEDU RES 84. . . . . . . . . . . . .

- Check s and controls 84. . . . . . . . . . . . . . . . . . . .

- Eng ine oil le vel che ck. 84. . . . . . . . . . . . . . . .

- Check of fuel syste m 85. . . . . . . . . . . . . . . . .

- Cooling syste m check 85. . . . . . . . . . . . . . . .

- Lubricat ing syst em che ck 85. . . . . . . . . . . . . .

- Ch eck in g/ re pl ac in g t he bl ow -by fi lt er 8 5. . . . .

- Check of drive belt tensioning 86. . . . . . . . . .

- Che ck of belts tear a nd w ear stat us 86. . . . .

- C heck and setting of t appet clearance 86. . . .

- C hang ing the e ngine oil and oil filter 87. . . . .

- Filter replaceme nt proce dure 87. . . . . . . . . .

- A lt e rn at or b el t - w at er p um p r ep la ce me nt 8 8

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Figure 1

The NEF F4BE0641A engines are characterized by a boostedOtto cycle with 6 cylinders and 2 valves per cylinder.

They are powered by indirect injection and common rail, andfully electronically managed so as to optimize the operationdepending on the use, thus minimizing both pollutingemissions and consumptions.

The section herein described is composed or four sections:

- Section of mechanical overhaul prescribed in accordanceto the engines 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 Motors.

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

102603

GENERAL SPECIFICATIONS

102602

SECTION 3 - USE 3CNG NEF ENGINES

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

Moreover, the devices fittedby the body builder shall always complywith the torque, rating and revs numberrequirementsto which the engine has been designed.

4 SECTION 3 - USE CNG NEF ENGINES

GENERAL PROPERTIES

*Type

...

Max. output kW(HP)

rpm

147(200)

2700

Max. torque Nm(kgm)

rpm

650(66)

1250

Loadless engineidling rpm 650

Loadless enginepeak rpm 2900

TURBOCHARGING with intercooler

Turbocharger type HOLSET HX 38 G

LUBRICATION Forced by gear pump, relief valve single action

oil filter

bar Oil pressure (warm engine)- idling bar - peak rpm bar 1.2

3.8

COOLING

Water pump control

By means of centrifugal pump, control thermostat, radiator,heat exchanger, intercooler

Through beltThermostat- start of opening- max opening

81 2 C96 C

FILLINGTotal capacity1st filling

literskg

--

URANIATurbo Gas15 W 40

- engine sumpliters

kg

min level8

7.2

max level10.89.7

- engine sump + filterliters

kg9

8.111.810.6

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PART ONE - MECHANICAL COMPONENTS


DIAGNOSI

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87508

87606

87509

Figure 2

Figure 3

Figure 4

ENGINE OVERHAULPreface

P a rt o f t h e o p er a ti o ns i l lu s tr a te d w i th i n t h is s e ct i on c a n b ep a rt ia ll y e xe cu te d w h il e t he e ng in e i s a ss em bl ed o n t hev e h ic l e, d e pe n di n g o n t h e r o o m a v a il a bl e f o r a c c e s s t o t h ee n g in e a n d o n t h e e q ui p me n t a p pl i ca t i on a s w e ll .

T he f ol lo wi ng i nf or ma ti on r el at es t o t he e ng in e o v er ha ulo p e r a t i o n s o n l y f o r w h a t c o n c e r n s t h e d i f f e r e n t c o m p o n e n t sc u s t om i s i n g t h e e n g i n e, a c c o rd i n g t o i t s s p e c i f i c d u t i e s .I n s e ct i on G en e ra l o v er h au l , a l l t h e o p er a t io n s o f e n g in eb l oc k o v er h au l h a ve b e en c on t e mp l a te d . T h er e fo r e t h e a b ov em e nt i on e d s e ct i on i s t o b e c o ns i de r ed a s f o ll o wi n g t h e p a r thereby described.

!With regard to the engine disassembly operations from

the machine, please apply for Information consulting the

specific manual. All operations of Engine disassemblyo pe ra ti on s a s w el l a s o ve rh au l o pe ra ti on s m us t b ee x ec ut e d b y q ua l if ie d t ec h ni c ia ns p ro v id e d w i th t hespecific tooling and equipment required.

T o a p p l y b r a c k e t s 9 9 3 4 1 0 0 9 o n t h e w h e e l b l o c k t o f a s t e n t h ee n gi n e t o t h e o v er h au l s t an d , r e mo v e t h e e l ec t ro n ic c o nt r olu n i t o n t h e l e f t - h a n d s i d e .

R e m o v e t h e c o n v e y o r ( 1 ) .

D i sc o nn e ct t h e p i pe s ( 3 ) a n d t h e c o nn e ct i ng p i pe ( 6 ) w i th t h eWastegate valve. Slacken the screws (2) and remove theturbocharger (7).

R e mo v e t h e s t ar t er ( 4 ) f r o m t h e f l y w h ee l c a se ( 5 ).

R e m o v e t h e e n g i n e c a b l e ( 1 ) b y d i s c o n n e c t i n g t h e c o n n e c t o r s : f r o m t h e i n j e c t o r w i r i n g , t h e s p a r k p l u g s , t h e g a s p r e s s u r e s e n s o r ,f r o m t h e t h r o t t l e v a l v e b o d y , f r o m t h e V D O a c t u a t o r , f r o m t h e t e m p e r a t u r e s e n s o r , f r o m t h e c o m p r e s s o r , f r o m t h e c o o l a n t f l u i d

temperature sensor, from the engine oil temperature/pressure sensor, from the engine rev sensor.

Engine disassembly on the stand


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87510

87512

87511

87513

87514

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

R e m o v e t h e e x h a u s t m a n i f o l d ( 2 ) b y s l a c k e n i n g t h e f a s t e n i n gs c r e ws ( 1 ) .

S l a c k e n t h e s c r e w s ( 1 ) a n d r e m o v e t h e s i x c o i l s ( 2 ) .

U s e t o o l 9 9 3 5 8 0 2 4 ( 2 ) t o r e m o v e t h e s p a r k p l u g s ( 1 ) .

R e m o v e t h e h e a t g u a r d ( 2 ) b y s l a c k e n i n g t h e s c r e w s ( 1 ) .

R e m o v e t h e e n g i n e c a b l e f a s t e n i n g p l a t e ( 2 ) b y s l a c k e n i n g t h es c r e w s ( 1 ) w h i c h t i g h t e n i t t o t h e h e a d .


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87515

87534

87524

87552

87578

87579

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

R e mo v e t h e s c re w s ( 2 ) a n d d i sc o nn e ct t h e i n je c to r s ( 1 ).D is co nn ec t t he f ee di ng p ip es ( 3) a nd r em ov e t he r ai l ( 5)

together with the pressure/temperature sensor (4).

S l a c k e n t h e c l a m p s ( 1 ) o f t h e s u c t i o n p i p e s .

S l ac k en t h e f a st e ni n g s c re w s ( 1 ) o f t h e e n gi n e b l oc k b r ac k eta n d r e mo v e t h e s u ct i on p i pe ( 2 ) a f te r d i sc o nn e ct i ng t h e u n io n( 4 ) a n d t h e p i p e ( 3 ) .

S l a c k e n t h e f a s t e n i n g n u t ( 2 ) o f t h e t i e r o d ( 1 ) f o r t h e t h r o t t l ev a l v e c o n t ro l .

D i sc o nn e ct t h e p i pe ( 4 ) f r om t h e c o mp r es s or ( 5 ).D i sc o nn e ct t h e s u ct i on m a ni f ol d ( 5 ) t o ge t he r w i th t h e t h ro t tl ev a l ve b o dy ( 3 ) b y s l ac k en i ng t h e h e ad f a st e ni n g s c re w s ( 1 ) .

S la ck en t he f as te ni ng s cr ew s ( 1) o f t he b ra ck et ( 2) o n t hee n g i n e b l o ck .R em ov e t he V DO c on t ro l a ct ua to r ( 3) a n d t he r el ev a nt

bracket.


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87580

87582

87581

87607

87602

87590

Figure 16

Figure 17

Figure 18

Figure 19

Figure 20

Figure 21

S l a c k e n t h e s c r e w s ( 2 ) o f t h e b r e a t h i n g c o v e r ( 1 ) .R em ov e t h e c ov e r ( 1 ) b y s la ck en in g t h e c la mp ( 5) o f t h ee n g i n e b l o c k c o n n ec t i n g p i p e .S l a c k e n t h e s c r e w s ( 4 ) a n d r e m o v e t h e f i v e t a p p e t c o v e r s ( 3 ) .

R e m ov e t h e f a st e ni n g s c r e ws ( 1 ) o f t h e c y li n de r h e ad ( 2 ).

H oo k t he b ra ck et s ( 1) w it h m et al r op es a n d r em ov e t hec y li n de r h e ad ( 2 ) f r om t h e e n g in e b l oc k .

S l ac k en t h e s c re w s ( 2 ) a n d r e mo v e t h e b r ea t h er ( 1 ).

R e m o v e t h e c y l i n d e r h e a d g a s k e t ( 1 ) .O p e r a t e t h e s u i t a b l e w r e n c h o n t h e b a c k s t a n d ( 3 ) t o r e l e a s e

the belt tension (2) and remove the belt.R em ov e t he s cr ew ( 4) a nd d is co nn ec t t he a ut om at icb a c k s ta n d ( 3 ) .

R e m o v e t h e s c r e w s ( 2 ) a n d e x t r a c t t h e a l t e r n a t o r ( 1 ) .

Cylinder head removal


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70140

70141

70143

87601

Figure 22

Figure 23

Figure 24

Figure 25

R e mo v e t h e s c re w s ( 2 ) a n d d i sc o nn e ct t h e a l te r na t or s u pp o rt(3).U s e t o o l 9 9 3 6 0 0 7 6 t o r e m o v e t h e o i l f i l t e r ( 1 ) .

R e mo v e t h e s c re w s ( 4 ) a n d t h e o i l p r es s ur e /t e mp e ra t u res e n s o r ( 3 ) .R e m o v e t h e s c r e w s ( 1 ) , t h e o i l f i l t e r / h e a t e x c h a n g e r s u p p o r t( 2 ) , t h e i n t e r m e d i a t e p l a t e ( 6 ) a n d t h e g a s k e t s .R e m o v e t h e o i l l e v e l s e n s o r ( 5 ) .

U s e w r e n c h 9 9 3 5 5 0 1 9 t o r e m o v e t h e s c r e w s ( 1 ) a n d ( 3 ) a n dd i sc o nn e ct t h e h y dr a ul i c p o we r s t ee r in g p u mp ( 2 ) t o ge t he r w i th t h e o i l r e se r vo i r ( 4 ) f r o m t h e a i r c o m pr e ss o r ( 5 ) .

R e m o v e t h e s c r e w s ( 2 ) a n d t h e n u t s ( 1 - 4 ) a n d e x t r a c t t h e a i r compressor (3).

I n s o m e a p p l i c a t i o n s , t h e i n t e g r a t e d o i l r e s e r v o i r ( 4 )i s n o t p r e s e n t o n t h e p o w e r s t e e r i n g p u m p ( 2 ) .!

T h e f i gu r e i l lu s tr a te s a s i ng l e- c yl i nd e r c o mp r es s or ,while on other ve rsion a double-cylinder c o m pr e s s or i s u s e d .

!


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70340

70146

Figure 26

Figure 27

Figure 28

Figure 29

A p pl y t h e t o o l 9 9 36 0 35 1 ( 2 ) t o t h e f l y w he e l h o u s in g ( 1 ), t os t o p t h e f l y w he e l ( 3 ) r o t a t io n .

L o o s e n t h e s c r e w s ( 4 )

R em ov e t he s cr ew s ( 2) a nd r em ov e t he p ul le y ( 3) a nd t heb u m p e r f l y w h e e l ( 1 ) .

R em ov e t he s cr ew s ( 6) a nd r em ov e t he h ub ( 5) a nd t hep h o n ic w h e e l ( 4 ) .

R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e w a t e r p u m p ( 2 ) .

R e m o v e t h e s c r e w s ( 3 ) a n d r e m o v e t h e r o l l e r ( 4 ) .

R e m o v e t h e s c r e w s ( 5 ) a n d r e m o v e t h e r p m s e n s o r ( 6 ) .

78256

A pp ly o n t he f ro nt t an g ( 2) o f t he d ri vi ng s ha ft f ix tu re9 9 34 0 05 5 ( 4 ) a n d t h ro u gh t h e g u i d in g h o le s o f t h e f i x t u rei t s e l f , d r i l l t h e i n t e r n a l s e a l r i n g ( 1 ) w i t h a d r i l l ( 3 . 5 m m ) t oa d e p t h o f 5 m m . .F i x f i x t u r e ( 4 ) t o t h e r i n g ( 1 ) b y m e a n s o f t h e 6 s c r e w s i n t h ek i t e p r o c e e d w i t h t h e r e m o v a l o f t h e r i n g b y s c r e w i n g u p t h es c r e w ( 3 ) .

Figure 30

78257

A p p l y t h e p r o p e r r o d ( 3 ) o f f i x t u r e 9 9 3 6 3 2 0 4 t o t h e e x t e r n a ls ea l r in g ( 2) a s s ho wn i n t h e f ig u re a nd u se l ev er ( 4) , t o r em ov ei t f r o m t h e f r o n t c o v e r ( 1 ) .

70148


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70149

70150

Figure 31

Figure 32

Figure 33

Figure 34

Figure 35

R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e f r o n t c o v e r ( 2 ) .

R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e o i l p u m p ( 2 ) .

Write down the screw (1) assembling positionb e c a us e t h e y e x h i b i t d i f fe r e n t l e n g t h s .

I t i s n o t p o s s i b l e t o o v e r h a u l t h e o i l p u m p ( 2 ) .

NOTE

NOTE

R e m o v e t o o l 9 9 3 6 0 35 1 ( 2 ) .R e mo v e t h e e n g in e ( 3 ) f l yw h ee l f i xi n g s c re w s ( 1 ) t o t h e e n gi n es h a f t ( 4 ) .

S c r e w t w o p i n s ( 2 ) e x h i b i t i n g a p r o p e r l e n g t h i n t o t h e e n g i n es h a f t h o l e s ( 3 ) .

Withdraw the engine flywheel (1) in order to sling it with theh o is t er a n d p o si t io n i t i n to t h e c o nt a in e r.

78258

A p p l y f i x t u r e 9 9 3 4 0 0 5 6 ( 3 ) o n t h e r e a r t a n g ( 5 ) o f t h e d r i v i n gs ha ft a n d t hr ou gh t h e g ui di ng h ol es o f t he f ix tu re , d ri ll t hei n t e r n a l s e a l r i n g ( 1 ) w i t h a d r i l l ( 3 , 5 m m ) t o a d e p t h o f 5mm.F i x f i x t u r e ( 3 ) t o t h e r i n g ( 1 ) b y m e a n s o f t h e 6 s c r e w s ( 4 ) i n

the kit e proceed with the removal of the ring by tightening thes c r e w ( 2 ) .P e rf o rm t h e r e m o va l o f t h e e x t e r na l s e al r i ng a s s h ow n a n dd e s c ri b e d i n F i g u re 3 0 .

70151

70152


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70153

87600

87603

70156

70157

Figure 36

Figure 37

Figure 38

Figure 39

Figure 40

R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e r e a r c o v e r ( 2 ) .

O v e r t u r n t h e e n g i n e .R e mo v e t he s c re w s ( 2 ), r e mo v e t he p l at e ( 3 ) a n d r e mo v e t h eo i l s u m p ( 1 ) .

R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e o i l s u c t i o n r o s e ( 3 ) .R e m o v e t h e s c r e w s ( 2 ) a n d r e m o v e t h e s t i f f e n i n g p l a t e ( 4 ) .

R em ov e t he s cr ew s ( 1) a nd r em ov e t he g ea r ( 3) f ro m t hec a m s h af t ( 2 ) .


NOTE

T h e s u mp s h ow n i n t h e f i gu r e i s t h e c h a r a ct e ri s ti c ss u m p f o r t r u c k a p p l i c a t io n s .!

R e m o v e t h e s c r e w s ( 2 ) a n d t h e t i m i n g g e a r c a s e ( 1 ) .


NOTE


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70209

70210

70211

Figure 41

Figure 42

Figure 43

I V E C O N o . 2 9 9 2 54 5 S E A L AN TA P P LI C A T I ON A R E A S

C le an a cc ur at el y t he t im in g g ea r c as e ( 1) a nd t he e ng i ne b lo ck .P e r f e c t s e a l i s o n l y o b t a i n e d b y c l e a n i n g a c c u r a t e l y t h e s u r f a c e

to seal.S m ea r t h e c a s e w i t h I V EC O N o . 2 9 92 5 45 t o o b t a in a b e ado f f e w m m d i a m e t e r .I t s h a ll b e u n if o rm ( n o c l o t s) , w i th o ut a i r b u bb l es , t h in a r ea sor discontinuities.A n y i m p e r f e ct i o n s h a l l b e c o r re c t e d a s s o o n a s p o s s ib l e .

A v o i d t o u s e e x c e s s m a t e r i a l t o s e a l t h e j o i n t .E x ce s si v e s e a l a nt c o ul d c o me o u t f r om j o in t s i de s a n d c a u s el u b r ic a n t p a s s ag e c l o g g in g .A f t e r a p p l y i n g t h e s e a l a n t , t h e j o i n t s h a l l b e a s s e m b l e d w i t h i n1 0 m i n u t e s .

D I A G R A M F O R T I G H T E N I N G T H E R E A R T I M I N G G E A R

C A S E F A S T E N I N G S C R E WS

R e f i t t h e c a s e ( 1 ) t o t h e e n g i n e b l o c k .S cr ew t he f as te ni ng s cr ew s i n t he s am e p os it io n f ou nd a tr e mo v al a n d t i gh t en t h em t o t h e f o ll o wi n g t o rq u e v a lu e s i n t h es e q u e n c e s h o w n i n t h e f i g u r e :

Screws M12 65 to 89 NmScrews M8 20 to 28 NmScrews M10 42 to 52 Nm

U s e a f e l t p e n t o m a r k t h e d r i v i n g g e a r ( 1 ) t o o t h f i t t e d o n t h eo u tp u t s h a f t ( 2 ) h a v i n g t h e m a rk () f o r t i m i n g o n t h e s i d esurface.

Installation of components

Timing


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70212

70214

70213

70215

Figure 44

Figure 45

Figure 46

Figure 47

D i r e c t t h e o u t p u t s h a f t ( 4 ) a n d t h e c a m s h a f t ( 2 ) s o t h a t w h e nf i tt i ng t h e d r i v en g e a r ( 1 ) o n t h e c a m sh a ft t h e m a r k s o n t h eg e a r s ( 1 a n d 3 ) a r e c o i n c i d i n g .

T ig h te n t he s cr ew s ( 1) f a st e ni ng g ea r ( 2) t o c a m sh af t ( 3) t o t hespecified torque.

I V E C O N o . 2 9 9 25 4 5 S E A L A N TA P P LI C A T I ON A R E A S

S E Q UE N C E F O R T I G H T E NI N G T H E F L Y W HE E LH O U S IN G F A S T E NI N G S C R E WS

R ef it t he h ou si ng ( 1) t o t he e ng in e b lo ck a nd s cr ew t hef a st e ni n g s c re w s i n t h e s a me p o si t io n f o un d a t r e mo v a l a n d

tighten them to the following torque values in the sequences h o w n i n t h e f i g u r e :

Screw s M12 75 to 95 NmScrew s M10 44 to 53 Nm

Mounting the flywheel housing

C l ea n a c cu r at e ly t h e f l yw h ee l h o us i ng ( 1 ) a n d t i mi n g g e a r c a secoupling surfaces.P e r f e c t s e a l i s o n l y o b t a i n e d b y c l e a n i n g a c c u r a t e l y t h e s u r f a c e

to seal.S me ar h ou si ng ( 1) w it h I VE CO N o. 2 99 25 45 t o o bt ai n a b ea do f f e w m m d i a m e t e r .I t s h al l b e u n if o rm ( n o c l o t s) , w i th o ut a i r b u b b le s , t h in a r ea sor discontinuities.

A n y i m pe r fe c ti o n s h al l b e c o rr e ct e d a s s o on a s p o ss i bl e .A v o i d t o u s e e x c e s s m a t e r i a l t o s e a l t h e j o i n t .E x ce s si v e s e a la n t c o ul d c o me o u t f r o m j o in t s i de s a n d c a u s el u b r ic a n t p a s s ag e c l o g g in g .A f t e r a p p l y i n g t h e s e a l a n t , t h e j o i n t s h a l l b e a s s e m b l e d w i t h i n1 0 m i n u te s .


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Figure 48

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A pp ly t oo l 9 93 46 25 3 p a r t ( 5) t o t he r ea r o ut pu t s ha ft t an g ( 6) ,s e c u r e i t b y s c r e w s ( 4 ) a n d f i t t h e n e w s e a l i n g r i n g ( 3 ) .

P o si t io n p a rt ( 1 ) o n p a rt ( 5 ), s c re w n u t ( 2 ) u n t il c o mp l et i n gs e a l i n g r i n g ( 3 ) f i t t i n g i n t o f l y w h e e l h o u s i n g ( 7 ) .

C h ec k c l ut c h p l at e s u pp o rt i ng s u rf a ce a n d t u rn i t i f s c or e d.

S c r e w t w o p i n s ( 2 ) h a v i n g s u i t a b l e l e n g t h i n t o s h a f t h o l e s ( 3 )

a n d r e mo v e t h e e n g i n e f l yw h ee l ( 1 ) u s i n g p r op e r s l i n g a n dhoister.

T ig h te n t he s cr ew s ( 4) f as te n in g t he e ng in e f ly wh ee l ( 3) t o t heo u tp u t s h af t . A p pl y t o ol 9 9 36 0 35 1 ( 2 ) t o t h e f l yw h ee l h o us i ng( 1 ) t o s t op e n gi n e f l yw h ee l ( 3 ) r o t a t io n .

Engine flywheel

T h e n o mi n a l t h ic k ne s s o f t h e e n g in e f l yw h ee l i s 4 9 .6 0 .1 3 m m o r 5 1 m m 0 .2 5 m m a a cc or di ng t o t heapplications.

NOTE

C he ck r in g g ea r t e et h ( 2) , i f b re ak a ge o r e x ce s si ve w e ar i sf o un d r e mo v e t h e r i ng g e ar f r om t h e e n gi n e f l yw h ee l ( 1 , F i gu r e1 0 4) u s in g a g e ne r ic b e at e r a n d f i t t h e n e w o n e , p r ev i ou s ly h e a t e d t o 1 5 0 C f o r 1 5 t o 2 0 m i n u t e s .C h am f er i ng o n r i ng g e ar i n si d e d i a m et e r s h al l b e f a ci n g t h ee n g i n e f l y w he e l .


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Figure 52

Figure 53

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Figure 56

T i g ht e n e n gi n e f l y w he e l ( 2 ) f a st e n in g s c re w s ( 1 ) i n t w o s t ag e s:

- 1 st stag e, tighte ning to 30 t o 4 N m t orque withdynamometric wrench;

- 2 n d s t a ge , t i g h t en i ng t o 6 0 5 angle.

F i t t h e o i l p u m p ( 1 ) .T i g h t e n t h e f a s t e n i n g s c r e w s ( 2 ) t o t h e s p e c i f i e d t o r q u e .

A p p l y a n e w s e a l i n g r i n g ( 2 ) t o t h e w a t e r p u m p ( 1 ) .

R e mo v e t h e s e al i ng r i ng ( 2 ) f r o m t h e f r on t c o ve r ( 1 ), c l ea na c c u r a t e l y t h e c o u p l i n g s u r f a c e s a n d s m e a r t h e m w i t h I V E C ON o . 2 9 9 2 5 4 5 .

T ig ht en in g t o a ng le i s p er fo rm ed u si ng t oo l99395216.

NOTE

F i t t h e w a t e r p u m p ( 1 ) .T i g ht e n t h e s c re w s ( 2 ) t o t h e s p ec i fi e d t o rq u e.


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Figure 57

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C l ea n a c cu r at e ly t h e f r o n t c o v e r ( 2 ) s u r f ac e a n d r e fi t i t .T i g h t e n t h e s c r e w s ( 1 ) t o t h e s p e c i f i e d t o r q u e .

A p pl y t o ol 9 9 34 6 25 2 p a rt ( 5 ) t o t h e f r o n t o u t p ut s h af t t a n g( 6) , s ec ur e i t b y s cr ew s ( 4) a nd f it t he n ew s ea li ng r in g ( 3) .P o si t io n p a rt ( 1 ) o n p a rt ( 5 ), s c re w n u t ( 2 ) u n t il c o mp l et i n gs e a li n g r i ng ( 3 ) f i t t in g i n to f r on t c o ve r ( 7 ).

F it t he p la t e ( 4) , t he s uc ti on r os e ( 3) , d ri ve i n t he f as te n in gs c r e w s ( 1 , 2 ) a n d t i g h t e n t h e m t o t h e p r e s c r i b e d t o r q u e .

S e t t h e g a s k e t ( 1 ) o n t h e o i l s u m p ( 2 ) .

I f n o t f a u l t y t h e g a s k e t c a n b e r e u s e d .NOTE


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Figure 61

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F i t t h e o i l s u m p ( 1 ) a n d a p p l y t h e p l a t e ( 3 ) t o i t .T i g ht e n t h e s c re w s ( 2 ) t o t h e s p ec i fi e d t o rq u e.

F i t t h e p h o n i c w h e e l ( 1 ) a n d t h e h u b ( 2 ) o n t h e o u t p u t s h a f t .

T i g ht e n t h e f a st e n in g s c re w s ( 3 ) i n t w o s t a g e s:

- 1st s ta ge , t ig ht en in g t o 5 0 5 Nm torque withdynamometric wrench;

- 2nd s t a g e , t i g h t e n i n g t o 9 0 angle.

F i t t h e d a m p e r f l y w h e e l ( 5 ) a n d t h e p u l l e y ( 6 ) .

T i g h t e n t h e f a s t e n i n g s c r e w s ( 7 ) t o 6 8 7 N m t o r q u e .

T ig ht en in g t o a ng le i s p er fo rm ed u si ng t oo l9 9 3 9 5 2 1 6 ( 4 ) .

NOTE

F i t a n e w s e a l i n g r i n g o n t h e s p e e d s e n s o r ( 3 ) .F i t t h e s p e e d s e n so r ( 3 ) o n t h e f r o nt c o ve r ( 1 ) a n d t i gh t en t h es c re w ( 2 ) t o t h e s p ec i fi e d t o rq u e.

F i t o n t h e e n g i n e b l o c k : a n e w g a s k e t ( 1 ) , t h e h e a t e x c h a n g e r ( 2 ) a n e w g a s k e t ( 3 ) a n d t h e o i l f i l t e r s u p

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