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SATIZ F4A EURO 4 NEF Series Technical And Repair Manual

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F4A EURO 4
NEF SERIES
Application Bus (SOR)
F4AE3682E
F4AE3682F
Technical and Repair manual

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Summary of Contents for SATIZ F4A EURO 4 NEF Series

  • Page 1 F4A EURO 4 NEF SERIES Application Bus (SOR) F4AE3682E F4AE3682F Technical and Repair manual...
  • Page 2 This publication describes the characteristics, data and correct methods for repair operations on each component of the ve- hicle. If the instructions provided are followed and the specified equipment is used, correct repair operations in the pro- grammed time will be ensured, safeguarding against possible accidents.
  • Page 3 F4A EURO 4 NEF ENGINES INDEX NEF F4A EURO 4 ENGINES Section Introduction Updating and Consultation General specifications Fuel Application to bus General overhaul and characteristics Tools Appendix Safety prescriptions PREFACE TO USER’S GUIDELINE MANUAL Section 1 describes the engines illustrating their features and working in general.
  • Page 4 F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 5: Table Of Contents

    F4A EURO 4 NEF ENGINES INTRODUCTION Introduction Page SAFETY PRESCRIPTIONS ....PREFACE TO USER’S GUIDELINE MANUAL - Symbols - Warnings ..... - General warnings .
  • Page 6 INTRODUCTION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 7 F4A EURO 4 NEF ENGINES INTRODUCTION UPDATE LISTS Section Description Page Date of revision Print P1D32N003 E Base - March 2007...
  • Page 8 INTRODUCTION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 9: Preface To User's Guideline Manual

    F4A EURO 4 NEF ENGINES INTRODUCTION PREFACE TO USER’S GUIDELINE MANUAL Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.

  • Page 10: General Warnings

    INTRODUCTION F4A EURO 4 NEF ENGINES General warnings Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks.
  • Page 11 F4A EURO 4 NEF ENGINES INTRODUCTION Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

  • Page 12: General Warnings On The Electric System

    INTRODUCTION F4A EURO 4 NEF ENGINES General warnings on the electric system 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.

  • Page 13: Bonding And Screening

    F4A EURO 4 NEF ENGINES INTRODUCTION Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: Electronic central units must be connected to system bonding when they are provided with a metallic shell.

  • Page 14: Optional Electrical And Mechanical Parts Installations

    INTRODUCTION F4A EURO 4 NEF ENGINES Optional electrical and mechanical parts installations Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling directives issued by IVECO Motors. It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel.

  • Page 15: Graphic Figures And Symbols

    F4A EURO 4 NEF ENGINES INTRODUCTION Graphic figures and symbols Removal Intake Disconnection Refitting Exhaust Connection Removal Operation Disassembly Fitting in place ρ Compression ratio Assembly Tolerance Tighten to torque Weight difference Tighten to torque + angle value Rolling torque α...

  • Page 16: Interpretation Of Symbols

    INTRODUCTION F4A EURO 4 NEF ENGINES Interpretation of symbols Where possible, the same sequence of procedures has been followed for easy reference. Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures.

  • Page 17: Key Of Lecture Of The Headings And Footnotes

    F4A EURO 4 NEF ENGINES INTRODUCTION Key of lecture of the headings and footnotes Type of Section Page vehicle title number When month - year update Basic edition referred to Printout Language is present (revi) to the month - year editorial number Publication basic edition...
  • Page 18 INTRODUCTION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 19 F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General specifications Page CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE ... . . LUBRICATION ......OIL PUMP .
  • Page 20 SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 21 F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE Technical Code Commercial Code F4AE3682E*P100 N60 ENT 4 F4AE3682E*P101 N60 ENT 4 F4AE3682F*P100 N60 ENT 4 F4AE3682F*P101 N60 ENT 4 Print P1D32N003 E Base - March 2007...
  • Page 22 SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 23: Lubrication

    F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS LUBRICATION Lubrication involves the heat exchanger as well, the turbo- Lubrication by forced circulation is achieved through oil rotary blower and the eventual compressor for any eventual com- expansion pump, placed in the front part of the basement, pressed air system.

  • Page 24: Oil Pump

    SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES OIL PUMP Figure 2 NOTE Since the oil pump cannot be overhauled, it shall be replaced when damaged. The oil pump is controlled directly by the drive shaft. 70576 HEAT EXCHANGER Figure 3 70480 1.

  • Page 25: Oil Pressure Relief Valve

    F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS Oil pressure relief valve Figure 4 Pressure regulation at 100°C oil temperature: - 1.2 bar min pressure; - 3.8 bar max. pressure 107418 By-pass valve to cut out clogged oil filter. Figure 5 Figure 6 Flow...

  • Page 26: Oil Vapour Recycling

    SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES OIL VAPOUR RECYCLING Figure 7 70484 Oil condensate Oil vapours 1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and condenses a part of vapours at the same time.

  • Page 27: Cooling System

    F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS COOLING SYSTEM - Fan with the purpose to increase radiator dissipation The engine cooling system, closed circuit forced circulation power: he belongs to the specific outfit as well. type, generally incorporates the following components: - An heat exchanger to cool lubrication oil (see - Expansion tank;...

  • Page 28: Water Pump

    SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES Water Pump Thermostat Figure 9 Figure 10 79458 The thermostat (1) of the by-pass type is located in the cylin- der head and doesn’t need regulations. Whenever doubts on its operation are present, replace it. On the thermostat body are fitted the thermometric trans- mitter/switch and water temperature sensor.

  • Page 29: Air Induction - Boost Diagram

    F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS AIR INDUCTION - BOOST DIAGRAM Figure 11 TURBOCHARGER AIR FILTRE EXHAUST RADIATOR 74195 Description The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust The turbocharger is composed by the following main parts: collector before the turbine and connected by piping to the one turbine, one transforming valve to regulate the boost...

  • Page 30: Deno X System

    SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES DeNO SYSTEM Composition and operation General Information The system is basically made up of: In order to contain emission of nitrogen oxides (NO ) within one reactive solution (water - urea : AdBlue) tank with the limits required by the Euro 4 standard, with low fuel level gauge;...

  • Page 31: Diagram

    F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS Diagram Figure 12 Engine cooling hot fluid AdBlue solution Pressurized air 116669 Air - AdBlue solution mix SCR SYSTEM LAYOUT 1. Bypass valve - 2. AdBlue solution tank - 3. Level indicator with temperature sensor - A. PUMP MODULE - 4. DCU control unit - 5.

  • Page 32: Pump Module

    SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES Pump module Dosing module Figure 13 Figure 15 102297 102299 1. Air pressure reducer - 2. Solenoid valve - 1. Connector dosing valve - 2. Injector pipe - 3. Air pressure sensors - 4. Filter - 5. Displacement pump 3.

  • Page 33: Tank

    F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS AdBlue fluid level gauge control Switch valve Figure 19 Figure 17 107107 102296 1. AdBlue fluid level gauge command - 2. AdBlue fluid 1. Electrical pins - 2. Output - 3. Input return pipe - 3.

  • Page 34: Exhaust Gas Temperature Sensor

    SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES Exhaust gas temperature sensor Figure 21 102303 The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to calculate the amount of urea to be injected into the system. Humidity detecting sensor Figure 22 114521...

  • Page 35: Nitric Oxide Detecting Sensor

    F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS Nitric oxide detecting sensor Figure 23 102302 1. Positive - 2. Earth - 3. CAN L line - 4. CAN H line - 5. Free The function of this sensor is to inform the control unit of the AdBlue (urea) fluid dosing and catalyst efficiency. Print P1D32N003 E Base - March 2007...
  • Page 36 SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 37 F4A EURO 4 NEF ENGINES SECTION 2 - FUEL SECTION 2 Fuel Page COMMON RAIL ......- General Specifications .
  • Page 38 SECTION 2 - FUEL F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 39: General Specifications

    F4A EURO 4 NEF ENGINES SECTION 2 - FUEL HIGH PRESSURE ELECTRONIC INJECTION SUPPLY SYSTEM (COMMON RAIL) General Specifications In order to reduce PARTICULATES emissions, very high injection pressures are required. The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision, obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
  • Page 40 SECTION 2 - FUEL F4A EURO 4 NEF ENGINES Fuel pressure sensor Injection control Assembled on a rail end, it measures the fuel pressure in the The control unit, depending on information coming from rail in order to determine the injection pressure. sensors, controls the pressure regulator, and changes pre-injection and main injection modes.

  • Page 41: Hydraulic System

    F4A EURO 4 NEF ENGINES SECTION 2 - FUEL HYDRAULIC SYSTEM Figure 2 High pressure Low pressure 119166 1. Injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical rotor pump - 5. High-pressure pump - 6. Prefilter assembled on chassis - 7.

  • Page 42: Fuel System Layout

    SECTION 2 - FUEL F4A EURO 4 NEF ENGINES FUEL SYSTEM LAYOUT The pressure relief valve (2) intervention brings about a fuel flow increase in the high-pressure pump cooling circuit, This fuel system is a Common Rail injection with CP3 high through inlet and drain piping (16) from piping (8).

  • Page 43: Fuel Prefilter

    F4A EURO 4 NEF ENGINES SECTION 2 - FUEL FUEL PREFILTER FUEL FILTER Figure 4 Figure 5 70494 99231 The fuel filter is of the high water separation type, is assembled on the right side of the vehicle chassis, and has the 1.

  • Page 44: Mechanical Feeding Pump

    SECTION 2 - FUEL F4A EURO 4 NEF ENGINES MECHANICAL FEEDING PUMP Bleeding condition Gear pump, placed on rear part of the high pressure pump, Figure 8 whose function is to feed the high pressure pump. It is driven by the high pressure pump’s shaft. Ordinary working condition Figure 6 72594...

  • Page 45: Cp3 High Pressure Pump

    F4A EURO 4 NEF ENGINES SECTION 2 - FUEL CP3 HIGH PRESSURE PUMP Pump provided with three radial pumping elements driven by the timing system gear, no need of timing. The mechanical feeding pump driven by the high pressure pump’s shaft is assembled to the rear side of the high pressure pump.

  • Page 46: Internal Structure

    SECTION 2 - FUEL F4A EURO 4 NEF ENGINES Internal structure Figure 10 Sec. B-B Sec. C-C 70498 1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — 7.

  • Page 47: Operating Principle

    F4A EURO 4 NEF ENGINES SECTION 2 - FUEL Operating principle Figure 11 Sec. B - B Sec. D - D 72597 1. Fuel exhaust connector to rail - 2. By-pass valve to common rail - 3. Pumping element - 4. Pump’s camshaft 5.
  • Page 48 SECTION 2 - FUEL F4A EURO 4 NEF ENGINES Figure 12 Figure 13 72601 72598 Sec. C - C Sec. A - A 1. Inlet to the pumping element - 2. Duct lines for the 1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel pump lubrication - 3.

  • Page 49: Operation

    F4A EURO 4 NEF ENGINES SECTION 2 - FUEL Operation RAIL The cylinder is filled through the cap intake valve only if the Figure 14 supply pressure is suitable to open the delivery valves set on the pumping elements (about 2 bars). The amount of fuel supplying the high-pressure pump is metered by the pressure regulator, placed on the low-pressure system;...

  • Page 50: Injector

    SECTION 2 - FUEL F4A EURO 4 NEF ENGINES INJECTOR Injection start The injector is similar as construction to the traditional ones, Figure 16 apart from the absence of plunger return springs. The injector can be deemed as composed of two parts: - actuator —...
  • Page 51 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION SECTION 3 Application to vehicles Page GENERAL SPECIFICATIONS ....GENERAL PROPERTIES ....PART ONE - MECHANICAL COMPONENTS ENGINE OVERHAUL .
  • Page 52 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Page Page - Overview of sensors ....PART FOUR - MAINTENANCE PLANNING ECM ELECTRONIC CONTROL UNIT (EDC 7) MAINTENANCE .

  • Page 53: General Specifications

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION GENERAL SPECIFICATIONS Figure 1 119091 F4AE3682 ENGINE The NEF F4A Euro 4 engines are characterised by four-stroke The section herein described is composed or four sections: diesel cycles supercharged with 4 or 6 cylinders with 4 valves - Section of mechanical overhaul prescribed in accordance per cylinder.

  • Page 54: General Properties

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES GENERAL PROPERTIES F4AE3682F* F4AE3682F F4AE3682F* F4AE3682F F4AE3682E* F4AE3682E F4AE3682E* F4AE3682E P100 P101 P100 P101 Type ρ Compression ratio 17 : 1 Max. output 2700 2700 2500 2500 Max. torque 850) 1000 1000 1250...

  • Page 55: Part One - Mechanical Components

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION DIAGNOSI PART ONE - MECHANICAL COMPONENTS Print P1D32N003 E Base - March 2007...
  • Page 56 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 57: Engine Overhaul

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION ENGINE OVERHAUL Because of the high pressure in the pipelines running Preface from the high pressure pump to the rail and from this Part of the operations illustrated within this section can be partially executed while the engine is assembled on the last one to the electro-injectors, it is absolutely vehicle, depending on the room available for access to the...
  • Page 58 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 6 119094 1. Connections for injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil pressure and temperature sensor - 5. Engine shaft sensor - 6. Control unit EDC7 - 7. Pressure adjuster - 8.
  • Page 59 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 8 Figure 10 74744 107247 Remove the nuts (7) and disconnect the electric wires from Remove from the rail (2): the fuel pipe (3) according to the the injectors (8). procedures described in Figure 14.
  • Page 60 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 12 Figure 14 114556 Remove the oil pipe (6) from the oil filter/ heating exchanger support (5). 70133 Remove the nuts (3) and remove the turbosupercharger (4) from the exhaust manifold (1). Remove the injector fixing screws and by means of tool 99342101 (1) withdraw the injectors (2) from the cylinder Remove the screws (2) and remove the exhaust manifold (1)
  • Page 61 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 16 Figure 19 74779 70142 Hook the brackets (1) with metal ropes and remove the Remove the screws (1) and the electronic control unit (2) cylinder head (2) from the block by means of a hoister. complete of heating exchanger.
  • Page 62 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 22 Figure 25 70148 Remove the screws (1) and remove the water pump (2). 70145 Remove the screws (3) and remove the roller (4). Remove the nut (1) and remove the phase sensor (2). Remove the screws (5) and remove the rpm sensor (6).
  • Page 63 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 28 Figure 31 107261 70152 Remove the screws (1 and 3) and take out the front cover (2). Screw two pins (2) exhibiting a proper length into the engine shaft holes (3).
  • Page 64 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 33 Figure 35 114560 119081 Remove the screws (1) and remove the rear cover (2). Remove the screws (1) and remove the oil suction rose (3). Write down the screw (1) assembling position Remove the screws (2) and remove the stiffening plate (4).

  • Page 65: Distribution Gear Box

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Distribution gear box Figure 39 Figure 38 107272 70210 DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR CASE FASTENING SCREWS LOCTITE 5205 SEALANT APPLICATION AREAS Refit the case (1) to the engine block. Clean accurately the timing gear case (1) and the engine Screw the fastening screws in the same position found at block.

  • Page 66: Flywheel Housing

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 41 Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities.
  • Page 67 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 45 Figure 47 70152 Screw two pins (2) having suitable length into shaft holes (3) and remove the engine flywheel (1) using proper sling and hoister. 70216 Figure 48 Apply on the rear tang (6) of the driving shaft part (5) of ’fixture 99346253, fix it with screws (4) and key on it the new seal ring (3).
  • Page 68 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 50 Figure 53 70223 70220 Remove the sealing ring (2) from the front cover (1), clean Fit the oil pump (1). accurately the coupling surfaces and smear them with IVECO Tighten the fastening screws (2) to the specified torque.
  • Page 69 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 56 Figure 59 α 119081 70363 Fit the plate (1), the rose pipe (2) and tighten the fastening Fit the phonic wheel (1) and the hub (2) on the output shaft. screws (3) to the specified torque.
  • Page 70 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 61 Figure 63 70231 70234 Fit on the engine block: a new gasket (1), the heat exchanger Position the alternator support (1) so that pins (3 and 4) are (2) a new gasket (3) and the oil filter support (4).
  • Page 71 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Refit the ECU (3) including the heat exchanger to the engine Figure 65 block and tighten the screws (2) to the specified torque. Replace support elastic elements (1). Figure 68 72505 Refit the air compressor (3).
  • Page 72 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 70 Figure 72 α 6-cylinder engine 70476 Tightening order layout for cylinder head fastening screws: step pre-tightening with a torque wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm •...
  • Page 73 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 74 Figure 76 70343 ROCKER ASSEMBLY COMPONENTS: 91572 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers. Assemble a new ring (3), lubricated with vaseline, on the fuel manifold (2) and insert it in the cylinder head housing so that Figure 77 the position ball (5) clashes with its housing (4).

  • Page 74: Tappet Play Adjustment

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Tappet play adjustment Figure 79 Figure 81 70520 70345 Adjust clearance between rockers and valves using setscrew Fit the rods (2). wrench (1), box wrench (3) and feeler gauge (2). Position jumpers (1) on valves with marks (→) facing the Clearance shall be as follows: intake valves 0.25 ±...

  • Page 75: Intake Manifold

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Intake manifold Figure 82 112876 In inlet manifold (3), air heater (5) for cold start-up is housed. In case of operation faults in air heater (5), the heater has to be replaced. In replacing air heater (5), you have to operate as follows: - Remove screws (6) securing heater (5) to inlet manifold (3).
  • Page 76 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 83 Figure 85 107287 114801 Apply LOCTITE 5999 on intake manifold (1) connection surface. Connect fuel new pipes (1) to rail (3) and to electric injector manifolds (2). Mount intake manifold (1) on cylinder head. Connect new pipe (5) to rail (3) and high pressure pump (8) Screw screws (2) and tighten them at prescribed torque.

  • Page 77: Wiring Support

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 89 Wiring support Figure 86 74756 74757 Check electrical cable (5) conditions, replace if damaged by Fit a new gasket (2) on the tappet cover (1). cutting the support (2) clamps and removing the screws (4) that secure it to connections (3).
  • Page 78 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 92 Figure 94 114802 Reconnect the turbosupercharger (3) with a new gasket to the exhaust manifold (1) and tighten the fastening nuts (2) to the specified torque. Connect oil pipe (4) to turbocharger (3). 107415 Connect pipe (2) to air compressor fitting (1) and head fitting (4).
  • Page 79 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 96 119094 1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Output shaft sensor - 6. EDC7 control unit - 7. Pressure regulator - 8. Fuel heater and fuel temperature sensor - 9.
  • Page 80 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Figure 97 Figure 99 85507 From the left side: Connect the fuel piping (2) to the rail by means of the union (1), to the high-pressure pump (9) by means of the union (5), and fasten it to the engine block with the specific clamps tightening the screws to the specified torque wrench setting.

  • Page 81: Poly-V Belt Tension Value

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Figure 100 114804 Reconnect fuel filter support (1) to engine block; screw screws (2 and 3) and tighten them at prescribed torque. Manually screw fuel filter (4) on support (1) up to ledge; screw filter for 3/4 turn.

  • Page 82: Turbosupercharger

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Turbosupercharger Figure 102 114805 GARRET TURBOSUPERCHARGER The booster system is composed of: air cleaner, turbosupercharger and intercooler. Verifying an anomalous operation of the engine, due to the booster system, it is recommended, before The air cleaner is a dry type composed of a filtering cartridge performing controls on the turbosupercharger, to that is periodically changeable.

  • Page 83: Check And Adjustment Turbosupercharger Actuator

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Turbosupercharger actuator replacement Check and adjustment Turbosupercharger actuator Figure 104 (Demonstrativ Figure 103 62873 114806 Cover the air, exhaust gas and lubrication oil inlets and Remove the elastic clip (4) and withdraw the tie rod (3) from outlets.

  • Page 84: Checks And Inspections

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Checks and inspections Check proper fuel pipe connection. Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check: - that there are no water leaks from the connecting sleeves of engine cooling circuit pipes and cab internal...

  • Page 85: Part Two - Electrical Equipment

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION PART TWO - ELECTRICAL EQUIPMENT Print P1D32N003 E Base - March 2007...
  • Page 86 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 87 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION LOCATION OF THE MAIN ELECTRICAL COMPONENTS Figure 105 119095 ENGINE VIEW LEFT SIDE 1. First Alternator - 2. Second Alternator - 3. Drive shaft revolution number sensor - 4. Engine Control unit - 5.

  • Page 88: Overview Of Sensors

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Overview of sensors Figure 107 119097 Ref. Description Coolant temperature sensor Electro-injector Rail pressure sensor Air temperature/pressure sensor Power steering level sensor Timing sensor Pressure regulator solenoid valve Fuel temperature sensor EDC7 control unit Engine oil level transmitter Drive shaft revolution number sensor...
  • Page 89 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION ECM (EDC 7) ECU Figure 108 117333 CONNECTOR VIEW 1. Chassis connector - 2. Sensor connector - 3. Electroinjector connector - 4. Atmospheric pressure sensor Print P1D32N003 E Base - March 2007...

  • Page 90: Electroinjectors Connector

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Electroinjectors connector Figure 109 50350 Cable Function Colour Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Pressure regulator solenoid valve (pin 1) Pressure regulator solenoid valve (pin 2) Cylinder 2 injector Cylinder 3 injector...

  • Page 91: Sensors Connector

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Sensor connector Figure 110 107769 Color Cable Function 1÷8 Timing sensor signal Timing sensor ground Rail pressure sensor ground Rail +5V pressure sensor supply Rail pressure sensor signal Water temperature sensor signal Fuel oil temperature sensor ground Flywheel sensor ground Flywheel sensor signal...

  • Page 92: Frame Connector

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Frame connector Figure 111 50350 Cable colour Ref. Function code Positive (+30) of central unit power supply Positive (+30) of central unit power supply Earth Earth Positive (+30) of central unit power supply Positive (+30) of central unit power supply Earth Earth...

  • Page 93: Ecm Central Unit Components (Edc 7)

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION ECM CENTRAL UNIT COMPONENTS (EDC Figure 112 Air temperature/pressure sensor (85156) This component combines a temperature and a pressure sensor. It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the exact amount of fuel to be injected at each cycle.
  • Page 94 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Crankshaft sensor (48035) This inductive type sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which close through the openings of a toothed wheel force fitted to the crankshaft. The same signal is used to manage the electronic rev counter.
  • Page 95 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Fuel temperature and pressure sensor Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command.
  • Page 96 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Coolant temperature sensor (85153) Figure 119 This is a variable resistance sensor that is able to measure coolant temperature and transmit a signal to the control unit reflecting the thermal conditions of the engine. The same signal is used by the control unit to manage the temperature gauge on the dash.

  • Page 97: Engine Wiring (Topographic)

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Engine wiring (Topographic) Figure 121 115708 Print P1D32N003 E Base - March 2007...

  • Page 98: Engine Wiring (Diagram)

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Engine wiring (Diagram) Figure 122 115709 Base - March 2007 Print P1D32N003 E...
  • Page 99 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Engine wiring legend Component Description code Cylinders 1 and 2 injection Cylinders 3 and 4 injections Water temperature sensor Oil temperature/pressure sensor Engine rpm sensor RAIL temperature/pressure sensor Air temperature/pressure sensor Cylinders 5 and 6 injectors Fuel oil temperature sensor Phase sensor...

  • Page 100: Fuel Pre-Filter

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Fuel pre-filter Figure 123 The water separation type fuel filter is mounted on the right hand side of the vehicle frame and has, on the cartridge base 3, a sensor 4 detecting the presence of water in the fuel. The filter support houses a manual priming pup 5 and a screw 2 to bleed the air from the system.
  • Page 101 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Pre-post heating resistance Figure 124 This resistance is located on the intake manifold. It is used to warm up the air in pre-post heating operations. It is powered by a remote control switch situated on the left hand side of the frame.

  • Page 102: Pressure Regulator - High Pressure Pump

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Pressure regulator - high pressure pump Figure 127 Pump with 3 radial pistons controlled by the timing gears, requiring no phase adjustment, with rotor type feed pump fitted to the back. A.

  • Page 103: Electroinjector

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Electroinjector Figure 128 The injector features a traditional construction, save for the fact that it has no needle return springs. The electroinjector essentially consists of two parts: - actuator - atomiser consisting of a pressure rod 1, a needle 2 and nozzle 3;...
  • Page 104 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Connecting connectors Figure 130 50343 WIRING DIAGRAM OF THE CONNECTIONS Figure 131 FAN SIDE 50349 Ref. Description Control unit Pin Cylinder 2 injector Cylinder 2 injector CONNECTOR 1 CONNECTOR 1 Cylinder 1 injector Cylinder 1 injector Cylinder 4 injector...

  • Page 105: Main Power Components

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION MAIN POWER COMPONENTS Alternators: main and secondary NOTE The secondary alternator is only present in the F4AE3682E engines Figure 132 L(D+) 7998 IG(15) Technical view Figure 133 Figure 135 8003 Wiring diagram A.

  • Page 106: Starter Motor

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Starter motor Supplier BOSCH Rated voltage Rated power Figure 136 50275 WIRING DIAGRAM POWER RELAY STARTER 50354 Base - March 2007 Print P1D32N003 E...

  • Page 107: Part Three - Troubleshooting

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION PART THREE - TROUBLESHOOTING Print P1D32N003 E Base - March 2007...
  • Page 108 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 109: Pt-01 Portable Tester

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Test parameters PT-01 PORTABLE TESTER Engine revolutions; Spark advance; Using PT-01 with portable tester it is possibile to execute troubleshooting and test the EDC7 electronic module of NEF Battery voltage; engines.
  • Page 110 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 111: Dtc Error Codes

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION DTC error codes with EDC7 central unit Print P1D32N003 E Base - March 2007...
  • Page 112 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 113 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 114 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 115 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 116 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 117 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 118 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 119 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 120 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 121 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 122 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 123 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 124 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 125 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 126 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 127 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 128 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 129 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 130 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 131 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 132 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 133 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 134 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 135: Guide To Diagnosis Through Symptoms

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION GUIDE TO DIAGNOSIS THROUGH SYMPTOMS Print P1D32N003 E Base - March 2007...
  • Page 136 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 137 F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Print P1D32N003 E Base - March 2007...
  • Page 138 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 139: Part Four - Maintenance Planning

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION PART FOUR - MAINTENANCE PLANNING Print P1D32N003 E Base - March 2007...
  • Page 140 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...

  • Page 141: Recovery

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION MAINTENANCE Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks.

  • Page 142: Unscheduled And Set-Interval Operations

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Unscheduled and set-interval operations Operations to be carried out in the course of the scheduled maintenance service. Unscheduled - Every 150,000 km - AdBlue system inspection test using diagnostic tools - AdBlue system pre-filter and filter replacement At set intervals - Every three months - Removal, cleaning and re-fitting of Adblue pre-filter...

  • Page 143: Maintenance Planning

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Cooling system check MAINTENANCE PLANNING The check must be executed both when the engine Engine oil level check disconnected and when it is running. The check must be executed when the engine is disconnected Check the pipelines from the engine to the radiator, from the and possibly cool.

  • Page 144: Changing Engine Oil

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Changing engine oil Figure 139 Figure 137 105167 Unscrew drain cap (1) and drain oil into special container. Remount drain cap on sump and tighten it at prescribed 105165 torque. Unthread control rod (1).

  • Page 145: Changing Engine Oil Filters

    F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION Changing engine oil filters Changing fuel pre-filter Figure 142 Figure 141 (Demonstration) 74341 Unscrew the pre-filter (1) and replace it. Before refitting the new cartridge, moisten the seal with diesel 75338 or engine oil.

  • Page 146: Changing Miscellaneous Drive Belts

    SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES Changing miscellaneous drive belts Checking valve clearance and adjustment if necessary To perform these operations correctly, proceed as described Figure 144 (Demonstration) in the appropriate chapter under the section ”GENERAL CHARACTERISTICS AND SERVICING”.
  • Page 147 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS SECTION 4 General overhaul and characteristics Page GENERAL CHARACTERISTICS ... . . CLEARANCE DATA ..... ENGINE OVERHAUL .
  • Page 148 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Page Page - Finding crankpin clearance ....- Fitting main bearings ....- Checking piston protrusion .
  • Page 149 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS GENERAL CHARACTERISTICS F4AE3682F F4AE3682F F4AE3682E F4AE3682E Type *P100 *P101 *P100 *P101 Cycle Four-stroke diesel engine Power Turbocharged with intercooler Injection Direct Number of cylinders ∅ Bore Stroke +.. = Total displacement 5880 TIMING...
  • Page 150 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES CLEARANCE DATA F4AE3682F F4AE3682F F4AE3682E F4AE3682E Type *P100 *P101 *P100 *P101 CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅ 1 102.009 to 102.031 ∅1 Cylinder barrels ∅1 Pistons ∅ 1 Size 60.5 ∅1...
  • Page 151 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4AE3682F F4AE3682F F4AE3682E F4AE3682E Type *P100 *P101 *P100 *P101 CYLINDER UNIT AND CRANKSHAFT COMPONENTS 2.705 to 2.735 Split ring slots 2.420 to 2.440 4.020 to 4.040 S 1* 2.560 to 2.605 Split rings 2.350 to 2.380...
  • Page 152 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES F4AE3682F F4AE3682F F4AE3682E F4AE3682E Type *P100 *P101 *P100 *P101 CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅ ∅ ∅ 1 Journals 82.993 to 83.013 ∅ 2 Crankpins 68.987 to 69.013 Main half bearings S 1* 2.456 to 2.464...
  • Page 153 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4AE3682F F4AE3682F F4AE3682E F4AE3682E Type *P100 *P101 *P100 *P101 CYLINDER HEAD — TIMING SYSTEM ∅ 1 Valve guide seats on ∅ 1 cylinder head 7.042 to 7.062 ∅ Valves: ∅...
  • Page 154 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES F4AE3682F F4AE3682F F4AE3682E F4AE3682E Type *P100 *P101 *P100 *P101 CYLINDER HEAD — TIMING SYSTEM Valve spring height: free spring 47.75 under a load equal to: 339.8 ± 19 N 35.33 741 ±...
  • Page 155 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4AE3682F F4AE3682F F4AE3682E F4AE3682E Type *P100 *P101 *P100 *P101 CYLINDER HEAD — TIMING SYSTEM ∅ 1 Tappet cap housing ∅ 1 on block 16.000 to 16.030 ∅ 2 Tappet cap outside ∅...
  • Page 156 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 157 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS ENGINE OVERHAUL Figure 3 ENGINE REMOVAL AT THE BENCH The following instructions assume that the engine has previously been placed on the rotating bench and that removal of all specific components of the Iveco Motors equipment have been already removed as well.
  • Page 158 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES REPAIR OPERATIONS Figure 6 CYLINDER UNIT Checks and measurements Figure 9 70163 Remove the screws (1) and disconnect camshaft (3) retaining plate (2). 70166 Once engine is disassembled, clean accurately the cylinder-block assembly.
  • Page 159 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Head face check on the cylinder group Figure 11 Figure 12 74772 Check that the head face, on the cylinder group, does not present deformations. This check can be carried out, after a previous grains (4) extraction by means of a calibrated ruler (2) and feeler gauge (3).
  • Page 160 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Checking cam lift and pin alignment Bushes Set the camshaft on the tailstock and using a 1/100 gauge set Figure 15 on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft.
  • Page 161 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Bush replacement Tappets Figure 17 Figure 18 70174 112890 To change the bushing (1), use the drift 99360362 (2) and grip MAIN DATA CONCERNING THE TAPPETS AND THE 99370006 (3) for its disassembly and assembly.
  • Page 162 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Fitting tappets — camshaft Figure 21 Figure 19 70238 Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque.
  • Page 163 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS OUTPUT SHAFT NOTE It is recommended to insert the found values in the Measuring journals and crankpins proper table. Figure 24 See Figure 25 and 29. Undersize classes are: 0.250 - 0.500 mm Journals and crankpins shall always be ground to the same undersize class.
  • Page 164 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Figure 26 Measured on a radius greater than 45.5 mm ↗ 0.500 between adjacent main journals 70577 MAIN OUTPUT SHAFT TOLERANCES Figure 27 INTERMEDIATE MAIN MAIN BEARING ON TIMING FIRST MAIN BEARING ON BEARINGS SYSTEM CONTROL SIDE...
  • Page 165 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Replacing oil pump control gear Finding journal clearance Figure 30 Figure 28 70161 Refit the output shaft (2). Check the backlash between output shaft main journals and 70184 the relevant bearings as follows: Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3).
  • Page 166 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Checking crankshaft shoulder clearance Figure 33 Figure 35 α 70188 stage, with tool 99395216 (1) set as shown in the 70190 figure, tighten the screws (2) with 90° ± 5° angle. This check is performed by setting a magnetic-base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 to 0.41.
  • Page 167 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Figure 38 Figure 37 32613 32614 Remove split rings (1) from piston (2) using pliers 99360183 Piston pin (1) split rings (2) are removed using a scriber (3). (3).
  • Page 168 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Measuring piston diameter Conditions for proper pin-piston coupling Figure 40 Figure 43 32619 32615 Lubricate the pin (1) and its seat on piston hubs with engine Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.
  • Page 169 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Connecting rods Figure 46 Figure 48 41104 DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).
  • Page 170 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Checking connecting rods Figure 49 Figure 50 (Demonstration) CONNECTING ROD BODY CONNECTI WEIGHT NG ROD No. CONNECTING ROD CAP CONNEC. ROD No. YEAR 61696 Check that the axes of the connecting rods (1) are parallel using tool (5) as follows: 70196 - fit the connecting rod (1) on tool (5) spindle and lock it...
  • Page 171 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Checking bending Connecting rod-piston coupling Figure 54 Figure 52 (Demonstration) 102596 Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the 61695 connecting rod (5) are read as shown in the figure.
  • Page 172 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Figure 59 NOTE Split rings are supplied spare with the following sizes: standard; 0.5 mm oversize. Figure 57 70202 DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL - Split ring openings shall be displaced with each other by 120°;...
  • Page 173 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Figure 61 Figure 64 α 70204 70207 - Lubricate the screws (1) with engine oil and then tighten If a different clearance value is found, replace the half bearings them to the specified torque using the torque wrench and repeat the check.
  • Page 174 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES CYLINDER HEAD Figure 67 Removing the valves Figure 66 70321 Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed.
  • Page 175 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS Checking cylinder head wet seal Figure 71 Figure 69 70323 70325 This check shall be performed using the proper tools. The rated thickness A for the cylinder head is 105 ± 0.25 mm, Use a pump to fill with water heated to approx.
  • Page 176 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES VALVES Figure 74 Figure 72 18882 Check the valve stem (1) using a micrometer (2), it shall be 6.970 ± 6.990. 107280 INTAKE AND EXHAUST VALVE MAIN DATA Removing carbon deposits, checking and Checking clearance between valve stem and grinding valves...
  • Page 177 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS VALVE GUIDE VALVE SEATS Regrinding — replacing the valve seats Figure 76 Figure 77 70330 INTAKE EXHAUST Check the valve seats (2). 79457 If slight scoring or burning is detected, regrind using a valve seat regrinding tool (1) following the inclination values shown Use a bore dial gauge to measure the inside diameter of the in Figure 78.
  • Page 178 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Figure 79 INTAKE EXHAUST 107282 Where valve seats cannot be recovered just regrinding them, In order to fit valve seats into cylinder head, the cylinder head has to be heated at 80 °C ÷ 100 °C and previously cooled inserts provided with spares can be mounted.
  • Page 179 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS VALVE SPRINGS Figure 84 Figure 82 50676 770321 MAIN DATA TO CHECK INTAKE AND EXHAUST Position on the cylinder head: the spring (4), the upper cap VALVE SPRINGS (3);...
  • Page 180 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Figure 86 88775 There are two types of head seals, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on Figure 86, at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average:...
  • Page 181 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS TIGHTENING TORQUE COMPONENT TORQUE 15 ± 3 1.5 ± 0.3 Screw M8 for fastening cylinder barrel lubricating nozzles 50 ± 6 5 ± 0.6 Screw M12 for fastening output shaft caps stage 80 ±...
  • Page 182 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES COMPONENT TORQUE 24 ± 4 2.4 ± 0.4 11/8 inch connection on filter support for turbine lubrication 10 ± 2 1 ± 0.2 Nut M12 for fastening turbine lubrication pipe 43 ±...
  • Page 183 F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS AUXILIARY COMPONENTS COMPONENT TORQUE Air compressor: 125 ± 19 12.5 ± 1.9 5/8 nut for fastening control gear on compressor shaft 77 ± 12 7.7 ± 1.2 Nut M12 for fastening to flywheel housing Alternator: 43 ±...
  • Page 184 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 185 F4A EURO 4 NEF ENGINES SECTION 5 - TOOLS SECTION 5 Tools Page TOOLS ....... . Print P1D32N003 E Base - March 2007...
  • Page 186 SECTION 5 - TOOLS F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 187 F4A EURO 4 NEF ENGINES SECTION 5 - TOOLS TOOLS TOOL No. DEFINITION 99317915 Set of 3 9x12 pin wrenches (14 - 17 - 19 mm) Revolving stand for overhauling units (700 daN/m capacity, 120 99322205 daN/m torque) 99340055 Tool to remove output shaft front gasket 99340056 Tool to remove output shaft rear gasket 99341001...
  • Page 188 SECTION 5 - TOOLS F4A EURO 4 NEF ENGINES TOOLS TOOL No. DEFINITION 99341015 Press 99342101 Tool to remove injectors 99346252 Tool for fitting output shaft front gasket 99346253 Tool for fitting output shaft rear gasket 99360076 Tool for disassembling cartridge filters 99360183 Pliers for removing/refitting piston rings (65 —...
  • Page 189 F4A EURO 4 NEF ENGINES SECTION 5 - TOOLS TOOLS TOOL No. DEFINITION 99360268 Tool for removing/refitting engine valves 99360330 Tool for rotating the engine flywheel 99360351 Tool for stopping the engine flywheel Beater for removing/refitting camshaft bushes (to be used with 99360362 99370006) 99360500...
  • Page 190 SECTION 5 - TOOLS F4A EURO 4 NEF ENGINES TOOLS TOOL No. DEFINITION 99360605 Band for fitting piston into cylinder barrel (60 — 125 mm) 99361037 Brackets for fastening engine to revolving stand 99322205 99363204 Tool to remove gaskets 99367121 Manual pump for pressure and vacuum measurements 99370006 Handgrip for interchangeable beaters...
  • Page 191 F4A EURO 4 NEF ENGINES SECTION 5 - TOOLS TOOLS TOOL No. DEFINITION 99389829 Joint torque wrench 9x12 - (5-60 Nm) Torque screwdriver for injector solenoid valve connector stop nut 99389834 setting Pair of gauges with ½” and ¾” square head for angle tightening 99395216 99395603 Dial gauge (0 —...
  • Page 192 SECTION 5 - TOOLS F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 193 F4A EURO 4 NEF ENGINES APPENDIX Appendix Page SAFETY PRESCRIPTIONS ....- Standard safety prescriptions ....- Prevention of injury .
  • Page 194 APPENDIX F4A EURO 4 NEF ENGINES Base - March 2007 Print P1D32N003 E...
  • Page 195 F4A EURO 4 NEF ENGINES APPENDIX - Do not execute any intervention if not provided with SAFETY PRESCRIPTIONS necessary instructions. Standard safety prescriptions - Do not use any tool or equipment for any different Particular attention shall be drawn on some precautions that operation from the ones they’ve been designed and must be followed absolutely in a standard working area and provided for: serious injury may occur.
  • Page 196 APPENDIX F4A EURO 4 NEF ENGINES - Avoid incorrect tightening or out of couple. Danger: Respect of the Environment incorrect tightening may seriously damage engine’s - Respect of the Environment shall be of primary components, affecting engine’s duration. importance: all necessary precautions to ensure - Avoid priming from fuel tanks made out of copper alloys personnel’s safety and health shall be adopted.

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