F4ae0481a 681a

EURO 3
NEF SERIES
Application to vehicles
N40
N40 ENT C
N60
N60 ENT C
Technical and Repair manual

This publication describes the characteristics, data and correct
methods for repair operations on each component of the 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.
Before starting to perform whatever type of repair, ensure that
all accident prevention equipment is available and efficient.
All protections specified by safety regulations, i.e.: goggles,
helmet, gloves, boot, etc. must be checked and worn.
All machining, lifting and conveying equipment should be in-
spected before use.
The data contained in this publication was correct at the time

of going to press but due to possible modifications made by
the Manufacturer for reasons of a technical or commercial na-
ture or for adaptation to the legal requirements of the differ-
ent countries, some changes may have occurred.
No part of this publication, including the pictures, may be re-
produced in any form or by any means.
Produced by:
Publication edited by
Iveco Motors
Iveco SpA
PowerTrain
Mkt. Advertising & Promotion
Viale dellIndustria, 15/17 B.U. TECHNICAL PUBLISHING
20010 Pregnana Milanese Iveco Technical Publications
Milano (Italy) Lungo Stura Lazio, 15/19
Print P1D32N001 E - 2nd Ed. 04.2007 10156 Turin - Italy
NEF ENGINES 1
NEF ENGINES
F4A Engines Part 1
Print P1D32N001 E Base - April 2007

2 NEF ENGINES
Base - April 2007 Print P1D32N001 E

NEF ENGINES 3
PRELIMINARY REMARKS
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.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assemblys
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - WARNINGS
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
Danger of serious damage for the assembly

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may
sometimes cause the warranty to become null and void.
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
NOTE It indicates an additional explanation for a piece of information.

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. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by IVECO Motors original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

NEF ENGINES 5
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.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO Motors commercial and assistance
network is available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

6 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.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO Motors system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.

NEF ENGINES 7
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.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding serial or chain connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR

d. DISTANCE ! 0

8 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.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F

NEF ENGINES 1
Part 1
F4A ENGINES
Section
General specifications 1
Fuel 2
Duty - Application to vehicles 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USERS GUIDELINE MANUAL
Section 1 describes the F4A engine illustrating its features

and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four sepa-

rate parts:
1. Mechanical part, related to the engine overhaul,

limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-

ne overhaul on stand and the necessary equipment to execute
such operations.
Installation general prescriptions are reported within the ap-
pendix.
The appendix reports general safety prescriptions to be follo-
wed by all operators whether being in-charge of installation or
maintenance, in order to avoid serious injury.

2 NEF ENGINES

NEF ENGINES 3
SPECIAL REMARKS
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.
Example
1 1 = housing for connecting rod small end bush

Tighten to torque
Tighten to torque + angular value

2 2 = housing for connecting rod bearings

4 NEF ENGINES
SYMBOLS - ASSISTANCE OPERATIONS
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly
Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Higher than.
Strained assembly
Maximum, peak
Undersized
Thickness
Less than.
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer
Replacement
Original spare parts

NEF ENGINES 5
UPDATING
Section Description Page Date of revision

6 NEF ENGINES

NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN IVECO CODE

AND IVECO MOTORS COMMERCIAL CODE 3
LUBRICATION (4 CYLINDERS) . . . . . . . . . . . . . 5
LUBRICATION (6 CYLINDERS) . . . . . . . . . . . . . 6
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 7
COOLING SYSTEM (4 CYLINDERS) . . . . . . . . . 8
COOLING SYSTEM (6 CYLINDERS) . . . . . . . . . 10
AIR INDUCTION - BOOST DIAGRAM . . . . . . . 12
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2 SECTION 1 - GENERAL SPECIFICATIONS NEF ENGINES

CORRESPONDENCE BETWEEN IVECO CODE AND IVECO MOTORS COMMERCIAL CODE
IVECO Motors
IVECO code
Commercial code
F4AE0481A*C1.. N40 ENT C
F4AE0681A*C1.. N60 ENT C


LUBRICATION (4 CYLINDERS) Lubrication involves the heat exchanger as well, the turbo-
blower and the eventual compressor for any eventual com-
Lubrication by forced circulation is achieved through oil rotary pressed air system. All these components may often vary ac-
expansion pump (1), placed in the front part of the basement, cording to the specific duty and will therefore be examined in
driven by the straight-tooth gear splined to the shafts bar hold. the specific section.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Figure 1
Oil recover from the

turbo-blower
To the exchan-
ger and to the
turbo-blower
Routing of oil under pressure
Routing of oil return by gravity to sump
Introduction of oil
LUBRICATION SYSTEM LAYOUT

LUBRICATION (6 CYLINDERS) Also in this case, the components such as the oil exchanger,
Even for the 6 cylinders version lubrication is obtained by the turbo-blower and the eventual compressor are specifically
forced circulation and achieved through an oil rotary expan- studied and made out to suit the equipment or the duty for
sion pump similar to the 4 cylinders one. which the engine has been developed.
Figure 2
Oil recover from the

turbo-blower
To the exchan-
ger and to the
turbo-blower
Routing of oil under pressure

Routing of oil return by gravity to sump
Introduction of oil
LUBRICATION SYSTEM LAYOUT

OIL VAPOUR RECYCLING
Figure 3
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.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).

COOLING SYSTEM (4 CYLINDERS)
The engine cooling system, closed circuit forced circulation

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

Figure 4
EXPANSION TANK
EXPANSION TANK
HEATER
(Optional)
RADIATOR
RADIATOR
Water coming out from thermostat
Water recirculating in engine
Water coming into pump

COOLING SYSTEM LAYOUT 74194

COOLING SYSTEM (6 CYLINDERS)

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

Figure 5
EXPANSION TANK
EXPANSION TANK
HEATER
(Optional)
RADIATOR
RADIATOR
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
COOLING SYSTEM LAYOUT

AIR INDUCTION - BOOST DIAGRAM

Figure 6
4 Cylinders version
AIR FILTRE TURBOCHARGER
EXHAUST
RADIATOR
6 Cylinders version
AIR FILTRE TURBOCHARGER
EXHAUST
RADIATOR
74195
Description
The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust
feeding pressure , one main body and one compressor. collector before the turbine and connected by piping to the
induction collector.
During engine working process, the exhaust emissions flow
through the body of the turbine, causing the turbine disk Its funchon is to restrict the exhaust of the emissions ,
wheels rotation. releasing part of them directly to the exhaust tube when the
boost feeding pressure, over the compressor, reaches the
The compressor rotor, being connected by shaft to the
prescribed bar value.
turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air through the air filter. The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
NEF ENGINES SECTION 2 - FUEL 1
SECTION 2
Fuel
Page
SYSTEM OF INJECTION FEEDING ELECTRONIC

TALL PRESSURE COMMON RAIL . . . . . . . . 3
WORKING PROCESS . . . . . . . . . . . . . . . . . . . . 5
FUEL SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . . 6
MECHANICAL FEEDING PUMP . . . . . . . . . . . . 8
CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . 9
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BOOST GAUGE VALVE . . . . . . . . . . . . . . . . . . . 14
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . 15
PRESSURE LIMITER FOR FUEL RETURN . . . . . . 16

2 SECTION 2 - FUEL NEF ENGINES

SYSTEM OF INJECTION FEEDING ELECTRONIC TALL PRESSURE 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 1450 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 1
1 6
3
9
10
5
11
74168
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engines cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engines oil temperature and pressure - 5. Driving shaft sensor -
6. Electro-injector - 7. Temperature and air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature
sensor - 10. Pressure gauge cable - 11. EDC 7 gearbox.
Through the sensors, present on the engine, the ECU con- The outlet voltage is proportional to the pressure or tem-
trols the engine operation. perature obtained by the sensor.
Air pressure/temperature sensor Engine oil temperature and pressure sensor
It is a component integrating a temperature sensor and a Same as air pressure/temperature sensor, it is fitted on the
pressure sensor. engine oil filter, in a horizontal position.
Fitted on the intake manifold, it measures the max. inlet air It measures engine oil temperature and pressure.
capacity to calculate precisely the fuel quantity to inject at
every cycle.

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.
The injection pressure value is used to control the pressure
and to determine the electric injection control length. Closed-loop control for injection pressure
Depending on engine load, measured by processing signals
Fuel temperature sensor coming from various sensors, the control unit controls the
It is a sensor that is equal to the previous one. regulator in order to always have the optimum pressure.
It measures fuel temperature to provide the control unit with Pilot and main injection spark advance control
an index of the diesel fuel thermal state. The control unit, depending on signals coming from various
sensors, computes the optimum injection point according to
an internal mapping.
Coolant temperature sensor
It is a variable-resistance sensor suitable to measure the Idle speed control
coolant temperature to provide the control unit with an The control unit processes signals coming from various
index of the engine thermal state. sensors and adjusts the amount of injected fuel.
It controls the pressure regulator and changes the injection
time of injectors.
Output shaft sensor
Within certain thresholds, it also takes into account the
It is an inductive sensor placed on the front engine part. battery voltage.
Signals generated through the magnetic flow that is closed on
the phonic wheel, change their frequencies depending on Maximum speed limiting
output shaft rotation speed. At 2700 rpm, the controlunit limits fuel flow-rate by reducing
the injectors opening time.
Over 3000 rpm it deactivates the injectors.
Timing sensor
It is an inductive sensor placed on the engine rear left part. Cut Off
It generates signals obtained from magnetic flow lines that are Fuel cut off upon release is controlled by the control unit
closed through holes obtained on the keyed gear on the performing the following logics:
camshaft. The signal generated by this sensor is used by the - it cuts off injectors supply;
ECU as injection phase signal. - it re-activates the injectors shortly before idle speed is
reached;
Though being equal to the flywheel sensor, it is NOT
interchangeable since it has a different outside shape. - it controls fuel pressure regulator.
Smoke control upon acceleration
System functionality With strong load requests, the control unit, depending on
Self-diagnosis signals received by air inlet meter and engine speed sensor,
controls the pressure regulator and changes the injectors
The ECU self-diagnostic system checks signals coming from
actuation time, in order to avoid exhaust smoke.
sensors by comparing them with threshold data.
Fuel temperature control
IVECO Code recognition When the fuel temperature exceeds 75 C (measured by the
sensor placed on fuel filter) the control unit intervenes by
The EDC7 control unit communicates with the Immobilizer
reducing injection pressure.
control unit (if fitted) to obtain the startup consent.
If the temperature exceeds 90 C, the power is reduced to
60%.
Engine pre-heating resistance check
AC compressor engagement control
The pre-post heating is activated when even only one of the
(if fitted)
water, air or fuel temperature sensors signals a temperature
The control unit is able to drive engagement and
that is less than 5 C.
disengagement of the electromagnetic compressor clutch
depending on coolant temperature.
Phase recognition If the coolant temperature reaches about 105 C, it
By means of signals coming from camshaft sensor and disengages the clutch.
flywheel sensor, the cylinder on which fuel must be injected
After Run
is recognised upon startup.
The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the
following startup.

WORKING PROCESS
Figure 2
High Pressure
Low Pressure
70492
1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on
chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

FUEL SYSTEM LAYOUT

This fuel system is a Common Rail injection with CP3 high
pressure pump and this layout is for 4 cylinder version.
(The 6 cylinder version is similar design as the 4 cylinder en-
gine).
The pressure regulator, placed upstream of the high-pressure
pump, adjusts the fuel flow that is necessary on the low-pres-
sure system. Afterwards, the high-pressure pump takes care
of supplying the rail properly. This arrangement, by pressuris-
ing the necessary fuel only, improves the energetic efficiency
and limits fuel heating in the system.
Function of the pressure relief valve (2), assembled on the
high-pressure pump, is keeping the pressure, at the pressure
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream.
The pressure relief valve (2) intervention brings about a fuel
flow increase in the high-pressure pump cooling circuit,
through inlet and drain piping (16) from piping (8).
The pressure relief valve housed on the cylinder head, as-
sembled on injector return (3), limits the fuel return flow
from injectors at a pressure of 1.3 to 2 bars.
Two by-pass valves are placed in parallel with the mechanical
supply pump.
The by-pass valve (18) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure ex-
ceeds the allowed threshold value.
The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
1. High-pressure pump. 2. Pressure relief valve on high-pressure pump, 5 bars. 3. Pressure relief valve assembled on fuel
return from injectors, 1.3 to 2 bars. 4. Rail overpressure valve. 5. Common Rail. 6. Pressure sensor. 7. Injector.
8. Return piping. 9. Control unit heat exchanger. 10. Mechanical priming pump. 11. Prefilter assembled on chassis.
12. Fuel tank. 13. Mechanical supply pump. 14. Fuel filter. 15. Pressure regulator. 16. High-pressure pump cooling
piping. 17. By-pass valve. 18. By-pass valve.

Figure 3

MECHANICAL FEEDING PUMP Jettison condition

Gear pump, placed on rear part of the high pressure pump,
Figure 6
whose function is to feed the high pressure pump. It is driven
by the high pressure pumps shaft.
Ordinary working condition

Figure 4
72594
72592 The dump by-pass valve (2) is activated in case, when the
engine is off, it is necessary to fill the feeding system through
the priming pump. In this condition the by pass valve (I) keeps
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, closed while the dump by-pass valve (2) opens up due to the
I - 2 By-pass valves in close position. pressure effect on the entry unit so the fuel flows to the
exhaust unit B.
Overpressure condition in Exhaust unit

Figure 5 NOTE The mechanical feeding pump cannot be replaced
separately, therefore it must not be disassembled
from the high pressure pump.
72593
The by-pass valve (I) is activated in case of overpressure on

B Exhaust unit. The actual pressure, overcoming the
resistance of the valves spring (I), connects the exhaust with
the entry through the gallery (2).

CP3 HIGH PRESSURE PUMP

Pump provided with 3 radial pumping elements driven by the
timing system gear, no need of timing. The mechanical
feeding pump driven by the high pressure pumps shaft is
assembled to the rear side of the high pressure pump.
NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
Figure 7
72595
1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear -
5. Connector to fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry
flowing from engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter -
9. Mechanical feeding pump.

High pressure pump-inside structure

Figure 8
Sec. B-B
Sec. C-C
70498
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft.
7. Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
Every pumping unit is composed of:

- a piston (5) actuated by a three-lobe element (2) floating - cap intake valve (3);
on the pump shaft (6). The element (2), being floating on - ball delivery valve (4).
a misaligned part of the shaft (6), when the shaft rotates,
does not rotate therewith but is only translated in a
circular movement along a wider radius, with the
resulting alternate actuation of the three pumping
elements;

Working principle
Figure 9
Sec. B - B
Sec. D - D 72597
1. Fuel exhaust connector to rail - 2. By-pass valve to common rail - 3. Pumping element - 4. Pumps camshaft
5. Pumping element fuel duct - 6. Fuel duct for pressure regulating gauge - 7. Pressure regulating gauge.
The pumping element (3) is orientated towards the pumps During compression phase of the pumping element, the fuel
camshaft (4). During the intake phase, the pumping element achieves the level of pressure determining the opening of the
is fed through the feeding line (5). The quantity of fuel to flow by-pass valve to common rail (2), feeding it through the
to the pumping element is determined by the pressure exhaust unit (I).
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.

Figure 10 Figure 11
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. Inlet to the pumping element exhaust flowing from pump with connector to high
4. Main feeding line to the pumping element - pressure pipe for common rail.
5. Pressure gauge - 6. Inlet to the pumping element -
7. Pressure gauge exhaust flue - 8. Flow limiting valve to 5
bar - 9. Fuel exhaust from pressure gauge inlet.
Figure 11 shows the fuel flow under high pressure running
through the exhaust galleries of the pumping elements.
Figure 10 shows the fuel runs at low pressure inside the
pump; the following elements are clearly visible: the main
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines (2).
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.

Operation RAIL
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 12
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; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail. 99232
The thereby-generated pressure makes the exhaust valve

open and the compressed fuel reaches the high-pressure 1. Rail 2. Fuel inlet from high-pressure pump -
circuit. 3. Overpressure valve 4. Pressure sensor.
The pumping element compresses the fuel till the top dead The rail volume is comparatively small to allow a quick
center (delivery stroke) is reached. Afterwards, the pressure pressurisation at startup, at idle and in case of high flow-rates.
decreases till the exhaust valve is closed. It anyway has enough volume as to minimise system spikes
The pumping element piston goes back towards the bottom and the use of plenum chambers caused by injectors
dead center and the remaining fuel is decompressed. openings and closings and by the high-pressure pump
operation. This function is further enabled by a calibrated
When the pumping element chamber pressure becomes less hole being set downstream of the high-pressure pump.
than the supply pressure, the intake valve is again opened and
the cycle is repeated. A fuel pressure sensor (4) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
The delivery valves must always be free in their movements, feed-back information, depending on which the rail pressure
free from impurities and oxidation. value is checked and, if necessary, corrected.
The rail delivery pressure is modulated between 250 and
1350 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.

BOOST GAUGE VALVE

The boost valve (1750 bars) is assembled to the rail with the purpose to protect the systems components in case of excessive
increase of pressure within the high pressure system. Pressure limiter.
The valve can be single-stage (as the one showed in the picture) or double-stage with double working limit (1750 bars and 800
bars).
In the second case, when the pressure within the high pressure system reaches 1750 bars, the valve is activated as a single-stage
one to exhaust the fuel and consequently reduce the pressure until reaching safety parameters. Then it provides mechanically
gauging the pressure into rail to aprx. 800 bars. This way the valve enables working of the engine for extended timing at limited
performances, avoiding the fuels overheating and preserving the exhaust galleries.
If the above mentioned valve is activated, the engine control module excludes by isolation the pressure gauge and records the
errore code 8.4.
The pump will flow the maximum delivery to the rail.
Figure 13
A B
70500 70502
1. Body 2. Small piston 3. Stop 4. Spring 5. Direct tank discharge 6. Seat on rail.
A Normally, the tapered piston end keeps closed the B If the 1750 bar fuel pressure is exceeded in rail, the small
discharge towards the tank. piston is displaced and the excess pressure is discharged
into the tank.

ELECTRO-INJECTOR Injection start

The injector is similar as construction to the traditional ones,
apart from the absence of plunger return springs. Figure 15
The injector can be deemed as composed of two parts:
- actuator spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position

15
Figure 14
70506
15
When coil (4) is energised, it makes shutter (6) move

upwards. The control volume (9) fuel flows towards flow
duct (12) making a pressure drop occur in control volume
(9). Simultaneously the fuel pressure into pressure chamber
(8) makes plunger (2) lift, with following fuel injection into the
cylinder.
Injection end
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
NOTE The injector cannot be overhauled and therefore

it must not be disassembled.
70505
1. Pressure rod 2. Plunger 3. Nozzle 4. Coil 5. Pilot

valve 6. Ball shutter 7. Control area 8. Pressure
chamber 9. Control volume 10. Control duct
11. Supply duct 12. Control fuel outlet 13. Electric
connection 14. Spring 15. High-pressure fuel inlet.

PRESSURE LIMITER FOR FUEL RETURN

It is housed on the rear of the cylinder head, and adjusts the
pressure of fuel returning from injectors at a pressure 1.3 and
2 bars. By guaranteeing this pressure to the return fuel, the
fuel vapours formation inside injectors is avoided, optimising
fuel spraying and combustion.
Figure 16
70507
A To tank B From injectors

NEF ENGINES SECTION 3 - APPLICATION TO VEHICLES 1
SECTION 3
Duty -
Application to vehicles
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
- Clearance data - 4 cyl. . . . . . . . . . . . . . . . . . . . 4
- Clearance data - 6 cyl. . . . . . . . . . . . . . . . . . . . 5
PART ONE - MECHANICAL COMPONENTS 7
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Engine setting operations for the assembly

on turning stand . . . . . . . . . . . . . . . . . . . . . . . 9
- Removal of components . . . . . . . . . . . . . . . . . 10
- Assembly of components . . . . . . . . . . . . . . . . 17
- Completion of the engine . . . . . . . . . . . . . . . . 29
- Checks and inspections . . . . . . . . . . . . . . . . . . 32
PART TWO - ELECTRICAL EQUIPMENT . . . 33
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 35
- Engine F4AE0481 . . . . . . . . . . . . . . . . . . . . . . 35
- Engine F4AE0681 . . . . . . . . . . . . . . . . . . . . . . 36
- Overview of sensors . . . . . . . . . . . . . . . . . . . . 37
- EDC 7 electronic control unit . . . . . . . . . . . . . 38
- Electroinjectors connector A . . . . . . . . . . . . 39
- Sensors connector C . . . . . . . . . . . . . . . . . . 40
- Connector for powering components and

for the functions envisaged in application B . 41
- Air temperature/pressure sensor (85156) . . . . 43
- Oil pressure/temperature sensor (42030) . . . . 43
- Crankshaft sensor (48035) . . . . . . . . . . . . . . . 44
- Timing system sensor (48042) . . . . . . . . . . . . 44

2 SECTION 3 - APPLICATION TO VEHICLES NEF ENGINES
Page Page
- Fuel pressure sensor (85157) . . . . . . . . . . . . . 45

PART FOUR - MAINTENANCE PLANNING . 85
- Coolant temperature sensor (47035) . . . . . . . 46
MAINTENANCE PLANNING . . . . . . . . . . . . . . 87
- Fuel temperature sensor (47042) . . . . . . . . . . 46
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
- Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Planning of controls
- Pre-post heating resistance . . . . . . . . . . . . . . . 48 and periodical intervention . . . . . . . . . . . . . . . 87
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . . 88
- Pressure regulator - high pressure pump . . . . . 49
MAINTENANCE PROCEDURES . . . . . . . . . . . . 88
- Electroinjector . . . . . . . . . . . . . . . . . . . . . . . . . 50
- Checks and controls . . . . . . . . . . . . . . . . . . . . 88
PART THREE - TROUBLESHOOTING . . . . . . 53
- Engine oil level check. . . . . . . . . . . . . . . . 88
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
BLINK-CODE - GENERAL INFORMATION . . . 56 - Check of fuel system . . . . . . . . . . . . . . . . 89
- Anomaly warning led . . . . . . . . . . . . . . . . . . . . 56 - Cooling system check . . . . . . . . . . . . . . . 89
- Detectable failures . . . . . . . . . . . . . . . . . . . . . . 56 - Lubricating system check . . . . . . . . . . . . . 89
BLINK-CODE (SOFTWARE 3.3_1 VERSION) . . 57 - Check of water presence within

fuel filter or pre-filter . . . . . . . . . . . . . . . . 89
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
- Checking/replacing the blow-by filter . . . . 89
GUIDELINE FOR TROUBLESHOOTING
WITH PT-01 PORTABLE TESTER . . . . . . . . . 71 - Check of drive belt tensioning . . . . . . . . . 90
PT-01 PORTABLE TESTER . . . . . . . . . . . . . . . . . 73 - Check of belts tear and wear status . . . . 90

- Main functions . . . . . . . . . . . . . . . . . . . . . . . . . 73 - Check and setting of tappet clearance . . . 90
- Test parameters . . . . . . . . . . . . . . . . . . . . . . . . 73
- Changing the engine oil and oil filter . . . . 91
FAILURE CODES (SOFTWARE VERSION 3.3_1) 74
- Filter replacement procedure . . . . . . . . . . 91
FAILURE CODES (SOFTWARE VERSION 4.1_2) 77
- Fuel filter replacement . . . . . . . . . . . . . . . 92
GUIDELINE FOR TROUBLESHOOTING
WITHOUT BLINK-CODE . . . . . . . . . . . . . . . 81 - Alternator belt - water pump replacement 92

GENERAL SPECIFICATIONS
Figure 1
101585
The NEF F4AE0481 and F4AE0681 engines are characterised The section herein described is composed or four sections:
by four-stroke diesel cycles supercharged with 4 or 6 cylinders
with 4 valves per cylinder. - Section of mechanical overhaul prescribed in accordance
to the engines specific duty, illustrating all necessary
They have high pressure injection fuelling (common rail) and operation to remove and assembly the external
are entirely electronically driven in order to optimise the components of the engine, including cylinder heads,
working process in accordance to the operation, limiting as gearbox of the timing system and of the front part cover;
much as possible the pollution emissions and consumption.
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.
Data, features and performances are valid only if the

setter fully complies with all the installation
prescriptions provided by IVECO.
Furthermore, the users assembled by the setter shall
always be in conformance to couple, power and
number of turns based on which the engine has been
designed.

Clearance data - 4 cyl.
F4AE0481A*C1
F4AE0481A*C1..
Type
Compression ratio 17 : 1
Max. output kW 125
(HP) (170)
rpm 2700
Max. torque Nm 560
(kgm) (56.0)
rpm 1200
Loadless engine
idling rpm 750
Loadless engine
peak rpm 3000
Bore x stroke 102 x 120
Displacement cm3 3920

TURBOCHARGING with intercooler
Turbocharger type GARRETT GT 22
LUBRICATION Forced by gear pump, relief valve single action

bar oil filter
Oil pressure (warm engine)

- idling bar 1.2
- peak rpm bar 3.8
COOLING By liquid
Water pump control Through belt
Thermostat
- start of opening C 81 2
FILLING
engine sump liters 5.3 8.3

ACEA E3/E5
URANIA LD5
engine sump + filter liters 6.3 9.3
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by IVECO.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.

Clearance data - 6 cyl.
F4AE0681A*C1
F4AE0681A*C1..
Type
Compression ratio 17 : 1
Max. output kW 202
(HP) (275)
rpm 2500
Max. torque Nm 930
(kgm) (93.0)
rpm 1250
Loadless engine
idling rpm 600
Loadless engine
peak rpm 2850
Bore x stroke 102 x 120
Displacement 5880
TURBOCHARGING with intercooler
Turbocharger type HOLSET HX35W
LUBRICATION Forced by gear pump, relief valve single action

oil filter
Oil pressure (warm engine)
bar - idling bar 1.2
Loadless engine
peak rpm rpm 3.8
COOLING By liquid
Water pump control Through belt
Thermostat
- start of opening C 81 2
FILLING
ACEA E3/E5 engine sump liters 8 10.8

URANIA LD5
engine sump + filter liters 9 11.8
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by IVECO.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.


DIAGNOSI
PART ONE - MECHANICAL COMPONENTS


ENGINE OVERHAUL
Preface Because of the high pressure in the pipelines running
Part of the operations illustrated within this section can be from the high pressure pump to the rail and from this
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 required NOT to:
engine and on the equipment application as well.
- disconnect the pipelines when the engine is
With regard to the engine disassembly operations from working;
! the machine, please apply for Information consulting - re-use the disassembled pipelines.
the specific manual. All operations of Engine
disassembly operations as well as overhaul operations
must be executed by qualified technicians provided Figure 4
with the specific tooling and equipment required.
The following information relates to the engine overhaul
operations only for what concerns the different components
customising the engine, according to its specific duties.
In section General overhaul, all the operations of engine
block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the

part hereby described.
Engine setting operations for the assembly on
turning stand
Figure 2
70127
The pipe (3) from the union (4) and from the supercharger
(8).
Remove the fuel pipe (2) from the rail and from the
high-pressure pump (9) and remove it from the engine block,
by removing the fixing screws (4 and 6)
70125 NOTE When unlocking the pipe (2) union (7), it is necessary
In order to apply to the engine block the engine fixing to prevent the union (10) rotation of the
brackets 99341009 to the stand for the overhaul, operating high-pressure pump (9), by using the proper wrench.
on the engine left side, it is necessary:
- to remove the fuel filter (5) from the support (1) by
means of tool 99360076; On the right side
- to remove the low pressure fuel pipe (2-3-4) from the
support (1) Figure 5
- to remove the support (1) bracket from the block
Figure 3
70128
70126 Remove screws (2) and detach oil pipe (3) from turbine (1)
and the engine crankcase.
In order to remove the low-pressure fuel pipe
(2-3-4, Figure 2) from the relevant connection Remove starter motor (5) from flywheel cover (4).
unions, it is necessary to press the fastener (1) as Apply to the block the bracket 99361037 and fix by means
shown in figure B.
After removing the pipe, position the fastener (1) of these latter the engine to the revolving stand 99322205.
into its lock position, figure A, in order to avoid Drain the engine oil by removing the plug from the sump.
possible deformations. Remove the fan from the engine shaft pulley.

Removal of components
Figure 6
78670
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. Injector - 7. Temperature-air pressure sensor - 8. Timing phase sensor -
9. Fuel temperature sensor and fuel heater - 10. Pressure adjuster - 11. Control unit EDC7.
Disconnect the engine wire by disconnecting the connectors: Figure 7

(1) from the injector harness (6); (7) air temperature
/pressure sensor: (3) fuel pressure sensor; (11) control unit;
(10) high pressure pump sensor; (8) timing phase sensor; (2)
engine coolant temperature sensor on thermostat (5) rpm
sensor;
91576
Remove from the rail: the fuel pipe (4) according to the
procedures described in Figure 3. Remove the fuel pipe (5)
from the rail (2) and from the manifolds (3) for injectors.
Remove the screws (1) and the rail (2).

Figure 8 Figure 10
70130 70132
Remove the blow-by filter. Loosen the tappet adjuster fixing nuts (1) and unscrew the
adjuster.
Remove from the fuel return pressure limiting device (1), the
Remove the screws (2), remove the equalizer unit (3)
pipe (2) as described in Figure 3.
composed by the support (6), equalizers (4), shafts (5) and
Remove the pipe (4) from the air supercharger (3) and from remove the bonds (7) from the valves. Remove the rods (8).
the union (5). Remove the nut (10) Loosen the elastic hose
clamp (6) and remove the oil vapor pipe (9). Figure 11
Remove the unions (13-11) and remove the pipe (12).
Remove the nuts (7) and remove the tappet (8) cover
complete of gasket.
Figure 9
70133
Remove the injector fixing screws and by means of tool

99342101 (1) withdraw the injectors (2) from the cylinder
head.
Figure 12
70131
Remove the nuts (7) and disconnect the electric wires from
the injectors (8).
Remove the screws (1) and remove the injector harness
support (2) complete of gasket.
Remove the screws (5) and remove the air
pressure/temperature sensor (6).
Remove the nuts (3) and withdraw the fuel manifolds (4).
NOTE The removed fuel manifold (4) shall not be used 70134
again and they must be replaced by new ones.
Remove the screw (4), loosen the clamp (2) and remove the
air conveyor (1) from the turbosupercharger (3).

Figure 13 Figure 15
70135 70137
Hook the brackets (1) with metal ropes and remove the
Remove the oil pipe (5) check clamp fixing screw (4) from cylinder head (2) from the block by means of a hoister.
the exhaust manifold (1).
Remove the oil pipe (5) from the oil filter/ heating exchanger
support (7). Figure 16
Remove the nuts (2) and remove the turbosupercharger (3)
from the exhaust manifold (1).
Remove the screws (6) and remove the exhaust manifold (1)
from the cylinder head.
Figure 14
70138
Remove the cylinder head gasket (1).
Loosen the stretch of the belt (2) by means of a proper
wrench, operating the automatic belt tightener (3) and
remove the belt.
Remove the screw (4) and the automatic tightener (3).
Figure 17
70136
Remove the screws (1) and remove the air conveyor (2)
complete of heater. Remove the screws (4), remove the
cover (3) and the relevant thermostat.
Remove the head cylinder (6) fixing screws (5).
NOTE The external screws pointed out are shorter.
70139
Remove the screws (2) and disconnect the alternator (1)

Figure 18 Figure 20
70140 70142
Remove the screws (2) and remove the alternator support Remove the screws (1) and the electronic control unit (2)
(3). complete of heating exchanger.
Remove the oil filter (1) by means of tool 99360076.
Figure 19 Figure 21
70141 70143
Remove the screws (4) and remove oil By means of wrench 99355019, remove the screws (1) and
temperature/pressure sensor. (3) and remove the hydraulic power steering pump (2)
complete of oil tank (4) from the air supercharger (5)
Remove the screws (1) and remove the oil filter/heating
exchanger support (2), middle plate (6) and relevant gaskets.
Remove the oil level sensor (5) Figure 22
70144
Remove the screws (2) and the nuts (1-4) and remove the
air supercharger (3)

Figure 23 Figure 26
70148
70145
Remove the screws (1) and remove the water pump (2).
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).
Remove the nuts (3) and remove the high-pressure pump (4)
complete of power supply pump (5). Figure 27
Figure 24
78256
70146
Apply on the front tang (2) of the driving shaft fixture
Apply the tool 99360351 (2) to the flywheel housing (1), to 99340055 (4) and through the guiding holes of the fixture
stop the flywheel (3) rotation. itself, drill the internal seal ring (1) with a drill ( 3.5 mm) to
Loosen the screws (4) a depth of 5 mm..
Fix fixture (4) to the ring (1) by means of the 6 screws in the
kit e proceed with the removal of the ring by screwing up the
Figure 25 screw (3).
Figure 28
70340
Remove the screws (2) and remove the pulley (3) and the 78257
bumper flywheel (1). Apply the proper rod (3) of fixture 99363204 to the external
Remove the screws (6) and remove the hub (5) and the seal ring (2) as shown in the figure and use lever (4), to
phonic wheel (4). remove it from the front cover (1).

Figure 29 Figure 32
70149
Remove the screws (1) and remove the front cover (2).
70152
NOTE Write down the screw (1) assembling position Screw two pins (2) exhibiting a proper length into the engine
because they exhibit different lengths. shaft holes (3).
Withdraw the engine flywheel (1) in order to sling it with the
hoister and position it into the container.
Figure 30
Figure 33
70150
Remove the screws (1) and remove the oil pump (2).
NOTE It is not possible to overhaul the oil pump (2).
Figure 31
78258
Apply fixture 99340056 (3) on the rear tang (5) of the driving
shaft and through the guiding holes of the fixture, drill the
internal seal ring (1) with a drill ( 3,5 mm) to a depth of 5
mm.
Fix fixture (3) to the ring (1) by means of the 6 screws (4)
in the kit e proceed with the removal of the ring by tightening
70151
the screw (2).
Remove tool 99360351 (2). Perform the removal of the external seal ring as shown and
Remove the engine (3) flywheel fixing screws (1) to the described in Figure 28.
engine shaft (4).

Figure 34 Figure 37
70153
Remove the screws (1) and remove the rear cover (2).
70156
NOTE Write down the screw (1) assembling position Remove the screws (1) and remove the gear (3) from the
because they exhibit different lengths. camshaft (2).
Figure 35
70154 Figure 38
Overturn the engine.
Remove the screws (2), remove the plate (3) and remove the
oil sump (1).
Figure 36
70157
Remove the screws (2) and the timing gearcase (1).
99222
NOTE Write down the screw (2) assembling position
Remove the screws (1) and remove the oil suction rose (3). because they exhibit different lengths.
Remove the screws (2) and remove the stiffening plate (4).

Assembly of components Figure 40

Figure 39
70210
70209
DIAGRAM FOR TIGHTENING THE REAR TIMING
LOCTITE 5205 SEALANT APPLICATION AREAS GEAR CASE FASTENING SCREWS
Clean accurately the timing gear case (1) and the engine Refit the case (1) to the engine block.
block. Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in
the sequence shown in the figure:
Screws M12 65 to 89 Nm
Perfect seal is only obtained by cleaning accurately Screws M10 42 to 52 Nm
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a bead
of few mm diameter.
NOTE Before any assembly operation always verify that
It shall be uniform (no clots), without air bubbles, thin the hole and screw threads have no evidence of
areas or discontinuities. wear or dirt.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint. Figure 41
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (max 10 minutes).
70211
Use a felt pen to mark the driving gear (1) tooth fitted on the
output shaft (2) having the mark () for timing on the side
surface.
NOTE Fasten screwing of the two pins to facilitate the

operation of engine driving shaft rotation.

Figure 42
Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a bead
of few mm diameter.
It shall be uniform (no clots), without air bubbles, thin
areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (max 10 minutes).
70212
Rotate the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding. Figure 45
Figure 43
Not available
On engines
F4AE0684H-E
F4HE0684E-F-J
70215
SEQUENCE FOR TIGHTENING THE FLYWHEEL

HOUSING FASTENING SCREWS
70213
Tighten the screws (1) fastening gear (2) to camshaft (3) to Refit the housing (1) to the engine block and screw the
the specified torque. fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
shown in the figure:
Figure 44 Screws M12 75 to 95 Nm
NOTE Before any assembly operation always verify that

the hole and screw threads have no evidence of
wear or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS

Figure 46 Figure 48
70152
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
70216 hoister.
Apply on the rear tang (6) of the driving shaft part (5) of Figure 49
fixture 99346253, fix it with screws (4) and key on it the new
seal ring (3).
Position part (1) on part (5) tighten nut (2) until seal ring (3)
is fully assembled into the flywheel housing box (7).
Figure 47
70218
Tighten the screws (4) fastening the engine flywheel (3) to

the output shaft. Apply tool 99360351 (2) to the flywheel
housing (1) to stop engine flywheel (3) rotation.
Figure 50
70217
Check ring gear teeth (2), if breakage or excessive wear is

found remove the ring gear from the engine flywheel (1)
using a suitable hammer and fit the new one, previously
heated to 150C for 15 to 20 minutes. Chamfering on ring 70219
gear inside diameter shall be facing the engine flywheel.
Tighten engine flywheel (2) fastening screws (1) in two
stages:
- 1st stage, tightening to 30 4 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 60 5 angle.
NOTE Tightening to angle is performed using tool

99395216.
Before any assembly operation always verify that
the hole and screw threads have no evidence of
wear or dirt.

Figure 51 Figure 54
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
Tighten the fastening screws (2) to the specified torque. LOCTITE 5205.
Figure 55
Figure 52
Clean accurately the front cover (2) surface and refit it.
70221
Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
Figure 56
Figure 53
70225
Apply on the front tang (6) of the driving shaft part (5) of
Fit the water pump (1). fixture 99346252, fix it with screws (4) and key on it the new
seal ring (3). Position part (1) on part (5), tighten nut (2) till
Tighten the screws (2) to the specified torque. complete assembly of seal ring (3) on the front cover (7).

Figure 57 Figure 60
99223 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.
Tighten the fastening screws (3) in two stages:
Figure 58 - 1st stage, tightening to 50 5 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 90 angle.
NOTE Tightening to angle is performed using tool

99395216 (4).
Fit the damper flywheel (5) and the pulley (6).

Tighten the fastening screws (7) to 68 7 Nm torque.
70227
Set the gasket (1) on the oil sump (2).
NOTE If not faulty the gasket can be reused. Figure 61

r
Figure 59
70230
Fit a new sealing ring on the speed sensor (3).

Fit the speed sensor (3) on the front cover (1) and tighten
the screw (2) to the specified torque.
70154
Fit the oil sump (1) and apply the plate (3) to it.

Figure 62 Figure 64
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). set against the engine block.
Tighten the screws (5) to the specified torque. Tighten the screws (2) to the specified torque.
Figure 63 Figure 65
70232 70139
Lubricate the sealing ring (2) with engine oil and set it on the Refit the alternator (1).
oil filter (3).
Tighten the screw (2) to the specified torque.
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3) by
turn. Figure 66
Apply a new sealing ring on the oil temperature/pressure
sensor (4) and fit it on the support (1).
Fit a new sealing ring (6) in the engine block seat.
70235
Refit the automatic belt tensioner (2).

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

Figure 67 Figure 70
70145
70320
Refit the high pressure pump (5) including the feed pump (6)
and tighten the nuts (3) to the specified torque. Fit the Refit the ECU (3) including the heat exchanger to the engine
support (4) with a new sealing ring, the timing sensor (2) with block and tighten the screws (2) to the specified torque.
a new sealing ring and tighten the relevant fastening nut (1)
to the specified torque.
NOTE Replace support elastic elements (1).
Figure 68
Figure 71
70144
Refit the air compressor (3). Tighten the screws (2) and the
nuts (1 and 4) to the specified torque. 70137
Figure 69 Apply a new gasket to the engine block and then place the
cylinder head (2) slung by the hanger brackets (1).
NOTE Before using the fixing screws again, measure them

twice as indicated in the picture, checking D1 and
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced.
D2 D1
70143
75703
Refit the hydraulic power steering pump (2) including the oil
tank (4) to the air compressor (5).
Use wrench 99355019 to tighten the fastening screws (3) to
the specified torque.

Figure 72 Figure 75

70338
70336 Fit a new sealing ring (2) lubricated with petroleum jelly and
Assemble cylinder head (1), tighten the screws (2) in three a new sealing washer (3) on injector (1).
following steps, following order and mode shown in the
figure below.
Figure 76
NOTE The angle tightening is carried out through tool
99395216 (3). Before any assembly operation
always verify that the hole and screw threads have
no evidence of wear or dirt.
Figure 73
6-cylinder engine A
70476
Tightening order layout for cylinder head fastening screws:
- 1st step pre-tightening with a torque wrench:
Screw 12x1.75x130 ( ) 35 5 Nm 70339
A Screw 12x1.75 x 150 ( ) 55 5 Nm

Fit injectors (1) on the cylinder head seats, directed so that
- 2nd step tightening with a 90 5 angle the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
- 3rd step tightening with a 90 5 angle
A = Front side Figure 77
Figure 74
4-cylinder engine A
70337
Cylinder head fastening screws tightening sequence:
- 1st stage pre-tightening, with a torque wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw12x1.75 x 150 ( ) 55 5 Nm
A = Front side
70133
- 2nd stage tightening with angle 90 5
- 3rd stage tightening with angle 90 5 Use tool 99342101 (1) to fit the injector (2) into its seat.
A = Front side Screw injector fastening screws without tightening them.
Figure 78 Figure 80
70343
91572 ROCKER ASSEMBLY COMPONENTS:

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
the position ball (5) clashes with its housing (4). Figure 81
NOTE Disassembled fuel manifolds (2) must not be used

again. Replace with new items.
Screw the fastening nuts (2, Figure 79) without locking them.
During this operation, the injector (1) shall be

moved so that the manifold (2) is properly inserted
into the fuel inlet hole (2, Figure 75). 70344
SHAFT-ROCKER MAIN DATA

Check that shaft/rocker coupling surfaces are not showing
Figure 79 excessive wear or damages.
Figure 82
32655
70342
Rocker control rods shall not be distorted; the ball seats in
Use the torque wrench to tighten gradually and alternately touch with the rocker adjusting screw and with tappets
the injector fastening screws (1) to 8.5 0.8 Nm torque. (arrows) shall not show seizing or wear; otherwise replace
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm them. Intake and exhaust valve control rods are identical and
torque. are therefore interchangeable.
Carry out the assembly of the equalisers unit , after previous

check of the components.

Figure 83 Figure 85
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:
exhaust manifold. - intake valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.
Figure 84
In order to more quickly perform the operating

clearance adjustment for rocker arms valves,
proceed as follows:
6-cylinder engine
Rotate the drive shaft, balance cylinder 1 valves and
adjust the valves marked by the asterisk as shown in
the table:
cylinder n. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *
the table:
70346
cylinder n. 1 2 3 4 5 6
Check that tappet adjusters (1) are loose to prevent their intake * * - * - -
balking on the rods (2, Figure 83) when refitting the rocker exhaust * - * - * -
assembly.
Then refit the rocker assembly consisting of: bracket (5), 4-cylinder engine
rockers (3), shafts (4) and secure them to the cylinder head Rotate the drive shaft, balance cylinder 1 valves and
by tightening the fastening screws (2) to 36 Nm torque. adjust the valves marked by the asterisk as shown in
the table:
cylinder n. 1 2 3 4
intake - - * *
exhaust - * - *
the table:
cylinder n. 1 2 3 4
intake * * - -
exhaust * - * -

Figure 86 Figure 89
70348
Smear the intake manifold (1) coupling surface with sealant 99226
IVECO No. 2992545 and fit it on the cylinder head.

Fittings of pipings (3) must be tightened with 20 Nm
torque by using special wrench 99389829 (4)
Figure 87 associated to tool 99317915 (4).
Connect the fuel pipe (2) to the rail (1) following the
procedure shown in the following figure.
99224
Fit the rail (2) and tighten the screws (1) to the specified Figure 90
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut (5) to the specified torque.
Figure 88
70126
Press the clamp (1) in arrow direction (Figure B) and connect

the pipe to the rail (2, Figure 89), reset the clamp to the initial
locking position A.
99225
Connect the fuel pipes (1) to rail (3) and injector manifolds NOTE Check proper fuel pipe connection.
(2).

Figure 91 Figure 94
70352 70355
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).
Fit a new gasket (1) on the support (2).
Figure 95
Figure 92
99229
99227
Fit the tappet cover (1) and tighten the nuts (2) to the
Fit the wiring support (2) and tighten the screws (1) to the specified torque.
specified torque.
Figure 93
Figure 96
99228 70357
Connect the electrical cables (1) to the injectors (3) and use Reconnect the exhaust manifold (2) with new gaskets.
the dynamometric wrench 99389834 (4) to tighten the Tighten the fastening screws (1) to the specified torque.
fastening nuts (2) to the specified torque.

Completion of the engine Figure 99

Figure 97
70360
70358
Fit the blow-by filter.
Reconnect the turbosupercharger (3) with a new gasket to Connect pipe (14) to tappet cover (10) and timing case (6)
the exhaust manifold (1) and tighten the fastening nuts (2) with connections (13-15) and new copper washers.
to the specified torque. Connect pipe (7) to timing case (6) connection and lock it
Connect the oil pipe (5) to the heat exchanger support (6) by the elastic clamp (8).
and secure it to the exhaust manifold (1) by screw (4). Fit a new sealing ring on pipe (11) connection and fit it on the
tappet cover (10).
Secure the pipe (11) to the tappet cover (10) with the clip
and the nut (12), connect pipe (4) to connection (5) and air
compressor (3).
Connect the pipe (2) to the pressure limiter (1) as shown in
the following figure.
Figure 98
Figure 100
70134
Connect the air duct (1) to the turbosupercharger (3) and 70126
lock it by clamp (2).
Secure the air duct (1) to the alternator support by screws Press the clamp (1) in arrow direction (Figure B) and connect
(4). the pipe.
Reset the clamp to the initial locking position A.
NOTE Check proper fuel pipe connection.

Figure 101
78670
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air temperature/pressure sensor - 8. Timing sensor -
9. Fuel heater and fuel temperature sensor - 10. Pressure regulator - 11. EDC7 control unit.
Reconnect the engine cable by connecting injector wiring (6) Apply to engine lifting hooks the lifting rig 99360555, hook
connectors (1); (7) air pressure/temperature sensor; (3) rail the latter to the hoister and remove the engine from the
pressure sensor; (11) control unit; (10) high pressure pump revolving stand. Remove the brackets 99361037.
sensor; (8) timing sensor; (2) engine coolant temperature
sensor on thermostat; (5) engine speed sensor.

Figure 102 Figure 104
70362
70128
Form the right side: Refit the bracket (2) including the fuel filter support (1) to the
engine block, tighten the screws (3) to the specified torque.
Refit the starter (5) to the flywheel housing (4) and tighten
the fastening nuts to the specified torque.
Fit the oil pipe (3) with a new sealing ring into the engine Figure 105
block and secure it to the turbosupercharger (1) by the
screws (2) tightened to the specified torque.
Figure 103
70125
Screw manually the fuel filter to the support (1), screw the
filter by turn, connect the pipes (2-3-4) to the relevant
support connections (1) as shown in the following figure.
Figure 106
70127
From the left side:

Connect the fuel pipe (2) to rail and to high pressure pump
(9), secure it by screws (4 and 6) tightened to the specified
torque.
Pipe connections (2) shall be tightened to 20 Nm

torque using the proper dynamometric wrench
99389834.
Connection (7) shall be tightened by holding at the 70126
same time the high pressure pump hexagon (10).
When removed pipe (2) shall always be replaced. Press the clamp (1) as shown in figure B.
After disconnecting the pipe, reset the clamp (1) to the initial
Connect pipe (3) to connection (4) and air locking position A, to prevent deformations.
compressor (8). When refitting is over, fill engine with the prescribed
lubricating oil in the specified quantity.

Checks and inspections
Check proper fuel pipe connection.

!
Start the engine and leave it running just above the

idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:
- that there are no water leaks from the connecting

sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- check carefully the connection between the low
pressure fuel pipes and the relevant connectors as
specified in paragraph Main servicing operations to be
performed on engine fitted on vehicle;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes;
- check also proper operation of the warning lights set on
the instrument panel and of the equipment
disconnected when engine was removed.

PART TWO - ELECTRICAL EQUIPMENT


LOCATION OF THE MAIN ELECTRICAL COMPONENTS

Engine F4AE0481 B C D E F
A
Figure 107
M L I H G 101585
ENGINE VIEW LEFT SIDE

A. Coolant temperature sensor - B. Electrinic injection electro valve - C. Engine preheat resistor - D. Fuel pressure sensor
- E. Oversupply air temperature/fuel pressure sensor - F. Hydraulic control low fluid level indicator - G. Distribution pulse
sensor - H. Fuel pressure adjuster electro valve - I. Fuel temperature sensor - L. EDC 7 electronic center -
M. Engine rpm sensor.
Figure 108
D C B A 50277
ENGINE VIEW EIGHT SIDE

A. Alternator - B. Oil temoerature/pressure sensor - C. Oil level transmitter - D. Starter motor.
Engine F4AE0681
A B C D E F
Figure 109
G
H
I
L 50339
M
ENGINE VIEW LEFT SIDE
A. Coolant temperature sensor - B. Electrinic injection electro valve - C. Engine preheat resistor - D. Fuel pressure sensor
- E. Oversupply air temperature/fuel pressure sensor - F. Hydraulic control low fluid level indicator - G. Distribution pulse
sensor - H. Fuel pressure adjuster electro valve - I. Fuel temperature sensor - L. EDC 7 electronic center -
M. Engine rpm sensor.
Figure 110
B
C
50338
D
ENGINE VIEW EIGHT SIDE
A. Alternator - B. Oil temoerature/pressure sensor - C. Oil level transmitter - D. Starter motor.

Overview of sensors
Figure 111
50367
Key
Ref. Description
1 Coolant temperature sensor
2 Electro-injector
3 RAIL pressure sensor
4 Air temperature/pressure sensor
5 Power steering level sensor
6 Timing sensor
7 Fuel temperature sensor
8 EDC7 control unit
9 Crankshaft sensor
10 Engine oil level transmitter
11 Engine oil pressure/temperature sensor
12 Pre-post hearing resistance

EDC 7 electronic control unit
Figure 112
C A
50351
A. Injector connector - B. Frame connector - C. Sensor connector.

The control unit is fitted onto the engine via a heat exchanger by means of elastic blocks which reduce the vibrations transmitted
to the unit by the engine.
The main relay which is normally used to power the system is located inside the control unit itself.

Electroinjectors connector A
Figure 113
12 16
6 11
1 5
50350
Cable Cable
ECU
Colour Colour Function (4 cylinders) Function (6 cylinders)
Pin
(4 cylinders) (6 cylinders)
1 - - - -
2 - - - -
3 - RU - Cylinder 2 injector
4 WP WP Cylinder 4 injector Cylinder 3 injector
5 - WV - Cylinder 4 injector
6 - RW - Cylinder 2 injector
7 - - - -
8 - - - -
9 RG RG Cylinder 1 injector Cylinder 1 injector
10 UN UN Cylinder 2 injector Cylinder 6 injector
11 UG UG Cylinder 3 injector Cylinder 5 injector
12 WR WR Cylinder 4 injector Cylinder 3 injector
13 RY RY Cylinder 1 injector Cylinder 1 injector
14 - W Cylinder 4 injector
15 UO UO Cylinder 2 injector Cylinder 6 injector
16 UY UY Cylinder 3 injector Cylinder 5 injector
Colour legend
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange

Sensors connector C
Figure 114 6 8 16 9 15 22
4
Colour legend 5
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange
1 3 23 30 36 29
50350
ECU Cable
Function
Pin Colour
14 - -
5 NW Ground for pressure regulator
6 - -
7 NP Control for pressure regulator
8 - -
9 PY Power supply for engine oil temperature pressure sensor
10 NY Power supply for air pressure temperature sensor
11 - -
12 GY Power supply for rail pressure sensor
1316 - -
17 YR Ground for fuel temperature sensor
18 YN Ground for coolant temperature sensor
19 PN Ground for engine oil temperature pressure sensor
20 GN Power supply for rail pressure sensor
21 N Power supply for air pressure / temperature sensor
22 - -
23 U Timing sensor
24 U Crankshaft sensor
25 R Crankshaft sensor
26 - -
27 GO Signal from rail pressure sensor
28 NG Signal from air pressure sensor
29 UO Signal from air temperature
30 R Ground for timing sensor
3132 - -
33 PO Signal from engine oil temperature sensor
34 YU Signal from diesel oil temperature sensor
35 PG Signal from engine oil pressure sensor
36 YO Signal from coolant temperature sensor

Connector for powering components and for the functions envisaged in application B
Figure 115
71 89 72 54 6 11
1
7
12
53 35 18 36 17
50350
ECU
Cable Function
Pin
1 8150 Direct positive from battery
2 0087 Negative for diesel oil filter heating relay
3 0000 Ground
4 0094 Positive for exhaust brake solenoid valve/control relay/pre-post hearing resistance
5 9068 Air-conditioning system remote-control switch drive signal
6 - -
8 7777 Positive for clutch sensor/Blink Code button/exhaust brake button/brake pedal switch on the
duplex (*)
9 0000 Ground
10 9067 Air-conditioning system remote-control switch drive signal (*)
11 9966 Negative for exhaust brake solenoid valve (*)
14 0000 Ground
15 0000 Ground
16 8885 Negative to turn on thermostarter relay
17-18 - -
19 0150 Negative for start-up buttons/stop from engine compartment/gearlever in neutral/hand brake
ON (*)
20 8037 Positive from key-operated switch at starting stage (+50)
21 8159 Positive from exhaust brake switch (*)
22 - Control from brake pedal position exhaust brake selector
23-25 -
26 - -
27 5162 Positive from blink code button (*)
28 5535 Positive for BLINK CODE LED warning light (*)
29 - -
30 1198 L line for 30 pin tester connector (pin 1)
31 2298 Line K for 30 pin tester connector (pin 2)
32 0169 PTO (*)
33-35 - -
36 8837 Positive for diesel oil filter heating relay
37 8888 Positive for starter motor
38 - -
(*) depending on the vehicle application.

ECU
Cable Function
Pin
39 8051 Positive from key-operated switch, +15
40 0027 Engine brake exclusion with ABS system engaged (*)
41 9907 Signal from handbrake engaged switch
42 6666 Signal from cab unhooked switch (*)
43 0115 Positive from gearbox on neutral switch (*)
44 9905 Positive from start button from engine compartment (*)
45 9906 Positive from stop button from engine compartment (*)
46 - -
47 - -
48 5198 Engine phase signal for diagnosis connector (pin 23)
49 5584 Signal for electronic rev counter
50 0158 Negative from accelerator pressed switch
51 - -
52 6109 CAN line (white wire) L
53 6108 CAN line (green wire) H
54 - -
55 5158 Positive for accelerator pedal position sensor
56 - -
57-58 - -
59 - -
60 - -
61 - -
62 5602 Clutch sensor (*)
63 - -
64 0535 Negative for BLINK CODE LED (*)
65 - -
66 - -
67-71 - -
72 0159 Signal from accelerator pressed switch
73 0159 Redundant signal from accelerator pressed switch
74 5155 -
75 - -
76 8158 Positive from secondary brake pedal switch (*)
77 5502 Signal from second speed limiter switch (*)
78 9071 Air-conditioning system (*)
79 - -
80 8153 Brake light signal
81 0157 Ground for accelerator pedal position sensor
82 - -
83 5157 Signal from accelerator pedal position sensor
87 5120 PTO (*)
(*) depending on the vehicle application.

Figure 116 Air temperature/pressure sensor (85156)

This component combines a temperature and a pressure
sensor.
It is fitted to the intake manifold so that, by measuring the
maximum quantity of air taken in, it makes it possible to
determine the exact amount of fuel to be injected at each
cycle.
This sensor is connected to the control unit via pins 21/C -
29/C - 10/C - 28/C.
It is powered at 5 V.
The output voltage is proportional to the pressure (or
temperature) measured by the sensor.
Pins 21/C - 29/C Temperature
Pins 10/C - 28/C Pressure
50324
EXTERIOR VIEW OF SENSOR

Oil pressure/temperature sensor (42030)
Figure 117 This component is identical to the air temperature/ pressure
sensor
It is mounted horizontally on the engine oil filter.
It measures the engine oil temperature and pressure.
It is connected to the control unit via pins 19C - 33C - 9C -
35C.
The values sent are transmitted to the EDC control unit
which, in its turn, controls the indicator on the dash (indicator
/ low pressure warning light).
Pins 19/C - 35/C Temperature
Pins 9/C - 33/C Pressure
The engine oil temperature is used by the EDC unit only.
50323
CONNECTION CONNECTOR
Figure 118 Control unit Pin

Ref
Ref. Description
Oil Air
1 Ground 19C 21C
2 Temp. signal 35C 29C
3 +5 9C 10C
4 Press. signal 33C 28C
50344
WIRING DIAGRAM

Crankshaft sensor (48035)

This inductive type sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which
close through the openings of a toothed wheel force fitted to the crankshaft. The same signal is used to manage the electronic
rev counter.
It is connected to the control unit via pins 25C - 24C.
The sensors resistance value is ca 900 .
Supplier BOSCH
Tightening torque 8 2 Nm
Timing system sensor (48042)

This inductive sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which
close through the holes situated in gears force fitted to the camshaft. The signal generated by this sensor is used by the ECU
as the injection timing signal.
Though it is similar to the crankshaft sensor, it is not interchangeable with the latter since its outer shape is different.
The sensors resistance value is ca 900 .
Supplier BOSCH
Tightening torque 8 2 Nm
Figure 119 Figure 120
180 15
2
3 1
8518 8519
TECHNICAL VIEW WIRING DIAGRAM

Figure 121
8520
PERSPECTIVE VIEW
Control unit Pin

Ref
Ref. Description
48035 48042
1 Signal 25C 23C
2 Signal 24C 30C
3 Shielding

Fuel pressure sensor (85157)

Fitted to one end of the rail, it measures the pressure of the existing fuel in order to determine the injection pressure.
The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
It is connected to the control unit on pins 20C - 27C - 12C.
It is powered at 5 V.
Figure 122
A - Distribution manifold
1 2 3
B - Fuel pressure sensor (85157)
Ref. Description Control unit pin

1 Ground 20C
2 Signal 27C
3 Power 12C

Figure 123 Coolant temperature sensor (47035)

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.
Its resistance at 20 C = 2.50 K.
It is placed in the upper engine part.
1 2 50321
Figure 124 Fuel temperature sensor (47042)

This sensor is identical to the previous one.
It measures the temperature of the fuel and transmits a signal
to the control unit reflecting the thermal conditions of the
diesel oil.
Its resistance at 20 C = 2.50 K.
The ECU manages the relay for the control of filter heating
when the temperature of the fuel drops to 36 C.
50322
ECU pin
Ref
Ref. Description
47035 47042
Figure 125
1 Ground 18C 17C
2 Signal 36C 34C
50348
A. Fuel temperature sensor B. Filter heating resistance

Fuel pre-filter Figure 126

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.
2 5
If the warning light lights up, take action immediately

to remove the cause, as common rail system
components deteriorate quickly if there is water or
impurities in the fuel.
3
000910t
Tightening torque
Bleed screw 2 6 to 8 Nm
Filtering cartridge 3 18 0.1 Nm
Sensor 4 0.8 0.1 Nm

Pre-post heating resistance Figure 127

B
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. A
Its resistance is ~ 0,5 .
A. - B. Connecting terminals
Starter Figure 128

The starter is usually driven by the starting block assembled
to the vehicles dashboard and provides positive voltage to pin
B20 of the EDC.
74166
A- Feeding relay of the starter

Pressure regulator - high pressure pump Figure 129

Pump with 3 radial pistons controlled by the timing gears,
requiring no phase adjustment, with rotor type feed pump
fitted to the back.
A. Connection between fuel discharge outlet and filter
support
B. Connection for fuel inlet from control unit heat
exchanger
C. Connection for fuel inlet from fuel filter
D. Connection between fuel outlet from feed pump and
filter
E. Connection between fuel outlet and rail
1. High pressure pump
2. Feed pump
3. Pressure regulator (N.O. solenoid valve modulated by
the control unit by means of PWM signal).
The pressure regulator is located at the inlet of the
high-pressure pump on the low-pressure circuit; its function
is to modulate the quantity of fuel to feed to the high-pressure
pump on the basis of commands received from the electronic
control unit.
It basically consists of the following parts:
- trapezoidal section shutter;
- valve control pin;
- pre-charging spring; A
- coils.
1 B
In the absence of the control signal, the pressure regulator is
normally open, and hence the high pressure pump is in its C
maximum delivery conditions. 3
The control unit modulates a PWM control signal which
reduces, to a greater or lesser extent, the section carrying the 2
D
fuel to the high pressure pump.
This component cannot be replaced individually and hence it E
cannot be taken down.
The amount of fuel feeding the high pressure pump is metered
by a proportional valve situated on the low pressure system
- managed by the EDC 7 control unit.
000912t
The delivery pressure to the rail is modulated between 250
and 1400 bar by the control unit working on the pressure
regulator solenoid valve.
It is a N.O. solenoid valve
Its resistance is ca 3.2 .
It is connected to the control unit via pins C5 - C7.

Electroinjector Figure 130

The injector features a traditional construction, save for the
fact that it has no needle return springs.
The electroinjector essentially consists of two parts:
- actuator - atomiser consisting of a pressure rod 1, a
needle 2 and nozzle 3;
- control solenoid valve, consisting of a coil 4 and pilot valve
5.
The solenoid valve controls the rise of the atomiser needle.
Injection starts
Upon being energised, coil 4 moves up the shutter 6. 50336
The fuel contained in the control volume 9 flows back

towards line 12 resulting in a pressure drop in the control
volume 9.
At the same time, the fuel pressure in the pressure chamber Figure 131
8 moves up the needle 2 resulting into the fuel being injected
into the cylinder.
Injection ends
When coil 4 is de-energised, the shutter 6 closes again so as
to re-create a balance of forces which moves the needle back
into its closed position and stops the injection process.
This is a N.O. solenoid valve.

Individually connected to EDC control unit on connector A.
The resistance of the coil of each individual injector is 0.56
0.57 .
000933t
INJECTION IN RESTING POSITION

1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil - 5. Pilot
valve - 6. Ball shutter - 7. Control area - 8. Pressure
chamber - 9. Control volume - 10. Control line - 11. Feed
line - 12. Control fuel outlet - 13. Electrical connection -
14. Spring - 15. High pressure fuel inlet.

Connecting connectors
Figure 132
1 2 3
50343
WIRING DIAGRAM OF THE CONNECTIONS
Figure 133
1 2 3 4 5 6
1 2 3
FAN SIDE
50349
Ref. Description Control unit Pin

1 Cylinder 2 injector 3A
CONNECTOR 1
3 Cylinder 1 injector 13 A
CONNECTOR 2
CONNECTOR 3


PART THREE - TROUBLESHOOTING


PREFACE Every time there is a breakdown claim and this breakdown is

actually detected, it is necessary to proceed inquiring the
A successful troubleshooting is carried out with the electronic unit in one of the ways indicated and then proceed
competence acquired by years of experience and attending with the diagnostic research making trials and tests in order to
training courses. have a picture of the working conditions and identify the root
causes of the anomaly.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper In case the electronic device is not providing any indication, it
consideration using them to acquire any useful information to will be necessary to proceed relying on the experience,
focus the intervention. adopting traditional diagnosis procedures.
After the detection of the existing anomaly, it is In order to compensate the operators lack of experience in
recommended to proceed with the operations of this new system, we are hereby providing the USERs
troubleshooting by decoding the auto-troubleshooting data GUIDELINE FOR TROUBLESHOOTING in the following
provided by the EDC system electronic central unit. pages.
The continuous efficiency tests of the components connected The GUIDELINE is composed of three different parts:
to, and the check of working conditions of the entire system - Blink Code, relating to the anomalies identified by the
carried out during working, can offer an important diagnosis gearbox, mainly of electric and electrical nature;
indication, available through the decoding of the - Troubleshooting guide using PT-01 portable tester.
failure/anomaly codes issued by blinking of the failure led: Tool identified as IVECO p/n 8093731.
the blink-code (whether programmed). - Guideline for troubleshooting without blink code, divided
Please consider that the interpretation of the indications per symptoms, describing all possible anomalies not
provided by the blink-code is not sufficient to guarantee the detected by the electronic gearbox, often of mechanical
solution to the existing anomalies. and hydraulic nature.
Using IVECO processing instruments, it is also possible to

establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input an
enquiry relying on memory files, in order to achieve any further
necessary information to identify the origin of the anomaly.
Any kind of operation on the electronic center unit
must be executed by qualified personnel, duly
authorized by IVECO.
Any unauthorized tamper will involve decay of

after-sales service in warranty.

BLINK-CODE - GENERAL INFORMATION Detectable failures

Sensors:
Anomaly warning led
The ECU is continuously screening, by complex - Air temperature boosting
auto-diagnosis routine procedures, its own working - Fuel temperature
conditions as well as the conditions of the components
connected to, and of the engine. - Pressure boosting
The detection of the anomaly provokes the lightening up of - Unit pressure
the warning led on the monitor and drive board, with id.
modes allowing a first selection of the problem according to - Flywheel
the level of importance. (Review the Users Manual of the - Camshaft
vehicle equipped with NEF engine to know the precise
position of the pushbutton and of the led). - Fuel pressure
Led in off position (no light): no anomalies detected or small - Quantity of air flow sucked
entity anomaly with no prejudice safe Engine working:
working conditions.
Lighted Led: significant anomaly. In this condition it is - Engine runaway speed rate
recommended to go to a diagnosis centre. - Injectors
Blinking led: serious anomaly requiring immediate repair - Fuel pressure driving system
intervention.
- Pre-post heating driving system
The emission of the codes of anomaly detected by Electro-valves:
auto-troubleshooting and saved in ECU memory starts after - Fuel pressure gauge
having pushed and released the pushbutton. (Review the
Users Manual of the vehicle equipped with NEF engine to Rel:
know the precise position of the pushbutton and of the led). - Main rel
The led, usually aside the pushbutton, will signal the light blink
codes by to series of emissions with different frequency, - Fuel electro-pump
highlighting the decimal numeration digits indicating the - Heated fuel filter
anomaly.
Feed tension
The slow blinking identify the unit where the anomaly occurs
(engine, injectors...) the fast blinking identify the specific failure. Leds:
A each push and release of the pushbutton, one only memory - Pre-post heating
code will be sorted. Therefore it is necessary to repeat the
procedure until when an identical failure data to the first one Gearbox:
received will be released as indication that all the failure file - Non-valid data set
memory has been analysed.
- Incorrect saving of files in memory
In case of no filed anomalies in memory, the led will light up
when the pushbutton is pressed and will then turn off aprx. 1 - Power control bench 1
second after release of the pushbutton without originating
- Power control bench 2
blinking.
Note: applying to the blink code troubleshooting procedure, - Internal failure (Gate Array)
it is possible to obtain information relating to currently - Sensor feed
occurring failures as well as to other anomalies occurred in the
past and not existing any more at present status. - Internal failure (re-start)
Therefore it is absolutely necessary, at the end of every repair - Incorrect engine disconnection
intervention, to clear the failure file memory in order to avoid
that any future troubleshooting operation will detect any - Defective EEPROM
solved anomaly whose root cause has already been corrected.
In the current equipment, clear operation is set pressing the
blink code pushbutton while the key change over switch is in
OFF position and keeping it pressed for 4 to 8 seconds after
turning the key change over switch in ON position.
Wait at least for 10 seconds before switching off the key Data, features and performances are valid only if the
change over switch. setter fully complies with all the installation
prescriptions provided by IVECO.
The evidence that the clearing operation has been correctly
made shall be obtained proceeding to switch OFF and ON Furthermore, the users assembled by the setter shall
again the key change over switch and further require blink always be in conformance to couple, power and
code troubleshooting, that shall terminate with no display of number of turns based on which the engine has been
blink code. designed.

BLINK-CODE (SOFTWARE 3.3_1 VERSION) In case of anomaly identified by intermitted blinking, that
Recovery means detected by the ECU and not existing any more, the
reduction of duty performances shall be active until
Following from the detection of significant or serious anomaly,
disconnection of the engine.
the ECU also drives the set up of specific strategies to allow
safe utilisation of the engine and to limit some injection The normal working conditions shall be recovered only at the
parameters within prescribed levels, based on the importance following start-up, while the anomaly data will be saved in
of the problem. the failure file memory.
The software applications currently in use, provide for four
safety levels characterised by the reduction of the vehicles
duty performances.
The table relating to the blink-codes reports some values of
power reduction, that actually indicate the limitation of duty
performances, automatically set by the gearbox based on the
anomaly occurring.
Blink-Code EDC Led Description of anomaly Power reduction

ENGINE
2.1 On Signal from cooling liquid temperature sensor 0
2.2 Off Signal from air temperature sensor, boosting 0
2.3 Off Signal from fuel temperature sensor 0
2.4 On Signal form sensor of pressure boosting 0
2.5 Off Signal from atmospheric pressure sensor 0
2.6 On Signal from oil pressure sensor 0
2.7 Off Signal from oil temperature sensor 0
2.8 Off Signal from heated filter driving rel 0
2.9 Off Signal from pre-post heating resistor driving rel 0
3.7 On Battery tension 0
3.8 Off Alert led pre-post heating 0
3.9 Off Pre-post heating resistor 0
INJECTORS
5.1 On Electro-valve injector of cylinder 1 0
5.5 On Electro-valve injector of cylinder 5 (*) 0
5.6 On Electro-valve injector of cylinder 6 (*) 0
5.7 On Power stage 1 (cylinders 1-4) 0
5.8 On Power stage 2 (cylinders 2-3) 0
Power reduction:
0 = no power reduction
1 = performance comparable to equivalent engine but in suction stroke
2 = 50% of couple
3 = Limited engine speed
4 = Engine disconnection (*): not applicable for the 4 cylinders
Blink-Code EDC Led Description of anomaly Power reduction

ENGINE RUNNING
6.1 On Signal from engine driving shaft sensor 2
6.2 On Signal from camshaft sensor 2
6.3 On Reliability of engine speed signal 0
6.4 Blinking Engine runaway speed rate 0
6.5 Off Rel of the starter 0
ENGINE RUNNING
7.2 Off CAN Line (For vehicles equipped with electrical system 0
provided with CAN Line)
7.6 Off Oil pressure alert led 0
FUEL PRESSURE
8.1 Blinking Control fuel pressure 3
8.2 Blinking Fuel pressure signal 3
8.3 Blinking Pressure regulating electro-valve 3
8.4 Blinking Intervention to double stage boosting valve 3
8.5 Blinking Rail Min/Max pressure failure 4
EDC
9.4 On Main rel 0
9.6 On Gearbox disconnection procedure 3
9.7 On Sensor feed 0
Power reduction:
0 = no power reduction
1 = performance comparable to equivalent engine but in suction stroke
2 = 50% of couple
3 = Limited engine speed
4 = Engine disconnection

POSSIBLE DERIVING
POSSIBLE CAUSE
BLINK ANOMALIES RECOMMENDED TESTS OR
EDC LED (*) = if available in the equip- REMARKS
CODE (*) = if available in the equip- INTERVENTION
ment
NEF ENGINES
ment
Print P1D32N001 E
2.1 On Short circuit of the sensor of en- Verify component correct work-
gine cooling liquid temperature, in ing and its resistor (2,5 kOhm at
positive or earth or in open cir- 20 C). In case the component
cuit. works, proceed checking the con-
nection between the sensor and
the gearbox connector to pin
C18 - C36.
2.2 Off Short circuit of the sensor of air Readout of parameters using
combustion temperature, in posi- multimeter. Verify correct work-
tive or earth or in open circuit. ing of the component and of its
(The sensor is integrated with the resistor between pin 1 and 2 (R =
air pressure sensor). 2,5 kOhm at 20 C). If the sensor
is working, proceed checking the
connection between the sensor
and the EDC connector to pin
C21 - C29.
2.3 Off Short circuit of the sensor of fuel Readout of parameters directly
temperature, in positive or earth on the sensor using multimetre .
or in open circuit. (R = 2,5 kOhm at 20 C). If the
sensor is working, proceed check-
ing the connection between the
sensor and the EDC connector to
pin C17 - C34.
2.4 On Short circuit of the sensor of air Readout of parameters using
combustion pressure on suction multimetre verifying feeding ten-
collector, in positive or earth or in sion to the sensor. (aprx. 5V).
open circuit; or fed by tension out In case of tension within specifica-
of specification. tion, check the wiring harness and
the connection between the sen-
sor and the EDC (Pin C10-C28).
SECTION 3 - APPLICATION TO VEHICLES
59
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60
POSSIBLE DERIVING
POSSIBLE CAUSE
ment
Base - April 2007

ment
2.5 Off Short circuit of the sensor of air Apply for customer assistance for The painting of the engine /EDC
pressure (integrated in EDC) in the intervention on the EDC. The may inficiate on the correct work-
positive or earth or in open circuit sensor is integrated in the EDC ing of the sensor.
and is not replaceable singularly.
2.6 On Short circuit of the sensor of en- Readout of parameters using
gine oil pressure, in positive or multimetre verifying feeding ten-
earth or in open circuit. (The sen- sion to the sensor. (aprx. 5V).
sor is integrated with the oil tem- In case of tension within specifica-
perature sensor). tion replace the sensor. In case of
tension out of specification, check
the wiring harness and the con-

nection between the sensor and
the EDC (Pin C9-C35).
2.7 Off Short circuit of the sensor of en- Sensor Readout using multi-
gine oil temperature. (integrated metre, between pin 1 and 2. (R =
with the oil pressure sensor) , in 2,5 kOhm at 20 C).
positive or earth or in open cir- If the sensor is working, proceed
cuit. checking the connection be-
tween the sensor and the EDC
(pin C19 - C33).
2.8 Off Incorrect working of the fuel filter Verify rel working status using
heating rel. the troubleshooting device. If the
result is negative, replace the rel
and test again.
If the anomaly still persists, check
the wiring harness and the con-
nections between rel and EDC
connector (pin B2 - B36)
NEF ENGINES
Print P1D32N001 E
POSSIBLE DERIVING
POSSIBLE CAUSE
ment
ment
NEF ENGINES
Print P1D32N001 E
2.9 Off Incorrect working of the pre-post Difficult starting with low external Verify rel working status using
heating drive rel. temperature, exhaust fumes im- the troubleshooting device.
mediately after starting. Check the correct working of the
rel (R= aprx. 15 Ohm).
In case the rel works, check the
wiring harness and the connec-
tions between rel and EDC con-
nector (pin B4 - B16)
3.7 On Signal for battery tension too high Idling accelerated. Carry out the due controls on the Eventually, the problem might not
or too low. battery and on the recharge sys- depend on the too high or too
tem. low tension but due to the incor-
rect detection of tension by the
If no anomaly is detected check EDC.
the efficiency of the Earth points
and the absence of fouling or ox-
idation on the feed wiring con-
nectors of the EDC.
3.8 Off Defective pre-heating led or wir- Led always on light even with Verify working status using
ing harness short circuit in posi- starting key in off position or al- troubleshooting device.
tive or earth or in open circuit. ways off. If the result is negative replace the
Possible difficult starting (with low led and drive troubleshooting
external temperature) and ex- operation again. If the failure per-
haust fumes at starting. sists check connections and wir-
ing harness between led and EDC
(pin B46)
3.9 Off Pre-heating has not been working Possible difficult starting (with low Using the multimetre, verify conti- Pre-heating is not working.
correctly. external temperature) and ex- nuity of pre-heating resistor in the
haust fumes at starting. suction collector (R = aprx. 0,5
Ohm).
If the component is working,
check the wiring harness and the
connection between the resistor
and the relevant driving rel.
61
Base - April 2007

62
POSSIBLE DERIVING
POSSIBLE CAUSE
ment
Base - April 2007

ment
5.1 On Electrical problem with Injector n. Engine running with one cylinder Check the correct couple lock Such failure may generate power
1 less. (1,5 +/- 0,25 Nm) of the cables stage insufficiency (in the EDC )
the fixing nuts to the injector elec- feeding the electro-injector, in-
tro-valve. volving working of only half of the
Verify the working status of the cylinders as a consequence, and
injectors bobbin (R = aprx. 0,56 memorisation of the error 5.7.
- 0,57 Ohm) and replace the in-
jector if defective.
With new working bobbin, pro-
ceed checking the wiring harness
and the connections between

electro-valve and EDC connector
(pin A9-A13) through the con-
nector 1 of the pin overhead 3
and 4.
5.2 On Electrical problem with injector Engine working with one cylinder Check the correct couple lock Such failure may generate power
n.2. less. (1,5 +/- 0,25 Nm) of the cables stage insufficiency (in the EDC )
injectors bobbin (R = aprx. 0,56 memorisation of the error 5.7
- 0,57 Ohm) and replace the in- within 6 cylinder engines and 5.8
jector if defective. within 4 cylinder engines.
and 3.
NEF ENGINES
Print P1D32N001 E
POSSIBLE DERIVING
POSSIBLE CAUSE
ment
ment
NEF ENGINES
Print P1D32N001 E
n.3. less. (1,5 +/- 0,25 Nm) of the cables stage insufficiency (in the EDC )
injectors bobbin (R = aprx. 0,56 memorisation of the error 5.7.
and 4.
n.4. less. (1,5 +/- 0,25 Nm) of the cables stage insufficiency (in the EDC)
and 2.
63
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64
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POSSIBLE CAUSE
ment
Base - April 2007

ment
5.5 On Electrical problem with injector n. Engine working with one cylinder Check the correct couple lock Such failure may generate power
5. less. (1,5 +/- 0,25 Nm) of the cables stage insufficiency (in the EDC )

and 4.
5.6 On Electrical problem with injector n. Engine working with one cylinder Check the correct couple lock Such failure may generate power
6. less. (1,5 +/- 0,25 Nm) of the cables stage insufficiency (in the EDC)
and 2.
NEF ENGINES
Print P1D32N001 E
POSSIBLE DERIVING
POSSIBLE CAUSE
ment
ment
NEF ENGINES
Print P1D32N001 E
5.7 On EDC output stage driving power Engine running with only 2 (3) Clear the failure memory and test It can happen if the external part
to electro-injector couples 2 and working cylinders. again. of the gearbox is driven to short
3. If the failure persists, and only circuit with the battery positive
after having excluded injector de- pole (accidental bridge made by
fect, eventually replace the EDC wrench or other metallic object).
with a new one re-programmed
by IVECO.
5.8 On EDC output stage driving power Engine running with only 2 (3) Clear the failure memory and test It can happen if the external part
to electro-injector couples 4-5-6. working cylinders. again. of the EDC is driven to short cir-
If the failure persists, and only cuit with the battery positive pole
after having excluded injector de- (accidental bridge made by
fect, eventually replace the EDC wrench or other metallic object)
with a new one re-programmed
by IVECO.
6.1 On Driving shaft sensor: no signal or Engine start requires more time Using the multimetre, verify the The failure is not detected when
unreliable signal. than usual. sensors resistor value as well as the engine is not running. If the
Power reduction and noise in- its working status (R = aprx. 900 driving shaft signal is not regularly
crease since the EDC is not con- Ohm). working, it is necessary to rely on
trolling the pre-injection and the If the component is working, and the speed signal of the camshaft
timing. the anomaly persists, check the sensor.
Engine working relies on recovery wiring harness
parameters. between the sensor and the EDC
connector (pin C24 - C25).
6.2 On Camshaft sensor: no signal or Difficult starting in all conditions. Using the multimetre, verify the The failure is not detected when
unreliable signal. Power reduction. sensors resistor value as well as the engine is not running. If the
its working status (R = aprx. 900 camshaft signal is not regularly
Ohm). Verify correct assembly of working, it is necessary to rely on
the sensor: replace it if defective. the phase signal of the driving
If the component is working, and shaft sensor.
the anomaly persists, check the
wiring harness between the sen-
sor and the EDC connector (pin
C24 - C25).
65
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POSSIBLE CAUSE
ment
Base - April 2007

ment
6.3 On Unreliable survey of engine Difficult starting in all conditions. Using the multimetre, verify the The failure is not detected when
speed. Power reduction. sensors resistor value as well as the engine is not running. If the
its working status (R = aprx. 900 camshaft signal is not regularly
Ohm). Verify correct assembly of working, it is necessary to rely on
the sensor: replace it if defective. the phase signal of the driving
If the component is working, and shaft sensor.
the anomaly persists, check the
wiring harness between the sen-
sor and the EDC connector (pin
C24 - C25).
6.4 Blinking Engine runaway speed rate. Verify the root-causes that might It is not a failure referred to one
have generated a sudden load loss component but the alert for an
to the engine, involving conse- actual engine runaway speed rate.
quent runaway speed rate.
Runaway speed rate might also
depend directly from the oper-
ator addicted to driving the ve-
hicle, which the engine is installed
to.
6.5 Off Incorrect working of starter rel. The engine does not start or dis- Using multimetre, check the rel.
connects. In case the component works,
connection between rel and
EDC connector (pin B27).
6.6 Off Signal from EDC to engine speed The engine speed indicator does Check the wiring harness and the
indicator. not work. connection between engine
speed indicator and EDC con-
nector (pin B49).
6.8 Off Synchronisation signal with Difficulties in communication be- Check the wiring harness and the
troubleshooting device. tween troubleshooting device connection between pin 23 of the
and EDC. troubleshooting tap end EDC
connector to in B48.
NEF ENGINES
Print P1D32N001 E
POSSIBLE DERIVING
POSSIBLE CAUSE
ment
ment
NEF ENGINES
Print P1D32N001 E
7.2 Off (*) (*) Check wiring harness, connection On the equipment that is not pro-
and locking resistor (120 Ohm) vided with the CAN line, this is
CAN Line Hardware defect. Possible incorrect working or blanked by a 120 Ohm resistor.
error alert signal of the electronic
control devices connected via
CAN Line.
7.6 Off Defective oil pressure led lamp, or Switching the key contact to ON Verify working status using
wiring harness short circuit in position, the led is not lighting on troubleshooting device. If the re-
positive or earth or in open cir- or keeps lighted. sult is negative replace the led and
cuit. drive troubleshooting operation
again.
In case of led correct working,
connections and wiring harness
between led and EDC connector
(pin B63) and the correct feed of
the gauge with incorporated led.
8.1 Blinking Fuel pressure modulation defect. Important power reduction. Verify if the fuel arrives directly to Further details relating to checks
the high pressure pump (no and controls to be made on the
(the gearcase must modify too If the injector remains locked outlets in the sucked line, clogged fuels circuit are available in
much the control signal at the open every now and then, filter or pre-filter, occluded pipes, Troubleshooting section 2.
pressure regulator in order to sudden and temporary decay of consistent fuel leakage).
module the calculated pressure the performances, with possible
in the rail). start-up and proper operation at Verify there is no fuel leakage or
low rpm and loads but the loss from the high pressure line
trouble shows up again with running from the pump and the
high rpm and loads. rail or from the cylinders head.
In case a flow limiter has been

activated, detect and identify the
injector that is not working any
more and replace it together with
its relevant high pressure filler.
67
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POSSIBLE DERIVING
POSSIBLE CAUSE
ment
Base - April 2007

ment
8.2 Blinking Rail pressure sensors signal short Significant power reduction. Readout of parameters using
circuit in positive or earth or in troubleshooting device.
open circuit.
Check the wiring harness and the
connection between the sensor
and the EDC Connector (Pin C12
-C20 -C27).
If everything is in order, replace

the sensor.
8.3 Blinking Pressure gauge short circuit in Significant power reduction. Using the multimetre, verify the The single replacement of the
positive or earth or in open cir- working status of the pressure pressure gauge only is not poss-
cuit. gauge electro-valve. ible.
Eventually blink code 8.1.
If the component is working,
connection between the gauge
and the EDC connector pin
C4-C5.
After having excluded any other
possibility, apply to IVECO Mo-
tors for the eventual replacement
of the pump with its gauge.
8.4 Blinking Incorrect working of the boost Significant power reduction. Replace the rail boost valve.
gauge valve (only if double-stage
type).
8.5 Blinking Anomaly in rail pressure. Significant power reduction. Verify if the fuel arrives directly to
(Dropped to minimum value or the high pressure pump (no
over maximum limit). Possible contemporary blink outlets in the sucked line, clogged
code 8.1 - 8.4. filter or pre-filter, occluded pipes,
consistent fuel leakage).
Verify there is no fuel leakage or

loss from the high pressure line
running from the pump and the
rail or from the cylinders head.
NEF ENGINES
Print P1D32N001 E
POSSIBLE DERIVING
POSSIBLE CAUSE
ment
ment
NEF ENGINES
Print P1D32N001 E
9.4 On Main rel is not disconnecting. The gearbox is always fed and the Try removing and replacing the The main rel is incorporated in
EDC led keeps light on even with fuse (to re-set the EDC) the EDC and is not replaceable
the key in Off position. singularly.
If the problem persists, apply to
The battery discharges. IVECO Motors for the eventual
replacement of the EDC.
9.6 On Anomaly within the routine con- Significant power reduction. Run the engine, drive it to idling The failure might be memorised
trol procedure that the gearbox and disconnect it correctly. even in case of engine working in
provides to the system at each different conditions than the ones
engine disconnection. of the equipment (such as engine
running on bench, without iner-
tial load).
9.7 On Anomaly within sensors feed. Memorisation of error on all sen- Verify working status and correct
sors fed by the EDC gearbox. assembly of the EDC connector
dedicated to sensors (C).
The engine does not start nor dis-
connects, or difficult starting and If the connector is working and
bad working of the engine. correctly assembled,
apply to IVECO Motors for the
eventual replacement of the
EDC.
69
Base - April 2007


GUIDELINE FOR TROUBLESHOOTING WITH PT-01 PORTABLE TESTER

IVECO P.N. 8093731


PT-01 PORTABLE TESTER Test parameters

- Engine revolutions;
Using PT-01 with portable tester it is possibile to execute - Spark advance;
troubleshooting and test the EDC7 electronic module of NEF - Battery voltage;
engines.
- Accelerator foot pedal position;
PT-01 has been designed and developed to ensure stoutness
and practicality and is particularly suitable to be used in work- - Over voltage pressure;
shop and industrial environment. - Over voltage air temperature;
The tool is connected to the engine gearbox by means of one - Cooling liquid temperature;
only cable providing both tester feed and communication with
the electronic module. - Fuel temperature;
Main functions - Oil temperature;

- Oil pressure;
Before connecting the tester to the electronic mod- - Fuel delivery;
! ule, check the wording on the electronic module to - Fuel pressure;
select the correct software on the tool.
- Rail pressure duty cycle electro-valve.
1 2 3 4 5 6 7 8 . A B C
u m m k a a * * . v a 0
a a software 3.3_1
a b software 4.1_2
Easy access to different functions is available through the

menu:
- ID. Reading of the electronic module;
- Reading of failure memory and relevant environment
conditions;
- Failure memory clear;
- Reading of working parameters;
- Reading of status parameters;
- Active troubleshooting (switching on heat starter, fuel
pump, EDC warning led and so on)

FAILURE CODES (SOFTWARE VERSION 3.3_1)

System
Blink code Warning type Failure description
degradation
VEHICLE
1.1 1 Vehicle Speed Signal 0
1.2 1 Multiple State Switch 0
1.3 0 Cruise Control Buttons 0
1.4 1 Accelerator Pedal Signal 2
1.5 0 Clutch signal 0
1.6 1 Service Brake signal (plaus.) 0
1.7 0 Accelerator Pedal (plaus.with brake) 0
1.8 0 Diagnostic lamp 0
1.9 0 Engine brake preselection button 0
ENGINE1
2.1 1 Coolant Temp. Signal 0
2.2 0 Boost Temp. Signal 0
2.3 0 Fuel Temp. Signal 0
2.4 1 Boost Pressure Signal 0
2.5 0 Atmospheric Pressure Signal 0
2.6 1 Oil Pressure Signal 0
2.7 1 Oil Temp. Signal 0
2.8 0 Power stage Fuel filter heater 0
2.9 1 HS Power stage cold start heater relay 0
ENGINE2
3.1 0 Adapt.cylinder balancing Cyl.1 0
3.2 0 Adapt.cylinder balancing Cyl.5 () 0
3.7 0 Battery voltage signal 0
3.8 0 LS Power stage cold start lamp 0
3.9 1 Cold start heater monitoring 0
System degradation: Blink types: Classification of power output:

0 = 0% derate 0 = No light LS = slight level
1 = slight derate 1 = Continous light HS = high level
2 = moderate derate 2 = Blinking light SS = moderate signal
3 = significant derate (): not applicable for the 4 cylinders
4 = engine stop

System
degradation
VGT
4.2 1 Turbo speed signal 0
4.3 1 Fuel limitation from VGT 0
4.4 2 Boost Pressure Control 2
4.5 1 CC HS Power stage 3 VGT 2
4.6 1 HS Powerstage engine brake 0
INJECTORS
5.1 1 Injector solenoid valve Cyl.1 0
5.2 1 Injector solenoid valve Cyl.5 () 0
5.7 1 Injector Booster Voltage C1 0
ENGINE SPEED
6.1 1 Increment speed signal 1
6.2 1 Segment speed signal 1
6.3 1 Engine speed sensing 1
6.4 2 Engine overspeed 0
6.5 1 HS power stage 8 for Starter control 0
6.6 0 SS power stage 1 for TD-signal 0
6.8 0 SS power stage 2 for sync.-signal 0
INTERFACES
7.2 1 CAN Hardware 0
7.3 0 CAN Transmission Control 0
7.4 0 CAN Aut.Traction Control (ASR) 0
DASHBOARD
7.1 0 LS Power stage 2 vehicle limit button 0
7.5 0 LS Power stage 3 engine brake lamp 0
7.6 0 LS Power stage 4 oil pressure lamp 0
7.7 0 SS Power stage 3 oil pressure gauge 0
7.6 0 LS Power stage 5 coolant temperature lamp 0
7.9 0 SS Power stage 4 coolant temperature gauge 0

4 = engine stop

System
degradation
FUEL PRESSURE
8.1 2 Fuel pressure monitoring CP3 3
8.2 2 System degradation 3
8.3 2 CC HS Power stage 1 fuel press. Control 3
8.4 2 Monitoring of rail pressure relief valve 3
8.5 2 Rail pressure Min/Max error 4
8.6 - CC HS Power stage 2 EGR control 0
8.7 - Air Mass Signal 0
8.8 - Ambient Temp. Signal 0
ECU
9.3 2 Truck Security System (Immobil.) 0
9.4 1 Main relay defect 0
9.6 1 ECU: Self Test Shutoff Paths 3
9.7 1 Power supply for sensors 0

3 = significant derate
4 = engine stop

FAILURE CODES (SOFTWARE VERSION 4.1_2)

System
degradation
VEHICLE
1.1 1 Vehicle Speed Signal 0
1.2 1** Multiple State Switch 0
1.3 0 Cruise Control Buttons 0
1.4 1 Accelerator Pedal Signal 2
1.5 0 Clutch signal 0
1.6 1 Service Brake signal (plaus.) 0
1.7 0 Accelerator Pedal (plaus.with brake) 0
1.8 0 Diagnostic lamp 0
1.9 0 Engine Brake Preselection button 0
ENGINE1
2.1 1 Coolant Temp. Signal 0
2.2 0 Boost Temp. Signal 0
2.3 0 Fuel Temp. Signal 0
2.4 1 Boost Pressure Signal 0
2.5 0 Atmospheric Pressure Signal 0
2.6 1 Oil Pressure Signal 0
2.7 1 Oil Temp. Signal 0
2.8 0 Power stage Fuel filter heater 0
2.9 1 HS Power stage cold start heater relay 0
ENGINE2
3.7 0 Battery voltage signal 0
3.8 0 LS Power stage cold start lamp 0
3.9 1* Cold start heater monitoring 0
*) System degradation for STUP failure not applicable (not available in ASAP)
*) Masked out
**) Masked out
4 = engine stop

System
degradation
VGT
4.2 1 Turbo speed signal 0
4.3 1 Fuel limitation from VGT 0
4.4 2 System degradation 2
4.5 1 CC HS Power stage 3 VGT 2
4.6 1 HS Powerstage engine brake 0
INJECTORS
ENGINE SPEED
6.1 1 Increment speed signal 1
6.2 1 Segment speed signal 1
6.3 0 Engine speed sensing 0
6.4 2 Engine overspeed 0
6.5 1 HS power stage 8 for Starter control 0
6.6 0 SS power stage 1 for TD-signal 0
6.8 0 SS power stage 2 for sync.-signal 0
INTERFACES
7.2 1 CAN Hardware 0
7.3 0 CAN Transmission Control 0
7.4 0 CAN Aut.Traction Control (ASR) 0
DASHBOARD
7.1 0 LS Power stage 2 vehicle lim.button 0
7.5 0 LS Power stage 3 Engine brake lamp 0
7.6 0 LS Power stage 4 oil press. lamp 0
7.7 0 SS Power stage 3 oil press. gauge 0
7.8 0 LS Power stage 5 coolant temp. lamp 0
7.9 0 SS Power stage 4 coolant temp. Gauge 0

3 = significant derate *) System degradation for STUP failure not applicable (not available in ASAP)
4 = engine stop *) Masked out **) Masked out (): not applicable for the 4 cylinders

System
degradation
FUEL PRESSURE
8.1 2 Rail pressure monitoring CP3 3
8.2 2 Fuel pressure signal 3
8.3 2 CC HS Power stage 1 fuel press. control 3
8.4 2 Monitoring of Press. Relief Valve(DBV) 3
8.5 2 Rail pressure Min/Max error 4
8.6 0 CC HS Power stage 2 EGR control 0
8.7 0 Air Mass Signal 0
8.8 0 Ambient Temp. Signal 0
ECU
9.3 2 Truck Security System (Immobil.) 0
9.4 1 Main relay defect 0
9.6 1 ECU: Self Test Shutoff Paths 3
9.6 2 System startup failure *
9.7 1 Power supply for sensors 0

3 = significant derate
4 = engine stop
*) System degradation for STUP failure not applicable (not available in ASAP)
*) Masked out
**) Masked out


GUIDELINE FOR TROUBLESHOOTING WITHOUT BLINK-CODE


POSSIBLE CAUSE RECOMMENDED TESTS OR
ANOMALY REMARKS
(*) = if available in the equipment INTERVENTION
Low performance at load request. Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact
NEF ENGINES
Print P1D32N001 E
that, in case of insufficient fuel feeding, the
Possible exessive smoke. engine control module tries to compen-
sate prolonging the injectors working
Possible blink-code 8.1 time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of over- is working correctly.
heating.
If the pump plunger is permanently de-
pressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter. Replace the air filter. Solve the cause of the filters obstruction.
Excessive fuel blow-by from rail boost Check the O Rings and the correct con- Unless the leakage is significant, no per-
valve. nection of the pipe fittings under the formance failures will be detected.
feeding pump (the lockers must stay out- To verify O-rings integrity, extract from
side and the fittings must be well locked). the tank the fuel recycling pipeline, seal
Visually check the low pressure pipeline the end and activate the priming pump
integrity. driving the low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve. there are any significant blow-by from the
boost gauge valve; in such case replace
the valve.
The engine suddenly stops (with no previ- Obstructed fuel filter. Replace the fuel filter. Solve the cause of the filters obstruction
ous problems) and does not start again. (empty and clean the tank and the part of
the circuit over the filter, refill with clean
fuel).
83
Base - April 2007

84
POSSIBLE CAUSE RECOMMENDED TESTS OR

ANOMALY REMARKS
(*) = if available in the equipment INTERVENTION
Base - April 2007

The engine disconnects or does not start. (*) Eliminate the short circuit and replace the Verify that the wire line, close to the
EDC. pedal, is not exposed to.
EDC burned by short circuit on the wir-
ing harness of the friction clutch.
Difficult start and low performance in all Inefficient high pressure pump. After having excluded any other possible
conditions. cause, replace the high pressure pump.
Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recog- In case of low entity blow-by, inficiating
gine running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of the mechanical working of the injector
pulsing within the relevant high pressure but not involving flow limiter activation,
pipe. there is no error memorisation in the en-
gine control module.

If the flow limiter is activated. Check error
code memory.
Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recog- Usually, whether such symptoms appear,
followed by huge white exhaust fumes, no return). nisable detecting by feeling the absence of it is instinctive to give up engine start.
and a fuel smell. pulsing within the relevant high pressure However, by insisting, it is possible to start
pipe. the engine.
As a matter of facts, by insisting, if within
the rail the pressure makes the flow li-
miter close up, the engine starts with one
cylinder less and gradually the grade of
fumes reduces and disappears.
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct
pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the orig-
screws. inal position.
The engine works with one cylinder less, Injector blocked in closed position. Identify the injector that is not working The non-working injector is easily recog-
without memorising failure blink codes in any more and the relating high pressure nisable detecting by feeling the absence of
the engine control module. filler. pulsing within the relevant high pressure
pipe.
NEF ENGINES
Print P1D32N001 E
PART FOUR - MAINTENANCE PLANNING


MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
Planning of controls and periodical intervention
Controls and periodical intervention Frequency (hours)
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily

Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
Replacement of engines oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
IVECO.

Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES Figure 135

Checks and controls
Engine oil level check.

The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided flexible

rod (1).
Figure 134
87757
To provide filling, operate through the upper top (1) or

through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
87756 flow easier.
Draw off the rod from its slot and check that the level is within Some applications are equipped with a level transmitter
the etched tags of minimum and maximum level. alerting dashboard instruments in case of insufficient
lubrication oil within the pan.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level. The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
In case the level results being close to the tag showing and detergent.
minimum level, provide filling lubrication of the engines Adequately protect the skin and the eyes, operate in
components. full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

Check of fuel system Check of water presence within fuel filter or pre-filter
The check must be executed both when the engine
disconnected and when it is running.
The check operation consists in examining the fuel pipelines The components of the system can be damaged very
running from the tank to the pre-filter (if provided in the quickly in presence of water or impurity within the
specific equipment), to the filter, to the injection pump and to fuel.
the injectors.
Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the
Cooling system check drainage of the water within the feed circuit.
Fuel filter is equipped with pump screw-valve to drain the
Check the pipelines from the engine to the radiator, from the water eventually mixed with fuel (some applications of 6
expansion tank and vice-versa. Find out any blow-by, verify the cylinders engines will be equipped with two fuel filters, both
status of the pipes specially close to the holding strips. provided with drainage.
Place a container underneath the filter and slightly loosen the
Verify that the radiator is clean, the correct working of the fan screw. Drain the water eventually contained in the filters
flywheels, the presence of any leakage from the connectors, bottom.
from the manifold and from the radiating unit.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.
Due to the high temperatures achieved by the
system, do not operate immediately after the engines
disconnection, but wait for the time deemed
necessary for the cooling.
Protect the eyes and the skin from any eventual high Checking/replacing the blow-by filter
pressure jet of cooling liquid.
Figure 136
The density of the cooling liquid must be checked any how

every year before winter season and be replaced in any case
every two year.
In case of new filling, proceed bleeding system,

through the bleeds on the engine.
If bleeding of the system is not carried out, serious

inconvenience might be caused to the engine due to
the presence of air pockets in the engines head.
Lubricating system check

Verify the presence of any oil leakage or blow-by from the

head, from the engine pan of from the heat exchanger.
The engine oil is highly polluting and harmful.

77835
In case of contact with the skin, rinse well with water

and detergent.
Unscrew the 6 screws (1) and remove cover (2).
Adequately protect the skin and the eyes, operate in Remove blow-by filters (3).
full compliance with safety regulations.
Disposal must be carried out properly, and in full Before assembling the new filters clean their housing.
compliance with the law and regulations in force.

Check of drive belt tensioning

Some applications are equipped with an automatic tensioner NOTE In order to more quickly perform the operating
that provides correcting belt tensioning. clearance adjustment for rocker arms valves,
proceed as follows:
Check of belts tear and wear status
Carefully verify the belts surface in order to detect any sign of cylinder n. 1 2 3 4
incision, crack, excessive wear in correspondence of toothing; intake - - * *
check end and surface grinding.
exhaust - * - *
Danger: if the engine is switched off but is still hot, 4-cylinder engines
unexpected motion of the belt may occur. Rotate the engine drive shaft balance the valves of the
Wait for engine temperature cooling as a precaution cylinder no.1 and adjust the valves marked by the star
in order to avoid serious danger injury. as indicated in the table:
cylinder n. 1 2 3 4
intake * * - -
exhaust * - * -
Rotate the drive shaft balance the valves of cylinder

Check and setting of tappet clearance 4 and adjust the valves marked by the asterisk as
shown in the table:
Figure 137
cylinder n. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *
6-cylinder engines
Rotate the engine drive shaft balance the valves of the
cylinder no.1 and adjust the valves marked by the star
as indicated in the table:
cylinder n. 1 2 3 4 5 6
intake * * - * - -
exhaust * - * - * -
Rotate the drive shaft balance the valves of cylinder

87673 6 and adjust the valves marked by the asterisk as
shown in the table:
Adjust clearance between rockers and valves using setscrew
wrench (1), box wrench (3) and feeler gauge (2).
Clearance shall be as follows:
- intake valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.

Changing the engine oil and oil filter

Warning: the oil filter contains inside a quantity of oil
Warning: We recommend to wear proper protec- of about 1 kg.
tions because of high motor service temperature. Place properly a container for the liquid.
The motor oil reaches very high temperature: you Warning: avoid the contact of skin with the motor oil:
must always wear protection gloves. in case of contact wash the skin with running water.
The motor oil is very pollutant: it must be disposed
of according to the rules.
Due to the several applications, the pan shape and the oil
quantity can change slightly. However, the following oper-
ations are valid for all applications.
We recommend to carry out the oil drainage when the motor - Replace the filtering cartidge with a new one and screw
is hot. manually until when the gasket is in contact with the
- Place a proper container for the oil collecting under the support.
pan connected with the drain plug. - Tigthen by means of the 99360076-tool of three fourth
- Unscrew the plug and then take out the control dipsick turn.
and the inserting plug to ease the downflow of the - Operate the motor for some minutes and check the level
lubrication oil. through the dipsick again. If it is necessary, carry out a
topping up to compensate the quantity of oil used for the
The oil motor is very pollutant and harmful. filling of the filtering cartridge.
In case of contact with the skin, wash with much water

and detergent.
Filter replacement procedure
Protect properly skin and eyes: operate according to
safety rules. Figure 138
Dispose of the residual properly following the rules.
- After the complete drainage, screw the plug and carry out
the clean oil filling.
Use only the recommended oil or oil having the re-

quested features for the corrrect motor functioning.
In case of topping up, dont mix oils having different
features.
If you dont comply with theses rules, the service war-
ranty is no more valid.
75338
- Check the level through the dipsick until when the filling Remove the oil filter (1) with tool 99360076.
is next to the maximum level notch indicated on the
dipsick.
NOTE Before refitting the new cartridges, moisten the seal
with engine oil.
Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in differ- Screw the oil filter (1) on by hand until it is in contact with the
ent positions: the following procedure is a valid guide for all mounting and then tighten by 3/4 of a turn to the required
applications. tightening torque.
- The filter is composed by a support and a filtering Screw the plug back on under the sump and tighten it to the
cartridge. For the cartridge replacement use the required torque.
9936076-tool. Pour oil into the engine through the filling-pipe (2) of the re-
quired grade and quantity.

Fuel filter replacement Alternator belt - water pump replacement
Figure 140
During this operation dont smoke and dont use free
flames.
Avoid to breathe the vapors coming from filter.
Figure 139
77839
75340
To remove and fit the belt (1) back on, you need to use an
- Drain the fuel inside the filter by operating the water appropriate tool on the tightener (2) in the direction shown
release screw. Collect the fuel in a container without by the arrow.
impurities.
- Unscrew the cartridge (1) by using the 99360076-tool. NOTE The tighteners are automatic, so they are not to be
- Collect the eventual fuel inside the filtering cartridge. adjusted after assembly.
- Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 10-15 Nm torque.

NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS 1
SECTION 4
General overhaul and characteristics
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
4 AND 6 ENGINE OVERHAUL . . . . . . . . . . . . . 11
ENGINE REMOVAL AT THE BENCH . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
- Checks and measurements . . . . . . . . . . . . . . . 12
- Head face check on the cylinder group . . . . . 13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Checking cam lift and pin alignment . . . . . . . . 15
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 16
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Fitting tappets camshaft . . . . . . . . . . . . . . . . 17
- 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 18
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 18
- Measuring journals and crankpins . . . . . . . . . . 18
- 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 20
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 22
- Finding journal clearance . . . . . . . . . . . . . . . . . 22
- Replacing oil pump control gear . . . . . . . . . . . 22
- Checking crankshaft shoulder clearance . . . . . 23
CONNECTING ROD PISTON ASSEMBLY . . 23
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Measuring piston diameter . . . . . . . . . . . . . . . 24

2 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS NEF ENGINES
Page Page
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Removing the valves . . . . . . . . . . . . . . . . . . . . 32
- Conditions for proper pin-piston coupling . . . 25
- Checking cylinder head wet seal . . . . . . . . . . . 33
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Checking cylinder head supporting surface . . . 33
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 26
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Removing carbon deposits, checking
- Checking torsion . . . . . . . . . . . . . . . . . . . . . . . 28 and grinding valves . . . . . . . . . . . . . . . . . . . . . 34
- Checking bending . . . . . . . . . . . . . . . . . . . . . . 28
- Checking clearance between valve stem and valve
guide and valve centering . . . . . . . . . . . . . . . . 34
- Fitting connecting rod-piston assembly . . . . . . 28
- Connecting rod-piston coupling . . . . . . . . . . . 28 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Checking connecting rods . . . . . . . . . . . . . . . 28 VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . 29 - Regrinding replacing the valve seats . . . . . . . 35
- Fitting connecting rod-piston assembly into cylinder VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 36

barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Finding crankpin clearance . . . . . . . . . . . . . . . 30 FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . 36
- Checking piston protrusion . . . . . . . . . . . . . . . 31 - Refitting the cylinder head . . . . . . . . . . . . . . . 37
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 32 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . 38

GENERAL SPECIFICATIONS
Type 4 CYLINDERS 6 CYLINDERS
Cycle Four-stroke diesel engine

Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 in-line 6 in-line

Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cm3 3920 5880
TIMING
start before T.D.C. A 18.5

end after B.D.C. B 29.5
start before B.D.C. D 67

end after T.D.C. C 35
Checking timing
mm -
X
mm -
X
Checking operation
mm 0.20 to 0.30
X
mm 0.45 to 0.55
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 ECU
Nozzle type Injectors
Injection sequence 1-3-4-2 1-5-3-6-2-4
bar
Injection pressure bar 250 - 1450

CLEARANCE DATA
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

1
Cylinder barrels 1 102.009 to 102.031
X
1 0.5
Spare pistons
1 type:
X Size X 60.5
Outside diameter 1 107.781 to 101.799
2 Pin housing 2 40.008 to 40.014
Piston cylinder barrels 0.116 to 0.134
Piston diameter 1 0.5
X
Piston protrusion X 0.28 to 0.52
3 Piston pin 3 39.9938 to 40.0002
Piston pin pin housing 0.0078 to 0.0202

Type 4 CYLINDERS 6 CYLINDER
X1 X1* 2.705 to 2.735

X2 Split ring slots X2 2.420 to 2.440
X3 X3 4.020 to 4.040
S 1 S 1* 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.975 to 4.000
* measured on 99 mm
1 0.100 to 0.175
Split rings - slots 2 0.040 to 0.900
3 0.020 to 0.065
Split rings 0.5
X1 Split ring end opening

X2 in cylinder barrel:
X1 0.30 to 0.40
X3
X2 0.60 to 0.80
X3 0.25 to 0.55
1
Small end bush
housing 1 42.987 to 43.013
Big end bearing
housing 2 72.987 to 73.013
2
3 Small end bush diameter

Outside 4 43.279 to 43.553
Inside 3 40.019 to 40.033
S Spare big end half
bearings S 1.955 to 1.968
Small end bush housing 0.266 to 0.566
Piston pin bush 0.0188 to 0.0392
Big end half bearings 0.250 ; 0.500


X
Size X -
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82.993 to 83.013
Crankpins 2 68.987 to 69.013
Main half bearings S 1* 2.456 to 2.464

Big end half bearings S 2* 1.955 to 1.968
S1 S 2
*provided as spare part
Main bearings
3 No. 15 / 1-7 3 87.982 to 88.008
No. 234/2-3-4-5-6 3 87.977 to 88.013
Half bearings Journals

No. 15 / 1-7 0.041 to 0.119
No. 234 / 2-3-4-5-6 0.041 to 0.103
Half bearings - Crankpins 0.033 to 0.041
Main half bearings

+ 0.250; + 0.500
Big end half bearings
Shoulder journal X1 37.475 to 37.545
X1
Shoulder main bearing X2 32.23
X2
X3
Shoulder half-rings X3 37.30
Output shaft shoulder 0.068 to 0.410

CYLINDER HEAD TIMING SYSTEM mm

1
Valve guide seats on

cylinder head 1 7.042 to 7.062
4 Valves:
4 6.970 to 6.990
60o 0.25o
4 6.970 to 6.990
45o 0.25o
Valve stem and guide 0.052 to 0.092
Housing on head for
valve seat:
1 34.837 to 34.863
1 1 34.837 to 34.863
Valve seat outside diameter;

2 valve seat angle on cylinder
head:
2 34.917 to 34.931
60
2 34.917 to 34.931

45
Sinking X 0.59 to 1.11
X X 0.96 to 1.48
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -


Valve spring height:
free spring H 47.75

H H1
H2 under a load equal to:
339.8 19 N H1 35.33
741 39 N H2 25.20
Injector protrusion X not adjustable

X
Camshaft bush
housings No. 1 (flywheel side) 59.222 to 59.248
Camshaft housings
No. 2-3-4-5/2-3-4-5-6-7 54.089 to 54.139
1 23 4 5
2
Camshaft journals:
15
53.995 to 54.045
17
1 3
Bush inside
diameter 54.083 to 54.147
Bushes and journals 0.113 to 0.165

Cam lift:
H H 6.045
H 7.582


1
Tappet cap housing
on block 1 16.000 to 16.030
2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.960 to 15.975
2
Between tappets and housings 0.025 to 0.070
Tappets -
1
Rocker shaft 1 21.965 to 21.977
Rockers 2 22.001 to 22.027
2
Between rockers and shaft 0.024 to 0.0162


4 AND 6 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. (See Section
3 of the manual herein).
The section illustrates therefore all the most important engine
overhaul procedures.
The following operations are relating to the 4 cylinder engine
but are similar and applicable for the 6 cylinder.
70160
Figure 1
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
NOTE Take note of lower and upper half-bearing

assembling positions since in case of reuse they shall
be fitted in the same position found at removal.
Figure 4 (Demonstrative)
70158
Loosen the fixing screws (1) and remove the rod caps (2).
Withdraw the pistons including the connecting rods from the
top of the engine block.
NOTE Keep the half-bearings into their housings since in

case of use they shall be fitted in the same position
found at removal.
70161
Use tool 99360500 (1) and hoist to remove the crankshaft (2)
Figure 2 from the block.
Figure 5
70159
Remove the screws (1) and the main bearing caps (2).
70162
Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).

zs
Figure 6 REPAIR OPERATIONS

CYLINDER UNIT
Checks and measurements
Figure 9
70163
Remove the screws (1) and disconnect camshaft (3) retaining

plate (2).
70166
NOTE Take note of plate (2) assembling position.
Once engine is disassembled, clean accurately the
cylinder-block assembly.
Use the proper rings to handle the cylinder unit.
Figure 7 The engine block shall not show cracks.
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free from seizing,
scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation, taper
and wear shall be performed using the bore dial gauge (1)
fitted with the dial gauge previously set to zero on the ring
gauge (2) of the cylinder barrel diameter.
NOTE Should the ring gauge be not available, use a

micrometer for zero-setting.
70164
Withdraw carefully the camshaft (1) from the engine block. Figure 10
Figure 8
70167
Measurements shall be performed on each cylinder, at three

different heights in the barrel and on two planes perpendicular
with each other: one parallel to the longitudinal axis of the
engine (A), and the other perpendicular (B). Maximum wear
is usually found on plane (B) in correspondence with the first
measurement.
70165 Should ovalisation, taper or wear be found, bore and grind the
cylinder barrels. Cylinder barrel regrinding shall be performed
according to the spare piston diameter oversized by 0.5 mm
Withdraw the tappets (1) from the engine block. and to the specified assembling clearance.
Figure 11 Head face check on the cylinder group
Figure 12
70170
Check that the head face, on the cylinder group, does not
present deformations.
This check can be carried out, after a previous grains (4)
extraction by means of a calibrated ruler (2) and feeler gauge
(3).
After verified the deformation areas, perform the flattening
of the face by means of grinding machine.
The flatness error must not be higher than 0.075 mm.
107267
NOTE In the event of grinding operation, all the barrels

must result of the same oversize (0.5 mm).
The block flattening could be performed only after
you have checked that, at finished work, the piston
projection from the cylinder barrel is not higher than
Check the bench bearing seats, proceeding as follows: the value prescribed.
- mount the bench caps on the supports without

bearings;
- screw the fixing screws to the torque prescribed; Check the conditions of the working plugs (1) of the cylinder
groups; replace them if rusty or in case of doubt about their
- by means of an adequate gauge, verify that the internal conditions.
diameter of the seats correspond to the value
prescribed. When flattening is finished, restore the cylinder barrel bevel
as shown in Figure 11.
If you detect a higher value, replace its block

D2 diameters:
D2 D1
75703

TIMING SYSTEM
Camshaft
Figure 13
70169
CAMSHAFT MAIN DATA (4 cyl.)

Specified data refer to pin standard diameter
Figure 14
79459
CAMSHAFT MAIN DATA (6 cylinders)

Specified data refer to pin standard diameter
Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bushes.
if they show any traces of seizing or scoring replace the

Checking cam lift and pin alignment BUSHES

Set the camshaft on the tailstock and using a 1/100 gauge set
Figure 16
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.
Figure 15
70172
Camshaft bush (2) shall be pressed into its housing.

Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
70171 Measurements shall be performed on two perpendicular
axes.
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
Figure 17
Sec. A-A
107399
CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)

* Value to be obtained after driving the bush.
Figure 18
sec. A-A
107268
MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING

*Height to be obtained after driving the bush.
Bush replacement Tappets

Figure 19 Figure 20
70174
112890
To replace bush (1), remove and refit it using the beater

99360362 (2) and the handgrip 99370006 (3).
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
NOTE When refitting the bush (1), direct it to make the

lubricating holes (2) coincide with the holes on the
block housing.

Fitting tappets camshaft Figure 23

Figure 21
70238
Set camshaft (3) retaining plate (1) with the slot facing the
70176
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Figure 24
Figure 22
70179
Check camshaft end float (1).

It shall be 0.23 0.13 mm.
70164
Figure 25
Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.

OUTPUT SHAFT
Measuring journals and crankpins NOTE It is recommended to insert the found values in the
proper table.
Figure 26 See Figure 27 and 29.
Undersize classes are:
Journals and crankpins shall always be ground to the

same undersize class.
Journals and crankpins undersize shall be marked on
the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
70182
Grind journals and crankpins if seizing, scoring or excessive

ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
4-cylinder engine
Figure 27
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value

Figure 28
measured on > 45.5 mm radius

between adjacent journals 70183
OUTPUT SHAFT MAIN TOLERANCES
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237

6-cylinder engine
Figure 29
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Figure 30
* Measured on a radius greater than 45.5 mm

** 0.500 between adjacent main journals 70577
MAIN OUTPUT SHAFT TOLERANCES

Figure 31
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING ON

SYSTEM CONTROL SIDE BEARINGS FRONT SIDE
70237
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY

Replacing oil pump control gear Finding journal clearance

Figure 34
Figure 32
70161
Refit the crankshaft (2).

Check the backlash between crankshaf main journals and the
relevant bearings as follows:
70184
Check that gear toothing (1) is not damaged or worn,

otherwise remove it using the proper puller (3). Figure 35
When fitting the new gear, heat it to 180C for 10 minutes
in an oven and then key it to the crankshaft.
Fitting main bearings
Figure 33
70186
- clean accurately the parts and remove any trace of oil;

- position a piece of calibrated wire (3) on the crankshaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
70185 supports.
NOTE Refit the main bearings that have not been

replaced, in the same position found at removal.
D2 diameters:
Main bearings (1) are supplied spare with 0.250 0.500 mm
undersize on the internal diameter.
NOTE Do not try to adapt the bearings. D2 D1
75703
Clean accurately the main half bearings (1) having the
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.

Figure 36 Checking crankshaft shoulder clearance
Figure 39
70187
Tighten the pre-lubricated screws (1) in the following three

successive stages:
70190
- 1st stage, with torque wrench to 50 6 Nm.
- 2nd stage, with torque wrench to 80 6 Nm. This check is performed by setting a magnetic-base dial gauge
(2) on the crankshaft (3) as shown in the figure, standard
Figure 37 value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft pins and main half bearings.
Figure 40
CONNECTING ROD PISTON ASSEMBLY

70188
- 3rd stage, with tool 99395216 (1) set as shown in the

figure, tighten the screws (2) with 90 5 angle.
Figure 38
70191
70189 CONNECTING ROD PISTON ASSEMBLY
- Remove caps from supports. COMPONENTS
The backlash between the main bearings and the pins is found 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
by comparing the width of the calibrated wire (2) at the 6. Half bearings - 7. Connecting rod - 8. Bush.
narrowest point with the scale on the envelope (1) containing
the calibrated wire. The numbers on the scale indicate the
backlash in mm. Replace the half bearings and repeat the check NOTE Pistons are supplied from parts with 0.5 mm
if a different backlash value is found. Once the specified backlash oversize.
is obtained, lubricate the main bearings and fit the supports by
tightening the fastening screws as previously described.
Figure 41 Pistons
Measuring piston diameter
Figure 44
32613
Remove split rings (1) from piston (2) using pliers 99360183 32615
(3).
Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
Figure 42
NOTE The diameter shall be measured at 60.5 mm from
the piston skirt.
Figure 45
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
Figure 43 be checked also with a feeler gauge (1) as shown in the figure.
84291
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter
Piston pins Split rings
Figure 46 Figure 48
18857
To measure the piston pin (1) diameter use the micrometer 16552
(2).
Use a micrometer (1) to check split ring (2) thickness.
Conditions for proper pin-piston coupling
Figure 47 Figure 49
32619
32620
Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity. Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).

Figure 50 Connecting rods

Figure 52
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).
79456
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one. MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
Figure 51
The surface of connecting rod and rod cap are
knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.
70194
Use feeler gauge (1) to measure the clearance between the

ends of the split rings (2) fitted into the cylinder barrel (3).

Figure 53 Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
CONNECTING ROD BODY Grind the bush to obtain the specified diameter.
1234 W
CONNECT- WEIGHT
ING ROD No.
0001 V
*
W
9999 X
CONNECTING ROD CAP

1234 A 123
CONNECTING YEAR DAY
ROD No.
0001 A 1998 001
B 1999
9999 C 2000 366
D 2001
70196
NOTE Every connecting rod is marked as follows:

- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary
to mark the new connecting rod with the same
numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
S X, 1901 to 1940 (blue marking);
For F4HE0684 engines:
S V, 1600 to 1640 (yellow marking);
S W, 1641 to 1680 (green marking);
S X, 1681 to 1720 (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.

Checking connecting rods Checking bending

Figure 54 Figure 56
61695
61696
Check connecting rod (5) bending by comparing two points
C and D of the pin (3) on the vertical plane of the connecting
Check that the axis of the connecting rods (1) are parallel rod axis.
using tool 99395363 (5) as follows: Position the vertical support (1) of the dial gauge (2) to rest
- fit the connecting rod (1) on tool 99395363 (5) spindle the latter on pin (3), point C.
and lock it with screw (4); Move the connecting rod forwards and backwards to find pin
- set the spindle (3) on V-blocks by resting the connecting top position, then in this condition reset the dial gauge (2).
rod (1) on the stop bar (2). Move the spindle with the connecting rod (5) and repeat the
Checking torsion check of the top point on the opposite side D of the pin (3).
The difference between point C and point D shall not exceed
Figure 55
0.08 mm.
Fitting connecting rod-piston assembly

Connecting rod-piston coupling
Figure 57
70198
61694
Check connecting rod (5) torsion by comparing two points The piston crown is marked as follows:
(A and B) of pin (3) on the horizontal plane of the connecting 1. Part number and design modification number;
rod axis. 2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
Position the dial gauge (2) support (1) to obtain a preload of block;
approx. 0.5 mm on the pin (3) in point A and then set the 3. Marking showing 1st slot insert testing;
dial gauge (2) to zero. Move the spindle (4) with the 4. Manufacturing date.
connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A and
B shall not exceed 0.08 mm.

Figure 58
NOTE Split rings are supplied spare with the following
sizes:
- standard, yellow marking;
- 0.5 mm oversize, yellow/green marking;
Figure 61
70199
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Figure 59
70200
Fit half bearings (1) on connecting rod and cap.
NOTE Refit the main bearings that have not been

replaced, in the same position found at removal.
Do not try to adapt the half bearings.
72705
Fitting connecting rod-piston assembly into
Position the piston (1) on the connecting rod according to cylinder barrels
the diagram shown in the figure, fit the pin (3) and stop it by
the split rings (2).
Figure 62
Fitting split rings
Figure 60
70201
32613 Lubricate accurately the pistons, including the split rings and
Use pliers 99360183 (3) to fit the split rings (1) on the piston the cylinder barrel inside.
(2). Use band 99360605 (2) to fit the connecting rod-piston
Split rings shall be fitted with the marking TOP facing assembly (1) into the cylinder barrels and check the following:
upwards and their openings shall be displaced with each - the number of each connecting rod shall correspond to
other by 120. the cap coupling number.
Figure 63
D2 diameters:
D2 D1
75703
70202
Figure 65
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same
weight;
- the arrow marked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
Finding crankpin clearance 70204
Figure 64 - Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench
(2).
Figure 66
70203
To measure the clearance proceed as follows:

- clean the parts accurately and remove any trace of oil; 70205
- set a piece of calibrated wire (2) on the output shaft pins - Apply tool 99395216 (1) to the socket wrench and
(1); tighten screws (2) of 60.
- fit the connecting rod caps (3) with the relevant half
bearings (4).

Figure 67 Checking piston protrusion
Figure 69
70206
- Remove the cap and find the existing clearance by

comparing the calibrated wire width (1) with the scale 70208
on the wire envelope (2).
Once connecting rod-piston assemblies refitting is over, use
dial gauge 39395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 to 0.52 mm.
Figure 68
70207
If a different clearance value is found, replace the half bearings

and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
Check manually that the connecting rods (1) are sliding

axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.10 to 0.33 mm.

CYLINDER HEAD Figure 71

Removing the valves
Figure 70
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. Then remove the
70319
cap (3) and the springs (4).
Intake (1) and exhaust (2) valves have heads with the same
diameter. Repeat this operation for all the valves.
The central notch of the exhaust valve (2) head distinguishes Overturn the cylinder head and withdraw the valves (5).
it from the intake valve.
Figure 72
NOTE Should cylinder head valves be not replaced,
number them before removing in order to refit
them in the same position.
A = intake side S = exhaust side
70322
Remove sealing rings (1 and 2) from the valve guide.
NOTE Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

Checking cylinder head wet seal Figure 75

Figure 73
70323 70325
This check shall be performed using the proper tools. The rated thickness A for the cylinder head is 105 0.25 mm,
max. metal removal shall not exceed thickness B by 1 mm.
Use a pump to fill with water heated to approx. 90C and 2
to 3 bar pressure.
Replace the core plugs (1) if leaks are found, use the proper After grinding, check valve sinking. Regrind the valve
punch for their removal/refitting. seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with

water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface
Figure 74
70324
Use a rule (2) and a feeler gauge (3) to check the cylinder
head (1) supporting surface.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.

VALVES Figure 78
Figure 76
EXHAUST INTAKE
VALVE VALVE
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 valve guide and valve centering
Figure 77
Figure 79
18625
Remove carbon deposits from valves using the proper metal 70327
brush.
Use a magnetic base dial gauge (1) set as shown in the figure,
Check that the valves show no signs of seizing, scoring or the assembling clearance shall be 0.052 0.092 mm.
cracking.
Turn the valve (2) and check that the centering error is not
Regrind the valve seats, if required, using tool 99305018 and
exceeding 0.03 mm.
removing as less material as possible.
VALVE GUIDE VALVE SEATS

Regrinding replacing the valve seats
Figure 80 Figure 81
70330
Check the valve seats (2). If slight scoring or burnout is found,

INTAKE EXHAUST regrind seats using tool 99305018 (1) according to the angle
70328 values shown in Figure 82.
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.
Figure 82
INTAKE EXHAUST
85486
VALVE SEAT MAIN DATA (4 CYL.)
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 - 100C and using the proper
them with the spare ones. Use tool 99305018 (Figure 81) to punch, fit the new valve seats, previously cooled, into the
remove as much material as possible from the valve seats cylinder head.
(take care not to damage the cylinder head) until they can
Use tool 99305018 to regrind the valve seats according to
be extracted from the cylinder head using a punch.
the values shown in Figure 82.

Figure 83 FITTING CYLINDER HEAD
Figure 85
70333
70334
After regrinding, check that valve (3) sinking value is the

specified one by using the base 99370415 (2) and the dial Lubricate the valve stems (1) and fit them into the relevant
gauge 99395603 (1). valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
VALVE SPRINGS NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
Figure 84
Figure 86
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

VALVE SPRINGS
Before refitting use tool 99305047 to check spring flexibility.
Compare load and elastic deformation data with those of the
new springs shown in the following table.
Height Under a load of

mm N
H 47.75 Free
H1 35.33 P 339.8 19 N 770321
H2 25.2 P1 741 39 N
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Refitting the cylinder head There are two types of head seals for F4AE04.., F4AE06.. and
F4HE06.. engines, for the thickness (1.25 mm Type A and
Figure 87 1.15 mm Type B) take the following measures:
- for each piston detect, as indicated on Figure 88, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:
S cil1 = S1 + S2
2
For 4 cylinder versions:
Repeat the operation for pistons 2, 3 and 4 and calculate
the average value.
S cil1 + S cil2 + S cil3 + S cil4
S=
70335 4
Check cleanness of cylinder head and engine block coupling For 6 cylinder versions:
surface. Repeat the operation for pistons 2, 3, 4, 5 and 6 and
Take care not to foul the cylinder head gasket. calculate the average value.
Set the cylinder head gasket (1) with the marking TOP (1)
facing the head. S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6
S=
The arrow shows the point where the gasket thickness is 6
given.
If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.
Figure 88 NOTE Before using the fixing screws again, measure them
D2 diameters:
D2 D1
75703
88775

TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Studs M6 for camshaft sensors 82 0.8 0.2
Studs M8 for feed pump 12 2 1.2 0.2
Screw M12 for fastening rear gear case 77 12 7.7 1.2
Nut M6 for fastening camshaft sensor 10 2 1 0.2
1st stage 81 0.8 0.1
Screw M8 for fastening oil pump 2nd stage 24 4 2.4 0.4
Screw M8 for fastening front cover 24 4 2.4 0.4
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening crankcase plate 43 5 4.3 0.4
Nut M18 for fastening high pressure pump gear 105 5 10.5 0.5
Nuts M8 for fastening fuel pump 24 4 2,4 0,4
inch plug on cylinder head 24 4 2.4 0.4
8,5 0,35 0.35 0.035
Screw M6 for fastening injectors
75 5
Nut fastening for injector feed connector 50 5 5 0.5
Nut M6 for flame start grille on intake manifold 82 0.8 0.2
Screw M8 for fastening intake manifold 24 4 2.4 0.4
Screw M12 for fastening rear brackets for engine lifting 77 12 7.7 1.2
Screws M8 for fastening Common Rail 24 4 2.4 0.4
Connectors M14 for high pressure fuel pipes 20 2 2 0.2
Screw M12 (12 x 1.75 x 130) for fastening cylinder head 35 5 3.5 0.5
Screw M12 (12 x 1.75 x 150) for fastening cylinder head
}1 st stage
55 5 5.5 0.5
2nd stage 90 5
3rd stage 90 5
Screw for fastening rocker bracket 36 5 3.6 0.5
Valve clearance adjusting nuts 24 4 2.4 0.4
Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 2 2 0.2
Screw M8 for fastening high pressure pipe connector 24 4 2.4 0.4
Screw M6 for fastening wiring bulkhead 10 2 1 0.2
Screw M8 for fastening electric wiring support for injector feed 24 4 2.4 0.4
Nuts for fastening wiring on each injector 1,5 0,25 0.15 0.025
Screw M12 for fastening fuel filter bracket 77 8 7.7 0.8
Screw M8 for fastening fuel filter holder 24 4 2.4 0.4
Fuel filter contact + turn
Screw M22 for fastening oil pressure relief valve on oil filter support 80 8 8 0.8
Screw M8 for radiator seal and oil filter support 24 4 2.4 0.4
Oil filter contact + turn
11/8 inch connection on filter support for turbine lubrication 24 4 2.4 0.4
Nut M12 for fastening turbine lubrication pipe 10 2 1 0.2
Screw M10 for fastening engine coolant inlet connection 43 6 4.3 0.6
90 elbow fastening (if required) to engine coolant inlet connection 24 4 2.4 0.4
Pipe on cylinder head for compressor cooling 22 2 2.2 0.2

TORQUE
COMPONENT
Nm kgm
Screw M6 for fastening engine coolant drain connector 10 2 1 0.2
Pin fastening on engine block for exhaust manifold 10 2 1 0.2
Screw M10 for fastening exhaust manifold on cylinder head 53 5 5.3 0.5
Screw M12 for fastening damper adapter 1st stage 50 5 5 0.5
and damper on output shaft 2nd stage 90
Screw M10 for fastening pulley on output shaft 68 7 6.8 0.7
Screw M8 for fastening water pump 24 4 2.4 0.4
Screw M10 for fastening auxiliary component control belt tensioners 43 6 4.3 0.6
Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 6 4.3 0.6
Screw M10 for fastening flywheel housing 85 10 8.5 1
Screw M12 for fastening flywheel housing 49 5 4.9 0.5
Screw M6 for fastening heat exchanger for control unit 10 2 1 0.2
Screw M8 for fastening heat exchanger for control unit 24 4 2.4 0.4
Connection M12 for fuel inlet-outlet on heat exchanger 12 2 1.2 0.2
Nut M8 for fastening valve cover 24 4 2.4 0.4
Screw M6 for fastening camshaft sensor 82 0.8 0.2
Screw M6 for fastening output shaft sensor 82 0.8 0.2
Screw M14 for fastening coolant temperature sensor 20 3 2 0.3
Screw M5 for fastening oil pressure/temperature sensor 61 0.6 0.1
Screw for fastening fuel pressure sensor 35 5 3.5 0.5
Screw M14 for fastening fuel temperature sensor 20 3 2 0.3
Screw for fastening air temperature/pressure sensor on intake manifold 61 0.6 0.1
Screw M12 for fastening engine oil level sensor 12 2 1.2 0.2
71 0.7 0.1
6-cyl. { pins
nuts
M8
M8 43 6 4 3 0.6
4.3 06
Turbine fixing to exhaust manifold
71
4-cyl. { pins
nuts
M8
M8 24 4
0 7 0.1
0.7 01
2.4 0.4
Adapter M12 on turbine for lubricant oil pipes (inlet) 35 5 3.5 0.5
Pipe fixing on adapter M10 for turbine lubrication 35 5 3.5 0.5
Oil pipe fixing on adapter M10 for turbine lubrication to block 43 6 4.3 0.6
Oil drain pipe fixing M8 on turbine 24 4 2.4 0.4
Connector fixing M6 for oil return from cylinder head to flywheel housing 10 2 1 0.2
Screw M12 for fastening engine flywheel 1st stage 30 4 3 0.4
2ndd stage 60 5
Screw M8 for fastening front bracket for engine lifting 24 4 2.4 0.4
Screw for fastening engine oil sump 24 4 2.4 0.4
Screw M8 for fastening cylinder barrel lubricating nozzles 15 3 1.5 0.3
Screw M12 for fastening output shaft caps 1st stage 50 6 5 0.6
2nd stage 80 6 8 0.6
3rdd stage 90 5
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening connecting rod caps 1st stage 60 5 6 0.5
2ndd stage 60 5
Alternator 2.4 0.4
M10 Screw, Bracket fixing on water feed pipefitting 43 6 2.4 0.4
M10 Screw, alternator locking 43 6 2.4 0.4
Starter 2.4 0.4
Starter fixing screw 43 6 2.4 0.4
Air supercharger:
Control gear 5/8 inch fixing nut on the supercharger shaft 125 19 12.5 1.9
Fixing nut M12 to the flywheel housing 77 12 7.7 1.2


NEF ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS NEF ENGINES

TOOLS
TOOL No. DEFINITION
99305018 Kit for valve seat regrinding
99305047 Spring load tester
99317915 Set of 3 pin wrenches (14 - 17 - 19 mm)
Revolving stand for overhauling units (700 daN/m capacity, 120

99322205 daN/m torque)
99331052 Adapter for measures on engine injectors (use with 99395872)
99340055 Tool to remove output shaft front gasket

TOOLS
TOOL No. DEFINITION
99340056 Tool to remove output shaft rear gasket
99341001 Double acting puller
99341009 Pair of brackets
99341015 Press
99342101 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket

TOOLS
TOOL No. DEFINITION
99346253 Tool for fitting output shaft rear gasket
99355019 Wrench (10mm) for hydraulic power steering pump check screw
99360076 Tool to remove oil filter (engine)
99360183 Pliers for removing/refitting piston rings (65 110 mm)
99360268 Tool for removing/refitting engine valves
99360292 Keying device for seal assembly on the valve guide

TOOLS
TOOL No. DEFINITION
99360339 Tool for rotating/stopping the engine flywheel
99360351 Equipment for flywheel holding
Beater for removing/refitting camshaft bushes (to be used with

99360362 993700069)
99360500 Tool for lifting the output shaft
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 125 mm)

TOOLS
TOOL No. DEFINITION
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99367121 Manual pump for pressure and depression measures
99370006 Handgrip for interchangeable beaters
99370415 Gauge base for different measurements (to be used with 99395603)
99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)

TOOLS
TOOL No. DEFINITION
Torque screwdriver for injector solenoid valve connector stop nut

99389834 setting
99395216 Pair of gauges with and square head for angle tightening
99395220 Universal goniometer/inclinometer
99395363 Complete bush testing square
99395603 Dial gauge (0 5 mm)
99395687 Bore meter

TOOLS
TOOL No. DEFINITION
Analog to digital multimeter for voltage, current intensity, resistance,

99395872 diodes, frequencies, capacity and registration of the minimum, average
and maximum values
8093731 Tester PT01


NEF ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX NEF ENGINES

NEF ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different
must be followed absolutely in a standard working area and operation from the ones theyve been designed and
whose non fulfillment will make any other measure useless or provided for: serious injury may occur.
not sufficient to ensure safety to the personnel in-charge of
maintenance. - In case of test or calibration operations requiring engine
running, ensure that the area is sufficiently aerated or
Be informed and inform personnel as well of the laws in force utilize specific vacuum equipment to eliminate exhaust
regulating safety, providing information documentation gas. Danger: poisoning and death.
available for consultation.
- Keep working areas as clean as possible, ensuring
adequate aeration.
- Ensure that working areas are provided with emergency During maintenance
boxes, that must be clearly visible and always provided - Never open filler cap of cooling circuit when the engine
with adequate sanitary equipment. is hot. Operating pressure would provoke high
- Provide for adequate fire extinguishing means, properly temperature with serious danger and risk of burn. Wait
indicated and always having free access. Their efficiency unit the temperature decreases under 50C.
must be checked on regular basis and the personnel must - Never top up an overheated engine with cooler and
be trained on intervention methods and priorities. utilize only appropriate liquids.
- Organize and displace specific exit points to evacuate the - Always operate when the engine is turned off: whether
areas in case of emergency, providing for adequate particular circumstances require maintenance
indications of the emergency exit lines. intervention on running engine, be aware of all risks
- Smoking in working areas subject to fire danger must be involved with such operation.
strictly prohibited. - Be equipped with adequate and safe containers for
- Provide Warnings throughout adequate boards signaling drainage operation of engine liquids and exhaust oil.
danger, prohibitions and indications to ensure easy - Keep the engine clean from oil tangles, diesel fuel and or
comprehension of the instructions even in case of chemical solvents.
emergency.
- Use of solvents or detergents during maintenance may
Prevention of injury originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Do not wear unsuitable cloths for work, with fluttering - Do not leave rags impregnated with flammable
ends, nor jewels such as rings and chains when working substances close to the engine.
close to engines and equipment in motion.
- Upon engine start after maintenance, undertake proper
- Wear safety gloves and goggles when performing the preventing actions to stop air suction in case of runaway
following operations: speed rate.
- filling inhibitors or anti-frost
- lubrication oil topping or replacement - Do not utilize fast screw-tightening tools.
- utilization of compressed air or liquids under pressure - Never disconnect batteries when the engine is running.
(pressure allowed: 2 bar)
- Disconnect batteries before any intervention on the
- Wear safety helmet when working close to hanging loads electrical system.
or equipment working at head height level.
- Disconnect batteries from system aboard to load them
- Always wear safety shoes when and cloths adhering to the with the battery loader.
body, better if provided with elastics at the ends.
- After every intervention, verify that battery clamp polarity
- Use protection cream for hands. is correct and that the clamps are tight and safe from
- Change wet cloths as soon as possible accidental short circuit and oxidation.
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections in
efficiency of earth and mass electrical connections. Ensure presence of electrical feed.
that hands and feet are dry and execute working - Before proceeding with pipelines disassembly
operations utilizing isolating foot-boards. Do not carry out (pneumatic, hydraulic, fuel pipes) verify presence of liquid
working operations if not trained for. or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
- Put the dirty rags with oil, diesel fuel or solvents in anti-fire injury and poisoning.
specially provided containers.

4 APPENDIX NEF ENGINES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engines
components, affecting engines duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys
personnels safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be
force regulating use and exhaust of liquids and engine
changed.
exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that personnel
equipment unless specifically approved by Iveco. is fully aware of such law prescriptions and of basic
preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any - Collect exhaust oils in adequate specially provided
unauthorized modification will compromise warranty containers with hermetic sealing ensuring that storage is
assistance and furthermore may affect engine correct made in specific, properly identified areas that shall be
working and duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having priory environment and within anti-acid containers. Warning:
removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80C temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and furthermore
may affect engine correct working and duration.

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EURO 3

Technical and Repair manual

The data contained in this publication was correct at the time

F4A Engines Part 1

Print P1D32N001 E Base - April 2007

Base - April 2007 Print P1D32N001 E

Danger for persons

Danger of serious damage for the assembly

NOTE It indicates an additional explanation for a piece of information.

Print P1D32N001 E Base - April 2007

Base - April 2007 Print P1D32N001 E

Print P1D32N001 E Base - April 2007

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Base - April 2007 Print P1D32N001 E

Bonding and screening

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

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR

Print P1D32N001 E Base - April 2007

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Base - April 2007 Print P1D32N001 E

Duty - Application to vehicles 3

Overhaul and technical specifications 4

Safety prescriptions Appendix

PREFACE TO USERS GUIDELINE MANUAL

Section 1 describes the F4A engine illustrating its features

Section 2 describes the type of fuel feed.

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

1. Mechanical part, related to the engine overhaul,

Sections 4 and 5 illustrate the overhaul operations of the engi-

Print P1D32N001 E Base - April 2007

Base - April 2007 Print P1D32N001 E

1 1 = housing for connecting rod small end bush

Print P1D32N001 E Base - April 2007

SYMBOLS - ASSISTANCE OPERATIONS

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Base - April 2007 Print P1D32N001 E

Section Description Page Date of revision

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Base - April 2007 Print P1D32N001 E

CORRESPONDENCE BETWEEN IVECO CODE

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

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

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

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

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Base - April 2007 Print P1D32N001 E

CORRESPONDENCE BETWEEN IVECO CODE AND IVECO MOTORS COMMERCIAL CODE

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Base - April 2007 Print P1D32N001 E

Oil recover from the

Routing of oil under pressure

Routing of oil return by gravity to sump

LUBRICATION SYSTEM LAYOUT

Print P1D32N001 E Base - April 2007

Oil recover from the

Routing of oil under pressure

LUBRICATION SYSTEM LAYOUT

Base - April 2007 Print P1D32N001 E

OIL VAPOUR RECYCLING