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WEBMNEF000

SHOP MANUAL

4D104E SERIES
S4D104E SERIES
DIESEL ENGINE
ENGINE MACHINE MODEL

4D104E SERIES WH609-1 - WH613-1
WH609-1 - WH613-1
S4D104E SERIES WH713-1 - WH714-1
WH714H-1 - WH716-1

NEF ENGINES ED. JANUARY 2004 1

CONTENT OF SECTIONS
Section

General specifications 1

Fuel 2

Duty - Industrial applications
Mechanical injection Engines 3

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the NEF 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 inconve-
niences.

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.

JANUARY 2004 NEF ENGINES .2 ED.

Example ∅1 Ø 1 = housing for connecting rod small end bush Tighten to torque Tighten to torque + angular value α ∅2 Ø 2 = housing for connecting rod bearings . NEF ENGINES ED. the same sequence of procedures has been followed for easy reference. (see next page) instead of giving descriptions of some operations or procedures. Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with. JANUARY 2004 3 SPECIAL REMARKS Where possible.

JANUARY 2004 NEF ENGINES Graph and symbols Removal Intake Disconnection Refitting Exhaust Connection Removal Operation Disassembly Fitting in place Assembly ρ Compression ratio Tolerance Tighten to torque Weight difference Tighten to torque + angle value Rolling torque α Replacement Press or caulk Original spare parts Regulation Rotation Adjustment Warning Angle ! Note 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 .4 ED.

JANUARY 2004 5 UPDATING Section Description Page Date of revision .NEF ENGINES ED.

JANUARY 2004 NEF ENGINES .6 ED.

3 SPECIFIC ENGINE CODE . . . . . . . . . . . . . .Description . . . . . . . . . . . . . . 9 AIR INDUCTION BOOST DIAGRAM . . . . . . . .NEF ENGINES ED. . . . . . 11 . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . 5 OIL VAPOUR RECIRCULATING SYSTEM . . . . . . . .GENERAL SPECIFICATIONS 1 SECTION 1 General Specifications Page ENGINE IDENTIFICATION CODE . . . . . . . JANUARY 2004 SECTION 1 . . . . . . . . . . . . . . . . 7 COOLING SYSTEM . . . . . 4 LUBRICATION .

JANUARY 2004 NEF ENGINES .GENERAL SPECIFICATIONS ED.2 SECTION 1 .

within D. X = 4 Injection in line pump 2 valves . Engine cycle — cylinder position Engine Range evolution 0= 4-stroke. JANUARY 2004 SECTION 1 .GENERAL SPECIFICATIONS 3 ENGINE IDENTIFICATION CODE F 4 B E 0 4 8 4 F * D + Exhaust emiss. 8 = DI. vehicles 9 = Army and tractors + X Y Y Y Y Y Y Y Y X = 6 Injection rotary pump 2 valves Model No. vertical A =Not struct. Feed/Injection Cylinder No.NEF ENGINES ED. TCA 0 = Different between the 5 = Genset followingspecifications 6 = Marine 1 = Truck 7 = Industrial and 2 = Bus fork lift truck 3 = Rail road 8 = Cars and similar 4 = M.T. level Homologation power Duty No. C =Struct 4 = 4 cylind.B. Engine series B = Not struct. 6 = 6 cylind.

Y XX . E = E (NRMM) U = EPA USA Power: G = Gas A = Not superch. level C = Euro3. M =Marine S = Supercharging T = Supercharging with aftercooler Engine block: N = Not struct.GENERAL SPECIFICATIONS ED. JANUARY 2004 NEF ENGINES SPECIFIC ENGINE CODE Y XX Y Y Y . M = Mechanical E = Electronic Total displacement or n.4 SECTION 1 . Feed system: S = Struct.C N = NEF Engine 40 = 4 liters E = Electronic N = Type of Engine block T = Supercharger with aftercooler C = Euro3 . XX Engineering code Exhaust emiss. of cylinders Engine series: N = Nef Engine EXAMPLES: N40ENT.

the lubrication oil flows to the driving shaft. engines) 1. Lubrication oil pipe to supercharger . Heat exchanger . Oil filter . placed in the front part of the turboblower for turbocompressed versions. JANUARY 2004 SECTION 1 .GENERAL SPECIFICATIONS 5 LUBRICATION Lubrication by forced circulation is achieved through oil Lubrication involves the heat exchanger (2. the camshaft and to the valve drive. Figure 1 Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil 1 2 5 3 4 003237t LUBRICATION SYSTEM LAYOUT (4 cyl. shaft’s bar hold. Heat exchanger body . to specific duty.2.NEF ENGINES ED. Oil rotary expansion pump - 5.3. All these components may often vary according to the From the pan.3). the rotary expansion pump (4). driven by the straight-tooth gear splined to the compressed air system. and for any basement.4.

3. JANUARY 2004 NEF ENGINES Figure 2 Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil 76212 LUBRICATION SYSTEM LAYOUT (6 cyl. Oil rotary expansion pump - 5.2.6 SECTION 1 . Lubrication oil pipe to supercharger . engines) 1.4.GENERAL SPECIFICATIONS ED. Heat exchanger body . Heat exchanger . Oil filter .

NEF ENGINES ED. Tappet Cap On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity.2. Valve . . JANUARY 2004 SECTION 1 . Breather pipe .GENERAL SPECIFICATIONS 7 OIL VAPOUR RECIRCULATING SYSTEM Figure 3 1 2 3 003240t 1. The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2). by suction as an example (connection towards these vapours shall be designed by the Engineer).3. to the Tappet cap underneath.

JANUARY 2004 NEF ENGINES .GENERAL SPECIFICATIONS ED.8 SECTION 1 .

placed in the front part of the subject to change according to the engine’s equipment. Also this liquid. engine block.GENERAL SPECIFICATIONS 9 COOLING SYSTEM The engine cooling system.Visc pusher fan. which has the duty to dissipate the heat . JANUARY 2004 SECTION 1 .Heat exchanger to cool the lubrication oil: even this type. shape and dimensions are . having the duty to increase the heat dissipating power of the radiator. component will have specific peculiarities based on the .Thermostat regulating the circulation of the cooling subtracted to the engine by the cooling liquid. generally incorporates the following components: component is part of the engine’s specific equipment. closed circuit forced circulation . .NEF ENGINES ED.Expansion tank. engines) . both for what concerns the compressor. placement.The circuit may eventually be extended to the equipment developed. This component as well will be specifically equipped based on the engine’s development. . if this is included in the equipment. Figure 4 TO RADIATOR FROM RADIATOR Water coming out from thermostat 003241t Water recirculating in engine Water coming into pump COOLING SYSTEM LAYOUT (4 cyl. .Radiator.Centrifugal water pump. placement and the dimensions.

GENERAL SPECIFICATIONS ED.10 SECTION 1 . JANUARY 2004 NEF ENGINES Figure 5 TO RADIATOR FROM RADIATOR 76216 Water coming out from thermostat Water recirculating in engine Water coming into pump COOLING SYSTEM LAYOUT (6 cyl. engines) .

. During engine working process. the exhaust emission flow through the body of the turbine. JANUARY 2004 SECTION 1 . part of them directly to the exhaust tube when the boost feeding pressure. being connected by shaft to the prescribed bar value.NEF ENGINES ED. reaches the The compressor rotor. turbine disk wheel. over the compressor. collector before the turbine and connected by piping to the induction collector. one main body and one compressor. rotates as long as this last one rotates.GENERAL SPECIFICATIONS 11 AIR INDUCTION BOOST DIAGRAM Figure 6 AIR FILTER TURBOCHARGER EXHAUST RADIATOR 74195 AIR FILTER 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. releasing wheel’s rotation. that is located on the exhaust feeding pressure . compressing the sucked air through the air filter. provoking the turbine disk It’s duty is to choke the exhaust of the emissions . The above mentioned air is then cooled by the radiator and flown through the piston induction collector. one transforming valve to regulate the boost regulate the pressure . The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

12 SECTION 1 .GENERAL SPECIFICATIONS ED. JANUARY 2004 NEF ENGINES .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .General information . . . . . . . . . .4 cylinder engines . . . 3 . .Example of identification . . . . . . 4 FEED PUMP . .Description of working principles . . . . . . . . . . . . . . . . . .NEF ENGINES ED. . . . . . . . . . . . . . 10 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . .FUEL 1 SECTION 2 Fuel Page INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .General information . . . 9 . . . . . . . . . . . . . 7 INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP . 11 . . 3 . . . . . . . . . . . . . . . . . .6 cylinder engines . . . . . . . . . . . . . . . . . . . 6 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . JANUARY 2004 SECTION 2 . . . . . . . . . . . .Description of working principles . . 5 PRIMING PUMP . . . . . . . 9 . . . 9 . . . . . . . .

JANUARY 2004 NEF ENGINES .FUEL ED.2 SECTION 2 .

Injectors Figure 1 2 1 4 7 5 3 6 74168 1. JANUARY 2004 SECTION 2 .5.Fuel filter (assembled to the engine in different positions according to equipment application and duty) . Fuel exhaust pipes from injectors . Injector . Electro-valve . Fuel feed rotary pump . KSB thermal bulb . assembled to the engine and driven by the camshaft .4.Fuel tank (placed on the machine) .FUEL 3 INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP 4 cylinder engines General information Fuel feed system is composed by: .Injector feed pipeline (from fuel feed pump to injectors) .Fuel feed rotary pump .Fuel delivery and back-flow to tank . Connector for LDA pressure gauge pipe within suction collector .Fuel pre-filter (if available.6.7. Injector feed pipes .2.3.Priming pump.NEF ENGINES ED. it is usually placed close to the engine on the machine frame) .

Feed pipeline from filter to fuel pump . This The fuel arrives therefore to the valve gauging the pressure last one is placed on the engine basement and is driven by inside feed pump. the camshaft.3. Fuel filter .2. Priming pump Description of working principles Fuel is sucked from the fuel tank by the priming pump.4. red to the tank again. (For applications to tors. JANUARY 2004 NEF ENGINES Figure 2 3 2 1 4 75807 1. Transfer pump is placed inside the feed pump. the fuel filter is provided The fuel drawing from the injectors is recovered and delive- with heater).4 SECTION 2 . and is bladed type. the fuel is piped to the union fitting delivers fuel throughout the delivery pipe fitting to the injec- vacuum chamber of the transfer pump.FUEL ED. be equipped in cold climate areas. Feed pipeline from priming pump to filter . . its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions. The distribution plunger further increases this pressure and Throughout the filter/s.

Drive lever .13.12.5.4. Diagram . Hydraulic head .NEF ENGINES ED. Advance converter .15. . Drive plate - 14. Counteracting spring. Speed gauge .6. Pivot . Drive shaft .9. Example of identification V = Distribution rotary plunger E = Pump dimensions 4 = 4 cylinders engine 12 = Distribution plunger in mm.8. Distribution plunger . JANUARY 2004 SECTION 2 . Delivery pipe fitting .FUEL 5 FEED PUMP The rotary type pump is driven by a gear mating the camshaft’s one. Cam disk . Transfer pump . Locking nut .2. of pump revolutions per minute LV = Left direction of rotation Figure 3 1 15 2 14 3 4 5 13 12 6 7 8 9 11 10 30454 Injection pump longitudinal section 1.10. 1150 = N°. Gauge pin .3.11.7.

Camshaft . It is assembled to the engine basement and driven by the camshaft.6 SECTION 2 .2. JANUARY 2004 NEF ENGINES PRIMING PUMP This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. Priming pump .FUEL ED. Figure 4 1 2 3246t 1. The picture here following shows the pump (1) and the position that the pump drive lever assumes depending on the camshaft rotation (2) and on its eccentricity.

there can be a heater assembled to (2) and a tempe- rature sensor (5). Fuel filter bearing.3. on the bearing (1) for those equipment applications requiring it (cold climate areas). Figure 5 5 1 1 2 4 4 3 3 3243t 3244t 1. Filter cartridge - 5.4.FUEL 7 FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. Water dump screw. Temperature sensor . Heater .NEF ENGINES ED. On the filter cartridge base (4) there is a water dump screw.2. JANUARY 2004 SECTION 2 . throughout which it is possible to provide regular drainage.

FUEL ED. JANUARY 2004 NEF ENGINES .8 SECTION 2 .

Injection pump .Fuel delivery and back-flow to tank .Fuel tank (placed on the machine) .Fuel pre-filter (if available.Injectors Figure 6 9 86495 1. assembled to the pump body . Injector.Injector feed pipeline (from fuel feed pump to injectors) .5.8.7.3.9.Fuel feed pump .FUEL 9 INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP 6 cylinder engines General information Fuel feed system is composed by: .4.Priming pump. it is usually placed close to the engine on the machine frame) . Injector fuel pipe 3 . JANUARY 2004 SECTION 2 .Fuel filter (assembled to the engine in different positions according to equipment application and duty) . Injector fuel pipe 4 . Injector fuel pipe 2 . Injector fuel pipe 6 . Injector fuel pipe 6 . Injector fuel pipe 1 . .7. Injector fuel pipe - 6. Injector fuel pipe 5 .2.NEF ENGINES ED.

the fuel filter is provided Fuel bleeding from the injectors is recovered and piped back with heater). Fuel filter . vacuum chamber of the transfer pump. to the pump. Feed pipeline from filter to fuel pump . Description of working principles Fuel is sucked from the fuel tank by the priming pump. the camshaft. . Timing plungers further increase the pressure and deliver fuel Throughout the filter/s.3. Transfer pump is placed inside the feed pump. the fuel is piped to the union fitting to the injectors throughout the delivery pipe fittings. its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions. JANUARY 2004 NEF ENGINES Figure 7 88139 1.10 SECTION 2 . Feed pipeline from priming pump to filter . Priming pump.4. (For applications to be equipped in cold climate areas.2. This Fuel is delivered to the pressure gauge valve within feed last one is placed on the engine basement and is driven by pump.FUEL ED. and is bladed type.

Filter cartridge - 5.6. Figure 8 76142 1. JANUARY 2004 SECTION 2 .3.4.NEF ENGINES ED. Bleender vent screw .2. Heater . there can be a heater assembled to (2) and a tempera- ture sensor (5). throughout which it is possible to provide regular drainage. Fuel filter bearing .FUEL 11 FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separa- tion of water from fuel. On the filter cartridge base (4) there is a water dump screw. Temperature sensor . on the bearing (1) for those equipment applications requiring it (cold climate areas). Water dump screw .

JANUARY 2004 NEF ENGINES .FUEL ED.12 SECTION 2 .

.BRAKES SECTION 3 Duty . . . . . . . . . . . . . . . . . . 8 PART ONE . . 69 . . .Installation of application components . . 15 . . . . . 44 . 11 OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checks and controls . . . . .Clearance data . . .Power take-off disassembly and assembly procedure . . . . . .INDUSTRIAL APPLICATION ED. . . . . . . . . . . . . . . . . . . . . . . .Assembly of additional masses . . .Preface . . . 45 . . . . . .DUTY . . . . . . . . . . . . . . . . . . . .Installation of application components . . .Feed system bleed procedure . . . . . 4 . . . . . 38 . .Preface . . . . . 3 . . . . . .6 cyl. . . . . . 28 .Completion of the engine . . . . . . . . 23 . . .Completion of the engine . . . 55 . . . 13 . . .Engine setting operations for the assembly on turning stand . . . . . . 44 OVERHAUL OF THE 6 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP . . 47 . . .Engine setting operations for the assembly on turning stand . . . 45 . . . . . . . . . . . . . . . 13 . . . . . . . . .industrial application Page GENERAL INFORMATION .Disassembly of application components .4 cyl. . . . . . . . . . . . . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 3 . . . . 44 . . . . . . . JANUARY 2004 NEF ENGINES 1 HYDRAULIC SYSTEM . . . . 13 . . . . . . . .MECHANICAL COMPONENTS . . . . . . . .Clearance data . 45 . . . . . . . . 28 . . . .Rotary feed pump disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Version equipped with mechanical feed pump 3 . . . . . . . . . . . . . . .Timing of additional masses .Disassembly of application components . . . . . . . . . . . . . . . .

. . . . . . . . . 97 . . . . . . . 84 . . . . . . . . . . . . . . . . . . .Check of belt’s tear and wear status . . . . . . . . . . .Rotary feed pump disassembly and . . . . . . . . . . . . . . . . . . . . . . . . .Feed system bleed procedure . . . 101 . . . . . . . . . . . . . . 98 . . . . . .Check of water presence within fuel filter or pre-filter . . . .Check of drive belt tensioning . . . . . . . . . . . . . .INDUSTRIAL APPLICATION Page Page . 75 . . . . . . . . . 100 . . . . . . . . .KSB Water temperature sensor .Oil pressure sensor . . . .Oil motor and filter replacement . . . . . . . . . . . . . . .Checks and controls . . . . . 97 (4 CYL. . . . . . 82 . 102 . . . . . . . . . . . . . 81 . .Planning of controls and periodical intervention 97 . . . .Alternator . 98 . . . 100 . . . . . . . . . . . . . . . . .Checks not included in maintenance . . . . . . .Fuel filter replacement . . . . . . . .Starter . . 86 . . . . . . . . . . . . . . 95 ELECTRICAL COMPONET LAYOUT MAINTENANCE PLANNING . . . . . . . . . . . . 99 ELECTRICAL COMPONET LAYOUT (6 CYL. .Engine oil level check. . . . . . . . . . . . . . 81 MAINTENANCE PROCEDURES . . . . . . . 84 . . . . . . . . . . . . . . . 87 PART TWO - ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . .Power take-off disassembly and assembly procedure . . . . . . . . . . . .Alternator . . 77 PART FOUR . . . . . . . 79 . . . . 102 . . . . . 2 NEF ENGINES ED. . . . . . . .Check and setting of tappet clearance . . . 80 planning-daily checks . .Cooling liquid temperature sensor . . 80 . . . . . . 82 . . . . . . . . . . . . . . . . . . . . . . 81 . . . . . . . . . . .TROUBLESHOOTING . . . . 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 . . . . . . . . . .Alternator belt replacement . . . . .Starter . . . . . . . . .Pre-post heating resistor . . . . . . . . . ENGINES WITH ROTARY PUMP) . 71 . . . . . . . . . . . . . . . . . . 83 . . . . .Pre-post heating resistor . . . . . . . . . 99 . . . . . . . . .Check of fuel system . . . . . . .Electrical diagram pin out . . . 100 .Electromagnets assembled to feed pump . . . . . . . . .MAINTENANCE PLANNING . 75 . 82 . . . . . . . . . . . . . . . . .Cooling system check . . . . . . . . . . . . . . . . . .Oil pressure sensor . 98 .Pre-post heating unit .DUTY . . . . . . . . . . . . . . . . . . .Lubricating system check . . . . . . . 85 . . . . . . . 86 . . . . . 81 . . . . . . . . . .Recovery . . . 86 . . . . . 99 . . . . . . . .Pre-post heating unit . . . . 85 . 85 assembly procedure . 84 . . . . . . . 98 . . . . . . . JANUARY 2004 SECTION 3 . . . . . . . . . . . . . . .Fuel filter . . . . . . . . . . . . .KSB Water temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical diagram pin out . . . . . . . . ENGINES WITH ROTARY POMP) . .Checks and controls . .Cooling liquid temperature sensor . . .Fuel filters . . . . . . . 75 PART THREE . .

the expanders assembled by the Setter or supercharged 4 and 6 cylinders each with 2 valves.directory of preventive and regular maintenance operations. . describing the connections of the ! version. .INDUSTRIAL APPLICATION ED. power take-off for the different collector configuration. JANUARY 2004 NEF ENGINES 3 GENERAL INFORMATION Version equipped with mechanical feed pump Figure 1 03220t Data. The picture shows application designed for 4 cylinders .SECTION 3 . priming pump.DUTY . technical specifications and performances NEF engines have been designed and developed ! granted shall be valid only if the Setter will follow and specifically for transportation by land and farming equipment comply with all installation prescriptions in general. 2 valves per cylinder. . gearbox of the timing system and of the front part cover. illustrating all necessary operations to remove and assembly the external components of the engine. having fuel feed different components. according to the equipment application. power and number of revolutions based on which the engine has been Feed is provided by rotary mechanical pump or on line designed. They are characteristed by diesel cycle 4 stroke atmospheric Furthermore. providing instructions for the execution of the main operations.troubleshooting directory. of the pre-post heating gearbox mechanical pump. (only for some versions) and of the sensors assembled to the engine.electrical directory. . It differs from other applications because of the provision of The section herein described is composed or four directories: different power. oil pan and boost turbine. must always comply with couple.directory of mechanical overhaul prescribed in accordance to the engine’s specific duty. including cylinder heads.

JANUARY 2004 SECTION 3 . intercooler Water pump control Through belt Thermostat .INDUSTRIAL APPLICATION Clearance data .5 : 1 Max.70 .peak rpm bar 3. regulating thermostat. features and performances are valid only if the setter fully complies with all the installation prescriptions provided ! Furthermore.5 Data. 4 NEF ENGINES ED. heat exchanger.4 cyl. power and number of turns based on which the engine has been designed. the users assembled by the setter shall always be in conformance to couple.5 engine sump + filter liters 9. . relief valve single action LUBRICATION oil filter Oil pressure (warm engine) bar . F4GE0404 Type A*D6 A*D6 ρ Compression ratio 17.0) (32.idling bar 0.50 COOLING By centrifugal pump. torque Nm 320 320 (kgm) (32.start of opening ºC 81 ± 2 FILLING 15W40 ACEA E3 engine sump liters 8. output kW 60 60 (HP) (81) (81) rpm 2300 2200 Max.DUTY .0) rpm 1400 1400 Loadless engine idling rpm 850 - Loadless engine peak rpm 2300 - Bore x stroke mm 104 x 132 Displacement cm3 4485 SUPPLY Direct injection intake Forced by gear pump.

. the users assembled by the setter shall always be in conformance to couple. regulating thermostat. heat exchanger. output kW 74 74 63 (HP) (100) (100) (85) rpm 2300 2200 2200 Max. intercooler Water pump control Through belt Thermostat .5) rpm 1400 1400 1400 Loadless engine idling rpm 850 850 850 Loadless engine peak rpm 2300 .5 : 1 Max.50 COOLING By centrifugal pump. power and number of turns based on which the engine has been designed. features and performances are valid only if the setter fully complies with all the installation prescriptions provided ! Furthermore.INDUSTRIAL APPLICATION ED.start of opening ºC 81 ± 2 FILLING 15W40 ACEA E3 engine sump liters 8.SECTION 3 . F4GE0454 Type A*D6 B*D6 E*D6 ρ Compression ratio 17.4 cyl.5 Data. torque Nm 398 398 365 (kgm) (39. relief valve single action LUBRICATION oil filter Oil pressure (warm engine) bar .idling bar 0. JANUARY 2004 NEF ENGINES 5 Clearance data .70 .8) (39. - Bore x stroke mm 104 x 132 Displacement cm3 4485 SUPERCHARGING without intercooler Direct injection Turbocharger type HOLSET HX25W Forced by gear pump.peak rpm bar 3.DUTY .5 engine sump + filter liters 9.8) (36.

idling bar 0.4 cyl.5:1 Max.peak rpm bar 3. F4GE0454 Type G*D6 H*D6 ρ Compression ratio 17. JANUARY 2004 SECTION 3 . intercooler Water pump control Through belt Thermostat .70 . heat exchanger. features and performances are valid only if the setter fully complies with all the installation prescriptions provided ! Furthermore. output kW 60 67 (HP) (81) (91) rpm 2000 2000 Max. - Loadless engine peak rpm rpm .INDUSTRIAL APPLICATION Clearance data . torque Nm 360 399 (kgm) (36. the users assembled by the setter shall always be in conformance to couple.start of opening ºC 81 ± 2 FILLING 15W40 ACEA E3 engine sump liters - engine sump + filter liters - Data.50 COOLING By centrifugal pump. power and number of turns based on which the engine has been designed. .DUTY . regulating thermostat.9) rpm 1400 1400 Loadless engine idling rpm .0) (39. relief valve single action oil filter bar Oil pressure (warm engine) . 6 NEF ENGINES ED. - Bore x stroke mm 104 X 132 Displacement cm3 6728 SUPERCHARGING without intercooler Direct injection Turbocharger type HOLSET HX25W LUBRICATION Forced by gear pump.

intercooler Water pump control Through belt Thermostat . output kW 94 82 (HP) (128) (111) rpm 2300 2200 Max.idling bar 0.5 Data.SECTION 3 .50 COOLING By centrifugal pump. torque Nm 500 480 (kgm) (50.5 engine sump + filter liters 9.70 . .0) (48. F4GE0484 Type C*D6 G*D6 ρ Compression ratio 17.DUTY .peak rpm bar 3.INDUSTRIAL APPLICATION ED. heat exchanger.5:1 Max. features and performances are valid only if the setter fully complies with all the installation prescriptions provided ! Furthermore.4 cyl.start of opening ºC 81 ± 2 FILLING 15W40 ACEA E3 engine sump liters 8. JANUARY 2004 NEF ENGINES 7 Clearance data . relief valve single action oil filter bar Oil pressure (warm engine) .0) rpm 1400 1400 Loadless engine idling rpm 850 - Loadless engine peak rpm rpm 2300 - Bore x stroke mm 104 X 132 Displacement cm3 4485 SUPERCHARGING with intercooler Turbocharger type HOLSET HX25W HOLSET HX27W LUBRICATION Forced by gear pump. the users assembled by the setter shall always be in conformance to couple. regulating thermostat. power and number of turns based on which the engine has been designed.

1) rpm 1400 Loadless engine idling rpm - Loadless engine peak rpm rpm - Bore x stroke mm 104 X 132 Displacement cm3 6728 SUPERCHARGING without intercooler Direct injection Turbocharger type HOLSET HX35W LUBRICATION Forced by gear pump.5:1 Max. torque Nm 441 (kgm) (44. 8 NEF ENGINES ED.70 . features and performances are valid only if the setter fully complies with all the installation prescriptions provided ! Furthermore.peak rpm bar 3. output kW 74 (HP) (100) rpm 2000 Max. .DUTY . heat exchanger.50 COOLING By centrifugal pump. intercooler Water pump control Through belt Thermostat .start of opening ºC 81 ± 2 FILLING 15W40 ACEA E3 engine sump liters 16 engine sump + filter liters 15 Data. regulating thermostat. F4GE0654 Type A*D6 ρ Compression ratio 17. 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.6 cyl. JANUARY 2004 SECTION 3 .idling bar 0.INDUSTRIAL APPLICATION Clearance data . relief valve single action oil filter bar Oil pressure (warm engine) .

idling bar 0. . F4GE0684 Type C*D6 G*D6 G*D6 Q*D6 ρ Compression ratio 17. heat exchanger.0) (67.50 COOLING By centrifugal pump. intercooler Water pump control Through belt Thermostat .0) (58.peak rpm bar 3.start of opening ºC 81 ± 2 FILLING 15W40 ACEA E3 engine sump liters 15 engine sump + filter liters 16 Data. torque Nm 700 675 580 582 (kgm) (70. - Loadless engine peak rpm rpm 2500 . output kW 129 110 107 112 (HP) 175 (149) (145) (152) rpm 2300 2000 2300 2200 Max.2) rpm 1400 1400 1400 1400 Loadless engine idling rpm 850 .70 . the users assembled by the setter shall always be in conformance to couple.5) (58.DUTY . - Bore x stroke mm 104 X 132 Displacement cm3 6728 SUPERCHARGING with intercooler Turbocharger type HOLSET HX35W LUBRICATION Forced by gear pump.5:1 Max. relief valve single action oil filter bar Oil pressure (warm engine) .SECTION 3 . features and performances are valid only if the setter fully complies with all the installation prescriptions provided ! Furthermore. power and number of turns based on which the engine has been designed.INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 9 Clearance data . regulating thermostat. . .6 cyl.

10 NEF ENGINES ED.DUTY .INDUSTRIAL APPLICATION . JANUARY 2004 SECTION 3 .

SECTION 3 .MECHANICAL COMPONENTS .INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 11 DIAGNOSI PART ONE .DUTY .

12 NEF ENGINES ED. JANUARY 2004 SECTION 3 .DUTY .INDUSTRIAL APPLICATION DIAGNOSI .

3 1 Figure 4 75670 Figure relevant to turbocompressed versions 3 In order to apply the brackets 99361037 to the engine block to fix it on to the stand 99322205 for the overhaul.Disassemble the starter. finally loosen and remove the union (5) from the block. 4 For specific application exigencies. loosen the screw (3) fixing the pipe throughout the stop collar (4) fixing the block. Provide for oil recovery and disposal in Properly hold the starter (1) and loosen the two fixing compliance with the law and regulations in force. 1 Within ”General overhaul” section. All operations of engine disassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. it is necessary to perform the following operations: On the right hand side: . plug the pipe ends and the exhaust of the turbo-blower. With regard to the engine disassembly operations.DUTY . JANUARY 2004 NEF ENGINES 13 OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface Figure 3 Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle.disassemble lubrication oil exhaust pipe from the turbo-blower: Underneath the turbo-blower loosen the two screws (2).INDUSTRIAL APPLICATION ED. Engine setting operations for the assembly on turning stand 75671 Figure 2 2 Only for turbocompressed versions . screws (2). all the operations of engine block overhaul have been contemplated. the oil filter (3) is directly 75672 ! assembled on to the heat exchanger:in such case it shall be disassembled using tool 99360076. 1 kg. Warning: the oil filter contains inside aprx. Therefore the above mentioned section is to be considered as following 5 the part hereby described. according to its specific duties. The following information relate to the engine overhaul operations only for what concerns the different components 3 customising the engine. ! please apply for information consulting the specific 2 manual. . drain the oil eventually still inside the pipes and plug them properly in order to avoid impurity inlet. depending on the room available for access to the engine and on the equipment application as well. engine oil.disassemble pipes (1) from the union (2) fitting the lubrication oil filter (assembled on the opposite side): unlock the nuts fixing the pipes (1) and remove them 2 from the union (2).SECTION 3 . some units can be ! assembled to the engine in different positions. of . assemble the bracket bearing 99361037 using the four screw threaded ports (3). 1 For some versions.

(loosen the guide pipe disassembling from the block). 1 kg. Loosen the screws (3) removing the bracket together with the filter bearing (4 and 5). rinse in running water. Using tool 99360076 operate on oil filter. . of Warning: avoid contact of engine oil with the skin: ! engine oil. 14 NEF ENGINES ED.INDUSTRIAL APPLICATION zs Figure 5 Figure 6 1 3 4 5 1 2 75673 75674 .Lift the engine using the rocker arm 99360595 and put with engine oil filter not directly assembled on to the it on the turning stand 99322205.Disassemble oil filter (1) and bracket as well (for versions . Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force. . . JANUARY 2004 SECTION 3 .Drain the oil through the cap underneath the plug.Assemble the second bracket 99361037 throughout the On the left hand side: screw-threaded ports (1). Warning: avoid contact of engine oil with the skin: in case of skin contamination rinse in running water. compliance with the law and regulations in force.Remove the oil level rod together with guide pipe (2). Warning: the oil filter contains inside aprx.DUTY . Provide tank with sufficient capacity to contain the Engine oil is highly pollutant: provide for disposal in liquid. ! in case of skin contamination. exchanger). properly pipe the screw-threaded port to avoid inlet of foreign matters. .

Screw out completely the faucet and.DUTY . JANUARY 2004 NEF ENGINES 15 zs Disassembly of application components Figure 9 Figure 7 1 75675 70126 For turbocompressed versions proceed disassembling the supercharger: To disconnect fuel pipelines (2 and 3. the feed pump and the engine head. it is . using equipment 99360076 disassemble oil filter (1). Pipe the ends of the pipelines as well as complete drainage of the fuel contained therein.Disconnect the LDA pipe (1) from the head and from condense drain faucet underneath said filter. Figure 8). . Carry out the feed pump.Disconnect fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump.Loosen the screw nuts fixing the supercharger on the picture A.Hold up the supercharger and after lifting it remove the gasket.loosen the fixing nut (1) and remove the lubrication pipe Necessary to press the locking fastener (1) as shown from the supercharger.Place a container under the fuel filter and screw out the . Figure 10 Figure 8 4 3 1 2 1 75676 75677 . in ! low pressure from the relating pipe fittings. fastener itself. to avoid any possible deformation of the exhaust manifold. . After having disconnected the pipeline. operation on the other end of the pipe and remove it from the upper part of the heat exchanger. Analogously carry out the same in picture B.Remove the fuel filter bearing (4) from the bracket fixed to the engine head. reset the locking fastener (1) in lock position as shown in.INDUSTRIAL APPLICATION ED. . SECTION 3 . . . .

5. Injector . out the nuts fixing the pipes to the pumping elements.Disconnect the pipelines (1) and (2) that provide feed . JANUARY 2004 SECTION 3 . loosen the fuel recovery pipe collar on the injection pump. . Rotary feed pump - 4.3. Rear bracket fixing screw (on suction collector plate) .INDUSTRIAL APPLICATION zs Figure 11 1 2 3 7 4 6 5 1. Figure 12 Figure 13 1 1 1 2 2 75678 75679 . 16 NEF ENGINES ED.DUTY . Connection nut to pumping elements . screw pump. pipe the pipeline ends. and 7.Loosen the two fixing screws and disassemble priming and fuel recovery between pump and injectors.2. Figure 11). Front bracket fixing screw (on suction collector plate). Fuel recovery pipeline to pump .7.Disassemble the injectors and remove them from their slot: remove the gaskets. operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery pipeline.6. loosen the screws holding the fixing brackets of such pipelines (1. Bracket fixing screw to injection pump side. .6.

Remove the belt tightener(2). Figure 15 2 86571 1 75682 .Remove the pulley support (8).Remove tappet caps: Loosen the four fixing screws (1) and lift the caps (2). . SECTION 3 . remove the gaskets. . . from the exhaust manifold side. 8 screws (1) fixing the suction manifold plate to the .Remove the engine block cooling system connector (3). the front cap has already been ! removed. loosen the eight (2) fixing screws. 75681 . For applications with automatic belt stretcher On the central cap there is a blow-by valve for the lubrication oil vapours. loosen the two fixing screws (2) and remove the complete rocker arm bearing. the fan cylinder head (two of them have already been pulley (5) and the jockey pulley (7).INDUSTRIAL APPLICATION ED. remove the gaskets.DUTY .Disassemble suction and exhaust manifolds: loosen the on the alternator fixing bracket (1). . screwed-out since fixing the pipe brackets to the injectors).Disassemble rocker arm bearings. All the gaskets shall always be replaced during Figure 17 assembly.Remove the alternator (3).Disassemble water temperature transmitter (1). JANUARY 2004 NEF ENGINES 17 zs Figure 14 Figure 16 1 2 2 1 75683 . Repeat the operation for all the remaining rocker arm bearings. the water pump (6). withdraw tappet rods. In the picture.Remove the belt (4) of the ancillary members by acting . .

JANUARY 2004 SECTION 3 . .DUTY .Disassemble oil level sensor (5) (whether provided). 75810 .Disassemble thermostat unit.Remove the belt stretcher bracket (3). Figure 19 88091 1 .Assemble the bracket in the original position fixing it with pressure/temperature sensor (3) (if fitted). the screws of the thermostat unit. 18 NEF ENGINES ED.Properly hold the alternator (1) separating it from its bearing by loosening the screw (2). .Disassemble injection pump (see specific procedure) and the power take-off underneath.Loosen the screws (1) and withdraw the alternator bearing (2). remove screw nut and washer. .Loosen screw (2.Loosen the screws (4) and disassemble the oil . Figure 20) in order to slide out POLY-V belt (2). .Disassemble the driven pulleys and the guide rollers . . interlayer plate (6) and relating gaskets. . remove the gasket (4) and the thermostat (5).Loosen screw (1) and relevant nut on belt stretcher bracket (3).Loosen the screws (1) and disassemble the oil filter/heat exchanger bearing (2). loosen the three fixing screws (1) and disassemble the thermostat unit (2) together with the bracket (3). 88089 Figure 21 .INDUSTRIAL APPLICATION zs For applications with traditional belt stretcher Figure 20 Figure 18 1 2 75686 . 4 Figure 22 2 5 3 75685 . .

JANUARY 2004 NEF ENGINES 19 zs Figure 23 Figure 25 2 2 1 3 3 4 75692 1 .Proceed disassembling the bearing.From the front. 75687 . . (Utilise starter holding down studs and fixing screw nuts). 1 2 The shape and the dimensions of the support of the ! alternator vary according to the use of the engine.Use the tool 99360339 (2) to operate on the flywheel cover box (1) in order to block flywheel rotation (3). . hook the brackets with metal ropes and. hoist withdraw cylinder head from the block. SECTION 3 . . Figure 26 .Loosen the screws (3) and disassemble the pulley (4). 75689 loosen the screws (1) and (2) fixing the cylinder head (3).Loosen the four screws (2) and disassemble the pulley (3) from the bearing underneath.INDUSTRIAL APPLICATION ED. throughout a . The relevant pictures provide a general trace of the intervention that is to be carried out. .Loosen the screws (1) and withdraw water pump (2). Figure 24 1 2 3 4 75688 4 3 .DUTY . The procedures described are always applicable.Loosen the flywheel fixing screws (4) to engine drive shaft. disassemble transmission pulley (1).Disassemble cylinder head.

Fix the tool to the ring Figure 30 tightening the 6 screws specially provided. . Throughout the tool guide ports. JANUARY 2004 SECTION 3 .Loosen the screws (1) and remove the front cover (2).Screw out the opposite screws (1) from the ports where the withdrawal pins shall be introduced (see picture following). 20 NEF ENGINES ED. Proceed withdrawing the ring (1) tightening the screw (3).Remove the flywheel block tool (2).Remove the engine drive shaft fixing ring from the front Take note of the screw (1) assembly position. since cover. Use the tool 99340055 (4) to operate on the ! the screws have different length. . . drill the internal holding ring (1) using Ø 3. 4 3 75691 . withdraw the external holding ring (2) from the front cover (1).Loosen remaining flywheel fixing screws (3) to the engine drive shaft (4). Figure 31 1 2 75688 . Figure 28 75811 .INDUSTRIAL APPLICATION zs Figure 27 Figure 29 70149 .Loosen the screws (1) and remove oil pump (2).5 mm drill for a 5mm depth. 00900t . front tang (2) of the engine drive shaft.Using the specially provided tie rod (3) for the tool 99363204 and the lever (4).DUTY .

since Throughout two guide pins (2) previously screwed up ! the screws have different length. into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist. drill the internal holding ring using Ø 3. . SECTION 3 . Throughout the tool guide ports. The relating illustrations provide general guidelines .Loosen the screws (2) and remove the flywheel cover box (1).Using the specially provided tie rod (3) for the tool of the operation to be performed. . 6 screws specially provided (4). The procedures 99363204 and the lever (4). disassemble the plate (3) and . JANUARY 2004 NEF ENGINES 21 zs Figure 32 Figure 34 1 4 2 3 70153 75690 . depth. ! pipe may vary according to the engine application.Loosen the screws (2). Take note of the screw (1) assembly position.Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. holding ring of the flywheel cover box.DUTY .5 mm drill for a 5mm . . Figure 35 Figure 33 00903t .Turn the engine upside-down.Proceed with drawing the ring (1) tightening the screw The shape and dimensions of the pan and of the rose (2).Remove the flywheel cover box fixing ring using the tool 99340056 (3) to operate on the back tang (5) of the 88046 engine drive shaft.INDUSTRIAL APPLICATION ED. . withdraw the external described are applicable anyway.Fix the tool 99340056 (3) to the ring (1) tightening the remove the oil pan (1).

Remove the screws (2) and disassemble the stiffening plate (3) Version with additional masses 70157 Figure 38 .INDUSTRIAL APPLICATION zs Version with suction rose type A Figure 39 Figure 36 70155 .Remove the screws (1) and (4) and disassembled the suction rose (5). . 22 NEF ENGINES ED.Loosen the screws (2) and remove the stiffening plate 70156 (4). 86578 By means of pin (1) lock the additional masses (2) in the P. Loosen the fixing screws (3) and remove the additional mases (2).DUTY .M. .Loosen the screws (1) and disassemble the gear from the Version with suction rose type B camshaft (2).S. Take note of the screw (2) assembly position. JANUARY 2004 SECTION 3 .Loosen the screws (1) and disassemble the oil suction rose pipe (3).Loosen the screws (2) and disassemble the timing gearbox (1). . Figure 37 Figure 40 86601 . since ! the screws have different length. .

Screw up two pins to facilitate operation of engine ! drive shaft rotation.With a pen marker. . Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. After having completed seal application. and wear nor dirt. with no air blisters. following the order as shown . Avoid using material in excess to seal the joint.Reassemble to box (1) to the engine block. Before assembly.SECTION 3 . block. the joints must be immediately assembled (10-20 minutes time).DUTY . thinner or irregular zones.Accurately clean the timing gearbox (1) and the engine in the picture. JANUARY 2004 NEF ENGINES 23 Installation of application components Figure 42 Figure 41 1 9 10 6 8 4 3 2 1 7 5 1 75711 75712 DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX . always check that the threads of Apply sealing LOCTITE 5205 on the box in order to ! the ports and of the screws have no evidence of tear form a kerbstone of a few mm. Screws M12 65 ÷ 89 Nm Screws M8 20 ÷ 28 Nm Screws M10 42 ÷ 52 Nm It is necessary and essential to clean the surface to ! be sealed in order to achieve excellent tight seal.INDUSTRIAL APPLICATION ED.Tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below. 70211 . It must be uniform (no crumbs). Figure 43 Any eventual imperfection shall be correct as soon as possible. Diameter. DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION WITHIN GEARBOX AREAS . mark the tooth (1) of the driving gear assembled to the engine drive shaft with (2) (→) timing notch.

the notches marked on the gears (1 and 3) shall match. . the joints must be immediately assembled (10-20 minutes time). thinner or irregular zones. Avoid using material in excess to seal the joint. 24 NEF ENGINES ED. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. APPLICATION.INDUSTRIAL APPLICATION zs Figure 44 It is necessary and essential to clean the surface to ! be sealed in order to achieve excellent tight seal.DUTY . Figure 45 Figure 47 1 16 15 8 14 7 17 6 18 13 5 19 12 70213 11 20 1 . tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below.Orient engine drive shaft (4) and camshaft (2) taking care that in phase of assembly of the driving gear (2) to the camshaft. It must be uniform (no crumbs). 21 Figure 46 4 9 10 3 75709 DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX. Screws M12 75 ÷ 95 Nm Screws M10 44 ÷ 53 Nm 1 75708 Before assembly.Reassemble the box (1) to the engine block. JANUARY 2004 SECTION 3 . . Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm.Tighten the screws (1) fixing the gear to the camshaft (3) 2 and lock them to the prescribed couple. always check that the threads of ! the ports and of the screws have no evidence of tear DIAGRAM SHOWING SEALING LOCTITE 5205 and wear nor dirt. 70212 . Diameter. with no air blisters. After having completed seal application. following the order as shown in the picture. Any eventual imperfection shall be correct as soon as possible.

. the detail (5) .Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling . which is 49.13 mm. handle the flywheel to place it in its housing inside the flywheel cover box. 3 .DUTY . seconds. tighten the screw nut (2) cover box. previously heated to 75692 150º C degrees for 15’ ÷ 20’. fix it tightening the screws (4) and shaft ports (3) and using them as guide. 0901t . bevelling must be made towards engine flywheel direction. Use tool 99360339 (2) to operate on the flywheel cover box (1) to block engine flywheel rotation. .Screw up to pins (2) having appropriate length. Whether tooth break or excessive wear is detected.Tighten the screws (4) fixing the engine flywheel (3) to the engine shaft. in the of the tool 99346252.Place detail (1) on detail (5). engine flywheel (1) properly placing it inside the flywheel . Figure 49 1 2 Figure 51 2 75696 In case of engine coupling with mechanical gears in 1 ! presence of friction.6 ± 0. JANUARY 2004 NEF ENGINES 25 zs Figure 48 Figure 50 1 4 2 3 75690 . . assemble the key the new holding ring on it (3). until complete assembly of the fixing ring (3) into the flywheel cover box (7).Apply to engine drive shaft rear tang (6).INDUSTRIAL APPLICATION ED.Using a hoist. verify surface status of the flywheel and eventually work it out to maintain rated engine flywheel thickness. SECTION 3 .Check the conditions of the rim tooth (2). disassemble 4 the rim from the engine flywheel using a common willow and replace with a new one.

Tighten the screws (2) and lock them to the prescribed couple. accurately clean the plug surface. Figure 55 . JANUARY 2004 SECTION 3 .Tighten fixing screws (2) and lock them to the prescribed .Apply to the water pump (1) a new fixing ring (2). .1st phase.2nd phase.Assemble oil pump (1). . . 76112 . couple. Angle dwell shall always be performed using ! 99395216 tool. tightening by means of dynamometric wrench to couple 30 ± 4 Nm. 60º ± 5º angle dwell.DUTY . . always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.Assemble the water pump (1). Before assembly. 26 NEF ENGINES ED.Remove the fixing ring (2) from the front cover (1). Figure 53 Figure 56 70220 70223 .INDUSTRIAL APPLICATION zs Figure 52 Figure 54 α 1 2 75695 70221 Tighten the engine flywheel (1) fixing screws (2) in two phases: .

Accurately clean the contact surface of engine block and apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs. . tighten the Figure 58 fixing screws (3) and fix them to the prescribed couple. SECTION 3 .Assemble the plate (1).Assemble the front cover (2) to the block and tighten the fixing screws (2. the rose pipe (2). 87260 .INDUSTRIAL APPLICATION ED.Assemble the plate (3). 75710 Figure 60 .Place the detail (2) on the detail (4). JANUARY 2004 NEF ENGINES 27 zs Figure 57 Figure 59 00902t . 4 and 1) to the prescribed torque. fix it with the screws (5) and key the new holding ring on it (7).DUTY . . the suction rose (5) and tighten . the screws (1) fixing them to the prescribed couple.Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252. Figure 61 75812 86601 . screw-up the threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover.

JANUARY 2004 SECTION 3 . Injection pump control gear .3. Injection pump gear . Additional masses. . Figure 62 Remove the lock pin (1) of the additional masses.DUTY .2. 86578 Timing of additional masses Match the signs (A) engraved on the gears for timing.INDUSTRIAL APPLICATION Assembly of additional masses Fit the additional masses (2) and tighten the screws (3) on the engine block. Camshaft control gear . Figure 63 86614 1.4.28 NEF ENGINES ED. insert the pin in the hole (B) on the balancing mass.

couple. Tighten Tighten the screws (5) and lock them to the prescribed the screws (2) and lock them to the prescribed couple.DUTY . SECTION 3 . Figure 65 1 2 75697 . always check that the threads of Before assembly.Assemble the following elements to the block: new gasket (1). oil filter 88046 bearing (4).Assemble oil pan (1). . always check that the threads of ! the ports and of the screws have no evidence of tear ! the ports and of the screws have no evidence of tear and wear nor dirt. and the distance ring (3). 3 The pictures illustrating the pan and of the rose pipe ! may not correspond to the ones of your model. JANUARY 2004 NEF ENGINES 29 zs Figure 64 Figure 66 .Tighten the fixing screws (2) and lock them to the 68 ± 7 Nm couple.Assemble the pulley (1) to the engine drive shaft .INDUSTRIAL APPLICATION ED. apply the plate over it (2). heat exchanger (2). Before assembly. . Figure 67 75814 . However the procedures described are applicable anyway. new gasket (3).Provide for new gasket replacement (1) of the oil pan (2). and wear nor dirt. .

30 NEF ENGINES ED. . further screw up the oil filter (3) by 3/4 turn. always check that the threads of ! the ports and of the screws have no evidence of tear and wear nor dirt. bearing (1) tightening the fixing screws to the prescribed couple. 76114 The shape and the dimensions of the alternator ! support vary according to the use of the engine. In some applications. .Apply.Tighten the screw without locking it (2). the bearing of the exchanger ! shall be assembled to a screw threaded union Figure 71 connected to the filter on the opposite side of the engine. Figure 69 87759 .Assemble the alternator bearing (1) ensuring that the Gasket assembly shall be made following the pins (3 and 4) are against the engine block. ! Do not grease the gasket.Place the gasket (1) over the block. Therefore the relevant pictures provide a general guideline of the intervention that is to be carried out. (if needed) new fixing ring on the oil temperature/pressure sensor (4) and assemble it to the . direction of wording printed on the gasket itself so that this will be readable as indicated in the picture.Lubricate the fixing ring (2) using engine oil and place it on the oil filter (3). . . The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface.Connect the alternator (1) to the support. It is recommended to keep However the procedures described are applicable.Manually start the oil filter (3) on the bearing union (1) until counter-boring. JANUARY 2004 SECTION 3 . .DUTY . .Tighten the screws (2) and lock them to the prescribed couple. 75686 . throughout two pipelines (see picture 2).INDUSTRIAL APPLICATION zs Figure 68 Before assembly. the gasket inside packaging until assembly to the cylinder head.Place a new fixing ring on the block housing (6). Verify that the engine block stand is clean. Figure 70 1 2 76113 .

026 19.963 10 4 1 5 11 α 13 7 2 8 14 9 3 6 12 76115 19. Tighten the screw-threaded nut (1) to the i 0.25 . with the centre bolts and moving out. torqued in stages: all bolts torqued to snug torque. Rocker arms- head itself on the engine block. . then 90 degrees rotation for all bolts.000 19. Bolts to be Replace if necessary. Support.026 75704 SHAFT AND ROCKER ARM BASIC DATA .00 75702 ROCKER ARM ADJUSTMENT SCREW If unscrewed. If the valves have been removed from the head.Lubricate cylinder head bolts and install to head. M12 x 70 50 Nm + 90 deg’s 1 M12 x 140 40 Nm + 180 deg’s M12 x 180 70 Nm + 180 deg’s 19.INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 31 zs Figure 72 Figure 74 1 4 2 1 3 3 2 2 1 3 75705 4 75688 . SECTION 3 . check adjustment quota.75 Nm couple.DUTY .Bolts must be torqued using stitching pattern starting of excessive wear shall be detected or damages.00 16. Spacer.000 19.975 18. Then a further 90 Figure 76 degrees for the M12 x 140 and M12 x 180. it is ROCKER ARM UNIT COMPONENTS: ! necessary to assemble them before assembling the 1. 4.0.Carry out the assembly of the rocker arms after previous and (2). Check the coupling surfaces of bearing and shaft: no evidence .3. Figure 73 Figure 75 18. Elastic ring . check of the components.2.Place the head (3) over the block and insert screws (1) .

* . check the Rocker Arm driving rods: these shall not be deformed. Before using the fixing screws again.32 NEF ENGINES ED.05 mm diameters: . measure them twice Correct working slack is: as indicated in the picture. - Exhaust * . 2 1 3 Figure 78 D2 D1 75703 75806 Adjust the slack between rocker arms and valves using socket . * - . balance the valves of cylinder 4 and adjust the valves identified by star symbol. as indicated in the following table: 4 cylinder engine Cylinder n° 1 2 3 4 Suction .05 mm. . as indicated in the following table: Cylinder n° 1 2 3 4 Suction * * . tappet (arrows) shall not present evidence of seizure or wear: Figure 80 in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable. checking D1 and D2 .DUTY . wrench (1)..suction valves 0.D2 < 0.55  0. balance the valves of cylinder 1 and adjust the valves identified by star symbol.Insert the tappet driving rods and the Rocker Arm unit. point wrench (3) and feeler gauge (2). proceed as following: Rotate the engine drive shaft. In order carry out a quicker adjustment of the ! working slack between rocker arms and valves.1 mm the screw must be replaced. * Rotate the engine drive shaft.1 mm the screw can be utilised again.D2 > 0.Tighten the screws (2) to the prescribed couple and contact with the Rocker Arm adjustment screw and with the assemble water temperature sensor (1). if D1 . JANUARY 2004 SECTION 3 . the spherical ends in .exhaust valves 0. if D1 .30  0. * * Exhaust .INDUSTRIAL APPLICATION Figure 77 Figure 79 2 1 32655 75683 Before executing assembly.

DUTY .Tighten the screws to the prescribed couple. .Assemble cylinder covers (2) with the respective gaskets. 1 2 Figure 84 1 4 2 5 3 75685 . During assembly of injectors. verify that the injector ! sphere is correctly positioned on the head housing. . SECTION 3 .Assemble thermostat unit (2) including thermostat (5) and gasket (4). Figure 83 1 1 75707 . The screws (1) have been have been utilised to fix 75681 ! the bracket (3). . In such case provide for replacement with new nods.INDUSTRIAL APPLICATION ED.Fit the seal nods and tighten the screws fixing them to the prescribed couple. Disassemble the bracket and reassemble components from 1 to 5 as shown in the picture.Assemble injectors after having replaced the sealing gasket (1).Assemble exhaust manifold (1) providing new gaskets Figure 82 (2). 2 75808 . The gasket must be new. Seal nods shall have no visible deformation. ! Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. . JANUARY 2004 NEF ENGINES 33 zs Figure 81 Always replace the gaskets using new ones.

tighten (syn. . on the water pump (6) and on the alternator (3). on the jockey pulley (2).INDUSTRIAL APPLICATION zs Figure 85 For applications with traditional belt stretcher Figure 86 2 3 88090 1 .DUTY .Assemble the pulley fan bearing tightening the screws to the prescribed couple. .Assemble the alternator tensioning bracket.In order to connect the POLY-V belt carry out the operations described on pages 18 and 19 vice versa.: tension) the belt by means of the automatic belt tensioner. . 75687 If the old belt is to be reassembled examine it ! carefully in order to see if there may be incisions or evident signs of yielding. For belt stretching turn the alternator as indicated in ! the figure. For applications with automatic belt tensioner . tighten screw (1) and the bolt that fixes the alternator to the support. 34 NEF ENGINES ED. 86571 Assemble belt Poli-V (4) on the pulley (5) of the engine shaft.Assemble the two pulleys (3) and fix them tightening the Figure 87 screws (2) of the bearing. . JANUARY 2004 SECTION 3 .Assemble the transmission pulley (1).

Also assemble the brackets (1) fixing the fuel pipelines ! components (3) and (4). .Tighten the screws (7) to the prescribed couple.If the pipe (6) of the suction manifold plate (1) has been removed. fixing the screws to the prescribed couple.Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple. also assemble . . 75700 For the versions provided with heater.DUTY . Pump assembly requires specific procedure as ! reported at the end of the hereby section. to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture. reassemble it after having fit a new gasket (5).Apply on the surface joining the suction manifold plate (1) a sufficient coat of Loctite 5999 and provide. . JANUARY 2004 NEF ENGINES 35 zs Figure 88 Figure 89 1 7 2 6 5 4 2 3 1 75701 . SECTION 3 .Also assemble feed pump (see specific procedure) and the power take-off underneath. Figure 90 1 2 75678 . .INDUSTRIAL APPLICATION ED.

Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold. Injector .DUTY .Fix the LDA pipeline (1) to the engine head and to the recovery between pump and injectors. Rear bracket fixing screw (on suction collector plate) . .Assemble the pipes (1) and (2) providing fuel feed and .7. Front bracket fixing screw (on suction collector plate) Figure 92 Figure 93 1 1 2 1 75677 75679 . Fuel recovery pipeline to pump . Rotary feed pump - 4. feed pump. Bracket fixing screw to injection pump side.6.3. fix the pipes to the injectors throughout the brackets previously assembled. Connection nut to pumping elements .2.5. 36 NEF ENGINES ED. JANUARY 2004 SECTION 3 .INDUSTRIAL APPLICATION zs Figure 91 1 2 3 7 4 6 5 1.

Operate in the The filter shall be priory filled with fuel to facilitate same way on the other end of the pipe. . To complete engine assembly it is necessary to remove it from the turning stand.Using rocker arm 99360595 hold the engine and loosen the screws fixing the brackets to the turning stand 99322205.Hold the turbocharger and place it on the exhaust feed pump. .Assemble the fuel filter bearing (4) to the bracket fixed For turbocompressed versions to the engine head.Tighten the lubrication pipe fixing ring.Screw up the fixing nuts of the turbocharger to the exhaust manifold tightening them to the prescribed couple.Disassemble the brackets from the engine after having Figure 95 properly put it on a wooden bearing.DUTY . 70126 To connect fuel pipelines (2 and 3. JANUARY 2004 NEF ENGINES 37 zs Figure 94 Figure 96 1 4 3 2 1 75675 75676 . After having connected the pipeline. manifold after having interposed the gasket. . reset the fastener (1) into block position as shown in picture A. . the upper part of the heat exchanger.Connect the fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to .INDUSTRIAL APPLICATION ED. Connect it to ! feed system bleed operations. proceed assembling the turbocharger: . SECTION 3 .Using 99360076 equipment assemble fuel filter (1). . . Figure 94) in low ! pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B.

38 NEF ENGINES ED. For turbocompressed versions . the oil filter (3) is directly placed on ! the heat exchanger: in this case it shall be assembled 75671 using tool 99360076. finally tighten the union (5) to the block.DUTY . tighten the screw (3) fixing the pipeline to the block throughout the fixing collar (4) to the block.reassemble the pipes (1) from the union (2) to the 1 lubrication oil filter (placed on the opposite side): tighten the pipe rings (1) and connect them to the union 5 In some cases.Reassemble the lubrication oil exhaust pipeline (1) from the turbocharger: from underneath the turbocharger tighten the two screws (2).INDUSTRIAL APPLICATION zs Completion of the engine Figure 98 Figure 97 2 2 3 3 1 4 75670 On the right hand side: . . JANUARY 2004 SECTION 3 .

SECTION 3 . Using tool 99360076 screw up oil filter.INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 39 zs Figure 99 Figure 100 3 4 5 1 1 2 75717 75673 . properly hold the starter (1) and On the left hand side: tighten the fixing screws to the prescribed couple.Assemble oil level rod together with guide pipe (2). .Install the engine on the machine (for installation operations please apply to specific issue).Fill up engine oil. .Assemble oil filter (1) together with bracket (for the versions with engine oil filter not directly assembled to the exchanger). tighten the screws (3) assembling the bracket (4) including filter bearing (5). .Reassemble the starter. .DUTY .

in case the pump shall be disassembled This procedure prescribes that: and reassembled later on without being repaired it will be ! . . since it is the more complex.Electrical connection to feed pump shall be disconnected.INDUSTRIAL APPLICATION zs Rotary feed pump disassembly and assembly In case feed pump replacement is necessary. . to pump.The fuel pipelines (from pumping elements to necessary to pr-set it while it is still assembled to the engine injectors. bleeding recovery pipes from injectors and disassemble it only afterwards. JANUARY 2004 SECTION 3 . . Engine versions with tool (99360339) Figure 102 2 1 75714 Disassemble the starter from the flywheel box (1) and use tool 99360339 (2) to rotate the flywheel. On the other hand. this shall be procedure supplied pre-set already as spare part. Engine versions with tool (99360330) Figure 101 1 88140 Disassemble the starter from the flywheel box and use tool 99360330 (2) to rotate the flywheel.Accelerator cable shall be disconnected. 40 NEF ENGINES ED.DUTY . LDA pipeline and feed provided by The following procedure analyses this second hypothesis priming pump) shall all be disassembled.

DUTY . The pin charged by excessive shearing stress In this way the P.S. Find the top dead centre with the tool (99395097) Figure 104 If the cap shown in Figure 103 is not included look for the position of the first cylinder at the compression end stage top dead centre removing the first injector and positioning tool 1.M. JANUARY 2004 NEF ENGINES 41 zs Figure 103 75698 . compression stage is determined.INDUSTRIAL APPLICATION ED. 1 88141 . SECTION 3 .Rotate with caution the flywheel following its own rotation sense to annul the gear slacks and at the same time keep the (→) pin pressed until when this last one Flywheel rotation shall be carried out with extreme is fitting into the port of the camshaft gear. 1 at the end of the may get damaged. Pre-charge the comparator. in cylinder N. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed. ! caution.

. . 42 NEF ENGINES ED. 1 must be carried out. 1 4 When the supply pump is to be assembled on the engine the P.Tighten the lateral screw (1) blocking rotation of the threaded ports (4. Hold the pump driving gear to avoid interference or ! crawling during timing gear rotation. together with the gasket. 2 3 75693 . . remove the cover (2) loosening the screws (1) in order to have access to the union fixing nut (3) to the pump driving gear.Withdraw the pump from the studs. from the pump shaft.DUTY .Properly hold the feed pump and loosen completely the fixing nuts. conditions at compression end stage cylinder No.Loosen the fixing nut (3) and remove the relating washer. Figure 106 . Absolutely keep removing them in order to enable moving the pump the slip washer (it is recommended to fix it with stripe backwards using 99340035 extractor. Figure 97) and withdraw the gear pump shaft.S. or wire to the pump).M.Assemble the 99340035 extractor throughout the two .INDUSTRIAL APPLICATION zs Figure 105 Figure 107 1 2 1 75694 75721 .From timing side.From the pump side.Partially loosen the lateral screw (2) locking the pump . JANUARY 2004 SECTION 3 . loosen the fixing nuts (1) without shaft and remove the slip washer (2). .

. Lock the nut to the 90-95 Nm couple. .Assemble the cover (2.On the timing side. Figure 109) including gasket and tighten the screws (1. Figure 109).Pull the pin outwards setting the camshaft gear free. fit the washer and screw up the fixing nut (3) to the pump shaft. Tighten the screw wrench).INDUSTRIAL APPLICATION ED. slot centre. 2 3 75715 .DUTY .Tighten the fixing nuts (1) locking the pump flange in the is free to rotate. LDA pipeline and feed provided by priming Figure 109 pump). . 99360339 or 99360330.Disassemble the flywheel rotation/locking tool ! not be utilised again. arrange the starting motor in its Always use original spare parts. connect acceleration cable.Connect all pipelines (from pumping elements to injectors.Partially loosen the screw (2) locking the pump shaft fitting the shaft into the gear port (not provided with rotation and fit the slip washer (1). seat. The gasket removed during pump disassembly shall . . In case pump removal has been carried out while the ! engine was assembled. JANUARY 2004 NEF ENGINES 43 zs Figure 108 Figure 110 1 1 2 75694 75721 .Assemble the pump pre-set in its housing on the engine. bleeding recovery pipes from injectors to pump. SECTION 3 . .Connect electrical connections to electro-magnets on 1 4 the hydraulic head and on KSB. . fixing above said washer: this way the feed pump shaft . throughout the specially appointed port.

.Assemble cover and gasket and tighten the screws to the prescribed couple. Preventively check that the liquid levels have been correctly restored.Carefully check the fuel connection pipes to the respective unions. oil pan and bearing.Check and blow by with care the engine cooling system.There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating. following: . let it run at revolution regimen slightly higher than idling and wait that the cooling 1 4 3 liquid temperature reaches the value enabling thermostat opening. carrying out frequent drainage.Cylinder head. there is a power take-off able to transmit motion to different auxiliary parts. . withdraw equipment that was disconnected during engine the power take-off (2). 2 . 75720 . Power take-off disassembly and assembly procedure Figure 112 Start the engine.Tighten the bleeder vent screw (3) ! assembly to the vehicle. The following tests shall be made after engine . Where designed.The two gaskets (4) shall be replaced in phase of . Disassembly of such mechanism shall be executed as .Loosen the bleeder vent screw (3) on the fuel filter (1) and keep working on the bleed lever of the priming pump (2). .Continue executing this operation until when fuel drains from the bleeder vent screw.There is no blow-by from pneumatic pipes (if provided). Checks and controls . .DUTY . . then check that: . reassemble. oil filter and heat exchanger as well as relating housings. 76211 In case any operation has been executed on the components of the feed circuit.There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and.There is no fuel leakage from fuel pipelines.Vary out the assembly fitting the power take-off in its housing.Loosen the two screws (3) and after having removed the dashboard containing the tools as well as of the cover (1) with a specially provided extractor. .INDUSTRIAL APPLICATION zs Feed system bleed procedure .Verify correct working of the lighting leds of the . it is necessary to execute bleeding of air within the system. disconnection. JANUARY 2004 SECTION 3 . 44 NEF ENGINES ED. eventually providing to further tighten the locking rings. providing new gasket and checking the sprocket Figure 111 gear meshing.

it is necessary to perform the following operations: On the right hand side: .disassemble lubrication oil exhaust pipe from the turbo-blower: Underneath the turbo-blower loosen the two screws (2). the oil filter (3) is directly 76146 ! assembled on to the heat exchanger:in such case it shall be disassembled using tool 99360076.DUTY . The following information relate to the engine overhaul operations only for what concerns the different components customising the engine.SECTION 3 . Provide for oil recovery and disposal in . some units can be 4 ! assembled to the engine in different positions.INDUSTRIAL APPLICATION ED. loosen the screw (3) fixing the pipe throughout the stop collar (4) fixing the block.Disassemble the starter. depending on the room available for access to the engine and on the equipment application as well. Warning: the oil filter contains inside aprx. All operations of engine disassembly 2 operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. compliance with the law and regulations in force. all the operations of engine block overhaul have been contemplated. finally loosen and remove the union (5) from the block. Therefore 1 the above mentioned section is to be considered as following the part hereby described. of engine oil.disassemble pipes (1) from the union (2) fitting the lubrication oil filter (assembled on the opposite side): unlock the nuts fixing the pipes (1) and remove them from the union (2). 1 kg. 3 1 75670 Figure 115 Picture of the turbo-compressed versions In order to apply the brackets 99361037 to the engine block to fix it on to the stand 99322205 for the overhaul. Properly hold the starter (1) and loosen the two fixing screws (2) . 3 For specific application exigencies. Within ”General overhaul” section. For some versions. ! please apply for information consulting the specific manual. JANUARY 2004 NEF ENGINES 45 OVERHAUL OF THE 6 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface For turbo-compressed versions Part of the operations illustrated within this section can be Figure 114 partially executed while the engine is assembled on the vehicle. according to its specific duties. Engine setting operations for the assembly on 5 turning stand Figure 113 2 75671 . With regard to the engine disassembly operations. drain the oil eventually still inside the pipes and plug them properly in order to avoid impurity inlet. plug the pipe ends and the exhaust of the turbo-blower.

Lift the engine using the rocker arm 99360595 and put it on the turning stand 99322205. Warning: avoid contact of engine oil with the skin: ! in case of skin contamination.Assemble the bracket bearing 99361037 using the four screw threaded ports (1). JANUARY 2004 SECTION 3 . of ! engine oil. Figure 118 76147 . Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force. rinse in running water. .Assemble the second bracket 99361037 throughout the screw-threaded ports (1). Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force. 76145 Figure 117 .DUTY . .INDUSTRIAL APPLICATION zs Figure 116 . Using tool 99360076 operate on oil filter. Warning: the oil filter contains inside aprx. (loosen the guide pipe disassembling from the block). properly pipe the screw-threaded port to avoid inlet of foreign matters. 76144 On the left hand side: . 1 kg.Disassemble oil filter (1) and bracket as well (for versions with engine oil filter not directly assembled on to the exchanger). Provide tank with sufficient capacity to contain the liquid. Warning: avoid contact of engine oil with the skin: in case of skin contamination rinse in running water.Remove the oil level rod together with guide pipe (2).Drain the oil through the cap underneath the plug. Loosen the screws (3) removing the bracket (4) together with the filter bearing (5). . 46 NEF ENGINES ED.

Loosen the screw nuts fixing the supercharger on the exhaust manifold. it is .Hold up the supercharger and after lifting it remove the gasket. fastener itself. Pipe the ends of the pipelines as well as . .Remove the fuel filter bearing from the bracket fixed to the engine head. . the feed pump. Carry out complete drainage of the fuel contained therein.Disconnect the LDA pipe (1) from the head and from the feed pump. Figure 122 Figure 120 76141 88142 . SECTION 3 . . to avoid any possible deformation of the lubrication pipe from the supercharger. .INDUSTRIAL APPLICATION ED.Disconnect fuel pipelines (2 and 3) respectively from recovery and supply between the pump and the priming pump to filter bearing and from this last one to injectors.DUTY .Loosen the fixing screw (3) and remove the exaust picture A. in ! low pressure from the relating pipe fittings.Disassemble the pipes (2) that constitute the fuel . operation on the other end of the pipe and remove it from the upper part of the heat exchanger. After having disconnected the pipeline. picture 8).Screw out completely the faucet and. JANUARY 2004 NEF ENGINES 47 zs Disassembly of application components Figure 121 Figure 119 76143 70126 For turbo-compressed versions proceed disassembling the supercharger: To disconnect fuel pipelines (2 and 3. 99360076 disassemble oil filters (1).loosen the fixing nut (1) and remove the lubrication pipe Necessary to press the locking fastener (1) as shown from the supercharger. . reset the locking fastener (1) in lock position as shown in. . using equipment the feed pump and the engine head.Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. . Analogously carry out the same in picture B.

JANUARY 2004 SECTION 3 .Remove fuel exhaust pipe (2) from the injectors by Loosen the fixing screws (1) and lift the caps (2).Loosen the screws (1. All the gaskets shall always be replaced during assembly. Figure 125) holding the fixing brackets of such pipelines. Figure 124 On the central cap there is a blow-by valve for the ! lubrication oil vapours. Figure 127 76148 Figure 125 84082 .48 NEF ENGINES ED. .Disconnect the supply pipe unit from the injectors (1). 76150 .DUTY .Remove injectors (2) with tool 99340205 (1) and take out the cylinder head. Figure 124) and (1.Remove tappet caps: . remove the gaskets. . removing screw (4) and seal (3). pipe the pipeline ends.INDUSTRIAL APPLICATION Figure 123 Figure 126 76149 88143 .

Workon the drive belt tensor (1) and extract the belt (3) injectors).Disassemble the belt tensor. withdraw tappet rods. cylinder head (some of them have already been screwed-out since fixing the pipe brackets to the .Disassemble suction and exhaust manifolds: loosen the .SECTION 3 .Loosen screw (1) and relevant nut on belt stretcher bracket (3). Figure 129 2 For applications with traditional belt stretcher Figure 131 1 75683 . from the water pump ones and eight (2) fixing screws. . Repeat the operation for all the remaining rocker arm bearings.Unloose the screw fixing the alternator to the upper bracket. from the belt rebound pulleys. remove the gaskets. from the exhaust manifold side loosen the from the belt pulleys. .Disassemble water temperature transmitter (1).INDUSTRIAL APPLICATION ED. .Loosen screw (2.Unloose the screws fixing the alternator’s protection to screws (1) fixing the suction manifold plate to the the support and remove it. 88089 . JANUARY 2004 NEF ENGINES 49 Figure 128 For applications with automatic belt stretcher Figure 130 1 2 3 76151 74171 . . .Remove belt stretcher bracket (3). . Figure 133 page 50) in order to slide out POLY-V belt (2). loosen the two fixing screws (2) and remove the complete rocker arm bearing.Disassemble the control pipe pulleys and the guide rollers.Disassemble rocker arm bearings.DUTY . .

DUTY .Loosen the screws (4) and disassemble the oil the thermostat (5). pressure/temperature sensor (3) (if fitted). Figure 133 . .Disassemble thermostat unit.Disassemble oil level sensor (5) (whether provided).Loosen the screws (1) and disassemble the oil filter/heat test bench keep bracket (3) assembled on it by fixing it exchanger bearing (2). throughout a bearing (2). gaskets. 50 NEF ENGINES ED. JANUARY 2004 SECTION 3 .INDUSTRIAL APPLICATION zs Figure 132 Figure 135 1 4 2 5 3 75685 .Disassemble cylinder head. 75686 .Loosen the screws (1) and withdraw the alternator hook the brackets with metal ropes and. The relevant pictures provide a general trace of the intervention that is to be carried out. .Properly hold the alternator (1) separating it from its bearing by loosening the screw (2). 1 2 The shape and the dimensions of the support of the ! alternator vary according to the use of the engine. remove the gasket (4) and . loosen the three fixing 70141 screws (1) and disassemble the thermostat unit (2) together with the bracket (3).Disassemble injection pump (see specific procedure). 88091 loosen the screws (1) and (2) fixing the cylinder head (3). The procedures described are always applicable. remove screw nut and washer. interlayer plate (6) and relating with the thermostat unit screws.In order to facilitate head overhauling operations at the . . . hoist withdraw cylinder head from the block. Figure 136 Figure 134 76152 .

equipment. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. .Loosen the flywheel fixing screws (4) to engine drive shaft.5 mm drill for a 5mm depth.Unloose the screws (3) and disassemble the damping . Throughout the tool guide ports. cover.INDUSTRIAL APPLICATION ED. SECTION 3 .Remove the screw (5) and disconnect the engine speed sensor (6). .Remove the screws (1) and disconnect the water pump flywheel covering box (1) in order to lock flywheel (3) (2). . the phonic wheel to be assembled Proceed withdrawing the ring (1) tightening the screw ! to the pulley (1) cannot be provided along with the (3). Fix the tool to the ring tightening the 6 screws specially provided.Remove the engine drive shaft fixing ring from the front flywheel (2) and the pulley (1). In same versions.Apply the suitable tool (2) described on page 70 on the . JANUARY 2004 NEF ENGINES 51 zs Figure 137 Figure 139 2 1 3 4 75692 70148 .DUTY . rotation.Remove the screw (3) and the roller (4). . drill the internal holding ring (1) using Ø 3. (use the starting motor fixing nuts and studs). Figure 138 Figure 140 1 2 3 74175 00900t .

Figure 142 Figure 144 1 2 4 3 70149 75691 . Take note of the screw (1) assembly position.Remove the flywheel block tool (2).INDUSTRIAL APPLICATION zs Figure 141 Figure 143 75811 75688 . JANUARY 2004 SECTION 3 . .Loosen the screws (1) and remove oil pump (2).Loosen remaining flywheel fixing screws (3) to the ! the screws have different length. withdraw the external holding ring (2) from the front cover (1). 99363204 and the lever (4). .DUTY . engine drive shaft (4). .Screw out the opposite screws (1) from the ports where the withdrawal pins shall be introduced (see picture following).Using the specially provided tie rod (3) for the tool . since . 52 NEF ENGINES ED.Loosen the screws (1) and remove the front cover (2).

Loosen the screws (2) and remove the flywheel cover Throughout two guide pins (2) previously screwed up box (1). .5 mm drill for a 5mm . SECTION 3 .DUTY . remove the oil pan (1). withdraw the external described are applicable anyway.Turn the engine upside-down.Proceed with drawing the ring (1) tightening the screw The shape and dimensions of the pan and of the rose (2). disassemble the plate (3) and depth. drill the internal holding ring using Ø 3.Remove the flywheel cover box fixing ring using the tool 99340056 (3) to operate on the back tang (5) of the . holding ring of the flywheel cover box.Loosen the screws (2). engine drive shaft.Fix the tool 99340056 (3) to the ring (1) tightening the 6 screws specially provided (4). JANUARY 2004 NEF ENGINES 53 zs Figure 145 Figure 147 1 4 2 3 70153 75690 . Throughout the tool guide ports. .Using the specially provided tie rod (3) for the tool of the operation to be performed. since ! the screws have different length.INDUSTRIAL APPLICATION ED. into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist. .Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. Take note of the screw (1) assembly position. Figure 146 Figure 148 00903t 88076 . The relating illustrations provide general guidelines . . ! pipe may vary according to the engine application. The procedures 99363204 and the lever (4).

.DUTY . since ! the screws have different length.Loosen the screws (2) and remove the stiffening plate (3).INDUSTRIAL APPLICATION zs Version with suction rose type A Figure 151 Figure 149 70156 .Loosen the screws (2) and remove the stiffening plate (4).Loosen the screws (1) and (4) and disassemble the oil suction rose pipe (3). Take note of the screw (2) assembly position. JANUARY 2004 SECTION 3 .Loosen the screws (2) and disassemble the timing gearbox (1). 86516 . . . 54 NEF ENGINES ED.Loosen the screws (1) and disassemble the gear from the 88074 camshaft (2). Version with suction rose type B Figure 152 Figure 150 70157 .Loosen the screws (1) and disassemble the oil suction rose pipe (3). .

Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. block. After having completed seal application. It must be uniform (no crumbs).DUTY . with no air blisters. Screw up two pins to facilitate operation of engine ! drive shaft rotation.SECTION 3 . JANUARY 2004 NEF ENGINES 55 Installation of application components Figure 154 Figure 153 1 9 10 6 8 4 3 2 1 7 5 1 75711 75712 DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX . .Tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below. Figure 155 Any eventual imperfection shall be correct as soon as possible. DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION WITHIN GEARBOX AREAS . Avoid using material in excess to seal the joint. Diameter. 70211 . thinner or irregular zones.Accurately clean the timing gearbox (1) and the engine in the picture.With a pen marker. the joints must be immediately assembled (10-20 minutes time). Screws M12 65 ÷ 89 Nm Screws M8 20 ÷ 28 Nm Screws M10 42 ÷ 52 Nm It is necessary and essential to clean the surface to ! be sealed in order to achieve excellent tight seal. mark the tooth (1) of the driving gear assembled to the engine drive shaft with (2) (→) timing notch.INDUSTRIAL APPLICATION ED. and wear nor dirt. following the order as shown . Before assembly.Reassemble to box (1) to the engine block. always check that the threads of Apply sealing LOCTITE 5205 on the box in order to ! the ports and of the screws have no evidence of tear form a kerbstone of a few mm.

Reassemble the box (1) to the engine block.Tighten the screws (1) fixing the gear to the camshaft (3) 2 and lock them to the prescribed couple.INDUSTRIAL APPLICATION zs Figure 156 It is necessary and essential to clean the surface to ! be sealed in order to achieve excellent tight seal. After having completed seal application. always check that the threads of ! the ports and of the screws have no evidence of tear DIAGRAM SHOWING SEALING LOCTITE 5205 and wear nor dirt. with no air blisters. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. Figure 157 Figure 159 1 16 15 8 14 7 17 6 18 13 5 19 12 70213 11 20 1 . 70212 . tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below. the notches marked on the gears (1 and 3) shall match. Avoid using material in excess to seal the joint. . JANUARY 2004 SECTION 3 .Orient engine drive shaft (4) and camshaft (2) taking care that in phase of assembly of the driving gear (2) to the camshaft. It must be uniform (no crumbs). thinner or irregular zones. following the order as shown in the picture.DUTY . Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. . the joints must be immediately assembled (10-20 minutes time). 21 Figure 158 4 9 10 3 75709 DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX. Any eventual imperfection shall be correct as soon as possible. APPLICATION. Screws M12 75 ÷ 95 Nm Screws M10 44 ÷ 53 Nm 1 75708 Before assembly. 56 NEF ENGINES ED.

verify surface status of the flywheel and eventually work it out to maintain rated engine flywheel thickness. JANUARY 2004 NEF ENGINES 57 zs Figure 160 Figure 162 1 4 2 3 75690 .Using a hoist. . previously heated to 75692 150º C degrees for 15’ ÷ 20’.Check the conditions of the rim tooth (2). seconds.DUTY . 3 . disassemble 4 the rim from the engine flywheel using a common willow and replace with a new one. bevelling must be made towards engine flywheel direction. .Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling .INDUSTRIAL APPLICATION ED. Use tool 99360339 (2) to operate on the flywheel cover box (1) to block engine flywheel rotation.Tighten the screws (4) fixing the engine flywheel (3) to the engine shaft.6 ± 0.Place detail (1) on detail (5). the detail (5) . SECTION 3 .Apply to engine drive shaft rear tang (6). fix it tightening the screws (4) and shaft ports (3) and using them as guide. assemble the key the new holding ring on it (3).Screw up to pins (2) having appropriate length. Figure 161 1 2 Figure 163 2 75696 In case of engine coupling with mechanical gears in 1 ! presence of friction.13 mm. . until complete assembly of the fixing ring (3) into the flywheel cover box (7). handle the flywheel to place it in its housing inside the flywheel cover box. tighten the screw nut (2) cover box. engine flywheel (1) properly placing it inside the flywheel . which is 49. in the of the tool 99346252. Whether tooth break or excessive wear is detected. 0901t .

1st phase. . Before assembly.Assemble oil pump (1). Figure 165 Figure 168 70220 70223 .INDUSTRIAL APPLICATION zs Figure 164 Figure 166 α 1 2 75695 70221 Tighten the engine flywheel (1) fixing screws (2) in two phases: . .DUTY . Angle dwell shall always be performed using ! 99395216 tool. .2nd phase.Assemble the water pump (1). 60º ± 5º angle dwell.Remove the fixing ring (2) from the front cover (1).Tighten the screws (2) and lock them to the prescribed couple. couple. 58 NEF ENGINES ED. JANUARY 2004 SECTION 3 .Apply to the water pump (1) a new fixing ring (2). 76112 .Tighten fixing screws (2) and lock them to the prescribed . . tightening by means of dynamometric wrench Figure 167 to couple 30 ± 4 Nm. accurately clean the plug surface. always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. .

. JANUARY 2004 NEF ENGINES 59 zs Figure 169 Figure 171 00902t .INDUSTRIAL APPLICATION ED.Assemble the plate (3). 88074 . fix it with the screws (5) and key the new holding ring on it (7). the rose pipe (5).Assemble plate (4).DUTY . Figure 172 75710 . 2 and 4) and fix them to the prescribed the screws (1) fixing them to the prescribed couple.Accurately clean the contact surface of engine block and apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs. couple. tighten the . Figure 173 75812 86516 . SECTION 3 . . screw-up the threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover.Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252.Place the detail (2) on the detail (4). suction rose (3) and tighten the fixing Figure 170 screws (2 and 1) locking them on the prescribed torque.Assemble the front cover (2) to the block and tighten fixing screws (1.

JANUARY 2004 SECTION 3 . gasket (1). couple 68 ± 7 Nm. . always check that the threads of Before assembly.Tighten the fixing screws (3) and clamp them to the .Provide for new gasket replacement (1) of the oil pan (2). new gasket (3). Figure 177 The pictures illustrating the pan and of the rose pipe ! may not correspond to the ones of your model. Tighten the screws (5) and lock them to the prescribed couple. . and wear nor dirt.Assemble the pulley (1) and the dumping flywheel (2) to 88075 the driving shaft. always check that the threads of ! the ports and of the screws have no evidence of tear ! the ports and of the screws have no evidence of tear and wear nor dirt. Before assembly. However the procedures described are applicable anyway.Fit the speed sensor (3) on the front cover (1) and Figure 175 tighten the screw (2) to the specified torque (if fitted). 70230 . . Figure 178 88076 70231 .Assemble oil pan (1). heat exchanger (2).DUTY .Assemble the following elements to the block: new the screws (2) and lock them to the prescribed couple.INDUSTRIAL APPLICATION zs Figure 174 Figure 176 1 2 3 74175 .Fit a new sealing ring on the speed sensor (3) (if fitted). apply the plate over it (2). Tighten . 60 NEF ENGINES ED. oil filter bearing (4).

always check that the threads of ! the ports and of the screws have no evidence of tear and wear nor dirt.Tighten the screws (2) and lock them to the prescribed couple. . . Figure 180 133. 134) For belt stretching rotate the alternator as indicated ! in the figure. SECTION 3 . . JANUARY 2004 NEF ENGINES 61 zs Figure 179 Before assembly.Place a new fixing ring on the block housing (6). . 3/4 turn. For applications with automatic belt stretcher Figure 183 70234 . further screw up the oil filter (3) by .DUTY .Apply. Figure 181 1 2 76113 .Tighten the screw (5) and lock it to the prescribed couple. .Assemble the alternator bearing (1) ensuring that the pins (3 and 4) are against the engine block. (if needed) new fixing ring on the oil temperature/pressure sensor (4) and assemble it to the Figure 182 bearing (1) tightening the fixing screws to the prescribed couple. lock screw (1) and screw (2.Lubricate the fixing ring (2) using engine oil and place it on the oil filter (3).Connect the alternator (1) to the support. 74177 .Connect the alternator (1) to the stretching bracket. . throughout two pipelines (see Figure 113). Figure 181). 88090 For applications with traditional belt stretcher For POLY-V belt connection carry out the operations described on 49 (Figures 130 and 131) and 50 (Figures 132.INDUSTRIAL APPLICATION ED.Manually start the oil filter (3) on the bearing union (1) 75686 until counter-boring. In some applications. the bearing of the exchanger ! shall be assembled to a screw threaded union connected to the filter on the opposite side of the engine.Tighten the screws (2). .Tighten without locking the screw (2). .

Assemble alternator safety guard. M12 x 70 50 Nm + 90 deg’s M12 x 140 40 Nm + 180 deg’s M12 x 180 70 Nm + 180 deg’s . Verify that the engine block stand is clean. . . JANUARY 2004 SECTION 3 . proceed examining it carefully to check there Figure 185 1 Figure 187 α 88092 . 76152 .Lubricate cylinder head bolts and install to head.Tighten the screw (3) to the specified torque.Turn the automatic belt tensioner (2) to fit the belt (1) and (2). . on pulleys and guide rollers.Refit the automatic belt tensioner (2). In case the same belt priory removed is assembled ! again.Place the head (3) over the block and insert screws (1) .INDUSTRIAL APPLICATION zs Figure 184 Figure 186 74178 . 62 NEF ENGINES ED. . Bolts to be the gasket inside packaging until assembly to the torqued in stages: all bolts torqued to snug torque. 90 degrees rotation for all bolts. it is ! necessary to assemble them before assembling the head itself on the engine block. 76214 The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface. It is recommended to keep with the centre bolts and moving out. then cylinder head. If the valves have been removed from the head.Bolts must be torqued using stitching pattern starting ! Do not grease the gasket. Then a further 90 degrees for the M12 x 140 and M12 x 180.Place the gasket (1) over the block.DUTY .

DUTY . Figure 189 Figure 191 18. in case of detection proceed replacing them. Tighten the screw-threaded nut (1) to the i 0.963 19. tappet (arrows) shall not present evidence of seizure or wear: Replace if necessary.026 19. .000 19.0.3.Carry out the assembly of the rocker arms after previous check of the components. the spherical ends in Check the coupling surfaces of bearing and shaft: no evidence contact with the Rocker Arm adjustment screw and with the of excessive wear shall be detected or damages. The rods driving the suction and exhaust valves are identical and therefore interchangeable.026 32655 75704 SHAFT AND ROCKER ARM BASIC DATA Before executing assembly.00 2 16. Elastic ring . Rocker arms- 4.2.975 18. .000 19. Support.00 2 75702 1 3 ROCKER ARM ADJUSTMENT SCREW 75705 If unscrewed. SECTION 3 . 1.75 Nm ROCKER ARM UNIT COMPONENTS: couple. check adjustment quota. JANUARY 2004 NEF ENGINES 63 zs Figure 188 Figure 190 4 1 1 3 19. Spacer.INDUSTRIAL APPLICATION ED.25 . check the Rocker Arm driving rods: these shall not be deformed.

64 NEF ENGINES ED.05 mm. JANUARY 2004 SECTION 3 .55  0. * . 1 2 3 4 5 6 Suction * * . as indicated in the following table: Cylinder n. * .Tighten the screws (2) to the prescribed couple and Exhaust * .1 mm the screw must be replaced. Figure 193 In order carry out a quicker adjustment of the ! working slack between rocker arms and valves. Adjust the slack between rocker arms and valves using socket wrench (1). * Rotate the engine drive shaft. balance the valves of cylinder 6 and adjust the valves identified by star symbol.05 mm . .30  0. balance the valves of cylinder 1 and adjust the valves identified by star symbol. * . proceed as following: 2 Rotate the engine drive shaft. * . 1 2 3 4 5 6 Suction . point wrench (3) and feeler gauge (2).Insert the tappet driving rods and the Rocker Arm unit. * . Before using the fixing screws again.1 mm the screw can be utilised again.suction valves 0. as indicated in the following table: 1 75683 Cylinder n.D2 < 0. if D1 . . * * Exhaust .DUTY .D2 > 0.INDUSTRIAL APPLICATION Figure 192 Figure 194 2 1 D2 D1 3 75703 . * - assemble water temperature sensor (1). - . measure them twice as indicated in the picture. Correct working slack is: . checking D1 and D2 diameters: 75806 if D1 .exhaust valves 0.

Tighten the screws to the prescribed couple. Figure 197 1 75707 . The screws (1) have been have been utilised to fix ! the bracket (3). JANUARY 2004 NEF ENGINES 65 zs Figure 195 Always replace the gaskets using new ones.INDUSTRIAL APPLICATION ED. Figure 198 1 4 2 5 76149 3 75685 . . The gasket (4) must be new. .Assemble injectors after having replaced the sealing gasket (1). . verify that the injector ! sphere is correctly positioned on the head housing.Fit the seal nods and tighten the screws (1) fixing them to the prescribed couple.Assemble thermostat unit (2) including thermostat (5) and gasket (4).Assemble exhaust manifold (1) providing new gaskets (2). Disassemble the bracket (3) and reassemble components from 1 to 5 as shown in the picture.Assemble cylinder covers (2) with the respective gaskets. . In such case provide for replacement with new nods.DUTY . SECTION 3 . 76206 Figure 196 . ! Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. During assembly of injectors.

! reported at the end of the hereby section. Figure 201 1 88144 .Also assemble feed pump (see specific procedure).If the pipe (7) of the suction manifold plate (1) has been . . also assemble Pump assembly requires specific procedure as ! components (4) and (5).Assemble the supply pump supply pipes (1). . reassemble it after having fit a new gasket (6).Tighten the screws (8) to the prescribed couple.DUTY . For the versions provided with heater. Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold. Fixing the screws (2) to to the injectors: use the same screws (2) fixing the the prescribed couple. .Also assemble the brackets (1) fixing the fuel pipelines (1) the gasket (3) and provide. manifold plate as shown in the picture. JANUARY 2004 SECTION 3 . removed.INDUSTRIAL APPLICATION zs Figure 199 Figure 200 76207 76208 . 66 NEF ENGINES ED.Apply on the surface joining the suction manifold plate .

Figure 202 and 2. JANUARY 2004 NEF ENGINES 67 zs Figure 202 Figure 204 1 76148 Figure 203 88146 .Fix the pipes to the injectors throughout the brackets previously assembled (fixing screw 1.DUTY .Fix the LDA pipeline (1) to the engine head and to the feed pump. Figure 205 1 76150 . .INDUSTRIAL APPLICATION ED. Figure 203).Assemble the supply pump pipes (1). SECTION 3 . 88145 .

Tighten the lubrication pipe fixing ring. .INDUSTRIAL APPLICATION zs Figure 206 Figure 208 76143 76141 . .Using 99360076 equipment assemble fuel filter (1). To complete engine assembly it is necessary to remove it from the turning stand. reset the fastener (1) into block position as shown in picture A.Connect the fuel pipelines (2 and 3) respectively from .Assemble the fuel filter bearing (4) to the bracket fixed For turbo-compressed versions to the engine head. feed pump.Disassemble the brackets from the engine after having properly put it on a wooden bearing.Assemble the turbocharger lubrication exhaust pipe by tightening the screws (3). Connect it to ! feed system bleed operations. Operate in the The filter shall be priory filled with fuel to facilitate same way on the other end of the pipe. 70126 To connect fuel pipelines (2 and 3. the upper part of the heat exchanger.DUTY .. .Using rocker arm 99360595 hold the engine and loosen Figure 207 the screws fixing the brackets to the turning stand 99322205. JANUARY 2004 SECTION 3 . 68 NEF ENGINES ED.Hold the turbocharger and place it on the exhaust priming pump to filter bearing and from this last one to manifold after having interposed the gasket. exhaust manifold tightening them to the prescribed couple.Screw up the fixing nuts (2) of the turbocharger to the . Figure 206) in low ! pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B. proceed assembling the turbocharger: . . After having connected the pipeline. connect the end to the engine block. . .

reassemble the pipes (1) from the union (2) to the 1 lubrication oil filter (placed on the opposite side): tighten the pipe rings (1) and connect them to the union 5 In some cases. For turbo-compressed versions . the oil filter (3) is directly placed on ! the heat exchanger: in this case it shall be assembled 75671 using tool 99360076.DUTY . tighten the screw (3) fixing the pipeline to the block throughout the fixing collar (4) to the block.Reassemble the lubrication oil exhaust pipeline (1) from the turbocharger: from underneath the turbocharger tighten the two screws (2). finally tighten the union (5) to the block. .INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 69 zs Completion of the engine Figure 210 Figure 209 2 2 3 3 1 4 75670 On the right hand side: . SECTION 3 .

. . .DUTY . Using tool 99360076 screw up oil filter. .Reassemble the starter. properly hold the starter (1) and On the left hand side: tighten the fixing screws to the prescribed couple. .INDUSTRIAL APPLICATION zs Figure 211 Figure 212 76146 76144 . JANUARY 2004 SECTION 3 .Fill up engine oil. 70 NEF ENGINES ED. tighten the screws (3) assembling the bracket (4) including filter bearing (5).Install the engine on the machine (for installation operations please apply to specific issue).Assemble oil filter (1) together with bracket (for the versions with engine oil filter not directly assembled to the exchanger).Assemble oil level rod together with guide pipe (2).

On the other hand. SECTION 3 . bleeding recovery pipes from injectors and disassemble it only afterwards. in case the pump shall be disassembled This procedure prescribes that: and reassembled later on without being repaired it will be ! . this shall be procedure supplied pre-set already as spare part. LDA pipeline and feed provided by The following procedure analyses this second hypothesis priming pump) shall all be disassembled.Electrical connection to feed pump shall be disconnected. Engine versions with tool (99360330) Figure 213 1 88140 Disassemble the starter from the flywheel box and use tool 99360330 to rotate the flywheel.The fuel pipelines (from pumping elements to necessary to pr-set it while it is still assembled to the engine injectors. to pump.INDUSTRIAL APPLICATION ED. .Accelerator cable shall be disconnected. . JANUARY 2004 NEF ENGINES 71 zs Rotary feed pump disassembly and assembly In case feed pump replacement is necessary. . since it is the more complex. Engine versions with tool (99360339) Figure 214 2 1 75714 Disassemble the starter from the flywheel box (1) and use tool 99360339 (2) to rotate the flywheel.DUTY .

72 NEF ENGINES ED. Find the top dead centre with the tool (99395097) Figure 216 If the cap shown in Figure 215 is not included look for the position of the first cylinder at the compression end stage top dead centre removing the first injector and positioning tool 1. ! caution. The pin charged by excessive shearing stress In this way the P.INDUSTRIAL APPLICATION zs Figure 215 88147 .Rotate with caution the flywheel following its own rotation sense to annul the gear slacks and at the same time keep the (→) pin pressed until when this last one Flywheel rotation shall be carried out with extreme is fitting into the port of the camshaft gear. 1 88141 .M.DUTY . in cylinder N.S. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed. 1 at the end of the may get damaged. Pre-charge the comparator. compression stage is determined. JANUARY 2004 SECTION 3 .

Assemble the 99340035 extractor throughout the two the slip washer (it is recommended to fix it with stripe threaded ports (4. . 2 3 75693 . JANUARY 2004 NEF ENGINES 73 zs Figure 217 Figure 219 1 2 1 88149 .Partially loosen the lateral screw (2) locking the pump shaft and remove the slip washer (2).M. When the supply pump is to be assembled on the engine the P.Properly hold the feed pump and loosen completely the pump shaft.DUTY . 1 Figure 218 must be carried out. loosen the fixing nuts (1) without 88148 removing them in order to enable moving the pump backwards using 99340035 extractor.From timing side. remove the cover (2) loosening the screws (1) in order to have access to the union fixing nut (3) to the pump driving gear.S.Tighten the lateral screw (1) blocking rotation of the . .From the pump side. Absolutely keep .INDUSTRIAL APPLICATION ED. from the pump shaft. conditions at compression end stage cylinder No. 1 4 Hold the pump driving gear to avoid interference or ! crawling during timing gear rotation. . fixing nuts. together with the gasket. SECTION 3 .Loosen the fixing nut (3) and remove the relating washer.Withdraw the pump from the studs. Figure 218) and withdraw the gear or wire to the pump). . .

arrange the starting motor in its seat. Figure 221).On the timing side. 74 NEF ENGINES ED.INDUSTRIAL APPLICATION zs Figure 220 Figure 222 1 2 1 88149 . rotation and fit the slip washer (1). Tighten the screw fixing above said washer: this way the feed pump shaft is free to rotate. bleeding recovery pipes from injectors to 1 4 pump. connect acceleration cable.Connect all pipelines (from pumping elements to injectors. Lock the nut to the 90-95 Nm couple. LDA pipeline and feed provided by priming pump).Assemble the pump pre-set in its housing on the engine. Figure 221) including gasket and ! not be utilised again.Partially loosen the screw (2) locking the pump shaft slot centre. 2 3 75715 . fit the washer and screw up the fixing nut (3) to the pump shaft. Figure 221 . JANUARY 2004 SECTION 3 . . . throughout the specially appointed port.Assemble the cover (2. . . tighten the screws (1.Disassemble the flywheel rotation/locking tool 99360339 or 99360330. In case pump removal has been carried out while the ! engine was assembled. 88148 fitting the shaft into the gear port (not provided with wrench). The gasket removed during pump disassembly shall .Pull the pin outwards setting the camshaft gear free.Connect electrical connections to electro-magnets on the hydraulic head and on KSB.Tighten the fixing nuts (1) locking the pump flange in the . Always use original spare parts.DUTY . .

.There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating.Check and blow by with care the engine cooling system. procedure Figure 224 Start the engine. Where designed. then check that: . oil filter and heat exchanger as well as relating housings. withdraw equipment that was disconnected during engine the power take-off (2).There is no fuel leakage from fuel pipelines. carrying out frequent drainage. Disassembly of such mechanism shall be executed as .Loosen the two screws (3) and after having removed the dashboard containing the tools as well as of the cover (1) with a specially provided extractor.Verify correct working of the lighting leds of the .There is no blow-by from pneumatic pipes (if provided). . Preventively check that the liquid levels have been Power take-off disassembly and assembly correctly restored. disconnection. .Loosen the bleeder vent screws (1) on the fuel filter supports.Cylinder head. SECTION 3 . there is a power take-off able to transmit motion to different auxiliary parts. let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening. .There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and. eventually providing to further tighten the locking rings.Assemble cover and gasket and tighten the screws to the prescribed couple. .INDUSTRIAL APPLICATION ED. it is necessary to execute bleeding of air within the system. then tighten the screws. .Switch starter revolution on. 76137 . following: . activating the priming pump and driving fuel delivery to the filters. 76140 In case any operation has been executed on the components of the feed circuit. providing new gasket and checking the sprocket Figure 223 gear meshing.The two gaskets (4) shall be replaced in phase of . . reassemble. oil pan and bearing. . .DUTY .Vary out the assembly fitting the power take-off in its housing.Continue executing this operation until when fuel drains Checks and controls from the bleeder vent screws. JANUARY 2004 NEF ENGINES 75 zs Feed system bleed procedure .Carefully check the fuel connection pipes to the respective unions. The following tests shall be made after engine ! assembly to the vehicle.

INDUSTRIAL APPLICATION zs .DUTY . JANUARY 2004 SECTION 3 . 76 NEF ENGINES ED.

JANUARY 2004 NEF ENGINES 77 DIAGNOSI PART TWO - ELECTRICAL EQUIPMENT .DUTY .INDUSTRIAL APPLICATION ED. SECTION 3 .

DUTY . 78 NEF ENGINES ED.INDUSTRIAL APPLICATION DIAGNOSI . JANUARY 2004 SECTION 3 .

SECTION 3 - DUTY - INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 79

ELECTRICAL COMPONET LAYOUT (4 CYL. ENGINES WITH ROTARY POMP)

Figure 225

3
2
4

A

1

B

8
5

7

6

75724

The electrical components provided with NEF F4GE04---
Engine are listed here following:
1. Cooling liquid temperature sensor;
2. Starter;
3. KSB Water temperature sensor;
4. Electromagnets assembled to feed pump:
(A) on hydraulic head unit
(B) on KSB;
5. Fuel heater;
6. Oil pressure sensor;
7. Heater for cold start-up (if included);
8. Alternator;

80 NEF ENGINES ED. JANUARY 2004 SECTION 3 - DUTY - INDUSTRIAL APPLICATION

Cooling liquid temperature sensor Starter
Figure 226 Figure 227

1
75717

Starter is usually driven by starting unit placed on the vehicle
dashboard and provides positive tension to the tele-switch
C assembled to the starter itself.
Specifications:
A B
BOSCH 3 kW - 12V

A C
B
KSB Water temperature sensor
75718

Figure 228
It is a component integrating a temperature sensor.
It is assembled to the engine head close to the thermostat
unit and its duty is to detect engine cooling liquid temperatu-
re.
Specifications:
Range of working temperatures:
Connection side -40 ÷ +150 ºC for < 10 min.
Bulb side on engine: -40 ÷ +140 ºC
Working tensions: 6 ÷ 28 V
Settings:
80 ºC 0.304 ÷ 0.342 kΩ
20 ºC 2.262 ÷ 2.760 kΩ
-10 ºC 8.244 ÷ 10.661 kΩ

75719

It is assembled to the cylinder head on the engine left hand
side.
Specifications:
Working tensions: 12 ÷ 24 V
Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 32±2 ºC Contact opening
upon increasing temperature
22±2 ºC Contact closure
upon decreasing temperature

SECTION 3 - DUTY - INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 81

Electromagnets assembled to feed pump Fuel filter

Figure 229 Figure 231

1

2

2 1
75724a

1 - Hydraulic head Electro-magnet; 2 - KSB 75716

Electro-magnet
1 - Fuel temperature sensor; 2 - Resistor for filter
heating;

Oil pressure sensor
On the fuel filter bearing there is the temperature sensor and
Figure 230 the fuel filter heating resistor connection.

Alternator
Figure 232

75722

It is assembled to the block on the engine’s left hand side.
Specifications:
Working tensions: 12 ÷ 24 V
75725
Contact closure
upon lower pressure: 0.2 bar
Contact opening
upon higher pressure: 0.9 bar It is place front view on the right hand side of the engine, and
is driven by tooth belt.
Specifications:
Rated tensions: 12 V
Current delivered: 90A (at 6000 rpm)
Absorption in stand-by: ≤ 1mA
Sense of rotation: clockwices

2W R It is a resistor assembled to the suction collector and is utilised to heat the air during pre-post heating operations.3A .DUTY .82 NEF ENGINES ED. the pre-post heating resistance according to the engine coolant temperature. Legend F= Fuse Specifications: R= Pre-post heating resistance Working tensions: 12 V Maximum possible T= Remote control switch Air flow: 2 cc / min GHC = Pre-post heating unit (pressure 138 kPa) Electrical diagram pin out PIN Description 1 Description Output for “cold start” signal lines 2 Not connected 3 Feedback signal input from pre-post heating resistance (FB) 4 Started engine signal input (D) 5 Start-up signal input (50) 6 Pre-post heating resistance supply remote control switch output (GH) 7 Supply positive (15) 8 Supply negative (31) 9 Not connected 10 Temperature analogue signal input (NTC) This unit operates. by means of the remote control switch.INDUSTRIAL APPLICATION Pre-post heating resistor Pre-post heating unit Figure 233 Figure 234 +0 30 F 15 7 4 6 GH F 30 50 5 NTC 10 T 31 8 N31 75723 1 3 FB 1. Features: Nominal voltage: 12 V Operating voltage: 7 V ÷ 16V Operating temperature: -40°C ÷ 85°C Maximum current in the GH line: 0. 88153 It is fed by a tele-switch usually placed very close to the engi- ne. JANUARY 2004 SECTION 3 .

4.En- gine are listed here following: 1.INDUSTRIAL APPLICATION ED. . ENGINES WITH ROTARY PUMP) Figure 235 88152 The electrical components provided with NEF F4GE06--. Engine stop assembled to feed pump. Heater for cold start-up (if included). Fuel heater. 8.DUTY . 3. Oil pressure sensor. JANUARY 2004 NEF ENGINES 83 ELECTRICAL COMPONET LAYOUT (6 CYL. 6. KSB Water temperature sensor. Alternator. 5.SECTION 3 . Engine oil lever transmitted. 9. 2. 7. Cooling liquid temperature sensor. Starter.

Specifications: A B BOSCH 4 kW . Specifications: Working tensions: 12 ÷ 24 V Electrical Power load: 2.304 ÷ 0.661 kΩ 75719 It is assembled to the cylinder head on the engine left hand side. Specifications: Range of working temperatures: Connection side -40 ÷ +150 ºC for < 10 min.INDUSTRIAL APPLICATION Cooling liquid temperature sensor Starter Figure 236 Figure 237 1 75717 Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch C assembled to the starter itself.84 NEF ENGINES ED.5 A (induction) 5. JANUARY 2004 SECTION 3 .262 ÷ 2.24V A C B KSB Water temperature sensor 75718 Figure 238 It is a component integrating a temperature sensor. It is assembled to the engine head close to the thermostat unit and its duty is to detect engine cooling liquid temperatu- re. Bulb side on engine: -40 ÷ +140 ºC Working tensions: 6 ÷ 28 V Settings: 80 ºC 0.DUTY .244 ÷ 10.0 A (resistance) Setting: 32±2 ºC Contact opening upon increasing temperature 22±2 ºC Contact closure upon decreasing temperature .760 kΩ -10 ºC 8.342 kΩ 20 ºC 2.

SECTION 3 - DUTY - INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 85

Oil pressure sensor Alternator
Figure 239 Figure 241

75722 75725

It is assembled to the block on the engine’s left hand side. It is place front view on the right hand side of the engine, and
is driven by tooth belt.
Specifications:
Specifications:
Working tensions: 12 ÷ 24 V
Rated tensions: 24 V
Contact closure
upon lower pressure: 0.2 bar Current delivered: 90A (at 6000 rpm)
Contact opening Absorption in stand-by: ≤ 1mA
upon higher pressure: 0.9 bar
Sense of rotation: clockwices

Fuel filters

Figure 240

76210

1 - Fuel temperature sensor;
2 - Resistor for filter heating;

On the fuel filter bearing there is the temperature sensor and
the fuel filter heating resistor connection.

86 NEF ENGINES ED. JANUARY 2004 SECTION 3 - DUTY - INDUSTRIAL APPLICATION

Pre-post heating resistor Pre-post heating unit

Figure 242 Figure 243

+0 30

F 15 7
4
6 GH F
30 50 5
NTC 10 T
31 8
N31
1 3 FB
75723
1.2W R

It is a resistor assembled to the suction collector and is utilised
to heat the air during pre-post heating operations. 88153

It is fed by a tele-switch usually placed very close to the engi-
ne. Legend
F= Fuse
Specifications: R= Pre-post heating resistance
Working tensions: 12 V Maximum possible T= Remote control switch
Air flow: 2 cc / min GHC = Pre-post heating unit
(pressure 138 kPa)
Electrical diagram pin out
PIN Description
1 Description
Output for “cold start” signal lines
2 Not connected
3 Feedback signal input from pre-post heating
resistance (FB)
4 Started engine signal input (D)
5 Start-up signal input (50)
6 Pre-post heating resistance supply remote
control switch output (GH)
7 Supply positive (15)
8 Supply negative (31)
9 Not connected
10 Temperature analogue signal input (NTC)

This unit operates, by means of the remote control switch,
the pre-post heating resistance according to the engine
coolant temperature.
Features:
Nominal voltage: 12 V
Operating voltage: 7 V ÷ 16V
Operating temperature: -40°C ÷ 85°C
Maximum current in the GH line: 0.3A

SECTION 3 - DUTY - INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 87

DIAGNOSI

PART THREE - TROUBLESHOOTING

88 NEF ENGINES ED.INDUSTRIAL APPLICATION DIAGNOSI . JANUARY 2004 SECTION 3 .DUTY .

Elim- inate the air from the injection pump by un- screwing the cap and working the fuel pump by hand. Dismantle and clean the injection pump.INDUSTRIAL APPLICATION No fuel in tank. Incorrect timing of injection pump. Re- move water from tank and refuel. SECTION 3 . examine and tighten the nuts on the or loose. present and also check the fuel pump. Replace bat- tery if necessary. Check and correctly time the injection See your dealer. pump. Refuel. battery terminals. ED. Faulty starter motor. a jet of compressed air. Check and recharge battery. ANOMALY POSSIBLE CAUSE REMEDY NOTE The engine does not start Battery flat or faulty. No power supply. Replace the cable ter- minals and the nuts if excessively corroded. Disconnect the hoses and clean them using Drain feed system. Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in fact pump. Overhaul or replace the fuel or transfer pump.DUTY . JANUARY 2004 MOTORI NEF 89 . Repair or replace the starter motor. Deposits or water in the fuel tank. Connections to battery terminals corroded Clean.

The engine cuts out. a jet of compressed air. corroded or chalky valves. Replace the valves. Adjust with adjustment screw. device for cold spark advance con. K. Idle rpm too low. Remove water from fuel tank and refuel. Broken injection pump controls. Clogged fuel filter. MOTORI NEF trol operating incorrectly.Check that the hoses are not cracked or the tem. Replace worn parts. JANUARY 2004 Abnormal clearance between camshaft Adjust clearance by replacing shims. unions loose. Dismantle and replace if necessary. Irregular flow of injection pump. rectify or replace the cyl- inder head seatings. low temperatures. Disconnect the hoses and clean them using Drain feed system. SECTION 3 . cams and tappets. Replace the fuel filters. Adjust flow.B. remove the air from the hoses and deaerate the in- jection pump and fuel filter by unscrewing the caps and working the primer pump by hand. 90 ANOMALY POSSIBLE CAUSE REMEDY NOTE The engine does not start at low temperatu. See your dealer. Replace the faulty parts. See your dealer.INDUSTRIAL APPLICATION .K. Impurities or water in the fuel lines.Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use at res forming due to the use of unsuitable fuel. Presence of air in the fuel and injection sys.DUTY . Dismantle and clean the injection pump. ED.S.Check or replace the injection pump. Burnt.

Clean the air filter or replace if necessary. Fouling in coolant openings in the cylinder Wash following the standards specified for head and cylinder groups. JANUARY 2004 Excessive piston wear.Check or replace injection pump.B. Check and correctly calibrate the regulator. Engine operation is irregular and lacks Incorrect timing of injection pump.DUTY . Incorrect calibration of speed regulator. Dry air cleaner blocked. Check or replace injection pump. power K. Check and adjust the tightness of the belt. Coolant level too low.K. MOTORI NEF 91 . Check timing and correctly set pump. Malfunctioning thermostat. Re- place the gasket.INDUSTRIAL APPLICATION Incorrect calibration of injection pump. Water pump drive belt slack. Replace the thermostat. bench so that the injection is at the specified rate. SECTION 3 . Check timing and tune correctly. Check the unit and replace if necessary. Incorrect engine timing. the type of descaling product used. Top-up radiator with coolant. See your dealer. functioning. check corret worching of such device.S. On applications provided with automatic tensioner. automatic cold advance device mal. Correct the delivery rate of the pump on a See your dealer. ED. ANOMALY POSSIBLE CAUSE REMEDY NOTE The engine overheats Faulty water pump.

device Check that the diaphragm is not perforated.Clean the nozzles of the atomisers using the power ation of injectors. appropriate tools and completely overhaul the injectors. See your dealer.INDUSTRIAL APPLICATION . that the counter spring is suitable and that it has the correct loading (check on test bench).Adjust the tie-rods so that the command gulation lever incorrectly adjusted. Incorrect set-up of injection pump. Check that there is adequate air pressure in- side the intake manifold in relation to the engine rpm under full-load conditions. Incorrect play between camshaft cams and Check and correct play tappets. SECTION 3 .A. Engine running with abnormal knocking Faulty operation of injectors.See your dealer.D. Correct the set-up of the pump so that in. Replace all injectors. jection occurs at the specified angle. lever can be moved to the full delivery posi- tion.DUTY . If necessary drain feed system. Clean or replace air cleaner. Faulty turbocharger. MOTORI NEF system. 92 ANOMALY POSSIBLE CAUSE REMEDY NOTE Engine operation is irregular and lacks Partial blockage of nozzles or faulty oper. Impurities or water in the fuel and injection Carefully clean the system and refuel. Tie rods between accelerator pedal and re. Replace complete unit. Air cleaner blocked. clean them and re- place those that are seriously dented. JANUARY 2004 Fuel lines blocked. Dismantle the hoses. Faulty operation of L. ED.

The engine smokes abnormally. There is an excessive delay on the injection Correct the set-up. Replace the rods. Replace with new bushings. accordance with the data given in the ca- libration table. MOTORI NEF 93 . rings.K. Adjust the play between camshaft cams and tappets and check that there are no broken springs.Check operation by a tester and adjust cor- ED.DUTY . Misalignment of rods. SECTION 3 .INDUSTRIAL APPLICATION Loose bushings in the rod seatings. Loosening of screws securing flywheel. JANUARY 2004 tioning. device out of calibration or malfunc.B. rectly as described in the manual.S. K. Check alignment of crankshaft. Crankshaft unbalanced. Black or Excessive maximum pump output. dark grey smoke. that there is no excessive play be- tween the valve stems and the valve guides. tappets and seatings. Noisy timing. Replace the loosened screws and tighten all the screws to the specified torque. Noise from piston journals due to excessive Replace the piston journal and/or the piston play of piston hubs and in the rod bushing. Disconnect the pump and adjust delivery in See your dealer. Replace the thrust half- or excessive play on shoulders. ANOMALY POSSIBLE CAUSE REMEDY NOTE Engine running with abnormal knocking Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and install play on one or more main or rod bearings smaller bearings. and rod bushing. pump.

Air cleaner blocked or deteriorated. See your dealer. worn cylinder liners. The holes in the atomisers (or some of Replace the injectors with a series of new in- them) are partially or entirely blocked. Injection hoses with an unsuitable internal Check conditions of the end or unions and diameter. automatic cold advance device mal. Loss of compression in the engine due to: Overhaul the engine or limit the interven- stuck or worn flexible rings. dark grey smoke.B. Black or The injection pump has an excessive ad. valves deteriorated or badly adjusted. Correct the set-up of the pump. Replace the injector.DUTY . jectors or clean and rectify the original ones MOTORI NEF using suitable equipment. tions to the relative parts. peated blocking. Blue. valves following wearing of guides or valve stems.S. ED. K.Replace the thermostat. te. tors or incorrectly calibrated. efficient). grey smoke tending to whi. SECTION 3 .Excessive delay in injection pump.Correct the set-up. end of hoses pinched due to re. different types of injec. JANUARY 2004 Faulty injector. by glued or worn rings or wearing of cylin- der liner walls. Engine oil passing through the intake guides.Recondition the cylinder head. Engine too cold (thermostat blocked or in.Check or replace injection pump. grey-blue.K. 94 ANOMALY POSSIBLE CAUSE REMEDY NOTE The engine smokes abnormally. vance. Leaking of oil from the piston rings caused Overhaul the engine.where necessary replace the hoses.Replace or calibrate the injectors. Clean or replace the filter element.INDUSTRIAL APPLICATION . See your dealer. Unsuitable injectors. functioning.

SECTION 3 .INDUSTRIAL APPLICATION ED.MAINTENANCE PLANNING . JANUARY 2004 NEF ENGINES 95 DIAGNOSI PART FOUR .DUTY .

96 NEF ENGINES ED. JANUARY 2004 SECTION 3 - DUTY - INDUSTRIAL APPLICATION

DIAGNOSI

SECTION 3 - DUTY - INDUSTRIAL APPLICATION ED. JANUARY 2004 NEF ENGINES 97

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 engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500

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

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.

98 NEF ENGINES ED. JANUARY 2004 SECTION 3 - DUTY - INDUSTRIAL APPLICATION

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 inconven-
iences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.

MAINTENANCE PROCEDURES Figure 245
Checks and controls

Engine oil level check.
The check must be executed when the engine is disconnected 1
and possibly cool.

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

Figure 244

MAX
2

75749
MIN
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
1 flow easier”.
Some applications are equipped with a level transmitter alert-
ing dashboard instruments in case of insufficient lubrication oil
within the pan.

75748
The engine oil is highly polluting and harmful.
Draw off the rod from its slot and check that the level is within
!
In case of contact with the skin, rinse well with water
the etched tags of minimum and maximum level. and detergent.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and Adequately protect the skin and the eyes, operate in
put it back in its slot. Draw it off again and check the level. full compliance with safety regulations.
In case the level results being close to the tag showing mini- Disposal must be carried out properly, and in full com-
mum level, provide filling lubrication of the engine’s compo- pliance with the law and regulations in force.
nents.

JANUARY 2004 NEF ENGINES 99 Check of fuel system Lubricating system check The check must be executed both when the engine discon. status of the pipes specially close to the holding strips. The check must be executed both when the engine discon- nected and when it is running. and in full com- Verify that the radiator is clean. ders engines will be equipped with two fuel filters.INDUSTRIAL APPLICATION ED. .DUTY . rinse well with water nected and when it is running. vided with drainage. Lock the screw (max 0. Verify the presence of any oil leakage or blow-by from the cific equipment). the presence of any leakage from the connectors. to the filter. Check of water presence within fuel filter or pre-filter Due to the high temperatures achieved by the sys- ! tem. screw.5 Nm locking couple) as soon as fuel starts bleeding. but wait for the time deemed necess- ary for the cooling. both pro- ! through the bleeds on the engine. serious in. to the injection pump and to the head. ! quickly in presence of water or impurity within the fuel. the correct working of the fan pliance with the law and regulations in force. The check must be executed both when the engine discon- ! In case of contact with the skin. the presence of air pockets in the engine’s head. Disposal must be carried out properly. proceed bleeding system. Drain the water eventually contained in the filter’s bot- convenience might be caused to the engine due to tom. from the manifold and from the radiating unit. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the spe. from the engine pan of from the heat exchanger. Place a container underneath the filter and slightly loosen the If bleeding of the system is not carried out. injectors. Fuel filter is equipped with pump screw-valve to drain the water eventually mixed with fuel (some applications of 6 cylin- In case of new filling. nected and when it is running. Timely proceed operating on the pre-filter (not avail- able on the engine block) to carry out the drainage of The density of the cooling liquid must be checked any how the water within the feed circuit. Cooling system check The engine oil is highly polluting and harmful. Protect the eyes and the skin from any eventual high The components of the system can be damaged very pressure jet of cooling liquid. operate in expansion tank and vice-versa. Check the pipelines from the engine to the radiator. do not operate immediately after the engine’s disconnection. Find out any blow-by. flywheels. verify the full compliance with safety regulations.SECTION 3 . every year before winter season and be replaced in any case every two year. from the Adequately protect the skin and the eyes. and detergent.

* 3 Rotate the drive shaft. . 1 2 3 4 intake * * .DUTY . proceed as follows: Check of belt’s tear and wear status rotate the drive shaft. * - 75806 Adjust clearance between rockers and valves using setscrew wrench (1). * * exhaust . 1 2 3 4 5 6 2 1 intake . * * exhaust .30 ± 0. * . . JANUARY 2004 SECTION 3 . balance cylinder 4 valves and Wait for engine temperature cooling as a precaution adjust the valves marked by the asterisk as shown in in order to avoid serious danger injury.100 NEF ENGINES ED. crack. ! ance adjustment for rocker arms — valves. Rotate the drive shaft. the table: cylinder n.55 ± 0. Working clearance shall be as follows: .05 mm.05 mm . 1 2 3 4 intake . - exhaust * . check end and surface grinding. cylinder n. .exhaust valves 0. box wrench (3) and feeler gauge (2). * - Check and setting of tappet clearance 4 cylinder engine Figure 246 cylinder n. - exhaust * .intake valves 0. excessive wear in correspondence of toothing.INDUSTRIAL APPLICATION Check of drive belt tensioning In order to more quickly perform the operating clear- Some applications are equipped with an automatic tensioner that provides correcting belt tensioning. un- ! expected motion of the belt may occur. balance cylinder 1 valves and adjust the valves marked by the asterisk as shown in the table: Carefully verify the belt’s surface in order to detect any sign of 4 cylinder engine incision. * . * Danger: if the engine is switched off but is still hot. balance cylinder 6 valves and adjust the valves marked by the asterisk as shown in the table: cylinder n. * . * . * . * . 1 2 3 4 5 6 intake * * .

it is necessary to re- place the filter. carry out a top- safety rules. the pan shape and the oil quantity can change slightly. .Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dip- sick.SECTION 3 .Tigthen by means of the 99360076-tool of three fourth In case of contact with the skin. tions. water and detergent. is hot. ! . JANUARY 2004 NEF ENGINES 101 Oil motor and filter replacement Whereas you replace the lubrication oil. don’t mix oils having different features. . However. . . ing of the filtering cartridge. wash with much turn. pan connected with the drain plug. The oil motor is very pollutant and harmful. According to the application the filter can be located in different Warning: We recommend to wear proper protec.Place a proper container for the oil collecting under the in case of contact wash the skin with running water. We recommend to carry out the oil drainage when the motor Place properly a container for the liquid. and the inserting plug to ease the downflow of the lubrica- tion oil. positions: the following procedure is a valid guide for all applica- ! tions because of high motor service temperature.Unscrew the plug and then take out the control dipsick according to the rules.DUTY . If it is necessary.Operate the motor for some minutes and check the level Protect properly skin and eyes: operate according to through the dipsick again. For the cartridge replacement use the 9936076-tool.Replace the filtering cartidge with a new one and screw manually until when the gasket is in contact with the sup- port. the following oper.The filter is composed by a support and a filtering cartridge. screw the plug and carry out the clean oil filling. the service war- ranty is no more valid. The motor oil is very pollutant: it must be disposed of . If you don’t comply with theses rules.After the complete drainage. . Use only the recommended oil or oil having the re- ! quested features for the corrrect motor functioning. Warning: avoid the contact of skin with the motor oil: . ping up to compensate the quantity of oil used for the fill- Dispose of the residual properly following the rules.INDUSTRIAL APPLICATION ED. The motor oil reaches very high temperature: you . must always wear protection gloves. In case of topping up. Warning: the oil filter contains inside a quantity of oil ations are valid for all applications. Due to the several applications. ! of about 1 kg.

Wait for the motor temperature lowering to avoid After filters replacement the supply equipment very serious accidents.Lock screw (1) and the bolt that fixes the alternator to the support . For applications with traditional belt stretcher Figure 247 According to the applications the filters position and the quan- tity can change. . . ! deaeration must be carried out.DUTY . Collect the fuel in a container without impu- rities. .Loosen the bolt that fixes the alternator to the support.Fit the new belt on the pulleys and guide rollers. . . .Tigthen through the 99360076-tool at 10-5 Nm torque.Stretch POLY-V belt. motor with an automatic screw coupling.Loosen screw (1) and the relevant nut on belt stretching bracket (3). . .Run the engine for a few hours and check proper belt stretching. During this operation don’t smoke and don’t use free We describe the replacement of a belt mounted on a 4-cylin- ! flames.Drain the fuel inside the filter by operating the water re- lease screw.Unscrew the cartridge by using the 99360076-tool.Collect the eventual fuel inside the filtering cartridge. However the following operations are valid for all applications.102 NEF ENGINES ED.Screw manually the new filtering cartdrige until when the gasket is completely on its seat. 88089 .Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge. ders motor with traditional belt tension and a 6-cylinders Avoid to breathe the vapors coming from filter. . . JANUARY 2004 SECTION 3 .INDUSTRIAL APPLICATION Fuel filter replacement Alternator belt replacement Due to several applications the belt run can change very much. Warning: with switched off motor (but still hot) the ! belt can operate without advance notice. .

Operate on the tightener (1) and withdraw the belt (3) from the alternator and water pumps from pulleys and from the returns pumps.Further adjustments are not required. .Replace the worn belt with a new one.Unscrew the screws which fix the belt guard (2) to the support and dismount it. . . . JANUARY 2004 NEF ENGINES 103 For applications with automatic belt stretcher Figure 248 1 2 3 74171 .Place the automatic tightener in order to key the belt in the functioning position. .SECTION 3 .Place the belt on the pulleys and the guide rollers. .DUTY .INDUSTRIAL APPLICATION ED.

JANUARY 2004 SECTION 3 .INDUSTRIAL APPLICATION .DUTY .104 NEF ENGINES ED.

. . . .Pistons . . . . . . . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . . . . . 4 ENGINE OVERHAUL . . . . . . . . 23 . . . . . . . . . 16 . . . . . . . . . . . . . . . . . . . . . . . . . 12 CYLINDER UNIT . . . . .Finding journal clearance . . . . . .Piston pins . . . . . . . . . . . . . . . . . . . . .Fitting main bearings . . . . . . . . . . . . . . . . . .Measuring piston diameter . . . . . . 11 REPAIR OPERATIONS . .Tappets . . . . 11 ENGINE REMOVAL AT THE BENCH . . . . . . . . . 21 . . . . . . . . . . . 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Replacing oil pump control gear . . .BRAKES SECTION 4 Overhaul and technical specifications Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . .Checks and measurements . . . . . . . . . . . . . . . .Bushes . . . . . . . . . . . . . . . . . . 24 . JANUARY 2004 NEF ENGINES 1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . 24 . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . . .Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 OUTPUT SHAFT .SECTION 4 . . . . . . . . . . . . . . . . . 25 . . . . 12 . . . .Checking cam lift and pin alignment . . . . . . . . 3 CLEARANCE DATA . . . . . . . . . . . . . . . . 17 . . . . 22 .Measuring journals and crankpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 BUSHES . . . . . . . . . . . 21 . . . . . . . . . . . . . . . . . . .Split rings . 21 . 13 . . . . . . . . . . . . . . . . . . . .OVERHAUL AND TECHNICAL SPECIFICATIONS ED. . . . . 14 .Bush replacement . . . . . . . . . . . . . . 16 . . . . . . . . . . . . . . . . . . . . . . . . . .Checking head supporting surface on cylinder unit . . . . . . . . 23 . . . . . .Connecting rods . . . . 13 TIMING SYSTEM . . . . . . . . . . . . 22 CONNECTING ROD — PISTON ASSEMBLY . . . 17 . . . . . . . . . . . . . . . . . . 13 . . . . . . . .Conditions for proper pin-piston coupling . . . . .Checking output shaft shoulder clearance . . . . . . . . . . .Fitting tappets — camshaft . . . . . . . . . . .

. . . . . . 29 VALVE SPRINGS . . . . . 34 CYLINDER HEAD . . . . . . . . .Checking cylinder head wet seal . . . . . . . . . . . . . . . . . . . 31 TIGHTENING TORQUE (FOR 4 AND 6 CYL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . . . . . . . 26 . . .OVERHAUL AND TECHNICAL SPECIFICATIONS Page Page . . 26 VALVES . . . . . . . . . . . . . . . . . . . . . .Checking connecting rods . . . . . . . .) . . . .Refitting the cylinder head . . . . . . . . . . . . . . 30 FITTING CYLINDER HEAD . 32 . . . . . . . . .Checking cylinder head supporting surface . . . . . . . . . . .Checking piston protrusion . . . . .Finding crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . . . . . . 31 . . . . . . . . . . . . . JANUARY 2004 SECTION 4 . . . . . . . . . . . . . . . .Checking torsion . .Regrinding — replacing the valve seats . 30 . . . . . . . . . . . . . . . .Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . 27 VALVE GUIDE . 33 . . . . . checking and grinding valves . . . . 33 . . . . . . . . . . . . . . .Fitting split rings . . . . . . . . . . . . .Checking clearance between valve stem and valve guide and valve centering . .Removing the valves . . . . . . . . . .Removing carbon deposits. 33 . . . . . . 32 . . 35 . . . . . . . . . . . . .Checking bending . . . . . . 26 . . . . . . . . 34 . . . . . . . . . . 27 VALVE SEATS . . . . . . . . . . . . . .Fitting connecting rod-piston assembly Connecting rod-piston coupling . . . . . . . . . . . . 2 NEF ENGINES ED. . . . . . . . .

C.D.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.D.381 to 0.C.152 to 0. D - end after T.SECTION 4 . B - start before B.D..C. C - Checking timing mm - X mm - X Checking operation mm 0.381 X mm 0.762 FUEL FEED Injection Type: Bosch VE 4/12 F VE 6/12 F Injectors Nozzle type DSLA 145 P Injection sequence 1-3-4-2 1-5-3-6-2-4 bar Injection pressure bar - . JANUARY 2004 NEF ENGINES 3 GENERAL SPECIFICATIONS Type 4 CYLINDERS 6 CYLINDERS Cycle Four-stroke diesel engine Power See properties described in Section 3 Injection Direct Number of cylinders 4 in-line 6 in-line ∅ Bore mm 104 Stroke mm 132 + + +.C. A - end after B. = Total displacement cm3 4485 6728 TIMING start before T.D.

4.010 to 0.8 X Piston protrusion X 0.9 Outside diameter ∅1 103.730 to 103. 0.022 .OVERHAUL AND TECHNICAL SPECIFICATIONS CLEARANCE DATA Type 4 CYLINDERS 6 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm ∅1 Cylinder barrels ∅1 104.294 Piston diameter ∅1 0. 4 NEF ENGINES ED.000 to 104.000 Piston pin — pin housing 0.010 to 38.994 to 38.52 ∅3 Piston pin ∅3 37.252 to 0. JANUARY 2004 SECTION 4 .748 ∅2 Pin housing ∅2 38.024 X Spare pistons ∅1 type: X Size X 55.016 Piston — cylinder barrels 0.28 to 0.

350 to 2.60 to 0. JANUARY 2004 NEF ENGINES 5 Type 4 CYLINDERS 6 CYLINDER CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm X1 X1 2.30 to 0.605 S2 Split rings S2 2.175 Split rings .968 Small end bush — housing - Piston pin — bush 0. 0.80 X3 0.987 ÷ 41.050 S 1 S1 2.955 to 1.slots 2 0.080 Split rings 0.030 to 4.110 3 0.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.039 Big end half bearings 0.987 to 73.013 ∅2 ∅4 ∅3 Small end bush diameter Outside ∅4 40.4.380 S3 S3 3.785 X2 Split ring slots X2 2.560 to 2.990 1 0.060 to 0.040 to 0.013 Big end bearing housing ∅2 72.019 to 38.033 S Spare big end half bearings S 1.250 to 0.8 X1 Split ring end opening X2 in cylinder barrel: X1 0.460 X3 X3 4.SECTION 4 .100 to 0.987 ÷ 41.40 X3 X2 0.55 ∅1 Small end bush housing ∅1 40.30 to 0.019 to 0.970 to 3.013 Inside ∅3 38.705 to 2.500 .440 to 2.

013 Half bearings — Journals No.28 to 37.545 X1 Shoulder main bearing X2 31.456 to 2.968 S1 S 2 Main bearings ∅3 No.064 to 0.350 to 37.059 to 0.095 No.650 37.982 to 88.475 to 37.955 to 1.013 ∅1 ∅2 Main half bearings S1 2.064 to 0.095 to 0.01 Crankpins p ∅2 68.OVERHAUL AND TECHNICAL SPECIFICATIONS Type 4 CYLINDERS 6 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm X Size X - Max.280 X2 X3 Shoulder half-rings X3 37.730 to 32.008 No.100 Half bearings .Crankpins 0. JANUARY 2004 SECTION 4 .250 to + 0.987 to 69.270 .464 Big end half bearings S2 1. 2 — 3 — 4 ∅3 87.99 to 83.977 to 88.6 NEF ENGINES ED.500 Big end half bearings Shoulder journal X1 37.38 Output shaft shoulder 0. 1 — 5 ∅3 87.090 Main half bearings + 0. 2—3—4 / 2-3-4-5-6 0. tolerance on connecting rod axis alignment - Journals ∅1 82. 1—5 / 1-7 0.

637 to 43.052 to 0.713 to 43.102 Valve seats - . JANUARY 2004 NEF ENGINES 7 Type 4 CYLINDERS 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM mm ∅1 Valve guide seats on cylinder head ∅1 8.039 ∅4 Valves: ∅4 7.092 Housing on head for valve seat: ∅1 46.987 to 47.013 ∅1 ∅1 43.063 to 47.102 X Sinking X 0.050 to 0.663 Valve seat outside diameter.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.84 0.089 α 60º ∅2 43. ∅ 2 valve seat angle on cylinder head: ∅2 47.739 α α 45º X 0.356 to 1.963 α α 45º Valve stem and guide 0.963 α 60º ∅4 7.943 to 7.943 to 7.019 to 8.050 to 0.102 Between valve seat and head 0.SECTION 4 .104 to 0.

222 to 59.147 Bushes and housings - on block Bushes and journals 0.02 641 N H2 38.139 ∅ ∅ ∅ No. JANUARY 2004 SECTION 4 .OVERHAUL AND TECHNICAL SPECIFICATIONS Type 4 CYLINDERS 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM mm Valve spring height: free spring H 63.248 housings No.045 1⇒7 ∅ ∅ 1 ∅ 3 Camshaft bush outside ∅ diameter: ∅ 59.20 Injector protrusion X - X Camshaft bush 59.038 to 0.05 H H1 H2 under a load equal to: 329 N H1 49.222 to 59.995 to 54. 1-5 Camshaft housings 54.8 NEF ENGINES ED.089 to 54.162 Cam lift: H H - H - .083 to 54. 2-3-4 1 23 4 5 ∅ 2 Camshaft journals: 1⇒5 ∅ 53.248 Bush inside ∅ diameter ∅ 54.

026 ∅2 Between rockers and shaft 0.954 ∅3 15.980 ∅2 Between tappets and housings 0.963 to 21.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.975 Rockers ∅2 19.025 to 0.000 to 19.063 . JANUARY 2004 NEF ENGINES 9 Type 4 CYLINDERS 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM mm ∅1 Tappet cap housing on block ∅1 - ∅2 ∅3 Tappet cap outside diameter: ∅2 15.924 to 15.070 Tappets - ∅ 1 Rocker shaft ∅1 21.965 to 15.025 to 0.SECTION 4 .

OVERHAUL AND TECHNICAL SPECIFICATIONS . JANUARY 2004 SECTION 4 .10 NEF ENGINES ED.

The section illustrates therefore all the most important engine overhaul procedures. 70161 Use tool 99360500 (1) and hoist to remove the output shaft (2) from the block. Figure 2 Figure 5 70159 70162 Remove the screws (1) and the main bearing caps (2). Keep the half-bearings into their housings since in ! case of use they shall be fitted in the same position found at removal. Withdraw the pistons including the connecting rods from the top of the engine block.OVERHAUL AND TECHNICAL SPECIFICATIONS ED. The following operations are relating to the 4 cylinders engine but are analogously applicable for the 6 cylinders. Figure 1 70160 The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2). JANUARY 2004 NEF ENGINES 11 ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH The following instructions are prescribed on the Figure 3 understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well. Remove the screws (2) and remove the oil nozzles (3). . 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. (See Section 3 of the manual herein).SECTION 4 . Remove the main half-bearings (1). Figure 4 70158 Remove the screws (1) fastening the connecting rod caps (2) and remove them.

Maximum wear is usually found on plane (B) in correspondence with the first measurement. use a ! micrometer for zero-setting. bore and grind 70165 the cylinder barrels. clean accurately the Take note of plate (2) assembling position. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0. 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). scores. 70166 Once engine is disassembled. taper or excessive wear. Should ovalisation. Inspection of cylinder barrel bore to check ovalisation. taper or wear be found. 12 NEF ENGINES ED. Inspect cylinder barrel surfaces. The engine block shall not show cracks. and the other perpendicular (B).OVERHAUL AND TECHNICAL SPECIFICATIONS zs REPAIR OPERATIONS CYLINDER UNIT Figure 6 Checks and measurements Figure 9 s 70163 Remove the screws (1) and disconnect camshaft (3) retaining plate (2). Figure 8 70167 Measurements shall be performed on each cylinder.5 mm and to the specified assembling clearance. ovalisation. cylinder-block assembly. taper and wear shall be performed using the bore dial gauge 99395687 (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter. Withdraw the tappets (1) from the engine block. 70164 Figure 10 Withdraw carefully the camshaft (1) from the engine block. JANUARY 2004 SECTION 4 . they shall be free from seizing. ! Use the proper rings to handle the cylinder unit. Figure 7 Check operating plug conditions and replace them in case of uncertain seal or if rusted. . Should the ring gauge be not available.

Replace if higher value is found.SECTION 4 .tighten the fastening screws to the specified torque.024/-0 . Checking head supporting surface on cylinder unit When finding the distortion areas. TIMING SYSTEM Camshaft Figure 12 70169 CAMSHAFT MAIN DATA (4 CYL.use the proper internal gauge to check whether the 0. all barrels shall have the same ! oversize (0.5 DIN OR ISO 1997 CUT OFF 2.5 mm . replace the cylinder unit.fit the main bearings caps on the supports without bearings. JANUARY 2004 NEF ENGINES 13 Figure 11 Check main bearing housings as follows: 104 +0.5 housing diameter is falling within the specified value. Check cylinder unit operating plug conditions. 1.075 mm.0 . α 70168 G In case of regrinding.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.) Specified data refer to pin standard diameter .5 mm). Planarity error shall not exceed 0. replace them in case of uncertain seal or if rusted. Rz = 1.

JANUARY 2004 SECTION 4 . 70171 Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.) Camshaft pin and cam surfaces shall be absolutely smooth. otherwise replace the camshaft.14 NEF ENGINES ED. check whether the alignment error is not exceeding 0. .OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 13 70512 MAIN DATA ABOUT CAMSHAFT PINS (6 CYL. Figure 14 70172 Camshaft bushes (2) shall be pressed into their housings. camshaft and the bushes.04 mm. 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 15 on the central support. Internal surfaces must not show seizing or wear. Use bore dial gauge (3) to measure camshaft front and rear bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.

JANUARY 2004 NEF ENGINES 15 Figure 16 Sec. A-A * 70513 MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS *Height to be obtained after driving the bushes.SECTION 4 .OVERHAUL AND TECHNICAL SPECIFICATIONS ED. . Figure 17 sec. A-A * 70173 CAMSHAFT BUSH AND HOUSING MAIN DATA * Value to be obtained after driving the bushes.

Figure 21 When refitting the bushes (1). RELEVANT HOUSINGS ON THE ENGINE BLOCK .16 NEF ENGINES ED. direct them to make ! the lubricating holes (2) coincide with the holes on the block housings. remove and refit them housings on the engine block. JANUARY 2004 SECTION 4 .OVERHAUL AND TECHNICAL SPECIFICATIONS Bush replacement Fitting tappets — camshaft Figure 18 Figure 20 70176 70174 Lubricate the tappets (1) and fit them into the relevant To replace front and rear bushes (1). 70164 Lubricate the camshaft bushes and fit the camshaft (1) taking care not to damage the bushes or the housings. MAIN DATA CONCERNING THE TAPPETS AND THE then tighten the screws (2) to the specified torque. using the beater 99360362 (2) and the handgrip 99370006 (3). Tappets Figure 22 Figure 19 70238 84053 Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator.

Grind journals and crankpins if seizing. See Figure 26. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to Figure 24 which the pins are to be ground. Undersize classes are: Journals and crankpins shall always be ground to the ! same undersize class.13 mm. 70180 Journals and crankpins undersize shall be marked on the side of the crank arm No. JANUARY 2004 NEF ENGINES 17 OUTPUT SHAFT Measuring journals and crankpins Figure 23 Figure 25 70179 70182 Check camshaft end float (1). ovalisation are found. scoring or excessive It shall be 0.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.SECTION 4 .99 83.1. For undersized journals: letter B For undersized crankpins and journals: letters MB Figure 26 82.98 69. Fit nozzles (2) and tighten the fastening screws (1) to the For undersized crankpins: letter M specified torque. It is recommended to insert the found values in the ! proper table.01 70181 FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value .01 68.23 ± 0.

OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 27 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 Taper 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 . JANUARY 2004 SECTION 4 .18 NEF ENGINES ED.

500 between adjacent main journals 70577 MAIN OUTPUT SHAFT TOLERANCES . JANUARY 2004 NEF ENGINES 19 Measuring journals and crankpins (6 cylinders) Figure 28 70514 FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value Figure 29 K * Measured on a radius greater than 45.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.SECTION 4 .5 mm **  0.

20 NEF ENGINES ED. JANUARY 2004 SECTION 4 .OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 30 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 Taper LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL CRITICAL  IMPORTANT ⊕ SECONDARY  .

half rings.fit caps (1). 70184 Check the backlash between output shaft main journals and Check that gear toothing (1) is not damaged or worn. Figure 34 When fitting the new gear.SECTION 4 . . with dynamometric wrench to 80 ± 6 Nm. Main bearings (1) are supplied spare with 0. ! Clean accurately the main half bearings (1) having the 70187 lubricating hole and fit them into their housings. with dynamometric wrench to 50 ± 6 Nm.250 — 0.OVERHAUL AND TECHNICAL SPECIFICATIONS ED. Tighten the pre-lubricated screws (1) in the following three successive stages: The second last main half bearing (1) is fitted with shoulder . .2nd stage. Fitting main bearings Figure 32 70186 . . .clean accurately the parts and remove any trace of oil. JANUARY 2004 NEF ENGINES 21 Replacing oil pump control gear Finding journal clearance Figure 31 Figure 33 70161 Refit the output shaft (2). including the half bearings (2) on the relevant 70185 supports. Do not try to adapt the bearings. Figure 35 Refit the main bearings that have not been replaced. the relevant bearings as follows: otherwise remove it using the proper puller (3).500 mm undersize on the internal diameter.position a piece of calibrated wire (3) on the output shaft pins (4) so that it is parallel to the longitudinal axis. ! in the same position found at removal.1st stage. heat it to 180°C for 10 minutes in an oven and then key it to the output shaft.

with tool 99395216 (1) set as shown in the 70190 figure. ! . standard value is 0. Once the specified backlash is obtained. 70191 CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. JANUARY 2004 SECTION 4 . The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire. 3rd stage.41. Split rings . Screws - 6. The numbers on the scale indicate the backlash in mm.OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 36 Checking output shaft shoulder clearance α Figure 38 70188 . Pistons are supplied spare with 0. This check is performed by setting a magnetic-base dial gauge (2) on the output shaft (3) as shown in the figure. Stop rings .5. Piston .3.4. Connecting rod . replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between output shaft pins and main half bearings.22 NEF ENGINES ED. CONNECTING ROD — PISTON ASSEMBLY 70189 Figure 39 .2. Replace the half bearings and repeat the check if a different backlash value is found.5 mm oversize. Half bearings .Remove caps from supports.7. Pin . lubricate the main bearings and fit the supports by tightening the fastening screws as previously described. Bush.068 to 0. tighten the screws (2) with 90° ± 5° angle.8. Figure 37 If higher value is found.

Figure 44 32614 Piston pin (1) split rings (2) are removed using a scriber (3).OVERHAUL AND TECHNICAL SPECIFICATIONS ED. (1) to determine the assembly clearance. PINS AND SPLIT RINGS . JANUARY 2004 NEF ENGINES 23 Pistons Measuring piston diameter Figure 40 Figure 43 32615 32613 Remove split rings (1) from piston (2) using pliers 99360183 Using a micrometer (2). measure the diameter of the piston (3). 70192 The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure. The diameter shall be measured at 12 mm from the Figure 41 ! piston skirt. Figure 42 87760 MAIN DATA CONCERNING KS.SECTION 4 . PISTON.

OVERHAUL AND TECHNICAL SPECIFICATIONS Piston pins Figure 48 Figure 45 18857 32620 To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2nd (2). using Conditions for proper pin-piston coupling a feeler gauge (1). and 3rd slot and the relevant housings on the piston (2). TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal. the clearance Split rings between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that Figure 47 the ring (2) protrudes half-way from the cylinder barrel (3). 16552 Use a micrometer (1) to check split ring (2) thickness. use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.24 NEF ENGINES ED. . In this position. the pin shall be fitted into the piston with a slight finger BETWEEN THE FIRST PISTON SLOT AND THE pressure and shall not be withdrawn by gravity. JANUARY 2004 SECTION 4 . Figure 46 Figure 49 32619 41104 Lubricate the pin (1) and its seat on piston hubs with engine DIAGRAM FOR MEASURING THE CLEARANCE X oil.

In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one. BUSH.SECTION 4 . on the bush with those set on the connecting rod small end. it is recommended not to smooth the When refitting take care to make coincide the oil holes set knurls. Otherwise replace. 0001 A 1998 001 Figure 51 ↓ B 1999 ↓ 70196 9999 C 2000 366 D 2001 Every connecting rod is marked as follows: ! .On body and cap with a number showing their coupling and the corresponding cylinder. . Grind the bush to obtain the specified diameter. Therefore. 1901 to 1940 (blue marking). CONNECTING ROD CAP Connecting rods 1234 A 123 CONNECTING YEAR DAY ROD No. The surface of connecting rod and rod cap are Removal and refitting shall be performed using the proper beater. ** Value not measurable in released condition Bushes Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen.OVERHAUL AND TECHNICAL SPECIFICATIONS ED. PISTON PIN AND HALF BEARINGS * Value for inside diameter to be obtained after driving in connecting rod small end and grinding. 1820 to 1860 (yellow marking). Material removal is not allowed. 87762 MAIN DATA FOR CONNECTING ROD. S W.On body with a letter showing the weight of the connecting rod assembled at production: S V. ! knurled to ensure better coupling. 0001 V * ↓ W 9999 X 70194 Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3). JANUARY 2004 NEF ENGINES 25 Figure 50 Figure 52 CONNECTING ROD BODY 1234 W CONNECT. S X. WEIGHT ING ROD No. 1861 to 1900 (green marking). Spare connecting rods are of the W class with green marking *. .

and lock it with screw (4).OVERHAUL AND TECHNICAL SPECIFICATIONS Checking connecting rods Checking bending Figure 53 Figure 55 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 axes of the connecting rods (1) are parallel rod axis. 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. rod axis.08 mm. . JANUARY 2004 SECTION 4 . point C.08 mm. The difference between point C and point D shall not exceed Figure 54 0.fit the connecting rod (1) on tool 99395363 (5) spindle the latter on pin (3). Manufacturing date. using tool 99395363 (5) as follows: Position the vertical support (1) of the dial gauge (2) to rest .5 mm on the pin (3) in point A and then set the 3. Part number and design modification number. then in this condition reset the dial gauge (2). approx.26 NEF ENGINES ED. 0. Fitting connecting rod-piston assembly Connecting rod-piston coupling Figure 56 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. 2. Move the spindle (4) with the 4. dial gauge (2) to zero. Marking showing 1st slot insert testing. this arrow shall face the front key of the engine Position the dial gauge (2) support (1) to obtain a preload of block. rod (1) on the stop bar (2). Move the connecting rod forwards and backwards to find pin . Arrow showing piston assembling direction into cylinder barrel. 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).set the spindle (3) on V-blocks by resting the connecting top position.

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 . Figure 58 70200 Fit half bearings (1) on connecting rod and cap.OVERHAUL AND TECHNICAL SPECIFICATIONS ED. Figure 61 Fitting split rings Figure 59 70201 32613 Lubricate accurately the pistons. standard. including the split rings and Use pliers 99360183 (3) to fit the split rings (1) on the piston the cylinder barrel inside. 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.5 mm oversize. JANUARY 2004 NEF ENGINES 27 Figure 57 Split rings are supplied spare with the following sizes: ! . Refit the main bearings that have not been replaced.SECTION 4 . yellow/green marking.the number of each connecting rod shall correspond to other by 120°. . Figure 60 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. Do not try to adapt the half bearings. yellow marking. 0. . fit the pin (3) and stop it by the split rings (2). (2). the cap coupling number. ! in the same position found at removal.

Finding crankpin clearance Figure 63 70205 . . ASSEMBLY FITTING INTO BARREL . 70206 .Split ring openings shall be displaced with each other by Figure 65 120°.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. .OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 62 Figure 64 α 70204 70202 .28 NEF ENGINES ED.fit the connecting rod caps (3) with the relevant half .Apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60°. .Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometric DIAGRAM FOR CONNECTING ROD-PISTON wrench (2).set a piece of calibrated wire (2) on the output shaft pins (1).connecting rod-piston assemblies shall have the same α weight. JANUARY 2004 SECTION 4 .clean the parts accurately and remove any trace of oil. Figure 66 70203 To measure the clearance proceed as follows: . comparing the calibrated wire width (1) with the scale on the wire envelope (2). .Remove the cap and find the existing clearance by bearings (4).

1 mm than the diameter measured at approx.SECTION 4 .OVERHAUL AND TECHNICAL SPECIFICATIONS ED. with respect to the top connecting rod cap fastening screws to the specified torque.C. 10 mm from screw end. of the engine block.52 mm. .D. check that their diameter measured at the centre of the thread length is not < 0.275 mm. Once connecting rod-piston assemblies refitting is over. lubricate dial gauge 39395603 (1) fitted with base 99370415 (2) to the main half bearings and fit them by tightening the check piston (3) protrusion at T. use Once the specified clearance has been obtained. JANUARY 2004 NEF ENGINES 29 Figure 67 Checking piston protrusion Figure 68 70207 If a different clearance value is found. Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float. Before the final fitting of the connecting rod cap ! fastening screws. replace the half bearings 70208 and repeat the check. measured with feeler gauge (2) is 0.28 to 0.250 to 0. Protrusion shall be 0.

Intake (1) and exhaust (2) valves have heads with different diameter. Repeat this operation for all the valves. 30 NEF ENGINES ED. ! Sealing rings (2) for exhaust valves are green. Then remove the cap (3) and the springs (4). . number ! them before removing in order to refit them in the same position. Figure 71 Should cylinder head valves be not replaced. 2 A = intake side 1 75752 Remove sealing rings (1 and 2) from the valve guide. JANUARY 2004 SECTION 4 . Overturn the cylinder head and withdraw the valves (5).OVERHAUL AND TECHNICAL SPECIFICATIONS CYLINDER HEAD Figure 70 Removing the valves 1 2 Figure 69 3 4 1 2 6 5 A 75751 Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the 75750 springs (4) the cotters (2) can be removed. Sealing rings (1) for intake valves are yellow.

! seats. Replace the cylinder head if leaks are found. Regrind the valve beater for their removal/refitting.SECTION 4 . Before refitting. smear the plug surfaces with ! water-repellent sealant. If higher values are found grind the cylinder head according to values and indications shown in the following figure.4 A B 0.20 mm. Use a pump to fill with water heated to approx. Replace the cup plugs (1) if leaks are found. max. Checking cylinder head supporting surface Distortion found along the whole cylinder head shall not exceed 0. use the proper After grinding.4 TOTAL C 0.25 mm.01 / ¯ 50 75753 75756 This check shall be performed using the proper tools. The rated thickness A for the cylinder head is 95 ± 0. to obtain the specified value. if required.4 C 0. metal removal shall not exceed thickness B by 1 mm. 90°C and 2 to 3 bar pressure. check valve sinking. .OVERHAUL AND TECHNICAL SPECIFICATIONS ED.025 / ¯ 25. JANUARY 2004 NEF ENGINES 31 Checking cylinder head wet seal Figure 73 Figure 72 D 1 0.

980. scoring or the assembling clearance shall be 0. using tool 99305018 and exceeding 0.052 ± 0.03 mm. removing as less material as possible.32 NEF ENGINES ED.87 44.OVERHAUL AND TECHNICAL SPECIFICATIONS VALVES Figure 76 Figure 74 EXHAUST INTAKE VALVE VALVE 18882 Check the valve stem (1) using a micrometer (2).87 70326 INTAKE AND EXHAUST VALVE MAIN DATA Removing carbon deposits. Use a magnetic base dial gauge (1) set as shown in the figure. 42.092 mm. Check that the valves show no signs of seizing.13 45. if required. cracking. JANUARY 2004 SECTION 4 . Turn the valve (2) and check that the centering error is not Regrind the valve seats. . checking and Checking clearance between valve stem and grinding valves valve guide and valve centering Figure 75 Figure 77 1 2 18625 Remove carbon deposits from valves using the proper metal 75757 brush.13 41. it shall be 6.960 to 6.

5º 59.5º 37. If slight scoring or burnout is found.OVERHAUL AND TECHNICAL SPECIFICATIONS ED. the values shown in Figure 80. INTAKE EXHAUST regrind seats using tool 99305018 (1) according to the angle 84046 values shown in Figure 80. the read value shall comply with the value shown in the figure.06 4.5º 30.5º 4.SECTION 4 . JANUARY 2004 NEF ENGINES 33 VALVE GUIDE VALVE SEATS Regrinding — replacing the valve seats Figure 78 Figure 79 1 2 75754 Check the valve seats (2). fit the new valve seats.5º 75. .5º 36.32 INTAKE EXHAUST VALVE SEAT MAIN DATA 75755 Should valve seats be not reset just by regrinding.5º 60.100°C and using the proper them with the spare ones.5º 60º 45º 74. previously cooled. Use a bore dial gauge to measure the inside diameter of the valve guides. replace Heat the cylinder head to 80° . Use tool 99305019 (Figure 79) to beater. (take care not to damage the cylinder head) until they can Use tool 99305019 to regrind the valve seats according to be extracted from the cylinder head using a punch. into the remove as much material as possible from the valve seats cylinder head.64 4.38 4. Figure 80 29.

Sealing rings (2) for intake valves are yellow and ! sealing rings (3) for exhaust valves are green.34 NEF ENGINES ED. 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).05 N 5 H1 49. the upper cap (3). 4 Compare load and elastic deformation data with those of the new springs shown in the following table.OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 81 FITTING CYLINDER HEAD Figure 83 1 3 1 2 3 1 2 75758 75759 After regrinding. valve guides according to the position marked at removal. use tool 99360268 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2). VALVE SPRINGS Figure 82 50676 Figure 84 1 2 MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS 3 Before refitting use tool 99305047 to check spring flexibility. Fit the sealing rings (2 and 3) on the valve guide. JANUARY 2004 SECTION 4 . .02 329 H2 38.20 641 75751 Position on the cylinder head: the spring (4). 6 Height Under a load of H (free) 63.

Set the cylinder head gasket (1) with the marking “N. The arrow shows the point wherethe gasketthickness isgiven.SECTION 4 . JANUARY 2004 NEF ENGINES 35 Refitting the cylinder head Before re-utilising the fixing screws for the cylinder Figure 85 ! head.OVERHAUL AND TECHNICAL SPECIFICATIONS ED. of component” (1) facing the head. . Take care not to foul the cylinder head gasket. 87759 Check cleanness of cylinder head and engine block coupling surface. verify there is no evidence of wear or deformation and in that case replace them.

0 ± 0.0 + 180º (M12x180) 70 + 180º 7.5x10) 80 ± 8 8.4 (M8x1.5 Final torque 50 .5 Oil rifle plugs (M10x1) 6±1 0.25x25) 24 ± 4 2.5x20) 33 ± 5 3.5) 49 ± 5 Oil pump (M8x1.9.25x45) 24 ± 4 2.4 ± 0.0 ± 0.5 Fuel pump gear (drive gear nut) Snug torque 15 .55 5.5) 11 ± 2 1.0 ± 0.0 + 90º (M12x140) 40 + 180º 4.20 1.4 (M8x1.0 ± 0.4 Cylinder head bolts (M12x70) 50 + 90º 5.1 (M14x1.5 (M10x1.8 ± 0.3.35 3.1 Front cover assembly (M8x1.0 ± 0.5 Rocker assys (M8) 24 ± 4 2.4 Oil pan assembly (M8x1.4 (M18x1.0 .5.3 ± 0.15 1.5 ± 0.4 Intake manifold (M8x1.4 (M8x1.5x12) 10 ± 1 1.4 ± 0.25x40) 24 ± 4 2.0 ± 0.0 Final torque 85 .5 Fan pulley (M6) 10 ± 2 1.0 ± 0.2.1 Fuel pump assembly M8 screw 24 ± 4 2.6 .3 Main bearing cap 1st stage 50 ± 6 5.0 ± 0.25x25) 24 ± 4 2.6 3rd stage 90º ± 5º Rear gear housing assembly 2.2 (M10) 43 ± 6 4.5 3rd stage 60º ± 5º Ladder frame assembly (M10x1.4 ± 0.25x70) 24 ± 4 2.5 .4 ± 0.4 ± 0.4 Assy air intake connection (M8x1.25) 1st stage 30 ± 3 3.2 Assemble oil suction tube (M8x1.4 ± 0.25) 24 ± 4 2.3 ± 0.9 ± 0.5x65) 43 ± 6 4.25x30) 24 ± 4 2.0 + 180º Assy rocker covers (M8x1.4 Water outlet connection (M8x1.1 ± 0.1.4 Fan support (M10x1.4 ± 0.5 ± 0.1 M10x1.4 ± 0.4 Connecting rod bolts (M11x1.6 Water pump (M8x1.4 ± 0.0 ± 0.5 .1 M6 nut 10 ± 1 1.25x10) 15 ± 3 1.25x25) 43 ± 5 4.OVERHAUL AND TECHNICAL SPECIFICATIONS TIGHTENING TORQUE (FOR 4 AND 6 CYL.4 ± 0.1 Exhaust manifold (M10x1.0 ± 0.6 2nd stage 80 ± 6 8.0 Timing pin cap of fuel pump 30 .25x25) 24 ± 4 4.3 ± 0.25) 24 ± 4 2. JANUARY 2004 SECTION 4 .0 .4 Oil bypass valve into lube filter head (M22x1.3 ± 0.25x20) 24 ± 4 2.4 ± 0.3 2nd stage 60 ± 5 6.0 . 36 NEF ENGINES ED.6 ± 0.50) 60 ± 9 6.25x25) 24 ± 4 2.8 Plug (M12x1.4 ± 0.90 8.4 ± 0.) COMPONENT TORQUE Nm kgm Cooling Nozzles (M8x1.4 ± 0.25x35) 24 ± 4 2.4 M6 screw 10 ± 1 1.25x30) 8±1 0.4 (M8x1.5 flange head nuts pre-torque 10 .9 Set timing pin 5±1 0.

4 ± 0.4 ± 0.2 Crankshaft pulley (M12x1.OVERHAUL AND TECHNICAL SPECIFICATIONS ED.3 ± 0.4 Fuel injectors 60 ± 5 6.9 ± 0.4 2nd stage 60º ± 5º Assy rear cover plate to flywheel housing (M8x1.5 ± 1.4 Alternator upper pivot to support (M10) 49 ± 5 4.2 Starter motor to gear case (M10) 49 ± 5 4.6 Alternator wiring (M6x1.4 ± 0.25x30) 24 ± 4 2.4 Alternator to water inlet conn.5 Flywheel housing (M12x120) 85 ± 10 8.5 ± 0.9 ± 0.SECTION 4 .4 ± 0.75x120) 43 ± 6 4.75x30) 77 ± 12 7.4 ± 0.3 ± 0.25) 1st stage 30 ± 4 3.75x10.5 (M10x40) 49 ± 5 4.5) 35 ± 5 3.4 Turbocharger to exhaust manifold (M10) 43 ± 6 4.7 ± 1.5 Flywheel housing (M12x1.5 Alternator mounting hardware (M12x1.0 nut) 10 ± 2 1.0 (M10x80) 49 ± 5 4. assy (M8x1.4 Screw M8 for fastening camshaft gear 36 ± 4 3.25x16) 24 ± 4 2.5 Oil drain (M8x1.5 Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.3 Screw M12 for fastening output shaft caps 1st stage 50 ± 6 5 ± 0.0 (M12x80) 85 ± 10 8.5 2ndd stage 60º ± 5º .25x16) 24 ± 4 2.0 ± 0.6 Oil feed to oil filter head 24 ± 4 2.25x30) 24 ± 4 2.4 Alternator to alternator support (M8x1.9 ± 0.6 3rdd stage 90º ± 5º Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.0 ± 0.9 ± 0.4 ± 0.6 2nd stage 80 ± 6 8 ± 0.0 ± 0.0 ± 0.9) 110 ± 5 11.5 Fuel lift pump 24 ± 4 2.5 ± 0.4 Screw M11 for fastening connecting rod caps 1st stage 60 ± 5 6 ± 0.5 ± 1.25x25) 24 ± 4 2.4 ± 0.4 Lower alternator mounting (M10x1. JANUARY 2004 NEF ENGINES 37 COMPONENT TORQUE Nm kgm Rear lifting bracket (M12x1.4 Oil feed to turbocharger (M12x1.6 ± 0.4 ± 0.

38 NEF ENGINES ED. JANUARY 2004 SECTION 4 .OVERHAUL AND TECHNICAL SPECIFICATIONS .

. . . .TOOLS ED. . .SECTION 5 .BRAKES SECTION 5 Tools Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . JANUARY 2004 NEF ENGINES 1 HYDRAULIC SYSTEM . 3 . .

TOOLS . JANUARY 2004 SECTION 5 .2 NEF ENGINES ED.

SECTION 5 - TOOLS ED. JANUARY 2004 NEF ENGINES 3

TOOLS

TOOL No. DEFINITION

99305019 Kit for valve seat regrinding

99305047 Spring load tester

Revolving stand for overhauling units (700 daN/m capacity, 120
99322205 daN/m torque)

99340035 Injection pump gear extractor.

99340055 Tool to remove output shaft front gasket

99340056 Tool to remove output shaft rear gasket

4 NEF ENGINES ED. JANUARY 2004 SECTION 5 - TOOLS

TOOLS

TOOL No. DEFINITION

99340205 Tool to remove injectors

99346252 Tool for fitting output shaft rear gasket

99346253 Tool for fitting output shaft rear gasket

99360076 Tool to remove oil filter (engine)

99360183 Pliers for removing/refitting piston rings (65 — 110 mm)

99360268 Tool for removing/refitting engine valves

SECTION 5 - TOOLS ED. JANUARY 2004 NEF ENGINES 5

TOOLS

TOOL No. DEFINITION

99360330 Flywheel crank handle (*)

99360339 Tool for stopping the engine flywheel (**)

99360344 Adapter, cylinder compression test (use with 99395682)

99360351 Tool for flywheel holding (***)

Beater for removing/refitting camshaft bushes (to be used with
99360362 993700069)

99360500 Tool for lifting the output shaft

DEFINITION 99360595 Lifting rig for engine removal/refitting 99360605 Band for fitting piston into cylinder barrel (60 — 125 mm) 99361037 Brackets for fastening engine to revolving stand 99322205 99363204 Tool to remove gaskets 99367121 Tool to remove gaskets 99370006 Interchangeable willow handgrip .TOOLS TOOLS TOOL No. JANUARY 2004 SECTION 5 .6 NEF ENGINES ED.

TOOLS ED. JANUARY 2004 NEF ENGINES 7 TOOLS TOOL No.SECTION 5 . DEFINITION 99370415 Gauge base for different measurements (to be used with 99395603) 99395097 Tool to check top dead centre (use with 99395604) Dial gauge holder for rotary injection pump timing (use with 99395100 99395603) 99395216 Pair of gauges with ½” and ¾” square head for angle tightening 99395220 All-purpose goniometer/Inclinometer 99395363 Complete bush testing square .

JANUARY 2004 SECTION 5 . DEFINITION 99395603 Dial gauge (0 — 5 mm) 99395604 Dial gauge (0 — 10 mm) 99395682 Diesel fuel engine cylinder compression control device (*) for engines F4GE0404B*D650 (***) for engines F4GE0484G*D666 F4GE0404H*D651 F4GE0684F*D601 F4GE0454G*D651 F4GE0684G*D600 F4GE0454G*D666 F4GE0454A*D610 F4GE0454H*D651 (****) for engines F4GE0404B*D650 F4GE0484G*D660 F4GE0454A*D606 F4GE0484G*D666 F4GE0484G*D660 F4GE0654A*D651 F4GE0484G*D666 F4GE0684Q*D650 F4GE0684F*D601 F4GE0404B*D651 F4GE0684G*D600 F4GE0454B*D651 F4GE0684Q*D650 F4GE0454E*D651 F4GE0454A*D610 (**) for engines F4GE0404A*D600 F4GE0454A*D605 F4GE0454A*D606 F4GE0454B*D651 F4GE0684F*D601 F4GE0684G*D600 F4GE0454A*D610 F4GE0454A*D605 .8 NEF ENGINES ED.TOOLS TOOLS TOOL No.

. . . 3 . . . . JANUARY 2004 NEF ENGINES 1 HYDRAULIC SYSTEM . . . . .APPENDIX ED. . . .BRAKES Appendix Page SAFETY PRESCRIPTIONS . . . . . .

2 NEF ENGINES ED. JANUARY 2004 APPENDIX .

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. Always keep working areas . undertake proper .In presence of current tension exceeding 48-60 V verify accidental short circuit and oxidation.lubrication oil topping or replacement speed rate.Wear safety gloves and goggles when performing the following operations: . available for consultation. not sufficient to ensure safety to the personnel in-charge of maintenance. . . . .Use of solvents or detergents during maintenance may originate toxic vapors.Ensure . .In case of test or calibration operations requiring engine running.Do not execute any intervention if not provided with necessary instructions.Never top up an overheated engine with cooler and areas in case of emergency. verify that battery clamp polarity . . diesel fuel and or chemical solvents. be aware of all risks involved with such operation.Keep the engine clean from oil tangles. .Never open filler cap of cooling circuit when the engine indicated and always having free access. nor jewels such as rings and chains when working close to engines and equipment in motion.Disconnect batteries from system aboard to load them with the battery loader. fuel pipes) verify presence of liquid . hydraulic. Prevention of injury .Wear safety helmet when working close to hanging loads or equipment working at head height level. JANUARY 2004 NEF ENGINES 3 SAFETY PRESCRIPTIONS Standard safety prescriptions . providing information documentation gas. . .Be equipped with adequate and safe containers for comprehension of the instructions even in case of drainage operation of engine liquids and exhaust oil. unit the temperature decreases under 50ºC. .Do not wear unsuitable cloths for work.Provide Warnings throughout adequate boards signaling danger. Whenever necessary wear safety mask.Ensure that working areas are provided with emergency boxes. (pressure allowed: ≤ 2 bar) . ends. Always wear adequate safety mask or goggles.utilization of compressed air or liquids under pressure .filling inhibitors or anti-frost preventing actions to stop air suction in case of runaway .After every intervention.Donotcarryout working operations if not trained for.Use protection cream for hands. Operating pressure would provoke high must be checked on regular basis and the personnel must temperature with serious danger and risk of burn.Provide for adequate fire extinguishing means. indications of the emergency exit lines.Do not use any tool or equipment for any different must be followed absolutely in a standard working area and operation from the ones they’ve been designed and whose non fulfillment will make any other measure useless or provided for: serious injury may occur. Wait be trained on intervention methods and priorities.Organize and displace specific exit points to evacuate the . bleeding and draining residual pressure or closing dump .Do not smoke nor light up flames close to batteries and or air under pressure.APPENDIX ED. . intervention on running engine. .Disconnect batteries before any intervention on the electrical system. properly . . emergency.Do not utilize fast screw-tightening tools.Always wear safetyshoes whenand clothsadhering tothe body. diesel fuel or solvents in anti-fire valves. Particular attention shall be drawn on some precautions that . ensuring adequate aeration.Do not leave rags impregnated with flammable substances close to the engine. . better if provided with elastics at the ends.Do not disconnect and connect electrical connections in that hands and feet are dry and execute working presence of electrical feed. operationsutilizingisolatingfoot-boards. providing for adequate utilize only appropriate liquids. specially provided containers. Danger: poisoning and death. . Their efficiency is hot.Put the dirty rags with oil.Keep working areas as clean as possible.Smoking in working areas subject to fire danger must be particular circumstances require maintenance strictly prohibited. that must be clearly visible and always provided with adequate sanitary equipment.Always operate when the engine is turned off: whether . During maintenance . Take all necessary precautions to any fuel material. .Never disconnect batteries when the engine is running. prohibitions and indications to ensure easy . efficiency of earth and mass electrical connections. .Upon engine start after maintenance.Before proceeding with pipelines disassembly (pneumatic. Non fulfillment of these prescriptions may cause serious injury and poisoning. with fluttering aerated.Change wet cloths as soon as possible is correct and that the clamps are tight and safe from . .

.Do not execute electric arc welding without having priory environment and within anti-acid containers. aerated. Warning: removed electronic gearbox.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. For engines equipped with electronic gearbox: .Avoid incorrect tightening or out of couple. requiring heating over 80ºC temperature.Do not connect any user to the engine electrical organizespecifictrainingcourses toensure thatpersonnel equipment unless specifically approved. 4 NEF ENGINES ED. storing them in aerated . properly identified areas that shall be working and duration. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration. Any . . is fully aware of such law prescriptions and of basic preventive safety measures. . . and/or with ducts not being provided with filters. far from heat sources and not exposed to fire danger. .Avoid priming from fuel tanks made out of copper alloys personnel’s safety and health shall be adopted. Provide for adequate board indications and .Do not vary or alter any data filed in the electronic gearbox driving the engine. affecting engine’s duration. exhaust oil.Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine changed.Remove electronic gearbox in case of any intervention intoxication and environment contamination. JANUARY 2004 APPENDIX GENERALMANUTENZIONE .Be informed and inform the personnel as well of laws in .Do not paint the components and the electronic connections. .Do not modify fuel systems or hydraulic system unless specific approval has been released.Respect of the Environment shall be of primary importance: all necessary precautions to ensure . battery exhalation represent serious danger of .Handle the batteries with care. Danger: Respect of the Environment incorrect tightening may seriously damage engine’s components.