NEF Engine Mechanical Pump

Mechanical NEF series pump
TIER 2/3
TEACHING MANUAL
EXCELLENCE
TECHNOLOGICAL
WARNING
This publication is a didactic support only.

Due to the natural and continuous evolution of the product, certain subjects
dealt with in this publication could not be updated
For repairs refer to the workshop manual.
CNH declines any liability for mistakes and

omissions due to improper operations on the engine.
DIDACTIC PUBLICATION NOT SUBJECT

TO UPDATING
Developed by:
IVECO Product Academy

Lungo Stura Lazio 15 / 19
10156 – Torino
Tel. 011.00.76279 – Fax 011.00.76237
1st Edition – 03 / 07
INDICE
Pagina
TECHNICAL CODING (4 cylinder – NEF TIER 2) 3

COMMERCIAL CODING (NEF TIER 2) 6
COMMERCIAL CODING (NEF TIER 3) 7
CORRELATION BETWEEN TECHNICAL AND COMMERCIAL CODES 8
MAIN CHARACTERISTICS OF THE F4BE ENGINES (NEF TIER 2) 9
MAIN CHARACTERISTICS OF THE F4GE ENGINES (NEF TIER 2) 14
MAIN CHARACTERISTICS OF THE F4GE ENGINES (NEF TIER 3) 21
GENERAL F4BE ENGINE CHARACTERISTICS (NEF TIER 2) 23
GENERAL F4GE ENGINE CHARACTERISTICS (NEF TIER 2) 33
GENERAL F4GE ENGINE CHARACTERISTICS (NEF TIER 3) 47
WALK−AROUND F4BE ENGINES (NEF TIER 2 – NO STRUCTURAL) 52
DESCRIPTION OF THE MAIN MECHANICAL ENGINE COMPONENTS 59
Crankshaft (NEF TIER 2/TIER 3) 59
Connecting rods (6 cylinder version)(NEF TIER 2/TIER 3) 60
Pistons (NEF TIER 2/TIER 3) 62
Camshaft (4/6 cylinder version) )(NEF TIER 2) 63
Camshaft (4/6 cylinder version) )(NEF TIER 3) 64
Timing system control (NEF TIER 2/TIER 3) 65
Valves activation (NEF TIER 2/TIER3) 66
Cylinder head (6 cylinder version) (NEF TIER 2/TIER 3) 67
Engine flywheel (NEF TIER 2/TIER 3) 69
Accessory Equipment Drive (4 cylinder version) 70
Accessory Equipment Drive (6 cylinder version) 71
EXHAUST GAS RECIRCULATION EGR SYSTEM (NEF TIER 3) 72
ADJUSTMENTS (NEF TIER 3) 74
LUBRICATION (4 cylinder version) )(NEF TIER 2/TIER 3) 78
LUBRICATION (6 cylinder version) )(NEF TIER 2/TIER 3) 79
Heat exchanger (NEF TIER 2) 80
Heat exchanger (NEF TIER 3) 81
Oil pump (NEF TIER 2/TIER 3) 82
Oil sump 83
Recirculation of oil vapour (NEF TIER 2/TIER 3) 84
COOLING (6 CYLINDER VERSION) (NEF TIER 2/TIER 3) 85
1
Water pump (NEF TIER 2/TIER 3) 86
TURBOCHARGING 87
MECHANICAL INJECTION SUPPLY SYSTEM 90
Fuel prefilter (NEF TIER 2/TIER 3) 90
Fuel filter (NEF TIER 2/TIER 3) 91
Priming pump (NEF TIER 2/TIER 3) 92
INJECTION ASSEMBLY (4 cylinder version) (NEF TIER 2) 93
INJECTION ASSEMBLY (6 cylinder version) (NEF TIER 2/TIER 3) 94
INJECTION PUMP (NEF TIER 2/TIER 3) 95
Mode of operation of injection pump 96
INJECTION PUMP TIMING STAGE 103
ELETRICAL COMPONENTS 109
TROUBLESHOOTING (NEF TIER 2) 110
TROUBLESHOOTING (NEF TIER 3) 119
TOOLS (NEF TIER 2) 126
TOOLS (NEF TIER 3) 131
DATA − F4BE ASSEMBLY CLEARANCES 137
DATA − F4GE ASSEMBLY CLEARANCES 143
2
TECHNICAL CODING (4 CYLINDERS-NEF TIER 2)
F 4 B E 0 4 8 4 F ∗ D +
Emissions level
Approved power
Application
Fuel / injection
D= TIER 2
N° Cylinders
Cylinder position:
0 = 4 vertical strokes
Engine
Type of base: AxC V

B = not structural 102 x 120 2 4 = 4 cylinders
G = not structural 104 x 132 2 6 = 6 cylinders
Engine
family
0 = ID Diesel asp.
5 = ID Diesel Diesel
superc.
4 = Agric. mach. – Earthmoving mach.
X Y Y Y Y Y Y Y Y
X= 6 2 valve rotative injection pump Sequential production number
3
F 4 G E 9 4 8 4 A ∗ J +
Emissions level
Approved power
Application
Fuel / injection
D= TIER 2
N° Cylinders J= TIER 3
Cylinder position:
Engine
Type of base: AxC V

Engine
family
0 = ID Diesel asp.
superc.
X Y Y Y Y Y Y Y Y
4
F 4 G E 9 6 8 4 R ∗ J +
Emissions level
Approved power
Application
Fuel / injection
D= TIER 2
N° Cylinders J= TIER 3
Cylinder position:
Engine
Type of base: AxC V

Engine
family
0 = ID Diesel asp.
superc.
X Y Y Y Y Y Y Y Y
5
COMMERCIAL CODING (NEF TIER 2)
N 6 0 M N T E
Emissions
C = Euro3
D = CE+EPA (double)
E = Europe (NRMM)
U = EPA - USA
G = gas
M = marine
F = fire prevention
Others
Aspiration
A = natural
S = supercharged
T = supercharged with intercooler
Base
N = not structural – standard timing system
S = not structural – narrow timing system
R = structural
Others
Injection / Management
E = electronic
M = mechanical
R = electronic regualtor
Displacement or number of cylinders

Litres per dispalcement > 10 litres
Litters x10 per displacement < 10 litters
N. of cylinders per VECTOR
For NEF the first figure also corresponds to the number of
cylinders
Engine family
N = NEF
S = Sofim HPI
C = Cursor
V = VECTOR
6
COMMERCIAL CODING (NEF TIER 3)
N 6 77 M N T X
Emissioni
C = Euro3
D = CE+EPA (doppia)
E = Europa (NRMM)
U = EPA – USA (TIER 2)
G = gas
M = marino
F = antincendio
X = TIER 3
Altri
Aspirazione
A = naturale
S = sovralimentato
T = sovralimentato con intercooler
Basamento
N = non strutturale - Distribuzione standard
S = non strutturale - Distribuzione stretta
R = strutturale
Altri
Iniezione / Gestione
E = elettronico
M = meccanico
R = regolatore elettronico
Cilindrata o numeri cilindri

Litri per cilindrata > 10 litri
Litri x10 per cilindrata < 10 litri
N. cilindri per VECTOR
Per NEF la prima cifra è anche il numero di cilindri
Famiglia motori
N = NEF
S = Sofim HPI
C = Cursor
V = VECTOR
7
TECHNICAL AND COMMERCIAL CODING CORRELATION (TIER 2)
TECHNICAL CODING COMMERCIAL CODING

F4BE0454… n.d.
F4BE0484… n.d.
F4BE0684… n.d.
F4GE0404… n.d.
F4GE0454… n.d.
F4GE0484… n.d.
F4GE0604… n.d.
F4GE0654… n.d.
F4GE0684… n.d.
8
MAIN F4BE ENGINE FEATURES (NEF TIER 2)
F4BE0454
A A*D6.. B*D6..
C 3922 cm3
D 74 kW 74 kW
2300 rpm. 2100 rpm.
E Direct injection
000863t
F Rotative injection pump
G Supercharge
H Not structural
A Engine type
B Number of cylinders
C Total displacement
D Maximum power currently available
E Injection type
F Injection system
G Air delivery system
H Type of block
9
F4BE0484
A G*D6.. F*D6.. E*D6.. D*D6..
C 3922 cm3
74 kW 86 kW 88 kW 95 kW
D
2200 rpm. 2200 rpm. 2200 rpm. 2200 rpm.
E Direct injection
000863t
G Supercharged
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
10
F4BE0684
A A*D4.. B*D4.. D*D4.. H*D4..
C 5883 cm3
129 kW 118 kW 105 kW 129 kW
D
2000 rpm. 2150 rpm. 2000 rpm. 2000 rpm.
E Direct injection
000863t
F Line injection pump
G T.C.A.
(Supercharged with intercooler)
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
11
F4BE0684
A F*D6.. G*D6.. K*D6..
C 5883 cm3
86 kW 74 kW 99 kW
D
2200 rpm. 2200 rpm 2100 rpm.
E Direct injection
000863t
G T.C.A.
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
12
F4BE0684
A L*D6.. M*D6.. N*D6..
C 5883 cm3
129 kW 118 kW 105 kW
D
2000 rpm 2150 rpm 2000 rpm
E Direct injection
000863t
G T.C.A.
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
13
MAIN F4GE ENGINE FEATURES (NEF TIER 2)
F4GE0404
A A*D6.. B*D6..
C 4485 cm3
60 kW 60 kW
D
2300 rpm 2200 rpm
E Direct injection
000863t
G Aspirated
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
14
F4GE0454
A A*D6.. B*D6.. E*D6.. G*D6.. H*D6..
C 4485 cm3
74 kW 74 kW 60 kW 67 kW
D
2300 rpm 2200 rpm 2000 rpm 2000 rpm
E Direct injection
000863t
G Supercharged
H Not structural
A Engine type
E Injection type
F Injection system
.
H Type of block
15
F4GE0484
A C*D6.. G*D6..
C 4485 cm3
94 kW 82 kW
D
2300 rpm 2200 rpm
E Direct injection
000863t
G T.C.A.
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
16
F4GE0604
A A*D6..
C 6728 cm3
81 kW
D
2500 rpm
E Direct injection
000863t
G Aspirated
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
17
F4GE0654
A A*D6..
C 6728 cm3
74 kW
D
2000 rpm
E Direct injection
000863t
G Supercharged
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
18
F4BE0684
A C*D6.. F*D6.. G*D6..
C 6728 cm3
129 kW 110 kW 107 kW
D
2300 rpm. 2000 rpm 2300 rpm
E Direct injection
000863t
G T.C.A.
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
19
F4BE0684
A Q*D6.. S*D6.. R*D6..
C 6728 cm3
112 kW 96 kW 85 kW
D
2200 rpm 2200 rpm 2200 rpm
E Direct injection
000863t
G T.C.A.
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
20
MAIN F4GE ENGINE FEATURES (NEF TIER 3)
F4GE9484
A A*J6
C 4485 cm3
94 kW
D
2300 rpm
E Direct injection
000863t
G T.C.A.
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
21
F4GE9684
A R*J6.. B*J6.. A*J6..
C 6728 cm3
125 kW 129 kW 129 kW
D
2100 rpm 2300 rpm 2200 rpm
E Direct injection
000863t
G T.C.A.
H Not structural
A Engine type
E Injection type
F Injection system
H Type of block
22
GENERAL F4BE ENGINE FEATURES (NEF TIER 2)
F4BE0454
Type
A*D6.. B*D6..
Cycle Diesel 4 stroke
Supply Supercharged
Injection Direct
Number of cylinders 4 in line
Bore mm 102
Stroke mm 120
Total displacement cm3 3922
Compression ratio 17,5 : 1

Maximum power
kW 74 74
rpm 2300 2100

Maximum torque
Nm 395 390
rpm 1400 1400

Low idle speed
rpm - -
High idle speed

rpm - -
23
F4BE0484
Type
A*D6.. B*D6..
TURBOCHARGING
Turbocharger type: HOLSET HX25W

Forced by means of gear pump,
LUBRICATION
pressure relief valve, oil filter
Oil pressure with engine
warm:
at idle speed bar 1,2
at maximum speed bar 3,8
COOLING Liquid
Water pump drive: Belt
Thermostat:
starts to open at: °C 81 ± 2
FILL UP
Total capacity 1st fill up
15 W40 ACEA E3
- engine sump litres
11
- engine sump + filter litres
12
SUPPLY
Bosch injection VE4 / 12 F 1100
Injectors DSLA 145 P603
Ignition order 1–3–4–2
Injection pressure bar 245
24
F4BE484
Type
G*D6.. F*D6.. E*D6.. D*D6..
Supply Supercharged with intercooler
Injection Direct
Bore mm 102
Stroke mm 120

Maximum power
kW 74 86 88 95
rpm 2200 2200 2200 22100

Maximum torque
Nm - 450 450 480
rpm - 1400 1400 1400

Low idle speed
rpm 850 850 850 -
High idle speed

rpm 2450 2450 2450 -
25
F4BE0484
Type
G*D6.. F*D6.. F*D6..
TURBOCHARGING With intercooler

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
Total capacity
1st fill up
15 W40 ACEA E3
- engine sump litres 11
- engine sump + filter litres 12
SUPPLY
Bosch injection VE4 / 12 F 1100
Injectors DSLA 145 P603
26
F4BE0684
Type
A*D4.. B*D4.. D*D4.. H*D4..
Injection Direct
Bore mm 102
Stroke mm 120

Maximum power
kW 129 118 105 129
rpm 2000 2150 2000 2000

Maximum torque
Nm 690 625 550 690
rpm 1400 1400 1400 1400

Low idle speed
rpm - - - -
High idle speed

rpm - - - -
27
F4BE0684
Type
A*D4.. B*D4.. D*D4.. H*D4..

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
Total capacity
1st fill up
15 W40 ACEA E3
SUPPLY
Bosch injection PE6
Injectors DSLA 145 P
Ignition order 1–5–3–6–2–4
28
F4BE0684
Type
F*D6.. G*D6.. K*D6..
Injection Direct
Bore mm 102
Stroke mm 120

Maximum power
kW 86 74 99
rpm 2000 2200 2100

Maximum torque
Nm - - 500
rpm - - 1400
Low idle speed
rpm - - -
High idle speed

rpm - - -
29
F4BE0684
Type
F*D6.. G*D6.. K*D6..

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
Total capacity
1st fill up
15 W40 ACEA E3
SUPPLY
Bosch injection VE6 / 12 F PES 6A
30
F4BE0684
Type
L*D6.. M*D6.. N*D6..
Injection Direct
Bore mm 102
Stroke mm 120

Maximum power
kW 129 118 105
rpm 2000 2150 2000

Maximum torque
Nm 690 620 555
rpm 1400 1400 1400

Low idle speed
rpm - - -
High idle speed

rpm - - -
31
F4BE0684
Type
L*D6.. M*D6.. N*D6..

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
Total capacity
1st fill up
15 W40 ACEA E3
SUPPLY
32
GENERAL F4GE ENGINE FEATURES (NEF TIER 2)
F4GE0404
Type
A*D6.. B*D6..
Supply Aspirated
Injection Direct
Bore mm 104
Stroke mm 132

Maximum power
kW 60 60
rpm 2300 2200

Maximum torque
Nm 320 320
rpm 1400 1400

Low idle speed
rpm 850 -
High idle speed

rpm 2300 -
33
F4GE0404
Type
A*D6.. B*D6..
LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
15 W40 ACEA E3
SUPPLY
Bosch injection VE4 / 12 F
34
F4GE0454
Type
A*D6.. B*D6.. E*D6.. G*D6.. H*D6..
Supply Supercharged
Injection Direct
Bore mm 104
Stroke mm 132
Total displacement
cm³ 4485

Maximum power
kW 74 74 63 60 67
rpm 2300 2200 2200 2000 2000

Maximum torque
Nm 398 398 365 360 399
rpm 1400 1400 1400 1400 1400

Low idle speed
rpm 850 850 850 - -
High idle speed

rpm 2300 - - - -
35
F4GE0454
Type
A*D6.. B*D6.. E*D6.. G*D6.. H*D6..
TURBOCHARGING

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
15 W40 ACEA
- engine sump
E3
litres 13
- engine sump + filter
litres 14
SUPPLY
Ignition order 1 –3 – 4 – 2
36
F4GE0684
Type
C*D6.. G*D6..
Supply Supercharged
Injection Direct
Bore mm 104
Stroke mm 132
Total displacement cm³ 4485
Maximum power
kW 94 82
rpm 2300 2200
Maximum torque
Nm 500 480
rpm 1400 1400

Low idle speed
rpm 850 -
High idle speed

rpm 2300 -
37
F4GE0484
Type
C*D6.. G*D6..
TURBOCHARGING

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
15 W40 ACEA E3 - engine sump

litres -
litres -
SUPPLY
38
F4GE0604
Type
A*D6..
Supply Aspirated
Injection Direct
Bore mm 104
Stroke mm 132
Maximum power
kW 81
rpm 2500
Maximum torque
Nm 440
rpm 1400
Low idle speed
rpm -
High idle speed

rpm -
39
F4GE0604
Type
A*D6..
LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
Total capacity
1st fill up
15 W40 ACEA E3
- engine sump
litres -
litres -
SUPPLY
Ignition order 1 –5 – 3 – 6 – 2 – 4
40
F4GE0654
Type
A*D6..
Supply Supercharged
Injection Direct
Bore mm 104
Stroke mm 132
Maximum power
kW 74
rpm 2000
Maximum torque
Nm 441
rpm 1400
Low idle speed
rpm -
High idle speed

rpm -
41
F4GE0654
Type
A*D6..
TURBOCHARGING

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP

litres -
litres -
SUPPLY
42
F4GE0684
Type
C*D6.. F*D6.. G*D6..
Injection Direct
Bore mm 104
Stroke mm 132
Maximum power
kW 129 110 107
rpm 2300 2000 2300
Maximum torque
Nm 700 675 580
rpm 1400 1400 1400

Low idle speed
rpm 850 - -
High idle speed

rpm 2500 - -
43
F4GE0684
Type
C*D6.. F*D6.. G*D6..
TURBOCHARGING

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP
Total capacity
1st fill up
15 W40 ACEA E3
- engine sump
litres 15
litres 16
SUPPLY
Ignition order 1 –5 – 3 – 6– 2 – 4
44
F4GE0684
Type
Q*D6.. S*D6.. R*D6..
Injection Direct
Bore mm 104
Stroke mm 132
Maximum power
kW 112 96 85
rpm 2200 2200 2200
Maximum torque
Nm 582 535 520
rpm 1400 1400 1400

Low idle speed
rpm - - -
High idle speed

rpm - - -
45
F4GE0684
Type
Q*D6.. S*D6.. R*D6..
TURBOCHARGING

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP

litres 15
litres 16
SUPPLY
Ignition order 1 –5 – 3 – 6– 2 – 4
46
GENERAL F4GE ENGINE FEATURES (NEF TIER 3)
F4GE9484
Type
A*J6..
Injection Direct
Bore mm 104
Stroke mm 132
Maximum power
kW 94
rpm 2300
Maximum torque
Nm 500
rpm 1300
Low idle speed
rpm -
High idle speed

rpm -
47
F4GE9484
Type
A*J6..
TURBOCHARGING

LUBRICATION
warm:
COOLING Liquid
Thermostat:
FILL UP

litres -
litres -
SUPPLY
48
F4GE9684
Type
R*J6.. B*J6.. A*J6..
Injection Direct
Bore mm 104
Stroke mm 132
Maximum power
kW 125 129 129
rpm 2100 2300 2200
Maximum torque
Nm 726 745 770
rpm 1250 1300 1250

Low idle speed
rpm - - -
High idle speed

rpm - - -
49
F4GE0684
Type
R*D6.. B*J6.. A*J6..
TURBOCHARGING

LUBRICATION
warm:
at idle speed bar 2
at maximum speed bar 4
COOLING Liquid
Thermostat:
FILL UP

litres 15
litres 16
SUPPLY
Ignition order 1 –5 – 3 – 6– 2 – 4
50
GENERAL
The new family of F4 engines is the result of a project developed on the basis of an
agreement forged between several of the world’s major OEMs: IVECO – New Holland -
Cummins, in order to provide an answer to new and more exacting requirements of
customers and the more stringent environment protection regulations.
In addition.reliability and cost savings were further enhanced by reducing the number of
engine parts and using the same parts for IVECO application engines and for engines
produced by the other partners participating to the project.
003220t
F4BE - 4 cylinder version
004868t
F4GE - 6 cylinder version
51
WALK-AROUND
F4BE engine
Top view
003221t
Top view legend

A. Alternator
B. Injector
C. Turbocompressor
D. Blow - by
E. Injection pump
F. Inlet manifold
G. Fuel filter
52
F4BE engine
Front view
003222t
Front view legend

A. Blow – by
B. Fuel filter
C. Priming pump
D. Fixed belt tensioner
E. Oil filter
F. Poly – V belt
G. Water pump
H. Alternator
I. Thermostat
53
F4BE engine
Right side view
003223t
Right side view legend

A. Blow – by
B. Turbocompressor
C. Thermostat
D. Alternator
E. Water pump
F. Poly – V belt
G. Union for oil filter
H. Starter motor
I. Oil exhaust pipe from turbocompressor
J. Exhaust manifold
54
F4BE engine
Left side view
003224t
Left side view legend

A. Blow – by
B. Fuel pipes for injectors
C. Injection pump
D. Oil filter
E. Priming pump
F. Fuel filter
G. Fuel heater
H. Poly – V belt
I. Air heater (it is not envisaged in the F4BE0484 F*D600 engine)
J. Intake manifold
55
F4BE engine
Rear view
003225t
Rear view legend

A. Blow – by
B. Fuel pipes for injectors
C. Wastegate valve
D. Turbocompressor
E. Oil exhaust pipe from turbocompressor
F. Alternator
G. Exhaust manifold
I. Engine flywheel
J. Oil filter
K. Injection pump
L. Air heater (it is not envisaged in the F4BE0484 F*D600 engine)
M. Intake manifold
56
F4BE engine main alternatives
Due to requirements dictated by the application, some auxiliary equipment may be

installed in different positions on the engine. The main assemblies subject to alternative
positioning are:
• Inlet manifold (A)
• Blow-by (B)
003226t
57
F4GE ENGINES (6 cylinders-NEF TIER 2)
004870t
1. Air conditioner compressor – 2. Turbocompressor – 3. Thermostat – 4. Front belt

stretcher – 5. Alternator – 6. Front belt stretcher inlet –
7. Water pump – 8. Fixed belt stretcher – 9. Damper pulley – 10. Oil sump –
11. Oil measuring stick – 12. Fuel filter – 13. Engine oil fill up opening –
14. Injection pump – 15. Intake manifold – 16. Blow - by
58
DESCRIPTION OF THE MAIN MECHANICAL COMPONENTS OF THE
ENGINE
Crankcase (NEF TIER 2/NEF TIER 3)

The crankcase is a cast iron structure containing the cylinder liners 1, the main bearing
housings 5 and the following seats: for the camshaft bushings 3 and the tappets, for the
water/oil heat exchanger 7, for the water pump 2 and for the oil pump 4.
The crankcase also contains the chambers for circulation of coolant and oilways for the
lubrication circuit feeding the various moving parts.
Soleplate 6 is applied to the underside of the crankcase to increase resistance to
mechanical stress.
86605
59
Crankshaft (6 cylinder version NEF TIER 2/NEF TIER 3)
The crankshaft is made of steel.
The crankshaft is held in five bearing housings for the four cylinder version of engine F4
and in seven bearing housings for the six cylinder version. The housings are induction
hardened.
The crankshaft features a series of internal oilways for lubrication purposes.
The crankshaft front spigot is fitted with the oil pump drive gear, the speed sensor phonic
wheel, the damper flywheel, and the auxiliary equipment driving pulley.
The rear spigot of the crankshaft is fitted with the timing gear and the engine flywheel
attachment hub.
The main bearing shells are made of steel with an antifriction alloy plating.
The penultimate main bearing shells are equipped with shoulders to limit crankshaft end
float.
Parts (1, 2) are mounted on the crankshaft rear spigot with an interference fit and cannot
be replaced.
003196t
1. Timing gear – 2. Flywheel hub – 3. Oil pump drive gear.
Crankshaft oil seals (NEF TIER 2/NEF TIER 3)

The front and rear oil seals are cassette type, with a radial seal. These oil seal rings
require special tools for disassembly and assembly as described in the specific heading.
60
Connecting rods (NEF TIER 2/TIER 3)
Forged in steel, the connecting rod big ends are made with an oblique splitting plane
angle, with separation of rod and cap achieved by means of the innovative fracture
splitting system rather than the conventional machining procedure.
The connecting rod big end bearing shells are made of steel plated with an antifriction
alloy.
000880t
Each connecting rod is marked:

• On the body and on the cap by a number indicating the match and the cylinder in
which they are assembled.
• The rod shank is marked with a letter indicating the weight class of the connecting
rod installed in production.
In the event of replacement, the spare parts catalogue only provides a single connecting
rod of intermediate weight compatible with all engines in circulation. In the event of partial
replacements, connecting rods that are still in good condition need not be replaced, even
though they may be of a different weight class.
61
Pistons (NEF TIER 2/TIER 3)
004963t
The piston crown features a high turbulence combustion chamber. The piston crown is
cooled by engine oil delivered by a spray nozzle installed in the crankcase, through the
annular chamber inside the piston.
There are three piston ring grooves; the first is composed of a trapezoidal section cast iron
insert.
The piston rings have different functions and different geometry.
1st piston ring with trapezoidal section and ceramic chrome plating.
2nd piston ring with torsional conical rectangular section.
3rd piston ring with double oil wiper with internal spring.
The identification number and manufacturing data are printed in the piston crown area 1.
62
Camshaft (4 – 6 Cylinder Version) (NEF TIER 2)
The camshaft is mounted in the crankcase on:

5 bearing housings, for 4 cylinder engines
7 bearing housings, for 6 cylinder engines
The front and rear bearing housings are equipped with steel bushings plated with
antifriction material assembled by means of an interference fit. The camshaft has two cam
lobes for each cylinder.
A. Intake valves control
B. Exhaust valves control
The camshaft is driven directly by the crankshaft by means of spur tooth gears.
The rear of the timing gear is marked with notches for activation of the timing sensor (4 + 1
for the four cylinder engine, and 6 + 1 for the six cylinder version).
003197t
63
Camshaft (4 – 6 Cylinder Version) (NEF TIER 3)
In the TIER 3 version, the profile of the exhaust cam has been modified to allow partial
opening of the related valve at intake (exhaust gas recirculation EGR). This profile is
shown the section S-S below.
The camshaft is mounted in the crankcase on:
5 bearing housings, for 4 cylinder engines;
7 bearing housings, for 6 cylinder engines.
The front and rear bearing housings are equipped with steel bushings plated with
antifriction material assembled by means of an interference fit. The camshaft has two cam
lobes for each cylinder.
The camshaft is driven directly by the crankshaft by means of spur tooth gears.
The rear of the timing gear is marked with notches for activation of the timing sensor (4 + 1
for the four cylinder engine, and 6 + 1 for the six cylinder version).
0052118t
A. Intake valves control

B. Exhaust valves control
64
Timing system control (NEF TIER 2/TIER 3)
Timing system control is carried out by means of a straight tooth gear keyed on the rear
tang of the engine shaft that engages with the one fixed on the camshaft.
Timing is carried out by having the groove that is marked with the two symbols in brackets
(zz) printed on the camshaft control gear with the tooth bevelled by the engine shaft gear.
0051067t
65
Valves activation (NEF TIER 2/TIER3)
84042
1. Rocker arm – 2. Rocker support – 3. Adjusting screw – 4. Rod – 5. Semi-cones –

6. Spring cup – 7. Spring – 8. Tappet – 9. Camshaft.
66
Cylinder head (6 cylinder version) (NEF TIER 2/TIER3)
The cast iron cylinder head is machined to accommodate the following parts:
• reported valve seats 4;
• injector 6 ;
• thermostat 5;
The cylinder head is also equipped with:
• exhaust manifold 1 in one block;
• intake manifold 2 with seat for cold start air heater 3 (if present in the application).
84043
Particolare testa cilindri con sedi valvole riportate
67
Valves and valve seats (6 cylinder version) (NEF TIER 2/TIER3)
84044
1. Intake valve – 2. Exhaust valve – A. Intake side – S. Exhaust side.
The valve seats machined in the cylinder head have the following angles:
- 45° for the exhaust valves
- 60° for the intake valves
The exhaust valves 2 have an identification recess at the centre of the poppet.
84045
The figure shows the oil seals mounted on the valve stems.
68
Valve guides (NEF TIER 2/TIER3)
The valve guides are not reported.
70328
Engine flywheel (NEF TIER 2/TIER 3)
The flywheel 1 needs not be fitted in a specific position on the crankshaft, as it is not
equipped with punch markings, notches, or reference holes for sensors or for timing
purposes. The fixing holes 2 are equally spaced so that the flywheel can effectively be
installed in various different positions.
86454
Tightening flywheel fixing screws:
1st phase 30 Nm ± 4 Nm
2nd phase 60° ± 5°
69
Accessory Equipment Drive (4 cylinder version)
A Poly-V 1 belt transmits drive from the crankshaft 4 to the water pump 3, the alternator 2.
According to the application, the belt can be tightened by the automatic tightener or by
using the slot in the alternator brackets.
003236t
1. Poly –V belt – 2. Alternator – 3. Water pump – 4. Pulley camshaft – 5. Fixed pulley
70
Accessory Equipment Drive (6 cylinder version)
A Poly-V 3 belt transmits drive from the crankshaft 5 to the water pump 4, the alternator 1.
According to the application, the belt can be tightened by the automatic tightener or by
using the slot in the alternator brackets.
0051015
1. Alternator – 2. Automatic belt stretcher – 3. Poly-V– belt4. Water pump

5. Engine shaft pulley – 6. Fixed jockey pulley
71
EGR EXHAUST GAS RECIRCULATION SYSTEM (NEF TIER 3)
The exhaust gases can be partially conveyed back into the cylinders to lower the
maximum values of the combustion temperature that are responsible for the production of
nitrogen oxides (NOx).
The exhaust gas recirculation system (EGR), lowering the combustion temperature by
decreasing the concentration of oxygen in the combustion chamber, is therefore an
effective system to control the emission of NOx.
Internal EGR acting on the exhaust valves
The internal EGR system, thanks to an appropriate exhaust cam design permits some of
the exhaust gases to be reintroduced back into the engine cylinders.
This type of EGR, internal EGR is not provided with any electronically controlled element:
the system is always on. Its configuration doesn't need any additional elements such as
control valves, pipes or heat exchangers.
The exhaust cam, besides the main lobe (1), has an additional lobe (3) compared to the
configuration without EGR. During the intake stroke of the cylinder under examination, this
lobe permits briefly opening the exhaust valve. In this way, recirculation is generated on
the cylinder in the intake stroke due to the greater pressure of the exhaust gases
compared to the intake gases.
0051076t
1. Exhaust
2. Intake
3. EGR
72
0051137t
1. Exhaust – 2. Intake
X = Crankshaft rotation in degrees

Y = Valve lift in mm
0051078t
1. Exhaust with EGR – 2. Intake
X = Crankshaft rotation in degrees

Y = Valve lift in mm
73
ADJUSTMENTS (NEF TIER 3)
TIMING ENGINE SHAFT / TIMING SYSTEM SHAFT
70211
Using a felt-tip pen, highlight the tooth of driving gear (1) mounted on engine shaft (2), on
the side surface of which mark (→) for timing is printed.
Note: Screw up two pins to make engine shaft rotation operation easier.
88566
Direct engine shaft (4) and timing system shaft (2) in such a way that when driven shaft (1)
is mounted on the latter, marks (3), printed on the gears, are matching.
74
FINDING TOP DEAD CENTRE (TDC) (NEF TIER 3)
TDC for cylinder 1

After dismounting starter, operate as follows:
0052042t
Fit the bracket for the flywheel retainer tool 99360339 (1) complete with rotation coil
(2).
Carefully rotate the flywheel in its direction of rotation to cancel out the gear
clearances.
Rotate the flywheel until the pin (4) that comes with tool 99360339 is engaged in the
recess in the flywheel (3).
TDC for the other cylinders (6-cylinder engine)
This operation can be carried out following the indications of the table below, for an ignition
sequence 1 – 5 – 3 – 6 – 2 – 4 and starting from the position of 1st cylinder at TDC and
after removing pin (4).
Cylinder at TDC Operation with 1st cylinder at TDC

5 Rotate the flywheel by 120° in its direction of rotation, with caution in
order to eliminate backlash of the gears, by means of the spinning coil
(2).
(2).
(2).
(2).
4 Rotate the flywheel by 600° in its direction of rotation, with caution
in order to eliminate backlash of the gears, by means of the
spinning coil (2)..
75
Find the top dead centre with the tool (99395097) – False injector
1
88141
Remove the rocker covers of the 1st cylinder; remove the 1st injector and place the tool (1)
to set the 1st cylinder top dead centre position (end-of-compression phase).
Pre-load the gauge.
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.
Once PMS has been obtained, lock the flywheel by means of tool 99360339.
76
MANUAL VALVE CLEARANCE ADJUSTMENT (NEF TIER 2/TIER 3)
On TIER 3 engines, due to the additional lobe for internal E.G.R., it is not possible to use
the valve clearance adjustment procedure that requires adjusting the clearance of all the
valves by positioning the crankshaft only twice.
Each cylinder must be checked by taking it to T.D.C. (top dead centre) at the
end of compression and adjusting the clearance of both valves solely on the
cylinder in question.
Adjust the clearance between the rockers and valves with the Allen wrench (1), box
wrench (3) and feeler gauge. The clearance is:
0.25 – 0.05 mm for the intake valves

0.50 – 0.05 mm for the exhaust valves
87673
77
LUBRICATION (4 cylinder version) (NEF TIER 2/TIER 3)
The following figures are illustrations representing the lubrication system on NEF series
engines. All these components may vary according to how they are uses.
The forced circulation lubrication system is made up of the following components:
• rotor oil pump, housed in the front of the crankcase and driven by a spur tooth gear
fitted on the crankshaft spigot;
• water / oil heat exchanger, housed in the crankcase, with oil filter support;
• oil pressure control valve incorporated in the filter support;
• by–pass valve to exclude a clogged oil filter, incorporated in the filter support;
• cartridge type oil filter.
Gravity oil return

circuit
Pressurized oil circuit
Oil filling
003237t
78
LUBRICATION (6 cylinder version) (NEF TIER 2/TIER3)
The following figures are illustrations representing the lubrication system on NEF series
engines. All these components may vary according to how they are uses.
The forced circulation lubrication system is made up of the following components:
• rotor oil pump, housed in the front of the crankcase and driven by a spur tooth gear
fitted on the crankshaft spigot;
• water / oil heat exchanger, housed in the crankcase, with oil filter support;
• oil pressure control valve incorporated in the filter support;
• by–pass valve to exclude a clogged oil filter, incorporated in the filter support;
• cartridge type oil filter.
Return route
Route of oil under pressure 003237t
79
Heat exchanger (NEF TIER 2)
003238t
1. Heat exchanger body

2. Internal gasket
3. Water - oil heat exchanger
4. Gasket between heat exchanger and cylinder block
5. Oil return to filter
6. Oil inlet from filter
80
Heat exchanger (NEF TIER 3)
0051052t
1. Heat exchanger body – 2. Gasket on ground – 3. Coolant/oil heat exchanger – 4.

Gasket between exchanger assembly and engine block – 5. Oil return to filter –
6. Oil inlet from the filter.
81
Oil pump (NEF TIER 2/TIER 3)
000891t
070150a
1. Crankshaft with oil pump drive gear
Capacity Pressure rpm Notes

14,6 [l/min.] 2 [bar] 750 Minimum
93,5 [l/min.] 4 [bar] 4200 Rated
82
Oil sump (F4GE) (NEF TIER 2)
NOTE: The following figures are illustrations and they may vary according to how they are
uses.
The oil sump (1) is fixed on the block by means of screws (2). The block and the oil sump
are sealed together by a thin gasket (3).
0051008t
Oil sump (NEF TIER 2/TIER 3)

The sump 1 is flexibly fixed to the crankcase by means of an aluminium plate 3.
The “C” section rubber gasket 2, fitted on the sump attachment profile, serves to enhance
oil tightness while also reducing the noise level.
This type of gasket should be renewed exclusively in the event of deterioration or
breakage.
It need not be renewed at each disassembly-reassembly.
70227
003260t
83
Recirculation of oil vapour (NEF TIER 2/TIER 3)
The oil vapour recirculation is enabled by valve 1 installed on the tappet cover 2.
Due to gravity, the condensed vapours fall down under the tappet cover 2 while the
remaining vapours are collected by the breather 3 and properly conveyed (i.e., on intake).
003240t
84
COOLING (6 cylinder version) (NEF TIER 2/TIER 3)
The engine cooling system, closed circuit forced circulation type, generally incorporates
the following components:
• heat exchanger to cool the lubrication oil: even this component is part of the
engine’s specific equipment;
• centrifugal water pump, placed in the front part of the engine block;
• thermostat regulating the circulation of the cooling liquid.
Water from the thermostat
Water circulating in the engine

Water to the pump
0051018t
85
WATER PUMP (NEF TIER 2/TIER 3)
The water pump, which is accommodated in a housing in the crankcase, is driven by a

Poly – V belt.
The almost total absence of external pipes, hoses and hose clamps eliminates the number
of connections and reduces possible sources of leaks. The engine temperature is
controlled by a thermostat. The coolant (a 50% water and Paraflu antifreeze solution)
circulates also in the oil heat exchanger.
70221
001515t
Capacity Pressure RPM

210 [l/min.]
2,00 – 2,45 [bar] 5000
12.6 [m3/h]
110 [l/min.]
0,50 – 0,65 [bar] 2500
6,6 [m3/h]
86
TURBOCHARGING
Engine boosting system with Garrett or Holset turbocharger with or without intercooler.
The choice of the type of turbocharger depends on the specific features of the application.
Exhaust
Hot intake air
000898t
Description
The turbocharger includes the following main parts: a turbine, a supercharging pressure
setting valve, a central body and a compressor.
The model and type of the radiator and air filter depicted in the figure vary according to the
application. Installation of these elements is to be carried out by the equipment fitter.
87
Turbocharging system with HOLSET HX25W turbocharger:
Exhaust outlet
0054083t
Exhaust inlet
Turbocharging system with HOLSET HX25 turbocharger and intercooler:
Operating diagram for

turbocharger
Exhaust
Hot aspirated air
Air inlet
0051010t
88
4 Cylinders version
AIR TURBOCHARGER
FILTRE
EXHAUST
RADIATOR
6 Cylinders version
AIR TURBOCHARGER
FILTRE
EXHAUST
RADIATOR
0052007t
89
MECHANICAL INJECTION SUPPLY SYSTEM
Fuel prefilter (NEF TIER 2/TIER 3)
In the filter support 1 are located the manual priming pump 4, the system bleeding screw 2
and the 3 cartridge.
003242t
90
Fuel filter (NEF TIER 2/TIER 3)
The fuel filter 4 type is high water separation ; the water drain screw 3 is installed at the
base of the cartridge. The heater 2 and the temperature sensor 5 for filters are installed on
the support 1.
3
3
Fuel filter A 003243t
Fuel filter B
003244t
Filters A and B according to equipment.
91
Priming pump (NEF TIER 2/TIER3)
The priming pump 1 is installed on the engine crankcase and it is driven by the camshaft
2. Its function is priming the fuel in the tank and send it to the injection pump.
2 003245T
92
INJECTION ASSEMBLY (4 cylinder version) (NEF TIER 2)
2 4
5
1
6
10
9
003248t
1. Injector 1 fuel pipe
5. Fuel exhaust pipe from injectors
6. Connection with the intake manifold for LDA
7. Thermal bulb for KKSB
8. Injection pump
9. Solenoid valve
10. Injector
93
INJECTION ASSEMBLY (6 cylinder version) (NEF TIER 2/TIER 3)
0051019t

5. Fuel exhaust pipe from injectors
8. Connection with the intake manifold for LDA
9. Thermal bulb for KKSB
10. Injection pump
11. Solenoid valve
12. Injector
94
INJECTION PUMP (NEF TIER 2/TIER 3)
The pump is rotary type, and it is driven by a gear coupled with the camshaft gear.
Marking
V = rotary distributor piston;

E = size of pump;
4 = for 4-cylinder engines;
12 = diameter distributor piston in mm;
1100 = pump rpm;
R = clockwise rotation;
30454
Longitudinal section of injection pump

1. Membrane - 2. Adjusting hub nut - 3. Feeler - 4. Control lever - 5. Speed controller -
6. Booster pump - 7. Driving shaft - 8. Cam disk - 9. Injection adjuster - 10. Distributor
piston - 11. Feed connection piece - 12. Hydraulic head - 13. Control plate –
14. Control rod - 15. Counterspring.
95
Mode of operation of injection pump
Supply step
003155t
1. Fuel intake pipe - 2. Solenoid valve - 3. Axial hub - 4. Compression chamber - 5. Fuel
pipe between pump element and injectors - 6. Distributor piston - 7. Bore for fuel cut-off -
8. Slide valve - 9. Injector
The distributor piston (6) is placed in the b.d.c. and the slide valve (8) shuts the bore for
the fuel cut-off (7). The fuel is fed into the compression chamber via feed pipe (1) that is
kept open by the solenoid valve (2).
Feed step
003156t
1. Fuel intake pipe - 2. Compression chamber - 3. Inner pipe of distributor piston - 4. Fuel
pipe between pump element and injectors - 5. Distributor piston - 6. Injectors
96
The distributor piston (5) is lifted under influence of the cam disk to the T.D.C. and rotates
at the same time around its own axis. By means of these two movements the fuel intake
pipe (1) is closed and the fuel in the compression chamber (2) is simultaneously
compressed. The inner pipe (3) of the distributor piston is connected to pipe (4) and makes
the fuel feed to the injectors (6) possible.
Feed end
003157t
1. Fuel intake pipe - 2. Compression chamber - 3. Feed pipe - 4. Pipe for fuel cut-off -
5. Slide valve - 6. Distributor piston.
The distributor piston (6) opens the high-pressure chamber by means of pipe (4) during its
lift to the T.D.C., by means of this a pressure compensation between inner chamber of the
distributor piston, feed pipe to the injection valves and inner chamber of the pump housing
takes place.
As the pressure subsequently is too low to operate the injection valve, the fuel is cut-off.
97
Stopping of engine
003158t
1. Fuel intake pipe - 2. Moveable valve pin - 3. Spring - 4. Solenoid valve -

5. Compression chamber.
The engine is stopped by means of disconnecting the starter contact.

The solenoid valve current (4) is interrupted. By means of the spring (3) the solenoid valve
presses the moveable valve pin (2) to the stop, and thus the fuel intake pipe (1) is
interrupted.
LDA device (load-dependent feed adjustment)
003163t
L.D.A. Mode of operation

The LDA device adjusts the fuel throughput independent of the air pressure in the suction
manifold. This air pressure acts upon the membrane (1) which is rigidly connected to the
controller pin (4). The lower part of the controller pin (4) is provided with a conical
mounting (5) with a feeler pin (6). By means of the axial displacement of the controller pin
(4) the feeler pin (6) is also displaced and acts upon the stop lever (7). The stop lever
98
rotates on its own axis (8) and acts upon the controller disk in such a way that the fuel
throughput is adjusted to the air quantity fed into the cylinders.
Starting
003161t
1. Starter lifter - 2. Leaf spring - 4. Slider - 5. Governor collar - 6. Solenoid valve -

7. Compression chamber.
If the solenoid valve (6) is supplied with current, fuel is fed into the compression chamber
(7); in this case the governor weights of the governor collar (5) are closed, and the leaf
spring (2) presses the lifter (1) and the slider (4) into the additional feed position.
Thus the whole lift of the pump element is used for the feed to the injection valve.
Starting device disconnected
003162t
1. Starter lever - 2. Leaf spring - 3. Tension lever - 4. Slider - 5. Governor collar - 6.

Solenoid valve - 7. Ground.
After starting of the engine the governor collar (5) moves axially as a result of the
centrifugal force caused by the expansion of the governor weights (7), and causes the
starter lifter (1) to contact the tension lever (3) and squeezes the leaf spring (2). Under
these conditions the slider (4) is moved to idling position.
99
Load-dependent start of delivery (L.F.B.)
30434
Design of the controller with feed-dependent adjustment

of the start of delivery
1. Control spring - 2. Governor collar - 3. Tension lever - 4. Starter lever - 5. Slider -

6. Distributor piston - 7. Control shaft - 8. Governor weights.
Description
The load-dependent adjustment of the start of delivery (LFB) enables a "smoother" engine
operation (reduced in noise). The LFB device is realized by means of the following
changes:
Governor collar with an additional bore to the antipump bore.
Controller shaft with an oblong hole and two cross holes
Pump housing with a hole that is closed from outside by means of a ball and that is
connected to the feed chamber.
100
Position of the governor collar in the LFB device
30435
a. Collar in idling position - b. Collar in movement -

c. Collar in adjustment condition, inner pressure loss -
1. Oblong hole in controller shaft - 2. Controller shaft - 3. Cross hole governor collar -
4. Governor collar - 5. Cross hole controller shaft - 6. Edge from controller center -
7. Cross hole controller shaft.
Mode of operation
Independent of the position of the outer accelerator pedal the fuel feed is reduced, if the
governor collar (4) is displaced by the governor weights of the controller by means of the
centrifugal force in case of an increase of the speed.
For a smoother engine operation and a reduced fuel feed the start of delivery must be
reduced. As the injection adjustment device in the rotary piston pump is a hydraulic device,
the pressure increase must be reduced in order to obtain a decreasing start of delivery:
this is obtained by means of the LFB device.
If the governor collar (4) that runs on the controller shaft (2) connects the bore (3) to the
hub (6) and the bore (7), a part of the diesel fuel under pressure is fed via the pipe (1 and
5) into the feed chamber.
This fuel causes a reduced pressure increase in the pump and a reduced start of delivery.
101
Cold start automatic injection advance system (KKSB)
003251t
1. KKSB Bulb
The KKSB device allows to set the required cold start injection advance.
102
INJECTION PUMP TIMING STAGE (NEF TIER 2/TIER 3)
With pin on the gear box.

Once the engine shaft has been timed with the camshaft bring the first cylinder on the
upper dead point. Such condition is obtained by rotating engine shaft until tool no.
99360616 is fitted into relating seat in timing system gear (see figure).
With false injector and head assembled.

Once the engine shaft is timed with the camshaft, in order to bring the first cylinder on the
upper dead point (end compression stage) use the false injector; Position it in the place of
the first injector, apply the comparator and preload it. Rotate the engine shaft properly until
the maximum value appears on the comparator and then check that the intake and
exhaust valves are both closed.
88141
103
The injection pump spare part is already pre-set, so it can be directly installed on the
timing gear, fixed on the gear casing and have the seal ensuring the pump pre-setting
removed by locking the corresponding shaft.
In order to check the timing for correct adjustment, install both the gauge 99395603 (2)
and the adapter 99395100 (1) on the pump as indicated.
003261t
Turn the crankshaft properly in order to take up slacks between gears and move the first
cylinder back in top dead position.
The gauge should display the required pre-set value (see Repair manual). If the required
value does not match the one on the gauge, loosen the screws fixing the pump to the gear
casing and, through the slots, turn the pump body until the correct pre-load value is
obtained.
If the injection pump has been overhauled it is not pre-set, so, install it after moving the
first cylinder to the top dead centre. Then, set the required pre-load value by means of
both the gauge and the adapter and fix it to the gear casing by acting on the slots.
Finally, check as previously described.
104
ROTARY FEED PUMP DISASSEMBLY AND ASSEMBLY PROCEDURE – BOSCH VE
(NEF TIER 2/TIER 3)
This procedure prescribes that:

- the fuel pipelines (from pumping elements to injectors, bleeding recovery pipes from
injectors to pump and feed provided by priming pump) shall all be disassembled;
- electrical connection to feed pump shall be disconnected;
- accelerator cable shall be disconnected.
Fix T.D.C. of 1st Cylinder (see “finding top dead centre (T.D.C.) – F4CE engines”).
2 1
88148
Unscrew the side screw that locks the pump shaft partially (1) and remove spacer (2). This
must be kept on a side (we recommend to fix it on the pump with a wire or a clip). Tighten
the lateral screw (1) blocking rotation of the pump shaft.
75693
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. Loosen the fixing nut (3) and remove the
relating washer.
105
1
88149
From the pump side, loosen the fixing nuts (1) without removing them in order to enable
moving the pump backwards using 99340035 extractor.
Assemble the extractor throughout the two threaded ports (4) and withdraw the gear from
the pump shaft.
Properly hold the feed pump and loosen completely the fixing nuts.
Withdraw the pump from the studs, together with the gasket.
When the supply pump is to be assembled on the engine the P.M.S. conditions at
compression end stage cylinder No. 1 must be carried out.
Attention:
Hold the pump driving gear to avoid interference or crawling during timing gear
rotation.
Assemble the pump pre-set in its housing on the engine, fitting the shaft into the gear port
(not provided with wrench).
Tighten the fixing nuts (1) locking the pump flange in the slot centre.
Attention:
The gasket removed during pump disassembly shall not be utilised again.
Always use original spare parts.
106
75693
On the timing side, throughout the specially appointed port, fit the washer and screw up
the fixing nut (3) to the pump shaft. Lock the nut to the 90 – 95 [Nm] couple.
2 1
88148
Loosen screw (1) that prevents pump shaft rotation and insert spacer (2). Tighten screw
(1)so that it locks spacer (2): in this way the supply pump shaft will be able to rotate freely.
Assemble the cover (2) including gasket and tighten the screws (1).
Disassemble the flywheel rotation/locking tool 99360339 or 99360330; arrange the starting
motor in its seat.
Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from
injectors to pump, LDA pipeline and feed provided by priming pump).
Connect electrical connections to electro-magnets on the hydraulic head and on K.K.S.B..
Note:
In case pump removal has been carried out while the engine was assembled, connect
acceleration cable.
107
Ignition pump control and timing
87720
With the injection pump inserted in relating seat and securing screws loosened, mount
comparator 99395605 (2) and 99395100 gauge tool (1), preloading the rod by 2,5 [mm].
Rotate the engine derive shaft to shift from the condition of the first cylinder to TDC end of
compression phase. Reset the dial gauges and rotate the engine drive shaft into the
opposite direction until recovering the condition of the 1st cylinder to TDC in phase of
compression (see “Find the top dead centre with the tool (99395097) – False injector”).
From this position on the comparator applied on the pump it must be possible to read the
value 1 ± 0,05 [mm].
Rotate the pump in anti-clockwise direction if the stroke is shorter or in clockwise direction
if the stroke is longer, until obtaining the stroke prescribed.
Checking these conditions, lock the pump by tightening the relevant nuts to the prescribed
pair.
Feed system bleed procedure
88304
In case any operation has been executed on the components of the feed circuit, it is
necessary to execute bleeding of air within the system.
Operate as follows:
- disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the
priming pump;
- continue the operation until when fuel outflows;
- connect the fuel pipe (1) to the filter.
108
ELECTRICAL COMPONENTS (NEF TIER 2/TIER 3)
• Pre-post heating kit (*).

• KKSB water temperature sensor on injection pump.
• Oil pressure sensors for the oil pressure warning lamp on the instrument panel.
• Thermal bulb for KKSB on injection pump.
(*) Control unit, engine water temperature sensor, heater
Pre-post heating control unit

Control unit 1 sets the heater (pre-post heating) operating time according to the signal
received by the engine water temperature sensor 2.
Operation diagram
003247t
1. Pre-post heating control unit – 2. Water temperature sensor – 3. Heater electromagnetic

switch 4. Heater – 5. Warning lamp on pre-heating warning panel.
109
TROUBLESHOOTING (NEF TIER 2)
110
Problems Possible causes Remedies
1. Battery partially discharged. Check and recharge battery. Replace if necessary.

2. Battery terminal connections corroded or Clean, inspect and tighten terminal nuts. Replace
loose. terminals and nuts if excessively corroded.
3. Injection pump timing incorrect Adjust injection pump timing
4. Impurities or water in fuel lines. Disconnect fuel lines from injection pump and clean
thoroughly.
If necessary clean and dry the fuel tank
Engine does not start 5. No fuel in tank. Fill tank.
1. Fuel supply pump malfunction Check and replace pump if necessary
2. Air in fuel system. Check fuel lines, unions, supply pump, filters and injection
pump for air, then bleed system.
3. Starter motor faulty Repair or replace starter motor.
111
4. Faulty cold start device. Check and replace thermostarter if necessary.

1. Idle speed too low. Adjust idle speed.
2. Irregular delivery from injection pump. Check injection pump delivery on test bench.
3. Impurities or water in fuel lines Disconnect fuel lines from injection pump and clean
thoroughly. If necessary clean and dry the fuel tank.
4. Fuel filters clogged. Renew filter cartridges.
5. Incorrect valve clearances. Adjust valve clearances.
6. Burnt or cracked valves. Replace valves.
Engine stalls
112
7. Air in fuel system. Check fuel lines, unions supply pump, filters and
injection pump for air, then bleed system.
8. Injection pump drive mechanism damaged. Replace damaged parts.

1. Coolant pump malfunction Overhaul pump or replace
2. Thermostat faulty Replace thermostat
3. Radiator inefficient Remove internal deposits by flushing. Check for leaks

and repair
4. Deposits in cylinder head and crankcase Flush out coolant system
coolant passages
5. Coolant pump and fan drive belt slack Check and adjust belt tension
6. Coolant level low Top up expansion tank with specified coolant mixture
The engine warms up too much 7. Incorrect timing motor phasing Check and adjust
113
8. Injection pump calibration incorrect – Calibrate pump on test bench to values specified in
delivering too much or too little fuel calibration tables
9. Air filter clogged Clean filter unit and replace filter element if necessary
1. Injection pump timing incorrect Do the correct injection pump phasing on the engine.
2. Auto advance in injection pump damaged Overhaul injection pump and adjust on test bench to
values specified in calibration table.
3. Distributor pumping journal worn Overhaul injection pump and adjust on test bench to
4. Injection pump delivery irregular Overhaul injection pump and adjust on test bench to
5. All-speed governor damaged Overhaul injection pump and adjust on test bench to
6. Injectors partially obstructed or damaged Clean, overhaul and calibrate injectors.
Engine lacks power and runs unevenly
7. Impurities or water in fuel lines Disconnect fuel lines from injection pump and clean
thoroughly. If necessary clean and dry the fuel tank.
114
8. Fuel supply pump damaged Replace fuel supply pump

9. Incorrect valve clearances. Adjust valve clearances
10. Cylinder compression low Test compression and overhaul engine if necessary
11. Air filter clogged Clean air filter unit and replace element if necessary
12. Tie-rod in linkage between accelerator and Adjust to correct lenght
injection pump incorrectly adjusted
13. Maximum speed screw on injection pump Adjust max, speed screw
incorrectly adjusted
1. Injectors partially obstructed or damaged Clean, overhaul and calibrate injectors

2. Impurities accumulating in fuel lines Clean fuel lines and replace severely dented pipes.
Clean injection pump if necessary
3. Incorrect injection pump timing Adjust injection pump timing
4. Crankshaft knocking due to to excessive Re-grind crankshaft journals and crankpins. Fit oversize
play in one or more main or big-end shell bearings and thrust washers
bearings or excessive endfloat
5. Crankshaft unbalanced Check crankshaft alignment and balance; replace if
necessary
6. Flywheel bolts loose Replace any bolts that have worked loose and tighten
all bolts to the specified preliminary and angular torque
Engine produces abnormal knocking noises values
115
7. Connecting rod axes not parallel Straighten connecting rods, check axes parallelism;
replace con rods if necessary.
8. Piston knock due to excessive wear Rebore cylinder liners and fit oversize pistons
9. Noise caused by excessive play of gudgeon Fit oversize gudgeon pin, rebore piston seats and
pins in small-end and piston bushings, or small-end bushings. Replace bushings
loose fit of small-end bushing
10. Excessive tappet/valve noise Check for broken springs or excessive play between
valve stems and guides, cam followers and bores.
Adjust valve clearances
1. Maximum delivery of injection pump too Adjust injectio pump on test bench to the values
high. specified in calibration table
2. Injection pump delivery excessively Adjust injectin pump/engine timing or check automatic
retarded or automatic advance regulator advance regulator
damaged.
3. Injection pump delivery excessively Adjust injection pump7engine timing
advanced
4. Injectors partially or totally obstructed Clean and overhaul injectors and adjust pressure
or incorrectly adjusted setting; replace if necessary
5. Air filter clogged Clean air filter unit and replace element if necessary
Engine produces excessive black or dark
grey smoke 6. Loss of engine compression due to: Replace damaged parts or, if necessary, recondition
116
- piston rings sticking; engine.

- cylinder liner wear;
- worn or incorrectly adjusted valves.
7. Damaged high-pressure fuel lines.. Inspect and replace if necessary

1. Injection pump delivery excessively Adjust injection pump/engine timing or check automatic
retarded or automatic advance regulator advance regulator
damaged.
2. Injectors obstructed or damaged Clean and overhaul injectors and adjust pressure
setting; replace if necessary.
3. Oil lealing past piston rings due to sticking Replace damaged parts or, if necessary, recondition
rings or cylinder linea wear. engine.
Blue, grey-blue or grey-white smoke
4. Oil leeaking through the inlet valve guides Recondition cylinder head
due to guide or valve stem wear
5. Engine does not reach correct operating Replace thermostat.
temperature (thermostat faulty).
117
1. Engine stop solenoid damaged. Replace solenoid.
2. All-speed governor damaged. Recondition injection pump and adjust on test bench to
values specified in calibration data chart..
Engine runs on after switching off

118
TROUBLESHOOTING (NEF TIER 3)
ANOMALY POSSIBLE CAUSE REMEDY NOTE
Check and recharge battery. Replace battery
The engine does not start
if necessary.
Battery flat or faulty.
Clean, examine and tighten the nuts on the battery

Connections to battery terminals
terminals. Replace the cable terminals and the nuts
corroded or loose.
if excessively corroded.
Incorrect timing of injection pump. Check and correctly time the injection pump. See your Iveco dealer.
Disconnect the hoses and clean them using a jet of

Deposits or water in the fuel tank. compressed air. Dismantle and clean the injection Drain feed system.
pump. Remove water from tank and refuel.
119
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or transfer pump.
Check the hoses to ensure that air is in fact present

Air bubbles in the fuel lines or and also check the fuel pump. Eliminate the air from
injection pump. the injection pump by unscrewing the cap and
working the fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.

The engine does not start at
Fuel system clogged with paraffin
low temperatures Replace the fuel with fuel suitable for use at low
crystals forming due to the use of
temperatures. Replace the fuel filters.
unsuitable fuel.
K.K.S.B. device for cold spark See your Iveco dealer.

advance control operating Check or replace the injection pump.
incorrectly.
The engine cuts out.
Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection pump. Adjust flow. See your Iveco dealer.
Disconnect the hoses and clean them using a jet of

Impurities or water in the fuel lines. compressed air. Dismantle and clean the injection pump. Drain feed system.
Remove water from fuel tank and refuel.
Clogged fuel filter. Dismantle and replace if necessary.

120
Check that the hoses are not cracked or the unions loose.
Presence of air in the fuel and Replace worn parts, remove the air from the hoses and
injection system. deaerate the injection pump and fuel filter by unscrewing
the caps and working the primer pump by hand.
Broken injection pump controls. Replace the faulty parts.
Abnormal clearance between

Adjust clearance by replacing shims.
camshaft cams and tappets.
Replace the valves, rectify or replace the cylinder head

Burn, corroded or chalky valves.
seatings.
Check the unit and replace if necessary.
The engine overheats Faulty water pump.
Replace the gasket.
Malfunctioning thermostat. Replace the thermostat.
Fouling in coolant openings in the Wash following the standards specified for the type
cylinder head and cylinder groups. of descaling product used.
On applications provided
with automatic tensioner,
Water pump drive belt slack. Check and adjust the tightness of the belt.
check corret worching of
such device.
121
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injection Correct the delivery rate of the pump on a bench so
See your Iveco dealer.
pump. that the injection is at the specified rate.
Dry air cleaner blocked. Clean the air filter or replace if necessary.
Engine operation is
Incorrect timing of injection pump. Check timing and correctly set pump.
irregular and lacks power
K.K.S.B. automatic cold advance

Check or replace injection pump.
device malfunctioning.
Excessive piston wear. Check or replace injection pump.

Incorrect calibration of speed
Check and correctly calibrate the regulator. See your Iveco dealer.
regulator.
Clean the nozzles of the atomisers using the
Partial blockage of nozzles or faulty
appropriate tools and completely overhaul the
operation of injectors.
injectors.
Impurities orwater in the fuel and If necessary drain feed

Carefully clean the system and refuel.
injection system. system.
122
Incorrect play between camshaft

Check and correct play
cams and tappets.
Faulty turbocharger. Replace complete unit.
Air cleaner blocked. Clean or replace air cleaner.

Check that the diaphragm is not perforated, that the
counter spring is suitable and that it has the correct
loading (check on test bench). Check that there is
Faulty operation of L.D.A. device . adequate air pressure inside the intakemanifold in See your Iveco dealer.
relation to the engine rpm under full-load conditions.
Tie rods between accelerator pedal

Adjust the tie-rods so that the command lever can be
and regulation lever incorrectly
moved to the full delivery position.
adjusted.
Engine running with
Faulty operation of injectors. Replace all injectors.
abnormal knocking.
Dismantle the hoses, clean them and replace those

Fuel lines blocked.
that are seriously dented.
Correct the set-up of the pump so that injection

Incorrect set-up of injection pump. See your Iveco dealer.
occurs at the specified angle.
Knocking of crankshaft causing

excessive play on one or more main Rectify the pins of the crankshaft and install smaller
or rod bearings or excessive play on bearings. Replace the thrust halfrings. .
shoulders..
Crankshaft unbalanced. Check alignment of crankshaft.

123
Loosening of screws securing Replace the loosened screws and tightenall the
flywheel. screws to the specified torque.
Misalignment of rods. Replace the rods.
Replace the piston journal and/or the pistonand rod

Noise from piston journals due to bushing.
excessive play of piston hubs and in
the rod bushing. Loose bushings in Replace with new bushings.
the rod seatings.
Adjust the play between camshaft cams and tappets

and check that there are no broken springs, that
Noisy timing.
there is no excessive play between the valve stems
and the valve guides, tappets and seatings.
Disconnect the pump and adjust delivery in
Excessive maximum pump output. accordance with the data given in the calibration See your Iveco dealer.
table.
K.K.S.B. device out of calibration or
Check operation by a tester and adjust See your Iveco dealer.
malfunctioning.
There is an excessive delay on the
Correct the set-up.
injection pump.
The injection pump has an excessive
Correct the set-up.
advance.
The holes in the atomisers (or some Replace the injectors with a series of new injectors
of them) are partially or entirely or clean and rectify the original ones using suitable
The engine smokes blocked. equipment.
abnormally.
Air cleaner blocked or deteriorated. Clean or replace the filter element.
Black or dark grey smoke.
Loss of compression in the engine
due to:
124
Overhaul the engine or limit the interventions to the

stuck or worn flexible rings;worn
relative parts.
cylinder liners;valves deteriorated or
badly djusted.
Unsuitable injectors, different types

Replace or calibrate the injectors..
of injectors r incorrectly calibrated.
Injection hoses with an unsuitable

Check conditions of the end or unions and here
internal iameter, end of hoses
necessary replace the hoses.
pinched due to repeated locking.
Excessive delay in injection pump. Correct the set-up of the pump. See your Iveco dealer.
K.K.S.B. automatic cold advance

Check or replace injection pump. See your Iveco dealer.
device malfunctioning.
Faulty injector. Replace the injector.

Leaking of oil from the piston rings
caused by glued or worn rings or
Blue, grey-blue, grey smoke
wearing of cylinder liner walls. Overhaul the engine.
tending to hite.
Engine oil passing through the intake

guides-valves following wearing of Recondition the cylinder head.
guides or valve stems.
Engine too cold (thermostat blocked

Replace the thermostat.
or inefficient).
125
TOOLS (NEF TIER 2)
TOOL No. DESIGNATION
Tool kit for valve seat regrinding

99305019
99305047 Spring load checking tool
Rotary stand for engine overhaul

99322205
(1000 N lifting, 120 N/m torque)
99340035 Puller for injection pump to engine mounting gear
99340055 Crankshaft front seal puller
99340056 Crankshaft rear seal puller
126
99340205 Injector removal tool
99346252 Driver for crankshaft front oil seal
99346253 Driver for crankshaft rear oil seal
99360076 Engine oil filter wrench
Pliers for disassembling/reassembling piston rings

99360183
(65-110mm)
99360268 Tool for disassembling/reassembling engine valves
127
Fitting used to check the pressure in the cylinders

99360344
(use with 99395682)
99360351 Locking tool for flywheel
Drift for removing and fitting camshaft bushings

99360362
(use with 99370006)
99360500 Lifting tool for crankshaft
99360595 Equalizer for removing and fitting engine
Insertion band for piston into cylinder liner (60-

99360605
125mm)
128
Brackets for securing engine to rotary stand

99361037
99322205
99363204 Oil seal puller tool
99370006 Handle for interchangeable beating device
Gauge support for different measurements

99370415
(use with 99395603)
Tool used to check the upper dead point

99395097
(use with 99395604)
Gauge support tool for rotary pump timing

99395100
(use with 99395603)
129
Pair of gauges for angle tightening with 1 /2“

99395216
and 3 /4 “square connector
99395220 Goniometer (universal inclinometer)
Complete square for connecting rod quadrature

99395363
check
99395603 Comparator (0-5mm)
99395604 Comparator (0-10 mm)
99395682 Diesel engine compression checking device
130
TOOLS (NEF TIER 3)
Rotary stand for engine overhaul

99322205
(1000 N lifting, 120 N/m torque)
99340035 Puller for injection pump to engine mounting gear
99340055 Crankshaft front seal puller
99340056 Crankshaft rear seal puller
99340205 Injector removal tool
99346252 Driver for crankshaft front oil seal
131
99346253 Driver for crankshaft rear oil seal
99360076 Engine oil filter wrench
Pliers for disassembling/reassembling piston rings

99360183
(65-110mm)
99360268 Tool for disassembling/reassembling engine valves
99360330 Flywheel crank handle
99360339 Tool for stopping the engine flywheel
132
Fitting used to check the pressure in the cylinders

99360344
(use with 99395682)
99360351 Locking tool for flywheel
Drift for removing and fitting camshaft bushings

99360362
(use with 99370006)
99360500 Lifting tool for crankshaft
99360595 Equalizer for removing and fitting engine
Insertion band for piston into cylinder liner (60-

99360605
125mm)
133
99360616 Engine TDC positioning tool
Brackets for securing engine to rotary stand

99361037
99322205
99363204 Oil seal puller tool
99370006 Handle for interchangeable beating device
Gauge support for different measurements

99370415
(use with 99395603)
Tool used to check the upper dead point

99395097
(use with 99395604)
134
Gauge support tool for rotary pump timing

99395100
(use with 99395603)
Pair of gauges for angle tightening with 1 /2“

99395216
and 3 /4 “square connector
99395603 Comparator (0-5mm)
99395604 Comparator (0-10 mm)
99395682 Diesel engine compression checking device
135
136
DATA - F4BE ASSEMBLY CLEARANCES (NEF TIER 2)
Type F4BE
CYLINDER BLOCK AND CRANK MEMBERS mm
Cylinder liners ∅1 102,01 ÷ 102,03
Pistons: supplied as spares

type
Distance X 61
Outside diameter ∅1 101,777 ÷ 101,795
Seat for pin ∅2 40,006 ÷ 40,012
Piston – cylinder liners 0,215 ÷ 0,253
Pistons diameter ∅1 0,5
Protrusion of pistons from

0,28 ÷ 0,52
crankcase X
Gudgeon pin ∅3 39,9968 ÷ 40,0032
Gudgeon pin – pin seat 0,0028 ÷ 0,0152
137
Type F4BE
Piston type
X1* 2,69
Piston ring grooves X2 2,425 ÷ 2,445
X3 4,04 ÷ 4,06
* measured on ∅ 99 mm
S1* 2,560 ÷ 2,605

Piston rings S2 2,310 ÷ 2,340
S3 3,075 ÷ 4,000
1 0,245 ÷ 0,265
Piston rings – grooves 2 0,085 ÷ 0,135
3 0,040 ÷ 0,985
Piston rings 0,5
Piston ring gaps in cylinder

liner:
X1 0,40 ÷ 0,70
X2 0,25 ÷ 0,55
X3 0,25 ÷ 0,55
Small end bushing seat
∅1 42,987 ÷ 43,013
Connecting rod bearing
seat
∅2 77,075 ÷ 78,25
Small end bushing diameter
outside ∅4 43,279 ÷ 43,553
inside ∅3 40,019 ÷ 40,033
Big end bearing shells
supplied as spares S 1,955 ÷ 1,968
Small end bushing – seat 0,266 ÷ 0,566
Gudgeon pin – bushing 0,0158 ÷ 0,0362
138
Type F4BE

Measurement distance
X -
Maximum error on
parallelism of connecting
rod axes = -
Main journals ∅1 82,99 ÷ 83,01
Crankpins ∅2 68,987 ÷ 69,013
Main bearing shells
S1* 2,456 ÷ 2,464
Big end bearing shells S2* 1,955 ÷ 1,968
* supplied as spare parts
Main bearing housings no:
no. 1–5 or ∅3 87,982 ÷ 88,008
no. 2–3–4 ∅3 87,977 ÷ 88,013
Bearing shells – main
journals:
no. 1–5 0,041 ÷ 0,119
no. 2–3–4 0,041 ÷ 0,103
Bearing shells – crankpins 0,033 ÷ 0,041
Main bearing shells

+ 0,250; + 0,500
Main journal of thrust

bearing X1 37,475 ÷ 37,545
Main bearing housing of

thrust bearing X2 25,98 ÷ 26,48
Shoulder half rings X3 37,28 ÷ 37,38
Crankshaft shoulder 0,068 ÷ 0,410
139
Type F4BE
CYLINDER HEAD – TIMING SYSTEM mm
Valve guide seats on

cylinder head ∅1 8,019 ÷ 8,039
Valves:
∅4 7,96 ÷ 7,98
α 60°
∅4 7,96 ÷ 7,98
α 45°
Valve stem and valve guide 0,052 ÷ 0,092
Seat on head for valve
seat:
∅1 46,987 ÷ 47,013
(∗)
∅1 43,637 ÷ 43,663
Valve seat outside
diameter; angle of valve
seats on cylinder head:
∅2 47,063 ÷ 47,089
(∗) α 60°
∅2 43,713 ÷ 43,739
α 45°
Recessing X 0,356 ÷ 1,102
(∗) X 0,104 ÷ 0,84
Between valve seat 0,050 ÷ 0,102

and head (∗) 0,050 ÷ 0,102
Valve seats - -
140
Type F4BE

Valve spring height:
free spring H 63,5
under load of:
329 H1 49,02
641 H2 38,2
Injector protrusion X not adjustable
Seats for camshaft

bushings n° 1–5 -
Seats for camshaft pins
n° 2–3–4 -
Camshaft main journals:

1⇒5 ∅
53,995 ÷ 54,045
Camshaft bushings outside

diameter:
∅ -
Bushing inside diameter

∅ -
Bushings and seats in
-
crankcase
Bushings and main journals 0,038 ÷ 0,162
Useful cam lift:
-
141
Type F4BE
Tappet plate seat in

crankcase ∅1 -
Tappet plate outside

diameter:
∅2 15,929 ÷ 15,959
∅3 15,965 ÷ 15,930
Between tappets and seats 0,025 ÷ 0,070
Tappets -
∅1
Rocker carrier spindle ∅1 18,963 ÷ 18,975
Rockers ∅2 19,000 ÷ 19,026
∅2
Between rockers and

0,025 ÷ 0,063
spindle
142
DATA – F4GE ASSEMBLY CLEARANCES (NEF TIER 3)
F4GE
Type
4 CYLINDER 6 CYLINDER
Cylinder liners ∅1 104,000 ÷ 104,024

> ∅1 0,4
Pistons: supplied as spares

type
Distance X 55,9
Outside diameter ∅1 103,714 ÷ 103,732
Seat for pin ∅2 38,010 ÷ 38,016
Piston – cylinder liners 0,252 ÷ 0,294
Pistons diameter ∅1 0,4
Protrusion of pistons from

0,28 ÷ 0,52
crankcase X
Gudgeon pin ∅3 37,994 ÷ 38,000
Gudgeon pin – pin seat 0,010 ÷ 0,022
143
F4GE
Type
Piston type
X1* 2,705 ÷ 2,735
Piston ring grooves X2 2,440 ÷ 2,460
X3 4,030 ÷ 4,050
S1* 2,560 ÷ 2,605

Piston rings S2 2,350 ÷ 2,380
S3 3,970 ÷ 3,990
1 0,100 ÷ 0,175
Piston rings – grooves 2 0,060 ÷ 0,110
3 0,040 ÷ 0,080
Piston rings 0,4
Piston ring gaps in cylinder

liner:
X1 0,30 ÷ 0,40
X2 0,60 ÷ 0,80
X3 0,30 ÷ 0,55
Small end bushing seat
∅1 40,987 ÷ 41,013
Connecting rod bearing
seat
∅2 72,987 ÷ 73,013
Small end bushing diameter
Inside ∅3 38,019 ÷ 38,033
Big end bearing shells 1,955 ÷ 1,968

supplied as spares S
Small end bushing – seat 0,019 ÷ 0,039
Gudgeon pin – bushing 0,250 ÷ 0,500
144
F4GE
Type

Measurement distance
X -
Maximum error on
parallelism of connecting
rod axes = -
Main journals ∅1 82,990 ÷ 83,010
Crankpins ∅2 68,987 ÷ 69,013
Main bearing shells
S1* 2,456 ÷ 2,464
Big end bearing shells S2* 1,955 ÷ 1,968
* supplied as spare parts
Main bearing housings no:
n° 1-5 or 1-7 ∅3 87,982 ÷ 88,008
n° 2-3-4 or 2-3-4-5-6 ∅3 87,977 ÷ 88,013
Bearing shells – main
journals:
n°. 1-5 or 1-7 0,064 ÷ 0,095
n° 2-3-4 or 2-3-4-5-6 0,059 ÷ 0,100
Bearing shells – crankpins 0,033 ÷ 0,041
Main bearing shells

+ 0,250; + 0,500
Main journal of thrust

bearing X1 37,475 ÷ 37,550 37,475 ÷ 37,545
Main bearing housing of

thrust bearing X2 32,180 ÷ 32,280
Shoulder half rings X3 37,280 ÷ 37,380
Crankshaft shoulder 0,095 ÷ 0,270 0,095 ÷ 0,265
145
F4GE
Type
Valve guide seats on

cylinder head ∅1 8,019 ÷ 8,039
Valves:
∅4 7,960 ÷ 7,980
α 60°
∅4 7,960 ÷ 7,980
α 45°
Valve stem and valve guide 0,059 ÷ 0,089
Seat on head for valve
seat:
∅1 46,987 ÷ 47,013
(∗)
∅1 43,637 ÷ 43,663
Valve seat outside
diameter; angle of valve
seats on cylinder head:
∅2 47,063 ÷ 47,089
(∗) α 60°
∅2 43,713 ÷ 43,739
α 45°
Recessing X 1 ÷ 1,52
(∗) X 1 ÷ 1,52
Between valve seat 0,050 ÷ 0,102

and head 0,050 ÷ 0,102
Valve seats - -
146
F4GE
Type

Valve spring height:
free spring H 63,50

under load of:
329 ± 19 N H1 49,02
641 ± 39 N H2 38,20
Injector protrusion X not adjustable
Seats for camshaft

bushings n° 1 59,222 ÷ 59,248
Seats for camshaft pins
n° 2-3-4-5 or 2-3-4-5-6-7 54,089 ÷ 54,139
Camshaft main journals:

1⇒5
1⇒7 ∅ 53,995 ÷ 54,045
Bushing inside diameter

∅ 54,083 ÷ 54,147
Bushings and main journals 0,038 ÷ 0,162

Useful cam lift:
-
147
F4GE
Type
Tappet plate seat in

crankcase ∅1 16,000 ÷ 16,030
Tappet plate outside

diameter:
∅2 15,929 ÷ 15,959
∅3 15,965 ÷ 15,980
Between tappets and seats -
Tappets -
∅1
Rocker carrier spindle ∅1 18,963 ÷ 18,975
Rockers ∅2 19,000 ÷ 19,026
∅2
Between rockers and

0,025 ÷ 0,063
spindle
148

NEF Engine Mechanical Pump

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NEF Engine Mechanical Pump

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Mechanical NEF series pump

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IVECO Product Academy

TECHNICAL CODING (4 cylinder – NEF TIER 2) 3

Type of base: AxC V

4 = Agric. mach. – Earthmoving mach.

X= 6 2 valve rotative injection pump Sequential production number

Type of base: AxC V

4 = Agric. mach. – Earthmoving mach.

X= 6 2 valve rotative injection pump Sequential production number

Type of base: AxC V

4 = Agric. mach. – Earthmoving mach.

X= 6 2 valve rotative injection pump Sequential production number

Displacement or number of cylinders

Cilindrata o numeri cilindri

TECHNICAL CODING COMMERCIAL CODING

F Rotative injection pump

F Rotative injection pump

F Line injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

F Rotative injection pump

Number of cylinders 4 in line

Total displacement cm3 3922

Compression ratio 17,5 : 1

rpm 2300 2100

rpm 1400 1400

High idle speed

Turbocharger type: HOLSET HX25W

Injectors DSLA 145 P603

Ignition order 1–3–4–2

Injection pressure bar 245

Number of cylinders 4 in line

Total displacement cm3 3922

Compression ratio 17,5 : 1

rpm 2200 2200 2200 22100

rpm - 1400 1400 1400

High idle speed

Turbocharger type: HOLSET HX25W

Injectors DSLA 145 P603

Ignition order 1–3–4–2

Injection pressure bar 245

Number of cylinders 6 in line

Total displacement cm3 5883

Compression ratio 17,5 : 1

rpm 2000 2150 2000 2000

rpm 1400 1400 1400 1400

High idle speed

Turbocharger type: HOLSET HX35W

Injectors DSLA 145 P

Ignition order 1–5–3–6–2–4

Injection pressure bar 245

Number of cylinders 6 in line