F4ae3481 Euro4 PDF

EURO 4
NEF SERIES
Application to vehicles
N40
N40 ENT C
N60
N60 ENT C
Technical and Repair manual

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

of going to press but due to possible modifications made by
the Manufacturer for reasons of a technical or commercial na-
ture or for adaptation to the legal requirements of the differ-
ent countries, some changes may have occurred.
No part of this publication, including the pictures, may be re-
produced in any form or by any means.
Produced by:
Publication edited by
Iveco Motors
Iveco SpA
PowerTrain
Mkt. Advertising & Promotion
Viale dell’Industria, 15/17 B.U. TECHNICAL PUBLISHING
20010 Pregnana Milanese Iveco Technical Publications
Milano (Italy) Lungo Stura Lazio, 15/19
Print P1D32N002 E - 1st Ed. 07.2006 10156 Turin - Italy
EURO 4 NEF ENGINES 3
PRELIMINARY REMARKS
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections of
units to/from the vehicle, overhauls at the bench and relating troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - WARNINGS
Danger for persons

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

Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes
guarantee lapse too.
General danger
! It includes the dangers of above described signals.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
NOTE It indicates an additional explanation for a piece of information.
Print P1D32N002 E Base - July 2006

4 EURO 4 NEF ENGINES
Base - July 2006 Print P1D32N002 E

EURO 4 NEF ENGINES
F4A Engines Part 1


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

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

Part 1
F4A ENGINES
Section
General specifications 1
Fuel 2
Application to vehicles 3
General overhaul and characteristics 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the F4A engine illustrating its features

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

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

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

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


UPDATING
Section Description Page Date of revision


EURO 4 NEF ENGINES GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 3
LUBRICATION (4 CYLINDERS) . . . . . . . . . . . . . 5
LUBRICATION (6 CYLINDERS) . . . . . . . . . . . . . 6
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . 7
- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 8
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 9
COOLING SYSTEM (4 CYLINDERS) . . . . . . . . . 10
COOLING SYSTEM (6 CYLINDERS) . . . . . . . . . 12
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
AIR INDUCTION - BOOST DIAGRAM . . . . . . . 15
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DeNOx 2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 16
- General Information . . . . . . . . . . . . . . . . . . . . . 16
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- AdBlue fluid level gauge control . . . . . . . . . . . . 18
- Pump module . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Dosing module . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Exhaust gas temperature sensor . . . . . . . . . . . . 19
- Humidity detecting sensor . . . . . . . . . . . . . . . . 20

2 GENERAL SPECIFICATIONS EURO 4 NEF ENGINES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code

F4AE3481 N40 ENT C
F4AE3681 N60 ENT C
F4AE3682 N60 ENT C


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

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

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

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

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

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

OIL PUMP Figure 3
NOTE Since the oil pump cannot be overhauled, it shall

be replaced when damaged.
The oil pump is controlled directly by the drive shaft.
70576
HEAT EXCHANGER
Figure 4
5
6
1
70480
1. Heat exchanger body with filter support - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat
exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.

Oil pressure relief valve

Figure 5
Pressure regulation at 100°C oil temperature:

- 1.2 bar min pressure;
- 3.8 bar max. pressure
107418
By-pass valve to cut out clogged oil filter.

Figure 6
Figure 7
Flow
70482
107419
Max blow-by:
MAIN DATA TO CHECK OIL PRESSURE RELIEF 20 cm3/1’ at 0.83 bar pressure and at 26.7°C oil temperature.
VALVE SPRING

OIL VAPOUR RECYCLING
Figure 8
Oil condensate
Oil vapours 109903
1. Pre-separator - 2. Bleeder on side

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
The condensed oil returns to the oil sump, whereas the residual vapour is conveyed, collected and discharged into the open
air through the bleeder on the side (2).

COOLING SYSTEM (4 CYLINDERS)

The engine cooling system, closed circuit forced circulation
type, generally incorporates the following components:
- Expansion tank; placement, shape and dimensions are
subject to change according to the engine’s equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
- Viscous pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as
well will be specifically equipped based on the engine’s
development.
- 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.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.

Figure 9
Expansion tank
Expansion tank
Heater
(optional)
Radiator
Radiator
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
74194
COOLING SYSTEM LAYOUT
COOLING SYSTEM (6 CYLINDERS)

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

Figure 10
Expansion tank
Expansion
tank
Heater
(optional)
Radiator
Radiator
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
COOLING SYSTEM LAYOUT

Water Pump Viscous fan

Figure 11 Figure 13
Sec. A-A 70486
The water pump is located in a housing obtained in the en-

gine block and is controlled by and a poly-V belt.
An automatic tensioner keeps the belt tension.
Thermostat
Figure 12
70487
Characteristics:
Max control speed: 2700 rpm
Max fan speed: 2565 rpm ± 50 rpm
Operating temperature: 72°C± 4°C at 2160 rpm
fan speed
79458
The thermostat (1) of the by-pass type is located in the cylin-

der head and doesn’t need regulations.
Whenever doubts on its operation are present, replace it.
On the thermostat body are fitted the thermometric trans-
mitter/switch and water temperature sensor.
A= stroke beginning: 79.0 — 83.0 °C
B= stroke at 96 °C ≥ 7.5 mm

AIR INDUCTION - BOOST DIAGRAM
Figure 14
4 Cylinders version
AIR FILTRE TURBOCHARGER
EXHAUST
RADIATOR
6 Cylinders version
AIR FILTRE TURBOCHARGER
EXHAUST
RADIATOR
74195
Description The turbocharger is equipped with a transforming valve to

The turbocharger is composed by the following main parts: regulate the pressure , that is located on the exhaust
one turbine, one transforming valve to regulate the boost collector before the turbine and connected by piping to the
feeding pressure , one main body and one compressor. induction collector.
During engine working process, the exhaust emissions flow It’s funchon is to restrict the exhaust of the emissions ,
through the body of the turbine, causing the turbine disk releasing part of them directly to the exhaust tube when the
wheel’s rotation. boost feeding pressure, over the compressor, reaches the
prescribed bar value.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates, The cooling process and the lubrication of the turbocharger
compressing the drawn air through the air filter. and of the bearings is made by the oil of the engine.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.

DeNOx 2 SYSTEM
General Information
To restrict the nitrogen oxide (NOx) emissions in the exhaust to within the limits prescribed by Euro 4 regulations, with low
fuel consumption levels, the vehicles have been fitted with a system for post-treatment of the substances present in the exhaust
gasses, basically comprising an electronically controlled oxidising catalytic converter.
The system, by means of the SCR (Selective Catalytic Reduction) process, transforms the nitrogen oxides (NOx) into inert
compounds: free nitrogen (N2) and water vapour (H2O).
The SCR process is based on a series of chemical reactions that, by reacting the ammonia with the oxygen in the exhaust gas,
results in reduction of the nitrogen oxides (NOx) present in the exhaust fumes.
Figure 15
A
A
A
108124
DIAGRAM OF SCR SYSTEM

A. PUMP MODULE - B. DOSING MODULE
1. AdBlue solution tank - 2. Intercept solenoid valve - 3. Volumetric pump - 4. AdBlue solution temperature sensor -
5. AdBlue level sensor - 6. Filter - 7. AdBlue temperature sensor - 8. AdBlue solution pressure sensor - 9. Pump Module
Control unit - 10. NOx humidity detection sensor - 11. Temperature sensor - 12. Injection solenoid valve - 13. Discharged
exhaust gas temperature sensor - 14. Catalytic converter - 15. Incoming exhaust gas temperature sensor - 16. Cooling
solenoid valve - 17. Prefilter.

The system essentially comprises: The pump module (2) picks up the reagent solution from the
tank (3) and sends it under pressure to the mixing and injec-
- a tank (9) of reagent solution (water - urea: AdBlue) with
tion module (7) to be injected into the exhaust pipe up-
a level indicator;
stream of the catalytic converter (4).
- a pump module (2);
The first phase of the process takes part in the first part of
- a mixing and injection module (7); the catalytic converter: due to the effect of the exhaust gas
temperature, the reagent solution evaporates instantly and,
- a catalytic converter (4);
by hydrolysis, converts into ammonia (2NH3) and carbon
- two temperature sensors (5 and 6) at the exhaust gas dioxide (CO2).
inlet and outlet to the catalytic converter (4);
Evaporation of the solution causes lowering of the exhaust
- a humidity sensor (1) fitted on the engine air intake pipe gas temperature, bringing it closer to the optimum tempera-
downstream of the air filter. ture required by the process.
The SCR system is electronically managed by the DCU The exhaust fumes, additioned with ammonia and at the re-
(Dosing Control Unit) incorporated in the pump module (2), action temperature, are introduced into the catalytic con-
which according to the number of engine revs, the torque verter, where the second phase of the process takes place:
delivered, the exhaust temperature, the amount of nitrogen by reacting with the oxygen in the exhaust gasses the ammo-
oxides and humidity in the incoming air, adjusts the flow rate nia is converted into free nitrogen (N2) and water vapour
of the AdBlue solution to be put into the system. (H2O).
Figure 16
108588
LOCATION OF SCR SYSTEM COMPONENTS ON THE VEHICLES
1. Humidity sensor for incoming air - 2. Pump module - 3. Tank of reagent solution (water - urea: AdBlue) -
4. Catalytic converter - 5. Temperature sensor for exhaust gas entering the catalytic converter - 6. Temperature sensor for
exhaust gas leaving the catalytic converter - 7. Mixing and injection module.
Tank Pump module

Figure 17 Figure 19
108508
The tank with the level indicator command contains the

reducing substance necessary for the SCR process,
comprising a solution of 35% urea and water, known as
AdBlue. 108128
1. AdBlue l tank return - 2. AdBlue return pipe from dosing

module - 3. AdBlue solution outlet - 4. AdBlue solution
infeed - 5. Electrical connection - 6. DCU control unit
connector - 7. Filter - 8. Prefilter.
AdBlue fluid level gauge control Dosing module
Figure 18 Figure 20
102296 108129
AdBlue fluid level gauge command1. AdBlue fluid intake 1. AdBlue infeed - 2. Electrical connection -
pipe - 2. AdBlue fluid return pipe - 3. Inlet pipe for hot 3. AdBlue outlet.
engine coolant fluid - 4. NTC sensor - 5. Outlet pipe for
Has the job of dosing the AdBlue solution to be sent into the
hot engine coolant fluid - 6. Float - 7. AdBlue fluid heater
exhaust pipe upstream of the catalytic converter.
coil.

Exhaust gas temperature sensor

Figure 21
102303
Figure 22
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Earth cable (white) - 6. Sensor.
The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to
calculate the amount of urea to be injected into the system.

Humidity detecting sensor

Figure 23
102311
1. Temperature - 2. Earth - 3. Humidity percent value - 4. Power supply.

This sensor is located on the air filter output conveyor, and is used to inform the control unit of the amount (percentage) of
humidity found in sucked air, to determine the calculation of nitric oxide emissions.
Figure 24
102312
ELECTRIC BLOCK DIAGRAM

1. Earth - 2. Temperature - 3. Power supply unit - 4. Humidity percent value - A. Sample frequency generator -
B. Reference oscillator - C. NTC temperature sensor - D. Amplifier lowpass filter.

EURO 4 NEF ENGINES FUEL 1
SECTION 2
Fuel
Page
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . 3
- General Specifications . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . 5
FUEL SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . . 6
FUEL PREFILTER . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MECHANICAL FEEDING PUMP . . . . . . . . . . . . 9
CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . 10
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DOUBLE STAGE OVERPRESSURE VALVE . . . . 14
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Injector in rest position . . . . . . . . . . . . . . . . . . 15
- Injection start . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Injection end . . . . . . . . . . . . . . . . . . . . . . . . . . 15
PRESSURE LIMITER FOR FUEL RETURN . . . . . . 15

2 FUEL EURO 4 NEF ENGINES

COMMON RAIL
General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 1
108501
1. Injectors connections - 2. Fuel pressure sensor - 3. Engine coolant temperature sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. EDC 7 control unit - 7. Pressure regulator - 8. Fuel heater and fuel
temperature sensor - 9. Camshaft sensor - 10. Air pressure/temperature sensor - 11. Injector.
Through the sensors, present on the engine, the ECU con- The outlet tension is proportional to the pressure or tem-
trols the engine operation. perature obtained by the sensor.
Air pressure/temperature sensor Engine oil temperature and pressure sensor
It is a component integrating a temperature sensor and a Same as air pressure/temperature sensor, it is fitted on the
pressure sensor. engine oil filter, in a horizontal position.
Fitted on the intake manifold, it measures the max. inlet air It measures engine oil temperature and pressure.
capacity to calculate precisely the fuel quantity to inject at
every cycle.

Fuel pressure sensor Injection control

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

HYDRAULIC SYSTEM
Figure 2
High pressure
Low pressure
108499
1. Injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical rotor pump - 5. High-pressure pump - 6. Prefilter assembled on
chassis - 7. Rail overpressure valve - 8. Pressure limiter for fuel return.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

FUEL SYSTEM LAYOUT

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

EXHAUST
Print P1D32N002 E
Figure 3
SUCTION (LOW PRESSURE)

HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE)
EURO 4 NEF ENGINES
HIGH PRESSURE
FUEL
114545
7
Base - July 2006

FUEL PREFILTER FUEL FILTER

Figure 4 Figure 5
70494
99231
The fuel filter is of the high water separation type, is

assembled on the right side of the vehicle chassis, and has the 1. Fuel filter support - 2. Fuel temperature sensor -
sensor (4) for detecting water in fuel placed on the cartridge 3. Electric fuel heater - 4. Fuel filter - 5. Adaptor -
(3) base. 6. Heater connector - 7. Gasket.
Manual priming pump (5) and air bleeding screw (2) from A. Outlet connection for fuel discharge to the tank
system are placed on filter support. B. Outlet connection to high-pressure pump
The presence of condensate into filter is signalled by sensor C. Discharge connection from high-pressure pump
(4) when a warning light on the instrument panel is lit. D. Inlet connection for fuel discharge from common rail
E. Inlet connection from fuel pump.
It is placed on engine block in the circuit between supply
pump and high-pressure pump (CP3).
If the warning light is on, it is necessary to im- Cartridge filtering degree: 4 microns.
! mediately operate to remove its cause; the common
rail system components are quickly damaged by the Pressure delta 2 bars.
presence of water or impurities in the fuel. The following are placed on the support: fuel temperature
sensor and heater resistances.
Fuel temperature, signalled by the related sensor to EDC7
control unit, allows a very accurate computation of the fuel
flow-rate to be injected into the cylinders.

MECHANICAL FEEDING PUMP Jettison condition

Gear pump, placed on rear part of the high pressure pump,
Figure 8
whose function is to feed the high pressure pump. It is driven
by the high pressure pump’s shaft.
Ordinary working condition
Figure 6
72594
The by-pass valve (2) intervenes when, with the engine off,
the supply system needs to be filled using the priming pump.
72592 In this situation, the by-pass valve (1) stays closed and the
by-pass valve (2) opens due to the incoming pressure. The
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, fuel flows out of outfeed B.
I - 2 By-pass valves in close position.
The mechanical feeding pump cannot be replaced

Overpressure condition in Exhaust unit ! separately, therefore it must not be disassembled
from the high pressure pump.
Figure 7
72593
The by-pass valve (I) is activated in case of overpressure on

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

CP3 HIGH PRESSURE PUMP

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

High pressure pump-inside structure

Figure 10
Sec. B-B
Sec. C-C
70498
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.
Every pumping unit is composed of: - cap intake valve (3);

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

Working principle
Figure 11
Sec. B - B
Sec. D - D
72597
1. Fuel exhaust connector to rail - 2. By-pass valve to common rail - 3. Pumping element - 4. Pump’s camshaft
5. Pumping element fuel duct - 6. Fuel duct for pressure regulating gauge - 7. Pressure regulating gauge.
The pumping element (3) is orientated towards the pump’s During compression phase of the pumping element, the fuel
camshaft (4). During the intake phase, the pumping element achieves the level of pressure determining the opening of the
is fed through the feeding line (5). The quantity of fuel to flow by-pass valve to common rail (2), feeding it through the
to the pumping element is determined by the pressure exhaust unit (I).
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
Figure 12 Figure 13
72601
72598
Sec. C - C Sec. A - A
1. Inlet to the pumping element - 2. Duct lines for the 1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
pump lubrication - 3. Inlet to the pumping element exhaust flowing from pump with connector to high
4. Main feeding line to the pumping element - pressure pipe for common rail.
5. Pressure gauge - 6. Inlet to the pumping element -
7. Pressure gauge exhaust flue - 8. Flow limiting valve to 5
bar - 9. Fuel exhaust from pressure gauge inlet.
Figure 12 shows the fuel runs at low pressure inside the Figure 13 shows the fuel flow under high pressure running
pump; the following elements are clearly visible: the main through the exhaust galleries of the pumping elements.
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines (2).
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.

Operation RAIL
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 14
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail. 108500
The thereby-generated pressure makes the exhaust valve

open and the compressed fuel reaches the high-pressure 1. Rail. — 2. Pressure sensor. — 3. Fuel inlet from
circuit. high-pressure pump. — 4. Overpressure valve.
The pumping element compresses the fuel till the top dead The rail volume is of reduced sizes to allow a quick
center (delivery stroke) is reached. Afterwards, the pressure pressurisation at startup, at idle and in case of high flow-rates.
decreases till the exhaust valve is closed. It anyway has enough volume as to minimise use of plenum
The pumping element piston goes back towards the bottom chambers caused by injectors openings and closings and by
dead center and the remaining fuel is decompressed. the high-pressure pump operation. This function is further
enabled by a calibrated hole being set downstream of the
When the pumping element chamber pressure becomes less high-pressure pump.
than the supply pressure, the intake valve is again opened and
the cycle is repeated. A fuel pressure sensor (2) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
The delivery valves must always be free in their movements, feed-back information, depending on which the rail pressure
free from impurities and oxidation. value is checked and, if necessary, corrected.
The rail delivery pressure is modulated between 250 and
1600 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection — reconnection time on DOUBLE STAGE OVERPRESSURE VALVE
the engine is highly reduced in comparison with traditional Once the valve has been mounted at one rail end, the valve
injection pumps, because it does not require setting. task is to protect system components in the case where a
If the pipe between fuel filter and high-pressure pump is to fault in either rail pressure sensor or pump pressure regulator
be removed-refitted, be sure that hands and components are CP3 causes pressure excessive increment in high pressure
absolutely clean. system.
The valve is of a definitely mechanical type and has double
operation threshold: 1750 bar and about 800 bar.
When pressure in the rail reaches 1750 bar, the valve first
operates as a single stage valve to cause fuel to be drained
away and pressure to be consequently decreased to safety
values, then it mechanically regulates pressure in the rail to
about 800 bar.
This valve enables to have the engine operated for long time
with limited performance and inhibits fuel excessive
overheating, so preserving the pipings returning from the
tank.

INJECTOR Injection start

The injector is similar as construction to the traditional ones, Figure 16
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator — spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift. 15
Injector in rest position

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

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

it must not be disassembled.
PRESSURE LIMITER FOR FUEL RETURN

It is housed on the rear cylinder head part, and adjusts the
pressure of fuel returning from injectors at a pressure
included between 1.3 to 2 bars. By guaranteeing this pressure
70505
to the return fuel, the fuel vapours formation inside injectors
1. Pressure rod — 2. Plunger — 3. Nozzle — 4. Coil — 5. Pilot is avoided, optimising fuel spraying and combustion.
valve — 6. Ball shutter — 7. Control area — 8. Pressure
chamber — 9. Control volume — 10. Control duct —
11. Supply duct — 12. Control fuel outlet — 13. Electric Figure 17
connection — 14. Spring — 15. High-pressure fuel inlet.
70507
A To tank — B From injectors

EURO 4 NEF ENGINES SECTION 3 - APPLICATION TO VEHICLES 1
SECTION 3
Application to vehicles
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
GENERAL PROPERTIES . . . . . . . . . . . . . . . . . . . 4
- 4 cylinder engines . . . . . . . . . . . . . . . . . . . . . . 4
PART ONE - MECHANICAL COMPONENTS 7
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Engine setting operations for the assembly

on turning stand . . . . . . . . . . . . . . . . . . . . . . . 9
- Distribution gear box . . . . . . . . . . . . . . . . . . . 17
- Distribution timing . . . . . . . . . . . . . . . . . . . . . . 17
- Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . 18
- Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . 19
- Tappet play adjustment . . . . . . . . . . . . . . . . . . 26
- Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . 27
- Wiring support . . . . . . . . . . . . . . . . . . . . . . . . 29
- Checks and inspections . . . . . . . . . . . . . . . . . . 33
PART TWO - ELECTRICAL EQUIPMENT . . . 35
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 37
- Engine F4AE3481 . . . . . . . . . . . . . . . . . . . . . . 37
- Engine F4AE3681 . . . . . . . . . . . . . . . . . . . . . . 38
- Engine F4AE3682 . . . . . . . . . . . . . . . . . . . . . . 39

2 SECTION 3 - APPLICATION TO VEHICLES EURO 4 NEF ENGINES
Page Page
PART FOUR - MAINTENANCE PLANNING . 89

- Overview of sensors . . . . . . . . . . . . . . . . . . . . 40
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 91
ECM ELECTRONIC CONTROL UNIT (EDC 7) 41
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
- Electroinjectors connector “A” . . . . . . . . . . . . 42
- Checks not included in maintenance
planning-daily checks . . . . . . . . . . . . . . . . . . . . 91
- Sensors connector “C” . . . . . . . . . . . . . . . . . . 43
- Inspection and/or maintenance interventions . 91
- “B” frame connector ................... 44
- Unscheduled and set-interval operations . . . . . 92
ECM CENTRAL UNIT COMPONENTS (EDC 7) 45
MAINTENANCE PLANNING . . . . . . . . . . . . . . 93
- Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Engine oil level check. . . . . . . . . . . . . . . . 93
- Pressure regulator - high pressure pump . . . . . 51
- Check of fuel system . . . . . . . . . . . . . . . . 93
- Electroinjector . . . . . . . . . . . . . . . . . . . . . . . . . 52
- Lubricating system check . . . . . . . . . . . . . 93
MAIN POWER COMPONENTS . . . . . . . . . . . . 54 - Cooling system check . . . . . . . . . . . . . . . 93
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 54 - Check of belt’s tear and wear status . . . . 93
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 55 - Changing engine oil . . . . . . . . . . . . . . . . . 94
PART THREE - TROUBLESHOOTING . . . . . . 57 - Changing engine oil filters . . . . . . . . . . . . 94
PT-01 PORTABLE TESTER . . . . . . . . . . . . . . . . . 59 - Changing fuel pre-filter . . . . . . . . . . . . . . . 94
- Main functions . . . . . . . . . . . . . . . . . . . . . . . . . 59 - Changing fuel filter . . . . . . . . . . . . . . . . . . 94
- Changing miscellaneous drive belts . . . . . 95

- Test parameters . . . . . . . . . . . . . . . . . . . . . . . . 59
- Connect - reconnect and clean AdBlue
DTC ERROR CODES system pre-filter . . . . . . . . . . . . . . . . . . . . 95
WITH EDC7 CENTRAL UNIT . . . . . . . . . . . . 61
- Checking valve clearance and adjustment
GUIDE TO DIAGNOSIS THROUGH SYMPTOMS 85 if necessary . . . . . . . . . . . . . . . . . . . . . . . . 95

GENERAL SPECIFICATIONS
Figure 1
108502
F4AE3681 ENGINE
The NEF F4AE engines are characterised by four-stroke diesel The section herein described is composed or four sections:
cycles supercharged with 4 or 6 cylinders with 4 valves per
- Section of mechanical overhaul prescribed in accordance
cylinder.
to the engine’s specific duty, illustrating all necessary
They have high pressure injection fuelling (common rail) and operation to remove and assembly the external
are entirely electronically driven in order to optimise the components of the engine, including cylinder heads,
working process in accordance to the operation, limiting as gearbox of the timing system and of the front part cover;
much as possible the pollution emissions and consumption.
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.
Data, features and performances are valid only if the
! setter fully complies with all the installation
prescriptions provided by Iveco Motors.
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.

GENERAL PROPERTIES - 4 cylinder engines
F4AE3481C F4AE3481D F4AE3481B F4AE3481A

(.14) (.16) (.18) (.185)
Type
ρ Compression ratio 17 : 1
Max. output kW 103 118 130 134
(HP) (140) (160) (180) (185)
rpm 2700 2700 2700 2700
Max. torque Nm 460 530 570 610

(kgm) (47) (54) (58) (62)
rpm 1200 1200 1200 1200
Loadless engine
idling rpm 750
Loadless engine
peak rpm 3000
Bore x stroke 102 x 120
Displacement cm3 3920

TURBOCHARGING with intercooler
Turbocharger type GARRETT GT 22

LUBRICATION Forced by gear pump, relief valve single action
oil filter
Oil pressure at 80° C:
bar
- at 750 rpm bar 2.0

- at 4200 rpm bar 4.0
COOLING By centrifugal pump, regulating thermostat, radiator,
heat exchanger, intercooler
Water pump control Through belt
Thermostat
- opening start 81 ± 2 °C
- max. opening 96 °C
FILLING
Min. level Max. level
Total capacity
ACEA E3/E5 - engine sump
Urania LD5 litres 5.3 8.3
kg 4.8 7.5
engine sump + filter

litres 6.3 9.3
kg 5.7 8.4
Data, features and performances are valid only if the technician fully complies with all the installation requirements provided
! by Iveco Motors.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.

F4AE3681C F4AE3681B F4AE3681D F4AE3681E F4AE3681A

(.18) (.22) (.25) (.28) (.30)
Type
Max. output kW 135 160 185 205 220
(HP) (185) (220) (250) (280) (300)
rpm 2700 2700 2700 2700 2700
Max. torque Nm 650 680 850 950 1050

(kgm) (66) (69) (87) (97) (107)
rpm 1200÷2100 1250÷2100 1250÷2100 1250÷2100 1250÷2100
Loadless engine
idling rp 650
Loadless engine
peak rpm 3000
Displacement cm 5900
Turbocharger type HOLSET HX 35 W

oil filter
bar

- at 4200 rpm bar 4.0
Thermostat
FILLING
Total capacity
ACEA E7
Urania LD7 - engine sump
ACEA E4 litres 8 10.8
Urania FE5W30 kg 7.2 9.7

litres 9 11.8
kg 8.1 10.6
! by Iveco Motors.

F4AE3682C F4AE3682F F4AE3682E F4AE3682B F4AE3682A

(.22) (.25) (.26) (.26) (.30)
Type
Max. output kW 160 185 194 194 220
(HP) (218) (252) (264) (264) (300)
rpm 2700 2700 2500 2500 2500
Max. torque Nm 680 850 930 1000 1050

(kgm) (69) (87) (95) (102) (107)
rpm 1200 1250 1250 1300 1300
Loadless engine
idling rpm 650
Loadless engine
peak rpm 3000
Displacement cm3 5900

Turbocharger type HOLSET HX 35 W

oil filter
bar

- at 4200 rpm bar 4.0
Thermostat
FILLING
Total capacity
ACEA E7
Urania LD7 - engine sump
ACEA E4 litres 8 10.8
Urania FE5W30 kg 7.2 9.7

litres 9 11.8
kg 8.1 10.6
! by Iveco Motors.

DIAGNOSI
PART ONE - MECHANICAL COMPONENTS


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

Engine setting operations for the assembly on
turning stand
Figure 2
70127
The pipe (3) from the union (4) and from the supercharger
(8).
Remove the fuel pipe (2) from the rail and from the
high-pressure pump (9) and remove it from the engine block,
by removing the fixing screws (4 and 6)
105163
NOTE When unlocking the pipe (2) union (7), it is necessary
to prevent the union (10) rotation of the
In order to apply to the engine block the engine fixing high-pressure pump (9), by using the proper wrench.
brackets 99341009 to the stand for the overhaul, operating
on the engine left side, it is necessary:
- to remove the fuel filter (4) from the support (1) by
means of tool 99360076; On the right side
- to remove the low pressure fuel pipe (2-3-5) from the
support (1) Figure 5
- to remove the support (1) bracket from the block
Figure 3
108478
Remove screws (2) and detach oil pipe (3) from turbine (1)
116237
and the engine crankcase.
Remove starter motor (5) from flywheel cover (4).
To disconnect the low pressure fuel pipe from the relevant
connecting joint, you need to hold the clasp (1) pressed, and Apply to the block the bracket 99361037 and fix by means
release the quick fitting joint (2). of these latter the engine to the revolving stand 99322205.
Drain the engine oil by removing the plug from the sump.
Remove the fan from the engine shaft pulley.

Figure 6
108501
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. EDC7 ECU - 7. Pressure limiter - 8. Fuel heater and fuel temperature sensor -
9. Timing sensor - 10. Air temperature/pressure sensor - 11. Injector.
Disconnect the engine cable by disconnecting the Figure 7

connectors: (1) from injector wiring (6); (7) air
pressure/temperature sensor; (3) fuel pressure sensor; (11)
ECU; (10) high pressure pump sensor; (8) timing sensor; (2)
engine coolant temperature sensor on thermostat; (5)
engine speed sensor;
108479
Disconnect from the rail (2): the fuel pipe (4) according to
procedures described in Figure 3. Disconnect fuel pipes (6)
from rail (2) and injector manifolds (5).
Remove the screws (1) and disconnect the rail (2).
Disconnect pipe (3) from compressor and engine block.

Figure 8 Figure 10
70132
Loosen tappet adjustment fastening nuts (1) and unscrew the

adjusters.
Remove the screws (2), remove the rocker assembly (3),
consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves.
Remove rods (8).
Figure 11
107248
Disconnect pipe (2) from pressure limiting device (1) for fuel
return, as described in Figure 3.
Remove screw (7). Loosen spring strip (3) and take off oil
vapours pipe (10).
Remove fittings (6 and 4) and take off pipe (5).
Remove nuts (9) and take off tappets cover (8) complete
with gasket.
Figure 9
70133
Remove injector fastening screws. Use tool 99342101 (1) to

remove injectors (2) from the cylinder head.
Figure 12
108476
Remove nuts (8) and disconnect the electrical cables from

injectors (7).
Remove screws (1) and disconnect injector wiring support
(2) including the gasket.
Remove screw (5) and take off air temperature/pressure
sensor (6).
Remove nuts (3) and remove fuel manifolds (4).
NOTE Disassembled fuel manifolds (4) must not be used 108480

again, but however replaced with other new ones.
Remove screw (4), loosen clamp (2) and disconnect air duct
(1) from turbosupercharger (3).

Figure 13 Figure 15
108481 70137
Hook brackets (1) with metal ropes and remove cylinder

Remove oil pipe (5) from exhaust manifold(2). head (2) from block using hoist.
Disconnect the oil pipe (5) from the heat exchanger/oil filter
support (6).
Figure 16
Remove the nuts (3) and disconnect the turbosupercharger
(4) from the exhaust manifold (2).
Remove the screws (1) and disconnect the exhaust manifold
(2) from the cylinder head.
108483
Figure 14 Remove cylinder head gasket (1).

Use the proper wrench to operate the automatic belt
tensioner (3) to loosen belt (2) tension and remove it;
Remove the screw (4) and the automatic belt tensioner (3).
Figure 17
108482
Remove the screws (1) and disconnect the air duct (2)
including the heater. Remove the screws (4), and take out the
cover (3) and the thermostat set underneath.
Remove the cylinder head (6) fastening screws (5).
108484
NOTE Pointed out external screws are shorter.
Remove the screws (2) and disconnect the alternator (1).

Figure 18 Figure 20
108485 70142
Remove the screws (1) and disconnect the ECU (2) including
Remove the screws (2) and disconnect the alternator the heat exchanger.
support (3).
Use tool 99360076 to remove the oil filter (1).
Figure 21
70143
Use wrench 99355019 (1) to remove the screws (3) and

Figure 19 disconnect the hydraulic power steering pump (2) including
the oil tank (4) from the air compressor (5).
Figure 22
108486
Remove the screws (4) and disconnect the oil

temperature/pressure sensor (4).
Remove the screws (5) and then remove: heat exchanger/oil
filter support (1), intermediate plate (6) and relevant gaskets. 70144
Remove the oil level sensor (2). Remove the screws (2) and the nuts (1-4) and disconnect the
air compressor (3).

Figure 23 Figure 26
70148
Remove the screws (1) and remove the water pump (2).
70145
Remove the screws (3) and remove the roller (4).
Remove the nut (1) and remove the phase sensor (2).
Remove the screws (5) and remove the rpm sensor (6).
Remove the nuts (3) and remove the high-pressure pump (4)
complete of power supply pump (5). Figure 27
Figure 24
78256
70146
Apply on the front tang (2) of the driving shaft fixture
Apply the tool 99360351 (2) to the flywheel housing (1), to 99340055 (4) and through the guiding holes of the fixture
stop the flywheel (3) rotation. itself, drill the internal seal ring (1) with a drill (∅ 3.5 mm) to
Loosen the screws (4). a depth of 5 mm..
Fix fixture (4) to the ring (1) by means of the 6 screws in the
kit e proceed with the removal of the ring by screwing up the
Figure 25 screw (3).
Figure 28
107260
78257
Remove screws (4) and dismount pulley (2). Apply the proper rod (3) of fixture 99363204 to the external
Remove screws (3) and dismount damper flywheel (1). seal ring (2) as shown in the figure and use lever (4), to
remove it from the front cover (1).
Unthread phonic wheel (5).
Figure 29 Figure 32
107261
70152
Remove the screws (1 and 3) and take out the front cover (2).
Screw two pins (2) exhibiting a proper length into the engine
shaft holes (3).
NOTE Write down the screw (1) assembling position Withdraw the engine flywheel (1) in order to sling it with the
because they exhibit different lengths. hoister and position it into the container.
Figure 30
Figure 33
70150
Remove the screws (1) and remove the oil pump (2).
NOTE It is not possible to overhaul the oil pump (2).
Figure 31
78258
Apply fixture 99340056 (3) on the rear tang (5) of the driving
shaft and through the guiding holes of the fixture, drill the
internal seal ring (1) with a drill (∅ 3,5 mm) to a depth of 5
mm.
Fix fixture (3) to the ring (1) by means of the 6 screws (4)
70151 in the kit e proceed with the removal of the ring by tightening
the screw (2).
Remove tool 99360351 (2). Perform the removal of the external seal ring as shown and
Remove the engine (3) flywheel fixing screws (1) to the described in Figure 28.
engine shaft (4).

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

Distribution gear box Figure 40

Figure 39
107272 70210
DIAGRAM FOR TIGHTENING THE REAR TIMING

LOCTITE 5205 SEALANT APPLICATION AREAS GEAR CASE FASTENING SCREWS
Clean accurately the timing gear case (1) and the engine Refit the case (1) to the engine block.
block. Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in
the sequence shown in the figure:
Screws M12 65 to 89 Nm
Screws M8 20 to 28 Nm
Perfect seal is only obtained by cleaning accurately Screws M10 42 to 52 Nm
! the surface to seal.
Smear the case with LOCTITE 5205 to obtain a bead
of few mm diameter. NOTE Before any assembly operation always verify that
the hole and screw threads have no evidence of
It shall be uniform (no clots), without air bubbles, thin wear or dirt.
areas or discontinuities.
Any imperfection shall be corrected as soon as
possible. Distribution timing
Avoid to use excess material to seal the joint.
Figure 41
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (max 10 minutes).
70211
Use a felt pen to mark the driving gear (1) tooth fitted on the
output shaft (2) having the mark (→) for timing on the side
surface.
NOTE Fasten screwing of the two pins to facilitate the

operation of engine driving shaft rotation.

Figure 42
Perfect seal is only obtained by cleaning accurately
! the surface to seal.
Smear the case with LOCTITE 5205 to obtain a bead
of few mm diameter.
It shall be uniform (no clots), without air bubbles, thin
areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (max 10 minutes).
70212
Rotate the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding. Figure 45
Figure 43
70215
SEQUENCE FOR TIGHTENING THE FLYWHEEL

HOUSING FASTENING SCREWS
70213
Tighten the screws (1) fastening gear (2) to camshaft (3) to Refit the housing (1) to the engine block and screw the
the specified torque. fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
shown in the figure:
Flywheel housing Screws M12 75 to 95 Nm
Figure 44 Screws M10 44 to 53 Nm
NOTE Before any assembly operation always verify that

wear or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS

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

the output shaft. Apply tool 99360351 (2) to the flywheel
housing (1) to stop engine flywheel (3) rotation.
Figure 50
70217
NOTE Where the engine is coupled to a mechanical

clutch, verify that the flywheel nominal thickness of
49.6 ± 0.13 mm. 70219
Tighten engine flywheel (2) fastening screws (1) in two

stages:
- 1st stage, tightening to 30 ± 4 Nm torque with
dynamometric wrench;
Check ring gear teeth (2), if breakage or excessive wear is - 2nd stage, tightening to 60° ± 5° angle.
found remove the ring gear from the engine flywheel (1)
using a suitable hammer and fit the new one, previously NOTE Tightening to angle is performed using tool
heated to 150°C for 15 to 20 minutes. Chamfering on ring 99395216.
gear inside diameter shall be facing the engine flywheel. Before any assembly operation always verify that
wear or dirt.

Figure 51 Figure 54
70223
70220
Remove the sealing ring (2) from the front cover (1), clean
Fit the oil pump (1).
accurately the coupling surfaces and smear them with IVECO
Tighten the fastening screws (2) to the specified torque. nr. 2992545.
Figure 55
Figure 52
70224
Clean accurately the front cover (2) surface and refit it.
70221
Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
Figure 56
Figure 53
70225
70222 Apply on the front tang (6) of the driving shaft part (5) of
Fit the water pump (1). fixture 99346252, fix it with screws (4) and key on it the new
seal ring (3). Position part (1) on part (5), tighten nut (2) till
Tighten the screws (2) to the specified torque. complete assembly of seal ring (3) on the front cover (7).

Figure 57 Figure 60
99223
107274
Fit the plate (1), the rose pipe (2) and tighten the fastening
screws (3) to the specified torque. Key phonic wheel (1) on engine shaft (2).
Mount damper flywheel (6), and screw securing screws (3)
Figure 58
and tighten them in two steps:
- 1st stage, tightening to 50 ± 5 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 90° angle.
NOTE Tightening to angle is performed using tool

99395216 (4).
Fit pulley (5).

Tighten the fastening screws (4) to 68 ± 7 Nm torque.
70227
Set the gasket (1) on the oil sump (2).
NOTE If not faulty the gasket can be reused. Figure 61

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

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

Figure 62 Figure 64
70231
70234
Fit on the engine block: a new gasket (1), the heat exchanger
(2) a new gasket (3) and the oil filter support (4). Position the alternator support (2) so that pins (3 and 4) are
set against the engine block.
Figure 63 Figure 65
70232 70139
Lubricate the sealing ring (2) with engine oil and set it on the Refit the alternator (1).
oil filter (3).
Tighten the screw (2) to the specified torque.
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3) by ¾
turn. Figure 66
Apply a new sealing ring on the oil temperature/pressure
sensor (4) and fit it on the support (1).
Fit a new sealing ring (6) in the engine block seat.
70235
Refit the automatic belt tensioner (2).

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

Figure 67 Figure 70
107259
Refit the ECU (2) including the heat exchanger to the engine
block and tighten the screws (1) to the specified torque.
70145 Connect cooling pipe (3) to electronic central unit (2).
Refit the high pressure pump (5) including the feed pump (6)
and tighten the nuts (3) to the specified torque. Fit the
support (4) with a new sealing ring, the timing sensor (2) with NOTE Replace support elastic elements (1).
a new sealing ring and tighten the relevant fastening nut (1)
to the specified torque.
Figure 71
Figure 68
70137
Apply a new gasket to the engine block and then place the
70144 cylinder head (2) slung by the hanger brackets (1).
Figure 72
Refit the air compressor (3). Tighten the screws (2) and the
nuts (1 and 4) to the specified torque.
Figure 69
70336
Assemble cylinder head (1), tighten the screws (2) in three
following steps, following order and mode shown in the
figure below.
70143 NOTE The angle tightening is carried out through tool

Refit the hydraulic power steering pump (2) including the oil 99395216 (3).
tank (4) to the air compressor (5). Before any assembly operation always verify that
Use wrench 99355019 to tighten the fastening screws (3) to the hole and screw threads have no evidence of
the specified torque. wear or dirt.

Figure 73 Figure 76
6-cylinder engine A
70476
Tightening order layout for cylinder head fastening screws:

- 1st step pre-tightening with a torque wrench:
• Screw 12x1.75x130 ( ) 35 ± 5 Nm
• Screw 12x1.75 x 150 ( ) 55 ± 5 Nm
- 2nd step tightening with a 90° ± 5° angle
- 3rd step tightening with a 90° ± 5° angle 70339
A = Front side Fit injectors (1) on the cylinder head seats, directed so that
the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
Figure 74
Figure 77
4-cylinder engine A
70337
Cylinder head fastening screws tightening sequence:

- 1st stage pre-tightening, with a torque wrench:
• Screw 12x1.75x130 ( ) 35 ± 5 Nm
• Screw12x1.75 x 150 ( ) 55 ± 5 Nm
A = Front side
70133
- 2nd stage tightening with angle 90° ± 5°
- 3rd stage tightening with angle 90° ± 5° Use tool 99342101 (1) to fit the injector (2) into its seat.
A = Front side Screw injector fastening screws without tightening them.
Figure 75
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).

Figure 78 Figure 80
70343
91572 ROCKER ASSEMBLY COMPONENTS:

1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
Assemble a new ring (3), lubricated with vaseline, on the fuel
manifold (2) and insert it in the cylinder head housing so that
the position ball (5) clashes with its housing (4). Figure 81
NOTE Disassembled fuel manifolds (2) must not be used

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

moved so that the manifold (2) is properly inserted
into the fuel inlet hole (2, Figure 76). 70344
SHAFT-ROCKER MAIN DATA

Check that shaft/rocker coupling surfaces are not showing
Figure 79 excessive wear or damages.
Figure 82
32655
108492
Rocker control rods shall not be distorted; the ball seats in
Use the torque wrench to tighten gradually and alternately touch with the rocker adjusting screw and with tappets
the injector fastening screws (1) to 8.5 ± 0.35 Nm torque. (arrows) shall not show seizing or wear; otherwise replace
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm them. Intake and exhaust valve control rods are identical and
torque. are therefore interchangeable.

Figure 83 Tappet play adjustment

Figure 85
70520
70345
Adjust clearance between rockers and valves using setscrew
Fit the rods (2). wrench (1), box wrench (3) and feeler gauge (2).
Position jumpers (1) on valves with marks (→) facing the Clearance shall be as follows:
exhaust manifold. - intake valves 0.25 ± 0.05 mm
- exhaust valves 0.50 ± 0.05 mm.
Figure 84
In order to more quickly perform the operating

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

Intake manifold
Figure 86
108493
In inlet manifold (4), air heater (2) for cold start-up is housed.
In case of operation faults in air heater (2), the heater has to be replaced.
In replacing air heater (2), you have to operate as follows:
- Remove screws (1) securing heater (2) to inlet manifold (4).
- Take heater (2) off inlet manifold (4) together with relating gasket (3).
Fit new heater (2) into the seat of inlet manifold (4) inverting dismounting operations.

Figure 87 Figure 89
108494 108496
Smear the intake manifold (1) coupling surface with IVECO Connect the fuel pipes (1) to rail (2) and injector manifolds
n. 2992545 and fit it on the cylinder head. (4).
Pipe connections shall be tightened to 20 Nm

torque, by using the proper torque wrench
99389829 together with tool 99317915.
Connect the fuel pipe (3) to the rail (2) following the
procedure shown in the following figure.
Figure 88 Figure 90
116237
To connect the low pressure fuel pipe to the connecting

joint, insert the quick fitting joint (2) into the connecting joint,
and push until the clip (3) is fastened.
108495
Fit air temperature sensor (4) and tighten securing screw (3). NOTE Check proper fuel pipe connection.
Fit rail (1) and tighten securing screw (2) at prescribed
torque.

Wiring support Figure 94

Figure 91
70352 70355
Check electrical cable (5) conditions, replace if damaged by Fit a new gasket (2) on the tappet cover (1).
cutting the support (2) clamps and removing the screws (5)
that secure it to connections (3).
Fit a new gasket (1) on the support (2).
Figure 95
Figure 92
99229
99227
Fit the tappet cover (1) and tighten the nuts (2) to the
Fit the wiring support (2) and tighten the screws (1) to the specified torque.
specified torque.
Figure 93 Figure 96
99228 108497
Connect the electrical cables (1) to the injectors (3) and use Reconnect the exhaust manifold (2) with new gaskets.
the dynamometric wrench 99389834 (4) to tighten the Tighten the fastening screws (1) to the specified torque.
fastening nuts (2) to the specified torque.

Figure 97 Figure 99
108498
Reconnect the turbosupercharger (3) with a new gasket to

the exhaust manifold (1) and tighten the fastening nuts (2)
to the specified torque.
Connect oil pipe (4) to heat exchanger support (5) and
107415
turbocharger (3).
Connect pipe (2) to air compressor fitting (1) and cylinder
head fitting (4).
Fit oil vapours pipe (5) into fitting located on supply box (7)
and constrain the pipe with spring strip (6).
Fit new seal ring (14) on pipe (5) and fit oil vapours pipe fitting
(5) into tappets cover (13).
Constrain pipe (5) securing bracket (12) by screw (11).
Fit new copper washers into fittings (10 and 8) and connect
pipe (9) to tappets cover (13) and supply box (7).
Connect fuel return pipe (3) to pressure limiting device, rail
and high pressure pump as described in following figure.
Figure 100
Figure 98
116237
To connect the low pressure fuel pipe to the connecting

joint, insert the quick fitting joint (2) into the connecting joint,
108480 and push until the clip (3) is fastened.
Connect the air duct (1) to the turbosupercharger (3) and

lock it by clamp (2). NOTE Check proper fuel pipe connection.
Secure air conveyor (1) to alternator support with screw (4).

Figure 101
108501
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. EDC7 control unit - 7. Pressure regulator - 8. Fuel heater and fuel temperature
sensor - 9. Timing sensor - 10. Air temperature/pressure sensor - 11. Injector.
Re-connect the engine wire by hooking up: the Apply to engine lifting hooks the lifting rig 99360555, hook
electroinjector wiring (11) to connections (1), the air the latter to the hoister and remove the engine from the
pressure/temperature sensor (10) the rail pressure sensor revolving stand. Remove the brackets 99361037.
(3), the EDC7 control unit (6), the pressure regulator (7), the
distribution phase sensor (9), the engine coolant
temperature sensor (2) and the engine revolution number
sensor (5).

Figure 102 Figure 104
70362
70128
Complete engine refitting as follows: Refit the bracket (2) including the fuel filter support (1) to the
engine block, tighten the screws (3) to the specified torque.
Form the right side:
Refit the starter (5) to the flywheel housing (4) and tighten
the fastening nuts to the specified torque. Figure 105
Fit the oil pipe (3) with a new sealing ring into the engine
block and secure it to the turbosupercharger (1) by the
screws (2) tightened to the specified torque.
Figure 103
105163
Screw manually the fuel filter (4) to the support (1), screw
the filter by 3/4 turn, connect the pipes (2-3-5) to the
relevant support connections (1) as shown in the following
figure.
Figure 106
70127
From the left side:

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

torque using the proper dynamometric wrench
99389834. 116237
Connection (7) shall be tightened by holding at the
same time the high pressure pump hexagon (10). To connect the low pressure fuel pipe to the connecting
When removed pipe (2) shall always be replaced. joint, insert the quick fitting joint (2) into the connecting joint,
Connect pipe (3) to connection (4) and air and push until the clip (3) is fastened.
compressor (8). When refitting is over, fill engine with the prescribed
lubricating oil in the specified quantity.

Checks and inspections
Check proper fuel pipe connection.

!
Start the engine and leave it running just above the

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

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


PART TWO - ELECTRICAL EQUIPMENT


LOCATION OF THE MAIN ELECTRICAL COMPONENTS

Engine F4AE3481
Figure 107
114546
ENGINE VIEW LEFT SIDE

1. Alternator - 2. Drive shaft revolution number sensor - 3. Engine Control unit - 4. Heater and fuel temperature sensor -
5. Pressure regulator - 6. Power steering oil level insufficient indicator control - 7. Air pressure/temperature sensor -
8. Rail pressure sensor - 9. Connections for electroinjectors - 10. Engine coolant temperature sensor.
Figure 108
114547
ENGINE VIEW RIGHT SIDE

1. Alternator - 2. Engine oil pressure /temperature sensor - 3. Starter motor.
Engine F4AE3681
Figure 109
114548

1. Alternator - 2. Drive shaft revolution number sensor - 3. Engine Control unit - 4. Heater and fuel temperature sensor -
5. Pressure regulator - 6. Power steering oil level insufficient indicator control - 7. Rail pressure sensor - 8. Connections for
electroinjectors -9. Engine coolant temperature sensor.
Figure 110
114549

1. Alternator - 2. Engine oil pressure /temperature sensor - 3. Starter motor.
Engine F4AE3682
Figure 111
114550

1. Primary alternator - 2. Secondary alternator - 3. Air conditioner compressor - 4. Drive shaft revolution number sensor -
5. Engine Control unit - 6. Heater and fuel temperature sensor - 7. Pressure regulator -
8. Connections for electroinjectors - 9. Engine coolant temperature sensor.
Figure 112
114921

1.Primary alternator - 2. Secondary Alternator - 3. Engine oil pressure /temperature sensor - 4. Starter motor.

Overview of sensors
Figure 113
114922
Key
Ref. Description
1 Coolant temperature sensor
2 Electro-injector
3 Rail pressure sensor
4 Air temperature/pressure sensor
5 Power steering level sensor
6 Timing sensor
7 Pressure regulator solenoid valve
8 Fuel temperature sensor
9 EDC7 control unit
10 Engine oil level transmitter
11 Drive shaft revolution number sensor
12 Engine oil pressure/temperature sensor
13 Pre-post hearing resistance

ECM ELECTRONIC CONTROL UNIT (EDC 7)

Figure 114
102373
A. Injector connector - B. Frame connector - C. Sensor connector.

Electroinjectors connector “A”

Figure 115
12 16
6 11
1 5
50350
Cable Cable
Pin Colour Colour Function (4 cylinders) Function (6 cylinders)
(4 cylinders) (6 cylinders)
1 HN LR Cylinder 3 injector Cylinder 5 injector
2 HR BC Cylinder 2 injector Cylinder 6 injector
3 - BL - Cylinder 4 injector
4 MB MB Cylinder 1 injector Cylinder 1 injector
5 HV MV Cylinder 4 injector Cylinder 3 injector
6 - HR - Cylinder 2 injector
7 - - - -
8 - - - -
9 V V Pressure regulator solenoid valve Pressure regulator solenoid valve
(pin 1) (pin 1)
10 C C Pressure regulator solenoid valve Pressure regulator solenoid valve
(pin 2) (pin 2)
11 - - - Cylinder 2 injector
12 BL HN Cylinder 4 injector Cylinder 3 injector
13 HG HG Cylinder 1 injector Cylinder 1 injector
14 - - - Cylinder 4 injector
15 MN VN Cylinder 2 injector Cylinder 6 injector
16 MV RG Cylinder 3 injector Cylinder 5 injector
Colour legend
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange

Sensors connector “C”

Figure 116
6 8 16 9 15 22
4
Colour legend 5
B black
R red
U blue
W white
P purple
G green
N brown
Y yellow
O orange
1 3 23 30 36 29
50350
Cable
Pin Function
Colour
1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 B Phase sensor PIN 2
10 R Phase sensor PINs 1 and 3
12 BN Rail temperature / pressure sensor PIN 1
13 HN Rail temperature / pressure sensor PIN 3
14 RV Rail temperature / pressure sensor PIN 2
15 CV Water temperature sensor PIN 1
16 - -
17 - -
18 CN Diesel oil temperature sensor PIN 2
19 B Rpm sensor PINs 1 and 3
23 R Rpm sensor PIN 2
24 GV Oil temperature / pressure sensor PIN 1
25 GN Air temperature / pressure sensor PIN 1
26 BG Water temperature sensor PIN 2
27 GR Oil temperature / pressure sensor PIN 4
28 NS Oil temperature / pressure sensor PIN 2
32 MN Oil temperature / pressure sensor PIN 3
33 CL Air temperature / pressure sensor PIN 3
34 LN Air temperature / pressure sensor PIN 4
35 BL Diesel oil temperature sensor PIN 1
36 BR Air temperature / pressure sensor PIN 2

“B” frame connector

Figure 117
71 89 72 54 6 11
1
7
12
53 35 18 36 17
50350
Cable colour
Ref. Function
code
1 - -
2 8150 Positive (+30) of central unit power supply
5 0000 Earth
6 0000 Earth
7 - -
10 0000 Earth
11 0000 Earth
12 8885 Positive for thermal start-up unit relay insertion
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 5173 Humidity sensor
32 9907 Positive from start button from engine compartment
33 5584 Engine rpm’s
34 6109 CAN - L line
35 6108 CAN - H line
40 8051 Positive (+15) from IBC3
47 9906 Positive from stop button from engine compartment
55 0043 Engine brake solenoid valve negative
58 9966 Engine brake solenoid valve positive
75 0094 Negative for thermal start-up unit relay insertion
89 2298 K ECM line
Figure 118 ECM CENTRAL UNIT COMPONENTS (EDC

7)
Air temperature/pressure sensor (85156)
This component combines a temperature and a pressure
sensor.
It is fitted to the intake manifold so that, by measuring the
maximum quantity of air taken in, it makes it possible to
determine the exact amount of fuel to be injected at each
cycle.
This sensor is connected to the control unit via pins 25/C -
36/C - 33/C - 34/C.
It is powered at 5 V.
The output voltage is proportional to the pressure (or
temperature) measured by the sensor.
Pins 25/C - 36/C Temperature
50324 Pins 33/C - 34/C Pressure
EXTERIOR VIEW OF SENSOR
Figure 119 Oil pressure/temperature sensor

This component is identical to the air temperature/ pressure
sensor
It is mounted horizontally on the engine oil filter.
It measures the engine oil temperature and pressure.
It is connected to the control unit via pins 24C - 27C - 32C
- 28C.
The values sent are transmitted to the EDC control unit
which, in its turn, controls the indicator on the dash (indicator
/ low pressure warning light).
Pins 24/C - 28/C Temperature
Pins 32/C - 27/C Pressure
50323 The engine oil temperature is used by the EDC unit only.
CONNECTION CONNECTOR
ECM Control unit Pin
Figure 120 Ref
Ref. Description
Oil Air
1 Ground 24C 25C
2 Temp. signal 28C 36C
3 +5 32C 33C
4 Press. signal 27C 34C
50344
WIRING DIAGRAM

Crankshaft sensor (48035)

This inductive type sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines
which close through the openings of a toothed wheel force fitted to the crankshaft. The same signal is used to manage the
electronic rev counter.
It is connected to the control unit via pins 23C - 19C.
The sensor’s resistance value is ca 900 Ω.
Supplier BOSCH
Tightening torque 8 ± 2 Nm
Timing system sensor (48042)
This inductive sensor is located in the left front part of the engine. It generates signals obtained from magnetic flux lines which
close through the holes situated in gears force fitted to the camshaft. The signal generated by this sensor is used by the ECU
as the injection timing signal.
Though it is similar to the crankshaft sensor, it is not interchangeable with the latter since its outer shape is different.
The sensor’s resistance value is ca 900 Ω.
Supplier BOSCH
Tightening torque 8 ± 2 Nm
Figure 121 Figure 122
180 ± 15
2
3 1
8518 8519
TECHNICAL VIEW WIRING DIAGRAM
Figure 123
8520
PERSPECTIVE VIEW
ECM Control unit Pin

Ref
Ref. Description
48035 48042
1 Signal 19C 10C
2 Signal 23C 9C
3 Shielding

Fuel pressure sensor (85157)

Fitted to one end of the rail, it measures the pressure of the existing fuel in order to determine the injection pressure.
The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the
injection electronic command.
It is connected to the control unit on pins 12C - 14C - 13C.
It is powered at 5 V.
Figure 124
108933
Ref. Description ECM Control unit pin

1 Ground 12C
2 Signal 14C
3 Power 13C

Figure 125 Coolant temperature sensor (85153)

This is a variable resistance sensor that is able to measure
coolant temperature and transmit a signal to the control unit
reflecting the thermal conditions of the engine.
The same signal is used by the control unit to manage the
temperature gauge on the dash.
Its resistance at 20 °C = 2.50 KΩ.
It is placed in the upper engine part.
1 2 50321
Figure 126 Fuel temperature sensor (47042)

This sensor is identical to the previous one.
It measures the temperature of the fuel and transmits a signal
to the control unit reflecting the thermal conditions of the
diesel oil.
Its resistance at 20 °C = 2.50 KΩ.
The ECU manages the relay for the control of filter heating
when the temperature of the fuel drops to ≤ 36 °C.
50322 ECM Control unit Pin

Ref
Ref. Description
85153 47042
1 Ground 15C 18C
2 Signal 26C 35C

Fuel pre-filter Figure 127

The water separation type fuel filter is mounted on the right
hand side of the vehicle frame and has, on the cartridge base
3, a sensor 4 detecting the presence of water in the fuel.
The filter support houses a manual priming pup 5 and a screw
2 to bleed the air from the system.
The presence of condensate in the filter and the filter clogged
condition are revealed by sensor 4 by turning on a single
warning light in the dash. 1
2 5
If the warning light lights up, take action immediately

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

Pre-post heating resistance Figure 128

This resistance is located on the intake manifold. B
It is used to warm up the air in pre-post heating operations.
It is powered by a remote control switch situated on the left
hand side of the frame.
A
Its resistance is ~ 0,5 Ω.
108909
A. - B. Connecting terminals
Resistance control remote control switch Figure 129

The remote control switch is connected to the EDC control
unit via pins 12B - 75B.
C
It is activated when the temperature of the water or the
diesel oil exceeds 5 °C.
The remote control switch coil resistance is about 15 Ω.
50325
C. Remote control switch
Exhaust brake solenoid valve (78050) Figure 130

This is a N.C. on-off solenoid valve.
It is positioned on the left hand side of the frame. By
controlling this solenoid valve, the ECU opens the passage for
the air coming from the aux. unit tank to control the exhaust
brake cylinder which, in its turn, closes the throttle valve in
the exhaust manifold.
It is connected to the control unit via pins 55B - 58B.
50328
A
A. Exhaust brake solenoid valve
Pressure regulator - high pressure pump Figure 131

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

it cannot be taken down. E
The amount of fuel feeding the high pressure pump is

metered by a proportional valve situated on the low pressure
system - managed by the EDC 7 control unit.
000912t
The delivery pressure to the rail is modulated between 250
and 1400 bar by the control unit working on the pressure
regulator solenoid valve.
It is a N.O. solenoid valve
Its resistance is ca 3.2 Ω.
It is connected to the control unit via pins A9 - A10.

Electroinjector Figure 132

The injector features a traditional construction, save for the
fact that it has no needle return springs.
The electroinjector essentially consists of two parts:
- actuator - atomiser consisting of a pressure rod 1, a
needle 2 and nozzle 3;
- control solenoid valve, consisting of a coil 4 and pilot
valve 5.
The solenoid valve controls the rise of the atomiser needle.
50336
Injection starts
Upon being energised, coil 4 moves up the shutter 6.
The fuel contained in the control volume 9 flows back
towards line 12 resulting in a pressure drop in the control
volume 9. Figure 133
At the same time, the fuel pressure in the pressure chamber
8 moves up the needle 2 resulting into the fuel being injected
into the cylinder.
Injection ends
When coil 4 is de-energised, the shutter 6 closes again so as
to re-create a balance of forces which moves the needle back
into its closed position and stops the injection process.
This is a N.O. solenoid valve.

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

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

Connecting connectors
Figure 134
1 2 3
50343
WIRING DIAGRAM OF THE CONNECTIONS
Figure 135
1 2 3 4 5 6
1 2 3
FAN SIDE
50349
6 cylinder
4 cylinder
Ref. Description Control unit
Control unit Pin
Pin
1 Cylinder 2 injector A15 A11
CONNECTOR 1
CONNECTOR 2
1 Cylinder 6 injector A15
CONNECTOR 3

MAIN POWER COMPONENTS

ALTERNATOR
Supplier BOSCH
Rated voltage 28V
Current 70A - 1800 RPM
Figure 136
B
+
W
L
15
7998
PERSPECTIVE VIEW S Figure 139
Figure 137 A
80
70
60
B
50
40
A 8003
30
WIRING DIAGRAM
A. Alternator B. Voltage regulator
20
Figure 138
10
0 rpm
2 4 6 8 10 12 14 16 8002
ALTERNATOR CURRENT DELIVERY CURVE
Characteristics
Rated voltage 28 V
Rated power 70 A
8000 Current at environment temperature 1800 RPM/35 A
At 25 ºC and rated voltage 6000 RPM/70 A
VOLTAGE REGULATOR TEMPERATURE Direction of rotation clockwise, seen from pulley
CHARACTERISTICS (6000 RPM) Weight 6.4 kg

STARTER MOTOR
Supplier BOSCH
Rated voltage 24V
Rated power 4kW
Figure 140
50275
WIRING DIAGRAM
50
30
POWER RELAY
STARTER
50354


PART THREE - TROUBLESHOOTING


PT-01 PORTABLE TESTER Test parameters

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

- Oil pressure;
Before connecting the tester to the electronic mod- - Fuel delivery;
! ule, check the wording on the electronic module to - Fuel pressure;
select the correct software on the tool.
- Rail pressure duty cycle electro-valve.
1 2 3 4 5 6 7 8 . A B C
u m m k a a * * . v a 0
In the tables at next pages there are shown failure codes.
These codes can be read and interpreted by diagnosis tool.
a a software 3.3_1
a b software 4.1_2
Easy access to different functions is available through the

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


DTC error codes

with EDC7 central unit


Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
be Measuring Values to be
DTC Failing component Visible failures Possible causes Repair actions Remarks
conditions detected
performed
113 ACCELERATOR Vehicle acceleration Accelerator pedal and Check the accelerator
PEDAL/BRAKE very slow. brake pressed pedal signal and pedal
PEDAL SUSPECT simultaneously (for mechanical movement.
Engine idle speed: 500
too long);
rpm.
Accelerator pedal
blocked or faulty;
Incorrect use of
vehicle.
116 CLUTCH SIGNAL The parameter reading Clutch switch faulty or Check clutch pedal switch
SUSPECT shows that the clutch is wiring problems in and wiring.
pressed. pedal.
117 BRAKE PEDAL Slight power reduction Main and secondary Check the
SIGNAL ERROR brake switch not synchronisation of both
synchronised. switches (signal) and
wiring.
One of the two brake
pedal switches may be
stuck.
119 PLAUSIBILITY +15 Possible mechanical Check wiring.
problem (in pawl) or
electrical problem.
121 SPEED LIMITER Warning light Short circuit or Check wiring.
W/LIGHT permanently off. defective wiring.
122 WARNING LIGHT Warning light Short circuit or Check wiring.
SECTION 3 - APPLICATION TO VEHICLES

EOBD permanently off. defective wiring.
123 EDC LAMP Warning light Short circuit or Check wiring.
permanently off. defective wiring.
124 COLD START Warning light Short circuit or Check wiring.
LAMP permanently off. defective wiring.
125 MAIN RELAY Possible problems Relay short circuit to Check wiring between
DEFECT during after-run. battery positive or ECM and battery.
earth.
Replace relay if necessary.
Base - July 2006
63
Base - July 2006
64
Checks to
conditions detected
performed

126 BATTERY Possible problems Alternator or battery Check wiring.
VOLTAGE during after-run. defective.
Replace alternator
Possible wiring regulator or battery
problem.
Replace the alternator if
necessary.
127 ENGINE BRAKE Engine brake not Relay or wiring Check wiring.
ELECTROVALVE operational. short-circuited or
interrupted.
128 MAIN RELAY - Possible problems Relay short circuit to Check wiring between
SHORT CIRCUIT during after-run. battery positive or ECM and battery.
TO BATTERY earth.
Relay may be faulty.
129 AIR-CONDITION Possible problems Relay short circuit to Check wiring between
ER COMPRESSOR during after-run. battery positive or ECM and battery.
RELAY earth.
12A RELAIS FOR Possible problems Relay short circuit to Check wiring between
ENGINE BRAKE during after-run. battery positive or ECM and battery.
VALVE earth.
12B THERMOSTARTE Heater not working. Relay or wiring Check wiring.
R RELAY 1 short-circuited or
(HEATER) interrupted.
12C THERMOSTARTE Heater not working. Relay or wiring Check wiring.
R RELAY 2 short-circuited or
interrupted.
12E MANAGEMENT Grid heater Grid heater short Check wiring and
SYSTEM permanently operating. circuited to earth. component.
PRE/POST-HEATI
EURO 4 NEF ENGINES

NG (ACTIVE)
Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
131 COOLANT No reaction noticeable Sensor short-circuited Check the wiring. Replace
TEMPERATURE on behalf of the driver. or value implausible sensor if necessary.
SENSOR
132 COOLANT Slight power reduction. Operation in extreme Ensure the engine is not
TEMPERATURE environmental working in extreme
SENSOR (TEST) conditions or sensor environmental conditions.
inaccurate.
Check the wiring and the
sensor accuracy.
Replace sensor if
necessary.
133 AIR Slight power reduction. Sensor short-circuited Check the wiring. Replace
TEMPERATURE or value implausible sensor if necessary
SENSOR BOOST
AIR
134 BOOST PRESSURE No reaction perceivable Sensor short-circuited Check the wiring. Also
SENSOR by the driver. or difference between check the environmental
environmental pressure sensor.
Parameter recovery
pressure and turbo
value: 2700 mbar. Replace sensor if
pressure implausible
necessary.
135 FUEL Slight power reduction. Sensor short-circuited Check the wiring. Replace
TEMPERATURE or value implausible sensor if necessary
SENSOR
136 RAIL PRESSURE Possible loss of Rail sensor value Check connections and

SENSOR OR performance. above threshold. correct operation of Rail
SIGNAL ERROR sensor (parameter
Sensor short-circuited
acquisition).
or faulty.
137 DBV VALVE Possible loss of Rail pressure sensor Check connections and
MANAGEMENT performance. value above threshold. correct operation of Rail
(BOOST pressure sensor
Sensor faulty or
PRESSURE) (parameter acquisition)
injection incorrect.
and injection
components.
Base - July 2006
65
Base - July 2006
66
Checks to
conditions detected
performed

138 OIL PRESSURE No reaction perceivable Sensor short-circuited Check the wiring and oil
SENSOR by the driver. or value implausible. level.
Parameter recovery Replace sensor if
value: 3000 mbar. necessary.
13A OIL No reaction perceivable Sensor short-circuited Check the wiring. Replace
TEMPERATURE by the driver. or value implausible. sensor if necessary.
SENSOR
Parameter recovery
value: coolant
temperature value (if
intact) otherwise
120°C).
13C ATMOSPHERIC No reaction perceivable Sensor short-circuited Check the wiring. Replace
TEMPERATURE by the driver. or value implausible. sensor if necessary.
SENSOR
Parameter recovery
(HUMIDTIY?)
value: 40°C.
141 CRANKSHAFT No reaction noticeable Signal interrupted or Check wiring and
SPEED on behalf of the driver. wiring problem. installation.
Sensor installation Replace sensor if
may not be correct. necessary.
142 ENGINE No reaction perceivable Signal interrupted or Check wiring and
WORKING ONLY by the driver. wiring problem. installation.
WITH CAMSHAFT
SENSOR
143 CAMSHAFT No reaction perceivable Signal interrupted or Check wiring and
SENSOR by the driver. wiring problem. installation.
EURO 4 NEF ENGINES

Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
144 FAULT BETWEEN No reaction noticeable Signal interrupted or Check wiring and
FLYWHEEL on behalf of the driver. wiring problem. installation of both
SENSOR AND sensors.
Flywheel and timing
CAMSHAFT
sensor installation may
be incorrect.
145 FAN RELAY No reaction perceivable Short circuit or fan Check the wiring and the
by the driver. actuator faulty. fan actuator.
Fan off. Replace the actuator if
necessary.
148 AIR-CONDITION Air conditioner Wiring or relay Check the wiring. Replace
ER COMPRESSOR permanently off. short-circuited. relay if necessary.
RELAY
149 PRE-HEATING Filter heater not Wiring or filter heater Check the wiring. Replace
RELAY FUEL working. short-circuited. the filter heater if
FILTER necessary.
151 HIGH PRESSURE
SYSTEM
152 FAULT ON THE Possible loss of High pressure system: Check the possible causes
FUEL PRESSURE performance. - possible leaks; listed above.
CONTROL OF
- injectors stuck
THE RAIL
open;
(POSITIVE
DEVIATION) - High pressure
pump faulty.

Low pressure system:
- low pressure
upstream of pump;
- Diesel filter
blocked or leak
upstream of high
pressure pump.
Base - July 2006
67
Base - July 2006
68
Checks to
conditions detected
performed

153 FAULT ON THE Possible loss of Possible pressure Check the possible causes
FUEL PRESSURE performance. regulator blocked or listed above.
CONTROL OF excessive pressure
THE RAIL upstream of pump.
(NEGATIVE
DEVIATION)
154 RAIL PRESSURE Possible loss of High pressure system: Check the possible causes
ERROR: TOO performance. - possible leaks; listed above.
LOW
- injectors stuck
open;
- High pressure
pump faulty.
- low pressure
upstream of pump;
- Diesel filter
blocked or leak
upstream of high
pressure pump.
155 RAIL PRESSURE Possible loss of Possible pressure Check the possible causes
ERROR: TOO performance. regulator blocked or listed above.
HIGH excessive pressure
upstream of pump.
EURO 4 NEF ENGINES

Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
156 HIGH PRESSURE Possible loss of High pressure system: Check the possible causes
SYSTEM performance. - possible leaks; listed above.
- injectors stuck
open;
- High pressure
pump faulty.
- low pressure
upstream of pump;
- Diesel filter
blocked or leak
upstream of high
pressure pump.
157 ERROR ON THE Possible loss of High pressure system: Check the possible causes
RAIL PRESSURE performance. - possible leaks; listed above.
(EXCESSIVE DUTY
- injectors stuck
CYCLE)
open;
- High pressure
pump faulty.
- low pressure
upstream of pump;
- Diesel filter
blocked or leak

upstream of high
pressure pump.
Base - July 2006
69
Base - July 2006
70
Checks to
conditions detected
performed

158 HIGH PRESSURE Possible loss of High pressure system: Check the possible causes
SYSTEM performance. - rail pressure sensor listed above.
defective;
- high pressure
pump faulty.
Possible problem also
in high pressure
system (MPROP)
159 PRESSURE MPROP Possible loss of Wiring damaged or Check wiring and
REGULATOR performance. disconnected; pressure regulator;
ERROR possible defective replace relay if necessary.
relay or pressure
regulator.
161 INJECTOR One or more injectors Possible short circuit Check wiring.
CYLINDER 1 / (bank 1 or bank 2) not in connections.
Possible internal problem
SHORT CIRCUIT operating.
Possible problem in also in ECM.
injector coil.
Replace the injector if
Possible problem in necessary.
control unit.
injector coil.
control unit.
EURO 4 NEF ENGINES

Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
injector coil.
control unit.
injector coil.
control unit.
injector coil.
control unit.
injector coil.
control unit.

167 INJECTOR One or more injectors Possible injector Check wiring.
CYLINDER 1 / (bank 1 or bank 2) not connection problem
OPEN CIRCUIT operating. (or disconnected
also in ECM.
internally).
Possible problem in
necessary.
control unit
(condenser).
Base - July 2006
71
Base - July 2006
72
Checks to
conditions detected
performed

also in ECM.
internally).
Possible problem in
necessary.
control unit
(condenser).
also in ECM.
internally).
Possible problem in
necessary.
control unit
(condenser).
16A INJECTOR One or more injectors Possible injector Check wiring.
also in ECM.
internally).
Possible problem in
necessary.
control unit
(condenser).
16B INJECTOR One or more injectors Possible injector Check wiring.
also in ECM.
internally).
Possible problem in
necessary.
control unit
(condenser).
EURO 4 NEF ENGINES

Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
16C INJECTOR One or more injectors Possible injector Check wiring.
also in ECM.
internally).
Possible problem in
necessary.
control unit
(condenser).
16D COMPRESSION Compression Test in After carrying out the
TEST IN progress. compression test, turn the
PROGRESS key OFF (after-run).
16E THE MINIMUM More than 2 injectors See individual faults in
NUMBER OF not operating. injectors.
INJECTIONS WAS
NOT REACHED:
STOP THE
ENGINE
171 BENCH 1 CC One or more injectors Possible injector Check wiring.
(bank 1 or bank 2) not connection problem.
operating.
Injectors also in ECM.
short-circuited.
necessary.
173 BENCH 2 CC One or more injectors Possible injector Check wiring.
(bank 1 or bank 2) not connection problem.
operating.
Injectors also in ECM.
short-circuited.

necessary.
17C BENCH 1 One or more injectors Fault in control unit. Replace the engine
INJECTORS (bank 1 or bank 2) may control unit.
CHECK not be operating.
(INTERNAL ECU)
189 EGR POWER ST. No fault perceived by Short circuit or EGR Check wiring.
SHORT TO BATT. the driver. actuator faulty.
Replace the EGR actuator
EGR not working. if necessary.
Base - July 2006
73
Base - July 2006
74
Checks to
conditions detected
performed

191 TURBINE Poor performance. VGT actuator or Check VGT wiring and
ACTUATOR wiring defective. actuator.
CONTROL
ELECTROVALVE
CONTROL
ELECTROVALVE
SHORT CIRCUIT
TO POSITIVE
193 TURBINE WHEEL Poor performance. Air filter blocked or Check the air filter and
REVS SENSOR turbine rpm sensor check parameters linked
signal implausible. with the turbine by
performing a road test
(parameter acquisition).
198 FAULT ON AT Poor performance. Sensor signal Determine which turbine
LEAST TWO OF implausible. component caused the
THE problem.
Sensor may be faulty.
FOLLOWING
SENSORS:
TURBINE SPEED,
BOOT PRESSURE
AND EXHAUST
GAS PRESSURE
199 TURBOCHARGER Poor performance. Turbo sensor or Check turbine sensors
CONTROL actuator may be faulty. and actuator (parameter
BOOST PRESSURE acquisition).
Air filter may be
FAILURE (PCR)
blocked. Check whether air filter is
blocked.
19A TURBINE IN Poor performance. Turbo sensor or Check turbine sensors
OVERSPEED (the actuator may be faulty. and actuator (parameter
fault is not displayed acquisition).
Air filter may be
if it is caused by a
blocked. Check whether air filter is
low atmosperic
blocked.
EURO 4 NEF ENGINES

pressure)
Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
19B TURBINE SPEED Poor performance. Air filter blocked or Check the air filter and
EXCEEDING turbine rpm sensor check parameters linked
EVERY signal implausible. with the turbine by
PERMITTED performing a road test
RANGE (parameter acquisition).
19F NOx SENSOR No effect perceived by Sensor signal Check the Nox sensor.
ERROR the driver. implausible.
Nox sensor may be
faulty.
1A5 TIMEOUT OF No effect perceived by Problems in the Check wiring.
CAN MESSAGE the driver. Denoxtronic (on the
Check and correct any
DM1DCU CAN line).
faults in the Denoxtronic
control unit
1A6 TIMEOUT OF No effect perceived by CAN configuration Check CAN line wiring.
CAN MESSAGE the driver. incorrect.
Check Denoxtronic
SCR1
CAN connections control unit wiring and
defective. operation.
Terminal resistance
not suitable.
1AE HUMIDITY No effect perceived by Sensor short-circuited Check wiring.
SENSOR the driver. or faulty.
Replace sensor if
necessary.

1AF SERIOUS EOBD No effect perceived by Problems in Ad-Blue Check the faults in the
FAULT FROM the driver. dosing system. Denoxtronic and consult
DENOXTRONIC the control unit
(EOBD FLASHING troubleshooting guide.
LIGHT)
1B1 ERROR ON CAN No effect perceived by CAN configuration Check CAN line wiring.
CONTROLLER A the driver. incorrect.
Check terminal
CAN connections resistances.
defective.
Terminal resistance
Base - July 2006
not suitable.
75
Base - July 2006
76
Checks to
conditions detected
performed

CONTROLLER B the driver. incorrect.
Check terminal
defective.
Terminal resistance
not suitable.
CONTROLLER C the driver. incorrect.
Check terminal
defective.
Terminal resistance
not suitable.
1B4 TIMEOUT CAN No effect perceived by CAN configuration Check CAN line wiring.
MESSAGE the driver. incorrect.
Check BC wiring and
BC2EDC1
CAN connections operation.
defective.
Terminal resistance
not suitable.
Check VCM wiring and
VM2EDC
defective.
Terminal resistance
not suitable.
1B7 ERROR ON No effect perceived by CAN configuration Check CAN line wiring.
MESSAGES CAN the driver. incorrect.
Check ECM wiring and
IN
TRANSMISSION
defective.
EURO 4 NEF ENGINES

Terminal resistance
not suitable.
Print P1D32N002 E
1B9 ERROR ON THE No effect perceived by MIL/Body Controller Consult the Body
EOBD LIGHT the driver. warning light Controller
MANAGED BY defective. troubleshooting guide and
THE CLUSTER) check the CAN line.
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
1BA TIMEOUT CAN No effect perceived by CAN messages from Consult the VCM
MESSAGE DASH the driver. VCM inconsistent. troubleshooting guide and
DISPLAY check the CAN line.
1BC TIMEOUT CAN No effect perceived by CAN messages from Consult the VCM
MESSAGE the driver. VCM inconsistent. troubleshooting guide and
AMBCOND check the CAN line.
1BD TIMEOUT CAN No effect perceived by CAN messages from Consult the VCM/BC
MESSAGE CCVS the driver. VCM or BC troubleshooting guide and
inconsistent. check the CAN line.
1C2 ERROR MESSAGE No effect perceived by CAN messages from Check the ETC
CAN ETC1 the driver. ETC (gearbox) connection with the CAN
inconsistent. line.
1C3 TIMEOUT IN No effect perceived by CAN messages from Check the TCO
RECEIVING TC01 the driver. TCO inconsistent. connection with the CAN
CAN MESSAGE line.
1C6 ERROR MESSAGE No effect perceived by CAN messages from Check the TCU
CAN TSC1-PE the driver. TCU (Transmission connection with the CAN
Control Unit) line.
inconsistent.
CAN TSC1-VE the driver. TCU (Transmission connection with the CAN
Control Unit) line.
inconsistent.
1D1 ECU OVERRUN No effect perceived by Electrical interference If the error persists to

MONITORING the driver. or internal control unit replace ECU.
ERROR problems.
1D2 ECU OVERRUN No effect perceived by Poor control unit Reprogram the central
MONITORING the driver. programming/flash unit. If the error is
ERROR repeated, replace the
Possible internal fault
central unit, if needed.
Base - July 2006
77
Base - July 2006
78
Checks to
conditions detected
performed

1D4 ECU OVERRUN No effect perceived by Ecu internal failure. If the error persists to
MONITORING the driver. replace ECU.
ERROR
ERROR
1D6 ECU INTERNAL Control unit Electronic If the error persists to
ERROR (TPU) deactivation. interference or replace ECU.
control unit faulty.
ERROR
1E2 IMMOBILIZER The engine fails to start Problem in CAN line Check the Immobiliser
or immobiliser control control unit is correctly
unit connected.
Enter the Immobiliser PIN
code during the
emergency procedure.
1E3 ERROR FOR ECU No effect perceived by Ecu internal failure. If the error persists to
INTERNAL the driver. replace ECU.
MONITORING
1E4 ERROR FOR ECU No effect perceived by Ecu internal failure. If the error persists to
INTERNAL the driver. replace ECU.
MONITORING
1E5 SENSORS POWER No effect perceived by Excessive/insufficient Check battery voltage or
SUPPLY FAULT the driver. battery voltage or connections with the
EURO 4 NEF ENGINES

(12V) possible internal ECM.
control unit problem.
Replace the control unit if
necessary.
Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
1E6 SENSOR POWER No effect perceived by Excessive/insufficient Check battery voltage or
SUPPLY 1 the driver. battery voltage or connections with the
possible internal ECM.
necessary.
necessary.
necessary.
1E9 ECU OVERRUN No effect perceived by Excessive/insufficient Check battery voltage or
MONITORING the driver. battery voltage or connections with the
ERROR possible internal ECM.
necessary.
1EA ECU OVERRUN No effect perceived by Excessive/insufficient Check battery voltage or
MONITORING the driver. battery voltage or connections with the
ERROR possible internal ECM.

necessary.
1EB ATMOSPHERIC No effect perceived by Fault in sensor inside Change ECU.
PRESSURE the driver. control unit.
SENSOR
Environmental pressure
recovery value: 700
mbar.
1FA TOO HIGH No reaction perceivable Particulate filter may Check filter.
NUMBER OF by the driver. be blocked.
REGENERATIONS
Too many filter
Base - July 2006
DEMAND
regenerations carried
out.
79
Base - July 2006
80
Checks to
conditions detected
performed

1FB PERMANENT No reaction perceivable Catalytic converter Check catalytic converter
RIGENERATION by the driver not installed or visually.
ON TRAP damaged.
PARTICLE
1FC FIRST SENSOR No reaction perceivable Temperature sensors Check information and
EXAUSTED GAS by the driver damaged or condition of sensors.
TEMPERATURE incorrectly fitted.
21F TOO HIGH No reaction noticeable Actuator coil faulty or Check actuator condition.
EFFICIENCY OF on behalf of the driver. not within specified
CATALYST tolerance limits.
SYSTEM
225 INTERRUPTED Slight power reduction. The control unit is Check wiring and then
AFTER-RUN turned off by the replace the main relay.
general switch instead
of by the key (k15).
Possible problem in
main relay or
connections.
228 MAIN RELAY - Slight power reduction. Short circuit in main Check wiring between
SHORT CIRCUIT relay or relay faulty. battery and ECM and then
TO GROUND replace the main relay.
232 COOLANT Slight power reduction. Extreme Ensure the engine is
TEMPERATURE environmental working in non-critical
SENSOR conditions or sensor conditions.
ABSOLUTE TEST incorrectly adjusted.
Check the sensor
connections and accuracy.
Replace sensor if
necessary.
236 RAIL PRESSURE Possible loss of Rail pressure sensor Check connections and
SENSOR OFFSET performance. value above threshold. correct operation of Rail
sensor (parameter
EURO 4 NEF ENGINES

acquisition). Replace
sensor if necessary.
Print P1D32N002 E
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
238 OIL LOW Slight power reduction. Sensor incorrectly Check the sensor
PRESSURE adjusted or faults in connections and accuracy.
lubrication system.
Check the lubrication
system.
23A OIL Slight power reduction. Sensor incorrectly Check the sensor
TEMPERATURE adjusted or faults in connections and accuracy.
ABOVE NORMAL lubrication system.
Check the lubrication
system.
259 PRESSURE MPROP Possible loss of Wiring damaged or Check wiring and
REGULATOR performance. disconnected; pressure regulator;
ERROR (SHORT possible defective replace relay if necessary.
CIRCUIT TO relay or pressure
POSITIVE) regulator.
27C BENCH 2 One or more injectors Fault in control unit. Replace the engine
INJECTORS (bank 1 or bank 2) may control unit.
CHECK not be operating.
(INTERNAL ECU)
CONTROL
ELECTROVALVE
SHORT CIRCUIT
TO GROUND
2A6 TIMEOUT OF No effect perceived by Problem in the Check the faults in the

CAN MESSAGE the driver. Denoxtronic (on the Denoxtronic and consult
SCR2 CAN line). the control unit
troubleshooting guide.
Check wiring.
2AF SERIOUS EOBD No effect perceived by Problems in Ad-Blue Check the faults in the
FAULT FROM the driver. dosing system. Denoxtronic and consult
DENOXTRONIC the control unit
(EOBD FLASHING troubleshooting guide.
LIGHT)
Base - July 2006
81
Base - July 2006
82
Checks to
conditions detected
performed

Check BC wiring and
BC2EDC2
defective.
Terminal resistance
not suitable.
2C6 TIMEOUT OF No effect perceived by CAN messages from Check the TCU
CAN MESSAGE the driver. TCU (Transmission connection with the CAN
TSC1-PE passive Control Unit) line.
inconsistent.
CAN TSC1-VR the driver. TCU (Transmission connection with the CAN
Control Unit) line.
inconsistent.
2C9 ERROR MESSAGE No effect perceived by CAN messages from Check the tachograph
CAN TIMEDATE the driver. TC (tachograph) connection with the CAN
inconsistent. line.
2FF ERROR CHECK Slight power reduction Oil over-diluted. Change the engine oil.
OF CRITICAL TIME
FOR OIL
DILUTION
359 SHORT CIRCUIT Possible loss of Wiring damaged or Check wiring and
TO GROUND OF performance. disconnected; pressure regulator;
METERING UNIT possible defective replace relay if necessary.
OUTPUT relay or pressure
regulator.
392 NO Poor performance. Connection damaged. Check VGT connection
EURO 4 NEF ENGINES

LOAD/EXCESSIVE and actuator.
Battery voltage
TEMP.FOR BPA
excessive (ECU
Print P1D32N002 E
POWER STAGE
overheating).
Print P1D32N002 E
EURO 4 NEF ENGINES

Checks to
conditions detected
performed
3AF DM1DCU SPN3 No effect perceived by Problems in Ad-Blue Check the faults in the
MESSAGE the driver. dosing system. Denoxtronic and consult
the control unit
TSC1-VE passive Control Unit) line.
inconsistent.
3C9 TIMEOUT OF No effect perceived by CAN configuration Check CAN line wiring.
CAN MESSAGE the driver. incorrect.
Check BC wiring and
HRDV
defective.
Terminal resistance
not suitable.
3D3 No effect perceived by Poor control unit Reprogram the central
the driver. programming/flash unit. If the error is
repeated, replace the
3FA REGENERATION No effect perceived by Too many Check particulate filter
DEMAND the driver. regenerations carried and faults in sensors.
NUMBER 2 out.
the control unit

TSC1-VR passive Control Unit) line.
inconsistent.
4FA REGENERATION No effect perceived by Too many Check particulate filter
DEMAND the driver. regenerations carried and faults in sensors.
NUMBER 3 out.
the control unit
Base - July 2006
83

GUIDE TO DIAGNOSIS THROUGH SYMPTOMS


Print P1D32N002 E
EURO 4 NEF ENGINES

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

the circuit over the filter, refill with clean
fuel).
Base - July 2006
87
Base - July 2006
88
POSSIBLE CAUSE RECOMMENDED TESTS OR
ANOMALY REMARKS
(*) = if available in the equipment INTERVENTION

The engine disconnects or does not start. (*) Eliminate the short circuit and replace the Verify that the wire line, close to the
EDC. pedal, is not exposed to.
EDC ”burned” by short circuit on the wir-
ing harness of the friction clutch.
Difficult start and low performance in all Inefficient high pressure pump. After having excluded any other possible
conditions. cause, replace the high pressure pump.
Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recog- In case of low entity blow-by, inficiating
gine running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of the mechanical working of the injector
pulsing within the relevant high pressure but not involving flow limiter activation,
pipe. there is no error memorisation in the en-
gine control module.
Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recog- Usually, whether such symptoms appear,
followed by huge white exhaust fumes, no return). nisable detecting by feeling the absence of it is instinctive to give up engine start.
and a fuel smell. pulsing within the relevant high pressure However, by insisting, it is possible to start
pipe. the engine.
As a matter of facts, by insisting, if within
the rail the pressure makes the flow li-
miter close up, the engine starts with one
cylinder less and gradually the grade of
fumes reduces and disappears.
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct
pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the orig-
screws. inal position.
The engine works with one cylinder less, Injector blocked in closed position. Identify the injector that is not working The non-working injector is easily recog-
without memorising failure blink codes in any more and the relating high pressure nisable detecting by feeling the absence of
the engine control module. filler. pulsing within the relevant high pressure
pipe.
EURO 4 NEF ENGINES

Print P1D32N002 E
PART FOUR - MAINTENANCE PLANNING


MAINTENANCE
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
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.
Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the 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.
Inspection and/or maintenance interventions
Type of intervention Regular intervals (km)

LUBRICATION, CHANGING OIL, FILTERS AND CHECKING FLUIDS
1 Changing engine oil * 40.000
1 Changing engine oil filter * 40.000
2 Changing fuel filter ** 80.000
3 Changing fuel pre-filter ** 80.000
CHECKS IN THE ENGINE BAY
• Checking state of auxiliary drive belts 40.000
• Changing auxiliary drive belts 240.000
• Checking of valve play and adjustment, if required 240.000
DIAGNOSTICS
• Check-up of engine’s EDC system using diagnostic tools 120.000
• AdBlue system inspection test using diagnostic tools * 120.000
(*) Value refers to heavy-duty use. Per vehicles mainly travelling on short-to-medium suburban routes: 60,000 km. For vehicles mainly travelling on long
motorway routes: 80,000 km..
(**) Value refers to heavy-duty use. Per vehicles mainly travelling on short-to-medium suburban routes: 120,000 km. For vehicles mainly travelling on long
motorway routes: 160,000 km..
The frequency of the maintenance operations is just an indication since the use of the EURO 4 NEF engine is the main
! characteristic to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.

Unscheduled and set-interval operations

Operations to be carried out in the course of the scheduled maintenance service.
Unscheduled - Every 150,000 km

- AdBlue system inspection test using diagnostic tools
- AdBlue system pre-filter and filter replacement
At set intervals - Every three months

- Removal, cleaning and re-fitting of Adblue pre-filter
At set intervals - Annually, before the winter season

- Coolant density control
At set intervals - Every two years

- Replacement of cartridge and cleaning of air filter container
- Replacement of engine coolant
Engine oil
Fulfils specifications:
ACEA E7 mineral-based SAE 15W40 Urania LD 7
ACEA E4 synthetic SAE 5W30 Urania FE5W30
IVECO Standard 18-1804

MAINTENANCE PLANNING Cooling system check

Engine oil level check The check must be executed both when the engine
disconnected and when it is running.
The check must be executed when the engine is disconnected
and possibly cool. Check the pipelines from the engine to the radiator, from the
The check can be made using the specially provided flexible expansion tank and vice-versa. Find out any blow-by, verify the
rod. status of the pipes specially close to the holding strips.
Draw off the rod from its slot and check that the level is within Verify that the radiator is clean, the correct working of the fan
the etched tags of minimum and maximum level. flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing Due to the high temperatures achieved by the
minimum level, provide filling lubrication of the engine’s ! system, do not operate immediately after the engine’s
components. disconnection, but wait for the time deemed
necessary for the cooling.
Protect the eyes and the skin from any eventual high
pressure jet of cooling liquid.
The engine oil is highly polluting and harmful.

! In case of contact with the skin, rinse well with water The density of the cooling liquid must be checked any how
and detergent. every year before winter season and be replaced in any case
Adequately protect the skin and the eyes, operate every two year.
in full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.
In case of new filling, proceed bleeding system,
! through the bleeds on the engine.
If bleeding of the system is not carried out, serious

inconvenience might be caused to the engine due to
Check of fuel system the presence of air pockets in the engine’s head.
The check must be executed both when the engine
disconnected and when it is running.
The check operation consists in examining the fuel pipelines
running from the tank to the pre-filter (if provided in the
Check of belt’s tear and wear status
specific equipment), to the filter, to the injection pump and to
the injectors. Carefully verify the belt’s surface in order to detect any sign of
incision, crack, excessive wear in correspondence of toothing;
check end and surface grinding.
Lubricating system check
The check must be executed both when the engine
disconnected and when it is running. Danger: if the engine is switched off but is still hot,
! unexpected motion of the belt may occur.
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan of from the heat exchanger. Wait for engine temperature cooling as a precaution
in order to avoid serious danger injury.

Changing engine oil Changing fuel pre-filter

Take out the oil level dipstick.
Remove the plug (1) from the oil sump and drain the engine Figure 143
oil off into a specific container.
Figure 141
74341
Unscrew the pre-filter (1) and replace it.

Before refitting the new cartridge, moisten the seal with diesel
or engine oil.
Screw the cartridge on by hand until it is in contact with the
77836
mounting and then tighten by 3/4 of a turn to the required
tightening torque.
Changing engine oil filters

Figure 142 When replacing the cartridge, it must not have been
pre-filled. This is to prevent impurities getting into
circulation that could damage the system
components, injectors/pump.
Changing fuel filter

Figure 144
75338
Remove the oil filter (1) with tool 99360076.
NOTE Before refitting the new cartridges, moisten the seal

with engine oil. 108503
Remove the fuel filter (1) with tool.

Screw the oil filter (1) on by hand until it is in contact with the Before refitting the new cartridge, moisten the seal with diesel
mounting and then tighten by 3/4 of a turn to the required or engine oil.
tightening torque. Screw the new one on by hand, taking care to check that the
Screw the plug back on under the sump and tighten it to the rubber seal and the mating surface are clean and in a perfect
required torque. state of repair. Screw the cartridge on by hand until it is in con-
Pour oil into the engine through the filling-pipe (2) of the re- tact with the mounting and then tighten by 3/4 of a turn to the
quired grade and quantity. required tightening torque.

Changing miscellaneous drive belts Checking valve clearance and adjustment if necessary
Figure 145 (Demonstration) To perform these operations correctly, proceed as described
in the appropriate chapter under the section ”GENERAL
CHARACTERISTICS AND SERVICING”.
77839
To remove and fit the belt (1) back on, you need to use an
appropriate tool on the tightener (2) in the direction shown
by the arrow.
NOTE The tighteners are automatic, so they are not to be

adjusted after assembly.
Connect - reconnect and clean AdBlue system pre-filter
Figure 146
108507
Remove pre-filter (1) of AdBlue system.Clean from possible

dirt and reposition pre-filter (1) in its seat.


EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS 1
SECTION 4
General overhaul and characteristics
Page
GENERAL CHARACTERISTICS -
4-CYLINDER ENGINES . . . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 12
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 20
4 AND 6 ENGINE OVERHAUL . . . . . . . . . . . . . 27
ENGINE REMOVAL AT THE BENCH . . . . . . . . 27
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 28
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 28
- Checks and measurements . . . . . . . . . . . . . . . 28
- Head face check on the cylinder group . . . . . 29
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 30
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Checking cam lift and pin alignment . . . . . . . . 31
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 32
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Fitting tappets — camshaft . . . . . . . . . . . . . . . . 33
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 34
- Measuring journals and crankpins . . . . . . . . . . 34
- 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 34
- 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 36
- Replacing oil pump control gear . . . . . . . . . . . 38

2 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS EURO 4 NEF ENGINES
Page Page
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 38 - Finding crankpin clearance . . . . . . . . . . . . . . . . 45

- Finding journal clearance . . . . . . . . . . . . . . . . . 38 - Checking piston protrusion . . . . . . . . . . . . . . . 46
- Checking crankshaft shoulder clearance . . . . . 39 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 47
CONNECTING ROD — PISTON ASSEMBLY . . 39
- Removing the valves . . . . . . . . . . . . . . . . . . . . 47
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
- Checking cylinder head wet seal . . . . . . . . . . . 48
- Measuring piston diameter . . . . . . . . . . . . . . . . 41
- Checking cylinder head supporting surface . . . 48
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Conditions for proper pin-piston coupling . . . . 41
- Removing carbon deposits, checking and
grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 42 - Checking clearance between valve stem and valve

guide and valve centering . . . . . . . . . . . . . . . . . 49
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 50
- Checking connecting rods . . . . . . . . . . . . . . . . 43
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
- Checking torsion . . . . . . . . . . . . . . . . . . . . . . . 43
- Regrinding — replacing the valve seats . . . . . . . 50
- Checking bending . . . . . . . . . . . . . . . . . . . . . . . 44
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 52
- Fitting connecting rod-piston assembly . . . . . . 44
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . 52
- Connecting rod-piston coupling . . . . . . . . . . . . 44
- Refitting the cylinder head . . . . . . . . . . . . . . . . 52
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 44
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 55
- Fitting connecting rod-piston assembly
into cylinder barrels . . . . . . . . . . . . . . . . . . . . . 45 AUXILIARY COMPONENTS . . . . . . . . . . . . . . . 57

GENERAL CHARACTERISTICS - 4-CYLINDER ENGINES

Type
(.14) (.16) (.18) (.185)
Cycle Four-stroke diesel engine

Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4
∅
Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cm3 3920
TIMING
start before T.D.C. A 8.5º

end after B.D.C. B 8.5º
start before B.D.C. D 51º

end after T.D.C. C 12.5º
Checking timing
mm -
X
mm -
X
Checking operation
mm 0.20 to 0.30
X
mm 0.45 to 0.55
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 ECU
Nozzle type Injectors
Injection sequence 1-3-4-2
bar
Injection pressure bar 250 - 1600

CLEARANCE DATA

Type
(.14) (.16) (.18) (.185)
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅1
Cylinder barrels ∅1 102.009 to 102.031
X
∅1 0.5
Pistons
∅1
X Size X 60.5 60.5
Outside diameter ∅1 101.721 to 101.739 101.781 to 101.799
∅2 Pin housing ∅2 40.010 to 40.016 40.008 to 40.014
Piston — cylinder barrels 0.271 to 0.309 0.211 to 0.249
Piston diameter ∅1 0.5
X
Piston protrusion X 0.28 to 0.52
∅ 3 Piston pin ∅3 39.9938 to 40.0002
Piston pin — pin housing 0.0098 to 0.0222 0.0078 to 0.0202


Type
(.14) (.16) (.18) (.185)
X1 X1* 2.705 to 2.735 2.705 to 2.735

X2 Split ring slots X 2 2.430 to 2.450 2.420 to 2.440
X3 X 3 4.040 to 4.060 4.020 to 4.040
S 1 S 1* 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.975 to 4.000
* measured on 98 mm ∅
1 0.100 to 0.175 0.100 to 0.175
Split rings - slots 2 0.050 to 0.100 0.040 to 0.90
3 0.040 to 0.085 0.020 to 0.065
Split rings 0.5
X1 Split ring end opening

X2 in cylinder barrel:
X1 0.30 to 0.40
X3
X2 0.60 to 0.80
X3 0.25 to 0.55
∅1
Small end bush
housing ∅1 42.987 to 43.013
Big end bearing
housing ∅2 72.987 to 73.013
∅ 2
∅ 3 Small end bush diameter
Inside ∅3 40.019 to 40.033

S
Spare big end half
bearings S 1.955 to 1.968
Piston pin — bush 0.0188 to 0.0392
Big end half bearings 0.250; 0.500


Type
(.14) (.16) (.18) (.185)

∅1 ∅2
Journals ∅1 82.993 to 83.013
Crankpins ∅2 68.987 to 69.013
Main half bearings S 1* 2.456 to 2.464

Big end half bearings S 2* 1.955 to 1.968
S 1 S 2
*provided as spare part
Main bearings
∅ 3 No. 1 — 5 ∅3 87.982 to 88.008
No. 2 — 3 — 4 ∅3 87.977 to 88.013
Half bearings — Journals

No. 1 — 5 0.044 to 0.106
No. 2 — 3 — 4 0.039 to 0.111
Half bearings - Crankpins 0.038 to 0.116
Main half bearings

+ 0.250; + 0.500
Big end half bearings
Shoulder journal X1 37.475 to 37.545
X 1
Shoulder main bearing X2 32.18 to 32.28
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.265


Type
(.14) (.16) (.18) (.185)
CYLINDER HEAD — TIMING SYSTEM mm

∅ 1
Valve guide seats on

cylinder head ∅1 7.042 to 7.062
∅ 2 Valves:
∅4 6.970 to 6.990
α 60o ± 0.25o
∅4 6.970 to 6.990
α α 45o ± 0.25o
Valve stem and guide 0.052 to 0.092
Housing on head for
valve seat:
∅1 34.837 to 34.863
∅ 1 ∅1 34.837 to 34.863
Valve seat outside diameter;

∅ 2 valve seat angle on cylinder
head:
∅2 34.917 to 34.931
α 60o
∅2 34.917 to 34.931
α
α 45o
X 0.36 to 0.94
Sinking
X X 0.73 to 1.31
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -


Type
(.14) (.16) (.18) (.185)

Valve spring height:
free spring H 47.75

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

X
Camshaft bush
housings No. 1 (flywheel side) 59.222 to 59.248
Camshaft housings
∅ ∅ ∅ No. 2-3-4-5 54.089 to 54.139
1 23 4 5
∅ 2
Camshaft journals:
1⇒5 ∅1-2-3 53.995 to 54.045
∅ 1 ∅ 3
Bushing inner
∅ diameter ∅ 54.083 to 54.147
Bushing and support pins 0.038 to 0.152

Cam lift:
H
H 7.582
H 6.045


Type
(.14) (.16) (.18) (.185)

∅1
Tappet cap housing
on block ∅1 16.000 to 16.030
∅2
∅ 3 Tappet cap outside
diameter: ∅2 15.924 to 15.954
∅3 15.960 to 15.975
∅2
Between tappets and hou-
0.025 to 0.070
sings
Tappets -
∅ 1
Rocker shaft ∅1 21.965 to 21.977
Rockers ∅2 22.001 to 22.027
∅ 2
Between rockers and shaft 0.024 to 0.062



Type (.18) (.22) (.25) (.28) (.30)

Injection Direct
Number of cylinders 6 in-line
∅
Bore mm 102
Stroke mm 120
TIMING


Checking timing
mm -
X
mm -
X
Checking operation
mm 0.20 to 0.30
X
mm 0.45 to 0.55
FUEL FEED

Injection sequence 1-5-3-6-2-4
bar
Injection pressure bar 250 - 1600

CLEARANCE DATA

Type (.18) (.22) (.25) (.28) (.30)

∅1
X
∅1 0.5
Pistons
∅1
X Size X 60.5 60.5
Outside diameter ∅1 101.721 to 101.739 101.781 to 101.799
∅2 Pin housing ∅2 40.010 to 40.016 40.008 to 40.014
X
Piston protrusion X -
∅ 3 Piston pin ∅3 39.9938 to 40.0002
Piston pin — pin housing 0.0098 to 0.0222 0.0078 to 0.0202


Type (.18) (.22) (.25) (.28) (.30)
X1 X1* 2.705 to 2.735 2.705 to 2.735

X2 Split ring slots X2 2.430 to 2.450 2.420 to 2.440
X3 X3 4.040 to 4.060 4.020 to 4.040
S 1 S 1* 2.560 to 2.605
S 3 S3 3.975 to 4.000
1 0.100 to 0.175 0.100 to 0.175
3 0.040 to 0.085 0.020 to 0.065
Split rings 0.5

X1 0.30 to 0.40
X3
X2 0.60 to 0.80
X3 0.25 to 0.55
∅1
Small end bush
housing ∅1 42.987 to 43.013
Big end bearing
housing ∅2 72.987 to 73.013
∅ 2
Inside ∅3 40.019 to 40.033

S
Spare big end half
Big end half bearings 0.250 - 0.500


Type (.18) (.22) (.25) (.28) (.30)

∅1 ∅2
Journals ∅1 82.993 to 83.013
Crankpins ∅2 68.987 to 69.013
Main half bearings S1 2.456 to 2.464

Big end half bearings S2 1.955 to 1.968
S 1 S 2
Main bearings
∅ 3 No. 1 — 7 ∅3 87.982 to 88.008
No. 2 — 3 — 4 — 5 — 6 ∅3 87.977 to 88.013
Half bearings — Journals

No. 1 — 7 0.044 to 0.106
No. 2 — 3 — 4 — 5 — 6 0.039 to 0.111
Main half bearings

+ 0.250; + 0.500
X 1
X 2
X 3


Type (.18) (.22) (.25) (.28) (.30)

∅ 1

∅ 4 Valves:
∅4 6.970 to 6.990
α 60o ± 0.25o
∅4 6.970 to 6.990
α α 45o ± 0.25o
Housing on head for
valve seat:
34.837 to 34.863
∅1
∅ 1 34.837 to 34.863
∅1
head:
∅2 34.917 to 34.931
α 60o
∅2 34.917 to 34.931
α
α 45o
X 0.36 to 0.94
Sinking
X X 0.73 to 1.31
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -


Type (.18) (.22) (.25) (.28) (.30)

free spring H 47.75

H H1
339.8 ± 19 N H1 35.33
741 ± 39 N H2 25.20

X
Camshaft bush
Camshaft housings
∅ ∅ ∅ No. 2-3-4-5-6-7 54.089 to 54.139
1 23 4 5
∅ 2
Camshaft journals:
1⇒7 ∅1-2-3 53.995 to 54.045
∅ 1 ∅ 3
Bushing inner
∅ diameter ∅ 54.083 to 54.147

Cam lift:
H
H 7.582
H 6.045


Type (.18) (.22) (.25) (.28) (.30)

∅1
Tappet cap housing
on block ∅1 16.000 to 16.030
∅2
diameter: ∅2 15.924 to 15.954
∅3 15.960 to 15.975
∅2
0.025 to 0.070
sings
Tappets -
∅ 1
Rockers ∅2 22.001 to 22.027
∅ 2



Type (.22) (.25) (.26) (.26) (.30)

Injection Direct
Number of cylinders 6
∅
Bore mm 102
Stroke mm 120
TIMING


Checking timing
mm -
X
mm -
X
Checking operation
mm 0.20 to 0.30
X
mm 0.45 to 0.55
FUEL FEED

Injection sequence 1-5-3-6-2-4
bar
Injection pressure bar 250 - 1450 250 - 1600

CLEARANCE DATA

Type (.22) (.25) (.26) (.26) (.30)

∅1
X
∅1 0.5
Pistons
∅1
X Size X 60.5
Outside diameter ∅1 101,721to 101,739 107.781 to 101.799
∅2 Pin housing ∅2 40,010 to 40,016 40.008 to 40.014
X
Piston protrusion X -
∅ 3 Piston pin ∅3 39.9938 to 40.0002
0.0098 to
Piston pin — pin housing 0.0078 to 0.0202
0.0222


Type (.22) (.25) (.26) (.26) (.30)
X1 X1* 2.705 to 2.735

2.705 to 2.735
X2 Split ring slots X2 2.430 to 2.450 2.420 to 2.440
X3 4.040 to 4.060 4.020 to 4.040
X3
S 1 S 1* 2.560 to 2.605
S 3 S3 3.975 to 4.000
1 0.100 to 0.175 0.100 to 0.175
0.040 to 0.085
3 0.020 to 0.065
Split rings 0.5

X1 0.30 to 0.40
X3
X2 0.60 to 0.80
X3 0.25 to 0.55
∅1
Small end bush
housing ∅1 42.987 to 43.013
Big end bearing
housing ∅2 72.987 to 73.013
∅ 2
Inside ∅3 40.019 to 40.033

S
Spare big end half
Big end half bearings 0.250 - 0.500


Type (.22) (.25) (.26) (.26) (.30)

∅1 ∅2
Journals ∅1 82.990 to 83.010
Crankpins ∅2 68.987 to 69.013
Main half bearings S 1* 2.456 to 2.464

Big end half bearings S 2* 1.955 to 1.968
S 1 S 2
Main bearings
∅ 3 No. 1-7 ∅3 87.982 to 88.008
No. 2—3-4-5-6 ∅3 87.977 to 88.013
Main bearings
No. 1-7 0.044 to 0.106
No. 2-3-4-5-6 ∅3 0.039 to 0.111
Main half bearings

+ 0.250; + 0.500
X 1
X 2
X 3


Type (.22) (.25) (.26) (.26) (.30)

∅ 1

∅ 4 Valves:
∅4 6.970 to 6.999
α 60o ± 0.25o
∅4 6.970 to 6.999
α α 45o ± 0.25o
Housing on head for
valve seat:
∅1 34.837 to 34.863
∅ 1 ∅1 34.837 to 34.863

head:
∅2 34.917 to 34.931
α 59.5o
∅2 34.917 to 34.931
α
α 44.5o
X 0.36 to 0.94
Sinking
X X 0.73 to 1.31
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -


Type (.22) (.25) (.26) (.26) (.30)

free spring H 47.75

H H1
339.8 ± 19 N H1 35.33
741 ± 39 N H2 25.20

X
Camshaft bush
Camshaft housings
∅ ∅ ∅ No. 2-3-4-5-6-7 54.089 to 54.139
1 23 4 5
∅ 2
Camshaft journals:
1⇒7 ∅ 53.995 to 54.045
∅ 1 ∅ 3
Bushing inner
∅ diameter ∅ 54.083 to 54.147

Cam lift:
H
H 7.582
H 6.045


Type (.22) (.25) (.26) (.26) (.30)

∅1
Tappet cap housing
on block ∅1 16.000 to 16.030
∅2
diameter: ∅2 15.924 to 15.954
∅3 15.960 to 15.975
∅2
0.025 to 0.070
sings
Tappets -
∅ 1
Rockers ∅2 22.001 to 22.027
∅ 2


4 AND 6 ENGINE OVERHAUL Figure 3

ENGINE REMOVAL AT THE BENCH
The following instructions assume that the engine has
previously been placed on the rotating bench and that
removal of all specific components of the Iveco Motors
equipment have been already removed as well. (See Section
3 of the manual herein).
The section illustrates therefore all the most important engine
overhaul procedures.
The following operations are relating to the 4 cylinder engine
but are similar and applicable for the 6 cylinder.
Figure 1
70160
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
NOTE Take note of lower and upper half-bearing

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

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

zs
Figure 6 REPAIR OPERATIONS

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

plate (2).
70166
Once engine is disassembled, clean accurately the

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

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

different heights in the barrel and on two planes perpendicular
with each other: one parallel to the longitudinal axis of the
engine (A), and the other perpendicular (B). Maximum wear
is usually found on plane (B) in correspondence with the first
measurement.
Should ovalisation, taper or wear be found, bore and grind the
70165
cylinder barrels. Cylinder barrel regrinding shall be performed
according to the spare piston diameter oversized by 0.5 mm
and to the specified assembling clearance.
Withdraw the tappets (1) from the engine block.
Figure 11 Head face check on the cylinder group
Figure 12
70170
Check that the head face, on the cylinder group, does not
present deformations.
This check can be carried out, after a previous grains (4)
extraction by means of a calibrated ruler (2) and feeler gauge
(3).
α After verified the deformation areas, perform the flattening of
the face by means of grinding machine.
The flatness error must not be higher than 0.075 mm.
107267
NOTE In the event of grinding operation, all the barrels The block flattening could be performed only after
must result of the same oversize (0.5 mm) ! you have checked that, at finished work, the piston
projection from the cylinder barrel is not higher than
the value prescribed.
Check the bench bearing seats, proceeding as follows: Check the conditions of the working plugs (1) of the cylinder
groups; replace them if rusty or in case of doubt about their
- mount the bench caps on the supports without bearings; conditions.
- screw the fixing screws to the torque prescribed; When flattening is finished, restore the cylinder barrel bevel
- by means of an adequate gauge, verify that the internal as shown in Figure 11.
diameter of the seats correspond to the value prescribed.
If you detect a higher value, replace its block

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

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

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

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

Internal surface must not show seizing or wear.
Using a bore gauge (3), measure the diameter of the bushing
(2) and of the intermediate seats (1) for the camshaft.
70171 Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two
perpendicular axes.
Figure 17
sec. A--A
107399
MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT

* Measurement to make after fitting the bushing.
Figure 18
Sec. A-A
107268
MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT

* Measurement to make after fitting the bushing.
Bush replacement Tappets

Figure 19 Figure 20
70174 70175
To change the bushing (1), use the drift 99360362 (2) and grip MAIN DATA CONCERNING THE TAPPETS AND THE
99370006 (3) for its disassembly and assembly. RELEVANT HOUSINGS ON THE ENGINE BLOCK
NOTE Upon assembly, the bushing (1) must be directed

so that the lubrication holes coincide with the holes
in the seat in the crankcase.

Fitting tappets — camshaft Figure 23
Figure 21
70238
Set camshaft (3) retaining plate (1) with the slot facing the top
of the engine block and the marking facing the operator, then
70176 tighten the screws (2) to the specified torque.
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Figure 24
Figure 22
70179
Check camshaft end float (1).

It shall be 0.23 ± 0.13 mm.
70164
Figure 25
Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
OUTPUT SHAFT
Measuring journals and crankpins NOTE It is recommended to insert the found values in the
proper table.
Figure 26 See Figure 27 and 29.
Undersize classes are: 0.250 - 0.500 mm
Journals and crankpins shall always be ground to the

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

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

Figure 28
measured on > 45.5 mm radius

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

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

CRITICAL ©
IMPORTANT ⊕
SECONDARY ⊝
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237

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

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

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

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

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

CRITICAL ©
IMPORTANT ⊕
SECONDARY ⊝

Replacing oil pump control gear Finding journal clearance
Figure 32 Figure 34
70161
Refit the output shaft (2).

70184 Check the backlash between output shaft main journals and
Check that gear toothing (1) is not damaged or worn, the relevant bearings as follows:
otherwise remove it using the proper puller (3). Figure 35
When fitting the new gear, heat it to 180°C for 10 minutes in
an oven and then key it to the crankshaft.
Fitting main bearings
Figure 33
70186
- clean accurately the parts and remove any trace of oil;

- position a piece of calibrated wire (3) on the crankshaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
70185 supports.
Figure 36
NOTE Refit the main bearings that have not been replaced,
in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm

undersize on the internal diameter.
NOTE Do not try to adapt the bearings.
70187
Clean accurately the main half bearings (1) having the
lubricating hole and fit them into their housings. Tighten the pre-lubricated screws (1) in the following three
successive stages:
The second last main half bearing (1) is fitted with shoulder half - 1st stage, with torque wrench to 50 ± 6 Nm.
rings. - 2nd stage, with torque wrench to 80 ± 6 Nm.

Figure 37 Checking crankshaft shoulder clearance
α Figure 39
70188
- 3rd stage, with tool 99395216 (1) set as shown in the 70190
figure, tighten the screws (2) with 90° ± 5° angle. This check is performed by setting a magnetic-base dial gauge
(2) on the crankshaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
Figure 38 If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft pins and main half bearings.
CONNECTING ROD — PISTON ASSEMBLY
70189 Figure 40
- Remove caps from supports.
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.
The numbers on the scale indicate the backlash in mm.
Replace the half bearings and repeat the check if a different
backlash value is found. Once the specified backlash is
obtained, lubricate the main bearings and fit the supports by
tightening the fastening screws as previously described.
70191
CONNECTING ROD — PISTON ASSEMBLY

COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE The pistons are fitted with a replacer in standard

size, or 0.5 mm oversize.

Figure 41 Figure 42
32613 32614
Remove split rings (1) from piston (2) using pliers 99360183 Piston pin (1) split rings (2) are removed using a scriber (3).
(3).
Figure 43
114923
MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter
ENFINES: F4AE3481D, F4AE3481B, F4AE3481A, F4AE3681D, F4AE3681A, F4AE3682F, F4AE3682E, F4AE3682B,
F4AE3682A
Figure 44
114924
MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter
ENFINES: F4AE3481C, F4AE3681C, F4AE3681B, F4AE3682C

Pistons Conditions for proper pin-piston coupling

Measuring piston diameter
Figure 45 Figure 48
32619
32615
Using a micrometer (2), measure the diameter of the piston Lubricate the pin (1) and its seat on piston hubs with engine
(1) to determine the assembly clearance. oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.
NOTE The diameter shall be measured at 60.5 mm from
the piston skirt.
Split rings
Figure 49
Figure 46
16552
Use a micrometer (1) to check split ring (2) thickness.

70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure. Figure 50
Piston pins
Figure 47
32620
18857
Check the clearance between the sealing rings (3) of the 2nd
To measure the piston pin (1) diameter use the micrometer and 3rd slot and the relevant housings on the piston (2), using
(2). a feeler gauge (1).
Figure 51 Connecting rods

Figure 53
41104
DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
107271
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
* Value for inside diameter to be obtained after driving in
connecting rod small end and grinding.
** Value not measurable in released condition
Figure 52
NOTE The surface of connecting rod and rod cap are

knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.
70194
Use feeler gauge (1) to measure the clearance between the

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

Figure 54 Checking connecting rods

Figure 55 (Demonstration)
CONNECTING ROD BODY
CONNECTI
NG ROD No.
WEIGHT *
CONNECTING ROD CAP
CONNEC. ROD No. YEAR DAY

61696
Check that the axes of the connecting rods (1) are parallel
70196 using tool (5) as follows:
- fit the connecting rod (1) on tool (5) spindle and lock it
NOTE Every connecting rod is marked as follows: with screw (4);
- set the spindle (3) on V-blocks by resting the connecting
- On body and cap with a number showing their rod (1) on the stop bar (2).
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary Checking torsion
to mark the new connecting rod with the same Figure 56 (Demonstration)
numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
S X, 1901 to 1940 (blue marking);

Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
Bushes
Check that the bush in the connecting rod small end is free 61694
from scoring or seizing and that it is not loosen. Otherwise
Check connecting rod (5) torsion by comparing two points
replace.
(A and B) of pin (3) on the horizontal plane of the connecting
Removal and refitting shall be performed using the proper rod axis.
beater.
Position the dial gauge (2) support (1) to obtain a preload of
When refitting take care to make coincide the oil holes set approx. 0.5 mm on the pin (3) in point A and then set the
on the bush with those set on the connecting rod small end. dial gauge (2) to zero. Move the spindle (4) with the
Grind the bush to obtain the specified diameter. connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A and
B shall not exceed 0.08 mm.

Checking bending Figure 59

Figure 57 (Demonstration)
102596
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
61695
connecting rod (5) are read as shown in the figure.
Check connecting rod (5) bending by comparing two points Figure 60

C and D of the pin (3) on the vertical plane of the connecting
rod axis.
Position the vertical support (1) of the dial gauge (2) to rest
the latter on pin (3), point C.
Swing the connecting rod back and forth looking for pin
highest position and, in such condition, reset comparator (2).
Move the spindle with the connecting rod (5) and repeat the
check of the top point on the opposite side D of the pin (3).
The difference between point C and point D shall not exceed
0.08 mm.
Fitting connecting rod-piston assembly

Connecting rod-piston coupling 72705
Position the piston (1) on the connecting rod according to

Figure 58 the diagram shown in the figure, fit the pin (3) and stop it by
the split rings (2).
Fitting split rings
Figure 61
70198
The piston crown is marked as follows:

1. Part number and design modification number.
2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine 32613
block.
Use pliers 99360183 (3) to fit the split rings (1) on the piston
3. Marking showing 1st slot insert testing.
(2).
4. Manufacturing date. Split rings shall be fitted with the marking “TOP” facing
upwards and their openings shall be displaced with each
other by 120°.

Figure 64
NOTE Split rings are supplied spare with the following
sizes:
- standard;
- 0.5 mm oversize.
Figure 62
70202
DIAGRAM FOR CONNECTING ROD-PISTON

ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120°;
- connecting rod-piston assemblies shall have the same
70200
weight;
Fit half bearings (1) on connecting rod and cap. - 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.
NOTE Refit the main bearings that have not been
replaced, in the same position found at removal.
Do not try to adapt the half bearings.
Finding crankpin clearance
Figure 65
Fitting connecting rod-piston assembly into

cylinder barrels
Figure 63
70203
To measure the clearance proceed as follows:

70201
- clean the parts accurately and remove any trace of oil;
Lubricate accurately the pistons, including the split rings and - set a piece of calibrated wire (2) on the output shaft pins
the cylinder barrel inside. (1);
Use band 99360605 (2) to fit the connecting rod-piston - fit the connecting rod caps (3) with the relevant half
assembly (1) into the cylinder barrels and check the following: bearings (4).
- the number of each connecting rod shall correspond to
the cap coupling number.

Figure 66 Figure 69
70204
70207
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench If a different clearance value is found, replace the half bearings
(2). and repeat the check.
Once the specified clearance has been obtained, lubricate
Figure 67 the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
α Before the final fitting of the connecting rod cap

! fastening screws, check that their diameter
measured at the centre of the thread length is not
< 0.1 mm than the diameter measured at approx. 10
mm from screw end.
Check manually that the connecting rods (1) are sliding

axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.10 to 0.33 mm.
70205 Checking piston protrusion

- Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60°.
Figure 70
Figure 68
70208
Once connecting rod-piston assemblies refitting is over, use

dial gauge 99395603 (1) fitted with base 99370415 (2) to
70206 check piston (3) protrusion at T.D.C. with respect to the top
- Remove the cap and find the existing clearance by of the engine block.
comparing the calibrated wire width (1) with the scale Protrusion shall be 0.28 to 0.52 mm.
on the wire envelope (2).

CYLINDER HEAD Figure 72

Removing the valves
Figure 71
70321
Valve removal shall be performed using tool 99360268 (1)

and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
70319
cap (3) and the springs (4).
Intake (1) and exhaust (2) valves have heads with the same
diameter. Repeat this operation for all the valves.
The central notch of the exhaust valve (2) head distinguishes Overturn the cylinder head and withdraw the valves (5).
it from the intake valve.
Figure 73
NOTE Should cylinder head valves be not replaced,

number them before removing in order to refit
them in the same position.
A = intake side — S = exhaust side
70322
Remove sealing rings (1 and 2) from the valve guide.
NOTE Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

Checking cylinder head wet seal Figure 76
Figure 74
70323 70325
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90°C and 2 The rated thickness A for the cylinder head is 105 ± 0.25 mm,
to 3 bar pressure. max. metal removal shall not exceed thickness B by 1 mm.
Replace the core plugs (1) if leaks are found, use the proper
punch for their removal/refitting.
After grinding, check valve sinking. Regrind the valve
seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with
water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface
Figure 75
70324
Use a rule (2) and a feeler gauge (3) to check the cylinder
head (1) supporting surface.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.

VALVES Figure 79
Figure 77
18882
Check the valve stem (1) using a micrometer (2), it shall be

107280 6.970 ± 6.990.
INTAKE AND EXHAUST VALVE MAIN DATA
Removing carbon deposits, checking and

grinding valves Checking clearance between valve stem and
valve guide and valve centering
Figure 78
Figure 80
18625
Remove carbon deposits from valves using the proper metal

brush. 70327
Check that the valves show no signs of seizing, scoring or Use a magnetic base dial gauge (1) set as shown in the figure,
cracking. the assembling clearance shall be 0.052 ± 0.092 mm.
Grind the valve seat, if necessary, using a grinding machine, Turn the valve (2) and check that the centering error is not
removing as little material as possible. exceeding 0.03 mm.

VALVE GUIDE VALVE SEATS

Regrinding — replacing the valve seats
Figure 81
Figure 82
70330
INTAKE EXHAUST Check the valve seats (2).

79457
If slight scoring or burning is detected, regrind using a valve
seat regrinding tool (1) following the inclination values shown
Use a bore dial gauge to measure the inside diameter of the in Figure 83.
valve guides, the read value shall comply with the value
shown in the figure.
Figure 83
EXHAUST INTAKE
107281
ENGINE VALVE SEATS MAIN DATA

Valve seats are cast on cylinder head and machined.

Figure 84
EXHAUST INTAKE
107282
Where valve seats cannot be recovered just regrinding them, In order to fit valve seats into cylinder head, the cylinder head
inserts provided with spares can be mounted. In this case, the has to be heated at 80 °C ÷ 100 °C and previously cooled
seats dimensioned as indicated in figure have to be new valve seats have to be mounted into cylinder head using
implemented on cylinder head and valve seats have to be special beater.
mounted.
Then, using a suitable tool, regrind the valve seats according
to the values shown in Figure 85.
Figure 85
INTAKE EXHAUST
107283
Figure 86 After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).
70333

VALVE SPRINGS Figure 89

Figure 87
50676
770321
MAIN DATA TO CHECK INTAKE AND EXHAUST Position on the cylinder head: the spring (4), the upper cap
VALVE SPRINGS (3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Before refitting, check spring flexibility. Compare load and
elastic deformation data with those of the new springs shown
in the following table. Refitting the cylinder head
Figure 90
Height Under a load of

mm N
H 47.75 Free
H1 35.33 P1 339.8 ± 19
H2 25.2 P2 741 ± 39
FITTING CYLINDER HEAD
Figure 88
70335
Check cleanness of cylinder head and engine block coupling

surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking “TOP” (1)
facing the head.
The arrow shows the point where the gasket thickness is
given.
NOTE Before reusing the cylinder head fastening screws

check whether they are free from damages or
distortions, otherwise replace.
70334
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.

Figure 91
88775
There are two types of head seals, for the thickness (1.25 mm
Type A and 1.15 mm Type B) take the following measures:
- for each piston detect, as indicated on Figure 91, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:
S cil1 = S1 + S2
2
For 4 cylinder versions:

Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
S cil1 + S cil2 + S cil3 + S cil4
S=
4
For 6 cylinder versions:
Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
the average value.
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6

S=
6
If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.


TIGHTENING TORQUE
COMPONENT TORQUE
Nm kgm
Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3
Screw M12 for fastening output shaft caps 1st stage 50 ± 6 5 ± 0.6
2nd stage 80 ± 6 8 ± 0.6
3rdd stage 90° ± 5°
Studs M6 for camshaft sensors 8±2 0.8 ± 0.2
Studs M8 for feed pump 12 ± 2 1.2 ± 0.2
Screw M12 for fastening rear gear case 77 ± 12 7.7 ± 1.2
Nut M6 for fastening camshaft sensor 10 ± 2 1 ± 0.2
1st stage 8±1 0.8 ± 0.1
Screw M8 for fastening oil pump 2nd stage 24 ± 4 2.4 ± 0.4
Screw M8 for fastening front cover 24 ± 4 2.4 ± 0.4
Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4
Screw M8 for fastening camshaft gear 36 ± 4 3.6 ± 0.4
Screw M11 for fastening connecting rod caps 1st stage 60 ± 5 6 ± 0.5
2ndd stage 60° ± 5°
Screw M10 for fastening crankcase plate 43 ± 5 4.3 ± 0.4
Nut M18 for fastening high pressure pump gear 105 ± 5 10.5 ± 0.5
Nuts M8 for fastening fuel pump 24 ± 4 2,4 ± 0,4
1/2 inch plug on cylinder head 24 ± 4 2.4 ± 0.4
Screw M6 for fastening injectors 8.5 ± 0.35 0.85 ± 0.035
Nut fastening for injector feed connector 50 ± 5 5 ± 0.5
Nut M6 for flame start grille on intake manifold 8±2 0.8 ± 0.2
Screw M8 for fastening intake manifold 24 ± 4 2.4 ± 0.4
Screw M12 for fastening rear brackets for engine lifting 77 ± 12 7.7 ± 1.2
Screws M8 for fastening Common Rail 24 ± 4 2.4 ± 0.4
Connectors M14 for high pressure fuel pipes 20 ± 2 2 ± 0.2
Screw M12 (12 x 1.75 x 130) for fastening cylinder head 35 ± 5 3.5 ± 0.5
Screw M12 (12 x 1.75 x 150) for fastening cylinder head
} 1st stage
55 ± 5 5.5 ± 0.5
2nd stage 90° ± 5°
3rd stage 90° ± 5°
Screw for fastening rocker bracket 36 ± 5 3.6 ± 0.5
Valve clearance adjusting nuts 24 ± 4 2.4 ± 0.4
Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 ± 2 2 ± 0.2
Screw M8 for fastening high pressure pipe connector 24 ± 4 2.4 ± 0.4
Screw M6 for fastening wiring bulkhead 10 ± 2 1 ± 0.2
Screw M8 for fastening electric wiring support for injector feed 24 ± 4 2.4 ± 0.4
Nuts for fastening wiring on each injector 1,5 ± 0,25 0.15 ± 0.025
Screw M12 for fastening fuel filter bracket 77 ± 8 7.7 ± 0.8
Screw M8 for fastening fuel filter holder 24 ± 4 2.4 ± 0.4
Fuel filter contact + 3/4 turn
Screw M22 for fastening oil pressure relief valve on oil filter support 80 ± 8 8 ± 0.8
Screw M8 for radiator seal and oil filter support 24 ± 4 2.4 ± 0.4
Oil filter contact + 3/4 turn

COMPONENT TORQUE
Nm kgm
11/8 inch connection on filter support for turbine lubrication 24 ± 4 2.4 ± 0.4
Nut M12 for fastening turbine lubrication pipe 10 ± 2 1 ± 0.2
Screw M10 for fastening engine coolant inlet connection 43 ± 6 4.3 ± 0.6
90° elbow fastening (if required) to engine coolant inlet connection 24 ± 4 2.4 ± 0.4
Pipe on cylinder head for compressor cooling 22 ± 2 2.2 ± 0.2
Screw M6 for fastening engine coolant drain connector 10 ± 2 1 ± 0.2
Pin fastening on engine block for exhaust manifold 10 ± 2 1 ± 0.2
Screw M10 for fastening exhaust manifold on cylinder head 53 ± 5 5.3 ± 0.5
Screw M12 for fastening damper adapter 1st stage 50 ± 5 5 ± 0.5
and damper on output shaft 2ndd stage 90°
Screw M10 for fastening pulley on output shaft 68 ± 7 6.8 ± 0.7
Screw M8 for fastening water pump 24 ± 4 2.4 ± 0.4
Screw M10 for fastening auxiliary component control belt tensioners 43 ± 6 4.3 ± 0.6
Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 ± 6 4.3 ± 0.6
Screw M10 for fastening flywheel housing 85 ± 10 8.5 ± 1
Screw M12 for fastening flywheel housing 49 ± 5 4.9 ± 0.5
Screw M6 for fastening heat exchanger for control unit 10 ± 2 1 ± 0.2
Screw M8 for fastening heat exchanger for control unit 24 ± 4 2.4 ± 0.4
Connection M12 for fuel inlet-outlet on heat exchanger 12 ± 2 1.2 ± 0.2
Nut M8 for fastening valve cover 24 ± 4 2.4 ± 0.4
Screw M6 for fastening camshaft sensor 8±2 0.8 ± 0.2
Screw M6 for fastening output shaft sensor 8±2 0.8 ± 0.2
Screw M14 for fastening coolant temperature sensor 20 ± 3 2 ± 0.3
Screw M5 for fastening oil pressure/temperature sensor 6±1 0.6 ± 0.1
Screw for fastening fuel pressure sensor 35 ± 5 3.5 ± 0.5
Screw M14 for fastening fuel temperature sensor 20 ± 3 2 ± 0.3
Screw for fastening air temperature/pressure sensor on intake manifold 6±1 0.6 ± 0.1
Screw M12 for fastening engine oil level sensor 12 ± 2 1.2 ± 0.2
7±1 0.7 ± 0.1
6-cyl. { pins
nuts
M10
M10 43 ± 6 4 3 ± 0.6
4.3 06
Turbine fixing to exhaust manifold
7±1
4-cyl. { pins
nuts
M8
M8 24 ± 4
0 7 ± 0.1
0.7 01
2.4 ± 0.4
Adapter M12 on turbine for lubricant oil pipes (inlet) 35 ± 5 3.5 ± 0.5
Pipe fixing on adapter M10 for turbine lubrication 35 ± 5 3.5 ± 0.5
Oil pipe fixing on adapter M10 for turbine lubrication to block 43 ± 6 4.3 ± 0.6
Oil drain pipe fixing M8 on turbine 24 ± 4 2.4 ± 0.4
Connector fixing M6 for oil return from cylinder head to flywheel housing 10 ± 2 1 ± 0.2
Screw M12 for fastening engine flywheel 1st stage 30 ± 4 3 ± 0.4
2ndd stage 60º ± 5º
Screw M8 for fastening front bracket for engine lifting 24 ± 4 2.4 ± 0.4
Screw for fastening engine oil sump 24 ± 4 2.4 ± 0.4

AUXILIARY COMPONENTS
COMPONENT TORQUE
Nm kgm
Air compressor:
5/8 nut for fastening control gear on compressor shaft 125 ± 19 12.5 ± 1.9
Nut M12 for fastening to flywheel housing 77 ± 12 7.7 ± 1.2
Alternator:
Screw M10 for fastening bracket to water inlet connector 43 ± 6 4.3 ± 0.6
Nut M10 for fastening alternator 43 ± 6 4.3 ± 0.6
Ventilation and heating unit:
Screw M10 for fastening bracket 43 ± 6 4.3 ± 0.6
Screw M10 for fastening compressor 24 ± 4 2.4 ± 0.4
Starter:
Screw for fastening starter 43 ± 6 4.3 ± 0.6


EURO 4 NEF ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS EURO 4 NEF ENGINES

TOOLS
TOOL No. DEFINITION
Device for checking the diesel supply circuit and common-rail

99305453 injection system
99317915 Set of 3 9x12 pin wrenches (14 - 17 - 19 mm)
Revolving stand for overhauling units (700 daN/m capacity, 120

99322205 daN/m torque)
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket
99341001 Double acting puller

TOOLS
TOOL No. DEFINITION
99341009 Pair of brackets
99341015 Press
99342101 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket
99360076 Tool for disassembling cartridge filters

TOOLS
TOOL No. DEFINITION
99360183 Pliers for removing/refitting piston rings (65 — 110 mm)
99360268 Tool for removing/refitting engine valves
99360330 Tool for rotating the engine flywheel
99360351 Tool for stopping the engine flywheel
Beater for removing/refitting camshaft bushes (to be used with

99360362 99370006)
99360500 Tool for lifting the output shaft

TOOLS
TOOL No. 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 Manual pump for pressure and vacuum measurements
99370006 Handgrip for interchangeable beaters

TOOLS
TOOL No. DEFINITION
99370415 Gauge base for different measurements (to be used with 99395603)
99389829 Joint torque wrench 9x12 - (5-60 Nm)
Torque screwdriver for injector solenoid valve connector stop nut

99389834 setting
99395216 Pair of gauges with ½” and ¾” square head for angle tightening
99395603 Dial gauge (0 — 5 mm)


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

2 APPENDIX EURO 4 NEF ENGINES

EURO 4 NEF ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

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

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

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

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EURO 4

Technical and Repair manual

The data contained in this publication was correct at the time

Danger for persons

Danger of serious damage for the vehicle

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

Print P1D32N002 E Base - July 2006

Base - July 2006 Print P1D32N002 E

EURO 4 NEF ENGINES

F4A Engines Part 1

Print P1D32N002 E Base - July 2006

Base - July 2006 Print P1D32N002 E

∅1 Ø 1 = housing for connecting rod small end bush

Print P1D32N002 E Base - July 2006

Graph and symbols

Tighten to torque + angle value Rolling torque

Surface for machining

Base - July 2006 Print P1D32N002 E

General overhaul and characteristics 4

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the F4A engine illustrating its features

Section 2 describes the type of fuel feed.

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

1. Mechanical part, related to the engine overhaul,

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

Print P1D32N002 E Base - July 2006

Base - July 2006 Print P1D32N002 E

Section Description Page Date of revision

Print P1D32N002 E Base - July 2006

Base - July 2006 Print P1D32N002 E

CORRESPONDENCE BETWEEN TECHNICAL CODE

- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 8

OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 9

COOLING SYSTEM (4 CYLINDERS) . . . . . . . . . 10

COOLING SYSTEM (6 CYLINDERS) . . . . . . . . . 12

AIR INDUCTION - BOOST DIAGRAM . . . . . . . 15

- AdBlue fluid level gauge control . . . . . . . . . . . . 18

- Exhaust gas temperature sensor . . . . . . . . . . . . 19

- Humidity detecting sensor . . . . . . . . . . . . . . . . 20

Print P1D32N002 E Base - July 2006

Base - July 2006 Print P1D32N002 E

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

Technical Code Commercial Code

Print P1D32N002 E Base - July 2006

Base - July 2006 Print P1D32N002 E

Oil recover from the

Routing of oil under pressure

LUBRICATION SYSTEM LAYOUT

Print P1D32N002 E Base - July 2006

Oil recover from the

Routing of oil under pressure

LUBRICATION SYSTEM LAYOUT

Base - July 2006 Print P1D32N002 E

OIL PUMP Figure 3

NOTE Since the oil pump cannot be overhauled, it shall

The oil pump is controlled directly by the drive shaft.

Print P1D32N002 E Base - July 2006

Oil pressure relief valve

Pressure regulation at 100°C oil temperature:

By-pass valve to cut out clogged oil filter.

Base - July 2006 Print P1D32N002 E

OIL VAPOUR RECYCLING