FPT Newholla w190c F4a

F4A EURO 4
NEF SERIES
Application Bus (SOR)
F4AE3682E
F4AE3682F
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 P1D32N003 E - 1st Ed. 03.2007 10156 Turin - Italy
F4A EURO 4 NEF ENGINES 3
INDEX NEF F4A EURO 4 ENGINES
Section
Updating and Consultation Introduction
General specifications 1
Fuel 2
Application to bus 3
General overhaul and characteristics 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the engines illustrating their 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.
Print P1D32N003 E Base - March 2007
4 F4A EURO 4 NEF ENGINES
Base - March 2007 Print P1D32N003 E

F4A EURO 4 NEF ENGINES INTRODUCTION 1
Introduction
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
PREFACE TO USER’S GUIDELINE MANUAL . 5
- Symbols - Warnings . . . . . . . . . . . . . . . . . . . . . 5
- General warnings . . . . . . . . . . . . . . . . . . . . . . . 6
- General warnings on the electric system . . . . . 8
- Bonding and screening . . . . . . . . . . . . . . . . . . . 9
- Optional electrical and mechanical parts installations 10
- Conversions between the main units of measurement

of the international system and most used derived
quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Graphic figures and symbols . . . . . . . . . . . . . . 11
- Interpretation of symbols . . . . . . . . . . . . . . . . . 12
- Key of lecture of the headings and footnotes . 13

2 INTRODUCTION F4A EURO 4 NEF ENGINES

UPDATE LISTS
Section Description Page Date of revision


PREFACE TO USER’S GUIDELINE MANUAL

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
Symbols - Warnings
Danger for persons

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

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

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

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

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

Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR

d. DISTANCE ! 0

Optional electrical and mechanical parts installations

Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling
directives issued by IVECO Motors.
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
Conversions between the main units of measurement of the international system and most used
derived quantities
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0° C = 32° F
1° C = (1 x 1.8 + 32) ° F

Graphic figures 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
Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Warning
! Preload
Note
Visual inspection
Number of revolutions
Fitting position check
Measurement
Value to find Temperature
Check
Equipment Pressure
bar
Oversized
Surface for machining
Higher than….
Machine finish
Maximum, peak
Undersized
Interference
Less than….
Strained assembly
Minimum
Selection
Thickness
Classes
Clearance
Oversizing
Lubrication Temperature < 0 °C
Damp Cold
Grease Winter
Temperature > 0 °C
Sealant
Hot
Adhesive
Summer
Air bleeding

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

Key of lecture of the headings and footnotes
Type of Section Page

vehicle title number
Printout Language Basic edition referred to When month - year update

number Publication month - year editorial is present (revi) to the
phase closing basic edition


F4A EURO 4 NEF ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 5
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . 6
- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 7
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 8
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AIR INDUCTION - BOOST DIAGRAM . . . . . . . 11
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DeNOx SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 12
- General Information . . . . . . . . . . . . . . . . . . . . 12
- Composition and operation . . . . . . . . . . . . . . . 12
- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Pump module 14
- Dosing module . . . . . . . . . . . . . . . . . . . . . . . . 14
- Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Switch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- AdBlue fluid level gauge control . . . . . . . . . . . . 15
- Exhaust gas temperature sensor . . . . . . . . . . . 16
- Humidity detecting sensor . . . . . . . . . . . . . . . . 16
- Nitric oxide detecting sensor . . . . . . . . . . . . . . 17

2 SECTION 1 - GENERAL SPECIFICATIONS F4A EURO 4 NEF ENGINES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code

F4AE3682E*P100 N60 ENT 4
F4AE3682E*P101 N60 ENT 4
F4AE3682F*P100 N60 ENT 4
F4AE3682F*P101 N60 ENT 4


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

Oil return to sump by fall
72513
Oil inlet
LUBRICATION SYSTEM LAYOUT

OIL PUMP Figure 2
NOTE Since the oil pump cannot be overhauled, it shall be

replaced when damaged.
The oil pump is controlled directly by the drive shaft.
70576
HEAT EXCHANGER
Figure 3
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 4
Pressure regulation at 100°C oil temperature:

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

Figure 5
Figure 6
Flow
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 7
70484
Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).

COOLING SYSTEM - Fan with the purpose to increase radiator dissipation

The engine cooling system, closed circuit forced circulation power: he belongs to the specific outfit as well.
type, generally incorporates the following components:
- An heat exchanger to cool lubrication oil (see
- Expansion tank; placement, shape and dimensions are LUBRICATION).
subject to change according to the equipment.
- Centrifugal water pump, placed in the front part of the
- Radiator, which has the duty to dissipate the heat engine block.
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the - Thermostat regulating the circulation of the cooling
equipment developed, both for what concerns the liquid.
placement and the dimensions. - The circuit may eventually be extended to the
compressor, if this is included in the equipment.
Delivery to heater
Return to heater
Delivery to diverter valve of
AdBlue system (provision)
Return from AdBlue system tank
Water leaving the thermostat
Water recirculating in the engine
Water entering the pump

116785
COOLING SYSTEM DIAGRAM

Water Pump Thermostat

Figure 9 Figure 10
79458
The thermostat (1) of the by-pass type is located in the cylin-

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

AIR INDUCTION - BOOST DIAGRAM
Figure 11
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 SYSTEM Composition and operation

General Information The system is basically made up of:
In order to contain emission of nitrogen oxides (NOx) within - one reactive solution (water - urea : AdBlue) tank with
the limits required by the Euro 4 standard, with low fuel level gauge;
consumption, the vehicles were provided with a system for - one switch valve;
post-processing these substances. The system includes an
- one pump module;
ozidizing catalyst with electronic control.
- one dosing module;
The system, by means of the SCR (Selective catalytic
- one injector;
reduction) process, transforms nitrogen oxides (NOx) into
inert compounds: free nitrogen (N2) and water vapour - one SCR catalytic converter;
(H2O). - two exhaust gas temperature sensors: one at catalyst
inlet, the other at catalyst outlet SCR;
The SCR process is based on a series of chemical reactions
which, by reaction of ammonia with the oxygen of exhaust - one humidity detection sensor mounted on engine air
gases, leads to the reduction of nitrogen oxides (NOx) in the inlet pipe downstream of air filter.
exhaust gases. - one
The recommended temperature range for the SCR process SCR system is electronically managed by DCU15 (Dosing
is between 180 °C and 350 °C. At lower temperatures, Control Unit, D) central unit incorporated in pump module;
conversion is not complete and does not ensure the required the unit regulates the flow rate of the reactive liquid to be let
nitrogen oxides reduction, while at higher temperatures, into the system depending on engine rpm’s, exhaust gas tem-
antagonist reactions occur, so that between 5% and 10% of perature, amount of nitrogen oxides and humidity of air
ammonia is lost in this reaction. sucked in.
The process uses a water solution of urea from which The pump withdraws the reactive solution from the tank,
sends the solution under pressure into the dosing module
ammonia is obtained.
where it is channelled together with compressed air from ve-
hicle pneumatic system and atomised by the injector up-
stream the catalyst.
In the first part of the catalyst, the first step of the process is
performed: under the effect of exhaust gas temperature, the
reactive solution instantaneously evaporates and is con-
verted into ammonia (2NH3) and carbon dioxide (CO2)
through hydrolysis, while, at the same time, exhaust gas tem-
perature is decreased owing to the evaporation of the sol-
ution and approaches the optimum temperature needed to
the process.
Exhaust gasses added with ammonia and subjected to reac-
tion temperature enter the catalyst, where the second step
of the process is performed: ammonia reacts with oxygen
and converts the nitrogen oxides of exhaust gasses into free
nitrogen (N2) and steam (H2O).

Diagram
Figure 12
Engine cooling hot fluid

AdBlue solution
Pressurized air
116669
Air - AdBlue solution mix
SCR SYSTEM LAYOUT

1. Bypass valve - 2. AdBlue solution tank - 3. Level indicator with temperature sensor - A. PUMP MODULE - 4. DCU control
unit - 5. Pressure adjustment valve - 6. Prefilter - 7. Positive-displacement pump - 8. Solenoid valve -
9. Pressure damper - 10. Filter - 11. AdBlue solution pressure sensor - 12 AdBlue solution temperature sensor - B. DOSING
MODULE: 13. Urea capacity control solenoid valve - 14. Air - AdBlue mixing chamber - 15. Temperature sensor of exhaust
gases in input - 16. Nitrogen oxides detecting sensor - 17. Temperature sensor of exhaust gases in output - 18. Catalyzer -
19. Injector - 20. Humidity detecting sensor -
C. Tubing with integrated resistance - D. To the control unit EDC 7UC 31.

Pump module Dosing module

Figure 13 Figure 15
102297 102299
1. Air pressure reducer - 2. Solenoid valve - 1. Connector dosing valve - 2. Injector pipe -
3. Air pressure sensors - 4. Filter - 5. Displacement pump 3. AdBlue inlet - 4. Compressed air inlet.
with pressure control valve and pressure damper -
The function of this module is to dose the AD blue solution
6. UDC15 control unit - 7. AdBlue solution pressure
to be conveyed to the injector.
sensor - 8. AdBlue solution temperature sensor
Injector
Figure 14 Figure 16
102300
102298
1. Compensating valve - 2. AdBlue solution inlet - Its function is to atomize the AdBlue solution in the exhaust
3. Filter - 4. Drain cap (tightening torque: 4+1 Nm) - pipe upstream the catalyst.
5. UDC15 control unit connectors - 6. Compressed
air inlet - 7. AdBlue solution return - 8. AdBlue
solution outlet - 9. Compressed air outlet

Switch valve AdBlue fluid level gauge control

Figure 19
Figure 17
107107
102296
1. Electrical pins - 2. Output - 3. Input 1. AdBlue fluid level gauge command - 2. AdBlue fluid
return pipe - 3. Inlet pipe for hot engine coolant fluid -
- Nominal voltage 24 V DC 4. NTC sensor - 5. Outlet pipe for hot engine coolant
- Working voltage 22 ÷ 32 V DC fluid - 6. Float - 7. AdBlue fluid heater coil
- Nominal current at 24V and 20°C, 0.75 A
- Coolant temperature: -40°C ÷ 125°C
- Working temperature: -40°C ÷ 105°C
- Flow rate: 350 l/h at (P1-P2): 75 mbar
- Maximum pressure: 2.5 bar.
Figure 20
Tank
Figure 18 (Demonstrative) 107109
FUNCTIONAL ELECTRICAL SCHEME
PIN DESCRIPTION
1 Level
2 Earth
3 Temperature
AdBlue liquid level gauge control is a device including: a set

of resistances, a float, an NTC temperature sensor and a pipe
coil for heating the liquid under low temperatures.
It warns the central unit about the variation in current owing
to the resistance, that is determined by float position in con-
109038 nection to AbBlue liquid level.
NTC temperature sensor controls the switch valve, which,
The tank is provided with a level gauge control containing the depending on temperature, either closes or opens the pass-
reducing material needed to SCR process; the material con- age of hot engine coolant in heating coil.
sists of a 35% aqueous urea solution, named AdBlue.

Exhaust gas temperature sensor

Figure 21
102303
The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to
calculate the amount of urea to be injected into the system.
Humidity detecting sensor

Figure 22
114521
1. Humidity percent value - 2. Power supply - 3. Temperature - 4. Earth

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.
Nitric oxide detecting sensor

Figure 23
102302
1. Positive - 2. Earth - 3. CAN L line - 4. CAN H line - 5. Free

The function of this sensor is to inform the control unit of the AdBlue (urea) fluid dosing and catalyst efficiency.


F4A EURO 4 NEF ENGINES SECTION 2 - FUEL 1
SECTION 2
Fuel
Page
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . 3
- General Specifications . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 5
FUEL SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . . 6
FUEL PREFILTER . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MECHANICAL FEEDING PUMP . . . . . . . . . . . . 8
- Ordinary working condition . . . . . . . . . . . . . . . 8
- Overpressure condition in exhaust unit . . . . . . 8
- Bleeding condition . . . . . . . . . . . . . . . . . . . . . . 8
CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . 9
- Internal structure . . . . . . . . . . . . . . . . . . . . . . . 10
- Operating principle . . . . . . . . . . . . . . . . . . . . . 11
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OVERPRESSURE VALVE . . . . . . . . . . . . . . . . . . . 13
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Injector in rest position . . . . . . . . . . . . . . . . . . 14
- Injection start . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Injection end . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRESSURE LIMITER FOR FUEL RETURN . . . . . . 14

2 SECTION 2 - FUEL F4A EURO 4 NEF ENGINES

HIGH PRESSURE ELECTRONIC INJECTION SUPPLY SYSTEM (COMMON RAIL)

General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 1
119094
1. Injectors connections - 2. Engine coolant temperature sensor - 3. Fuel pressure 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
119166
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 The pressure relief valve (2) intervention brings about a fuel
This fuel system is a Common Rail injection with CP3 high flow increase in the high-pressure pump cooling circuit,
pressure pump and this layout is for 6 cylinder version. through inlet and drain piping (16) from piping (8).
The pressure regulator, placed upstream of the high-pressure The pressure relief valve housed on the cylinder head, as-
pump, adjusts the fuel flow that is necessary on the low-pres- sembled on injector return (3), limits the fuel return flow
sure system. Afterwards, the high-pressure pump takes care from injectors at a pressure of 1.3 to 2 bars.
of supplying the rail properly. This arrangement, by pressuris- Two by-pass valves are placed in parallel with the mechanical
ing the necessary fuel only, improves the energetic efficiency supply pump.
and limits fuel heating in the system.
The by-pass valve (18) allows fuel to flow from mechanical
Function of the pressure relief valve (2), assembled on the pump outlet to its inlet, when the fuel filter inlet pressure ex-
high-pressure pump, is keeping the pressure, at the pressure ceeds the allowed threshold value.
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream. The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
Figure 3
EXHAUST
INTAKE (LOW PRESSURE)
HIGH-PRESSURE PUMP SUPPLY

(LOW PRESSURE)
HIGH PRESSURE
108608
1. High-pressure pump. — 2. Pressure relief valve on high-pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel
return from injectors, 1.3 to 2 bars. — 4. Rail overpressure valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. —
8. Return piping. — 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. —
12. Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High-pressure pump cooling
piping. — 17. By-pass valve. — 18. By-pass valve.

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 Bleeding condition

Gear pump, placed on rear part of the high pressure pump,
Figure 8
whose function is to feed the high pressure pump. It is driven
by the high pressure pump’s shaft.
Ordinary working condition
Figure 6
72594
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.

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

Operating principle
Figure 11
Sec. B - B
Sec. D - D
72597
1. Fuel exhaust connector to rail - 2. By-pass valve to common rail - 3. Pumping element - 4. Pump’s camshaft
5. 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 Figure 14
supply pressure is suitable to open the delivery valves set on
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; 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.
The thereby-generated pressure makes the exhaust valve
107422
open and the compressed fuel reaches the high-pressure
circuit.
The pumping element compresses the fuel till the top dead 1. Rail. — 2. Pressure sensor. — 3. Fuel inlet from
center (delivery stroke) is reached. Afterwards, the pressure high-pressure pump — 4. Overpressure valve.
decreases till the exhaust valve is closed. The rail volume is of reduced sizes to allow a quick
The pumping element piston goes back towards the bottom pressurisation at startup, at idle and in case of high flow-rates.
dead center and the remaining fuel is decompressed. It anyway has enough volume as to minimise use of plenum
chambers caused by injectors openings and closings and by
When the pumping element chamber pressure becomes less the high-pressure pump operation. This function is further
than the supply pressure, the intake valve is again opened and enabled by a calibrated hole being set downstream of the
the cycle is repeated. high-pressure pump. A fuel pressure sensor (4) is screwed to
The delivery valves must always be free in their movements, the rail. The signal sent by this sensor to the electronic
free from impurities and oxidation. control unit is a feed-back information, depending on which
the rail pressure value is checked and, if necessary, corrected.
The pressure of fuel delivered to rail is modulated by
electronic control unit through pressure regulator solenoid
valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection — reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are OVERPRESSURE VALVE
absolutely clean.
Overpressure valve is mounted at one rail end. Overpressure
valve task is to protect system components should rail
pressure sensor or CP3 pump pressure regulator
malfunctioning cause a pressure excessive increase in high
pressure system. When pressure in rail is reaching 1750 bar,
the valve at start operates in order to make fuel flow and
consequently decrease pressure to safety values, then
mechanically regulates pressure in rail. The valve enables to
operate engine for long times with limited performance and
prevents fuel excessive overheating, so preserving pipes for
fuel return to 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
F4A EURO 4 NEF ENGINES SECTION 3 - BUS APPLICATION 1
SECTION 3
Application to vehicles
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
GENERAL PROPERTIES . . . . . . . . . . . . . . . . . . . 4
PART ONE - MECHANICAL COMPONENTS 5
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 7
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Engine setting operations for the assembly

on turning stand . . . . . . . . . . . . . . . . . . . . . . . 7
- Distribution gear box . . . . . . . . . . . . . . . . . . . 15
- Distribution timing . . . . . . . . . . . . . . . . . . . . . . 15
- Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . 16
- Engine flywheel . . . . . . . . . . . . . . . . . . . . . . . . 17
- Tappet play adjustment . . . . . . . . . . . . . . . . . . 24
- Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . 25
- Wiring support . . . . . . . . . . . . . . . . . . . . . . . . 27
- Poly-V belt tension value . . . . . . . . . . . . . . . . . 31
- Turbosupercharger . . . . . . . . . . . . . . . . . . . . . 32
- Check and adjustment Turbosupercharger

actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Turbosupercharger actuator replacement . . . . 33
- Checks and inspections . . . . . . . . . . . . . . . . . . 34
PART TWO - ELECTRICAL EQUIPMENT . . . 35
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 37

2 SECTION 3 - BUS APPLICATION F4A EURO 4 NEF ENGINES
Page Page
- Overview of sensors . . . . . . . . . . . . . . . . . . . . 38 PART FOUR - MAINTENANCE PLANNING . 89
ECM ELECTRONIC CONTROL UNIT (EDC 7) 39 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 91
- Electroinjectors connector . . . . . . . . . . . . . . . . 40 - Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
- Sensors connector . . . . . . . . . . . . . . . . . . . . . . 41 - Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . . 91
- Frame connector . . . . . . . . . . . . . . . . . . . . . . 42
- Inspection and/or maintenance interventions . 91
ECM CENTRAL UNIT COMPONENTS (EDC 7) 43
- Unscheduled and set-interval operations . . . . . 92
- Engine wiring (topographic) . . . . . . . . . . . . . . . 47
MAINTENANCE PLANNING . . . . . . . . . . . . . . 93
- Engine wiring (Diagram) . . . . . . . . . . . . . . . . . . 48
- Engine oil level check. . . . . . . . . . . . . . . . 93
- Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 50
- Check of fuel system . . . . . . . . . . . . . . . . 93
- Pressure regulator - high pressure pump . . . . . 52
- Lubricating system check . . . . . . . . . . . . . 93
- Electroinjector . . . . . . . . . . . . . . . . . . . . . . . . . 53
- Cooling system check . . . . . . . . . . . . . . . 93
MAIN POWER COMPONENTS . . . . . . . . . . . . 55
- Check of belt’s tear and wear status . . . . 93
- Alternators: main and secondary . . . . . . . . . . . 55
- Changing engine oil . . . . . . . . . . . . . . . . . 94
- Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . 56
- Changing engine oil filters . . . . . . . . . . . . 95
PART THREE - TROUBLESHOOTING . . . . . . 57
- Changing fuel pre-filter . . . . . . . . . . . . . . . 95
PT-01 PORTABLE TESTER . . . . . . . . . . . . . . . . . 59
- Changing fuel filter . . . . . . . . . . . . . . . . . . 95
- Main functions . . . . . . . . . . . . . . . . . . . . . . . . . 59
- Changing miscellaneous drive belts . . . . . 96
- Test parameters . . . . . . . . . . . . . . . . . . . . . . . . 59
- Connect - reconnect and clean AdBlue
DTC ERROR CODES system pre-filter . . . . . . . . . . . . . . . . . . . . 96
WITH EDC7 CENTRAL UNIT . . . . . . . . . . . . 61
- Checking valve clearance and adjustment
GUIDE TO DIAGNOSIS THROUGH SYMPTOMS 85 if necessary . . . . . . . . . . . . . . . . . . . . . . . . 96

GENERAL SPECIFICATIONS
Figure 1
119091
F4AE3682 ENGINE
The NEF F4A Euro 4 engines are characterised by four-stroke The section herein described is composed or four sections:
diesel cycles supercharged with 4 or 6 cylinders with 4 valves
- Section of mechanical overhaul prescribed in accordance
per cylinder.
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
F4AE3682F
F4AE3682F* F4AE3682F
F4AE3682F* F4AE3682E
F4AE3682E* F4AE3682E
F4AE3682E*
P100 P101 P100 P101
Type
ρ Compression ratio 17 : 1
Max. output kW 185 185 194 194
rpm 2700 2700 2500 2500
Max. torque Nm 850) 850 1000 1000

rpm 1250 1250 1250 1250
Loadless engine
idling rpm 650
Loadless engine
peak rpm 3000
Bore x stroke 102 x 120
Displacement cm3 5880

TURBOCHARGING with intercooler
Turbocharger type HOLSET HX 35 W

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
Total capacity
ACEA E3/E5 - engine sump
Urania LD5 litres 14.8
kg 13.3
engine sump + filter
litres 15.8
kg 14.2
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.

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
85507
Disconnect lines (3 and 7) from fittings (4 and 6) and

compressor (8).
Disconnect fuel line (2) from rail, unlocking fitting (1) from
high pressure pump (9) and disconnect it from cylinder
removing mount screws (4 and 6).
114554
NOTE When unlocking the pipe (2) union (5), it is necessary
to prevent the union rotation of the high-pressure
In order to apply to the engine block the engine fixing 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 and 6) 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
119094
1. Connections for injectors - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil pressure and
temperature sensor - 5. Engine shaft sensor - 6. Control unit EDC7 - 7. Pressure adjuster -
8. Fuel temperature sensor and fuel heater - 9. Timing phase sensor - 10. Temperature-air pressure sensor - 11. Injector
Disconnect engine cable by releasing connectors from: Figure 7

- electroinjector wiring (11);
- air temperature-pressure sensor (10);
- fuel pressure sensor (3);
- EDC 7 ECU (6),
- pressure regulator (7);
- timing phase sensor (9);
- engine coolant temperature sensor (2);
- engine rpm sensor (5);
- engine oil temperature-pressure sensor (4);
- fuel temperature sensor (8).
Remove alternator belts from hydrofan pump.
Remove pump from engine.
85508
Unscrew the screws (7), remove the bracket (6), and remove
the alternator (1).
Remove the oil level piping (2).
Detach the automatic belt tightener (5), the roller (3), and
the alternator (4).
Figure 8 Figure 10
74744
107247
Remove the nuts (7) and disconnect the electric wires from
Remove from the rail (2): the fuel pipe (3) according to the the injectors (8).
procedures described in Figure 14. Remove the fuel pipe (5)
from the rail (2) and from the manifolds (4) for injectors. Remove the screws (1) and remove the injector harness
support (2) complete of gasket.
Remove the screws (5) and remove the air
pressure/temperature sensor (6).
Remove the nuts (3) and withdraw the fuel manifolds (4).
The removed fuel manifold (4) shall not be used

! again and they must be replaced by new ones.
Figure 9
Figure 11
107248
Disconnect pipe (2) from fuel return pressure limiting device 70132
(1) as described in Figure 14.
Remove screw (7). Loosen spring strip (3) and disconnect oil Loosen the tappet adjuster fixing nuts (1) and unscrew the
vapours pipe (10). adjuster.
Remove the screws (2), remove the equalizer unit (3)
Remove fittings (6 and 4) and disconnect pipe (5).
composed by the support (6), equalizers (4), shafts (5) and
Remove nuts (9) and take off tappets cover (8) complete remove the bonds (7) from the valves. Remove the rods (8)
with gasket.

Figure 12 Figure 14
114556
Remove the oil pipe (6) from the oil filter/ heating exchanger
support (5).
70133
Remove the nuts (3) and remove the turbosupercharger (4)
from the exhaust manifold (1).
Remove the injector fixing screws and by means of tool
99342101 (1) withdraw the injectors (2) from the cylinder Remove the screws (2) and remove the exhaust manifold (1)
head. from the cylinder head.
Figure 15
Figure 13
85510
Remove the screws (1) and remove the air conveyor (2)
complete of heater. Remove the screws (4), remove the
cover (3) and the relevant thermostat.
116783
Remove the head cylinder (6) fixing screws (5).
Remove the screw (2), loosen the clamp and remove the air
conveyor (1) from the turbosupercharger (5)
The external screws pointed out are shorter.
Unscrew nipple (4) and remove oil pipe (3) from
turbocharger (5). !

Figure 16 Figure 19
74779 70142
Hook the brackets (1) with metal ropes and remove the Remove the screws (1) and the electronic control unit (2)
cylinder head (2) from the block by means of a hoister. complete of heating exchanger.
Remove the cylinder head gasket.
Figure 17
Figure 20
114558
Remove the screws (2) and remove the alternator support 85511
(3).
Remove the oil filter (1) by means of tool 99360076. Using wrench 99355019, remove the screws (1 and 3) and
disconnect the power steering pump (2) from the air
Figure 18 compressor (4).
Figure 21
74777
Remove the screws (4) and remove oil
temperature/pressure sensor.
72505
Remove the screws (1) and remove the oil filter/heating Remove the screws (2) and the nuts (1-4) and remove the
exchanger support (2), middle plate (6) and relevant gaskets. air supercharger (3)
Remove the oil level sensor (5)

Figure 22 Figure 25
70148
Remove the screws (1) and remove the water pump (2).
70145
Remove the screws (3) and remove the roller (4).
Remove the nut (1) and remove the phase sensor (2).
Remove the screws (5) and remove the rpm sensor (6).
Remove the nuts (3) and remove the high-pressure pump (4)
complete of power supply pump (5). Figure 26
Figure 23
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 24 screw (3).
Figure 27
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 28 Figure 31
107261
70152
Remove the screws (1 and 3) and take out the front cover (2).
Screw two pins (2) exhibiting a proper length into the engine
shaft holes (3).
NOTE Write down the screw (1) assembling position Remove engine flywheel, where present, (1) to allow slinging
because they exhibit different lengths. with lifting device and place it in container.
NOTE Engine F4AE3682E*P101 is not equipped with

Figure 29
flywheel.
Figure 32
70150
Remove the screws (1) and remove the oil pump (2).
NOTE It is not possible to overhaul the oil pump (2).
Figure 30
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 27.
engine shaft (4).

Figure 33 Figure 35
114560
119081
Remove the screws (1) and remove the rear cover (2).
Remove the screws (1) and remove the oil suction rose (3).
Write down the screw (1) assembling position Remove the screws (2) and remove the stiffening plate (4).
! because they exhibit different lengths.
Figure 36
Figure 34
70156
Remove the screws (1) and remove the gear (3) from the
camshaft (2).
72506 Figure 37
Overturn the engine.
Remove the screws (2) and detach the oil sump (1).
70157
Remove the screws (2) and the timing gearcase (1).
Write down the screw (2) assembling position

! because they exhibit different lengths.

Distribution gear box Figure 39

Figure 38
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 40
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 41
Perfect seal is only obtained by cleaning accurately
! the surface to seal.
Smear the case with LOCTITE 5205 to obtain a bead
of few mm diameter.
It shall be uniform (no clots), without air bubbles, thin
areas or discontinuities.
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 44
Figure 42
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 43 Screws M10 44 to 53 Nm
NOTE Before any assembly operation always verify that

wear or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS

Figure 45 Figure 47
70152
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
70216 hoister.
Apply on the rear tang (6) of the driving shaft part (5) of Figure 48
’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 46
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 49
α
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

Check ring gear teeth (2), if breakage or excessive wear is stages:
found remove the ring gear from the engine flywheel (1) - 1st stage, tightening to 30 ± 4 Nm torque with
using a suitable hammer and fit the new one, previously dynamometric wrench;
heated to 150°C for 15 to 20 minutes. Chamfering on ring - 2nd stage, tightening to 60° ± 5° angle.
gear inside diameter shall be facing the engine flywheel.
NOTE Tightening to angle is performed using tool
99395216.
NOTE Il motore F4AE3682E*P101 non è fornito di Before any assembly operation always verify that
volano motore. the hole and screw threads have no evidence of
wear or dirt.

Figure 50 Figure 53
70223
70220
Remove the sealing ring (2) from the front cover (1), clean
Fit the oil pump (1).
accurately the coupling surfaces and smear them with IVECO
Tighten the fastening screws (2) to the specified torque. nr. 2992545.
Figure 54
Figure 51
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 55
Figure 52
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 56 Figure 59
119081 70363
Fit the plate (1), the rose pipe (2) and tighten the fastening Fit the phonic wheel (1) and the hub (2) on the output shaft.
screws (3) to the specified torque.
Tighten the fastening screws (3) in two stages:
Figure 57 - 1st stage, tightening to 50 ± 5 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 90° angle.
Tightening to angle is performed using tool

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

Tighten the fastening screws (7) to 68 ± 7 Nm torque.
85518
Set the gasket (1) on the oil sump (2).
If not faulty the gasket can be reused. Figure 60

! r
Figure 58
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.
72506
Fit the oil sump (1).


Figure 61 Figure 63
70231 70234
Fit on the engine block: a new gasket (1), the heat exchanger Position the alternator support (1) so that pins (3 and 4) are
(2) a new gasket (3) and the oil filter support (4). set against the engine block.
Tighten the screws (5) to the specified torque. Tighten the screws (2) to the specified torque.
Figure 64
Figure 62
107276
70145
Lubricate the sealing ring (6) with engine oil and set it on the
oil filter (4). Refit the high pressure pump (5) including the feed pump (6)
and tighten the nuts (3) to the specified torque. Fit the
Screw manually to seat the oil filter (4) on the support support (4) with a new sealing ring, the timing sensor (2) with
connection (3) and then screw again the oil filter (3) by ¾ a new sealing ring and tighten the relevant fastening nut (1)
turn. to the specified torque.
Apply a new sealing ring on the oil temperature/pressure
sensor (8) and fit it on the support (3).
Fit a new sealing ring (5) in the engine block seat.
Mount oil delivery pipe (1) screwing nipple (2).
Mount oil level sensor.

Figure 65 Refit the ECU (3) including the heat exchanger to the engine
block and tighten the screws (2) to the specified torque.
Replace support elastic elements (1).

!
Figure 68
72505
Refit the air compressor (3). Tighten the screws (2) and the
nuts (1 and 4) to the specified torque.
Figure 66
70137
Apply a new gasket to the engine block and then place the
cylinder head (2) slung by the hanger brackets (1).
Figure 69
85511
Reconnect the power steering pump (2) to the air

compressor (4).
Screw and tighten the fastening screws (1 and 3) to the
specified tightening torque. α
Figure 67
70336
Assemble cylinder head (1), tighten the screws (2) in three

following steps, following order and mode shown in the
figure below.
NOTE The angle tightening is carried out through tool

99395216 (3).
Before any assembly operation always verify that
wear or dirt.
70320

Figure 70 Figure 72
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.
NOTE Before using the fixing screws again, measure them

twice as indicated in the picture, checking D1 and Figure 73
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced.
D2 D1
75703
Figure 71
70133
Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).

Figure 74 Figure 76
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 77
NOTE Disassembled fuel manifolds (2) must not be used

again. Replace with new items.
Screw the fastening nuts (2, Figure 75) 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 72). 70344
SHAFT-ROCKER MAIN DATA

Check that shaft/rocker coupling surfaces are not showing
Figure 75 excessive wear or damages.
Figure 78
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 79 Tappet play adjustment

Figure 81
70520
70345
Adjust clearance between rockers and valves using setscrew
Fit the rods (2). wrench (1), box wrench (3) and feeler gauge (2).
Position jumpers (1) on valves with marks (→) facing the Clearance shall be as follows:
exhaust manifold. - intake valves 0.25 ± 0.05 mm
- exhaust valves 0.50 ± 0.05 mm.
Figure 80
In order to more quickly perform the operating

clearance adjustment for rocker arms — valves,
proceed as follows:
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 - * - * - *
Rotate the drive shaft, balance cylinder 6 valves and
adjust the valves marked by the asterisk as shown in
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 79) when refitting the rocker exhaust * - * - * -
assembly.
Then refit the rocker assembly consisting of: bracket (5),
rockers (3), shafts (4) and secure them to the cylinder head
by tightening the fastening screws (2) to 36 Nm torque.

Intake manifold
Figure 82
112876
In inlet manifold (3), air heater (5) for cold start-up is housed.
In case of operation faults in air heater (5), the heater has to be replaced.
In replacing air heater (5), you have to operate as follows:
- Remove screws (6) securing heater (5) to inlet manifold (3).
- Take heater (5) off inlet manifold (3) together with relating gasket (4).
Fit new heater (5) into the seat of inlet manifold (3) inverting dismounting operations.
Apply a new seal ring to air temperature/pressure sensor (2) and mount the sensor on intake manifold (3) tightening screw
(1) at prescribed torque.

Figure 83 Figure 85
114801 107287
Apply LOCTITE 5999 on intake manifold (1) connection

surface. Connect fuel new pipes (1) to rail (3) and to electric injector
manifolds (2).
Mount intake manifold (1) on cylinder head.
Connect new pipe (5) to rail (3) and high pressure pump (8)
Screw screws (2) and tighten them at prescribed torque.
screwing nipples (4 and 7).
Secure pipe(5) to engine block by screws(6).
NOTE Pipes (1 and 5) are subjected to high pressures;

consequently, the must always be replaced at every
dismounting operation.
The fittings of pipes (1 and 5) must be tightened at
20 Nm torque by using wrench (4) and torque
wrench 99389829.
Figure 84
107286
Mount rail (2) on cylinder head (3).

Tighten securing screws (1) at prescribed torque.

Wiring support Figure 89

Figure 86
74756 74757
Check electrical cable (5) conditions, replace if damaged by Fit a new gasket (2) on the tappet cover (1).
cutting the support (2) clamps and removing the screws (4)
that secure it to connections (3).
Fit a new gasket (1) on the support (2).
Figure 87 Figure 90
99227 107411
Fit the wiring support (2) and tighten the screws (1) to the Fit the tappet cover (2) and tighten the nuts (1) to the
specified torque. specified torque.
Figure 88 Figure 91
99228 107412
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 92 Figure 94
114802
Reconnect the turbosupercharger (3) with a new gasket to

the exhaust manifold (1) and tighten the fastening nuts (2)
to the specified torque.
Connect oil pipe (4) to turbocharger (3).
107415
Connect pipe (2) to air compressor fitting (1) and head fitting
(4).
Fit, into fitting located on timing system box (7), oil vapours
pipe (5) and constrain it by spring strip (6).
Mount a new seal ring (14) on pipe (5) and fit the fitting of
oil vapours pipe (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 to timing system box (7).
Connect fuel return pipe (3) to pressure limiting device, rail
and high pressure pump as described at next figure
Figure 93
Figure 95
116784
117186
Connect the air duct (3) to the turbosupercharger (2) and

lock it by clamp (1).
Secure the air duct (3) to the alternator support by screws
(4).
NOTE Check proper fuel pipe connection.

Figure 96
119094
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. EDC7 control unit - 7. Pressure regulator - 8. Fuel heater and fuel temperature
sensor - 9. 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 97 Figure 99
85507
From the left side:

Connect the fuel piping (2) to the rail by means of the union
(1), to the high-pressure pump (9) by means of the union
(5), and fasten it to the engine block with the specific clamps
tightening the screws to the specified torque wrench setting.
85519 The unions of the piping (2) must be tightened to a

Fit the alternators (1 and 4), the roller (3), and the bracket ! torque wrench setting of 20 Nm using a suitable
(7) tightening the fastening screws to the specified torque wrench and torque wrench 99389834.
wrench setting. The union (5) must be tightened by keeping the
Refit the automatic belt tightener (5). Screw the screw (6) union of the high-pressure pump still at the same
and tighten it to the specified torque wrench setting using the time (9).
specific wrench, turning the automatic belt tightener (5) in The piping (2) must be replaced with new piping
order to put the belt (8) on the pulleys and on the guide each time it is removed.
rollers. Connect the piping (3 and 7) to the unions (4 and
Fit the oil level piping (2). 6) and to the air compressor (8).
107249
Complete engine refitting as follows:

Form the right side:
reconnect starter (2) to flywheel covering box and tighten
securing nuts (3) at prescribed torque.
Fit the oil pipe (4) with a new sealing ring into the engine
block and secure it to the turbosupercharger (1) by the
screws (5) tightened to the specified torque.

Figure 100
114804
Reconnect fuel filter support (1) to engine block; screw

screws (2 and 3) and tighten them at prescribed torque.
Manually screw fuel filter (4) on support (1) up to ledge;
screw filter for 3/4 turn.
Connect pipes (5-6-7) to their fittings on support (1) as
described in next figure.
Figure 101
117186
To connect low pressure fuel line to fitting , insert the latter

in quick coupling fitting (2) and press till clip is properly
inserted in seat (1).
NOTE Check proper fuel pipe connection.
When refitting is over, fill engine with the prescribed

lubricating oil in the specified quantity.
Poly-V belt tension value
Function Belt value as Value with

new used belt
(N) (N)
Water pump/alternator 1060 ÷ 1295 628 ÷ 785

Turbosupercharger
Figure 102
114805
GARRET TURBOSUPERCHARGER
The booster system is composed of: air cleaner,

turbosupercharger and intercooler.
Verifying an anomalous operation of the engine, due
The air cleaner is a dry type composed of a filtering cartridge ! to the booster system, it is recommended, before
that is periodically changeable. performing controls on the turbosupercharger, to
check the efficiency of the sealing gaskets and the fix-
The turbosupercharger has got the function of using the ing of the connection sleeves, making sure of clog-
energy of engine exhaust gas in order to send pressure air to ging absence inside intake sleeves, air cleaner or in-
the cylinders. side radiators. If the turbosupercharger damage is
It is essentially composed of: due to a lack of lubrication, check that the oil circula-
tion pipes are not broken or obstructed, in such case
- a main body where a shaft supported by bushes is replace them or eliminate the trouble.
located. At the ends of the bushes the turbine rotor and
compressor rotor are fitted;
- a turbine body and a compressor body fitted on the end
of the main body;
- a waste gate valve applied on the turbine body used for
determining the portion of exhaust gases and sending a Bearing end play check
part of them directly to the exhaust pipe, when the Position the tracer point of the magnetic-base dial gauge on
booster pressure downstream the supercharger reaches the turbosupercharger shaft end and set to zero the dial
the calibration value; gauge.
- the intercooler is composed of a radiator applied on the Move the turbosupercharger shaft axially and check that the
engine coolant radiator, and it is used for lowering the clearance is not higher than the prescribed value.
temperature of the air coming out from the
turbosupercharger to send it to the cylinders. Replace the turbosupercharger if a different value is found.

Check and adjustment Turbosupercharger Turbosupercharger actuator replacement

actuator
Figure 104
Figure 103 (Demonstrativ
62873
114806
Cover the air, exhaust gas and lubrication oil inlets and
outlets. Remove the elastic clip (4) and withdraw the tie rod (3) from
the lever (5).
Carry out an accurate external cleaning of the
turbosupercharger, using the anticorrosive and antioxidant Remove the nuts (2) and remove the actuator (1) from the
solution and perform the check on the actuator (6). supporting bracket. Fit the new actuator following the re-
moval operations in reverse order and fitting a new clip (4),
Clamp the turbosupercharger in a vice. tighten the nuts (2) to 5.6 — 6.8 Nm torque.
Disconnect the pipe of the actuator (6) and apply to the Check and adjust the actuator (1), if required, as described
actuator union, the pipe of pump 99367121 (1). in the relevant chapter.
Apply the magnetic-base dial gauge (2) on the exhaust gas Then, paint the nut (6) with safety paint.
inlet flange in the turbine.
Before refitting the turbosupercharger on engine, fill the
Position the tracer point of the gauge (2) on the tie rod (3) central body with engine oil.
end and set to zero the gauge (2).
Through the pump (1) let in compressed air, in the actuator
(6), at the prescribed pressure and make sure that such value
is kept constant for the whole check time, otherwise replace
the actuator (6).
In the above-mentioned conditions, the tie rod must have
carried out the prescribe stroke.
During the operation, beat slightly the actuator (6)

! in order to eliminate possible sticking of the actuator
internal spring.
If a different value is found, loosen the nut (5) and operate

properly the knurled ring nut (4).

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
Figure 105
119095
ENGINE VIEW LEFT SIDE

1. First Alternator - 2. Second Alternator - 3. Drive shaft revolution number sensor - 4. Engine Control unit -
5. Heater and fuel temperature sensor - 6. Rail pressure sensor - 7. Connections for electroinjectors -
8. Engine coolant temperature sensor.
Figure 106
119096
ENGINE VIEW RIGHT SIDE
1. First Alternator - 2. Second Alternator - 3. Engine oil pressure /temperature sensor - 4. Starter motor.

Overview of sensors
Figure 107
119097
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 (EDC 7) ECU
Figure 108
117333
CONNECTOR VIEW
1. Chassis connector - 2. Sensor connector - 3. Electroinjector connector - 4. Atmospheric pressure sensor

Electroinjectors connector
Figure 109
12 16
6 11
1 5
50350
Cable
Pin Function
Colour
1 CL Cylinder 5 injector
2 CB Cylinder 6 injector
3 CN Cylinder 4 injector
4 MB Cylinder 1 injector
5 MV Cylinder 3 injector
6 HR Cylinder 2 injector
7 - -
8 - -
9 V Pressure regulator solenoid valve (pin 1)
10 C Pressure regulator solenoid valve (pin 2)
11 MN Cylinder 2 injector
12 HN Cylinder 3 injector
13 HG Cylinder 1 injector
14 VB Cylinder 4 injector
15 VN Cylinder 6 injector
16 VG Cylinder 5 injector
Color legend
A light blue L blue V green
B white M brown W hazelnut
C orange N black Z violet
G yellow R red
H grey S pink

Sensor connector
Figure 110
107769
Pin Color Cable Function

1÷8 - -
9 B Timing sensor signal
10 R Timing sensor ground
11 - -
12 BZ Rail pressure sensor ground
13 HN Rail +5V pressure sensor supply
14 RV Rail pressure sensor signal
15 CV Water temperature sensor signal
16 - -
17 - -
18 CN Fuel oil temperature sensor ground
19 B Flywheel sensor ground
20 - -
21 - -
22 - -
23 R Flywheel sensor signal
24 GV Oil temperature and pressure sensor ground
25 GN Air temperature and pressure sensor ground
26 BG Water temperature sensor ground
27 GR Oil temperature sensor ground
28 NS Oil temperature sensor signal
29 -
30 -
31 -
32 MN Oil pressure sensor supply + 5 V
33 CR Air pressure sensor supply + 5 V
34 LN Air pressure sensor signal
35 BL Fuel oil temperature sensor signal
36 BH Air temperature sensor signal
Color legend
A light blue L blue V green
B white M brown W hazelnut
C orange N black Z violet
G yellow R red
H grey S pink
Frame connector
Figure 111
71 89 72 54 6 11
1
7
12
53 35 18 36 17
50350
Cable colour
Ref. Function
code
1 - -
2 - Positive (+30) of central unit power supply
5 - Earth
6 - Earth
7 - -
10 - Earth
11 - Earth
12 - Positive for thermal start-up unit relay insertion
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - Humidity sensor
32 - Positive from start button from engine compartment
33 - Engine rpm’s
34 - CAN - L line
35 - CAN - H line
40 - Positive (+15) from IBC3
47 - Positive from stop button from engine compartment
55 - Engine brake solenoid valve negative
58 - Engine brake solenoid valve positive
75 - Negative for thermal start-up unit relay insertion
89 - K ECM line
Figure 112 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 113 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 114 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 115 Figure 116
180 ± 15
2
3 1
8518 8519
TECHNICAL VIEW WIRING DIAGRAM
Figure 117
8520
PERSPECTIVE VIEW
ECM Control unit Pin

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

Fuel temperature and pressure sensor

Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value
(feedback).
The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection
command.
This sensor is connected to the control unit on pins 12C - 14C- 13C.
The power supply is 5 Volt.
Figure 118
0051065t
Fuel pressure sensor connector
Ref. Description ECU pin

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

Figure 119 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 120 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

Engine wiring (Topographic)

Figure 121
10
11
1
6
13
12
5
115708

Engine wiring (Diagram)

Figure 122
1 2 8 5 10
13
12
11 6 7 3 9 4 115709

Engine wiring legend
Component
code Description
1 Cylinders 1 and 2 injection

2 Cylinders 3 and 4 injections
3 Water temperature sensor
4 Oil temperature/pressure sensor
5 Engine rpm sensor
6 RAIL temperature/pressure sensor
7 Air temperature/pressure sensor
8 Cylinders 5 and 6 injectors
9 Fuel oil temperature sensor
10 Phase sensor
11 Pump pressure adjustment sensor
12 Signal connector
13 Power connector

Fuel pre-filter Figure 123

The water separation type fuel filter is mounted on the right
hand side of the vehicle frame and has, on the cartridge base
3, a sensor 4 detecting the presence of water in the fuel.
The filter support houses a manual priming pup 5 and a screw
2 to bleed the air from the system.
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 124

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 125

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 (if present) Figure 126

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 127

Pump with 3 radial pistons controlled by the timing gears,
requiring no phase adjustment, with rotor type feed pump
fitted to the back.
A. 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 128

The injector features a traditional construction, save for the
fact that it has no needle return springs.
The electroinjector essentially consists of two parts:
- actuator - atomiser consisting of a pressure rod 1, a
needle 2 and nozzle 3;
- 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 129
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 130
1 2 3
50343
WIRING DIAGRAM OF THE CONNECTIONS
Figure 131
1 2 3 4 5 6
1 2 3
FAN SIDE
50349
Ref. Description Control unit Pin

1 Cylinder 2 injector 11
CONNECTOR 1
CONNECTOR 2
CONNECTOR 3

MAIN POWER COMPONENTS

Alternators: main and secondary
NOTE The secondary alternator is only present in the F4AE3682E engines
Figure 132
B+
S
L(D+)
7998
IG(15)
Technical view
Figure 133 Figure 135
A
8003
Wiring diagram
A. Alternator - B. Voltage regulator
Figure 134
8002
Managing the alternating current supply
Specifications
Rated voltage 28 V
Rated current 90 A + 140 A
Current at environmental temperature 1800 RPM/40 A
at 25 ºC and rated voltage 6000 RPM/10 A
8000
Clockwise direction of rotation,viewed from pulley
Voltage regulator temperature specifications Weight 7.8 kg
(6000 rpm)

Starter motor
Supplier BOSCH
Rated voltage 24V
Rated power 4kW
Figure 136
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


Checks to
be Measuring Values to be
DTC Failing component Visible failures Possible causes Repair actions Remarks
performed conditions detected
113 ACCELERATOR Vehicle acceleration Accelerator pedal and Check the accelerator
Print P1D32N003 E
PEDAL/BRAKE very slow. brake pressed pedal signal and pedal
PEDAL SUSPECT simultaneously (for mechanical movement.
Engine idle speed: 500
too long);
rpm.
F4A EURO 4 NEF ENGINES
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.
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.
SECTION 3 - BUS APPLICATION
63
Base - March 2007

64
Checks to
126 BATTERY Possible problems Alternator or battery Check wiring.
Base - March 2007

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
NG (ACTIVE)
Print P1D32N003 E
Checks to
131 COOLANT No reaction noticeable Sensor short-circuited Check the wiring. Replace
Print P1D32N003 E
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.
65
Base - March 2007

66
Checks to
138 OIL PRESSURE No reaction perceivable Sensor short-circuited Check the wiring and oil
Base - March 2007

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.
Print P1D32N003 E
Checks to
144 FAULT BETWEEN No reaction noticeable Signal interrupted or Check wiring and
Print P1D32N003 E
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.
67
Base - March 2007

68
Checks to
153 FAULT ON THE Possible loss of Possible pressure Check the possible causes
Base - March 2007

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.
Print P1D32N003 E
Checks to
156 HIGH PRESSURE Possible loss of High pressure system: Check the possible causes
Print P1D32N003 E
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.
69
Base - March 2007

70
Checks to
158 HIGH PRESSURE Possible loss of High pressure system: Check the possible causes
Base - March 2007

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.
Print P1D32N003 E
Checks to
Print P1D32N003 E
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).
71
Base - March 2007

72
Checks to
Base - March 2007

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).
Print P1D32N003 E
Checks to
16C INJECTOR One or more injectors Possible injector Check wiring.
Print P1D32N003 E
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.
73
Base - March 2007

74
Checks to
191 TURBINE Poor performance. VGT actuator or Check VGT wiring and
Base - March 2007

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.
pressure)
Print P1D32N003 E
Checks to
19B TURBINE SPEED Poor performance. Air filter blocked or Check the air filter and
Print P1D32N003 E
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
not suitable.
75
Base - March 2007

76
Checks to
Base - March 2007

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.
Terminal resistance
not suitable.
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 P1D32N003 E
Checks to
1BA TIMEOUT CAN No effect perceived by CAN messages from Consult the VCM
Print P1D32N003 E
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.
77
Base - March 2007

78
Checks to
Base - March 2007

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
(12V) possible internal ECM.
control unit problem.
Replace the control unit if
necessary.
Print P1D32N003 E
Checks to
1E6 SENSOR POWER No effect perceived by Excessive/insufficient Check battery voltage or
Print P1D32N003 E
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
DEMAND
regenerations carried
out.
79
Base - March 2007

80
Checks to
1FB PERMANENT No reaction perceivable Catalytic converter Check catalytic converter
Base - March 2007

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
acquisition). Replace
sensor if necessary.
Print P1D32N003 E
Checks to
238 OIL LOW Slight power reduction. Sensor incorrectly Check the sensor
Print P1D32N003 E
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)
81
Base - March 2007

82
Checks to
Base - March 2007

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
LOAD/EXCESSIVE and actuator.
Battery voltage
TEMP.FOR BPA
excessive (ECU
POWER STAGE
overheating).
Print P1D32N003 E
Checks to
3AF DM1DCU SPN3 No effect perceived by Problems in Ad-Blue Check the faults in the
Print P1D32N003 E
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
83
Base - March 2007


GUIDE TO DIAGNOSIS THROUGH SYMPTOMS


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
Print P1D32N003 E
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).
87
Base - March 2007

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
Base - March 2007

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.
Print P1D32N003 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 F4A 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 Figure 139
Figure 137
105167
Unscrew drain cap (1) and drain oil into special container.
105165
Remount drain cap on sump and tighten it at prescribed
torque.
Unthread control rod (1).
Figure 138
Figure 140
105166
Unscrew cap (1) of filler located on top of engine.

105168
From filler (1), fill oil into engine according to prescribed

quantity and quality (See table REFILLING in GENERAL
PROPERTIES).
Screw up again cap (1, Figure 138) of filler located on top of
engine.

Changing engine oil filters Changing fuel pre-filter
Figure 141 (Demonstration) Figure 142
74341
Unscrew the pre-filter (1) and replace it.

75338
Before refitting the new cartridge, moisten the seal with diesel
or engine oil.
Remove the oil filter (1) with tool 99360076.
Screw the cartridge on by hand until it is in contact with the
mounting and then tighten by 3/4 of a turn to the required
NOTE Before refitting the new cartridges, moisten the seal tightening torque.
with engine oil.
When replacing the cartridge, it must not have been
Screw the oil filter (1) on by hand until it is in contact with the pre-filled. This is to prevent impurities getting into
mounting and then tighten by 3/4 of a turn to the required circulation that could damage the system
tightening torque. components, injectors/pump.
Screw the plug back on under the sump and tighten it to the
required torque.
Pour oil into the engine through the filling-pipe (2) of the re-
quired grade and quantity. Changing fuel filter
Figure 143
108503
Remove the fuel filter (1) with tool.

Before refitting the new cartridge, moisten the seal with diesel
or engine oil.
Screw the new one on by hand, taking care to check that the
rubber seal and the mating surface are clean and in a perfect
state of repair. Screw the cartridge on by hand until it is in con-
tact with the mounting and then tighten by 3/4 of a turn to the
required tightening torque.

Changing miscellaneous drive belts Checking valve clearance and adjustment if necessary
Figure 144 (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 145
108507
Remove pre-filter (1) of AdBlue system.Clean from possible

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

F4A EURO 4 NEF ENGINES SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS 1
SECTION 4
General overhaul and characteristics
Page
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 11
ENGINE REMOVAL AT THE BENCH . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
- Checks and measurements . . . . . . . . . . . . . . . 12
- Head face check on the cylinder group . . . . . 13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Checking cam lift and pin alignment . . . . . . . . 14
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Fitting tappets — camshaft . . . . . . . . . . . . . . . . 16
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 17
- Measuring journals and crankpins . . . . . . . . . . 17
- Replacing oil pump control gear . . . . . . . . . . . 19

2 SECTION 4 - GENERAL OVERHAUL AND CHARACTERISTICS F4A EURO 4 NEF ENGINES
Page Page
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 19 - Finding crankpin clearance . . . . . . . . . . . . . . . . 26
- Finding journal clearance . . . . . . . . . . . . . . . . . 19 - Checking piston protrusion . . . . . . . . . . . . . . . 27
- Checking crankshaft shoulder clearance . . . . . 20 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 28
CONNECTING ROD — PISTON ASSEMBLY . . 20 - Removing the valves . . . . . . . . . . . . . . . . . . . . 28
- Measuring piston diameter . . . . . . . . . . . . . . . . 22 - Checking cylinder head wet seal . . . . . . . . . . . 29
- Checking cylinder head supporting surface . . . 29

- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Conditions for proper pin-piston coupling . . . . 22
- Removing carbon deposits, checking and
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 22 - Checking clearance between valve stem and valve
guide and valve centering . . . . . . . . . . . . . . . . . 30
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Checking connecting rods . . . . . . . . . . . . . . . . 24
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Checking torsion . . . . . . . . . . . . . . . . . . . . . . . 24
- Regrinding — replacing the valve seats . . . . . . . 31
- Checking bending . . . . . . . . . . . . . . . . . . . . . . . 25
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Fitting connecting rod-piston assembly . . . . . . 25
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . 33
- Connecting rod-piston coupling . . . . . . . . . . . . 25
- Refitting the cylinder head . . . . . . . . . . . . . . . . 33
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 25
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 35
- Fitting connecting rod-piston assembly
into cylinder barrels . . . . . . . . . . . . . . . . . . . . . 26 AUXILIARY COMPONENTS . . . . . . . . . . . . . . . 37

GENERAL CHARACTERISTICS
F4AE3682F F4AE3682F F4AE3682E F4AE3682E

Type
*P100 *P101 *P100 *P101
Cycle Four-stroke diesel engine

Power Turbocharged with intercooler
Injection Direct
Number of cylinders 6
∅
Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cm3 5880
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 1-5-3-6-2-4
bar
Injection pressure bar 250 - 1600

CLEARANCE DATA

Type
*P100 *P101 *P100 *P101
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
Outside diameter ∅1 101.781 to 101.799
∅2 Pin housing ∅2 40.008 to 40.014
Piston — cylinder barrels 0.211 to 0.249
Piston diameter ∅1 0.5 - 1.0
X
Piston protrusion X 0.28 to 0.52
∅ 3 Piston pin ∅3 39.9938 to 40.0002
Piston pin — pin housing 0.0078 to 0.0202


Type
*P100 *P101 *P100 *P101
X1 X1* 2.705 to 2.735

X2 Split ring slots X2 2.420 to 2.440
X3 X3 4.020 to 4.040
S 1 S 1* 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.975 to 4.000
* measured on 98 mm ∅
1 0.100 to 0.175
Split rings - slots 2 0.040 to 0.90
3 0.020 to 0.065
Split rings 0.5 - 1.0
X1 Split ring end opening
X 2 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 - 0.750 - 1.000


Type
*P100 *P101 *P100 *P101

∅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; + 0.750; + 1.000
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
*P100 *P101 *P100 *P101
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 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
*P100 *P101 *P100 *P101

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
Outside diameter
∅ Load bushing
59.222 to 59.248
3,3 kN ∅
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
*P100 *P101 *P100 *P101

∅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


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
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.
Figure 2 70161
Use tool 99360500 (1) and hoist to remove the crankshaft (2)
from the block.
Figure 5
70159
Remove the screws (1) and the main bearing caps (2).
70162
Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).

zs
Figure 6 REPAIR OPERATIONS

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

plate (2).
70166
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
74772
Check that the head face, on the cylinder group, does not
present deformations.
This check can be carried out, after a previous grains (4)
extraction by means of a calibrated ruler (2) and feeler gauge
(3).
α After verified the deformation areas, perform the flattening of
the face by means of grinding machine.
107267 The flatness error must not be higher than 0.075 mm.
NOTE The block flattening could be performed only after

NOTE In the event of grinding operation, all the barrels you have checked that, at finished work, the piston
must result of the same oversize (0.5 mm) projection from the cylinder barrel is not higher than
the value prescribed.
Check the conditions of the working plugs (1) of the cylinder

Check the bench bearing seats, proceeding as follows: 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
as shown in Figure 11
- by means of an adequate gauge, verify that the internal
diameter of the seats correspond to the value prescribed. TIMING SYSTEM
If you detect a higher value, replace its block Camshaft
Figure 13
79459
CAMSHAFT MAIN DATA
The data listed are refereed to the standard pin diameter.
Surfaces of both shaft support pins and cams must be very present, shaft and relating bushing have to be replaced.
smooth; on the contrary, if meshing traces and scoring are

Checking cam lift and pin alignment Bushes

Set the camshaft on the tailstock and using a 1/100 gauge set
Figure 15
on the central support, check whether the alignment error is
not exceeding 0.04 mm, otherwise replace the camshaft.
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 14
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 16
Sec. A-A
107268
MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT

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

Figure 17 Figure 18
70174 112890
To change the bushing (1), use the drift 99360362 (2) and grip MAIN DATA CONCERNING THE TAPPETS AND THE
99370006 (3) for its disassembly and assembly. 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 21
Figure 19
70238
Set camshaft (3) retaining plate (1) with the slot facing the top
of the engine block and the marking facing the operator, then
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 22
Figure 20
70179
Check camshaft end float (1).

It shall be 0.23 ± 0.13 mm.
70164
Figure 23
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 24 See Figure 25 and 29.
Undersize classes are: 0.250 - 0.500 mm
Journals and crankpins shall always be ground to the

! same undersize class.
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.
Figure 25
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value

Figure 26
* Measured on a radius greater than 45.5 mm

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

Figure 27
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 28 Figure 30
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 31
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 29
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 32
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 33 Checking crankshaft shoulder clearance
α Figure 35
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 34
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 36
- 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
twice as indicated in the picture, checking D1 and
D2 diameters: CONNECTING ROD — PISTON ASSEMBLY
if D1 - D2 < 0,1 mm the screw can be utilised again; COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
D2 D1
NOTE The pistons are fitted with a replacer in standard

75703 size, or 0.5 mm oversize.

Figure 37 Figure 38
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 39
114923
MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter

Measuring piston diameter Conditions for proper pin-piston coupling
Figure 40 Figure 43
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 44
Figure 41
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 45
Piston pins
Figure 42
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 46 Connecting rods

Figure 48
41104
DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
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 47

D2 diameters:
D2 D1
75703
70194
Use feeler gauge (1) to measure the clearance between the

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

Figure 49 Checking connecting rods

Figure 50 (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 51 (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 Connecting rod-piston coupling

Figure 52 (Demonstration) Figure 54
102596
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
61695 cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Check connecting rod (5) bending by comparing two points
C and D of the pin (3) on the vertical plane of the connecting Figure 55
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

72705
Figure 53
Insert elastic rings (2) to secure pin (1).
Fitting split rings

Figure 56
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 59
NOTE Split rings are supplied spare with the following
sizes:
- standard;
- 0.5 mm oversize.
Figure 57
70202
DIAGRAM FOR CONNECTING ROD-PISTON

ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120°;
- 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 60
Fitting connecting rod-piston assembly into

cylinder barrels
Figure 58
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 61 Figure 64
70204 70207
- Lubricate the screws (1) with engine oil and then tighten If a different clearance value is found, replace the half bearings
them to the specified torque using the torque wrench and repeat the check.
(2).
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
Figure 62 connecting rod cap fastening screws to the specified torque.

α
D2 diameters:
D2 D1
75703
Check manually that the connecting rods (1) are sliding

axially on the output shaft pins and that their end float,
70205
measured with feeler gauge (2) is 0.10 to 0.33 mm.
- Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60°.
Checking piston protrusion
Figure 65
Figure 63
70208
70206
Once connecting rod-piston assemblies refitting is over, use
- Remove the cap and find the existing clearance by dial gauge 99395603 (1) fitted with base 99370415 (2) to
comparing the calibrated wire width (1) with the scale check piston (3) protrusion at T.D.C. with respect to the top
on the wire envelope (2). of the engine block.
Protrusion shall be 0.28 to 0.52 mm.

CYLINDER HEAD Figure 67

Removing the valves
Figure 66
70321
Valve removal shall be performed using tool 99360268 (1)

and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. 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 68
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 71
Figure 69
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 70
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 74
Figure 72
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 73
Figure 75
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 76
Figure 77
70330
INTAKE EXHAUST Check the valve seats (2).

79457
If slight scoring or burning is detected, regrind using a valve
seat regrinding tool (1) following the inclination values shown
Use a bore dial gauge to measure the inside diameter of the in Figure 78.
valve guides, the read value shall comply with the value
shown in the figure.
Figure 78
EXHAUST INTAKE
107281
ENGINE VALVE SEATS MAIN DATA

Valve seats are cast on cylinder head and machined.

Figure 79
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 80.
Figure 80
INTAKE EXHAUST
107283
Figure 81 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 84

Figure 82
50676
770321
MAIN DATA TO CHECK INTAKE AND EXHAUST Position on the cylinder head: the spring (4), the upper cap
VALVE SPRINGS (3); 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 85
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 83
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.

D2 diameters:
70334 if D1 - D2 < 0,1 mm the screw can be utilised again;
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
D2 D1
Fit the sealing rings (2 and 3) on the valve guide.
75703
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.

Figure 86
88775
There are two types of head seals, for the thickness (1.25 mm
Type A and 1.15 mm Type B) take the following measures:
- for each piston detect, as indicated on Figure 86, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:
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
pins M10 7±1 0 7 ± 0.1
0.7 01
Turbine fixing to exhaust manifold { nuts M10 43 ± 6 4 3 ± 0.6
4.3 06
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
Starter:
Screw for fastening starter 43 ± 6 4.3 ± 0.6


F4A EURO 4 NEF ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS F4A EURO 4 NEF ENGINES

TOOLS
TOOL No. DEFINITION
99317915 Set of 3 9x12 pin wrenches (14 - 17 - 19 mm)
Revolving stand for overhauling units (700 daN/m capacity, 120

99322205 daN/m torque)
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket
99341001 Double acting puller
99341009 Pair of brackets

TOOLS
TOOL No. DEFINITION
99341015 Press
99342101 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket
99360076 Tool for disassembling cartridge filters
99360183 Pliers for removing/refitting piston rings (65 — 110 mm)

TOOLS
TOOL No. DEFINITION
99360268 Tool for removing/refitting engine valves
99360330 Tool for rotating the engine flywheel
99360351 Tool for stopping the engine flywheel
Beater for removing/refitting camshaft bushes (to be used with

99360362 99370006)
99360500 Tool for lifting the output shaft
99360595 Lifting rig for engine removal/refitting

TOOLS
TOOL No. DEFINITION
99360605 Band for fitting piston into cylinder barrel (60 — 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99367121 Manual pump for pressure and vacuum measurements
99370006 Handgrip for interchangeable beaters
99370415 Gauge base for different measurements (to be used with 99395603)

TOOLS
TOOL No. DEFINITION
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)


F4A 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 F4A EURO 4 NEF ENGINES

F4A 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 F4A 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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F4A EURO 4

Technical and Repair manual

The data contained in this publication was correct at the time

INDEX NEF F4A EURO 4 ENGINES

Updating and Consultation Introduction

General overhaul and characteristics 4

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the engines illustrating their 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-

Base - March 2007 Print P1D32N003 E

PREFACE TO USER’S GUIDELINE MANUAL . 5

- General warnings on the electric system . . . . . 8

- Bonding and screening . . . . . . . . . . . . . . . . . . . 9

- Optional electrical and mechanical parts installations 10

- Conversions between the main units of measurement

- Graphic figures and symbols . . . . . . . . . . . . . . 11

- Key of lecture of the headings and footnotes . 13

Print P1D32N003 E Base - March 2007

Base - March 2007 Print P1D32N003 E

Section Description Page Date of revision

Print P1D32N003 E Base - March 2007

Base - March 2007 Print P1D32N003 E

PREFACE TO USER’S GUIDELINE MANUAL

Danger for persons

Danger of serious damage for the assembly

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

Print P1D32N003 E Base - March 2007

Base - March 2007 Print P1D32N003 E

Print P1D32N003 E Base - March 2007

General warnings on the electric system

Base - March 2007 Print P1D32N003 E

Bonding and screening

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

1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

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

Print P1D32N003 E Base - March 2007

Optional electrical and mechanical parts installations

Base - March 2007 Print P1D32N003 E

Graphic figures and symbols

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Print P1D32N003 E Base - March 2007

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

Base - March 2007 Print P1D32N003 E

Key of lecture of the headings and footnotes

Type of Section Page

Printout Language Basic edition referred to When month - year update

Print P1D32N003 E Base - March 2007

Base - March 2007 Print P1D32N003 E

CORRESPONDENCE BETWEEN TECHNICAL CODE

- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 7

OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 8

AIR INDUCTION - BOOST DIAGRAM . . . . . . . 11

- Composition and operation . . . . . . . . . . . . . . . 12

- AdBlue fluid level gauge control . . . . . . . . . . . . 15

- Exhaust gas temperature sensor . . . . . . . . . . . 16

- Humidity detecting sensor . . . . . . . . . . . . . . . . 16

- Nitric oxide detecting sensor . . . . . . . . . . . . . . 17

Print P1D32N003 E Base - March 2007