Case New Holland Kobelco Iveco Komatsu F4CE F4DE F4GE F4HE Service Repair Manual For Engine Overhaul (Mechanical Injection and Electronic Common Rail) PDF

ENGINES
CNH
NEF
F4CE - F4DE - F4GE - F4HE
4 Cylinders, Mechanical and
Electronic Drive Common Rail
ENGINES
CNH NEF
4 Cylinders, Mechanical
and Electronic
Drive Common Rail
Repair
Manual
Tier III
Print No. 87659057A
English
Repair
Manual
Tier III
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REPAIR INSTRUCTION MANUAL
CNH ENGINES
ENGINES FAMILY:
F4CE9484 -- F4DE9484 -- F4GE9484 -- F4HE9484
All theinformation, illustrations anddata providedby this manual arebased uponthe most recent informationavailable
at the time of its publication.
CNH ITALIA S.p.A. reserves the right to implement modifications, at any time, without communications.
CNH ITALIA S.p.A.
STAMPATO N. 87659057A
Edizione -- May 2007
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2 ENGINE
2
TROUBLESHOOTING
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- This Manual is written for an expert technician to
provide the technical information required to per-
form repair operations on this machine.
- Please read carefully this manual for the correct
information regarding the repair procedures.
- For any question or comment, or in case any
error regarding the content of this manual is
found, you are asked to please contact:
CNH ITALIA S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PARTS & SERVICE
Fax ++39 011 0077357
TO THE READER
SYMBOLS
This manual includes safety warning symbols and indications to recall the attention on possible personal
injuries or damages to the machine.
This symbol recalls the attention to points relative to safety.
When you see this symbol, it is necessary to proceed with attention since there is the possibility of
personal injuries.
Comply scrupulously with the precautions identified by this symbol.
The safety warning symbol is also used to attract attention to the weight of a component or a part.
To prevent personal injuries or damages, make sure that the appropriate lifting equipment and
techniques are implemented when handling heavy loads.
!
IN--1
FOREWORD
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UNITS OF MEASURE
In this manual, the units of measure of the IS (International System) are used.
The units of measure of the MKSA system are listed in parenthesis after the units of the International system.
Example: 24.5 Mpa (250 kgf/cm
2
).
Here below, a conversion table of the units of the IS and some units of measure of other systems is listed. as
a reference.
IN--2
FOREWORD
Quantity
To convert
from
(SI)
into
(Others)
Multiply
by
Quantity
To convert
from
(SI)
into
(Others)
Multiply
by
Length
mm in 0.03937
Pressure
MPa kgf/cm
2
10.197
Length
mm ft 0.003281
Pressure
MPa psi 145.0
L US gal 0.2642
Power
kW PS 1.360
Volume L US qt 1.057
Power
kW HP
m
3
yd
3
1.308 Temperature C F C x 1.8 + 32
Mass kg lb 2.205
Velocity
km/h mph 0.6214
Force
N kgf 0.10197
Velocity
min
--1
rpm 1.0
Force
N lbf 0.2248
Flow
L/min US gpm 0.2642
Torque
N.m kgf.m 0.10197
Flow
mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
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Section
Introduction
General specifications 1
Fuel 2
Duty - Industrial application 3
Overhaul and technical specifications 4
Tools 5
Engine technical cards 6
Safety prescriptions Appendix
NEF ENGINES
NEF ENGINES 1
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2 NEF ENGINES
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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 = housing for connecting rod small end bush
2 = housing for connecting rod bearings

Tighten to torque
Tighten to torque + angular value
1
2
NEF ENGINES 3
SPECIAL REMARKS
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4 NEF ENGINES
SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
Compression ratio
Tighten to torque
Tolerance
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fitting position check
Preload
Measurement
Value to find
Check
Number of revolutions
Equipment Temperature
Surface for machining
Machine finish
bar
Pressure
Interference
Strained assembly
Oversized
Higher than.
Maximum, peak
Thickness
Clearance
Undersized
Less than.
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 C
Cold
Winter
Air bleeding
Temperature > 0 C
Hot
Summer
CNH
PARTS
Replacement
Original spare parts
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NEF ENGINES 5
UPDATING
Section Description Page Date of revision
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6 NEF ENGINES
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INTRODUCTION 1 NEF ENGINES
Introduction
Page
PREFACE TO USERS GUIDELINE MANUAL 3 . . . .
SYMBOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Service operations 3 . . . . . . . . . . . . . . . . . . . . . .
GENERAL WARNINGS 5 . . . . . . . . . . . . . . . . . . . . .
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM 7 . . . . . . . . . . . . . . .
- Bonding and screening 8 . . . . . . . . . . . . . . . . . . .
OPTIONAL ELECTRICAL AND MECHANICAL
PARTS INSTALLATIONS 9 . . . . . . . . . . . . . . . . . .
CONVERSIONS BETWEEN THE MAIN UNITS
OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED
QUANTITIES 9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 INTRODUCTION NEF ENGINES
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Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assemblys
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
Section 1 describes the engines illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate 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 inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such
operations.
The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order
to prevent serious accidents taking place.
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.
General danger
It includes the dangers of above described signals.
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.
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.
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
SYMBOLS - Warnings
It indicates an additional explanation for a piece of information.
!
NOTE
PREFACETOUSERSGUIDELINE MANUAL
Service operations
Example
1 = housing for connecting rod small end bush
2 = housing for connecting rod bearings

Tighten to torque
Tighten to torque + angular value
1
2
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Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly

Compression ratio
Tighten to torque
Tolerance
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation
Adjustment
Angle
Angular value
!
Warning
Note
Preload
Visual inspection
Fitting position check
Number of revolutions
Measurement
Value to find
Check
Temperature
Equipment
bar
Pressure
Surface for machining
Machine finish
Oversized
Higher than.
Maximum, peak
Interference
Strained assembly
Undersized
Less than.
Minimum
Thickness
Clearance
Selection
Classes
Oversizing
Lubrication
Damp
Grease
Temperature < 0 C
Cold
Winter
Sealant
Adhesive
Temperature > 0 C
Hot
Summer
Air bleeding
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GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggestedtocontact
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 andall inflammable fluids andliquids must be handledwith care, according towhat containedon 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 original spares.
During workshopactivity, always keepthe work place clean; timely clear or clean floors fromaccidental liquidor oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
!
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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; CNH commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
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 fromheating 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.
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GENERAL WARNINGS ON THE ELECTRIC SYSTEM
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.
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 CNHsystemand 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.
Connectors present must be seen fromcable side. Connectors views containedin the manual are representative of cable
side.
!
NOTE
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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.
1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR
d. DISTANCE !0
88039
Figure 1
Figure 2
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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.
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/cm
2
1 kg/cm
2
= 0.981 bar
1 bar = 10
5
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/cm
2
according to ratio 1:1
1 kg/cm
2
= 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F
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SECTION 1 - GENERAL SPECIFICATIONS 1 NEF ENGINES
SECTION 1
General Specifications
Page
NOMENCLATURE (Coding of the engines of origin) 3
LUBRICATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL VAPOUR RECIRCULATING SYSTEM 7 . . . . . . .
COOLING SYSTEM 7 . . . . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION BOOST DIAGRAM 9 . . . . . . . . . .
- Boosting version engines 9 . . . . . . . . . . . . . . . . .
- Description 9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Inter-cooled engine version 10 . . . . . . . . . . . . . . .
- Description 10 . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) 11
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2 SECTION 1 - GENERAL SPECIFICATIONS NEF ENGINES
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NOMENCLATURE (Coding of the engines of origin)
F 4 B E 9 4 8 4 E * J +
J = TIER 3
4 = 4- cylinders
Emission level
No. of cylinders
Power homologated
Use
Inlet / injection
Configuration of cylinders
Engine
Type of cylinder block:
C = structural 2-valves
D = structural 4-valves
G = non structural 2-valves
H = non structural 4-valves
Engines
family
8 = Diesel turbocharged
Direct Injection with
Intercooler
5 = Diesel turbocharged
Direct Injection
4 = Earth Moving Machines and Tractors
X = 6 Rotary injection pump 2-valves
1 Common rail 4-valves
2 Common rail 2-valves
5 Rotary injection pump 4-valves
Y = Engine variant
Production progressive number
X Y Y Y Y Y Y Y Y
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Figure 3
LUBRICATION
Lubrication by forced circulation is achieved through oil rotary
expansion pump, placed in the front part of the basement,
driven by the straight-tooth gear splinedto the shafts bar hold.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Lubrication involves the heat exchanger (2,3), the
turboblower for turbocompressed versions, and for any
compressed air system.
All these components may often vary according to the specific
duty.
LUBRICATION SYSTEM LAYOUT
1. Heat exchanger body - 2. Lubrication oil pipe to supercharger - 3. Oil filter - 4. Heat exchanger -
5. Oil rotary expansion pump.
116396
Routing of oil under
pressure
Routing of oil return
by gravity to sump
Introduction of oil
Some groups can be located on the engine in
different positions due to requirements dictated by
the application, and have variable shapes and
dimensions depending upon the use and the
versions of the engine itself.
NOTE
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Figure 4
LUBRICATION DIAGARAM (Other application)
Lines of oil under pressure
Return lines of oil by
gravity
Oil filler
112885
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3240t
Figure 5
OIL VAPOUR RECIRCULATING SYSTEM
1. Valve - 2. Breather pipe - 3. Tappet Cap
On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity,
to the Tappet cap underneath.
The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example (con-
nection towards these vapours shall be designed by the Engineer).
1
2
3
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Figure 6
COOLING SYSTEM
The engine cooling system, closed circuit forced circulation
type, generally incorporates the following components:
- Expansion tank; placement, shape and dimensions are
subject to change according to the engines equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
- Visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engines
development.
- Heat exchanger to cool the lubrication oil: even this
component is part of the engines specific equipment.
- Centrifugal water pump, placed in the front part of the
engine block.
- Thermostat regulating the circulation of the cooling liquid.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
COOLING SYSTEM LAYOUT
FROM RADIATOR
TO RADIATOR
03241t
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Figure 7
AIR FILTER
TURBOCHARGER
EXHAUST
4 cylinders version
88208
AIR INDUCTION BOOST DIAGRAM
Boosting version engines
Description
The turbocharger is composed by the following main parts:
one turbine, one transforming valve to regulate the boost
feeding pressure , one main body and one compressor.
During engine working process, the exhaust emission flow
through the body of the turbine, provoking the turbine disk
wheels rotation.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter.
The air coming out of the compressor is sent via the intake
manifold directly to the pistons.
The turbocharger is equipped with a transforming valve to
regulate the pressure , that is located on the exhaust collector
before the turbine and connected by piping to the induction
collector.
Its duty is tochoke the exhaust of the emissions , releasing part
of them directly to the exhaust tube when the boost feeding
pressure, over the compressor, reaches the prescribed bar
value.
The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
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74195
Figure 8
The turbocharger is composed by the following main parts:
one turbine, one transforming valve to regulate the boost
feeding pressure , one main body and one compressor.
During engine working process, the exhaust emission flow
through the body of the turbine, provoking the turbine disk
wheels rotation.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
The turbocharger is equipped with a transforming valve to
regulate the pressure , that is located on the exhaust collector
before the turbine and connected by piping to the induction
collector.
Its duty is tochoke the exhaust of the emissions , releasing part
of them directly to the exhaust tube when the boost feeding
pressure, over the compressor, reaches the prescribed bar
value.
The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
Description
RADIATOR
AIR FILTER
TURBOCHARGER
EXHAUST
4 cylinders version
Inter-cooled engine version
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EXHAUSTGAS RE-CIRCULATIONSYSTEM
(EGR)
In the TIER 3 version, the profile of the exhaust cam has been
modified in order to allow the partial opening of the relative
valve during the aspiration phase (re-circulation of EGR
exhaust gas) with the subsequent re-introduction of part of
the exhaust gas into the engine cylinders.
The exhaust gases can partially be re-directed into the
cylinders so as to reduce the maximum combustion
temperature values responsible for the production of nitric
acid (NO
x
).
The exhaust gas re-circulation system (EGR), reducing the
combustion temperature by means of the diminishing of the
concentration of oxygen in the combustion chamber,
represents therefore an efficient control system of the
emission of NO
x
.
Figure 9
A. Aspiration valve control - B. Exhaust valve control.
114789
The internal EGR system is not equipped with any
electronically controlled elements: the systemis always active.
Its configuration does not need additional elements
i.e.checking valves, piping or heat exchangers.
The exhaust cam (B) has another lobe apart from the major
lobe (see Section. A-A fig.) with respects to the configuration
without EGR.
The additional lobe, during the aspiration phase in the cylinder
in question, allows a brief opening of the exhaust valve
generating re-circulation due tothe intake of the exhaust gases
caused by depression which is created in the aspiration phase
inside the cylinder.
For the dimension of the camshaft, please refer to Section 6
General Mechanical Overhaul
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SECTION 2 - FUEL 1 NEF ENGINES
SECTION 2
Fuel
Page
4-CYLINDER ENGINES WITH BOSCH ROTARY
MECHANICAL PUMP 3 . . . . . . . . . . . . . . . . . .
- General information 3 . . . . . . . . . . . . . . . . . . . . .
- Description of working principles 4 . . . . . . . . . . .
FEED PUMP 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Example of identification 5 . . . . . . . . . . . . . . . . .
CP3 HIGH PRESSURE PUMP 6 . . . . . . . . . . . . . . .
- High pressure pump-inside structure 7 . . . . . . . .
- Working principle 8 . . . . . . . . . . . . . . . . . . . . . .
- Operation 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RAIL 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELIEF VALVE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMING PUMP 11 . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FILTER 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH PRESSURE ELECTRONIC INJECTION SYSTEM
(COMMON RAIL) 14 . . . . . . . . . . . . . . . . . . . . .
EDC 7 OPERATION 15 . . . . . . . . . . . . . . . . . . . . . .
WORKING PROCESS 16 . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM LAYOUT 17 . . . . . . . . . . . . . . . . . . .
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2 SECTION 2 - FUEL NEF ENGINES
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74168
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure
gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.
4-CYLINDER ENGINES WITH BOSCH ROTARY MECHANICAL PUMP
General information
Fuel feed system is composed by:
- Fuel tank (placed on the machine)
- Fuel delivery and back-flow to tank
- Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)
- Priming pump, assembled to the engine and driven by the camshaft
- Fuel filter (assembled to the engine in different positions according to equipment application and duty)
- Fuel feed rotary pump
- Injector feed pipeline (from fuel feed pump to injectors)
- Injectors
Figure 1
1
2
7
4
5
3
6
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Figure 2
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Description of working principles
Fuel is sucked from the fuel tank by the priming pump. This
last one is placed on the engine basement and is driven by
the camshaft.
Throughout the filter, the fuel is piped to the union fitting
vacuum chamber of the transfer pump. (For applications to
be equipped in cold climate areas, the fuel filter is provided
with heater).
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
The fuel arrives therefore to the valve gauging the pressure
inside feed pump.
The distribution plunger further increases this pressure and
delivers fuel throughout the delivery pipe fitting to the
injectors.
The fuel drawing from the injectors is recovered and delivered
to the tank again.
116385
Some groups can be located on the engine in
different positions due to requirements dictated by
the application, and have variable shapes and
dimensions depending upon the use and the
versions of the engine itself.
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Injection pump longitudinal section
1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk -
9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate -
14. Gauge pin - 15. Counteracting spring.
30454
Figure 3
FEED PUMP
The rotary type pump is driven by a gear mating the camshafts one.
Example of identification
V = Distribution rotary plunger
E = Pump dimensions
4 = 4 cylinders engine
12 = Distribution plunger in mm.
1150 = N. of pump revolutions per minute
LV = Left direction of rotation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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Figure 4
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.
CP3 HIGH PRESSURE PUMP
Pump provided with 3 radial pumping elements driven by the
timing system gear, no need of timing. The mechanical
feeding pump driven by the high pressure pumps shaft is
assembled to the rear side of the high pressure pump.
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.
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70498
Figure 5
Every pumping unit is composed of:
- a piston (5) actuated by a three-lobe element (2) floating
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;
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.
Sec. B-B
Sec. C-C
- cap intake valve (3);
- ball delivery valve (4).
High pressure pump-inside structure
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Figure 6
Working principle
72597
1. Fuel outlet joint to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element inlet duct - 6.
Pressure regulator inlet duct - 7. Pressure regulator.
Sec. D-D
The pumping element (3) is orientated towards the pumps
camshaft (4). During the intake phase, the pumping element
is fed through the feeding line (5). The quantity of fuel to flow
to the pumping element is determined by the pressure
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.
During compression phase of the pumping element, the fuel
achieves the level of pressure determining the opening of the
by-pass valve to common rail (2), feeding it through the
exhaust unit (I).
Sec. B-B
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Figure 7
72601
1. Inlet to pumping element - 2. Pump lubrication ducts -
3. Inlet to pumping element - 4. Pumping element feeding
main duct - 5. Pressure regulator - 6. Pumping element
inlet - 7. Regulator discharge duct - 8. Pressure relief valve
5 bar - 9. Fuel discharge from regulator inlet.
Sec. C - C
72598
Figure 7 shows the fuel runs at lowpressure inside the pump;
the following elements are clearly visible: the main feeding
line to the pumping elements (4); the feeding lines to the
pumping elements (1-3-6), the duct lines run for the pump
lubrication (2), the pressure gauge (5), the flow limiting valve
to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
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.
Figure 8
Sec. A - A
1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
exhaust flowing from pump with connector to high
pressure pipe for common rail.
Figure 8 shows the fuel flow under high pressure running
through the exhaust galleries of the pumping elements.
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Figure 9
Operation
The cylinder is filled through the cap intake valve only if the
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
open and the compressed fuel reaches the high-pressure
circuit.
The pumping element compresses the fuel till the top dead
center (delivery stroke) is reached. Afterwards, the pressure
decreases till the exhaust valve is closed.
The pumping element piston goes back towards the bottom
dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and
the cycle is repeated.
The delivery valves must always be free in their movements,
free from impurities and oxidation.
The rail delivery pressure is modulated between 250 and
1600 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
1. Rail 2. Fuel inlet from high-pressure pump
3. Overpressure valve - 4. Pressure sensor.
The rail volume is comparatively small to allow a quick
pressurisation at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise system spikes
and the use of plenum chambers caused by injectors
openings and closings and by the high-pressure pump
operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
A fuel pressure sensor (4) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
value is checked and, if necessary, corrected.
RAIL
108609
RELIEF VALVE
Mounted on the end of the rail, it has the function of
protecting the systems components in case the failure of the
rail pressure sensor or the pressure regulator of pump CP3
causes an excessive pressure increase in the high-pressure
plant.
When the rail pressure reaches 1800 bars, the valve initially
intervenes in order to allowthe fuel to flowand subsequently
to reduce the pressure within safety limits and then it
mechanically regulates the rail pressure to approx. 800 bars.
This valve allows the engine to work for long periods at a
limited efficiency and avoids the excessive overheating of the
fuel preserving the return pipes to the tank.
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PRIMING PUMP
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to
the engine basement and driven by the camshaft.
Figure 10
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.
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Figure 11
FUEL FILTER
The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and
separation of water from fuel.
On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the
bearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperature
sensor. On some versions, a water presence sensor is present at filtering cartridge base.
1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.
88210
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Figure 12
1. Fuel filter bearing- 2. Heater - 3. Water dump screw- 4. Filter cartridge -
5. Temperature sensor.
3244t
1
2
5
4
3
3243t
1
3
4
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Figure 1
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engines cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engines oil temperature and pressure -
5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and air pressure sensor -
8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor -
10. Pressure gauge cabling - 11. EDC 7 gearbox.
HIGH PRESSURE ELECTRONIC INJECTION
SYSTEM (COMMON RAIL)
Introduction
Extremely high injection pressures are necessary in order to
reduce PARTICULATE emissions.
The common rail system makes it possible to inject fuel at
pressures of up to 1450 - 1600 bar, while the injection preci-
sion obtained by electronic control of the system serves to
optimise operation of the engine while limiting emissions and
fuel consumption.
For engines more powerful than 152 kW, the CRIN2 injec-
tors have DLLA nozzles that work up to a pressure of 1600
bar, whilst for engines less powerful than 152 kW, DSLA
nozzles are fitted which work a pressures up to 1450 bar.
Description of system
The injection system is composed of an electrical part and a
hydraulic part.
Electrical system
The electronic control unit monitors engine control para-
meters by means of the various sensors on the engine.
107851
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EDC 7 OPERATION
Engine preheating element control
Pre-post heating is activated when even just one of the water,
air or fuel temperature sensors detects a temperature 5 C.
Phase recognition
By means of signals transmitted by the camshaft and
crankshaft sensors, the cylinder into which fuel must be
injected is determined at the time of starting.
Injection control
On the basis of information transmitted by the sensors, the
control unit administrates the pressure regulator and
modifies the pre-injection and main injection mode.
On F4 engines pre-injection is activated at all engine speeds.
Injection pressure closed loop control
On the basis of the engine load, as determined by processing
of data transmitted by the various sensors, the control unit
administrates the regulator to maintain injection pressure at
constantly optimal values.
Pilot and main injection advance control
On the basis of signals transmitted by the various sensors, the
control unit determines the optimum injection point on the
basis of internal mapping.
Idle speed control
The control unit processes signals transmitted by the various
sensors and adjusts the quantity of fuel injected.
It also controls the pressure regulator and modulates
injection duration of the electro-injectors.
Within specific limits, the control unit also monitors battery
voltage.
Overheating protection
If the water temperature reaches 110 C, the control unit
reduces engine performance.
When the temperature returns below 100 C, the engine
resumes normal operation, (in some applications, the over
boosting temperature is the reference temperature).
Maximum engine speed limiting
Depending on the application, the control unit memory can
contain appropriate engine speed limits. When the engine
speed surpasses these limits the control unit activates power
reduction strategies by controlling energization time of the
electro-injectors. In some applications the maximum limiting
response consists in stopping the engine.
Cut Off
Fuel cut-off in release phases is managed by the control unit
with the following logical interventions:
- disactivation of the electro-injectors;
- reactivation of electro-injectors immediately prior to
arrival at idle speed;
- control of fuel pressure regulator.
Smoke control under acceleration
With intense load demands, in accordance with signals
received from the air inlet meter and the engine speed
sensor, the control unit manages the pressure regulator and
modulates the activation time of the electro-injectors to
prevent the emission of smoke from the exhaust.
After Run
After the engine is stopped, the control unit microprocessor
saves various parameters to the EEPROM memory, including
the faults log so that they will be available the next time the
engine is started.
Control of working speed in normal operating
conditions
Each time work load varies, the control unit adjusts torque
so as to maintain the engine in maximum power conditions.
If the load causes a reduction in power, the control unit
increases torque i.e. it increases the amount of fuel injected
in order to restore the engine to maximum power.
Recovery strategies
Recovery strategies are characterized by certain differences
as application varies, i.e.
- Control of fuel leaks
In the case of fuel supply problems, the system controls
the engine with suitable constant power values obtained
with a low number of revs and high torque values in
order to inject the maximum quantity of fuel.
- Control of pressure in the rail
When the pressure in the rail exceeds safety values, the
engine reduces power.
- Synchronism problems
In the case of synchronism problems, faulty rev sensors,
the systemcontrols the engine by increasing the number
of revs in order to improve interpretation of the signals.
- Power restrictions as operating temperature increases
When the temperature of the supercharging air rises
above 88 C, power reduction is started; when a
temperature of 120 C is reached, performance is
further reduced and is comparable to that of the same
engine if it were aspirated.
- Reduction of power as reference temperature varies
In normal operating conditions, the system knows the
supercharging air, oil and water temperatures.
If the temperature of the engine water is not available,
the system takes the temperature of the oil as reference
and when this reaches the threshold of 103 C, it starts
to reduce the power available. On reaching 113 C,
power is reduced to 50%.
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Figure 2
1. Electro-injector - 2. Common Rail - 3. Pressure limiting device for fuel return -
4. Common rail pressure relief valve - 5. Pre-filter mounted on the frame - 6. High-pressure pump -
7. Mechanical vane pump - 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
WORKING PROCESS
High Pressure
Low Pressure
Fuel outlet
108607
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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 SYSTEM LAYOUT
This fuel system is a Common Rail injection with CP3 high
pressure pump and this layout is for 4 cylinder version.
(The 6 cylinder version is similar design as the 4 cylinder en-
gine).
The pressure regulator, placed upstreamof the high-pressure
pump, adjusts the fuel flowthat is necessary on the low-pres-
sure system. Afterwards, the high-pressure pump takes care
of supplying the rail properly. This arrangement, by pressuris-
ing the necessary fuel only, improves the energetic efficiency
and limits fuel heating in the system.
Function of the pressure relief valve (2), assembled on the
high-pressure pump, is keeping the pressure, at the pressure
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream.
The pressure relief valve (2) intervention brings about a fuel
flow increase in the high-pressure pump cooling circuit,
through inlet and drain piping (16) from piping (8).
The pressure relief valve housed on the cylinder head, as-
sembled on injector return (3), limits the fuel return flow
from injectors at a pressure of 1.3 to 2 bars.
Two by-pass valves are placed in parallel with the mechanical
supply pump.
The by-pass valve (18) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure ex-
ceeds the allowed threshold value.
The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
108608
Figure 3
INTAKE (LOW PRESSURE)
HIGH PRESSURE
HIGH-PRESSURE PUMP SUPPLY
(LOW PRESSURE)
EXHAUST
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SECTION 3 - INDUSTRIAL APPLICATION 1 NEF ENGINES
SECTION 3
Engine
GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . .
PART ONE - MECHANICAL COMPONENTS 5 . .
OVERHAUL OF THE 4 CYLINDER ENGINE
PROVIDED WITH MECHANICAL ROTARY
PUMP 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Preface 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Engine setting operations for the assembly on turning
stand 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly of application components 9 . . . . .
- Installation of rear components 18 . . . . . . . . . . . .
- Installation of rear components with reduced
distribution 21 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Flywheel installation 23 . . . . . . . . . . . . . . . . . . . . .
- Installation of front components 23 . . . . . . . . . . .
- Assembly of additional masses 25 . . . . . . . . . . . .
- Timing of additional masses 23 . . . . . . . . . . . . . . .
- Completion of engine re-assembly 35 . . . . . . . . .
- Rotary feed pump disassembly and assembly
procedure 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Feed system bleed procedure 39 . . . . . . . . . . . . .
- Power take-off disassembly and assembly
procedure 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checks and controls 40 . . . . . . . . . . . . . . . . . . . .
PART ONE - MECHANIC OVERHAUL OF ENGINES
WITH ELECTRONIC CONTROL
(COMMON RAIL) 41 . . . . . . . . . . . . . . . . . . . . . .
RAIL 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RELIEF VALVE 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRO-INJECTOR 43 . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE LIMITER FOR FUEL RETURN 44 . . . . . . .
GENERAL SPECIFICATIONS 45 . . . . . . . . . . . . . . . . .
- Section pictures of complete engine - common rail
version 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 SECTION 3 - INDUSTRIAL APPLICATION NEF ENGINES
x
Page
- Engine setting operations for the assembly on
turning stand 46 . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OVERHAUL 46 . . . . . . . . . . . . . . . . . . . . . . .
- Preface 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly of application components 48 . . . . .
- Assembly of application components 55 . . . . . . .
- Completion of the engine 65 . . . . . . . . . . . . . . . .
PART TWO -
ELECTRICAL EQUIPMENT - MECHANICALS
ENGINES 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES
WITH ROTARY PUMP) 69 . . . . . . . . . . . . . . . . . . .
- Cooling liquid temperature sensor 70 . . . . . . . . . .
- Starter 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- KSB Water temperature sensor 70 . . . . . . . . . . . .
- Electromagnets assembled to feed pump 71 . . . .
- Oil pressure switch 71 . . . . . . . . . . . . . . . . . . . . .
- Alternator 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Pre-post heating resistor 71 . . . . . . . . . . . . . . . . .
PART TWO -
ELECTRICAL EQUIPMENT - ELECTRONICS
ENGINES 73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OF MAIN ELECTRICAL
COMPONENTS 75 . . . . . . . . . . . . . . . . . . . . . . . . .
- EDC7 ECU 76 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connector to injectors (A) 77 . . . . . . . . . . . . . . .
- Feed connector (B) to components and to functions
of the specific equipment 78 . . . . . . . . . . . . . . . . .
- Connector to sensors (C) 79 . . . . . . . . . . . . . . . .
- Temperature and air-pressure sensor 80 . . . . . . .
- Sensor of engines oil temperature and
pressure 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Driving shaft sensor 80 . . . . . . . . . . . . . . . . . . . . .
- Timing system sensor 80 . . . . . . . . . . . . . . . . . . . .
Page
- Fuel pressure sensor 81 . . . . . . . . . . . . . . . . . . . .
- Fuel temperature sensor 81 . . . . . . . . . . . . . . . . .
- Resistor pre-post heating 81 . . . . . . . . . . . . . . . . .
- Cooling liquid temperature sensor 81 . . . . . . . . . .
- Starter 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electro-injectors 82 . . . . . . . . . . . . . . . . . . . . . . . .
PART THREE - TROUBLESHOOTING
(MECHANICALS ENGINES) 83 . . . . . . . . . . . . . . .
(ELECTRONICS ENGINES) 91 . . . . . . . . . . . . . . .
METHODS OF DIAGNOSIS 93 . . . . . . . . . . . . . . . . .
FAULT CODES 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PART FOUR - MAINTENANCE PLANNING 99 . . .
MAINTENANCE PLANNING 101 . . . . . . . . . . . . . . . .
- Recovery 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Planning of controls and periodical intervention 101
- Checks not included in maintenance planning-daily
checks 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE PROCEDURES 102 . . . . . . . . . . . . . .
- Checks and controls 102 . . . . . . . . . . . . . . . . . . . .
- Engine oil level check. 102 . . . . . . . . . . . . . . .
- Check of fuel system 102 . . . . . . . . . . . . . . . .
- Cooling system check 103 . . . . . . . . . . . . . . .
- Lubricating system check 103 . . . . . . . . . . . . .
- Check of water presence within fuel filter or
pre-filter 103 . . . . . . . . . . . . . . . . . . . . . . . . . .
- Check of drive belt tensioning 104 . . . . . . . . .
- Check of belts tear and wear status 104 . . . .
- Check and setting of tappet clearance 104 . . .
- Oil motor and filter replacement 104 . . . . . . .
- Fuel filter replacement 105 . . . . . . . . . . . . . . .
- Alternator belt replacement 106 . . . . . . . . . . .
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Figure 1
GENERAL INFORMATION
NEF engines have been designed and developed by Iveco
Motors specifically for transportation by land and farming
equipment in general.
They are characteristed by diesel cycle 4 stroke atmospheric
or supercharged 4 and 6 cylinders each with 2 valves.
Feed is provided by rotary mechanical pump or on line
according to the equipment application.
It differs from other applications because of the provision of
different power, power take-off for the different collector
configuration, priming pump, oil pan and boost turbine.
The section herein described is composed or four directories:
- directory of mechanical overhaul prescribed in
accordance to the engines specific duty, illustrating all
necessary operations to remove and assembly the
external components of the engine, including cylinder
heads, gearbox of the timing system and of the front part
cover;
- electrical directory, describing the connections of the
different components, of the pre-post heating gearbox
(only for some versions) and of the sensors assembled to
the engine;
- troubleshooting directory;
- directory of preventive and regular maintenance
operations, providing instructions for the execution of the
main operations.
The picture shows application designed for 4
cylinders version, 2 valves per cylinder, having fuel
feed mechanical pump
Data, technical specifications and performances
grantedshall be validonly if the Setter will followand
comply with all installation prescriptions provided
by Iveco Motors.
Furthermore, the expanders assembled by the
Setter must always comply with couple, power and
number of revolutions based on which the engine
has been designed.
NOTE
NOTE
03220t
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PART ONE - MECHANICAL COMPONENTS
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The following information relate to the engine overhaul
operations only for what concerns the different components
customising the engine, according to its specific duties.
With regard to the engine disassembly operations,
please apply for information consulting the specific
manual. All operations of engine disassembly
operations as well as overhaul operations must be
executed by qualified engineers provided with the
specific tooling and equipment required.
Figure 2
Within General overhaul section, 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
For specific application exigencies, some units can
be assembled to the engine in different positions.
- disassemble lubrication oil exhaust pipe from the
turbo-blower:
Underneath the turbo-blower loosen the two screws
(2), loosen the screw (3) fixing the pipe throughout the
stop collar (4) fixing the block; finally loosen and remove
the union (5) fromthe block; plug the pipe ends and the
exhaust of the turbo-blower.
Figure 3
75671
75672
- Disassemble the starter;
Properly hold the starter (1) and loosen the fixing screws
(2);
- assemble the bracket bearing 99361037 using the four
screw threaded ports (3).
2
3
4
1
5
1
2
3
Figure 4
OVERHAUL OF THE 4 CYLINDER ENGINE
PROVIDED WITH MECHANICAL ROTARY
PUMP
Preface
Part of the operations illustrated within this section can be
partially executed while the engine is assembled on the
vehicle, depending on the room available for access to the
engine and on the equipment application as well.
NOTE
NOTE
75670
In order to apply the brackets 380000661 to the engine
block to fix it on to the stand 380000301 for the overhaul,
it is necessary to perform the following operations:
On the right hand side:
- disassemble pipes (1) from the union (2) fitting the
lubrication oil filter (assembled on the opposite side):
unlock the nuts fixing the pipes (1) and remove themfrom
the union (2); drain the oil eventually still inside the pipes
and plug them properly in order to avoid impurity inlet.
For some versions, the oil filter (3) is directly
assembled on to the heat exchanger:in such case
it shall be disassembled using tool 380000670.
Warning: the oil filter contains inside aprx. 1 kg. of
engine oil. Provide for oil recovery and disposal in
compliance with the law and regulations in force.
3
2
1
NOTE
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Figure 5
From the left-hand side:
- Assemble the second bracket 380000661 throughout
the screw-threaded ports (1).
- Lift the engine using the rocker arm 380000216 and put
it on the turning stand 380000301.
- Drain the oil through the cap underneath the plug.
Figure 6
On the left hand side:
- Disassemble oil filter (1) and bracket as well (for versions
with engine oil filter not directly assembled on to the
exchanger);
Using tool 380000670 operate on oil filter;
Loosen the screws (3) removing the bracket together
with the filter bearing (4 and 5).
75673
Warning: the oil filter contains inside aprx. 1 kg. of
engine oil.
Provide tank with sufficient capacity to contain the
liquid.
Warning: avoid contact of engine oil with the skin:
in case of skin contamination rinse in running water.
Engine oil is highly pollutant: provide for disposal in
- Remove the oil level rod together with guide pipe (2);
(loosen the guide pipe disassembling from the block);
properly pipe the screw-threaded port to avoid inlet of
foreign matters.
75674
Warning: avoid contact of engine oil with the skin:
in case of skin contamination, rinse in running water.
Engine oil is highly pollutant: provide for disposal in
2
1
3
4
5
1
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Figure 7
Proceed disassembling the supercharger:
- loosen the fixing nut (1) and remove the lubrication pipe
from the supercharger. Analogously carry out the same
operation on the other end of the pipe and remove it
from the upper part of the heat exchanger.
- Loosen the screw nuts fixing the supercharger on the
exhaust manifold.
- Hold up the supercharger and after lifting it remove the
gasket.
75675
1
Disassembly of application components
70126
Figure 8
To disconnect fuel pipelines (2 and 3, Figure 8), in
low pressure from the relating pipe fittings, it is
Necessary to press the locking fastener (1) as
shown in picture B.
After having disconnected the pipeline, reset the
locking fastener (1) in lock position as shown in.
picture A, to avoid any possible deformation of the
fastener itself.
NOTE
Figure 9
- Place a container under the fuel filter and screw out the
condense drain faucet underneath said filter. Carry out
complete drainage of the fuel contained therein.
- Screw out completely the faucet and, using equipment
380000670 disassemble oil filter (1).
- Disconnect fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one to
the feed pump.
- Remove the fuel filter bearing (4) from the bracket fixed
to the engine head.
90502
Figure 10
75677
- Disconnect the LDA pipe (1) from the head and from
the feed pump. Pipe the ends of the pipelines as well as
the feed pump and the engine head.
1
BOSCH VE 4/12 F Pump
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7
6 5
1
2
3
4
Figure 11
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing
screw (on suction collector plate).
75680
- Disconnect the pipelines (1) and (2) that provide feed
and fuel recovery between pump and injectors; screw
out the nuts fixing the pipes to the pumping elements;
loosen the fuel recovery pipe collar on the injection
pump; operate on the nuts assembled to the injectors
and loosen the screws fixing the fuel recovery pipeline;
loosen the screws holding the fixing brackets of such
pipelines (1,6, and 7, SENZA CODICE); pipe the
pipeline ends.
- Disassemble the injectors and remove them from their
slot: remove the gaskets.
Figure 12
75679
1 1
2
- Loosen the two fixing screws (2) and disassemble
priming pump (1).
88102
Figure 13
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1
2
Figure 14
- Remove tappet caps:
Loosen the four fixing screws (1) and lift the caps (2);
remove the gaskets.
87406
On the central cap there is a blow-by valve for the
lubrication oil vapours.
All the gaskets shall always be replaced during
assembly.
NOTE
Figure 15
- Disassemble suction and exhaust manifolds: loosen the
8 screws (1) fixing the suction manifold plate to the
cylinder head (two of them have already been
screwed-out since fixing the pipe brackets to the
injectors); from the exhaust manifold side;
loosen the (2) fixing screws; remove the gaskets.
87409
Figure 16
- Disassemble rocker arm bearings; loosen the two fixing
screws (2) and remove the completerocker armbearing;
withdraw tappet rods. Repeat the operation for all the
remaining rocker arm bearings.
- Disassemble water temperature transmitter (1).
75683
Figure 17
- Remove the belt tightener (2).
- Remove the belt (4) of the ancillary members by acting
on the alternator fixing bracket (1).
- Remove the alternator (3), the water pump (6), the fan
pulley (5) and the jockey pulley (7).
- Remove the pulley support (8).
- Remove the engine block cooling system connector (3).
86571
For applications with automatic belt stretcher
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- Loosen screw (1) and relevant nut on belt stretcher
bracket (3).
- Loosen screw (2, Figure 19) in order to slide out
POLY-V belt (2).
- Remove the belt stretcher bracket (3).
- Disassemble the driven pulleys and the guide rollers.
88089
88091
- Loosen the screws (1) and withdraw the alternator
bearing (2).
75686
- Properly hold the alternator (1) separating it from its
bearing by loosening the screw (2); remove screw nut
and washer.
1 2
Figure 18
Figure 19
Figure 20
The shape and the dimensions of the support of
the alternator vary according to the use of the
engine. The relevant pictures provide a general
trace of the intervention that is to be carried out.
The procedures described are always applicable.
NOTE
1
2
4
5
3
Figure 21
75685
- Disassemble thermostat unit; loosen the three fixing
screws (1) and disassemble the thermostat unit (2)
together with the bracket (3); remove the gasket (4) and
the thermostat (5).
- Assemble the bracket in the original position fixing it with
the screws of the thermostat unit.
For applications with traditional belt stretcher
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Figure 22
Figure 23
- Disassemble cylinder head;
loosen the screws (1) and (2) fixing the cylinder head (3);
hook the brackets with metal ropes and, throughout a
hoist withdraw cylinder head from the block.
75688
3
4
1
2
3
4
1
2
75692
- Use the tool 380000988 (2) to operate on the flywheel
cover box (1) in order to block flywheel rotation (3).
(Utilise starter holding down studs andfixing screwnuts).
- Loosen the flywheel fixing screws (4) to engine drive
shaft.
- Loosen the screws (1) and disassemble the pulley (2).
90504
In some versions there is provided 380000144 tool
checking the flywheel.
Figure 24
75810
- Loosen the screws (4) and disassemble the oil
pressure/temperature sensor (3) (if fitted).
- Loosen the screws (1) and disassemble the oil filter/heat
exchanger bearing (2), interlayer plate (6) and relating
gaskets.
- Disassemble oil level sensor (5) (whether provided).
- Disassemble injection pump (see specific procedure)
and the power take-off underneath.
Figure 25
NOTE
The shape and the dimensions of thesupport of the
alternator vary according to the use of the engine.
The relevant pictures provide a general trace of the
intervention that is to be carried out.
The procedures described are always applicable.
NOTE
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Figure 26
Figure 27
Figure 28
- Remove the engine drive shaft fixing ring from the front
cover. Use the tool 380000665 (4) to operate on the
front tang (2) of the engine drive shaft. Throughout the
tool guide ports, drill the internal holding ring (1) using
3,5 mm drill for a 5mm depth. Fix the tool to the ring
tightening the 6 screws specially provided.
Proceed withdrawing the ring (1) tightening the screw
(3).
78256
00904t
- Using the specially provided tie rod (3) for the tool
380000669 and the lever (4), withdraw the external
holding ring (2) from the front cover (1).
- Loosen the screws (1 and 3) and remove the front cover
(2).
Take note of the screw(1 and 3) assembly position,
since the screws have different length.
Figure 29
- Loosen the screws (1) and remove oil pump (2).
75811
- Screwout the opposite screws (1) fromthe ports where
the withdrawal pins shall be introduced (see picture
following).
- Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (4).
- Remove the flywheel block tool (2).
75691
1
2
3
4
Figure 30
116242
NOTE
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Figure 31
75690
- Screw up two medium length screws in the ports (4) to
sling the flywheel with a hoist.
Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine
flywheel withdrawal by means of a hoist.
00903t
- Remove the flywheel cover box fixing ring using the
tool 380000663 (3) to operate on the back tang (5) of
the engine drive shaft. Throughout the tool guide ports,
drill the internal holding ring using 3,5 mm drill for
a 5mm depth.
- Fix the tool 380000663 (3) to the ring (1) tightening the
6 screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using the specially provided tie rod (3) for the tool
380000669 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
Figure 32
70153
- Loosen the screws (2) and remove the flywheel cover
box (1).
Take note of the screw(1) assembly position, since
the screws have different length.
Figure 33
- Turn the engine upside-down.
- Loosen the screws (2), disassemble the plate (3) and
remove the oil pan (1).
88046
The shape and dimensions of the pan and of the
rose pipe may vary according to the engine
application. The relating illustrations provide
general guidelines of the operation to be
performed. The procedures described are
applicable anyway.
1
2
3
4
Figure 34
NOTE
NOTE
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- Loosen the screws (1) and disassemble the oil suction
rose pipe (3).
- Loosen the screws (2) and remove the stiffening plate
(4).
90505
Figure 35
- Loosen the screws (1) and disassemble the gear fromthe
camshaft (2).
70157
- Loosen the screws (2) and disassemble the timing
gearbox (1).
Figure 36
Version with suction rose type B
Figure 37
Figure 38
- Remove the screws (1) and (4) and disassembled the
suction rose (5).
- Remove the screws (2) and disassemble the stiffening
plate (3)
Version with suction rose type A
99222
86601
Figure 39
86578
By means of pin (1) lock the additional masses (2) in the
P.M.S. Loosen the fixing screws (3) and remove the additional
masses (2).
Version with additional masses
NOTE
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- Loosen the screws (2) and remove the flywheel cover
box (1).
87424
87422
- Remove the screws (1) and disassemble the gears (3)
and (4) from the camshaft (2).
87655
- Remove the gear (1) transmitting motion to the ignition
pump and the relevant support.
Version with reduced distribution
Figure 40
Figure 41
Figure 42
NOTE
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- Reassemble to box (1) to the engine block.
- Tighten the fixing screws in the same position as found
out during disassembly and fix the screws to the locking
couples listed here below, following the order as shown
in the picture.
Screws M12 65 89 Nm
Screws M8 20 28 Nm
Screws M10 42 52 Nm
DIAGRAM SHOWING SCREW
TIGHTENING TO FIX REAR GEARBOX
It is necessary and essential to clean the surface to
be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order to
form a kerbstone of a few mm. Diameter.
It must be uniform (no crumbs), with no air blisters,
thinner or irregular zones.
Any eventual imperfection shall be correct as soon
as possible.
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both sides
of the joint and obstruct lubricant passages.
Couplings must be assembled within 10 minutes
after completing the sealing operation.
Figure 43
Installation of rear components
DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION WITHIN GEARBOX AREAS
- Accurately clean the timing gearbox (1) and the engine
block.
75712
!
75711
Figure 44
Figure 45
70211
- With a felt-tip pen, highlight the conducting gear tooth
(1) mounted on the engine shaft (2) upon the upright
surface on which a groove has been created for the
ignition timing.
Screw up two pins to facilitate operation of engine
drive shaft rotation.
Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt.
1
1
2
3
4
5
6
7
8
9 10
1
NOTE
NOTE
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Figure 46
90506
- Turn the engine shaft (3) and the distribution shaft (4)
so that by mounting the bevel gear on the latter (1) the
stencilled mark on the gear (1) coincides with the groove
on the gear tooth (2).
Figure 47
90507
- Tighten the screws (1) fixing the gear to the camshaft (3)
and lock them to the prescribed couple.
Figure 48
75708
APPLICATION.
1
Figure 49
90508
- Position comparator (1) on timing system gear (2) and
check that the clearance between gears (2) and (3) is
within 0.076 0.280 mm range.
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Apply sealing LOCTITE 5205 on the box in order
to forma kerbstone of a fewmm. Diameter. It must
be uniform(no crumbs), with no air blisters, thinner
or irregular zones.
as possible.
much sealing material would drop out on both
sides of the joint and obstruct lubricant passages.
Figure 50
75709
DIAGRAM SHOWING SCREW
TIGHTENING TO FIX FLYWHEEL COVER BOX.
- Reassemble the box (1) to the engine block, tighten the
fixing screws in the same position as found out during
disassembly and fix the screws to the locking couples
listed here below, following the order as shown in the
picture.
Screws M12 75 95 Nm
Screws M10 44 53 Nm
!
the ports and of the screws have no evidence of tear
and wear nor dirt.
1
2
3 4
5
6
7
8
9 10
11
12
13
14
15 16
17
18
19
20
21
1
Figure 51
Figure 52
- Apply to engine drive shaft rear tang (6), the detail (5)
of the tool 380000666, fix it tightening the screws (4)
and key the new holding ring on it (3).
- Place detail (1) on detail (5), tighten the screw nut (2)
until complete assembly of the fixing ring (3) into the
flywheel cover box (7).
1 2
0901t
75696
NOTE
- Check the contact surface (1) of the clutch plate and if
it is scratched, proceed with turning.
- Check ring gear teeth (2), if breakage or excessive wear
is found remove the ring gear from the engine flywheel
(1) using a suitable hammer and fit the new one,
previously heated to 150C for 15 to 20 minutes.
Chamfering on ring gear inside diameter shall be facing
the engine flywheel.
x
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Installation of rear components with reduced
distribution
70211
- With a felt-tip pen, highlight the conducting gear tooth
(1) mounted on the engine shaft (2) upon the upright
surface on which a groove (3) has been created for the
ignition timing.
Screw up two pins to facilitate operation of engine
drive shaft rotation.
- Turn the engine shaft (3) and the distribution shaft (4)
so that by mounting the bevel gear on the latter (1) the
stencilled mark on the gear (1) coincides with the groove
on the gear tooth (2).
87653
- Place the dial gauge (1) on the timing gear (2) and check
that the slack between the gears (2) and (3) is included
in the range between 0,076 0,280 mm.
87654
- Fit the screws (1) fastening the gears (2) to the camshaft
(3) and tighten them to the prescribed pair.
87655
- Spline the gear (1) transferring motion to the ignition
pump.
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
NOTE
114791
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APPLICATION
87656
Apply sealing LOCTITE 5205 on the box in order
to forma kerbstone of a fewmm. Diameter. It must
be uniform(no crumbs), with no air blisters, thinner
or irregular zones.
as possible.
much sealing material would drop out on both
sides of the joint and obstruct lubricant passages.
- Re-assemble the box (1) to the engine basement.
- Tighten the fastening screws (2) to the same position
detected before disassembly.
87659
- Apply to the rear tongs hold (3) of the engine drive shaft
the part (6) of the tool 380000664, fix it with the screws
(1) and spline the new tight ring to it (2).
- Place the part (5) on the part (6), tighten the nut (4)
until tight ring assembly (2) into the flywheel box is
completed.
- Fit the power take-off gear (2) (if available) into the
specially provided housing and fasten the screws (1),
87657
87658
Figure 58
Figure 59
Figure 60
Figure 61
NOTE
NOTE
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Figure 62
- Tighten the screws (4) fixing the engine flywheel (3) to
the engine shaft. Use tool 380000988 (2) to operate on
the flywheel cover box (1) to block engine flywheel
rotation.
- Screw up two hooks or trail rings in the flywheel (1)
threaded ports (4) for handling .
- Using a hoist, handle the flywheel to place it in its housing
inside the flywheel cover box.
- Screw up to pins (2) having appropriate length, in the
shaft ports (3) and using them as guide, assemble the
engine flywheel (1) properly placing it inside the flywheel
cover box.
75690
Figure 63
75692
1
2
3
4
2
1
3
4
Figure 64
Tighten the engine flywheel (1) fixing screws (2) in two

phases:
- 1st phase; tightening by means of dynamometric wrench
to couple 30 4 Nm;
- 2nd phase, 60 5 angle dwell with tool 380000304.
1
2
75695
70220
- Assemble oil pump (1).
- Tighten fixing screws (2) and lock themto the prescribed
couple.
Figure 65
Figure 66
70221
- Apply to the water pump (1) a new fixing ring (2).
CNH
PARTS
- Assemble the water pump (1).
- Tighten the screws (2) and lock them to the prescribed
couple.
Figure 67
76112
Flywheel installation Installation of front components
NOTE
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Figure 68
- Assemble the plate (3), the suction rose (5) and tighten
the fixing screws (1, 2 and 4) to the prescribed torque.
Figure 69
- Apply on engine drive shaft front tang (6) the detail (4)
of the tool 380000666, fix it with the screws (5) and key
the new holding ring on it (7).
- Place the detail (2) on the detail (4), screw-up the
threaded nut until carrying out the complete assembly
of the holding ring (7) to the front cover.
CNH
PARTS
00902t
- Assemble the front cover (2) to the block and tighten
the screws (1) fixing them to the prescribed couple.
Figure 70
Figure 71
- Accurately clean the contact surface of engine block and
apply sealing LOCTITE 5205 on it in order to form a
uniform and continuous kerbstone with no crumbs.
86601
75710
Figure 72
87260
- Assemble the plate (1), the rose pipe (2), tighten the
fixing screws (3) and fix them to the prescribed couple.
Figure 73
- Remove the fixing ring (2) from the front cover (1),
accurately clean the plug surface.
106549
106550
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Figure 74
Figure 75
Fit the additional masses (2) and tighten the screws (3) on
the engine block.
Remove the lock pin (1) of the additional masses.
86578
Assembly of additional masses
Timing of additional masses
Version with reduced distribution
Match the signs (A) engraved on the gears for timing, insert the pin in the hole (B) on the balancing mass.
86614
1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) -
4. Additional masses.
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Figure 76
75814
CNH
PARTS
- Assemble the following elements to the block: new
gasket (1), heat exchanger (2), new gasket (3), oil filter
bearing (4).
Tighten the screws (5) and lock them to the prescribed
couple.
75697
- Assemble the pulley (1) to the engine drive shaft , and
the distance ring (3).
- Tighten the fixing screws (2) and lock them to the 68
7 Nm couple.
Figure 77
- Provide for newgasket replacement (1) of theoil pan (2).
The pictures illustrating the pan and of the rose
pipe may not correspond to the ones of your
model. However the procedures described are
applicable anyway.
- Assemble oil pan (1), apply the plate over it (2). Tighten
the screws (2) and lock them to the prescribed couple.
88046
Figure 78
Figure 79
1 2
3
NOTE
NOTE
NOTE
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Figure 80
Figure 81
76114
75686
- Connect the alternator (1) to the support.
- Tighten the screw without locking it (2).
Figure 82
Figure 83
- Place the gasket (1) over the block.
The choice of the gaskets thickness shall be made in
consideration of the cylinder protrusion measured with
respect to the blocks upper surface.
Verify that the engine block stand is clean.
Do not grease the gasket. It is recommended to
keep the gasket inside packaging until assembly to
the cylinder head.
Gasket assembly shall be made following the
direction of wording printed on the gasket itself so
that this will be readable as indicated in the picture.
76113
1 2
87759
- Lubricate the fixing ring (2) using engine oil and place it
on the oil filter (3).
- Manually start the oil filter (3) on the bearing union (1)
until counter-boring, further screw up the oil filter (3) by
3/4 turn.
- Place a new fixing ring on the block housing (6).
- Apply, (if needed) new fixing ring on the oil
temperature/pressure sensor (4) and assemble it to the
bearing (1) tightening the fixing screws to the prescribed
couple.
CNH
PARTS
- Assemble the alternator bearing (1) ensuring that the
pins (3 and 4) are against the engine block.
- Tighten the screws (2) and lock them to the prescribed
couple.
The shape and the dimensions of the alternator
support vary according to the use of the engine.
Therefore the relevant pictures provide a general
guideline of the intervention that is to be carried out.
However the procedures described are applicable.
NOTE
NOTE
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Figure 84
Figure 85
75688
- Place the head (3) over the block and insert screws (1)
and (2).
If the valves have been removed from the head, it
is necessary to assemble them before assembling
the head itself on the engine block.
76115
Figure 86
- Carry out the assembly of the rocker arms after previous
check of the components.
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms-
4. Support.
Figure 87
75702
SHAFT AND ROCKER ARM BASIC DATA
Check the coupling surfaces of bearing and shaft: no evidence
of excessive wear shall be detected or damages.
Replace if necessary.
CNH
PARTS
Figure 88
ROCKER ARM ADJUSTMENT SCREW
If unscrewed, check adjustment quota.
Tighten the screw-threaded nut (1) to the i 0.4 - 0.6 Nm
couple.
- Lubricate cylinder head bolts and install to head.
- Bolts must be torqued using stitching pattern starting
with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque, then
90 degrees rotation for all bolts. Then a further 90
degrees for the M12 x 140 and M12 x 180.
M12 x 70 50 Nm + 90 degs
M12 x 140 40 Nm + 180 degs
M12 x 180 70 Nm + 180 degs
1
2
3
4 5
6
7 8
9
10 11
12
13 14
1
2
3
4
75705
1
2
3
4
1
2
3
75704
18.975
18.963
19.000
19.026
19.000
19.026
1
19.00
16.00
NOTE
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Figure 89
Figure 90
32655
Before executing assembly, check the Rocker Arm driving
rods: these shall not be deformed; the spherical ends in
contact with the Rocker Armadjustment screwand with the
tappet (arrows) shall not present evidence of seizure or wear:
in case of detection proceed replacing them.
The rods driving the suction and exhaust valves are identical
and therefore interchangeable.
75703
- Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure themtwice
as indicated in the picture, checking D1 and D2
diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced;
Figure 91
75683
- Tighten the screws (2) to the prescribed couple and
assemble water temperature sensor (1).
Figure 92
75806
CNH
PARTS
Adjust the slack between rocker arms and valves using socket
wrench (1), point wrench (3) and feeler gauge (2).
Correct slack is:
- suction valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.
1
2
D1 D2
2
1
3
On TIER 3 engines, due to the additional lobe for
the INTERNAL E.G.R., it is not possible to use the
valve clearance adjustment procedure that
requires adjusting the clearance of all the valves by
positioning the crankshaft 2 times only.
Each cylinder must be checked by taking it to the
T.D.C. (top dead centre) at the end of compression
and adjusting the clearance of both valves on the
cylinder in question.
NOTE
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75685
Figure 93
Figure 94
- Assemble exhaust manifold (1) providing new gaskets
(2).
Figure 95
75808
- Assemble thermostat unit (2) including thermostat (5)
and gasket (4).
- Tighten the screws to the prescribed couple.
Figure 96
- Assemble injectors after having replaced the sealing
gasket (1).
75707
The screws (1) have been have been utilised to fix
the bracket (3).
Disassemble the bracket and reassemble
components from 1 to 5 as shown in the picture.
The gasket must be new.
CNH
PARTS
CNH
PARTS
CNH
PARTS
1
- Assemble cylinder covers (2) with the respectivegaskets;
- Fit the seal nods and tighten the screws fixing them to
the prescribed couple.
During assembly of injectors, verify that theinjector
sphere is correctly positioned on the head housing.
Always replace the gaskets using new ones.
Check the threads of the fixing screws: there shall
be no evidence of wear or dirt deposit.
Seal nods shall have no visible deformation. In such
case provide for replacement with new nods.
CNH
PARTS
1
2
1
2
3
4
5
The illustration of exhaust manifold may be not
matching your model. Anyhow, described
procedure is applicable.
NOTE
87406
NOTE
NOTE
NOTE
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Figure 97
Figure 98
88090
If the old belt is to be reassembled examine it
carefully in order to see if there may be incisions or
evident signs of yielding.
75687
CNH
PARTS
1
3
2
- Assemble the pulley fan bearing tightening the screws to
the prescribed couple.
- Assemble the alternator tensioning bracket.
- Mount pulley (3) and secure it to support through
screws (2).
- Assemble the transmission pulley (1).
- Fit the new belt onto the pulleys and guide rollers.
- Tighten the control belt turning the alternator as
illustrated.
- Tighten the screws (1) and the alternator fixing bolt to
the support.
NOTE
For applications with automatic belt tensioner
Figure 99
86571
Assemble belt Poli-V (4) on the pulley (5) of the engine shaft,
on the jockey pulley (2), on the water pump (6) and on the
alternator (3), tighten (syn.: tension) the belt by means of the
automatic belt tensioner.
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- Apply on the surface joining the suction manifold plate
(1) a sufficient coat of Loctite 5999 and provide. fixing
the screws to the prescribed couple.
- If the pipe (6) of the suction manifold plate (1) has been
removed, reassemble it after having fit a new gasket (5).
- Tighten the screws (7) to the prescribed couple.
75701
3
4
5
6
7
1
2
Figure 100
For the versions provided with heater, also
assemble components (3) and (4).
CNH
PARTS
NOTE
- Assemble the brackets (1) fixing the fuel pipelines to the
injectors: use the same screws (2) fixing the manifold
plate as shown in the picture.
Figure 101
CNH
PARTS
75700
1
2
88102
- Assemble priming pump (1) providing new gasket and
tighten the screws (2) to the prescribed couple.
- Also assemble feed pump (see specific procedure) and
the power take-off underneath.
Pump mounting requires specific procedure
contained in this section.
Figure 102
NOTE
88102
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Figure 103
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing
screw (on suction collector plate).
75680
7
6 5
1
2
3
4
BOSCH VE 4/12 F pump
- Assemble the pipes (1) and (2) providing fuel feed and
recovery between pump and injectors;
Screw up the locking nuts and tighten the screws fixing
the fuel recovery manifold; fix the pipes to the injectors
throughout the brackets previously assembled.
Figure 104
75679
1 1
2
Figure 105
75677
- Fix the LDA pipeline (1) to the engine head and to the
feed pump.
1
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70126
Figure 106
To connect fuel pipelines (3 and 4, Figure 108) in
low pressure from the relating connection unions
it is necessary to press the locking fastener (1) as
shown in picture B.
After having connected the pipeline, reset the
fastener (1) into block position as shown in picture
A.
NOTE
Figure 107
Proceed assembling the turbocharger:
- Hold the turbocharger and place it on the exhaust
manifold after having interposed the gasket.
- Screw up the fixing nuts of the turbocharger to the
exhaust manifold tightening them to the prescribed
couple.
- Tighten the lubrication pipe fixing ring. Operate in the
same way on the other end of the pipe. Connect it to
the upper part of the heat exchanger.
To complete engine assembly it is necessary to remove it
from the turning stand.
- Using rocker arm 380000301 hold the engine and
loosen the screws fixing the brackets to the turning stand
380000301.
- Disassemble the brackets 380000661 from the engine
after having properly put it on a wooden bearing.
75675
1
Figure 108
- Assemble the fuel filter bearing (4) to the bracket fixed
to the engine head.
- Connect the fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one to
feed pump.
- Using 99360076 equipment assemble fuel filter (1).
90502
The filter shall be priory filled with fuel to facilitate
feed system bleed operations.
NOTE
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1
2
3
4
1
5
75670
Figure 109
On the right hand side:
- reassemble the pipes (1) from the union (2) to the
lubrication oil filter (placed on the opposite side): tighten
the pipe rings (1) and connect them to the union
In some cases, the oil filter (3) is directly placed on
the heat exchanger: in this case it shall be
assembled using tool 99360076.
- Reassemble the lubrication oil exhaust pipeline (1) from
the turbocharger: from underneath the turbocharger
tighten the two screws (2); tighten the screw (3) fixing
the pipeline to the block throughout the fixing collar (4)
to the block; finally tighten the union (5) to the block.
Figure 110
75671
Completion of the engine
3 1
2
Figure 111
75717
Figure 112
75673
On the left hand side:
- Assemble oil filter (1) together with bracket (for the
versions with engine oil filter not directly assembled to
the exchanger); tighten the screws (3) assembling the
bracket (4) including filter bearing (5).
Using tool 99360076 screw up oil filter;
- Assemble oil level rod together with guide pipe (2).Fill up
engine oil.
- Install the engine on the machine (for installation
operations please apply to specific issue).
2
1
5
4
3
NOTE
- re-assemble the starting engine (1); opportunely support
the starting engine (1) and tighten the two fastening
screws to the prescribed torque.
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Figure 113
Rotary feed pump disassembly and assembly
procedure
This procedure prescribes that:
- the fuel pipes (from the pumping elements to
the injectors, recovering blow-by from the
injectors to the pump and the supply from the
priming pump) have all been removed;
- the electrical connections have been
disconnected.
- Accelerator cable shall be disconnected.
In case feed pump replacement is necessary, this shall be
supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the engine
and disassemble it only afterwards.
The following procedure analyses this second hypothesis
since it is the more complex.
Disassemble the starter from the flywheel box and use tool
380002385 to rotate the flywheel.
75714
Figure 114
Engine versions with tool (380002385)
Engine versions with tool (380000988)
88140
1
1
2
Disassemble the starter from the flywheel box (1) and use
tool 380000988 (2) to rotate the flywheel.
Figure 115
88141
Find the top dead centre with the tool (380000977) - False
injector
1
Remove the rocker covers of the 1
st
cylinder; remove the 1
st
injector and place the tool (1) to set the 1
st
cylinder top dead
centre position (end-of-compression phase). Pre-load the
gauge.
The searched condition is obtained by rotating the engine
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
valves are both closed.
Once PMS has been obtained, lock the flywheel by means of
tool 380000988 (Figure 114).
Figure 116
84071
Searching for the top dead centre with timing gear blocking
pin
Turn the flywheel until, when pushing the pin 380002729 (1),
it blocks the gear (2) obtaining the TDC of the 1 cylinder.
NOTE
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Figure 117
- Unscrew the side screw that locks the pump shaft
partially (1) and remove spacer (2). This must be kept on
a side (we recommend to fix it on the pump with a wire
or a clip).
- Tighten the lateral screw (1) blocking rotation of the
pump shaft.
- From timing side, remove the cover (2) loosening the
screws (1) in order to have access to the union fixing nut
(3) to the pump driving gear.
- Loosen the fixing nut (3) and remove the relating
washer.
Figure 118
Figure 119
75693
75694
- From the pump side, loosen the fixing nuts (1) without
removing them in order to enable moving the pump
backwards using 380000322 extractor.
- Assemble the 380000322 extractor throughout the two
threaded ports (4, Figure 118) and withdraw the gear
from the pump shaft.
- Properly hold the feed pump and loosen completely the
fixing nuts.
- Withdraw the pump from the studs, together with the
gasket.
When the supply pump is to be assembled on the engine the
P.M.S. conditions at compression end stage cylinder No. 1
must be carried out.
Hold the pump driving gear to avoid interference
or crawling during timing gear rotation.
75721
2 1
1
1
2 3
4
BOSCH VE 4/12 F Pump
NOTE
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75694
Figure 120
- Assemble the pump pre-set in its housing on the engine,
fitting the shaft into the gear port (not provided with
wrench).
- Tighten the fixing nuts (1) locking the pump flange in the
slot centre.
- On the timing side, throughout the specially appointed
port, fit the washer and screwup the fixing nut (3) to the
pump shaft. Lock the nut to the 90-95 Nm couple.
Figure 121
Figure 122
75693
- Loosen screw (1) that prevents pump shaft rotation and
insert spacer (2). Tighten screw(1)so that it locks spacer
(2): in this way the supply pump shaft will be able to
rotate freely.
- Assemble the cover (2, Figure 121) including gasket and
tighten the screws (1, Figure 121).
- Disassemble the flywheel rotation/locking tool
380000388 or 380002385; arrange the starting motor in
its seat.
- Connect all pipelines (from pumping elements to
injectors, bleeding recovery pipes from injectors to
pump, LDA pipeline and feed provided by priming
pump).
- Connect electrical connections to electro-magnets on
the hydraulic head and on KSB.
The gasket removed during pump disassembly shall
not be utilised again.
Always use original spare parts.
CNH
PARTS
If the pump has been removed with the engine
mounted, connect the accelerator cable, if present
in the application.
1
1
2 3
4
1 2
75721
Figure 123
- With the injection pump inserted in relating seat and
securing screws loosened, mount comparator
380000228 (2) and 380000229 gauge tool (1),
preloading the rod by 2.5 mm.
- Rotate the engine derive shaft to shift fromthe condition
of the first cylinder to TDC end of compression phase.
Reset the dial gauges and rotate the engine drive shaft
into the opposite direction until recovering the
condition of the 1st cylinder to TDC in phase of
compression (see Figure 116).
From this position on the comparator applied on the
pump it must be possible to read the value listed on the
pumping element pre-lift table. Section 4.
- Rotate the pump in anti-clockwise direction if the stroke
is shorter or in clockwise direction if the stroke is longer,
until obtaining the stroke prescribed.
- Checking these conditions, lock the pump by tightening
the relevant nuts to the prescribed pair.
Ignition pump control and timing
87720
(Demonstration)
NOTE
NOTE
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Power take-off disassembly and assembly
procedure
75720
1
2
3 4
Where designed, there is a power take-off able to transmit
motion to different auxiliary parts.
Disassembly of such mechanism shall be executed as
following:
- Loosen the two screws (3) and after having removed the
cover (1) with a specially provided extractor, withdraw
the power take-off (2).
- The two gaskets (4) shall be replaced in phase of
reassemble.
- Vary out the assembly fitting the power take-off in its
housing, providing newgasket and checking the sprocket
gear meshing.
- Assemble cover and gasket and tighten the screws to the
prescribed couple.
Figure 124
Figure 125
- Disconnect the fuel pipe (1) of the filter and repeat
working on the drain lever (2) of the priming pump.
- Continue the operation until when fuel outflows.
- Connect the (1) to the filter.
87751
Feed system bleed procedure
Version with A type fuel filter Figure 126
In case any operation has been executed on the components
of the feed circuit, it is necessary to execute bleeding of air
within the system.
- Loosen the bleeder vent screw (3) on the fuel filter (1)
and keep working on the bleed lever of the priming
pump (2).
- Continue executing this operation until when fuel drains
from the bleeder vent screw.
- Tighten the bleeder vent screw (3).
76211
Version with B type fuel filter
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Checks and inspections
The following tests shall be made after engine
assembly to the vehicle.
Preventively check that the liquid levels have been
correctly restored.
- There is no water bleeding from the manifolds
connecting engine cooling circuit pipelines and cabin
internal heating, eventually providing to further tighten
the locking rings.
- Carefully check the fuel connection pipes to the
respective unions.
- There is no oil leakage from the lubrication circuit of the
various pipelines connecting cover and cylinder head, oil
pan and bearing, oil filter and heat exchanger as well as
relating housings.
- There is no fuel leakage from fuel pipelines.
- There is no blow-by from pneumatic pipes (if provided).
- Verify correct working of the lighting leds of the
dashboard containing the tools as well as of the
equipment that was disconnected during engine
disconnection.
- Check and blow by with care the engine cooling system,
carrying out frequent drainage.
Start the engine, let it run at revolution regimen
slightly higher than idling and wait that the cooling
liquid temperature reaches the value enabling
thermostat opening, then check that:
NOTE
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PART ONE -
MECHANIC OVERHAUL OF ENGINES WITH ELECTRONIC CONTROL
(COMMON RAIL)
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Figure 127
1. Rail 2. Fuel inlet from high-pressure pump
3. Overpressure valve - 4. Pressure sensor.
The rail volume is comparatively small to allow a quick
pressurisation at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise system spikes
and the use of plenum chambers caused by injectors
openings and closings and by the high-pressure pump
operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
A fuel pressure sensor (4) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
value is checked and, if necessary, corrected.
RAIL
108609
RELIEF VALVE
Mounted on the end of the rail, it has the function of
protecting the systems components in case the failure of the
rail pressure sensor or the pressure regulator of pump CP3
causes an excessive pressure increase in the high-pressure
plant.
When the rail pressure reaches 1800 bars, the valve initially
intervenes in order to allowthe fuel to flowand subsequently
to reduce the pressure within safety limits and then it
mechanically regulates the rail pressure to approx. 800 bars.
This valve allows the engine to work for long periods at a
limited efficiency and avoids the excessive overheating of the
fuel preserving the return pipes to the tank.
15
70505
Figure 128
The injector is similar as construction to the traditional ones,
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.
Injector in rest position
1. Pressure rod 2. Plunger 3. Nozzle 4. Coil 5. Pilot
valve 6. Ball shutter 7. Control area 8. Pressure
chamber 9. Control volume 10. Control duct
11. Supply duct 12. Control fuel outlet 13. Electric
connection 14. Spring 15. High-pressure fuel inlet.
ELECTRO-INJECTOR
As for NEF TIER 3 engines, BOSCH - CRIN2
electro-injectors with different injection tubes are used
working on power developed by the engine.
Jet
Powers
kW
Pressures
bar
DLLA Up to 152 250 1600
DSLA Lower to 152 250 1400
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70506
Figure 129
When coil (4) is energised, it makes shutter (6) move
upwards. The control volume (9) fuel flows towards flow
duct (12) making a pressure drop occur in control volume
(9). Simultaneously the fuel pressure into pressure chamber
(8) makes plunger (2) lift, with following fuel injection into the
cylinder.
Injection end
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
Injection start
The injector cannot be overhauled and therefore
it must not be disassembled.
15
NOTE
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 and 2 bars. By guaranteeing this
pressure to the return fuel, the fuel vapours formation inside
injectors is avoided, optimising fuel spraying and combustion.
70507
Figure 130
A To tank B From injectors
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Figure 1
GENERAL SPECIFICATIONS
Section pictures of complete engine - common rail
version
The and F4DE9684 engines are turbocharged a 4-stroke
diesel engines with 6 cylinders, with 4 valves per cylinder.
They have high pressure injection fuelling (common rail) and
are entirely electronically driven in order to optimise the
working process in accordance to the operation, limiting as
much as possible the pollution emissions and consumption.
The section herein described is composed or four sections:
- Section of mechanical overhaul prescribed in
accordance to the engines specific duty, illustrating all
necessary operation to remove and assembly the
external components of the engine, including cylinder
heads, gearbox of the timing systemand of the front part
cover;
- 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 enginehas
been designed.
116362
NOTE
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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 4, 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.
With regard to the engine disassembly operations
from the machine, please apply for Information
consulting 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.
In order to apply the brackets 380000661 to the engine block
to fix it on to the stand for the overhaul, it is necessary to
perform the following operations on the left hand side of the
engine:
- Using the tool 380000670 disassembly the fuel filter (6)
and remove it from the support (1);
- Disconnect the electrical connection (2) from the
support (1) and the heaters one (placed on the filter
support as well);
- Disconnect the fuel low pressure pipelines (3-4-5) from
the support (1);
- Disconnect pipeline (9) from the support (1);
- Remove the sustaining support bracket (1) from the
block.
Figure 2
70126
Figure 3
Press clamp (1), as shown in Figure B, to disconnect
the low pressure fuel pipes (3 4 5, Figure 4)
from the corresponding connections.
After disconnecting the pipe, reset the clamp (1) in
locking position (Figure A) to prevent distortions.
Disconnect the high pressure fuel pipeline (7, Figure 4) from
the rail diffuser and from the high pressure pump (8) and
disassemble it from the engine block removing the fixing
clamps.
Disconnect the pipeline (9) from the high pressure pump.
Because of the high pressure in the pipelines
running fromthe high pressure pump to the rail and
from this last one to the electro-injectors, it is
absolutely required NOT to:
- disconnect the pipelines when the engine is
working;
- re-use the disassembled pipelines.
Engine setting operations for the assembly on
turning stand
ENGINE OVERHAUL
Preface
Part of the operations illustrated within this section can be
partially executed while the engine is assembled on the
vehicle, depending on the room available for access to the
engine and on the equipment application as well.
NOTE
NOTE
NOTE
116364
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On the right side of the engine
Figure 4
Disconnect the oil filling pipe (1).
Unscrewthe fixing screws and disconnect the starting motor
(2) from its seat.
Figure 5
Disconnect the lubricating pipe (2) fromthe upper side of the
heat exchanger on the turbo blower (1).
Undo the fastening screws (4) and remove the support (3).
Disassemble the thermostat body including the seal.
Figure 6
Make holes (1) and (2) on both sides of the engine base,
brackets 380000661 and then fix by means of the later, the
engine to revolving stand 380000301.
Empty the engine oil by removing the cap of the sump.
116365
116366
116367
Collect and dispose of the engine oil according to
enforced regulations.
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Figure 7
Disassembly of application components
1. Connections for Electro-injectors - 2. Engine cooling liquid temperatures sensor - 2. Cable of the fuel pressure sensor -
4. Sensor of engines oil temperature and pressure - 5. Driving shaft sensor -
6. Electro-injector - 7. Temperature - air pressure sensor - 8. Timing system sensor - 9. Cable of fuel heater and fuel
temperatures sensor - 10. Cable of pressure regulating gauge - 11. EDC 7 electronic module.
Disconnect the engines cable from the connectors (1,
SENZA CODICE) wiring harness to
Electro-injectors (6); (7) air pressure/temperature sensor; (3)
fuel pressure sensor;
(11) engine control module; (10) high pressure pump sensor;
(8) timing system sensor; (2) Thermostat sensor of engine
cooling liquids temperature; (5) sensor of engines
revolutions.
Disassemble the engine from the engine block removing the
fixing clamps.
116360
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Figure 8
Remove the screws (1) and disconnect the rail (2).
Disconnect from the rail (2): the fuel pipe (7) according to
procedures described in figure (24). Disconnect fuel pipes (5)
from rail (2) and injector manifolds (6).
Figure 9
Figure 10
Disconnect the fuel return pressure limiter (1), the pipeline
by acting on the connections as described on Figure 6.
Remove the external vent pipe (2).
Loosen the nuts (3) and disconnect the tappet cap (4).
Figure 11
116368
116369
Now disassemble the supercharger:
Unscrew fixing nuts (3) of the turbo-blower (4) on exhaust
manifold (4).
Hold up turbo-blower (4) and get the seal.
Undo the fastening screws (1) and detach the exhaust mani-
fold (2).
On the opposite side, loosen the fixing screws (2) of the inlet
manifold (1) and disassemble the joint to the air heater for
the cold start.
Remove the pressure-air temperature sensor from the
induction manifold (1).
116370
116371
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Figure 12
Undo the fastening screws and remove the belt tightener (2).
Undo the fastening screws and remove the drawback pulley
(3 and 5).
Undo the fastening screws and remove the belt tightener (7).
Undo the fastening screws on the cylinder head and remove
the support (6).
Undo the fastening screws and remove the ventilator
support (1).
Figure 13
Figure 14
Remove nuts (3) and remove fuel manifolds (4).
Remove nuts (6) and disconnect the electrical cables from
injectors (5).
Remove screws (1) and disconnect injector wiring support
(2) including the gasket.
Disassembled fuel manifolds (4) must not be used
again, but however replaced with other new ones.
Figure 15
70132
Loosen tappet adjustment fastening nuts (1) and unscrewthe
adjusters.
Remove the screws (2), remove the rocker assembly (3),
consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves.
Remove rods (8).
116378
70133
Remove injector fastening screws. Use tool 380001099 (1)
to remove injectors (2) from the cylinder head.
116372
NOTE
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Figure 16
Figure 17
Figure 18
Figure 19
116373
116374
Remove the fastening screws (1) from the cylinder head (2).
The highlighted screws are shorter. NOTE
Fix suitable clips (1) to the cylinder head (2).
By means of opportune metal cables and a hoist, detach the
cylinder head (2) from the engine crankcase.
116377
Use tool 380000670 to remove the oil filter (1).
Unscrew the fixing screws (1) and disassemble the pipeline
union (2).
88555
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Figure 20
Figure 21
88557
88556
Disconnect connector (1) fromthe oil temperature pressure
sensor.
Unscrewscrews (2) and disconnect oil temperature pressure
sensor (3).
Unscrewscrews(4) and disconnect oil filter support (5) from
the base, and remove the relevant seals.
Remove the heat exchanger from its seat.
Remove nuts (1) and disconnect high pressure pump (2)
along with the fuel pump (3).
Figure 22
Figure 23
88558
Apply the tool (1) to stop flywheel rotation (2) through the
hole (3) made on the base. Tool (1) positioned in hole (3)
is to be inserted in the groove made on the flywheel blocking
its rotation.
Loosen the engine shaft flywheel fixing screws.
Undo the screws (1), disassemble the silencer (2) and the
pulley (3).
The blocking tool of the engine flywheel can facilitate disas-
sembly of dampening flywheel (2) assembled on pulley (3).
116376
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Figure 24
Figure 25
Remove the ring sealing the engines driving shaft from the
front cover. Use the tool 380000665 (4) to operate on the
front bar hold of the driving shaft. Through the steering holes
of the tool, perforate the inside holding ring (1) with a straight
way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool
to the ring tightening the 6 screws provided with the
equipment. Then proceed removing the ring (2) by tightening
the screw (3).
00900t
Figure 26
00904t
Using the specific tie rod (3) of the tool 380000669 and the
ancillary lever (4), remove the external holding ring (2) from
the front cover (1).
Remove the screws (1) and take out the front cover (2).
Take note of screw (1) assembling positions since
they have different lengths.
88560
1
2
NOTE
Figure 27
88561
Remove two opposite screws (1) from the area where the
withdrawal pins will be introduced (2, Figure 28).
Loosen the remaining flywheel fixing screws (3) from the
driving shaft (2).
Remove the flywheel locking tool (4).
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Figure 28
Figure 29
Tighten two screws of medium length into the holes (4) to
sling the flywheel with the hoist.
Throughout the two guide pins (2) previously screw into the
driving shaft holes (3) withdraw the engine flywheel (1) after
slinging it with the hoist.
00903t
Undo the screws (1) and remove the bevel gear (3) fromthe
distribution shaft (2).
Remove the holding ring of the flywheel cover box using the
tool 380000663 (3) to operate on the driving shafts back bar
hold (5).
Through the steering holes of the tool, perforate the inside
holding ring with a straight way drill (diam. 3,5mm) for the
depth of 5mm.
Fix the tool 380000663 (3) to the ring (1) tightening the 6
screws provided with the equipment (4).
Then proceed removing the ring (1) by tightening the screw
(2).
Using a specific tie rod of the tool 99363204 and an ancillary
lever, remove the external holding ring (2) from the front
cover.
88562
Figure 30
88307
Turn the engine upside down.
Remove screws (2) and disconnect oil sump (1).
Disconnect the high pressure pump stroke sensor.
Unscrew the screws(3) and remove timing gear distribution
box (4) from the base.
Figure 31
88564
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Figure 32
Assembly of application components
70211
With a felt-tip pen, highlight the conducting gear tooth (1)
mounted on the engine shaft (2) on the upright surface
where a groove has been created for the ignition timing.
Fasten screwing of the two pins to facilitate the
operation of engine driving shaft rotation.
Figure 33
NOTE
116375
Turn the engine shaft and the distribution shaft so that, by
mounting the bevel gear on the latter, the tooth with the gear
groove of the engine shaft coincides between the two marks
created on the bevel gear (1).
Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead (1) 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 (10 20 minutes).
Figure 34
88567
Tighten the screws (1) fastening gear (2) to camshaft (3) to
the specified torque (36 Nm 4 Nm).
Figure 35
70214
LOCTITE 5205 SEALANT APPLICATION AREAS
Clean accurately the timing gear case and the engine block.
NOTE
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Figure 36
88569
Before any assembly operation always verify that
the hole and screw threads have no evidence of
wear or dirt.
GEARCASE FIXING SCREW TIGHTENING DIAGRAM
Reassemble box (1) on the engine.
Tighten fixing screws (2) on the same position from where
they had been removed up to the tightening torque indicated
below.
Screws M8 20 28 Nm
Screws M10 42 52 Nm
Reconnect stroke sensor (3) of the high pressure pump.
Figure 37
88570
Apply tool 380000664 part (6) to the rear output shaft tang
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into housing.
NOTE
Figure 38
Figure 39
Figure 40
88571
Put a new seal ring on the water pump.
Assemble water pump (1); tighten the screws (2) up to the
prescribed torque.
88572
Disassemble seal ring (2) from the front cap (1), clean the
coupling surface accurately.
88573
Accurately clean the contact surface on the engine block and
position seal (1) on the base.
x
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Figure 41
Figure 42
88574
Assemble oil pump (1) on the block and tighten the screws
up to the prescribed torque.
Apply tool 380000666 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Position part (2) on part (4), screw nut (3) until completing
sealing ring (7) fitting into front cover (1).
CNH
PARTS
88575
Figure 43
Adjust the pulley (3), and the silencer (1) on the engine shaft.
Tighten screws (1) up to torque 68 7 Nm.
Assemble a new seal ring on the revolution sensor.
Assemble the revolution sensor in the front cap and tighten
the fixing screws up to the prescribed torque.
116376
Figure 44
88307
Fit the new sheath on the basement.
Assemble the oil pan (1).
Fit the screws (2) and tighten them to the prescribed pair.
Tighten the exhaust caps to the prescribed pair.
Figure 45
wear or dirt.
Check the contact surface (1) of the clutch plate and if it is
scratched, proceed with turning.
Check ring gear teeth (2), if breakage or excessive wear is
found remove the ring gear from the engine flywheel (1)
using a suitable hammer and fit the new one, previously
heated to 150C for 15 to 20 minutes. Chamfering on ring
gear inside diameter shall be facing the engine flywheel.
88581
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Figure 46
88582
Figure 47
Figure 48
Screw two manoeuvring hooks or lunettes on flywheel (1)
using holes (4).
With the help of a hoist bring the flywheel closer to its seat
inside the flywheel housing box.
Screwtwo pins (2) with proper length for shaft holes (3) and
use them as guides, assemble engine flywheel (1) by arrang-
ing it properly in the flywheel housing box.
88583
Screw engine flywheel (3) fixing screws (4) on the engine
shaft. Put the tool in the proper hole (2) in order to block
engine flywheel rotation.
88584
Tightening to angle is performed using tool
380000304. Before any assembly operation always
verify that the hole and screw threads have no
evidence of wear or dirt.
Tighten engine flywheel (1) fastening screws (2).
NOTE
Figure 49
Figure 50
88586
80359
CNH
PARTS
Fit on the engine block: a new gasket (1), the heat exchanger
(2) a new gasket (3) and the oil filter support (4).
Tighten the screws (5) to the specified torque.
wear or dirt.
CNH
PARTS
Lubricate the sealing ring (2) with engine oil and set it on the
oil filter (3).
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3) by
turn.
Apply a new sealing ring on the oil temperature/pressure
sensor (4) and fit it on the support (1).
Tighten the screws (5) to the specified torque.
Fit a new sealing ring (6) in the engine block seat.
NOTE
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Re-attach the ventilator support (1) fastening the screws to
the prescribed torque.
Re-attach the support (6) tightening the fastening screws to
the cylinder head.
Re-attach the belt tightener (7) and the drawback pulleys (3
and 5).
Re-assemble the belt tightener (2).
Figure 51
Figure 52
88587
Assemble pipeline union (1) and tighten screws (2) up to the
prescribed torque.
wear or dirt.
NOTE
116378
CNH
PARTS
Apply a new gasket to the engine block and then place the
cylinder head (2) slung by the hanger brackets (1).
116374
Figure 53
88590
Refit the high pressure pump (2) including the feed pump (3)
and tighten the nuts (1) to the specified torque.
Figure 54
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Figure 55
Assemble cylinder head (1), tighten the screws (2) in three
following steps, following order and mode shown in the
figure below.
The angle tightening is carried out through tool
380000304 (3).
70336
Tightening order layout for cylinder head fastening screws:
- 1
st
step pre-tightening with dynamometric wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
A Screw 12x1.75 x 150 ( ) 55 5 Nm
- 2
nd
step tightening with a 90 5 angle
- 3
rd
step tightening with a 90 5 angle
A = Front side
70476
Figure 56
A
6-cylinder engine
NOTE
Figure 57
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).
CNH
PARTS
70339
Fit injectors (1) on the cylinder head seats, directed so that
the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
Figure 58
70133
Use tool 380001099 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.
Figure 59
75703
D1 D2
NOTE Before using the fixing screws again, measure them
twice as indicated in the picture, checking D1 and
D2 diameters:
if D1- D2 <0,1 mmthe screwcan be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced.
x
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Figure 60
Figure 61
Figure 62
Figure 63
70341
Fit a new sealing ring (3) lubricated with vaseline on the fuel
manifold (2) and fit it into the cylinder head seat so that the
positioning ball (5) is coinciding with the relevant housing (4).
Screwthe fastening nuts (2, Figure 61) without locking them.
CNH
PARTS
Disassembled fuel manifolds (2) must not be used
again, but however replaced with other new ones.
During this operation, the injector (1) shall be
moved so that the manifold (2, Figure 58) is
properly inserted into the fuel inlet hole (2,
Figure 60).
70342
Use the torque wrench to tighten gradually and alternately
the injector fastening screws (1) to 8.5 0.8 Nm torque.
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm
torque.
Carry out the assembly of the equalisers unit , after previous
check of the components.
70343
ROCKER ASSEMBLY COMPONENTS:
1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
SHAFT-ROCKER MAIN DATA
Check that shaft/rocker coupling surfaces are not showing
excessive wear or damages.
Rocker control rods shall not be distorted; the ball seats in
touch with the rocker adjusting screw and with tappets
(arrows) shall not show seizing or wear; otherwise replace
them. Intake and exhaust valve control rods are identical and
are therefore interchangeable.
32655
CNH
PARTS
Figure 64
NOTE
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Figure 65
Figure 66
Figure 67
70345
Fit the rods (2).
Position jumpers (1) on valves with marks () facing the
exhaust manifold.
70346
Check that tappet adjusters (1) are loose to prevent their
balking on the rods (2, Figure 65) when refitting the rocker
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.
70520
Adjust clearance between rockers and valves using setscrew
wrench (1), box wrench (3) and feeler gauge (2).
Clearance shall be as follows:
- intake valves 0.25 0.05 mm
valve clearance adjustment procedure that
requires adjusting the clearance of all the valves by
NOTE
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Figure 68
Apply to the coupling surface of the intake manifold (1)
equipped with heater a sufficient coat of LOCTITE 5999 and
provide tightening the screws (2) to the prescribed matching
couple.
Fit temperature and air pressure sensor.
70352
Figure 69
Check electrical cable (5) conditions, replace if damaged by
cutting the support (2) clamps and removing the screws (5)
that secure it to connections (3).
Fit a new gasket (1) on the support (2).
CNH
PARTS
Figure 70
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.
wear or dirt.
NOTE
Connect the electric cables to the electro-injectors (3) and
with dynamometric wrench 380000158, fasten fixing nuts to
the prescribed (4) torque.
Figure 71
Fit a new gasket (2) on the tappet cover (1).
Place the tappet cover on, install the bolts in the correct
position and tighten.
CNH
PARTS
70355
116371
116379
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Figure 72
Connect the oil discharge pipe (2) to the turbo-compressor
junction (1) and to the support of the oil filter heat
exchanger.
Assemble the support (3) and fasten with the screws (4).
Reconnect the exhaust manifold (2) with new gaskets.
Tighten the fastening screws (1) to the specified torque.
Sling the turbocharger (4) and place it over the manifold after
having first inserted a newgasket, tighten the fastening screws
(3) to the specified torque.
CNH
PARTS
Assemble the rail (2) and fasten the fixing screws (1) to the
prescribed torque.
Connect newfuel pipes (6) to the rail (2) and to the manifold
for electro-injectors (5).
Figure 73
116380
Connect the fuel pipe (4) to the rail based on the procedure
described in the following illustration.
The pipe joints (3) must be fastened to the 20 Nm
torque.
NOTE
70126
Press the clamp (1) in arrowdirection (Figure B) and connect
the pipe to the rail, reset the clamp to the initial locking
position A.
Check proper fuel pipe connection.
Figure 74
NOTE
CNH
PARTS
116370
Figure 75
116366
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Figure 76
Connect the piping (2) to the fuel return pressure limiting
device (1).
Connect the external vent pipe (3) to the head cover and to
the crankcase.
Figure 77
Assemble the bracket and the support (1) of the fuel filter (6).
Proceed connecting in sequence the pipelines (9,3,4 and 5)
of the support (1) to the high pressure pump (8).
Connect the pipeline (7) fromthe high pressure pump to the
rail diffuser.
Figure 78
70126
All the fuel pipelines are fixed using the clamps shown in the
picture.
For the connection of the pipes, press the clamp (I) following
the arrows direction (Figure B) and connect the pipe to the
clamp on the high pressure pump or on the support of the
fuel filter.
Reset the clamp in the initial locking A position.
In case the pipes are re-employed, they must keep
the sealing tops at the edges.
Make sure that the fuel pipeline is correctly
connected.
Reconnect the engine harness to all the sensors, the engine
control module and the rail diffuser.
Figure 79
Assemble oil filling pipe (1).
Screw fixing screws and assemble starting motor (2) in place.
Completion of the engine
Properly handle the engine holding it by a lifter, remove it
from the rotating shaft, remove the brackets 380000661 and
place it on proper suitable support to carry out the
completion.
116381
116365
116364
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PART TWO -
ELECTRICAL EQUIPMENT - MECHANICALS ENGINES
N
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Figure 80
Below there are listed the electric components which are
present on F4GE94--- engines.
1. Cooling liquid temperature sensor;
2. Starter;
3. KSB Water temperature sensor;
4. Electromagnets assembled to feed pump:
(A) on hydraulic head unit
(B) on KSB;
5. Oil pressure sensor;
6. Resistance for cold start up (where provided for);
7. Alternator;
ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES WITH ROTARY PUMP)
116392
A
B
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Cooling liquid temperature sensor
It is a component integrating a temperature sensor.
It is assembled to the engine head close to the thermostat unit
and its duty is to detect engine cooling liquid temperature.
Specifications:
Range of working temperatures:
Connection side -40 +150 C for < 10 min.
Bulb side on engine: -40 +140 C
Working tensions: 6 28 V
Settings:
80 C 0.304 0.342 k
20 C 2.262 2.760 k
-10 C 8.244 10.661 k
Starter
Starter is usually driven by starting unit placed on the vehicle
dashboard and provides positive tension to the tele-switch as-
sembled to the starter itself.
Specifications:
BOSCH 3 kW - 12V
Figure 81
Figure 82
75717
KSB Water temperature sensor
It is assembled to the cylinder head on the engine left hand si-
de.
Specifications:
Working tensions:12 24 V
Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 633 C Contact opening
upon increasing temperature
533 C Contact closure
upon decreasing temperature
Figure 83
75718
B
C
A
A
B
C
1
75719
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Figure 84
Oil pressure switch
Figure 85
Electromagnets assembled to feed pump
75724a
1 - Hydraulic head Electro-magnet; 2 - KSB
Electro-magnet
75722
It is assembled to the block on the engines left hand side.
Specifications:
Working tensions: 12 24 V
Contact closure
upon lower pressure: 0.2 bar
Contact opening
upon higher pressure: 0.9 bar
2
1
Alternator
It is place front view on the right hand side of the engine, and
is driven by tooth belt.
Specifications:
Working tension: 12 V
Current delivered: 90A (at 6000 rpm)
Absorption in stand-by: 1mA
Sense of rotation: clockwices
75725
Figure 86
Pre-post heating resistor
It is a resistor assembled to the suction collector and is utilised
to heat the air during pre-post heating operations.
It is fed by a tele-switch usually placed very close to the engine.
Specifications:
Working tension: 12 V
Maximum possible
air flow: 2 cc / min
(pressure 138 kPa)
Figure 87
75723
N
O
T

F
O
R

P
R
I
N
T
x
N
O
T

F
O
R

P
R
I
N
T
PART TWO -
ELECTRICAL EQUIPMENT - ELECTRONICS ENGINES
N
O
T

F
O
R

P
R
I
N
T
x
N
O
T

F
O
R

P
R
I
N
T
Figure 88
The and F4DE9684 engines are fully driven by the electronic
engine control module.
Through the engine control module it is possible to verify the
correct working of the engine. (See part three of the hereby
users guide specifically dedicated to diagnostic).
The electrical and electronic components of the engine are
listed here following:
1. Temperature sensor of cooling liquid;
2. Electro-injector;
3. Starter;
4. Pressure sensor assembled to rail diffuser;
5. Temperature and air pressure sensor;
6. Timing system sensor;
7. Fuel temperature sensor;
8. EDC7 electronic module (not positioned on engine);
9. Driving shaft sensor;
10. Sensor of engines oil temperature and pressure;
11. Pre-post heating resistor.
LOCATION OF MAIN ELECTRICAL COMPONENTS
116382
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I
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Figure 89
A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled);
C - Connector to sensors.
01525t
EDC7 ECU
x
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R
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Connector to injectors (A)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
-
-
MN
MV
VB
HR
-
-
MB
VN
VG
HN
HG
CN
CB
CL
-
-
Injector cylinder 2 (**)
Injector cylinder 3 (**) / Injector cylinder 4 (*)
Earth
Injector cylinder
Injector cylinder 1 (*) / (**)
Injector cylinder 1 (*) / (**)
Figure 90
12 16
11 6
1 5
50350
(*) Only for 4 cyl. versions
(**) Only for 6 cyl. versions
Colour legend
C ORANGE
A SKY BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
PIN ECU CABLE COLOUR FUNCTION
N
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F
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R

P
R
I
N
T
Feed connector (B) to components and to functions of the specific equipment
1
2
3
4
7
8
9
12/13
14/15
16
19
20
27
28
31
32
36
37
39
44
45
46
49
50
52
53
55
62
63
64
72
73
78
81
83
87
8150
0087
0000
8885/0159
8150
7777
0000
8150
0000
0094
0150
8153
0156
5535
2298
-
8837
8888
8051
9905
9906
5553
5584
0158
6109
6108
5158
0160
5503
0535
0159
0159
8162
0157
5157
-
Figure 91
Negative for switch of fuel filter heater/starter
Earth
Positive for pre-post heating resistor
Positive driven by battery
Positive for blink-code button/ oil low pressure led/ pre-heating led/
Air conditioner switch (if available) / EDC
Earth
Positive driven by battery
Earth
Negative for post-heating resistor
Negative start-stop push buttons from eng./accelerator pressed
Positive from change over switch to key in starting phase (+50)
Positive from blink-code button
Positive for EDC diagnostic led
K Line for diagnosis connector, 30 poles (2 pin)
Negative for multi-switch couple-limiter
Positive for fuel filter heating switch
Positive for starter
Positive from key switch/ L line for diagnosis connector 30 poles (pin 11)
Negative from starter push button from engine
Negative from engine stop push button from engine
Negative for pre-heating led in on position
Diagnosis connector (pin 28)
Negative from accelerator push button pressed
CAN Line (whether equipped), diagnosis connector (pin 22)
CAN Line (whether equipped), diagnosis connector (pin 22)
Positive for sensor of foot accelerator pedal pos. / Earth multi-switch
Negative for clutch sensor
Negative for engine oil low pressure led
Negative for EDC diagnosis led
Positive from pressed accelerator push button / multi-switch signal
Positive redundant from pressed accelerator push button
Positive air conditioner device (whether equipped)
Negative sensor of foot accelerator pedal pos. / Earth multi-switch
Signal from sensor of foot accelerator pedal pos. / Signal multi-switch
Positive for couple multi-switch limiter
6 54 72 89
71
53
35
1
11
7
12
03210t
18 36 17
x
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Connector to sensors (C)
Figure 92
5
7
9
10
12
17
18
19
20
21
23
24
25
27
28
29
30
33
34
35
36
C
V
MN
CR
HN
BL
CV
GV
BZ
GN
R
B
R
RV
LN
BH
B
GR
CN
NS
BG
Earth for pressure regulator
Pressure regulating drive
Feed for engine oil temperature/pressure sensor
Feed for air pressure and temperature sensor
Feed for rail pressure sensor
Earth for fuel temperature sensor
Earth for cooling liquid temperature sensor
Earth for engine oil temperature pressure
Feed for rail pressure sensor
Feed for air pressure - temperature sensor
Timing system sensor
Driving shaft sensor
Signal from rail pressure sensor
Signal from air pressure sensor
Signal from air temperature sensor
Earth for timing system sensor
Signal from engine oil temperature sensor
Signal from fuel temperature sensor
Signal from engine oil pressure
Signal from cooling oil temperature
6 8
4
5
1
3 23 30 36
29
22
15 9
03211t
16
Colour legend
C ORANGE
A SKY BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
N
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R

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R
I
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T
Temperature and air-pressure sensor
Sensor of engines oil temperature and
pressure
It is a component integrating one temperature sensor and a
pressure one.
It is assembled on the engine oil filter support.
It measures the temperature and the pressure of the engines
oil.
It is connected to the engine control module by 19Cand 33C,
9C and 35C.
19C Earth
33C NTC signal (temperature)
9C +5V feed
35C Signal (pressure)
Timing system sensor
Figure 93 Figure 94
2 3 1
50342
50319
2 3 1
50342
50320
88438
Figure 95
It is a component integrating one temperature sensor and a
pressure one.
It is assembled to the suction inlet manifold and measures the
maximumcapacity of air introduced, in order toprovide tothe
engine control module the necessary data to calculate the
quantity of fuel to be injected per each cycle.
It is connected to the engine control module by 21C and 29C
pin (temperature), 10C and 28C (pressure) and has a 5 volt
feeding.
21C Earth
29C NTC signal (temperature)
10C +5V feed
28C Signal (pressure)
It is an inductive type sensor and it is placed on the front part
of the engine.
It generates some signals originated by the magnetic flowlines
that close up through the openings of a phonic wheel splined
to the driving shaft. The same signal is utilised to control the
eventual electronic engine speed indicator placed on the
vehicle instrument board.
It is connected to the engine control module by pin 25C
(signal) and 24C (signal). The third pin is for screening.
The resistance value of the sensor is of about 900 .
It is an inductive type sensor and it is placed on the back left
part of the engine.
It generates some signals originated by the magnetic flowlines
that close up through the ports drilled on the gear splined to
the camshaft. The signal generated by this sensor is utilised by
the electronic engine control module as signal of injection
phase.
Even being equal to the flywheel sensor it is not
interchangeable since the external shape is different.
(signal) and 30C (signal). The third pin is for screening.
The resistance value of the sensor is of about 900 .
x
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Fuel pressure sensor
Figure 96
Resistor pre-post heating
Figure 97
Cooling liquid temperature sensor
It is a sensor with variable resistor, able to detect the cooling
liquid temperature to provide to the engine control module
an index of the engine thermal status.
Usually, the same signal is driven by the engine control module
to the temperature device placed within the vehicles
dashboard.
(Earth) and 36C (temperature signal).
The resistor to 20 C = 2,5 k.
1 - Earth; 2- Signal; 3- Feed.
Fuel temperature sensor
1 - Fuel temperature sensor
Figure 98
88440
It is a sensor assembled to one end of the rail and measures
the pressure of the fuel available in order to determine the
injection pressure.
The value of the injection pressure is utilised to control the
pressure itself and to determine the duration of the electronic
injection device.
(Earth), 27C (signal) and 12C (feed).
It has 5 volt feeding.
It is a sensor with variable resistor, able to detect the fuel
temperature to provide to the engine control module an
index of the fuel thermal status.
(Earth) and 34C (temperature signal).
The resistor to 20 C = 2,5 k.
It is a resistor placedon the suction inlet manifoldand is utilised
to heat the air during the heating pre-post operations.
It is fed by a tele-switch usually placed very close to the engine.
116383
116384
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I
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T
Electro-injectors
This is a N.A. type solenoid valves
They are individually connected to the EDC gearcase on con-
nector A.
The resistance of each injector coil is 0.56 0.57 .
Starter
The starter is usually driven by the starting block assembled to
the vehicles dashboard and provides positive voltage to pin
B20 of the EDC.
Figure 99
1. Feeding relay of the starter
Figure 100
88314
PIN EDC
REFERENCE REFERENCE
CONNECTOR 1
CONNECTOR 2
1
2
3
4
Injector cylinder 2
Injector cylinder 2
Injector cylinder 1
Injector cylinder 1
3 A
6 A
13 A
9 A
1
2
3
4
Injector cylinder 4
Injector cylinder 4
Injector cylinder 3
Injector cylinder 3
5 A
14 A
12 A
4 A
1
2
3
4
Injector cylinder 6
Injector cylinder 6
Injector cylinder 5
Injector cylinder 5
10 A
15 A
16 A
11 A
CONNECTOR 3
6 cylinder engines
50343
50349
x
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F
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P
R
I
N
T
(MECHANICALS ENGINES)
N
O
T

F
O
R

P
R
I
N
T
x
N
O
T

F
O
R

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Figure 1
CNH -- EST DIAGNOSTIC TOOL
The EST system allows carrying out diagnoses onmainmachine assemblies by detecting the operating parameters of electronic
control components (control units, sensors etc.) and the check of flow--rates, pressures and temperatures; it is further arranged
for searching inconveniences and detect data for electronically--controlled CNH engines.
88201
Code Description Language
380060157 Italian
380060158 French
380060159 English
380060160
CE EST diagnostic kit
German
380060161
CE EST diagnostic kit
Spanish
380060162 Holland
380060163 Danish
380060164 Portuguese
N
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FAULT CODES
Failure code Failure description
Vehicle 1 ((Sensors / Consistency tests)
1.1.2 ACCELERATOR PEDAL
1.1.9 PLAUSIBILITY +15
1.1.A PLAUSIBILITY +50
Vehicle 2 (Indicator lamps / Relais / Actuators)
1.2.3 EDC LAMP
1.2.5 MAIN RELAY DEFECT
1.2.6 BATTERY VOLTAGE
1.2.8 MAIN RELAY - SHORT CIRCUIT TO BATTERY
1.2.9 AIR-CONDITIONER COMPRESSOR RELAY
1.2.B THERMOSTARTER RELAY 1 (HEATER)
1.2.E MANAGEMENT SYSTEM PRE/POST-HEATING (ACTIVE)
2.2.5 INTERRUPTED AFTER-RUN
2.2.8 MAIN RELAY - SHORT CIRCUIT TO GROUND
Engine 1 (Temperature and pressure sensors)
1.3.1 COOLANT TEMPERATURE SENSOR
1.3.2 COOLANT TEMPERATURE SENSOR (TEST)
1.3.3 AIR TEMPERATURE SENSOR BOOST AIR
1.3.4 BOOST PRESSURE SENSOR
1.3.5 FUEL TEMPERATURE SENSOR
1.3.6 RAIL PRESSURE SENSOR OR SIGNAL ERROR
1.3.7 DBV VALVE MANAGEMENT (BOOST PRESSURE)
1.3.8 OIL PRESSURE SENSOR
1.3.A OIL TEMPERATURE SENSOR
2.3.2 COOLANT TEMPERATURE SENSOR ABSOLUTE TEST
2.3.6 RAIL PRESSURE SENSOR OFFSET
2.3.8 OIL LOW PRESSURE
2.3.A OIL TEMPERATURE ABOVE NORMAL
Engine 2 (Speed sensors/actuators)
1.4.1 CRANKSHAFT SPEED
1.4.2 ENGINE WORKING ONLY WITH CAMSHAFT SENSOR
1.4.3 CAMSHAFT SENSOR
1.4.4 FAULT BETWEEN FLYWHEEL SENSOR AND CAMSHAFT
Damage information
1.4.D ENGINE OVERSPEED
1.5.B HIGH PRESSURE TEST (DEACTIVATES RAIL PRESS.MONITORING)
1.9.D INDICATES TORQUE LIMITATION DUE TO PERFORMANCE LIMITER
4.9.E INDICATES THE TORQUE LIMITATION DUE TO ENGINE PROTECTION
6.9.E INDICATES TORQUE LIMITATION DUE TO FUEL QUANTITY LIMITATION
N
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F
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Fuel metering
1.5.1 HIGH PRESSURE SYSTEM
1.5.2 FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (POSITIVE DEVIATION)
1.5.3 FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (NEGATIVE DEVIATION)
1.5.4 RAIL PRESSURE ERROR: TOO LOW
1.5.5 RAIL PRESSURE ERROR: TOO HIGH
1.5.7 ERROR ON THE RAIL PRESSURE (EXCESSIVE DUTY CYCLE)
1.5.9 PRESSURE MPROP REGULATOR ERROR
2.5.9 PRESSURE MPROP REGULATOR ERROR (SHORT CIRCUIT TO POSITIVE)
3.5.9 SHORT CIRCUIT TO GROUND OF METERING UNIT OUTPUT
Injectors 1
1.6.1 INJECTOR CYLINDER 1 / SHORT CIRCUIT
1.6.7 INJECTOR CYLINDER 1 / OPEN CIRCUIT
1.6.A INJECTOR CYLINDER 4 / OPEN CIRCUIT
1.6.B INJECTOR CYLINDER 5 / OPEN CIRCUIT
1.6.C INJECTOR CYLINDER 6 / OPEN CIRCUIT
1.6.E THE MINIMUM NUMBER OF INJECTIONS WAS NOT REACHED: STOP THE ENGINE
Injectors 2
1.7.1 BENCH 1 CC
1.7.3 BENCH 2 CC
1.7.C BENCH 1 INJECTORS CHECK (INTERNAL ECU)
2.7.C BENCH 2 INJECTORS CHECK (INTERNAL ECU)
Boosting system and turbine speed
1.9.E TORQUE REDUCTION DUE TO SMOKE LIMITATION
Interfaces 1 (CAN-Bus)
1.B.1 ERROR ON CAN CONTROLLER A
1.B.3 ERROR ON CAN CONTROLLER C
1.B.4 TIMEOUT CAN MESSAGE BC2EDC1
1.B.5 TIMEOUT CAN MESSAGE VM2EDC
1.B.D TIMEOUT CAN MESSAGE CCVS
2.B.4 TIMEOUT CAN MESSAGE BC2EDC2
Interfaces 2 (CAN line timeout messages)
1.C.6 ERROR MESSAGE CAN TSC1-PE
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1.C.8 ERROR MESSAGE CAN TSC1-VE
1.C.9 ERROR MESSAGE CAN TF
2.C.6 TIMEOUT OF CAN MESSAGE TSC1-PE PASSIVE
3.C.8 TIMEOUT OF CAN MESSAGE TSC1-VE PASSIVE
ECU 1 (internal checks)
1.D.1 ECU OVERRUN MONITORING ERROR
1.D.6 ECU INTERNAL ERROR (TPU)
1.D.7 INTERNAL ECU ERROR (VARIANT AREA)
3.D.3 ERRORE INTERNO CENTRALINA
ECU 2 (Power supply / Immobilizer / Runaway / Sensor power supply)
1.E.1 ECU: SHORT CIRCUIT OR OPEN CIRCUIT
1.E.3 ERROR FOR ECU INTERNAL MONITORING
1.E.4 ERROR FOR ECU INTERNAL MONITORING
1.E.5 SENSORS POWER SUPPLY FAULT (12V)
1.E.6 SENSOR POWER SUPPLY 1
1.E.9 ECU OVERRUN MONITORING ERROR
1.E.A ECU OVERRUN MONITORING ERROR
1.E.B ATMOSPHERIC PRESSURE SENSOR
2.E.1 SHORT CIRCUIT TO BATT OR GROUND, NO LOAD, EXCESS.TEMP. FOR LOW SIDE POWER STAGE
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N
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T

F
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PART FOUR - MAINTENANCE PLANNING
N
O
T

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MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
Planning of controls and periodical intervention
Controls and periodical intervention
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . .
Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of engines oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency (hours)
Daily
Daily
-
4000
500
1000
500
1500
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
CNH.
NOTE
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Checks not included in maintenance planning-daily checks
It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES
Checks and controls
Engine oil level check
The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided flexible
rod (1).
Figure 2
Drawoff the rod fromits slot andcheck that the level is within
the etched tags of minimum and maximum level.
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
minimum level, provide filling lubrication of the engines
components.
In order to guarantee a perfect performance, the following
pages contain the checks, surveys andadjustments which need
to be made on all the various vehicle elements according to
scheduled deadlines.
To provide filling, operate through the upper top (1) or
through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier.
Some applications are equipped with a level transmitter
alerting dashboard instruments in case of insufficient
lubrication oil within the pan.
Figure 3
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Disposal must be carried out properly, and in full
75748
75749
1
MAX
MIN
1
2
x
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Check of fuel system
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
specific equipment), to the filter, to the injection pump and to
the injectors.
Cooling system check
Check the pipelines from the engine to the radiator, from the
expansion tank and vice-versa. Find out any blow-by, verify the
status of the pipes specially close to the holding strips.
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.
Due to the high temperatures achieved by the
system, do not operate immediately after the engines
disconnection, but wait for the time deemed
necessary for the cooling.
Protect the eyes and the skin from any eventual high
pressure jet of cooling liquid.
Lubricating system check
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan of from the heat exchanger.
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Disposal must be carried out properly, and in full
Check of water presence within fuel filter or pre-filter
The components of the system can be damaged
very quickly in presence of water or impurity within
the fuel.
Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the
drainage of the water within the feed circuit.
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any case
every two year.
In case of new filling, proceed bleeding system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious
inconvenience might be caused to the engine due
to the presence of air pockets in the engines head.
Fuel filter is equipped with pump screw-valve to drain the
water eventually mixed with fuel (some applications of 6
cylinders engines will be equipped with two fuel filters, both
provided with drainage.
Place a container underneath the filter and slightly loosen the
screw. Drain the water eventually contained in the filters
bottom.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.
NOTE
NOTE
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x
Check of drive belt tensioning
Some applications are equipped with an automatic tensioner
that provides correcting belt tensioning.
Check of belts tear and wear status
Carefully verify the belts surface in order to detect any sign of
incision, crack, excessive wear in correspondence of toothing;
check end and surface grinding.
Adjust clearance between rockers and valves using setscrew
wrench (1), box wrench (3) and feeler gauge (2).
Working clearance shall be as follows:
- intake valves 0.25 0.05 mm
Check and setting of tappet clearance
Figure 4
2
1
3
75806
Danger: if the engine is switched off but is still hot,
unexpected motion of the belt may occur.
Wait for engine temperature cooling as a precaution
in order to avoid serious danger injury.
valve clearance adjustment procedure that requires
adjusting the clearance of all the valves by
NOTE
Oil motor and filter replacement
Due to the several applications, the pan shape and the oil
quantity can change slightly. However, the following oper-
ations are valid for all applications.
We recommend to carry out the oil drainage when the motor
is hot.
- Place a proper container for the oil collecting under the
pan connected with the drain plug.
- Unscrew the plug and then take out the control dipsick
andthe inserting plug toease the downflowof the lubrica-
tion oil.
Warning: We recommend to wear proper protec-
tions because of high motor service temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves.
The oil motor is very pollutant and harmful.
In case of contact with the skin, wash with much water
and detergent.
Protect properly skin and eyes: operate according to
safety rules.
Dispose of the residual properly following the rules.
- After the complete drainage, screwthe plug and carry out
the clean oil filling.
!
Use only the recommended oil or oil having the re-
quested features for the corrrect motor functioning.
In case of topping up, dont mix oils having different
features.
If you dont comply with theses rules, the service war-
ranty is no more valid.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dip-
sick.
N
O
T

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T
Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in differ-
ent positions: the following procedure is a valid guide for all
applications.
- The filter is composed by a support and a filtering car-
tridge. For the cartridge replacement use the
380000670-tool.
Warning: the oil filter contains inside a quantity of oil
of about 1 kg.
Place properly a container for the liquid.
Warning: avoid the contact of skin with the motor oil:
in case of contact wash the skin with running water.
The motor oil is very pollutant: it must be disposed
of according to the rules.
- Replace the filtering cartidge with a new one and screw
manually until when the gasket is in contact with the sup-
port.
- Tigthen by means of the 380000670-tool of three fourth
turn.
- Operate the motor for some minutes and check the level
through the dipsick again. If it is necessary, carry out a top-
ping up to compensate the quantity of oil used for the fill-
ing of the filtering cartridge.
Fuel filter replacement
According to the applications the filters position and the quan-
tity can change.
However the following operations are validfor all applications.
- Drain the fuel inside the filter by operating the water re-
lease screw. Collect the fuel in a container without impu-
rities.
- Unscrew the cartridge by using the 380000670-tool.
- Collect the eventual fuel inside the filtering cartridge.
- Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 380000670-tool at 10-5 Nmtorque.
During this operation dont smoke and dont use free
flames.
Avoid to breathe the vapors coming from filter.
!
After filters replacement the supply equipment
deaeration must be carried out.
N
O
T

F
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T
Alternator belt replacement
Due to several applications the belt run can change very much.
We describe the replacement of a belt mounted on a 4-cylin-
ders motor with traditional belt tension.
Warning: with switched off motor (but still hot) the
belt can operate without advance notice.
Wait for the motor temperature lowering to avoid
very serious accidents.
Figure 5
- Loosen screw (1) and the relevant nut on belt stretching
bracket (3).
- Loosen the bolt that fixes the alternator to the support.
- Fit the new belt on the pulleys and guide rollers.
- Stretch POLY-V belt (2).
- Lock screw(1) and the bolt that fixes the alternator tothe
support
- Run the engine for a few hours and check proper belt
stretching.
88089
CNH
PARTS
x
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1 NEF ENGINES
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS 5 . . . . . . . . . . . . . . .
CLEARANCE DATA 6 . . . . . . . . . . . . . . . . . . . . .
TABLE OF PRE-DELIVERY VALUES FOR BOSCH
INJECTION PUMPS 12 . . . . . . . . . . . . . . . . . . . .
MECHANICALS ENGINES OVERHAUL 13 . . . . . .
ENGINE REMOVAL AT THE BENCH 13 . . . . . . . .
REPAIR OPERATIONS 14 . . . . . . . . . . . . . . . . . . . .
CYLINDER UNIT 14 . . . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements 14 . . . . . . . . . . . . . . .
- Checking head supporting surface on cylinder unit 15
TIMING SYSTEM 16 . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and pin alignment 171 . . . . . . . .
BUSHES 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Bush replacement 18 . . . . . . . . . . . . . . . . . . . . . .
- Tappets 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting tappets camshaft 18 . . . . . . . . . . . . . . . .
OUTPUT SHAFT 19 . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring journals and crankpins (4 cylinders) 19
- Replacing oil pump control gear 21 . . . . . . . . . . .
- Fitting main bearings 21 . . . . . . . . . . . . . . . . . . . .
- Finding journal clearance 21 . . . . . . . . . . . . . . . . .
- Checking output shaft shoulder clearance 22 . . .
CONNECTING ROD PISTON ASSEMBLY 22 . .
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2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS NEF ENGINES
Page
- Pistons 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring piston diameter 23 . . . . . . . . . . . . . . . .
- Piston pins 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Conditions for proper pin-piston coupling 24 . . . .
- Split rings 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods 25 . . . . . . . . . . . . . . . . . . . . . . .
- Bushes 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly 26 . . . . . .
- Connecting rod-piston coupling 26 . . . . . . . . . . . .
- Fitting split rings 26 . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly into cylinder
barrels 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Finding crankpin clearance 27 . . . . . . . . . . . . . . . .
- Checking piston protrusion 28 . . . . . . . . . . . . . . .
CYLINDER HEAD 29 . . . . . . . . . . . . . . . . . . . . . . . .
- Removing the valves 29 . . . . . . . . . . . . . . . . . . . .
- Checking cylinder head wet seal 30 . . . . . . . . . . .
- Checking cylinder head supporting surface 30 . . .
VALVES 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing carbon deposits, checking and grinding
valves 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking clearance between valve stem and valve
guide and valve centering 31 . . . . . . . . . . . . . . . . .
VALVE GUIDE 32 . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS 32 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regrinding replacing the valve seats 32 . . . . . . .
VALVE SPRINGS 33 . . . . . . . . . . . . . . . . . . . . . . . . .
Page
FITTING CYLINDER HEAD 33 . . . . . . . . . . . . . . . .
- Refitting the cylinder head 34 . . . . . . . . . . . . . . . .
TIGHTENING TORQUE 35 . . . . . . . . . . . . . . . . . .
ELECTRONICS ENGINES OVERHAUL 37 . . . . . . .
ENGINE REMOVAL AT THE BENCH 37 . . . . . . . .
REPAIR OPERATIONS 38 . . . . . . . . . . . . . . . . . . . .
CYLINDER UNIT 38 . . . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements 38 . . . . . . . . . . . . . . .
- Checking head supporting surface on cylinder unit 39
TIMING SYSTEM 40 . . . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and pin alignment 41 . . . . . . . . .
BUSHES 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Bush replacement 42 . . . . . . . . . . . . . . . . . . . . . .
- Tappets 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting tappets camshaft 43 . . . . . . . . . . . . . . . .
OUTPUT SHAFT 44 . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring journals and crankpins (4 cylinders) 46
- Replacing oil pump control gear 48 . . . . . . . . . . .
- Fitting main bearings 48 . . . . . . . . . . . . . . . . . . . .
- Finding journal clearance 48 . . . . . . . . . . . . . . . . .
- Checking output shaft shoulder clearance 49 . . . .
CONNECTING ROD PISTON ASSEMBLY 49 . .
- Pistons 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring piston diameter 50 . . . . . . . . . . . . . . . .
- Piston pins 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Conditions for proper pin-piston coupling 51 . . . .
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- Connecting rods 52 . . . . . . . . . . . . . . . . . . . . . . .
- Bushes 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly 53 . . . . . .
- Connecting rod-piston coupling 53 . . . . . . . . . . . .
- Fitting split rings 54 . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly into cylinder
barrels 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Finding crankpin clearance 55 . . . . . . . . . . . . . . . .
- Checking piston protrusion 56 . . . . . . . . . . . . . . .
CYLINDER HEAD 57 . . . . . . . . . . . . . . . . . . . . . . . .
- Removing the valves 57 . . . . . . . . . . . . . . . . . . . .
- Checking cylinder head wet seal 58 . . . . . . . . . . .
Page
- Checking cylinder head supporting surface 58 . . .
VALVES 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing carbon deposits, checking and grinding
valves 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking clearance between valve stem and valve
guide and valve centering 59 . . . . . . . . . . . . . . . . .
VALVE GUIDE 60 . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS 60 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regrinding replacing the valve seats 60 . . . . . . .
VALVE SPRINGS 62 . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING CYLINDER HEAD 62 . . . . . . . . . . . . . . . .
- Refitting the cylinder head 63 . . . . . . . . . . . . . . . .
TIGHTENING TORQUE 64 . . . . . . . . . . . . . . . . . .
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GENERAL SPECIFICATIONS
Type 4 CYLINDERS
Cycle Four-stroke diesel engine
Power See properties described in Section 3
Injection Direct
Number of cylinders 4 in-line
Bore mm 104
Stroke mm 132
+ + +.. = Total displacement cm
3
4485
TIMING
start before T.D.C. A
end after B.D.C. B
-
-
start before B.D.C. D
end after T.D.C. C
-
-
X
Checking timing
mm
X
mm
Checking operation
mm
X
mm
-
-
0.25 to 0.05
0.50 to 0.05
FUEL FEED
Injection
Type: Bosch VE 4/12 F
Nozzle type -
Injection sequence 1 - 3 - 4 - 2
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CLEARANCE DATA
Type 4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm
1
X
Cylinder barrels 1
104.000 to 104.024
0.4
1
X
2
Spare pistons
type:
Size X
Outside diameter 1
Pin housing 2
55.9
103.714 to 103.732
38.010 to 38.016
Piston cylinder barrels 0.268 to 0.310
CNH
PARTS
Piston diameter 1 0.4
X
Piston protrusion X 0.28 to 0.52
3
Piston pin 3 37.994 to 38.000
Piston pin pin housing 0.010 to 0.022
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Type 4 CYLINDERS
X
1
3
2
X
X
X1*
Split ring slots X 2
X 3
* measured on a of
99.00 mm
2.705 to 2.735
2.440 to 2.460
4.030 to 4.050
1
3
2
S
S
S
S 1*
Split rings S 2
S 3
2.560 to 2.605
2.350 to 2.380
3.970 to 3.990
1
Split rings - slots 2
3
0.100 to 0.175
0.060 to 0.110
0.040 to 0.080
CNH
PARTS
Split rings 0.4
X 1
3
2 X
X
Split ring end opening
in cylinder barrel:
X 1
X 2
X 3
0.30 to 0.40
0.60 to 0.80
0.30 to 0.55
1
2
Small end bush
housing 1
Big end bearing
housing 2
40.987 to 41.013
72.987 to 73.013
S
3
Small end bush diameter
Outside 4
Inside 3
Spare big end half
bearings S
38.019 to 38.033
1.955 to 1.968
Piston pin bush 0.019 to 0.039
CNH
PARTS
Big end half bearings 0.250 to 0.500
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Type 4 CYLINDERS
X
Size X
Max. tolerance
on connecting rod
axis alignment
-
-
Journals 1
Crankpins 2
82.99 to 83.01
68.987 to 69.013
1 2
S 1 S 2
Main half bearings S 1
Big end half bearings S 2
2.456 to 2.464
1.955 to 1.968
3
Main bearings
No. 1 5 3
No. 2 3 4 3
87.982 to 88.008
87.977 to 88.013
Half bearings Journals
No. 1 5
No. 2 3 4
0.022 to 0..053
0.019 to 0.055
Half bearings - Crankpins 0.019 to 0.058
CNH
PARTS
Main half bearings
Big end half bearings
0.250 to 0.500
1 X
Shoulder journal X 1 37.475 to 37.550
X 2
Shoulder main bearing X 2 32.180 to 32.280
X 3
Shoulder half-rings X 3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.270
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Type 4 CYLINDERS
CYLINDER HEAD TIMING SYSTEM mm
1
Valve guide seats on
cylinder head 1 8.019 to 8.039
4 Valves:
4
7.960 to 7.980
60
7.960 to 7.980
45
Valve stem and guide 0.059 to 0.086
1
Housing on head for
valve seat:
1
1
46.987 to 47.013
43.637 to 43.663
2
Valve seat outside diameter;
valve seat angle on cylinder
head:
2
47.063 to 47.089
60
43.713 to 43.739
45
X
X
Sinking X
1 to 1.52
1 to 1.52
Between valve seat
and head
0.050 to 0.102
0.050 to 0.102
CNH
PARTS
Valve seats -
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Type 4 CYLINDERS
H
H 1
H 2
Valve spring height:
free spring H
under a load equal to:
339.8 9 N H1
741 39 N H2
63.50
49.02
38.20
X
Injector protrusion X -

1 2 3 4 5
Camshaft bush
housings No. 1-5
Camshaft housings
No. 2-3-4
59.222 to 59.248
54.089 to 54.139
1
2
3
Camshaft journals:
1 5 53.995 to 54.045
Bush inside
diameter 54.083 to 54.147
Bushes and journals 0.038 to 0.162
H
Cam lift:
H
H
-
-
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Type 4 CYLINDERS
1
Tappet cap housing
on block 1 16,000 16,030
2
3
2
Tappet cap outside
diameter: 2
3
15.924 to 15.954
15.965 to 15.980
Between tappets and housings -
CNH
PARTS
Tappets -
1
Rocker shaft 1 18.963 to 18.975
2
Rockers 2 19.000 to 19.026
Between rockers and shaft 0.025 to 0.063
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TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS
INJECTION PUMP CALIBRATION
Overhaul and calibration interventions are up to BOSCH assistance network.
The contract technical specification containing the data tocalibrate the pumpat the bench is identifiedby the code shown
on injection pump body and is available at BOSCH technical assistance network.
Otherwise, refer to CNH Technical Assistance Service.
NOTE
Technical
Code
Pre-lift
(mm)
F4GE9454C*J602 0.7
F4GE9484A*J601 0.65
F4GE9484A*J602 0.65
F4GE9484D*J600 0.65
4-CYLINDER ENGINES
F4GE9484D*J603 0.65
4-CYLINDER ENGINES
F4GE9484E*J600 0.75
F4GE9484F*J600 0.8
F4GE9484H*J600 0.65
F4GE9484J*J600 0.8
F4GE9484K*J601 -
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70159
70158
70160
70161
70162
Figure 1
Figure 2
Figure 3
Figure 4
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdrawthe pistons including the connecting rods fromthe
top of the engine block.
Remove the screws (1) and the main bearing caps (2).
The second last main bearing cap (1) and the relevant
support are fitted with shoulder half-bearing (2).
Use tool 380000362 (1) and hoist to remove the output
shaft (2) from the block.
Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
Keep the half-bearings into their housings since in
case of use they shall be fitted in the same position
found at removal.
Take note of lower and upper half-bearing
assembling positions since in case of reuse they
shall be fitted in the same position found at
removal.
Figure 5
MECHANICALS ENGINES OVERHAUL
ENGINE REMOVAL AT THE BENCH
The following instructions are prescribed on the
understanding that the engine has previously been placed on
the rotating bench and that removal of all specific
components of the equipment have been already removed
as well. (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 cylinders
engine but are analogously applicable for the 6 cylinders.
NOTE
NOTE
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70163
70165
70164
70166
70167
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Remove the screws (1) and disconnect camshaft (3) retaining
plate (2).
Withdraw carefully the camshaft (1) from the engine block.
Withdraw the tappets (1) from the engine block.
Once engine is disassembled, clean accurately the
cylinder-block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free fromseizing,
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.
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 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.
Take note of plate (2) assembling position.
REPAIR OPERATIONS
CYLINDER UNIT
Checks and measurements
Should the ring gauge be not available, use a
micrometer for zero-setting.
s
NOTE
NOTE
zs
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Figure 11
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them
in case of uncertain seal or if rusted.
In case of regrinding, all barrels shall have the same
oversize (0.5 mm).
Checking head supporting surface on cylinder
unit
Check main bearing housings as follows:

- fit the main bearings caps on the supports without
bearings;
- tighten the fastening screws to the specified torque;
- use the proper internal gauge to check whether the
housing diameter is falling within the specified value.
Replace if higher value is found.
107804
NOTE
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70169
Figure 12
TIMING SYSTEM
Camshaft
CAMSHAFT MAIN DATA (4 CYL.)
Specified data refer to pin standard diameter
70512
Figure 13
MAIN DATA ABOUT CAMSHAFT PINS (6 CYL.)
Camshaft pin and cam surfaces shall be absolutely smooth;
if they show any traces of seizing or scoring replace the
camshaft and the bushes.
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70171
70172
Figure 14
Figure 15
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
Camshaft bush (2) shall be pressed into its housing.
Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.
BUSHES Checking cam lift and pin alignment
Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Figure 16
MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (4-cylinder engines)
* Value to be obtained after driving the bushes.
107399
Sec. A-A
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70174
84053
70176
70164
70238
Figure 17
To replace the bearing (1) use tool 380000667 (2) and
handle 380000668 (3) to remove and install it.
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Lubricate the camshaft support bearing and install the
camshaft (1) being careful to ensure that the bearing or the
shaft support seats are not damaged during the operation.
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
Bush replacement Fitting tappets camshaft
CNH
PARTS
When installing the bearing (1) it must be oriented
so that the lubrication holes are aligned with those
on the seats of the crankcase
Tappets
Figure 18
Figure 19
Figure 20
Figure 21
NOTE
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70179
70180
70182
Figure 22
Figure 23
Figure 24
Figure 25
Check camshaft end float (1).
It shall be 0.23 0.13 mm.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
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.
It is recommended to insert the found values in the
proper table.
See Figure 25.
Undersize classes are:
Journals and crankpins shall always be ground to
the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
OUTPUT SHAFT
Measuring journals and crankpins
108487
NOTE
NOTE
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TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL
SHAPE
Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
OSCILLATION
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
70183
Figure 26
OUTPUT SHAFT MAIN TOLERANCES
70237
MAIN BEARING ON TIMING
SYSTEM CONTROL SIDE
INTERMEDIATE MAIN
BEARINGS
FIRST MAIN BEARING
ON FRONT SIDE
measured on > 45.5 mm radius
between adjacent journals
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70184
70185
Figure 27
Figure 28
Figure 29
Figure 30
Refit the output shaft (2).
Check the backlash between output shaft main journals and
the relevant bearings as follows:
Refit the main bearings that have not been
replaced, in the same position found at removal.
CNH
PARTS
Fitting main bearings
CNH
PARTS
Do not try to adapt the bearings.
Main bearings (1) are supplied spare with 0.250 0.500 mm
undersize on the internal diameter.
Clean accurately the main half bearings (1) having the
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
Check that gear toothing (1) is not damaged or worn,
otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180C for 10 minutes
in an oven and then key it to the output shaft.
Finding journal clearance
- clean accurately the parts and remove any trace of oil;
- position a piece of calibrated wire (3) on the output shaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
supports.
70186
70161
Replacing oil pump control gear
NOTE
NOTE
75703
D1 D2
D2 diameters:
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This check is performed by setting a magnetic-base dial gauge
(2) on the output shaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.
70188
70189
70190
70191
Figure 31
Figure 32
Figure 33
Figure 34
- 3
rd
stage, with tool 380000304 (1) set as shown in the
figure, tighten the screws (2) with 90 5 angle.
- 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.
CONNECTING ROD PISTON ASSEMBLY
COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
Checking output shaft shoulder clearance

Pistons are supplied spare with 0.4 mm oversize.
CONNECTING ROD PISTON
ASSEMBLY
NOTE
Figure 35
70187
Tighten the pre-lubricated screws (1) in the following three
successive stages:
- 1
st
stage, with dynamometric wrench to 50 6 Nm.
- 2
nd
stage, with dynamometric wrench to 80 6 Nm.
N
O
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F
O
R

P
R
I
N
T
32615
32614
32613
70192
87760
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Remove split rings (1) frompiston (2) using pliers 380000221
(3).
Piston pin (1) split rings (2) are removed using a scriber (3).
Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in thefigure.
The diameter shall be measured at 12 mmfromthe
piston skirt.
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS
Pistons
Measuring piston diameter
NOTE
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T

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P
R
I
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T
32619
32620
16552
18857
41104
Figure 41
Figure 42
Figure 43
Figure 44
Figure 45
To measure the piston pin (1) diameter use the micrometer
(2).
Conditions for proper pin-piston coupling
Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.
Use a micrometer (1) to check split ring (2) thickness.
Check the clearance between the sealing rings (3) of the 2
nd
and 3
rd
slot and the relevant housings on the piston (2), using
a feeler gauge (1).
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).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
Piston pins
Split rings
N
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R
I
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T
70194
88607
Figure 46
Use feeler gauge (1) to measure the clearance between the
ends of the split rings (2) fitted into the cylinder barrel (3).
The surface of connecting rod and rod cap are
knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.
Connecting rods
Figure 47
NOTE
Figure 48
80339
Every connecting rod is marked as follows:
- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary
to mark the newconnecting rod with the same
numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
S X, 1901 to 1940 (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
NOTE
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R
I
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T
70198
Figure 49
Fitting connecting rod-piston assembly
Connecting rod-piston coupling
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrowshowing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Marking showing 1
st
slot insert testing;
4. Manufacturing date.
Figure 50
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
70199
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
72705
32613
Figure 51
Figure 52
Position the piston (1) on the connecting rod according to
the diagram shown in the figure, fit the pin (3) and stop it by
the split rings (2).
Fitting split rings
Use pliers 380000221 (3) to fit the split rings (1) on thepiston
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
Split rings are supplied spare with the following
sizes:
- standard;
- 0.4 mm oversize.
NOTE
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R
I
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T
70200
70201
Figure 53
Figure 54
Fit half bearings (1) on connecting rod and cap.
Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
Use band 380000220 (2) to fit the connecting rod-piston
assembly (1) into the cylinder barrels and check thefollowing:
- the number of each connecting rod shall correspond to
the cap coupling number.
Fitting connecting rod-piston assembly into
cylinder barrels
Do not try to adapt the half bearings.
NOTE
70202
70203
Figure 55
Figure 56
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same
weight;
- the arrowmarked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
Finding crankpin clearance
To measure the clearance proceed as follows:
- clean the parts accurately and remove any trace of oil;
- set a piece of calibrated wire (2) on the output shaft pins
(1);
- fit the connecting rod caps (3) with the relevant half
bearings (4).
75703
D1 D2
D2 diameters:
N
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P
R
I
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T
70204
70205
70206
Figure 57
Figure 58
Figure 59
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2).
- Apply tool 380000304 (1) to the socket wrench and
tighten screws (2) of 60.
- Remove the cap and find the existing clearance by
comparing the calibrated wire width (1) with the scale
on the wire envelope (2).
70207
Figure 60
If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
Check manually that the connecting rods (1) are sliding
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.250 to 0.275 mm.
70208
Figure 61
Once connecting rod-piston assemblies refitting is over, use
dial gauge 39395603 (1) fitted with base 380000364 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 to 0.52 mm.
Checking piston protrusion
N
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I
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T
75750
Figure 62
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch () of the exhaust valve (2) head
distinguishes it from the intake valve.
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
CYLINDER HEAD
Removing the valves
Valve removal shall be performed using tool 380000302 (1)
and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (5).
75751
75752
Figure 63
Figure 64
Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
1
2
A
1 2
3
4
5
6
2
1
NOTE
NOTE
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I
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T
Figure 65
Figure 66
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90C and 2
to 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
Replace the cylinder head if leaks are found.
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.
Checking cylinder head wet seal
Before refitting, smear the plug surfaces with
water-repellent sealant.
Checking cylinder head supporting surface
75756
The rated thickness A for the cylinder head is 95 0.25 mm,
max. metal removal shall not exceed thickness B by 0.13 mm.
After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
75753
1
0,4 C
D
0,025 / 25,4
0,4 TOTAL C
0,01 / 50
A B
NOTE
NOTE
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T

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R
I
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T
18625
18882
75757
Figure 67
Figure 68
Figure 69
Figure 70
VALVES
INTAKE AND EXHAUST VALVE MAIN DATA
Remove carbon deposits from valves using the proper metal
brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, using tool 99305018 and
removing as less material as possible.
Check the valve stem (1) using a micrometer (2), it shall be
7.960 7.980.
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.056 0.096 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
Removing carbon deposits, checking and
grinding valves
CNH
PARTS
Checking clearance between valve stem and
valve guide and valve centering
2
1
116395
INTAKE
VALVE
EXHAUST
VALVE
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T
EXHAUST
70328
75754
Figure 71
Figure 72
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.
Check the valve seats (2). If slight scoring or burnout is found,
regrind seats using tool 99305018 (1) according to the angle
values shown in Figure 73.
VALVE SEATS
Regrinding replacing the valve seats
VALVE SEAT MAIN DATA
INTAKE
EXHAUST
INTAKE
Figure 73
CNH
PARTS
Should valve seats be not reset just by regrinding, replace
them with the spare ones. Use adequate tool to remove as
much material as possible from the valve seats (take care not
to damage the cylinder head) until they can be extracted
from the cylinder head using a punch.
Heat the cylinder head to 80 - 100C and using the proper
beater, fit the new valve seats, previously cooled, into the
cylinder head.
Use adequate tool to regrind the valve seats according to the
values shown in figure.
1
2
VALVE GUIDE
116356
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T
Height Under a load of
mm N
H (free) 63.50 0
H
1
49.02 329
H
2
38.20 641
50676
75759
75751
Figure 74
Figure 75
Figure 76
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
Before refitting use adequate tool to check spring flexibility.
Compare load and elastic deformation data with those of the
new springs shown in the following table.
FITTING CYLINDER HEAD
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 380000302 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
CNH
PARTS
VALVE SPRINGS
75758
Figure 77
After regrinding, check that valve (3) sinking value is the
specified one by using the base 380000364 (2) and the dial
gauge 380000228 (1).
1
2
3
3 1
1
2
1 2
3
4
5
6
NOTE
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T

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R
I
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T
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.
87759
Figure 78
Refitting the cylinder head
CNH
PARTS
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 , 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:
For 4 cylinder versions:
Repeat the operation for pistons 2, 3 and 4 and calculate
the average value.
88775
Figure 79
S
cil1
=
S1 +S2
2
CNH
PARTS
S =
S
cil1
+S
cil2
+S
cil3
+S
cil4
4
75703
D1 D2
D2 diameters:
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TIGHTENING TORQUE
COMPONENT
TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15 3 1.5 0.3
Main bearing cap 1st stage
2nd stage
50 6
80 6
5.0 0.6
8.0 0.6
3rd stage 90 5
Rear gear housing assembly
(M8x1.25x40)
(M8x1.25x25)
(M10x1.5)
24 4
24 4
49 5
2.4 0.4
2.4 0.4
4.9 0.5
Oil pump (M8x1.25x30) 8 1 0.8 0.1
Front cover assembly
(M8x1.25x45)
(M8x1.25x30)
24 4
24 4
2.4 0.4
2.4 0.4
Connecting rod bolts (M11x1.25) 1st stage
2nd stage
30 3
60 5
3.0 0.3
6.0 0.5
3rd stage 60 5
Ladder frame assembly (M10x1.25x25) 43 5 4.3 0.5
Oil rifle plugs
(M10x1)
(M14x1.5)
6 1
11 2
0.6 0.1
1.1 0.2
Assemble oil suction tube (M8x1.25x20) 24 4 2.4 0.4
Oil pan assembly
(M8x1.25x25)
(M18x1.50)
24 4
60 9
2.4 0.4
6.0 0.9
Set timing pin 5 1 0.5 0.1
Fuel pump assembly
M8 screw
M6 screw
M6 nut
24 4
10 1
10 1
2.4 0.4
1.0 0.1
1.0 0.1
M10x1.5 flange head nuts pre-torque
Final torque
10 - 15
50 - 55
1.0 - 1.5
5.0 - 5.5
Fuel pump gear (drive gear nut) Snug torque
Final torque
15 - 20
85 - 90
1.5 - 2.0
8.5 - 9.0
Timing pin cap of fuel pump 30 - 35 3.0 - 3.5
Rocker assys (M8) 24 4 2.4 0.4
Cylinder head bolts
(M12x70)
(M12x140)
(M12x180)
50 + 90
40 + 180
70 + 180
5.0 + 90
4.0 + 180
7.0 + 180
Assy rocker covers (M8x1.25x25) 24 4 2.4 0.4
Intake manifold (M8x1.25) 24 4 2.4 0.4
Assy air intake connection (M8x1.25) 24 4 2.4 0.4
Oil bypass valve into lube filter head (M22x1.5x10) 80 8 8.0 0.8
Plug (M12x1.5x12) 10 1 1.0 0.1
Exhaust manifold (M10x1.5x65) 43 6 4.3 0.6
Water pump (M8x1.25x25) 24 4 2.4 0.4
Water outlet connection
(M8x1.25x35)
(M8x1.25x70)
24 4
24 4
2.4 0.4
2.4 0.4
Fan support (M10x1.5x20) 33 5 3.3 0.5
Fan pulley
(M6)
(M10)
10 2
43 6
1.0 0.2
4.3 0.6
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COMPONENT
TORQUE
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 12 7.7 1.2
Crankshaft pulley (M12x1.75x10.9) 110 5 11.0 0.5
Flywheel housing
(M12x120)
(M12x80)
(M10x80)
(M10x40)
85 10
85 10
49 5
49 5
8.5 1.0
8.5 1.0
4.9 0.5
4.9 0.5
Flywheel housing (M12x1.25) 1st stage 30 4 3.0 0.4
2nd stage 60 5
Assy rear cover plate to flywheel housing (M8x1.25x16) 24 4 2.4 0.4
Fuel injectors 60 5 6.0 0.5
Fuel lift pump 24 4 2.4 0.4
Turbocharger to exhaust manifold (M10) 43 6 4.3 0.6
Oil feed to oil filter head 24 4 2.4 0.4
Oil feed to turbocharger (M12x1.5) 35 5 3.5 0.5
Oil drain (M8x1.25x16) 24 4 2.4 0.4
Alternator to alternator support (M8x1.25x30) 24 4 2.4 0.4
Alternator to water inlet conn. assy (M8x1.25x30) 24 4 2.4 0.4
Lower alternator mounting (M10x1.25x25) 24 4 2.4 0.4
Alternator upper pivot to support (M10) 49 5 4.9 0.5
Alternator mounting hardware (M12x1.75x120) 43 6 4.3 0.6
Alternator wiring (M6x1.0 nut) 10 2 1.0 0.2
Starter motor to gear case (M10) 49 5 4.9 0.5
Screw M8 for fastening cylinder barrel lubricating nozzles 15 3 1.5 0.3
Screw M12 for fastening output shaft caps 1
st
stage
2
nd
stage
d
50 6
80 6
5 0.6
8 0.6
2 stage
3
rd
stage 90 5
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M11 for fastening connecting rod caps 1
st
stage
d
60 5 6 0.5
Screw M11 for fastening connecting rod caps 1 stage
2
nd
stage
60 5
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70159
70158
70160
70161
70162
Figure 1
Figure 2
Figure 3
Figure 4
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.
Remove the screws (1) and the main bearing caps (2).
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
Use tool 380000362 (1) and hoist to remove the crankshaft
(2) from the block.
Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
Keep the half-bearings into their housings since in
case of use they shall be fitted in the same position
found at removal.
Take note of lower and upper half-bearing
assembling positions since in case of reuse they shall
be fitted in the same position found at removal.
Figure 5
ELECTRONICS ENGINES OVERHAUL
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.
NOTE
NOTE
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P
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I
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T
70163
70165
70164
70166
70167
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Remove the screws (1) and disconnect camshaft (3) retaining
plate (2).
Withdraw carefully the camshaft (1) from the engine block.
Withdraw the tappets (1) from the engine block.
Once engine is disassembled, clean accurately the
cylinder-block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free fromseizing,
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.
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
cylinder barrels. Cylinder barrel regrinding shall be performed
according to the spare piston diameter oversized by 0.4 mm
and to the specified assembling clearance.
Take note of plate (2) assembling position.
REPAIR OPERATIONS
CYLINDER UNIT
Checks and measurements
Should the ring gauge be not available, use a
micrometer for zero-setting.
s
NOTE
NOTE
zs
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Figure 11
In case of regrinding, all barrels shall have the same
oversize (0.4 mm).
Checking head supporting surface on cylinder
unit
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them
in case of uncertain seal or if rusted.
Check main bearing housings as follows:

- fit the main bearings caps on the supports without
bearings;
- tighten the fastening screws to the specified torque;
- use the proper internal gauge to check whether the
housing diameter is falling within the specified value.
Replace if higher value is found.
107804
NOTE
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P
R
I
N
T
70169
Figure 12
TIMING SYSTEM
Camshaft
CAMSHAFT MAIN DATA (4 cyl.)
Figure 13
MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders)
Camshaft pin and cam surfaces shall be absolutely smooth;
if they show any traces of seizing or scoring replace the
camshaft and the bush.
84089
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I
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70171
70172
Figure 14
Figure 15
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
Camshaft bush (2) shall be pressed into its housing.
Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.
BUSHES Checking cam lift and pin alignment
Set the camshaft on the tailstock and using a 1/100 gauge set
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 mmfor intake cams, in case of different values
replace the camshaft.
Figure 16
CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)
* Value to be obtained after driving the bush.
107399
Sec. A-A
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Figure 17
Figure 18
MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS
*Height to be obtained after driving the bush.
70174
To replace bush (1), remove and refit them using the beater
380000367 (2) and the handgrip 380000368 (3).
Bush replacement
CNH
PARTS
When refitting the bush (1), direct them to make
the lubricating holes (2) coincide with the holes on
the block housing.
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
Tappets
Figure 19
107268
sec. A-A
NOTE
112890
N
O
T

F
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P
R
I
N
T
70176
70164
70238
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Lubricate the camshaft bush and fit the camshaft (1) taking
care not to damage the bush or the housings.
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
Fitting tappets camshaft
Figure 20
Figure 21
Figure 22
Figure 23
70179
70180
Check camshaft end float (1).
It shall be 0.23 0.13 mm.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Figure 24
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I
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70182
Figure 25
Figure 26
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.
It is recommended to insert the found values in the
proper table.
See Figure 26.
Undersize classes are:
Journals and crankpins shall always be ground to
the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB.
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value
OUTPUT SHAFT
Measuring journals and crankpins
108487
NOTE
NOTE
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I
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70183
Figure 27
OUTPUT SHAFT MAIN TOLERANCES
70237
SYSTEM CONTROL SIDE
INTERMEDIATE MAIN
BEARINGS
FIRST MAIN BEARING
ON FRONT SIDE
measured on > 45.5 mm radius
between adjacent journals
SHAPE
Roundness
SHAPE
Cilindricity //
Parallelism //
Straightness
OSCILLATION
OSCILLATION
Total oscillation
CRITICAL
IMPORTANT
SECONDARY
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Figure 28
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Figure 29
MAIN OUTPUT SHAFT TOLERANCES
* Measured on a radius greater than 45.5 mm
** 0.500 between adjacent main journals
70577
Measuring journals and crankpins (6 cyl.)
107269
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70237
SYSTEM CONTROL SIDE
INTERMEDIATE MAIN
BEARINGS
FIRST MAIN BEARING ON
FRONT SIDE
Figure 30
SHAPE
Roundness
SHAPE
Cilindricity //
Parallelism //
Straightness
OSCILLATION
OSCILLATION
Total oscillation
CRITICAL
IMPORTANT
SECONDARY
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70184
70185
Figure 31
Figure 32
Figure 33
Figure 34
Refit the crankshaft (2).
Check the backlash between crankshaf main journals and the
relevant bearings as follows:
CNH
PARTS
Fitting main bearings
CNH
PARTS
Do not try to adapt the bearings.
Main bearings (1) are supplied spare with 0.250 0.500 mm
undersize on the internal diameter.
Clean accurately the main half bearings (1) having the
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
Check that gear toothing (1) is not damaged or worn,
otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180C for 10 minutes
in an oven and then key it to the crankshaft.
- 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
supports.
70186
70161
Replacing oil pump control gear Finding journal clearance
NOTE
NOTE
75703
D1 D2
D2 diameters:
Revi - February 2007
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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.
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.
70188
70189
70190
70191
Figure 35
Figure 36
Figure 37
Figure 38
- 3
rd
stage, with tool 380000304 (1) set as shown in the
figure, tighten the screws (2) with 90 5 angle.
- 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.
COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
Checking crankshaft shoulder clearance

The pistons are supplied spare with the following
sizes:
- standard;
- 0.4 mm oversize.
NOTE
70187
Tighten the pre-lubricated screws (1) in the following three
successive stages:
- 1
st
stage, with torque wrench to 50 6 Nm.
- 2
nd
stage, with torque wrench to 80 6 Nm.
Figure 39
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2.420
2.440
2.705
2.735
38.010
38.016
37.994
38.000
3.970
3.990
2.350
2.380
220
2.560
2.605
1.5
*
32615
32614
32613
70192
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Remove split rings (1) frompiston (2) using pliers 380000221
(3).
Piston pin (1) split rings (2) are removed using a scriber (3).
Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in thefigure.
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter
Pistons
Measuring piston diameter
114797
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32620
16552
32619
18857
Figure 45
Figure 46
Figure 47
Figure 48
To measure the piston pin (1) diameter use the micrometer
(2).
Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.
Check the clearance between the sealing rings (3) of the 2
nd
and 3
rd
slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Piston pins
Figure 49
MAIN DATA OF THE PISTON WITHOUT PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter
Conditions for proper pin-piston coupling
114798
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41104
Figure 50
Figure 51
Figure 52
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).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
70194
Use feeler gauge (1) to measure the clearance between the
ends of the split rings (2) fitted into the cylinder barrel (3).
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
Connecting rods
* Value for inside diameter to be obtained after driving in
connecting rod small end and grinding.
The surface of connecting rod and rod cap are
knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.
88607
NOTE
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70196
Figure 53
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
Every connecting rod is marked as follows:
- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary
to mark the newconnecting rod with the same
numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
S X, 1901 to 1940 (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
*
CONNECTING ROD BODY
CONNECT-
ING ROD
BODY
CONNECT-
ING ROD
BODY
CONNECT-
ING ROD
BODY
CONNECT-
ING ROD
BODY
CONNECTING ROD
BODY
CONNECTING ROD BODY
NOTE
70198
Figure 54
Fitting connecting rod-piston assembly
Connecting rod-piston coupling
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrowshowing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Manufacturing date.
4. Marking showing 1
st
slot insert testing;
Figure 55
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
108597
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72705
32613
70200
70201
Figure 56
Figure 57
Figure 58
Figure 59
Position the piston (1) on the connecting rod according to
the diagram shown in the figure, fit the pin (3) and stop it by
the split rings (2).
Fitting split rings
Use pliers 380000221 (3) to fit the split rings (1) on thepiston
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
Fit half bearings (1) on connecting rod and cap.
Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
Use band 380000220 (2) to fit the connecting rod-piston
assembly (1) into the cylinder barrels and check thefollowing:
- the number of each connecting rod shall correspond to
the cap coupling number.
Split rings are supplied spare with the following
sizes:
- standard, yellow marking;
- 0.4 mm oversize, yellow/green marking;
Fitting connecting rod-piston assembly into
cylinder barrels
Do not try to adapt the half bearings.
NOTE
NOTE
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70203
70204
70205
70206
Figure 60
Figure 61
Figure 62
Figure 63
Figure 64
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same
weight;
- the arrowmarked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
Finding crankpin clearance
To measure the clearance proceed as follows:
- clean the parts accurately and remove any trace of oil;
- set a piece of calibrated wire (2) on the output shaft pins
(1);
- fit the connecting rod caps (3) with the relevant half
bearings (4).
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench
(2).
- Apply tool 380000304 (1) to the socket wrench and
tighten screws (2) of 60.
- Remove the cap and find the existing clearance by
comparing the calibrated wire width (1) with the scale
on the wire envelope (2).
108596
Before the final fitting of the connecting rod cap
fastening screws, check that their diameter
measured at the centre of the thread length is not
< 0.1 mm than the diameter measured at approx.
10 mm from screw end.
NOTE
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70207
70208
Figure 65
If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
Once connecting rod-piston assemblies refitting is over, use
dial gauge 380000228 (1) fitted with base 380000364 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 to 0.52 mm.
Checking piston protrusion
Figure 66
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70319
Figure 67
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch () of the exhaust valve (2) head
distinguishes it from the intake valve.
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
CYLINDER HEAD
Removing the valves
Valve removal shall be performed using tool 380000302 (1)
and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (5).
70321
70322
Figure 68
Figure 69
Remove sealing rings (1 and 2) from the valve guide.
Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
NOTE
NOTE
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70323
Figure 70
Figure 71
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90C and 2
to 3 bar pressure.
Replace the core plugs (1) if leaks are found, use the proper
punch for their removal/refitting.
Replace the cylinder head if leaks are found.
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.
Checking cylinder head wet seal
Before refitting, smear the plug surfaces with
water-repellent sealant.
Checking cylinder head supporting surface
70325
The rated thickness Afor the cylinder head is 105 0.25 mm,
max. metal removal shall not exceed thickness B by 1 mm.
After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
NOTE
NOTE
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18625
18882
70327
Figure 72
Figure 73
Figure 74
Figure 75
VALVES
INTAKE AND EXHAUST VALVE MAIN DATA
Remove carbon deposits from valves using the proper metal
brush.
Check that the valves show no signs of seizing, scoring or
cracking.
If necessary, rectify the valve seats, taking away the least
amount of material possible.
Check the valve stem (1) using a micrometer (2), it shall be
6.970 6.990.
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.052 0.092 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
Removing carbon deposits, checking and
grinding valves
CNH
PARTS
Checking clearance between valve stem and
valve guide and valve centering
INTAKE
VALVE
EXHAUST
VALVE
107280
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EXHAUST
79457
70330
70331
Figure 76
Figure 77
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.
Should slight scratches or burns be found, go over with the
adequate tool (1) according to the inclination values
indicated in the Figure 78.
VALVE SEATS
Regrinding replacing the valve seats
VALVE SEAT MAIN DATA (4 CYL.)
INTAKE EXHAUST
INTAKE
Figure 78
VALVE GUIDE
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70332
Figure 79
Should valve seats be not reset just by regrinding, replace
them with the spare ones. Using a suitable tool, remove as
much material as possible from the valve seats (take care not
to damage the cylinder head) until they can be extracted
from the cylinder head using a punch.
Heat the cylinder head to 80 - 100C and using the proper
punch, fit the new valve seats, previously cooled, into the
cylinder head.
Therefore, with an adequate tool, go over the valve seats
according to the values stated in the Figure 78.
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
EXHAUST INTAKE
Figure 80
70333
After regrinding, check that valve (3) sinking value is the
specified one by using the base 380000364 (2) and the dial
gauge 380000228 (1).
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50676
70334
770321
Figure 81
Figure 82
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
Before refitting use tool to check spring flexibility. Compare
load and elastic deformation data with those of the new
springs shown in the following table.
FITTING CYLINDER HEAD
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 380000302 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
CNH
PARTS
VALVE SPRINGS
Figure 83
NOTE
Height Under a load of
mm N
H 47.75 Free
H
1
35.33 P 339.8 19 N
H
2
25.2 P1 741 39 N
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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.
70335
Figure 84
Refitting the cylinder head
CNH
PARTS
88775
Figure 85
CNH
PARTS
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 85, 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:
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
the average value.
If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.
S =
S
cil1
+S
cil2
+S
cil3
+S
cil4
+S
cil5
+S
cil6
6
S
cil1
=
S1 +S2
2
S =
S
cil1
+S
cil2
+S
cil3
+S
cil4
4
75703
D1 D2
D2 diameters:
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TIGHTENING TORQUE
COMPONENT
TORQUE
COMPONENT
Nm kgm
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
47 5
24 4
7.7 1.2
4.7 0.5
2.4 0.4
Nut M6 for fastening camshaft sensor 10 2 1 0.2
Screw M8 for fastening oil pump
1
st
stage
2
nd
stage
8 1
24 4
0.8 0.1
2.4 0.4
Screw M8 for fastening front cover 24 4 2.4 0.4
Screw M10 for fastening crankcase plate 43 5 4.3 0.4
Nut M18 for fastening high pressure pump gear 105 5 10.5 0.5
Nuts M8 for fastening fuel pump 24 4 2.4 0.4
inch plug on cylinder head
24 4
36 5
12 2
2.4 0.4
3.6 0.5
1.2 0.2
Screw M6 for fastening injectors
1
st
stage
d
8.5 0.35 0.85 0.035
Screw M6 for fastening injectors
1 stage
2
nd
stage 75 5
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
1
st
stage
}
35 5 3.5 0.5
Screw M12 (12 x 1.75 x 150) for fastening cylinder head
1
st
stage
}
55 5 5.5 0.5
2
nd
stage 90 5
3
rd
stage 90 5
Screw for fastening rocker bracket 36 5 3.6 0.5
Valve clearance adjusting nuts 24 4 2.4 0.4
Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 2 2 0.2
Screw M8 for fastening high pressure pipe connector 24 4 2.4 0.4
Screw M6 for fastening wiring bulkhead 10 2 1 0.2
Screw M8 for fastening electric wiring support for injector feed 24 4 2.4 0.4
Nuts for fastening wiring on each injector 1.5 0.25 0.15 0.025
Screw M12 for fastening fuel filter bracket 77 8 7.7 0.8
Screw M8 for fastening fuel filter holder 24 4 2.4 0.4
Fuel filter contact + turn
Screw M22 for fastening oil pressure relief valve on oil filter support 80 8 8 0.8
Screw M8 for radiator seal and oil filter support 24 4 2.4 0.4
Oil filter contact + turn
11/8 inch connection on filter support for turbine lubrication 24 4 2.4 0.4
Nut M12 for fastening turbine lubrication pipe 10 2 1 0.2
Screw M10 for fastening engine coolant inlet connection 43 6 4.3 0.6
90 elbow fastening (if required) to engine coolant inlet connection 24 4 2.4 0.4
Pipe on cylinder head for compressor cooling 22 2 2.2 0.2
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COMPONENT
TORQUE
COMPONENT
Nm kgm
Screw M6 for fastening engine coolant drain connector 10 2 1 0.2
Pin fastening on engine block for exhaust manifold 10 2 1 0.2
Screw M10 for fastening exhaust manifold on cylinder head 53 5 5.3 0.5
Screw M12 for fastening damper adapter 1
st
stage
50 5 5 0.5
Screw M12 for fastening damper adapter 1 stage
and damper on output shaft 2
nd
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
Screw M12 for fastening flywheel housing
85 10
49 5
8.5 1
4.9 0.5
Screw M6 for fastening heat exchanger for control unit
Screw M8 for fastening heat exchanger for control unit
10 2
24 4
1 0.2
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 M8
t M8
6-cyl.
7 1
43 6
0.7 0.1
4 3 0 6
Turbine fixing to exhaust manifold
{
nuts M8
6-cyl.
{
pins M8
43 6
7 1
4.3 0.6
0 7 0 1
u b e g to e aust a o d
4-cyl.
{
pins M8
nuts M8
7 1
24 4
0.7 0.1
2.4 0.4
Adapter M12 on turbine for lubricant oil pipes (inlet) 35 5 3.5 0.5
Pipe fixing on adapter M10 for turbine lubrication 35 5 3.5 0.5
Oil pipe fixing on adapter M10 for turbine lubrication to block 43 6 4.3 0.6
Oil drain pipe fixing M8 on turbine 24 4 2.4 0.4
Connector fixing M6 for oil return from cylinder head to flywheel housing 10 2 1 0.2
Screw M12 for fastening engine flywheel 1
st
stage
d
30 4 3 0.4
Screw M12 for fastening engine flywheel 1 stage
2
nd
stage
60 5
Screw M8 for fastening front bracket for engine lifting 24 4 2.4 0.4
Screw for fastening engine oil sump 24 4 2.4 0.4
Screw M8 for fastening cylinder barrel lubricating nozzles 15 3 1.5 0.3
Screw M12 for fastening output shaft caps 1
st
stage
2
nd
stage
d
50 6
80 6
5 0.6
8 0.6
2 stage
3
rd
stage 90 5
Screw M11 for fastening connecting rod caps 1
st
stage
d
60 5 6 0.5
Screw M11 for fastening connecting rod caps 1 stage
2
nd
stage
60 5
Alternator
M10 Screw, Bracket fixing on water feed pipefitting 43 6 4.3 0.6
M10 Screw, alternator locking 43 6 4.3 0.6
Starter
Starter fixing screw 43 6 4.3 0.6
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SECTION 5 - TOOLS 1 NEF ENGINES
SECTION 5
Tools
Page
TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 SECTION 5 - TOOLS NEF ENGINES
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TOOLS
TOOL NO. DESCRIPTION
380000144 Tool for flywheel holding
380000216 Lifting rig for engine removal/refitting
380000220 Band for fitting piston into cylinder barrel (60 125 mm)
380000221 Pliers for removing/refitting piston rings (65 110 mm)
380000228 Dial gauge (0 5 mm)
380000229
Dial gauge holder for rotary injection pump timing (use with
380000228)
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380000301
Revolving stand for overhauling units (1000 daN/m capacity, 120
daN/m torque)
380000302 Tool for removing/refitting engine valves
380000304 Pair of gauges with and square head for angle tightening
380000322 Injection pump gear extractor.
380000362 Tool for lifting the output shaft
380000364 Gauge base for different measurements (to be used with 380000228)
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380000661 Brackets for fastening engine to revolving stand 99322205
380000663 Tool to remove output shaft rear gasket
380000664 Tool for fitting output shaft rear gasket
380000665 Tool to remove output shaft front gasket
380000666 Tool for fitting output shaft rear gasket
380000667
Beater for removing/refitting camshaft bushes (to be used with
380000668)
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v
380000668 Interchangeable willow handgrip
380000669 Tool to remove gaskets
380000670 Tool to remove oil filter (engine)
380000671 Tool to remove injectors
380000988 Tool for stopping the engine flywheel
380000989 Adapter, cylinder compression test (use with 380001006)
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380000997 Gauge base for different measurements (to be used with 380001005)
380001005 Dial gauge (0 10 mm)
380001006 Diesel fuel engine cylinder compression control device
380002385 Flywheel crank handle
3800002729 Band for fitting piston into cylinder barrel (60 125 mm)
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SECTION 6 - ENGINES FEATURES F4CE - F4DE - F4GE - F4HE 1 NEF ENGINES
SECTION 6
Engines features
Page
ENGINES F4CE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General characteristics 3 . . . . . . . . . . . . . . . . . .
- Clearance data 9 . . . . . . . . . . . . . . . . . . . . . . . .
ENGINES F4DE 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Clearance data 19 . . . . . . . . . . . . . . . . . . . . . . . .
ENGINES F4GE 25 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Clearance data 27 . . . . . . . . . . . . . . . . . . . . . . . .
ENGINES F4HE 35 . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Clearance data 37 . . . . . . . . . . . . . . . . . . . . . . . .
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2 SECTION 6 - ENGINES FEATURES F4CE - F4DE - F4GE - F4HE NEF ENGINES
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F4CE ENGINES
General characteristics
Type F4CE9484
Power Supercharged with intercooler
Injection Direct
Bore mm 104
Stroke mm 132
3
4485
TIMING
end after B.D.C. B
-
-
end after T.D.C. C
-
-
X
Checking timing
mm
X
mm
Checking operation
mm
X
mm
-
-
0.25 to 0.05
0.50 to 0.05
FUEL FEED
Injection
Type: Bosch VE 4/12 F
Nozzle type -
bar
Injection pressure bar -
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Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
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.
NOTE
Type
F4CE9484A*J600
Compression ratio 16.5:1

Max. output kW
(HP)
rpm
56
(76)
2300
Max. torque Nm
(kgm)
rpm
340
(34.7)
1300
Loadless engine
idling rpm
-
Loadless engine
peak rpm rpm
-
Bore x stroke mm
Displacement cm
3
104 x 132
4485
SUPERCHARGING
with intercooler
SUPERCHARGING
Turbocharger type
-
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
Forced by gear pump, relief valve single action
oil filter
-
-
COOLING
Water pump control
Thermostat
- start of opening C
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
engine sump + filter
liters
-
-
N
O
T

F
O
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P
R
I
N
T
by FPT.
NOTE
Type
F4CE9484D*J600

Max. output kW
(HP)
rpm
82
(111)
2200
Max. torque Nm
(kgm)
rpm
455
(46.4)
14000
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
SUPERCHARGING with intercooler
Turbocharger type HOLSET HX25
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
T

F
O
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P
R
I
N
T
by FPT.
NOTE
Type
F4CE9484L*J600

Max. output kW
(HP)
rpm
78
(106)
2300
Max. torque Nm
(kgm)
rpm
448
(45.7)
1300
Loadless engine
idling
rpm -
Loadless engine
peak
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
Turbocharger type -
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
T

F
O
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P
R
I
N
T
by FPT.
NOTE
Type
F4CE9484M*J601

Max. output kW
(HP)
rpm
71
(97)
2300
Max. torque Nm
(kgm)
rpm
418
(42,6)
1300
Loadless engine
idling
rpm -
Loadless engine
peak
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
Turbocharger type -
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
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R
I
N
T
by FPT.
NOTE
Type
F4CE9484N*J601

Max. output kW
(HP)
rpm
63
(86)
2300
Max. torque Nm
(kgm)
rpm
370
(37.7)
1300
Loadless engine
idling
rpm -
Loadless engine
peak
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
Turbocharger type -
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
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Clearance data
Type F4CE9484
1
X
Cylinder barrels 1
104.000 to 104.024
0.4
1
X
2
Pistons
Size X
Outside diameter 1
Pin housing 2
55.9
103.714 to 103.732
38.010 to 38.016
CNH
PARTS
X
Piston protrusion X -
3
Piston pin 3 37.994 to 38.000
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Type F4CE9484
X
1
3
2
X
X
X1*
X 3
* measured on 101 mm
2.705 to 2.735*
2.440 to 2.460
4.030 to 4.050
1
3
2
S
S
S
S 1*
Split rings S 2
S 3
2.560 to 2.605
2.350 to 2.380
3.970 to 3.990
1
3
0.100 to 0.175
0.060 to 0.110
0.040 to 0.080
CNH
PARTS
Split rings 0.4
X 1
3
2 X
X
in cylinder barrel:
X 1
X 2
X 3
0.30 to 0.40
0.60 to 0.80
0.30 to 0.55
1
2
Small end bush
housing 1
Big end bearing
housing 2
40.987 to 41.013
72.987 to 73.013
S
3
Outside 4
Inside 3
Spare big end half
bearings S
38.019 to 38.033
1.955 to 1.968
CNH
PARTS
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Type F4CE9484
X
Size X
Max. tolerance
on connecting rod
axis alignment
-
-
Journals 1
Crankpins 2
82.990 to 83.010
68.987 to 69.013
1 2
S 1 S 2
2.456 to 2.464
1.955 to 1.968
3
Main bearings
No. 1 5 3
No. 2 3 4 3
87.982 to 88.008
87.977 to 88.013
No. 1 5
No. 2 3 4
0.064 to 0.095
0.059 to 0.100
CNH
PARTS
Main half bearings
0.250 to 0.500
1 X
X 2
X 3
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Type F4CE9484
1
4 Valves:
4
7.960 to 7.980
60
7.960 to 7.980
45
1
Housing on head for
valve seat:
1
1
46.987 to 47.013
43.637 to 43.663
2
head:
2
47.063 to 47.089
60
o
43.713 to 43.739
45
o
X
X
Sinking X
1 to 1.52
1.05 to 1.52
Between valve seat
and head
0.050 to 0.102
0.050 to 0.102
CNH
PARTS
Valve seats -
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Type F4CE9484
H
H 1
H 2
free spring H
339.8 9 N H1
741 39 N H2
63.50
49.02
38.20
X
Injector protrusion X not adjustable

1 2 3 4 5
Camshaft bush
housings No. 1-5
Camshaft housings
No. 2-3-4
59.222 to 59.248
54.089 to 54.139
1
2
3
Camshaft journals:
1 5 53.995 to 54.045
Bush inside
Bushes and journals
Housings and journals
0.038 to 0.162
0.044 to 0.144
H
Cam lift:
H
H
11.02
10.74
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Type F4CE9484
1
Tappet cap housing
on block 1 16,000 16,030
2
3
2
Tappet cap outside
diameter: 2
3
15.929 to 15.959
15.965 to 15.980
Between tappets and housings 0.020 to 0.065
CNH
PARTS
Tappets -
1
2
Rockers 2 19.000 to 19.026
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F4DE ENGINES
Type F4DE9484
Power Supercharged with intercooler
Injection Direct
Bore mm 104
Stroke mm 132
3
4485
TIMING
end after B.D.C. B
-
-
end after T.D.C. C
-
-
X
Checking timing
mm
X
mm
Checking operation
mm
X
mm
-
-
0.20 to 0.30
0.45 to 0.55
FUEL FEED
Injection
Type: Bosch high pressure common rail
EDC7 ECU
Injectors CRIN 2
Nozzle type DSLA and DLLA
bar
Injection pressure bar 0.250 - 1600
N
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by FPT.
NOTE
Type
F4DE9464B*J101

Max. output kW
(HP)
rpm
97
(132)
2200
Max. torque Nm
(kgm)
rpm
534
(54.4)
1400
Loadless engine
idling rpm
-
Loadless engine
peak rpm rpm
-
2500
Bore x stroke mm
Displacement cm
3
104 x 132
4485
SUPERCHARGING
with intercooler
SUPERCHARGING
Turbocharger type
-
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
T

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O
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P
R
I
N
T
by FPT.
NOTE
Type
F4DE9484D*J101

Max. output kW
(HP)
rpm
89
(121)
2200
Max. torque Nm
(kgm)
rpm
563
(57.4)
14000
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
SUPERCHARGING
with intercooler
SUPERCHARGING
Turbocharger type
-
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
T

F
O
R

P
R
I
N
T
by FPT.
NOTE
Type
F4DE9484E*J100

Max. output kW
(HP)
rpm
82
(111)
2200
Max. torque Nm
(kgm)
rpm
520
(53)
1400
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
SUPERCHARGING
with intercooler
SUPERCHARGING
Turbocharger type
-
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
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Clearance data
Type F4DE9484
1
X
Cylinder barrels 1
104.000 to 104.024
0.4
1
X
2
Spare pistons
type:
Size X
Outside diameter 1
Pin housing 2
55.9
103.714 to 103.732
38.010 to 38.016
CNH
PARTS
X
Piston protrusion X -
3
Piston pin 3 37.994 to 38.000
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Type F4DE9484
X
1
3
2
X
X
X1*
X 3
2.705 to 2.735
2.440 to 2.460
4.030 to 4.050
1
3
2
S
S
S
S 1*
Split rings S 2
S 3
* measured on 98 mm
2.560 to 2.605
2.350 to 2.380
3.970 to 3.990
1
3
0.100 to 0.175
0.060 to 0.110
0.040 to 0.080
CNH
PARTS
Split rings 0.4
X 1
3
2 X
X
in cylinder barrel:
X 1
X 2
X 3
0.30 to 0.40
0.60 to 0.80
0.30 to 0.55
1
2
Small end bush
housing 1
Big end bearing
housing 2
42.987 to 43.553
72.987 to 73.013
S
3
Outside 4
Inside 3
Spare big end half
bearings S
38.019 to 38.033
1.955 to 1.968
CNH
PARTS
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Type F4DE9484
1 2
S 1 S 2
Journals 1
Crankpins 2
*provided as spare part
82.99 to 83.01
68.99 to 69.01
2.456 to 2.464
1.955 to 1.968
3
Main bearings
No. 1 5 3
No. 2 3 4 3
87.982 to 88.008
87.977 to 88.013
No. 1 5
No. 2 3 4
0.041 to 0.119
0.041 to 0.103
CNH
PARTS
Main half bearings
0.250 to 0.500
1 X
X 2
X 3
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Type F4DE9484
1
2
3
2
Valve guides
3
-
-
Valve guides and seats on head -
CNH
PARTS
Valve guides -
4 Valves:
4
6.970 to 6.999
60
o
0.25
o
6.970 to 6.999
45
o
0.25
o
1
Housing on head for
valve seat:
1
1
34.837 to 34.863
34.837 to 34.863
2
head:
2
34.917 to 34.931
60
o
34.917 to 34.931
45
o
X
X
Sinking X
0.59 to 1.11
0.96 to 1.48
Between valve seat
and head
0.054 to 0.094
0.054 to 0.094
CNH
PARTS
Valve seats -
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P
R
I
N
T
Type F4DE9484
H
H 1
H 2
free spring H
339.8 9 N H1
741 39 N H2
47.75
35.33
25.2
X

1 2 3 4 5
Camshaft bush
housings No. 1-5
Camshaft housings
No. 2-3-4
59.222 to 59.248
54.089 to 54.139
1
2
3
Camshaft journals:
1 5 53.995 to 54.045
Bush inside
H
Cam lift:
H
H
6.045
7.582
N
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F
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P
R
I
N
T
Type F4DE9484
1
Tappet cap housing
on block 1 16.000 to 16.030
2
3
2
Tappet cap outside
diameter: 2
3
15.924 to 15.954
15.960 to 15.975
CNH
PARTS
Tappets -
1
2
Rockers 2 22.001 to 22.027
N
O
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F
O
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P
R
I
N
T
by CNH.
NOTE
F4GE ENGINE
Type
F4CE9454C*J602

Max. output kW
(HP)
rpm
67
(91)
2300
Max. torque Nm
(kgm)
rpm
372
(38)
1300
Loadless engine
idling rpm
1150
Loadless engine
peak rpm
rpm 2530
Bore x stroke mm
Displacement cm
3
104 x 132
4485
SUPERCHARGING
with intercooler
SUPERCHARGING
Turbocharger type
HOLSET HX25
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump
liters
liters
13
14
N
O
T

F
O
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P
R
I
N
T
by CNH.
NOTE
Type
F4GE9484D*J600

Max. output kW
(HP)
rpm
93
(126)
2200
Max. torque Nm
(kgm)
rpm
510
(52)
1250
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump
liters
liters
-
-
N
O
T

F
O
R

P
R
I
N
T
by CNH.
NOTE
Clearance data
Type
F4GE9484E*J600

Max. output kW
(HP)
rpm
90
(122)
2000
Max. torque Nm
(kgm)
rpm
525
(53.5)
1200
Loadless engine
idling
rpm
-
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump
liters
liters
-
-
N
O
T

F
O
R

P
R
I
N
T
by CNH.
NOTE
Type
F4GE9484F*J600

Max. output kW
(HP)
rpm
74
(101)
2200
Max. torque Nm
(kgm)
rpm
-
(-)
-
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
T

F
O
R

P
R
I
N
T
by CNH.
NOTE
Type
F4GE9484H*J600

Max. output kW
(HP)
rpm
84
(114)
2000
Max. torque Nm
(kgm)
rpm
495
(50.5)
1200
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
T

F
O
R

P
R
I
N
T
by CNH.
NOTE
Type
F4GE9484J*J600

Max. output kW
(HP)
rpm
88
(120)
2200
Max. torque Nm
(kgm)
rpm
515
(52.5)
1250
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
N
O
T

F
O
R

P
R
I
N
T
by CNH.
NOTE
Type
F4GE9484A*J601

Max. output kW
(HP)
rpm
94
(128)
2300
Max. torque Nm
(kgm)
rpm
1300
515
(52.5)
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
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NOTE
Type
F4GE9484K*J601

Max. output kW
(HP)
rpm
74
(101)
2300
Max. torque Nm
(kgm)
rpm
-
(-)
-
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
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by CNH.
NOTE
Type
Type
F4GE9484A*J602
F4GE06

Max. output kW
(HP)
rpm
94
(128)
2300
Max. torque Nm
(kgm)
rpm
515
(52.5)
1300
Loadless engine
idling
rpm -
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
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O
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by CNH.
NOTE
Type
F4GE9484D*J603

Max. output kW
(HP)
rpm
93
(126)
2200
Max. torque Nm
(kgm)
rpm
510
(52)
1250
Loadless engine
idling
rpm
-
Loadless engine
peak rpm
rpm -
Bore x stroke mm
Displacement cm
3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump*
liters
liters
-
-
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F4HE ENGINES
Type F4HE9484
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4
Bore mm 104
Stroke mm 132
3
4485
TIMING
end after B.D.C. B
18.5
29.5
end after T.D.C. C
67
35
X
Checking timing
mm
X
mm
Checking operation
mm
X
mm
-
-
0.20 to 0.30
0.45 to 0.55
FUEL FEED
Injection
Type: Bosch
high pressure common rail
EDC7 ECU
Injector CRIN 2
Nozzle type DSLA and DLLA
bar
Injection pressure bar 250 - 1600
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NOTE
Type
F4HE9484C*J102

Max. output kW
(HP)
rpm
82
(111)
2200
Max. torque Nm
(kgm)
rpm
1400
516
(52.6)
Loadless engine
idling
rpm 950
Loadless engine
peak rpm
rpm 2430
Bore x stroke mm
Displacement cm
3
104 x 132
4485
Turbocharger type -
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
-
-
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 2
15W40 ACEA E3
FILLING
- engine sump
liters
liters
-
-
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Clearance data
Type F4HE9484
1
X
Cylinder barrels 1
1
104.000 to 104.024
0.4
1
X
2
Spare pistons
type:
Size X
Outside diameter 1
Pin housing 2
55.9
103.714 to 103.732
38.010 to 38.016
CNH
PARTS
X
Piston protrusion X 0.28 to 0.52
3
Piston pin 3 37.994 to 38.000
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Type F4HE9484
X
1
3
2
X
X
X1*
X 3
* measured on 101 mm
2.705 to 2.735
2.440 to 2.460
4.030 to 4.050
1
3
2
S
S
S
S 1*
Split rings S 2
S 3
2.560 to 2.605
2.350 to 2.380
3.970 to 3.990
1
3
0.100 to 0.175
0.060 to 0.110
0.040 to 0.080
CNH
PARTS
Split rings 0.4
X 1
3
2 X
X
X 1
X 2
X 3
0.30 to 0.40
0.60 to 0.80
0.30 to 0.55
1
2
Small end bush
housing 1
Big end bearing
housing 2
40.987 to 41.013
72.987 to 73.013
S
3
Inside 3
Big end half
bearings S
38.019 to 38.033
1.955 to 1.968
CNH
PARTS
Big end half bearings 0.250 ; 0.500
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Type F4HE9484
X
Size X
Max. tolerance
on connecting rod
axis alignment
-
-
1 2
S 1 S 2
Journals 1
Crankpins 2
82.99 to 83.01
68.987 to 69.013
2.456 to 2.464
1.955 to 1.968
3
Main bearings
No. 1 5 / 1- 7 3
No. 2 3 4 3
87.982 to 88.008
87.977 to 88.013
No. 15 / 1-7
No. 234 / 2-3-4-5-6
0.041 to 0.119
0.041 to 0.103
CNH
PARTS
Main half bearings
0.250 to 0.500
1 X
X 2
X 3
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Type F4HE9484
1
4 Valves:
4
6.970 to 6.990
60
o
0.25
o
6.970 to 6.990
45
o
0.25
o
1
Housing on head for
valve seat:
1
1
34.837 to 34.863
34.837 to 34.863
2
head:
2
34.917 to 34.931
60
o
34.917 to 34.931
45
o
X
X
Sinking X
0.59 to 1.11
0.96 to 1.48
Between valve seat
and head
0.054 to 0.094
0.054 to 0.094
CNH
PARTS
Valve seats -
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Type F4HE9484
H
H 1
H 2
free spring H
339.8 9 N H1
741 39 N H2
47.75
35.33
25.2
X

1 2 3 4 5
Camshaft bush
housings No. 1
(flywheel side)
Camshaft housings
No. 2-3-4-5/2-3-4-5-6-7
59.222 to 59.248
54.089 to 54.139
1
2
3
Camshaft journals:
1 5 53.995 to 54.045
Bush inside
H
Cam lift:
H
H
6.045
7.582
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Type F4HE9484
1
Tappet cap housing
on block 1 16.000 to 16.030
2
3
2
Tappet cap outside
diameter: 2
3
15.924 to 15.954
15.960 to 15.975
CNH
PARTS
Tappets -
1
2
Rockers 2 22.001 to 22.027
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APPENDIX 1 NEF ENGINES
Appendix
Page
SAFETY PRESCRIPTIONS 3 . . . . . . . . . . . . . . . . .
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2 APPENDIX NEF ENGINES
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Particular attention shall be drawn on some precautions that
must be followed absolutely in a standard working area and
whose non fulfillment will make any other measure useless
or not sufficient to ensure safety to the personnel in-charge
of maintenance.
Be informed and informpersonnel as well of the laws in force
regulating safety, providing information documentation
available for consultation.
- Keep working areas as clean as possible, ensuring
adequate aeration.
- Ensure that working areas are provided with emergency
boxes, that must be clearly visible and always provided
with adequate sanitary equipment.
- Provide for adequate fire extinguishing means, properly
indicated and always having free access. Their efficiency
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities.
- Organize and displace specific exit points to evacuate
the areas in case of emergency, providing for adequate
indications of the emergency exit lines.
- Smoking in working areas subject to fire danger must be
strictly prohibited.
- Provide Warnings throughout adequate boards signaling
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of
emergency.
- Do not execute any intervention if not provided with
necessary instructions.
- Do not use any tool or equipment for any different
operation from the ones theyve been designed and
provided for: serious injury may occur.
- In case of test or calibration operations requiring engine
running, ensure that the area is sufficiently aerated or
utilize specific vacuum equipment to eliminate exhaust
gas. Danger: poisoning and death.
SAFETY PRESCRIPTIONS
Standard safety prescriptions
Prevention of injury
- Do not wear unsuitable cloths for work, with fluttering
ends, nor jewels such as rings and chains when working
close to engines and equipment in motion.
- Wear safety gloves and goggles when performing the
following operations:
- filling inhibitors or anti-frost
- lubrication oil topping or replacement
- utilization of compressed air or liquids under pressure
(pressure allowed: 2 bar)
- Wear safety helmet when working close to hanging
loads or equipment working at head height level.
- Always wear safety shoes when and cloths adhering to
the body, better if provided with elastics at the ends.
- Use protection cream for hands.
- Change wet cloths as soon as possible
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry
out working operations if not trained for.
- Do not smoke nor light up flames close to batteries and
to any fuel material.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.
During maintenance
- Never open filler cap of cooling circuit when the engine
is hot. Operating pressure would provoke high
temperature with serious danger and risk of burn. Wait
unit the temperature decreases under 50C.
- Never top up an overheated engine with cooler and
utilize only appropriate liquids.
- Always operate when the engine is turned off: whether
particular circumstances require maintenance
intervention on running engine, be aware of all risks
involved with such operation.
- Be equipped with adequate and safe containers for
drainage operation of engine liquids and exhaust oil.
- Keep the engine clean from oil tangles, diesel fuel and or
chemical solvents.
- Use of solvents or detergents during maintenance may
originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Do not leave rags impregnated with flammable
substances close to the engine.
- Upon engine start after maintenance, undertake proper
preventing actions to stop air suction in case of runaway
speed rate.
- Do not utilize fast screw-tightening tools.
- Never disconnect batteries when the engine is running.
- Disconnect batteries before any intervention on the
electrical system.
- Disconnect batteries from system aboard to load them
with the battery loader.
- After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
from accidental short circuit and oxidation.
- Do not disconnect and connect electrical connections
in presence of electrical feed.
- Before proceeding with pipelines disassembly
(pneumatic, hydraulic, fuel pipes) verify presence of liquid
or air under pressure. Take all necessary precautions
bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
injury and poisoning.
APPENDIX 3 NEF ENGINES
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- Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
personnels safety and health shall be adopted.
- Be informed and inform the personnel as well of laws in
force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate board indications and
organize specific training courses to ensure that
personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Collect exhaust oils in adequate specially provided
containers with hermetic sealing ensuring that storage is
made in specific, properly identified areas that shall be
aerated, far from heat sources and not exposed to fire
danger.
- Handle the batteries with care, storing them in aerated
environment and within anti-acid containers. Warning:
battery exhalation represent serious danger of
intoxication and environment contamination.
Respect of the Environment - Avoid incorrect tightening or out of couple. Danger:
incorrect tightening may seriously damage engines
components, affecting engines duration.
- Avoid priming from fuel tanks made out of copper alloys
and/or with ducts not being provided with filters.
- Do not modify cable wires: their length shall not be
changed.
- Do not connect any user to the engine electrical
equipment unless specifically approved by Iveco.
- Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any
unauthorized modification will compromise warranty
assistance and furthermore may affect engine correct
working and duration.
For engines equipped with electronic gearbox:
- Do not execute electric arc welding without having
priory removed electronic gearbox.
- Remove electronic gearbox in case of any intervention
requiring heating over 80C temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.
4 APPENDIX NEF ENGINES
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Case New Holland Kobelco Iveco Komatsu F4CE F4DE F4GE F4HE Service Repair Manual For Engine Overhaul (Mechanical Injection and Electronic Common Rail) PDF

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ENGINES

Tighten to torque + angle value Rolling torque

Tighten to torque + angle value Rolling torque

Tighten the engine flywheel (1) fixing screws (2) in two

Check main bearing housings as follows:

Checking output shaft shoulder clearance

Check main bearing housings as follows:

Checking crankshaft shoulder clearance

Compression ratio 16.5:1

Compression ratio 16.5:1

Compression ratio 16.5:1

Compression ratio 16.5:1

Compression ratio 16.5:1

Compression ratio 16.5:1

Compression ratio 16.5:1

Compression ratio 16.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

Compression ratio 17.5:1

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