F4ce de Ge He9684 87 9454

N TIER
3 SERIES
Industrial application
N45
N45 ENT.X - N45 MSS.X - N45 MNS.X
N45 MRT.X - N45 MST.X - N45 MNT.X
N67
N67 ENT.X - N67 ERT.X
N67 MST.X - N67 MRT.X - N67 MNT.X
Technical and Repair manual

This publication contains data, features, instructions and
methods for performing repair interventions on the assembly
and its components.
This publication is addressed to qualified, specialised
personnel.
Check that you have the publication related to the assembly
on which you are about to work available before you start.
Make sure that you have all the necessary safety apparatuses,
such as, for example, protective eyewear, helmet, gloves,
footwear, etc. Check that the working, lifting and transport
equipment etc. is available and in working order. Make sure
that the group is prepared and secured.
Proceed by carefully observing the instructions contained
herein and use the indicated specific tools to ensure correct
repair procedures, observance of time schedules and safety of
operators.
All repair interventions are aimed at restoring the conditions
of operation, efficiency and safety contemplated by FPT.
All on-group interventions, aimed at implementing changes,
alterations or other not authorised by FPT will relieve FPT
from responsibility. Specifically, the warranty (where
applicable) will be immediately cancelled.
FPT cannot be held responsible for repair interventions.
FPT is available to provide any additional information needed
for performing the inventions and indications in the cases and
situations not contemplated in this publication.
The data contained in this publication may not be up-to-date
if changes are made by the manufacturer at any time for
technical or commercial reasons or if required to meet legal
requirements of countries worldwide.
Contact a FPT dealership before proceeding in the event of
differences between the contents of this publication and the
actual assembly.
Reproduction, even partial, of this text and the illustrations
contained herein is prohibited.
Publication edited by
FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print P2D32N003 E - 3a Ed. 05.2010

1st Updating 09.2012
N TIER 3 SERIES 1
N TIER 3 ENGINES
N F4HE engines Part 1
N F4CE engines Part 2
N F4DE engines Part 3
N F4GE engines Part 4
PT-BOX Instructions Part 5
Print P2D32N003 E Base - May 2010

2 N TIER 3 SERIES
Base - May 2010 Print P2D32N003 E

N TIER 3 SERIES INTRODUCTION 1
Introduction
Page
PREFACE TO USERS GUIDELINE MANUAL . . . . 3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . . . 7
- Bonding and screening . . . . . . . . . . . . . . . . . . . 8
CONVERSIONS BETWEEN THE MAIN UNITS

OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED
QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
KEY OF LECTURE OF THE HEADINGS

AND FOOTNOTES . . . . . . . . . . . . . . . . . . . . . 10

2 INTRODUCTION N TIER 3 SERIES

PREFACE TO USERS GUIDELINE MANUAL

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections
are indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the 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 engine illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four 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.
SYMBOLS - Warnings
Danger for persons

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

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

Service operations
Example
1 1 = housing for connecting rod small end bush

Tighten to torque
Tighten to torque + angular value

2 2 = housing for connecting rod bearings

Removal
Disconnection Intake
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

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

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

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT 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.

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

Bonding and screening

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

d. DISTANCE ! 0

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
Type of Section Page

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

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

F4HE N ENGINES 1
Part 1
F4HE N SERIES
Section
General specifications 1
Fuel 2
Industrial application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix

2 F4HE N ENGINES

F4HE N ENGINES 3
UPDATING
Section Description Page Date of revision
3 Industrial application 19 Revi-September 2012

Revi - September 2012
4 F4HE N ENGINES

F4HE N ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL

CODE AND COMMERCIAL CODE . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- 4-cylinder engine version . . . . . . . . . . . . . . . . . 4
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 6
- Version with blow-by filter . . . . . . . . . . . . . . . . 6
- Version without blow-by filter . . . . . . . . . . . . . 7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8
AIR INDUCTION - BOOST DIAGRAM . . . . . . . 10
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EXHAUST GAS RE-CIRCULATION

SYSTEM (EGR) . . . . . . . . . . . . . . . . . . . . . . . . 11

2 SECTION 1 - GENERAL SPECIFICATIONS F4HE N ENGINES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code

F4HE9484A*J101
N45 ENT.X
F4HE9484A*J105
F4HE9684P*J101
F4HE9687B*J101
F4HE9687E*J101
F4HE9687X*J101
F4HE9684A*J100 N67 ENT.X
F4HE9684Q*J100
F4HE9684W*J100
F4HE9687P*J100
F4HE9687A*J100

LUBRICATION Lubrication involves the heat exchanger as well, the turbo--

blower and the eventual compressor for any eventual com-
Lubrication by forced circulation is achieved through oil rotary
pressed air system. All these components may often vary ac-
expansion pump (1), placed in the front part of the basement,
cording to the specific duty and will therefore be examined in
driven by the straight-tooth gear splined to the shafts bar hold.
the specific section.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
4-cylinder engine version

Figure 1 (Demonstration)
Oil recover from the

turbo-blower
To the
exchanger
and to the
turbo--
blower
Routing of oil return by gravity to sump 108511
Routing of oil return by gravity to sump

Introduction of oil
LUBRICATION SYSTEM LAYOUT

(4-cylinder engines)

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

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

108512
Routing of oil return by gravity to sump
Introduction of oil

(6-cylinder engines)

OIL VAPOUR RECYCLING

Version with blow-by filter
Figure 3
70484
Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine.

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

Version without blow-by filter

Figure 4
Oil condensate
Oil vapours 109903
1. Pre-separator - 2. Bleeder on side.

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

COOLING SYSTEM - Heat exchanger to cool the lubrication oil: even this
The engine cooling system, closed circuit forced circulation component is part of the engines specific equipment.
type, generally incorporates the following components: - Centrifugal water pump, placed in the front part of the
- Expansion tank; placement, shape and dimensions are engine block.
subject to change according to the engines equipment. - Thermostat regulating the circulation of the cooling liquid.
- Radiator, which has the duty to dissipate the heat - The circuit may eventually be extended to the
subtracted to the engine by the cooling liquid. Also this compressor, if this is included in the equipment.
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
- Viscous pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engines
development.

Figure 5 (Demonstration) Expansion tank
Expansion tank
Heater
(optional)
Radiator
Radiator
Water coming out from thermostat
Water recirculating in engine
Water coming into pump

74194
COOLING SYSTEM LAYOUT

4-cylinder engines

The engine cooling system, closed circuit forced circulation
type, is of a similar design as the 4 cylinders engine.
It incorporates necessary components such as the radiator,
the heat exchanger, the expansion tank and some ancillary
components such as the heater or the compressor for the
compressed air.
Such components always vary according to the engines equip-
ment and duty.
Expansion tank
Expansion
tank
Heater
(optional)
Radiator
Radiator
108513

6-cylinder engines
AIR INDUCTION - BOOST DIAGRAM
Figure 7
4 Cylinders version
AIR FILTRE TURBOCHARGER
EXHAUST
RADIATOR
6 Cylinders version
EXHAUST
RADIATOR
74195
Description The turbocharger is equipped with a transforming valve to

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

EXHAUST GAS RE-CIRCULATION SYSTEM The internal EGR system is not equipped with any
(EGR) electronically controlled elements: the system is always active.
In the TIER 3 version, the profile of the exhaust cam has been Its configuration does not need additional elements
modified in order to allow the partial opening of the relative i.e.checking valves, piping or heat exchangers.
valve during the aspiration phase (re-circulation of EGR The exhaust cam (B) has another lobe apart from the major
exhaust gas) with the subsequent re-introduction of part of lobe (see Section. A-A fig.) with respects to the configuration
the exhaust gas into the engine cylinders. without EGR.
The exhaust gases can partially be re-directed into the The additional lobe, during the aspiration phase in the cylinder
cylinders so as to reduce the maximum combustion in question, allows a brief opening of the exhaust valve
temperature values responsible for the production of nitric generating re-circulation due to the intake of the exhaust gases
acid (NOx). caused by depression which is created in the aspiration phase
The exhaust gas re-circulation system (EGR), reducing the inside the cylinder.
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 NOx .
Figure 8
114789
A. Aspiration valve control - B. Exhaust valve control.


F4HE N ENGINES SECTION 2 - FUEL 1
SECTION 2
Fuel
Page
HIGH PRESSURE ELECTRONIC INJECTION SYSTEM

(COMMON RAIL) . . . . . . . . . . . . . . . . . . . . . 3
- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Description of system . . . . . . . . . . . . . . . . . 3
- Electrical system . . . . . . . . . . . . . . . . . . . . . . 3
EDC 7 OPERATION . . . . . . . . . . . . . . . . . . . . . 5
WORKING PROCESS . . . . . . . . . . . . . . . . . . . . 6
FUEL SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . . 8
MECHANICAL FEEDING PUMP . . . . . . . . . . . . 10
- Ordinary working condition . . . . . . . . . . . . . 10
- Overpressure condition in Exhaust unit . . . . 10
- Jettison condition . . . . . . . . . . . . . . . . . . . . . 10
CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . 11
- High pressure pump-inside structure . . . . . . 12
- Working principle . . . . . . . . . . . . . . . . . . . . 13
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . 16
- Injector in rest position . . . . . . . . . . . . . . . . 16
- Injection start . . . . . . . . . . . . . . . . . . . . . . . . 16
- Injection end . . . . . . . . . . . . . . . . . . . . . . . . 16
PRESSURE LIMITER FOR FUEL RETURN . . . . . . 17

2 SECTION 2 - FUEL F4HE N ENGINES

HIGH PRESSURE ELECTRONIC INJECTION For engines more powerful than 152 kW, the CRIN2 injec-
SYSTEM (COMMON RAIL) tors have DLLA nozzles that work up to a pressure of 1600
Introduction bar, whilst for engines less powerful than 152 kW, DSLA
Extremely high injection pressures are necessary in order to nozzles are fitted which work a pressures up to 1450 bar.
reduce PARTICULATE emissions.
Description of system
The common rail system makes it possible to inject fuel at
pressures of up to 1450 - 1600 bar, while the injection preci- The injection system is composed of an electrical part and a
sion obtained by electronic control of the system serves to hydraulic part.
optimise operation of the engine while limiting emissions and
fuel consumption. Electrical system
The electronic control unit monitors engine control para-
meters by means of the various sensors on the engine.
4 cylinders version
Figure 1
108501
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.

6 cylinders version
Figure 2
107851
11. EDC 7 gearbox.

EDC 7 OPERATION Smoke control under acceleration

Engine preheating element control With intense load demands, in accordance with signals
received from the air inlet meter and the engine speed
Pre-post heating is activated when even just one of the water,
sensor, the control unit manages the pressure regulator and
air or fuel temperature sensors detects a temperature 5 C.
modulates the activation time of the electro-injectors to
Phase recognition prevent the emission of smoke from the exhaust.
By means of signals transmitted by the camshaft and After Run
crankshaft sensors, the cylinder into which fuel must be
After the engine is stopped, the control unit microprocessor
injected is determined at the time of starting.
saves various parameters to the EEPROM memory, including
Injection control the faults log so that they will be available the next time the
engine is started.
On the basis of information transmitted by the sensors, the
control unit administrates the pressure regulator and Control of working speed in normal operating
modifies the pre-injection and main injection mode. conditions
On F4 engines pre-injection is activated at all engine speeds.
Each time work load varies, the control unit adjusts torque
Injection pressure closed loop control so as to maintain the engine in maximum power conditions.
If the load causes a reduction in power, the control unit
On the basis of the engine load, as determined by processing increases torque i.e. it increases the amount of fuel injected
of data transmitted by the various sensors, the control unit in order to restore the engine to maximum power.
administrates the regulator to maintain injection pressure at
constantly optimal values. Recovery strategies
Pilot and main injection advance control Recovery strategies are characterized by certain differences
as application varies, i.e.
On the basis of signals transmitted by the various sensors, the
control unit determines the optimum injection point on the - Control of fuel leaks
basis of internal mapping. In the case of fuel supply problems, the system controls
the engine with suitable constant power values obtained
Idle speed control with a low number of revs and high torque values in
The control unit processes signals transmitted by the various order to inject the maximum quantity of fuel.
sensors and adjusts the quantity of fuel injected. - Control of pressure in the rail
It also controls the pressure regulator and modulates When the pressure in the rail exceeds safety values, the
injection duration of the electro-injectors. engine reduces power.
Within specific limits, the control unit also monitors battery
voltage. - Synchronism problems
In the case of synchronism problems, faulty rev sensors,
Overheating protection the system controls the engine by increasing the number
If the water temperature reaches 110 C, the control unit of revs in order to improve interpretation of the signals.
reduces engine performance. - Power restrictions as operating temperature increases
When the temperature returns below 100 C, the engine When the temperature of the supercharging air rises
resumes normal operation, (in some applications, the over above 88 C, power reduction is started; when a
boosting temperature is the reference temperature). temperature of 120 C is reached, performance is
Maximum engine speed limiting further reduced and is comparable to that of the same
engine if it were aspirated.
Depending on the application, the control unit memory can
contain appropriate engine speed limits. When the engine - Reduction of power as reference temperature varies
speed surpasses these limits the control unit activates power In normal operating conditions, the system knows the
reduction strategies by controlling energization time of the supercharging air, oil and water temperatures.
electro-injectors. In some applications the maximum limiting If the temperature of the engine water is not available,
response consists in stopping the engine. the system takes the temperature of the oil as reference
and when this reaches the threshold of 103 C, it starts
Cut Off to reduce the power available. On reaching 113 C,
Fuel cut-off in release phases is managed by the control unit power is reduced to 50%.
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.

WORKING PROCESS
4 Cylinders version
Figure 3
High Pressure
Low Pressure
Fuel outlet
158007
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.

6 cylinders version
Figure 4
High Pressure
Low Pressure
Fuel outlet
158008
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.

FUEL SYSTEM LAYOUT The pressure relief valve (2) intervention brings about a fuel
This fuel system is a Common Rail injection with CP3 high flow increase in the high-pressure pump cooling circuit,
pressure pump and this layout is for 4 cylinder version. through inlet and drain piping (16) from piping (8).
The pressure regulator, placed upstream of the high-pressure The pressure relief valve housed on the cylinder head, as-
pump, adjusts the fuel flow that is necessary on the low-pres- sembled on injector return (3), limits the fuel return flow
sure system. Afterwards, the high-pressure pump takes care from injectors at a pressure of 1.3 to 2 bars.
of supplying the rail properly. This arrangement, by pressuris- Two by-pass valves are placed in parallel with the mechanical
ing the necessary fuel only, improves the energetic efficiency supply pump.
and limits fuel heating in the system.
The by-pass valve (18) allows fuel to flow from mechanical
Function of the pressure relief valve (2), assembled on the pump outlet to its inlet, when the fuel filter inlet pressure ex-
high-pressure pump, is keeping the pressure, at the pressure ceeds the allowed threshold value.
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream. The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
4 cylinders version
Figure 5
EXHAUST
SUCTION (LOW PRESSURE)
HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE)
HIGH PRESSURE
114545
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

The 6 cylinder version is similar design.
6 Cylinders version
Figure 6
EXHAUST
INTAKE (LOW PRESSURE)
HIGH--PRESSURE PUMP SUPPLY

(LOW PRESSURE)
HIGH PRESSURE
114545
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.

MECHANICAL FEEDING PUMP Jettison condition

Gear pump, placed on rear part of the high pressure pump,
Figure 9
whose function is to feed the high pressure pump. It is driven
by the high pressure pumps shaft.
Ordinary working condition

Figure 7
72594
The dump by-pass valve (2) is activated in case, when the

engine is off, it is necessary to fill the feeding system through
72592 the priming pump. In this condition the by pass valve (I) keeps
closed while the dump by-pass valve (2) opens up due to the
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, pressure effect on the entry unit so the fuel flows to the
I - 2 By-pass valves in close position. exhaust unit B.
NOTE The mechanical feeding pump cannot be replaced

Overpressure condition in Exhaust unit separately, therefore it must not be disassembled
from the high pressure pump.
Figure 8
72593
The by-pass valve (I) is activated in case of overpressure on

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

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.
NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
Figure 10
72595
1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear -
5. Connector to fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry
flowing from engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter -
9. Mechanical feeding pump.

High pressure pump-inside structure

Figure 11
Sec. B-B
Sec. C-C
70498
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft.
7. Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
Every pumping unit is composed of: - cap intake valve (3);

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

Working principle
Figure 12
Sec. B-B
Sec. D-D
72597
The pumping element (3) is orientated towards the pumps During compression phase of the pumping element, the fuel
camshaft (4). During the intake phase, the pumping element achieves the level of pressure determining the opening of the
is fed through the feeding line (5). The quantity of fuel to flow by-pass valve to common rail (2), feeding it through the
to the pumping element is determined by the pressure exhaust unit (I).
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
Figure 13 Figure 14
72601
72598
Sec. C - C Sec. A - A
1. Cylinder. 2. Three-lobe element. 3. Cap intake 1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft. exhaust flowing from pump with connector to high
7. Low-pressure fuel inlet. 8. Pumping elements supplying pressure pipe for common rail.
fuel ducts.
Figure 13 shows the fuel runs at low pressure inside the Figure 14 shows the fuel flow under high pressure running
pump; the following elements are clearly visible: the main through the exhaust galleries of the pumping elements.
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.

Operation RAIL
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 15
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 108609
in the rail.
The thereby-generated pressure makes the exhaust valve 1. Rail 2. Fuel inlet from high-pressure pump
open and the compressed fuel reaches the high-pressure 3. Overpressure valve - 4. Pressure sensor.
circuit. The rail volume is comparatively small to allow a quick
The pumping element compresses the fuel till the top dead pressurisation at startup, at idle and in case of high flow-rates.
center (delivery stroke) is reached. Afterwards, the pressure It anyway has enough volume as to minimise system spikes
decreases till the exhaust valve is closed.
and the use of plenum chambers caused by injectors
The pumping element piston goes back towards the bottom openings and closings and by the high-pressure pump
dead center and the remaining fuel is decompressed. operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and A fuel pressure sensor (4) is screwed to the rail. The signal
the cycle is repeated. sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
The delivery valves must always be free in their movements, value is checked and, if necessary, corrected.
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.
RELIEF VALVE
If the pipe between fuel filter and high-pressure pump is to Mounted on the end of the rail, it has the function of
be removed-refitted, be sure that hands and components are protecting the systems components in case the failure of the
absolutely clean. 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 allow the fuel to flow and 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.

ELECTRO-INJECTOR Injection start

As for NEF TIER 3 engines, BOSCH - CRIN2 Figure 17
electro-injectors with different injection tubes are used
working on power developed by the engine.
Powers Pressures
Jet kW bar
DLLA Up to 152 250 1600 bar
DSLA Lower to 152 250 1450 bar
15
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

Figure 16
70506
When coil (4) is energised, it makes shutter (6) move

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

it must not be disassembled.
70505
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.

PRESSURE LIMITER FOR FUEL RETURN

It is housed on the rear of the cylinder head, and adjusts the
pressure of fuel returning from injectors at a pressure 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.
Figure 18
70507
A To tank B From injectors


F4HE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 1
SECTION 3
Duty-industrial application
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
- Section pictures of complete engine -

common rail version . . . . . . . . . . . . . . . . . . . . 3
- Clearance data - 4 cyl. . . . . . . . . . . . . . . . . . . . 4
PART ONE -
MECHANICAL COMPONENTS . . . . . . . . . . . 7
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Engine setting operations for the assembly

on turning stand . . . . . . . . . . . . . . . . . . . . . . . 9
- Disassembly of application components . . . . . 10
- Assembly of application components . . . . . . . 17
- Completion of the engine . . . . . . . . . . . . . . . . 29
- Checks and inspections . . . . . . . . . . . . . . . . . . 30
PART TWO -
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . 31
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 33
- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Cable on engine . . . . . . . . . . . . . . . . . . . . . . . 35
- Injectors connector (A) . . . . . . . . . . . . . . . . . . 36
- Sensors connector (C) . . . . . . . . . . . . . . . . . . 36
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . 37
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Supercharging air pressure - temperature sensor 38
- Engine oil temperature-pressure sensor . . . . . 38

2 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE N ENGINES
Page Page
- Fuel temperature and pressure sensor . . . . . . . 39 - Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . . 58
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . . 40
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . 58
- Pre-post heating resistance and contactor . . . . 41
- Coolant temperature sensor . . . . . . . . . . . . . . 42 - Engine oil level check . . . . . . . . . . . . . . . . 58
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 43 - Combustion system inspection . . . . . . . . 59
- High pressure pump - pressure regulator . . . . 44 - Cooling system inspection . . . . . . . . . . . . 59
PART THREE - TESTS - TROUBLESHOOTING . 45 - Lubricating system inspection . . . . . . . . . 59
- PT-BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 - Inspection of water presence within
fuel filter or pre-filter . . . . . . . . . . . . . . . . 59
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
- Inspection/replacement of blow-by filter . 60
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Inspection of drive belt tensioning . . . . . . 60
PART FOUR -
MAINTENANCE PLANNING . . . . . . . . . . . . . 55 - Inspection and setting of tappet clearance 60
MAINTENANCE PLANNING . . . . . . . . . . . . . . . . 57 - Oil motor and filter replacement . . . . . . . 61
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 - Fuel filter replacement . . . . . . . . . . . . . . . 62
- Regular maintenance and inspection planning . 57 - Alternator belt replacement . . . . . . . . . . . 62

GENERAL SPECIFICATIONS
Section pictures of complete engine - common rail version
Figure 1
108540
The NEF F4HE engines are characterised by four-stroke diesel The section herein described is composed or four sections:
cycles supercharged with 4 or 6 cylinders with 4 valves per
cylinder. - Section of mechanical overhaul prescribed in accordance
to the engines specific duty, illustrating all necessary
They have high pressure injection fuelling (common rail) and operation to remove and assembly the external
are entirely electronically driven in order to optimise the components of the engine, including cylinder heads,
working process in accordance to the operation, limiting as gearbox of the timing system and of the front part cover;
much as possible the pollution emissions and consumption.
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.
NOTE 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.

Clearance data - 4 cyl.

F4HE9484A
Type *J101 *J105
Compression ratio 16.5 : 1
Max. output kW 104
(HP) 141
rpm 2200
Max. torque Nm 608
(kgm) 60.8
rpm 1600
Loadless engine
idling rpm -
Loadless engine
peak rpm -
Bore x stroke 104 x 132
Displacement cm3 4485
TURBOCHARGING with intercooler
Turbocharger type HOLSET HX27W
Forced by gear pump, relief valve single action

z LUBRICATION
oil filter
bar
Oil pressure (warm engine)

- idling bar 0.7
- peak rpm bar 4.0
COOLING By liquid
Water pump control Through belt
Thermostat
- start of opening C 81 2
FILLING
engine sump liters 5.3

15W40 ACEA E3
engine sump + filter liters 6.3
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78).

! Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system;
if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by FPT.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.

F4HE9684
Type P*J101 A*J100 Q*J100 W*J100
Max. output kW 175 154 143 134
(HP) 238 210 195 180
rpm 2200 2200 2200 2200

Max. torque Nm 1020 950 850 800
(kgm) 102 95 85 80
rpm 1500 1400 1400 1400
Loadless engine
idling rpm
-
Loadless engine
peak rpm rpm
-

Turbocharger type HOLSET HX35
LUBRICATION
Forced by gear pump, relief valve single action
Oil pressure (warm engine) oil filter
bar - idling bar
0.7
- peak rpm bar 3.5
COOLING By liquid
Thermostat
FILLING
engine sump liters 15

15W40 ACEA E3
engine sump + filter liters 15 + 1

provided by FPT.

F4HE9684
Type B*J101 E*J101 P*J101 A*J100 X*J101
Max. output kW 129 123 175 154 112
(HP) 175 170 240 210 150
rpm 2200 2200 2200 2200 2200

Max. torque Nm 753 747 1020 950 705
(kgm) 75,3 74,7 102 95 70,5
rpm 1400 1400 1500 1400 1400

Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -

LUBRICATION Forced by gear pump, relief valve single action oil filter

bar
- idling bar 0.7
- peak rpm bar 3.5
COOLING By liquid

Thermostat
FILLING
15W40 ACEA E3 engine sump liters 15
engine sump + filter liters 15 + 1

provided by FPT.

DIAGNOSI
PART ONE -
MECHANICAL COMPONENTS


ENGINE OVERHAUL - disconnect the high pressure fuel pipeline from the rail
Preface diffuser and from the high pressure pump and
disassemble it from the engine block removing the fixing
Part of the operations illustrated within this section can be
clamps.
partially executed while the engine is assembled on the
vehicle, depending on the room available for access to the - disconnect the pipeline feeding the mechanic pump that
engine and on the equipment application as well. is combined to the high pressure pump through the
exchanger of the engine control module;
- disassemble the oil introduction tube (if present) by
NOTE With regard to the engine disassembly operations undoing and removing the fixing screws. Remove the
from the machine, please apply for Information O-ring from the tube.
consulting the specific manual.
All operations of Engine disassembly operations as NOTE Because of the high pressure in the pipelines
well as overhaul operations must be executed by running from the high pressure pump to the rail and
qualified technicians provided with the specific from this last one to the electro-injectors, it is
tooling and equipment required. absolutely required NOT to:
- disconnect the pipelines when the engine is
The following information relates to the engine overhaul working;
operations only for what concerns the different components - re-use the disassembled pipelines.
customising the engine, according to its specific duties.
In section General overhaul, all the operations of engine
block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the Figure 3
part hereby described.
Engine setting operations for the assembly on

turning stand
Figure 2
116237
To disconnect the low pressure fuel pipe from the relevant

connecting joint, you need to hold the clasp (1) pressed, and
release the quick fitting joint (2).
To connect the low pressure fuel pipe to the connecting
108541
joint, insert the quick fitting joint (2) into the connecting joint,
and push until the clip (3) is fastened.
In order to apply the brackets 99361037 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 99360073 disassembly the fuel filter and
remove it from the support;
- disconnect the electrical connection from the support
and the heaters one (placed on the filter support as
well);
- disconnect the fuel low pressure pipelines from the
support;
- disconnect pipeline from the support;
- remove the sustaining support bracket from the block;

On the right hand side of the engine: Figure 5

1
Figure 4
2
74166
Remove the starter (2) from the flywheel housing (1).

Apply brackets 99361037 to engine block and use them to
secure the engine to the revolving stand 99322205. Remove
114790 sump cap and drain out oil.
Remove the fan from the output shaft pulley.
Remove the screws and remove the oil pipe (1) from the
turbocharger pipe (2) and from the engine block.
Collect and dispose of engine oil according to rules

in force.
Disassembly of application components

Figure 6
107246
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. EDC 7 gearbox - 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. Electro-injector.
Disconnect the engines cable from the connectors wiring Figure 8

harness to
Electro-injectors (1); (10) air pressure/temperature sensor; 1
(3) fuel pressure sensor;
(6) engine control module; (9) timing system sensor; (2)
Thermostat sensor of engine cooling liquids temperature; (5)
sensor of engines revolutions.
6
2 5
4
Figure 7
3
74170
Disconnect the pipeline (2) from the fuel recover

pressure-limiter, working on the connections as described in
Figure 3.
Unscrew the nut and loosen the clamp tightening the oil
vapour pipe.
Remove the pipe (6).
Undo the screws (3) and, if present, disassemble the blow-by
filter (4).
Remove on the nuts and tappet cover.
108543
Disconnect from the rail (2): the fuel pipe (7) according to Figure 9
procedures described in Figure 3. Disconnect fuel pipes (5)
from rail (2) and injector manifolds (6).
NOTE When releasing pipe (6) connections (4) to rail (2),

use the proper wrench to avoid rotation of flow
limiters (3).
Remove the screws (1) and disconnect the rail (2).
74744
Remove nuts (7) and disconnect the electrical cables from

injectors (8).
Remove screws (1) and disconnect injector wiring support
(2) including the gasket.
Remove screws (5), disconnect air pressure/temperature
sensor (6).
Remove nuts (3) and remove fuel manifolds (4).
NOTE Disassembled fuel manifolds (4) must not be used

again, replace with new ones during reassembly.

Figure 10 Figure 12
70132 108545
Loosen tappet adjustment fastening nuts (1) and unscrew the Release on the drive belt tensioner (1) and extract the belt
adjusters. (2) from the belt pulleys from the water pump ones and from
Remove the screws (2), remove the rocker assembly (3),
the belt rebound pulleys;
consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves. Disassemble the belt tensioner (1).
Remove rods (8).
Loosen the screws fixing the alternator to the support and
Figure 11 disassemble it.
Figure 13
70133
Remove injector fastening screws. Use tool 99342101 (1) to

remove injectors (2) from the cylinder head.
108546
Disconnect the oil pipeline (3) from the supports of the heat
exchanger / oil filter and from the pipe fitting (4) to the
turbine.
Remove the fixing nuts and disassemble the turbocharger (1)
from the exhaust collector (2).
Loosen the screws and disassemble the exhaust collector (2)
from the cylinder head.

Figure 14 Figure 17
108547
108580
Remove the screws (4) and disconnect the oil

On the opposite side, loosen the fixing screws of the inlet
manifold (1) and disassemble the joint to the air heater (2) temperature/pressure sensor (3).
for the cold start. Remove the screws (1) and then remove: heat exchanger/oil
filter support (2), intermediate plate (6) and relevant gaskets.
Remove the oil level sensor (5).
Figure 15
Figure 18
74779 74174
Hook brackets (1) with suitable lifting chains and remove Remove the screws (1) and disconnect the ECU (2) including
cylinder head (2) from block using hoist. the heat exchanger.
Figure 19
Figure 16
1 4 3
74176
108549
Remove the screws (2) and disconnect the alternator Unloose the screws (3) and remove the cap (1). Keep the
support (3). gasket (4), the power take-off (2) and the second gasket (4).
Use tool 99360076 to remove the oil filter (1).
Figure 20 Figure 23
70145 116241
Remove the nut (1) and disconnect the timing sensor (2). Remove the screws (1) and disconnect the water pump (2).
Remove the nuts (3) and disconnect the high pressure pump Remove the screw (3) and the roller (4).
(4) including the feed pump (5). Remove the screw (5) and disconnect the engine speed
sensor (6).
Figure 24
Figure 21
00900t
Remove the ring sealing the engines driving shaft from the
front cover. Use the tool 99340055 (4) to operate on the
front bar hold of the driving shaft. Through the steering holes
70146
of the tool, perforate the inside holding ring (1) with a straight
Fit tool 99360339 (2) to the flywheel housing (1) to stop way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool
flywheel (3) rotation. to the ring tightening the 6 screws provided with the
equipment. Then proceed removing the ring (2) by tightening
Loosen the screws (4). the screw (3).
Figure 22
Figure 25
108548
Remove the screws (3) and disassemble the damping

flywheel (2) and the pulley (1).
00904t
Using the specific tie rod (3) of the tool 99363204 and the
ancillary lever (4), remove the external holding ring (2) from
the front cover (1).

Figure 26 Figure 29
70152
116242
Remove the screws (1 and 3) and take out the front cover Tighten two screws of medium length into the holes (4) to
(2). sling the flywheel with the hoist.
Throughout the two guide pins (2) previously screw into the
NOTE Take note of screw (1) assembling positions since driving shaft holes (3) withdraw the engine flywheel (1) after
they have different lengths. slinging it with the hoist.
Figure 30
Figure 27
Remove the screws (1) and disconnect the oil pump (2).
00903t
Figure 28 Remove the holding ring of the flywheel cover box using the
tool 99340056 (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 99340056 (3) to the ring 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.
70151
Remove two opposite screws (1) from the area where the
withdrawal pins will be introduced (2, Figure 29).
Loosen the remaining flywheel fixing screws (3) from the
driving shaft (4).
Remove the flywheel locking tool 99360351.
Figure 31 Figure 33
70153
Remove the screws (2) and take out the rear cover (1). 86516
Remove the screws (1 and 4) and disassemble the oil suction

NOTE Take note of screw (2) assembling positions since tube (5). Remove the screws (2) and disassemble the
they have different sizes. stiffening plate (3).
NOTE For engines the stiffening plate (4) has a single

Figure 32 element.
Figure 34
74775
Overturn the engine.

70156
Remove the screws (2), disassemble the plate (3) and
disconnect the oil sump (1). Remove the screws (1) and remove the gear (3) from the
camshaft (2).
Figure 35
NOTE The shape and the dimensions of the oil pan and
of the suction tube may vary according to the duty
of the engine. The relevant pictures of the
instructions are therefore providing an outline of
the intervention to be executed.
However the procedures described are still
applicable.
70157
Remove the screws (2) and disconnect the timing gear case
(1).
NOTE Take note of screw (2) assembling positions since

they have different sizes.

Assembly of application components Figure 37
Figure 36
70210
70209
LOCTITE 5205 SEALANT APPLICATION AREAS DIAGRAM FOR TIGHTENING THE REAR TIMING
Clean accurately the timing gear case (1) and the engine GEAR CASE FASTENING SCREWS
block. Refit the case (1) to the engine block.
Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in
the sequence shown in the figure:
Screws M12 65 to 89 Nm
NOTE Perfect seal is only obtained by cleaning accurately Screws M8 20 to 28 Nm
the surface to seal. Screws M10 42 to 52 Nm
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
NOTE Before any assembly operation always verify that
It shall be uniform (no clots), without air bubbles, the hole and screw threads have no evidence of
thin areas or discontinuities. wear or dirt.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint. Figure 38
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).
70211
With a felt-tip pen, highlight the conducting gear tooth (1)

mounted on the engine shaft (2) upon the side surface of
which a groove has been created for the ignition timing.
NOTE Fasten screwing of the two pins to facilitate the

operation of engine driving shaft rotation.

Figure 39
NOTE Perfect seal is only obtained by cleaning accurately
the surface to seal.
bead of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
possible.
Avoid to use excess material to seal the joint.
114791
Turn the engine shaft (3) and the distribution shaft (4) so that
by mounting the bevel gear on the latter (1) the stencilled
Figure 42
mark on the gear (1) coincides with the groove on the gear
tooth (2).
Figure 40
70215
SEQUENCE FOR TIGHTENING THE FLYWHEEL

70213 HOUSING FASTENING SCREWS
Tighten the screws (1) fastening gear (2) to camshaft (3) to
Refit the housing (1) to the engine block and screw the
the specified torque.
fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
Figure 41 shown in the figure:

the hole and screw threads have no evidence of
wear or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS

Figure 43 Figure 45
70152
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
0901t
hoister.
Apply tool 99346253 part (6) to the rear output shaft tang Figure 46
(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 flywheel housing (7).
Figure 44
Apply tool 99360339 (2) to the flywheel housing to stop

engine flywheel (3) rotation. Tighten the screws (1) fastening
the engine flywheel (3) to the output shaft.
Figure 47
70217
Check the supporting surface (1) of the clutch plate and if it

is scratched, it is necessary to carry out turning.
70219
Tighten engine flywheel (2) fastening screws (1) in two

stages:
- 1st stage, tightening to 30 4 Nm torque with
dynamometric wrench;
Check ring gear teeth (2), if breakage or excessive wear is - 2nd stage, tightening to 60 5 angle.
found remove the ring gear from the engine flywheel (1,
Figure 43) using a suitable hammer and fit the new one, NOTE Tightening to angle is performed using tool
previously heated to 150C for 15 to 20 minutes. Chamfering 99395216.
on ring gear inside diameter shall be facing the engine Before any assembly operation always verify that
flywheel. the hole and screw threads have no evidence of
wear or dirt.

Figure 48 Figure 51
106549
70220
Remove the sealing ring (2) from the front cover (1), clean
Fit the oil pump (1).
accurately the coupling surfaces and smear them with
Tighten the fastening screws (2) to the specified torque. LOCTITE 5205.
Figure 52
Figure 49
106550
Clean accurately the front cover (2) surface and refit it.
70221
Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
Figure 53
Figure 50
00902t
70222
Apply tool 99346252 part (4) to the front output shaft tang
Fit the water pump (1). Position part (2) on part (4), screw nut (3) until completing
Tighten the screws (2) to the specified torque. sealing ring (7) fitting into front cover (1).

Figure 54 Figure 57
108548
Assemble the pulley (1) and the damping flywheel (2) to the
108553 driving shaft.
Fit the plate (1), the oil pick up tube (2) and tighten the
fastening screws (3) to the specified torque. Tighten the fixing screws (3) and clamp them to the couple
68 7 Nm.
Figure 55 Figure 58
116245
Set the gasket (1) on the oil sump (2). Fit a new sealing ring on the speed sensor (3).
NOTE The pictures of the instructions relating to the oil pan Fit the speed sensor (3) on the front cover (1) and tighten
and to thesuction rose may not reflect the actual the screw (2) to the specified torque.
shape and dimensions of your engine equipment.
However the procedures described are still appli- Figure 59
cable.
Figure 56
108576
Fit on the engine block: a new gasket (1), the heat exchanger
74775
Fit the oil sump (1) and apply the plate (3) to it. (2) a new gasket (3) and the oil filter support (4).
Tighten the screws (2) to the specified torque. Tighten the screws (5) to the specified torque.
NOTE Before any assembly operation always verify that NOTE Before any assembly operation always verify that
the hole and screw threads have no evidence of the hole and screw threads have no evidence of
wear or dirt. wear or dirt.

Figure 60 Figure 62
108578 114792
Refit the alternator (1).
Lubricate the sealing ring (2) with engine oil and set it on the Tighten the screw (2) to the specified torque.
oil filter (3).
Screw manually to seat the oil filter (3) on the support Figure 63
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).
Fit a new sealing ring (6) in the engine block seat.
Figure 61
114793
Refit the automatic belt tensioner (2).
Tighten the screw (3) to the specified torque using a wrench,
turn the automatic belt tensioner (2) to fit the belt (1) on
pulleys and guide rollers.
Figure 64
70234
Position the alternator support (1) so that pins (3 and 4) are

set against the engine block.
70145
Refit the high pressure pump (6) including the feed pump (5)
and tighten the nuts (3) to the specified torque. Fit the
NOTE Before any assembly operation always verify that support (4) with a new sealing ring, the timing sensor (2) with
the hole and screw threads have no evidence of a new sealing ring and tighten the relevant fastening nut (1)
wear or dirt. to the specified torque.

Figure 65 For 6 cylinder engines

Figure 68
1 4 3
2
74176
76152
Insert the power take-off (2) equipped with the gasket (4),
the cover (I) and its gasket (4). - Disassemble cylinder head;
Tighten the screws (3) to the prescribed matching couple. loosen the screws (1) and (2) fixing the cylinder head (3);
hook the brackets with metal ropes and, throughout a
Figure 66 hoist withdraw cylinder head from the block.
1 Figure 69
74174

Assemble the electronic gearbox (2) equipped with the
exchanger to the engine, fixing it with the screws (1). 70336
In case the rubber buffers are cracked or excessively
deformed, provide replacing them. Assemble cylinder head (1), tighten the screws (2) in three
following steps, following order and mode shown in the
figure below.
For 4 cylinder engines
NOTE The angle tightening is carried out through tool
Figure 67 99395216 (3).
1
2 the hole and screw threads have no evidence of
wear or dirt.
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 mm the screw can be utilised again;
4 if D1 - D2 > 0,1 mm the screw must be replaced.
75688
- Disassemble cylinder head; D2 D1

loosen the screws (1) and (2) fixing the cylinder head
(3); hook the brackets with metal ropes and, 75703
throughout a hoist withdraw cylinder head from the
block.
Figure 70 Figure 73
6-cylinder engine A
70476
Tightening order layout for cylinder head fastening screws:

- 1st step pre-tightening with dynamometric wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75 x 150 ( ) 55 5 Nm
70339
- 2nd step tightening with a 90 5 angle
Fit injectors (1) on the cylinder head seats, directed so that
- 3rd step tightening with a 90 5 angle the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
A = Front side
NOTE Between the phases, wait a few minutes for settling Figure 74
Figure 71
4-cylinder engine A
70337
Cylinder head fastening screws tightening sequence:

70133
- 1st stage pre-tightening, with a torque wrench::
Screw 12x1.75x130 ( ) 35 5 Nm Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw12x1.75 x 150 ( ) 55 5 Nm
A = Lato anteriore Screw injector fastening screws without tightening them.
- 2nd stage tightening with angle 90 5
- 3rd stage tightening with angle 90 5
NOTE Between the phases, wait a few minutes for settling
Figure 72
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).
Figure 75 Figure 77
91572 70343
ROCKER ASSEMBLY COMPONENTS:

1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
Fit a new sealing ring (3) lubricated with petroleum jelly on
the fuel manifold (2) and fit it into the cylinder head seat so
that the positioning ball (5) is coinciding with the relevant Figure 78
housing (4).

again. Replace with new items.
The fuel manifolds (2) for engines have 2
positioning spheres.
Screw the fastening nuts (2, Figure 76) without locking them.
NOTE During this operation, the injector (1) shall be

moved so that the manifold (2, Figure 72) is
properly inserted into the fuel inlet hole (2,
Figure 75).
SHAFT-ROCKER MAIN DATA
Check that shaft/rocker coupling surfaces are not showing
Figure 76 excessive wear or damages.
Figure 79
32655
70342
Rocker control rods shall not be distorted; the ball seats in
Use the torque wrench to tighten gradually and alternately touch with the rocker adjusting screw and with tappets
the injector fastening screws (1) to 8.5 0.8 Nm torque. (arrows) shall not show seizing or wear; otherwise replace
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm them. Intake and exhaust valve control rods are identical and
torque. are therefore interchangeable.
Carry out the assembly of the equalisers unit , after previous
check of the components.

Figure 80 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.
To place the cylinder at top dead centre, the end of the
compression stroke, position tool 99395097 in the injector
seat of the cylinder whose valves you wish to balance.
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.
Adjust the slack between rocker arms and valves using socket
70345 wrench (1), point wrench (3) and feeler gauge (2).
Fit the rods (2).
Correct slack is:
Position jumpers (1) on valves with marks () facing the - suction valves 0.25 0.05 mm
exhaust manifold. - exhaust valves 0.50 0.05 mm.
Figure 81 4 cylinder engines
IGNITION SEQUENCE: 1 3 4 - 2
Adjust intake and

Engine shaft Bilance exhaust valves
starting and valves
clearance cylinder
rotation cylinder n
n
1 al PMS 1 1
180 3 3
180 4 4
180 2 2
6 cylinder engines
IGNITION SEQUENCE: 1 - 5 - 3 - 6 - 2 - 4
70346
Check that tappet adjusters (1) are loose to prevent their Adjust intake and
balking on the rods (2, Figure 80) when refitting the rocker Engine shaft Bilance exhaust valves
assembly. starting and valves
clearance cylinder
Then refit the rocker assembly consisting of: bracket (5), rotation cylinder n
n
rockers (3), shafts (4) and secure them to the cylinder head
by tightening the fastening screws (2) to 36 Nm torque. 1 al PMS 1 1
120 5 5
Figure 82 120 3 3
120 6 6
120 2 2
120 4 4
70520

Figure 83 Figure 86
108547
Apply to the coupling surface of the intake manifold (1)

108569
equipped with heater (2) a sufficient coat of LOCTITE 5999
and provide tightening the screws to the prescribed matching
couple.
NOTE Pipe (7) connections shall be tightened to 20 Nm
torque, using the proper wrench (5) and the
Figure 84 torque wrench 99389829 (4).
Connections (6) shall be tightened by holding the
flow limiting valve hexagon (1) with the proper
wrench.
Connect the fuel pipe (3) to the rail (2) following the
procedure shown in the following figure.
Figure 87
108567
Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut to the specified torque.
Figure 85
116237
In order to connect the low-pressure fuel pipes to the

connection joint, insert the rapid fitting joint into the latter,
(2) and press until the clip fastens securely (3).
NOTE Check proper fuel pipe connection.
108568
Connect new fuel pipes (1) to rail (3) and injector manifolds
(2).
Figure 88 Connect the electrical cables (1) to the injectors (3) and use
the torque wrench 99389834 (4) to tighten the fastening
nuts (2) to the specified torque.
Figure 91
70352
Check electrical cable (5) conditions, replace if damaged by

cutting the support (2) clamps and removing the screws (4)
that secure it to connections (3).
Fit a new gasket (1) on the support (2). 70355
Fit a new gasket (2) on the tappet cover (1).

Figure 89 Place the tappet cover on, install the bolts in the correct
position and tighten.
Figure 92
108570
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.

wear or dirt.
Figure 90
108572
Reconnect the exhaust manifold (2) with new gaskets. Tighten

the fastening screws (1) to the specified torque.
Sling the turbocharger (1) and place it over the manifold after
having first inserted a new gasket.
Connect the oil pipeline (3) to the support of the heat
exchanger /oil filter. Fix the pipe (3) to the pipe fitting on the
turbocharger.
108571

Figure 93 Figure 95
6
2 5
4
3
74170
If present, insert blow-by filter (4) and tighten the screws (3).
Connect the pipeline (6) and fix the oil vapour recover pipe 108541
through the clamp (5); lock up the nut fixing it to the upper
edge. Assemble the bracket and the support of the fuel filter.
Proceed connecting the pipelines (9,3,4 and 5) of the support
Connect the pipeline (2) to the pressure- limiter (1). to the high pressure pump.
Connect the pipeline from the high pressure pump to the
engine control module heat exchanger.
Connect the pipeline from the high pressure pump to the rail
Completion of the engine diffuser.
Properly handle the engine holding it by a lifter, remove it
from the rotating shaft, remove the brackets 99341009 and Figure 96
place it on proper suitable support to carry out the
completion.
Proceed assembling the oil filter.
Figure 94
116237
All the low-pressure fuel pipes are fastened with clips shown
in the picture.
In order to connect the low-pressure fuel pipes to the
2 connection joint, insert the rapid fitting joint into the latter,
(2) and press until the clip fastens securely (3).
Assemble the starter (2) to the internal part of the flywheel

cover.
Assemble the oil feeding pipe using a new O-ring. Fix with NOTE In case the pipes are re-employed, they must keep
three M12x25 screws. 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 (see Figure 6, page 10).

Checks and inspections
NOTE The following checking inspections must be carried

out after the engine assembly on the vehicle .
Start the engine and leave it running just above the

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

sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- check carefully the connection between the low
pressure fuel pipes and the relevant connectors;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes (if
fitted);
- check also proper operation of the warning lights set on
the instrument panel and of the equipment
disconnected when engine was removed.
- Carefully check and bleed the engine cooling equipment
by repeated draining operations.

PART TWO -
ELECTRICAL EQUIPMENT


LOCATION OF THE MAIN ELECTRICAL COMPONENTS

108641
The NEF F4HE engines are fully driven by the electronic The electrical and electronic components of the engine are
engine control module, which is assembled directly to the listed here following:
engine by means of a heat exchanger enabling its cooling,
1. Coolant temperature sensor.
utilising rubber buffers to reduce vibration originated by the
engine. 2. Electro-injector.
Through the engine control module it is possible to verify the 3. RAIL pressure sensor.
correct working of the engine. (See part three of the hereby
4. Air temperature/pressure sensor.
users guide specifically dedicated to diagnostic).
6. Timing sensor.
7. Solenoid valve for pressure regulator.
8. Fuel temperature sensor.
9. EDC electronic control unit.
10. Crankshaft sensor.
11. Engine oil pressure/temperature sensor.
12. Heating element for pre-post heating.

EDC7 ECU
Figure 98
01525t
A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled);
C - Connector to sensors.

Cable on engine
All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary
version, in other words at the approval stage.
Figure 99
0051064t
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor -
5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor -
8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Rail temperature and pressure sensor -
11. Pressure regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).

Injectors connector (A) Sensors connector (C)
ECU PIN FUNCTION ECU PIN ECU PIN

1 Cylinder 5 injector 1 -
7 - 7 -
8 - 8 -
9 Pressure regulator 9 Timing sensor
10 Pressure regulator 10 Timing sensor
12 Cylinder 3 injector 12 Negative for rail temperature and pressure sensor
13 Cylinder 1 injector 13 Positive for rail temperature and pressure sensor
14 Cylinder 4 injector 14 Signal from rail temperature and pressure sensor
15 Cylinder 6 injector 15 Coolant temperature sensor
17 -
18 Signal from fuel temperature sensor
19 Engine rpm sensor
20 -
21 -
22 -
23 Engine rpm sensor
Negative for engine oil pressure and temperature
24
sensor
25 Negative for air temperature and pressure sensor
26 Coolant temperature sensor
27 Signal from engine oil pressure sensor
28 Signal from engine oil temperature sensor
29 -
30 -
31 -
Positive for engine oil pressure and temperature
32
sensor
33 Positive for air temperature and pressure sensor
34 Signal from air pressure sensor
35 Negative for fuel temperature sensor
36 Signal from air temperature sensor

Crankshaft sensor
This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from
a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is 900 .
Figure 100
50319
Crankshaft sensor
Timing sensor
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a
magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by
the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance
is 900 .
Figure 101
50320
Timing sensor
3 2 1
50342 50288
Connector Wiring diagram

ECU pin
Ref. Description
Camshaft sensor Timing sensor
1 Signal 19C 10C
2 Signal 23C 9C
3 Shield

Supercharging air pressure - temperature sensor

This component incorporates a temperature sensor and a pressure sensor.
Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate
calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 25C - 36C - 33C - 34C.
The power supply is 5 volt
Voltage at the sensor output is proportional to the detected pressure or temperature.
Pin 25C - 36C Temperature
Pin 33C - 34C Pressure
Engine oil temperature-pressure sensor

This component is analogous to the air temperature-pressure sensor.
The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position.
This sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 24C - 28C - 32C - 27C.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative
device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.
Pin 24C - 28C Temperature
Pin 32C - 27C Pressure
Figure 102
50324 50344
Wiring diagram
ECU Pin
Ref. Description
Oil Air
1 Ground 24C 25C
2 NTC signal (temperature) 28C 36C
3 +5 V power input 32C 34C
4 Signal (pressure) 27C 34C

Fuel temperature and pressure sensor

Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback).
The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection
command.
This sensor is connected to the control unit on pins 12C - 14C- 13C.
The power supply is 5 Volt.
Figure 103
0051065t
Fuel pressure sensor connector
Ref. Description ECU pin

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

Electro-injectors
The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The impedance of the coil of each injector is 0.56 - 0.57 .
Ref. Description ECU pin

1 Cylinder 2 injector 11 A
2 Cylinder 2 injector 6A
CONNECTOR 1
CONNECTOR 2
CONNECTOR 3
Figure 104
50343
Figure 105
50349

Pre-post heating resistance and contactor

The pre-post heating resistance is located on the intake manifold.
The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor.
The resistance impedance is approximately 0.5 .
Figure 106
B
108909
A. - B. Connection terminals
Figure 107
002371t
A. Control contactor
The control contactor is connected to the control unit B connector.

The contactor is tripped with water and/or fuel temperature below 5 C.
The contactor impedance is approximately 15 .
Do not use flammable gases or liquids to provoke the engine ignition.

These substances in contact with the resistance could easily become inflamed creating situations of serious danger.

Coolant temperature sensor

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication
of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
This sensor is connected to the control unit on pins 15C - 26C.
The impedance of the coolant temperature sensor at 20 C is approximately 2.50 .
Figure 108
107471

Fuel temperature sensor

This sensor is identical to the coolant temperature sensor.
This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.
The fuel temperature sensor is connected to the control unit on pins 35C -18C.
The sensor impedance at 20 C is approximately 2.50 .
Figure 109
0051140t
1. Fuel temperature sensor - 2. Filter heating resistance.
The ECU drives the filter heater contactor at fuel temperature 5 C.
107799 107798
Connector
ECU Pin
Ref. Description
Coolant Fuel
1 Ground 15C 35C
2 Temperature signal 26C 18C

High pressure pump - pressure regulator
Figure 110
000912t
A. Pressure regulator.
The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the
pressure regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 and 1450 bar by the electronic control unit by controlling the pressure
regulator solenoid valve.
- This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on pins 9A - 10A.
- The solenoid valve impedance is approximately 3.2 .

PART THREE -
TROUBLESHOOTING


PT - BOX
PT - BOX is a test tool to be connected to a Laptop.
Figure 111
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator - 5. Serial port indicator -
6. Error indicator - 7. CAN line indicator - 8. Line K indicator for automatic management
PT-BOX functions:
- ECU ID reading;
- Failure memory reading;
- Flight recorder reading;
- Parameters reading;
- Failure memory cleaning;
- Active diagnosis: actuators activation/testing;
- Programming of repalced components and parameters/second level;
- Acquisition/Saving of parameters

PREFACE Every time there is a breakdown claim and this breakdown is

actually detected, it is necessary to proceed inquiring the
A successful troubleshooting is carried out with the electronic unit in one of the ways indicated and then proceed
competence acquired by years of experience and attending with the diagnostic research making trials and tests in order to
training courses. have a picture of the working conditions and identify the root
causes of the anomaly.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper In case the electronic device is not providing any indication, it
consideration using them to acquire any useful information to will be necessary to proceed relying on the experience,
focus the intervention. adopting traditional diagnosis procedures.
Using FPT processing instruments, it is also possible to
establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input an
enquiry relying on memory files, in order to achieve any further
necessary information to identify the origin of the anomaly.
NOTE Any kind of operation on the electronic center unit

must be executed by qualified personnel, duly
authorized by FPT.
Any unauthorized tamper will involve decay of

after-sales service in warranty.

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


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)
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
Interfaces 2 (CAN line timeout messages)
1.C.6 ERROR MESSAGE CAN TSC1-PE


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.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


Print P2D32N003 E
F4HE N ENGINES
POSSIBLE CAUSE RECOMMENDED TESTS OR
ANOMALY (*) = if available in the equipment INTERVENTION REMARKS
Low performance at load request. Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact
that, in case of insufficient fuel feeding, the
Possible exessive smoke. engine control module tries to compen-
sate prolonging the injectors working
Possible blink-code 8.1 time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of over- is working correctly.
heating.
If the pump plunger is permanently de-
pressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter. Replace the air filter. Solve the cause of the filters obstruction.
Excessive fuel blow-by from rail boost Check the O Rings and the correct con- Unless the leakage is significant, no per-
valve. nection of the pipe fittings under the formance failures will be detected.
feeding pump (the lockers must stay out- To verify O-rings integrity, extract from
side and the fittings must be well locked). the tank the fuel recycling pipeline, seal
Visually check the low pressure pipeline the end and activate the priming pump
integrity. driving the low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve. there are any significant blow-by from the
boost gauge valve; in such case replace
the valve.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION

The engine suddenly stops(with no previ- Obstructed fuel filter. Replace the fuel filter. Solve the cause of the filters obstruction
ous problems) and does not start again. (empty and clean the tank and the part of
the circuit over the filter, refill with clean
fuel).
Base - May 2010
53
Base - May 2010
54

The engine disconnects or does not start. (*) Eliminate the short circuit and replace the Verify that the wire line, close to the
EDC. pedal, is not exposed to.
EDC burned by short circuit on the wir-
ing harness of the friction clutch.
Difficult start and low performance in all Inefficient high pressure pump. After having excluded any other possible
conditions. cause, replace the high pressure pump.
Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recog- In case of low entity blow-by, inficiating
gine running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of the mechanical working of the injector
pulsing within the relevant high pressure but not involving flow limiter activation,
pipe. there is no error memorisation in the en-
gine control module.
If the flow limiter is activated. Check error
code memory.
Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recog- Usually, whether such symptoms appear,
followed by huge white exhaust fumes, no return). nisable detecting by feeling the absence of it is instinctive to give up engine start.
and a fuel smell. pulsing within the relevant high pressure However, by insisting, it is possible to start
pipe. the engine.
As a matter of facts, by insisting, if within
the rail the pressure makes the flow li-
miter close up, the engine starts with one
cylinder less and gradually the grade of
fumes reduces and disappears.
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct
pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the orig-
screws. inal position.
The engine works with one cylinder less, Injector blocked in closed position. Identify the injector that is not working The non-working injector is easily recog-
without memorising failure blink codes in any more and the relating high pressure nisable detecting by feeling the absence of
the engine control module. filler. pulsing within the relevant high pressure
pipe.
F4HE N ENGINES
Print P2D32N003 E
PART FOUR -
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.
Regular maintenance and inspection planning
Checks and periodical inspections Frequency (hours)
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily

Inspection presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . Daily
Inspection blow-by filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Inspection of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Inspection and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When anomaly occurs
Replacement of engines oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of blow by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
NOTE 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
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.

Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconven-
iences, even serious, during engine running. Such checks are usually up to the operators and to the 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
Figure 113
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) placed on the right hand side of the EDC.
Figure 112
108540
To provide filling, operate through the upper top or through

2 the lateral top (2, Figure 112). During filling operation, the tops
must be removed as well as the rod in order to make the oil
74174
flow easier.
Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, proceed The engine oil is highly polluting and harmful.
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 of contact with the skin, rinse well with water
In case the level results being close to the tag showing mini- and detergent.
mum level, provide filling lubrication of the engines compo-
nents. Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

Combustion system inspection Lubricating system inspection

The check must be executed both when the engine discon- The check must be executed both when the engine discon-
nected and when it is running. nected 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 spe- Verify the presence of any oil leakage or blow-by from the
cific equipment), to the filter, to the high pressure pump and head, from the engine pan of from the heat exchanger.
to the rail diffuser and from this last one to the head.
Special attention must be paid to the connections on the high

pressure pipelines. The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Due to the high pressure within the pipelines running
from the high-pressure pump to the rail diffuser and
Adequately protect the skin and the eyes, operate in
from this last one to the electro-injectors, special
full compliance with safety regulations.
attention must be aid also in checking presence of any
leakage or blow-by.
compliance with the law and regulations in force.
Protect the eyes and the skin from any eventual high
pressure jet: these may deeply penetrate under the
skin surface provoking serious poisoning.
Inspection of water presence within fuel filter or pre-filter
NOTE The components of the common rail system can be

damaged very quickly in presence of water or im-
Cooling system inspection purity within the fuel.
The check must be executed both when the engine discon-
nected and when it is running. Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the drain-
Check the pipelines from the engine to the radiator, from the age of the water within the feed circuit.
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 sys-

tem, do not operate immediately after the engines
disconnection, but wait for the time deemed necess-
ary for the cooling.
pressure jet of cooling liquid.
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.
NOTE 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.

Inspection/replacement of blow-by filter

The filter in subject has been developed and equipped for the NOTE On TIER 3 engines, due to the additional lobe for
collection, filtering and condense of the lubricating oil vapours. the INTERNAL E.G.R., it is not possible to use the
valve clearance adjustment procedure that requires
Within the filter unit (1) two cartridge filters are included (2). adjusting the clearance of all the valves by
positioning the crankshaft 2 times only.
Each cylinder must be checked by taking it to the
Figure 114 T.D.C. (top dead centre) at the end of compression
and adjusting the clearance of both valves on the
cylinder in question.
1 2
74188
The check of the filtering element is carried out by removing

the cover and drawing off the cartridges (2).
Inspection of drive belt tensioning

The drive belt tensioning control is made using an automatic
tensioning device therefore no intervention is required apart
from checking the wear status of the belt itself.
Inspection and setting of tappet clearance
Figure 115
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
- exhaust valves 0.50 0.05 mm.

Oil motor and filter replacement 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-
Warning: We recommend to wear proper protec- ent positions: the following procedure is a valid guide for all ap-
tions because of high motor service temperature. plications.
The motor oil reaches very high temperature: you - The filter is composed by a support and a filtering car-
must always wear protection gloves. tridge. For the cartridge replacement use the
9936076-tool.
Warning: the oil filter contains inside a quantity of oil

Due to the several applications, the pan shape and the oil of about 1 kg.
quantity can change slightly. However, the following oper-
ations are valid for all applications. Place properly a container for the liquid.
We recommend to carry out the oil drainage when the motor Warning: avoid the contact of skin with the motor oil:
is hot. in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the The motor oil is very pollutant: it must be disposed
pan connected with the drain plug. of according to the rules.
- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the lubrica-
tion oil.
- Replace the filtering cartidge with a new one and screw

manually until when the gasket is in contact with the sup-
The oil motor is very pollutant and harmful. port.
In case of contact with the skin, wash with much water - Tigthen by means of the 99360076-tool of three fourth
and detergent. turn.
Protect properly skin and eyes: operate according to - Operate the motor for some minutes and check the level
safety rules. through the dipsick again. If it is necessary, carry out a top-
Dispose of the residual properly following the rules. ping up to compensate the quantity of oil used for the fill-
ing of the filtering cartridge.
- After the complete drainage, screw the 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.

Fuel filter replacement Alternator belt replacement

Due to several applications the belt run can change very much.
During this operation dont smoke and dont use free

flames.
Avoid to breathe the vapors coming from filter.
Warning: with switched off motor (but still hot) the

belt can operate without advance notice.
According to the applications the filters position and the quan-
Wait for the motor temperature lowering to avoid
tity can change.
very serious accidents.
However the following operations are valid for 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 99360076-tool. For applications with automatic belt stretcher, the procedure
- Collect the eventual fuel inside the filtering cartridge. is the following:
- Clean the gasket seat on the support and oil slightly the Figure 116
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 10-15 Nm torque.
108545
- Operate on the tightener (1) and withdraw the belt (2)

from the alternator and water pumps from pulleys and
from the returns pumps.
- Replace the worn belt with a new one.
- Place the belt on the pulleys and the guide rollers.
- Place the automatic tightener in order to key the belt in
the functioning position.
- Further adjustments are not required.

F4HE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
4 AND 6 ENGINE OVERHAUL . . . . . . . . . . . . . 11
ENGINE REMOVAL AT THE BENCH . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
- Checks and measurements . . . . . . . . . . . . . . . 12
- Checking head supporting surface on

cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Checking cam lift and pin alignment . . . . . . . . 15
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 16
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Fitting tappets camshaft . . . . . . . . . . . . . . . . 17
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 18
- Measuring journals and crankpins . . . . . . . . . . 18
- Measuring journals and crankpins (6 cyl.) . . . . 20
- Replacing oil pump control gear . . . . . . . . . . . 22
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 22
- Finding journal clearance . . . . . . . . . . . . . . . . . 22
- Checking crankshaft shoulder clearance . . . . . 23
CONNECTING ROD PISTON ASSEMBLY . . 23
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE N ENGINES
Page Page
- Removing the valves . . . . . . . . . . . . . . . . . . . . 31

- Measuring piston diameter . . . . . . . . . . . . . . . . 24
- Checking cylinder head wet seal . . . . . . . . . . . 32
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Checking cylinder head supporting
surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Conditions for proper pin-piston
coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 26 - Removing carbon deposits, checking and
grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Checking clearance between valve stem and
- Fitting connecting rod-piston assembly . . . . . . 27 valve guide and valve centering . . . . . . . . . . . . 33
- Connecting rod-piston coupling . . . . . . . . . . . . 27 VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 28
- Regrinding replacing the valve seats . . . . . . . 34
- Fitting connecting rod-piston assembly into
cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . 28
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Finding crankpin clearance . . . . . . . . . . . . . . . . 29 FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . 36
- Checking piston protrusion . . . . . . . . . . . . . . . 30 - Refitting the cylinder head . . . . . . . . . . . . . . . . 37
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 31 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 38

Type 4 CYLINDERS 6 CYLINDERS
Cycle Four-stroke diesel engine

Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6

Bore mm 104
Stroke mm 132
+ + +.. = Total displacement cm3 4485 6728
TIMING
start before T.D.C. A 18.5

end after B.D.C. B 29.5
start before B.D.C. D 67

end after T.D.C. C 35
Checking timing
mm 0.20 to 0.30
X
X mm 0.45 to 0.55
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 ECU
Injector CRIU 2
Nozzle type DSLA and DLLA
Injection sequence 1-3-4-2 1-5-3-6-2 -4
bar
Injection pressure bar 250 - 1600

CLEARANCE DATA
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

1
Cylinder barrels 1 102.009 to 102.031
X
1 0.4
Pistons
1
X Size X 55.9 / 49.5 ()
Outside diameter 1 103.714 to 103.732 / 103.759 to 103.777 ()
2 Pin housing 2 38.010 to 38.016
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 0.01 to 0.022
() Valid for engines F4HE9684P

F4HE9684A
F4HE9687P
F4HE9687A

X1 X1* 2.705 to 2.735

Split ring slots X2 2.440 to 2.460 / 2.420 to 2.440 ()
X2
X3 4.030 to 4.050
X3
* measured on 101 mm
S 1 S1 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110 / 0.040 to 0.090 ()
3 0.040 to 0.080
Split rings 0.4
X1
Split ring end opening
X2 X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3 Small end bush diameter
Inside 3 38.019 to 38.033

S Big end half
bearings S 1.955 to 1.968
Piston pin bush 0.019 to 0.039
Big end half bearings 0.250 ; 0.500
() Valid for engines F4HE9684P

F4HE9684A
F4HE9687P
F4HE9687A


X
Size X -
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82.99 to 83.01
Crankpins 2 68.987 to 69.013
Main half bearings S1 2.456 to 2.464

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

No. 15 / 1-7 0.041 to 0.119
No. 234 / 2-3-4-5-6 0.041 to 0.103
Half bearings - Crankpins 0.033 to 0.041
Main half bearings
0.250 to 0.500
Big end half bearings
Shoulder journal X1 37.475 to 37.545
X 1
Shoulder main bearing X2 32.180 to 32.280
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.265

CYLINDER HEAD TIMING SYSTEM mm

1
Valve guide seats on

cylinder head 1 7.042 to 7.062
4 Valves:
4 6.970 to 6.990
60o 0.25o
4 6.970 to 6.990
45o 0.25o
Valve stem and guide 0.052 to 0.092

Housing on head for
valve seat:
1 34.837 to 34.863
1 1 34.837 to 34.863
Valve seat outside diameter;

2 valve seat angle on cylinder
head:
2 34.917 to 34.931
60o
2 34.917 to 34.931
45o

X 0.59 to 1.11
X Sinking X 0.96 to 1.48
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -


Valve spring height:
free spring H 47.75

H H1
H 2 under a load equal to:
339.8 9 N H1 35.33
741 39 N H2 25.2
Injector protrusion X -
X
Camshaft bush housings No. 1

(flywheel side) 59.222 to 59.248
Camshaft housings
No. 2-3-4-5/2-3-4-5-6-7 54.089 to 54.139
1 23 4 5
2
Camshaft journals:
15
53.995 to 54.045
17
1 3
Bush inside
diameter 54.083 to 54.147
Bushes and journals 0.038 to 0.162

Cam lift:
H
H 6.045
H 7.582


1
Tappet cap housing
on block 1 16.000 to 16.030
2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.960 to 15.975
2
Between tappets and housings 0.025 to 0.070
Tappets -
1
Rocker shaft 1 21.965 to 21.977
Rockers 2 22.001 to 22.027
2
Between rockers and shaft 0.024 to 0.162


4 AND 6 ENGINE OVERHAUL Figure 3

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

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

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

zs
Figure 6 REPAIR OPERATIONS

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

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

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

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

different heights in the barrel and on two planes perpendicular
with each other: one parallel to the longitudinal axis of the
engine (A), and the other perpendicular (B). Maximum wear
is usually found on plane (B) in correspondence with the first
measurement.
Should ovalisation, taper or wear be found, bore and grind the
70165
cylinder barrels. Cylinder barrel regrinding shall be performed
according to the spare piston diameter oversized by 0.4 mm
and to the specified assembling clearance.
Withdraw the tappets (1) from the engine block.
Figure 11 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.
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.
107804
NOTE In case of regrinding, all barrels shall have the same

oversize (0.4 mm).

TIMING SYSTEM
Camshaft
Figure 12
70169
CAMSHAFT MAIN DATA (4 cyl.)

Specified data refer to pin standard diameter
Figure 13
84089
MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders)

Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bush.
if they show any traces of seizing or scoring replace the
Checking cam lift and pin alignment BUSHES

Set the camshaft on the tailstock and using a 1/100 gauge set
Figure 15
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.
Figure 14
70172
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.
70171 Measurements shall be performed on two perpendicular
axes.
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
Figure 16
Sec. A-A
107399
CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)

* Value to be obtained after driving the bush.
Figure 17
sec. A-A
107268
MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING

*Height to be obtained after driving the bush.
Bush replacement Tappets

Figure 18 Figure 19
70174
112890
To replace bush (1), remove and refit it using the beater

99360362 (2) and the handgrip 99370006 (3).
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
NOTE When refitting the bush (1), direct it to make the

lubricating holes (2) coincide with the holes on the
block housing.

Fitting tappets camshaft Figure 22
Figure 20
70238
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.
70176
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Figure 23
70179
Check camshaft end float (1).

Figure 21 It shall be 0.23 0.13 mm.
Figure 24
70164
70180
Lubricate the camshaft bush and fit the camshaft (1) taking
care not to damage the bush or the housings.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
OUTPUT SHAFT
Measuring journals and crankpins NOTE It is recommended to insert the found values in the
proper table.
Figure 25 See Figure 26.
Undersize classes are:
NOTE Journals and crankpins shall always be ground to

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

ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
Figure 26
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value

Figure 27
measured on > 45.5 mm radius

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

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

CRITICAL
IMPORTANT
SECONDARY
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237

Measuring journals and crankpins (6 cyl.)
Figure 28
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Figure 29
* Measured on a radius greater than 45.5 mm

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

Figure 30
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING ON

SYSTEM CONTROL SIDE BEARINGS FRONT SIDE
70237

Roundness
SHAPE
Cilindricity //
Parallelism //
Straightness
OSCILLATION
Total oscillation

CRITICAL
IMPORTANT
SECONDARY

Replacing oil pump control gear Finding journal clearance

Figure 33
Figure 31
70161
Refit the crankshaft (2).

Check the backlash between crankshaf main journals and the
70184
relevant bearings as follows:
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 Figure 34
in an oven and then key it to the crankshaft.
Fitting main bearings
Figure 32
70186
- clean accurately the parts and remove any trace of oil;

- position a piece of calibrated wire (3) on the crankshaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
70185
supports.
NOTE Refit the main bearings that have not been

replaced, in the same position found at removal.
D2 diameters:
if D1 - D2 > 0,1 mm the screw must be replaced.
Main bearings (1) are supplied spare with 0.250 0.500 mm
undersize on the internal diameter. D2 D1
NOTE Do not try to adapt the bearings.

75703
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.

Figure 35 Checking crankshaft shoulder clearance
Figure 38
70187
Tighten the pre-lubricated screws (1) in the following three

successive stages: 70190
- 1st stage, with torque wrench to 50 6 Nm.
- 2nd stage, with torque wrench to 80 6 Nm. This check is performed by setting a magnetic-base dial gauge
(2) on the crankshaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
Figure 36
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft pins and main half bearings.
CONNECTING ROD PISTON ASSEMBLY

70188
- 3rd stage, with tool 99395216 (1) set as shown in the Figure 39
figure, tighten the screws (2) with 90 5 angle.
Figure 37
70191
70189 CONNECTING ROD PISTON ASSEMBLY

COMPONENTS
- Remove caps from supports.
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
The backlash between the main bearings and the pins is
6. Half bearings - 7. Connecting rod - 8. Bush.
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. NOTE The pistons are supplied spare with the following
Replace the half bearings and repeat the check if a different sizes:
backlash value is found. Once the specified backlash is - standard;
obtained, lubricate the main bearings and fit the supports by - 0.4 mm oversize.
tightening the fastening screws as previously described.
Figure 40 Pistons
Measuring piston diameter
Figure 43
32613
32615
Remove split rings (1) from piston (2) using pliers 99360183
(3). Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
Figure 41
Figure 44
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 42
1.5
2.705 2.420
2.560 2.735 2.440
* 2.605
220
2.350
2.380
3.970
3.990 38.010 37.994
38.016 38.000
114797
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter

Figure 45
114798
MAIN DATA OF THE PISTON WITHOUT PIN TUNNEL AND PLASTIC RINGS
Piston pins
Figure 46
Figure 48
18857
To measure the piston pin (1) diameter use the micrometer

16552
(2).
Use a micrometer (1) to check split ring (2) thickness.
Conditions for proper pin-piston coupling
Figure 47 Figure 49
32619
Lubricate the pin (1) and its seat on piston hubs with engine 32620
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 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Figure 50 Connecting rods

Figure 52
41104
DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3). 88607
In this position, use a feeler gauge to check the clearance (X)

between ring and slot: found value shall be the specified one. MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
* Value for inside diameter to be obtained after driving in

connecting rod small end and grinding.
Figure 51
NOTE The surface of connecting rod and rod cap are

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

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

Figure 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
CONNECTING ROD BODY
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
CONNECT- CONNECT-
ING ROD ING ROD *
BODY BODY
Fitting connecting rod-piston assembly

Connecting rod-piston coupling
Figure 54
CONNECTING ROD BODY
CONNECTING ROD CONNECT- CONNECT-

BODY ING ROD ING ROD
BODY BODY
70196
70198
NOTE Every connecting rod is marked as follows:
The piston crown is marked as follows:
- On body and cap with a number showing their 1. Part number and design modification number;
coupling and the corresponding cylinder. 2. Arrow showing piston assembling direction into cylinder
In case of replacement it is therefore necessary barrel, this arrow shall face the front key of the engine
to mark the new connecting rod with the same block;
numbers of the replaced one. 3. Manufacturing date.
- On body with a letter showing the weight of 4. Marking showing 1st slot insert testing;
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
Figure 55
S X, 1901 to 1940 (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
108597
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.

Figure 56 Figure 58
72705
70200
Position the piston (1) on the connecting rod according to
the diagram shown in the figure, fit the pin (3) and stop it by Fit half bearings (1) on connecting rod and cap.
the split rings (2).
Fitting split rings
Figure 57 replaced, in the same position found at removal.
Do not try to adapt the half bearings.
Fitting connecting rod-piston assembly into

32613 cylinder barrels
Use pliers 99360183 (3) to fit the split rings (1) on the piston Figure 59
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
NOTE Split rings are supplied spare with the following

sizes:
- standard;
- 0.4 mm oversize.
70201
Lubricate accurately the pistons, including the split rings and

the cylinder barrel inside.
Use band 99360605 (2) to fit the connecting rod-piston
assembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to
the cap coupling number.

Figure 60 Figure 62
108596
70204
DIAGRAM FOR CONNECTING ROD-PISTON - Lubricate the screws (1) with engine oil and then tighten
ASSEMBLY FITTING INTO BARREL them to the specified torque using the torque wrench
(2).
- Split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same Figure 63
weight;
- the arrow marked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
Finding crankpin clearance
Figure 61
70205
- Apply tool 99395216 (1) to the socket wrench and

tighten screws (2) of 60.
Figure 64
70203
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).
NOTE Before the final fitting of the connecting rod cap

70206
fastening screws, check that their diameter
measured at the centre of the thread length is not - Remove the cap and find the existing clearance by
< 0.1 mm than the diameter measured at approx. comparing the calibrated wire width (1) with the scale
10 mm from screw end. on the wire envelope (2).

Figure 65 Checking piston protrusion
Figure 66
70207
70208
If a different clearance value is found, replace the half bearings
and repeat the check. Once connecting rod-piston assemblies refitting is over, use
dial gauge 99395603 (1) fitted with base 99370415 (2) to
Once the specified clearance has been obtained, lubricate check piston (3) protrusion at T.D.C. with respect to the top
the main half bearings and fit them by tightening the of the engine block.
connecting rod cap fastening screws to the specified torque.
Protrusion shall be 0.28 to 0.52 mm.
Check manually that the connecting rods (1) are sliding

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

CYLINDER HEAD Figure 68

Removing the valves
Figure 67
70321
Valve removal shall be performed using tool 99360268 (1)

and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
70319
cap (3) and the springs (4).
Intake (1) and exhaust (2) valves have heads with the same
diameter. Repeat this operation for all the valves.
The central notch () of the exhaust valve (2) head Overturn the cylinder head and withdraw the valves (5).
distinguishes it from the intake valve.
Figure 69
NOTE Should cylinder head valves be not replaced,

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

Sealing rings (2) for exhaust valves are green.

Checking cylinder head wet seal Figure 71
Figure 70
70323 70325
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90C and 2 The rated thickness A for the cylinder head is 105 0.25 mm,
to 3 bar pressure. max. metal removal shall not exceed thickness B by 1 mm.
Replace the core plugs (1) if leaks are found, use the proper
punch for their removal/refitting.
NOTE After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with
water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface

Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.

VALVES Figure 74
Figure 72
EXHAUST INTAKE
VALVE VALVE
18882
Check the valve stem (1) using a micrometer (2), it shall be

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

grinding valves Checking clearance between valve stem and
valve guide and valve centering
Figure 73
Figure 75
18625
Remove carbon deposits from valves using the proper metal

brush. 70327
Check that the valves show no signs of seizing, scoring or Use a magnetic base dial gauge (1) set as shown in the figure,
cracking. the assembling clearance shall be 0.052 0.092 mm.
If necessary, rectify the valve seats, taking away the least Turn the valve (2) and check that the centering error is not
amount of material possible. exceeding 0.03 mm.

VALVE GUIDE VALVE SEATS

Regrinding replacing the valve seats
Figure 76
Figure 77
70330
INTAKE EXHAUST Should slight scratches or burns be found, go over with the
79457
adequate tool (1) according to the inclination values
Use a bore dial gauge to measure the inside diameter of the indicated in the Figure 78.
valve guides, the read value shall comply with the value
shown in the figure.
Figure 78
INTAKE EXHAUST
70331
VALVE SEAT MAIN DATA (4 CYL.)

Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 - 100C and using the proper
them with the spare ones. Using a suitable tool, remove as punch, fit the new valve seats, previously cooled, into the
much material as possible from the valve seats (take care not cylinder head.
to damage the cylinder head) until they can be extracted
Therefore, with an adequate tool, go over the valve seats
from the cylinder head using a punch.
according to the values stated in the Figure 78.
Figure 79
EXHAUST INTAKE
70332
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
Figure 80 After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).
70333

VALVE SPRINGS FITTING CYLINDER HEAD

Figure 81 Figure 82
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

VALVE SPRINGS 70334
Before refitting use tool to check spring flexibility. Compare

load and elastic deformation data with those of the new Lubricate the valve stems (1) and fit them into the relevant
springs shown in the following table. valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
Height Under a load of
mm N
H 47.75 Free
H1 35.33 P 339.8 19 N
H2 25.2 P1 741 39 N
Figure 83
770321
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).

Refitting the cylinder head 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:
Figure 84
- 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:
S cil1 = S1 + S2
For 4 cylinder versions: 2
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
S cil1 + S cil2 + S cil3 + S cil4

70335 S=
4
Check cleanness of cylinder head and engine block coupling For 6 cylinder versions:
surface.
Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
Take care not to foul the cylinder head gasket. the average value.
Set the cylinder head gasket (1) with the marking TOP (1)
facing the head.
The arrow shows the point where the gasket thickness is S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6
given. S=
6
If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.
Figure 85

D2 diameters:
D2 D1
75703
88775

TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Studs M6 for camshaft sensors 82 0.8 0.2
Studs M8 for feed pump 12 2 1.2 0.2
Screw M12 for fastening rear gear case 77 12 7.7 1.2
Nut M6 for fastening camshaft sensor 10 2 1 0.2
1st stage 81 0.8 0.1
Screw M8 for fastening oil pump 2nd stage 24 4 2.4 0.4
Screw M8 for fastening front cover 24 4 2.4 0.4
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw 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 2.4 0.4
1st stage 8.5 0.35 0.85 0.035
Screw M6 for fastening injectors
2nd stage 75 5
Nut fastening for injector feed connector 50 5 5 0.5
Nut M6 for flame start grille on intake manifold 82 0.8 0.2
Screw M8 for fastening intake manifold 24 4 2.4 0.4
Screw M12 for fastening rear brackets for engine lifting 77 12 7.7 1.2
Screws M8 for fastening Common Rail 24 4 2.4 0.4
Connectors M14 for high pressure fuel pipes 20 2 2 0.2
Screw M12 (12 x 1.75 x 130) for fastening cylinder head 35 5 3.5 0.5
Screw M12 (12 x 1.75 x 150) for fastening cylinder head
}1 st stage
55 5 5.5 0.5
2nd stage 90 5
3rd stage 90 5
Screw for fastening rocker bracket 36 5 3.6 0.5
Valve clearance adjusting nuts 24 4 2.4 0.4
Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 2 2 0.2
Screw M8 for fastening high pressure pipe connector 24 4 2.4 0.4
Screw M6 for fastening wiring bulkhead 10 2 1 0.2
Screw M8 for fastening electric wiring support for injector feed 24 4 2.4 0.4
Nuts for fastening wiring on each injector 1.5 0.25 0.15 0.025
Screw M12 for fastening fuel filter bracket 77 8 7.7 0.8
Screw M8 for fastening fuel filter holder 24 4 2.4 0.4
Fuel filter contact + 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

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 1st stage 50 5 5 0.5
and damper on output shaft 2nd stage 90
Screw M10 for fastening pulley on output shaft 68 7 6.8 0.7
Screw M8 for fastening water pump 24 4 2.4 0.4
Screw M10 for fastening auxiliary component control belt tensioners 43 6 4.3 0.6
Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 6 4.3 0.6
Screw M10 for fastening flywheel housing 85 10 8.5 1
Screw M12 for fastening flywheel housing 49 5 4.9 0.5
Screw M6 for fastening heat exchanger for control unit 10 2 1 0.2
Screw M8 for fastening heat exchanger for control unit 24 4 2.4 0.4
Connection M12 for fuel inlet-outlet on heat exchanger 12 2 1.2 0.2
Nut M8 for fastening valve cover 24 4 2.4 0.4
Screw M6 for fastening camshaft sensor 82 0.8 0.2
Screw M6 for fastening output shaft sensor 82 0.8 0.2
Screw M14 for fastening coolant temperature sensor 20 3 2 0.3
Screw M5 for fastening oil pressure/temperature sensor 61 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 61 0.6 0.1
Screw M12 for fastening engine oil level sensor 12 2 1.2 0.2
71 0.7 0.1
6-cyl. { pins
nuts
M8
M8 43 6 4.3 0.6
Turbine fixing to exhaust manifold
4-cyl. { pins
nuts
M8
M8
71
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 1st stage 30 4 3 0.4
2nd 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 1st stage 50 6 5 0.6
2nd stage 80 6 8 0.6
3rd stage 90 5
Screw M10 for fastening connecting rod caps 1st stage 60 5 6 0.5
2nd 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


F4HE N ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS F4HE N ENGINES

TOOLS
TOOL NO. DESCRIPTION
99327281 Tester PT-BOX
99317915 Set of 3 pin wrenches (14 - 17 - 19 mm)
Revolving stand for overhauling units (700 daN/m capacity, 120

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

TOOLS
99341009 Pair of brackets
99341015 Press
99342101 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket
99360076 Tool to remove oil filter (engine)

TOOLS
99360183 Pliers for removing/refitting piston rings (65 110 mm)
99360268 Tool for removing/refitting engine valves
99360339 Tool for rotating/stopping the engine flywheel
99360351 Equipment for flywheel holding
Beater for removing/refitting camshaft bushes (to be used with

99360362 993700069)
99360500 Tool for lifting the output shaft

TOOLS
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99370006 Handgrip for interchangeable beaters
99370415 Gauge base for different measurements (to be used with 99395603)

TOOLS
99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)
Torque screwdriver for injector solenoid valve connector stop nut

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


F4HE N ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX F4HE N ENGINES

F4HE N ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

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

4 APPENDIX F4HE N ENGINES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

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

F4CE N ENGINES 1
Part 2
F4CE N SERIES
Section
Fuel 2
Industrial application 3
Tools 5

2 F4CE N ENGINES

F4CE N ENGINES 3
UPDATING

4 F4CE N ENGINES

F4CE N ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
Page
CORRESPONDENCE BETWEEN TECHNICAL

CODE AND COMMERCIAL CODE . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- 4-cylinder engine version . . . . . . . . . . . . . . . 4
OIL VAPOUR RECIRCULATING SYSTEM . . . . . 6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 7
AIR INDUCTION - BOOST DIAGRAM . . . . . . . 9
- Description . . . . . . . . . . . . . . . . . . . . . . . . . 9
EXHAUST GAS RE-CIRCULATION

SYSTEM (EGR) . . . . . . . . . . . . . . . . . . . . . . . . 10

2 SECTION 1 - GENERAL SPECIFICATIONS F4CE N ENGINES


F4CE9484F*J600 N45 MRT.X
F4CE9684L*J602
N67 MRT.X
F4CE9684N*J600

LUBRICATION Lubrication circle also includes the heat exchanger, the

Forced-circulation lubrication, is obtained by means of the oil turbo-blower for the turbo-compressed version and
lobe pump fitted in the front part of the basement, driven by eventually the compressor for the compressed air system.
the splined bush, keyed on the hold of the engine drive shaft. These components may often vary according to the specific
From the pan, the lubrication oil flows to the driving shaft, to duty.
4- cylinder engine version

Routing of oil return by gravity to

sump
88203
Introduction of oil
LUBRICATION SYSTEM LAYOUT (Engines with 4 cylinders)

1. Lubrication oil pipe to supercharger - 2. Oil filter - 3. Heat exchanger body - 4. Heat exchanger -
5. Oil rotary expansion pump.

6- cylinder engine version Also in this case, the components such as the oil exchanger,
Even for the 6 cylinders version lubrication is obtained by the turbo-blower and the eventual compressor are specifically
forced circulation and achieved through an oil rotary expan- studied and made out to suit the equipment or the duty for
sion pump similar to the 4 cylinders one. which the engine has been developed.
Figure 2
Routing of oil return by gravity to sump 88205
Introduction of oil
LUBRICATION SYSTEM LAYOUT (6-cylinder engines)

1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine - 5. Oil pump

OIL VAPOUR RECIRCULATING SYSTEM
Figure 3
3240t
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).

COOLING SYSTEM - Visc pusher fan, having the duty to increase the heat
The engine cooling system, closed circuit forced circulation type, will be specifically equipped based on the engines
generally incorporates the following components: development.
- Expansion tank; placement, shape and dimensions are - Heat exchanger to cool the lubrication oil: even this
subject to change according to the engines equipment. component is part of the engines specific equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this - Centrifugal water pump, placed in the front part of the
component will have specific peculiarities based on the engine block.
equipment developed, both for what concerns the - Thermostat regulating the circulation of the cooling liquid.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.

TO RADIATOR
FROM
RADIATOR
117592

COOLING SYSTEM LAYOUT (4-cylinder engines)


The engine cooling system, closed circuit forced circulation
type, is of a similar design as the 4 cylinders engine.
It incorporates necessary components such as the radiator,
the heat exchanger, the expansion tank and some ancillary
components such as the heater or the compressor for the
compressed air.
Such components always vary according to the engines equip-
ment and duty.
117592
COOLING SYSTEM LAYOUT (6-cylinder engines)

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

The turbocharger is composed by the following main parts: regulate the pressure , that is located on the exhaust collector
one turbine, one transforming valve to regulate the boost before the turbine and connected by piping to the induction
feeding pressure , one main body and one compressor. collector.
During engine working process, the exhaust emissions flow Its funchon is to restrict the exhaust of the emissions , releasing
through the body of the turbine, causing the turbine disk part of them directly to the exhaust tube when the boost
wheels rotation. feeding pressure, over the compressor, reaches the
turbine disk wheel, rotates as long as this last one rotates, The cooling process and the lubrication of the turbocharger
compressing the drawn air through the air filter. and of the bearings is made by the oil of the engine.

emission of NOx .
Figure 7
114789

F4CE N ENGINES SECTION 2 - FUEL 1
SECTION 2
Fuel
Page
4-CYLINDER ENGINES WITH BOSCH VE 4/12 F

ROTARY MECHANICAL PUMP . . . . . . . . . . . . 3
- General information . . . . . . . . . . . . . . . . . . . . 3
- Description of working principles . . . . . . . . . . . 4
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Example of identification . . . . . . . . . . . . . . . . . 5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6-CYLINDER ENGINES WITH BOSCH VE 6/12 F

ROTARY MECHANICAL PUMP . . . . . . . . . . . . 8
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 SECTION 2 - FUEL F4CE N ENGINES

4-CYLINDER ENGINES WITH BOSCH VE 4/12 F 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
2
1
4
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.

Figure 2
116385
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 The fuel arrives therefore to the valve gauging the pressure
last one is placed on the engine basement and is driven by inside feed pump.
the camshaft.
The distribution plunger further increases this pressure and
Throughout the filter, the fuel is piped to the union fitting delivers fuel throughout the delivery pipe fitting to the
vacuum chamber of the transfer pump. (For applications to injectors.
be equipped in cold climate areas, the fuel filter is provided
The fuel drawing from the injectors is recovered and
with heater).
delivered to the tank again.
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.

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
Figure 3
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
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.

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 4
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.

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.
Figure 5
88210
1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.


General information
- Fuel feed pump
- Injectors
Figure 6
86495
1. Injector fuel pipe 1 - 2. Injector fuel pipe 2 - 3. Injector fuel pipe 3 - 4. Injector fuel pipe 4 - 5. Injector fuel pipe -
6. Injector fuel pipe 5 - 7. Injector fuel pipe 6 - 7. Injector fuel pipe 6 - 8. Injection pump - 9. Injector.

Figure 7
114799
Fuel is sucked from the fuel tank by the priming pump. This
Fuel is delivered to the pressure gauge valve within feed
last one is placed on the engine basement and is driven by
pump.
the camshaft.
Timing plungers further increase the pressure and deliver fuel
Throughout the filter/s, the fuel is piped to the union fitting
to the injectors throughout the delivery pipe fittings.
vacuum chamber of the transfer pump. (For applications to
be equipped in cold climate areas, the fuel filter is provided Fuel bleeding from the injectors is recovered and piped back
with heater). to the pump.

PRIMING PUMP
Figure 8
88209

FUEL FILTER
On the filter cartridge base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the
bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a
temperature sensor (5).
Figure 9
88210
1. Fuel filter bearing - 2. Filter cartridge - 3. Bleender vent screw.


F4CE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 1
SECTION 3
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
- Version equipped with mechanical

feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4CE ENGINE CHARACTERISTICS . . . . . . . . . . . 4
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . 4
- 6-cylinder engines . . . . . . . . . . . . . . . . . . . . . . 5
PART ONE - MECHANICAL COMPONENTS . . 7
OVERHAUL OF THE ENGINE PROVIDED

WITH MECHANICAL ROTARY PUMP . . . . . . 9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Engine setting operations for the assembly

on turning stand . . . . . . . . . . . . . . . . . . . . . . . 9
- Installation of application components . . . . . . 17
- Rotary feed pump disassembly and assembly

procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Feed system bleed procedure . . . . . . . . . . . . . 32
- Power takeoff . . . . . . . . . . . . . . . . . . . . . . . . . 32
PART TWO -
ELECTRICAL COMPONET LAYOUT . . . . . . . . . . 35
- Cooling liquid temperature sensor . . . . . . . . . 36
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Pre-post heating resistor . . . . . . . . . . . . . . . . . 36
- Pre-post heating unit . . . . . . . . . . . . . . . . . . . . 37
- KSB Water temperature sensor . . . . . . . . . . . 37

2 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4CE N ENGINES
Page
- Electromagnets assembled to feed pump . . . . 38
- Oil pressure switch . . . . . . . . . . . . . . . . . . . . . 38
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
PART THREE - TROUBLESHOOTING . . . . . . . . 41
PART FOUR - MAINTENANCE PLANNING . . . 49
MAINTENANCE PLANNING . . . . . . . . . . . . . . . . 51
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
- Planning of controls and periodical

intervention . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
- Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . . 52
- Checks and controls . . . . . . . . . . . . . . . . . . . . 52

GENERAL INFORMATION
Version equipped with mechanical feed pump
Figure 1
114800
NEF engines have been designed and developed by FPT

specifically for transportation by land and farming equipment NOTE Data, technical specifications and performances
in general. granted shall be valid only if the Setter will follow and
comply with all installation prescriptions provided
They are featured by 4 stroke diesel cycle having 4 cylinder
by FPT.
boost with 2 valves per cylinder.
Furthermore, the expanders assembled by the
Feed is provided by rotary mechanical pump or on line Setter must always comply with couple, power and
according to the equipment application. number of revolutions based on which the engine
has been designed.
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
NOTE The picture shows application designed for 4 cover;
cylinders version, 2 valves per cylinder, having fuel - electrical directory, describing the connections of the
feed mechanical pump. 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.
F4CE ENGINE CHARACTERISTICS

4-cylinder engines
F4CE9484F*J600
Type

Max. output kW 74
(HP) (101)
rpm 2200
Max. torque Nm 430
(kgm) (44)
rpm 1250
Loadless engine
idling rpm -
Loadless engine
peak rpm -
Bore x stroke mm 104 x 132
SUPERCHARGING with intercooler

LUBRICATION Forced-circulation by means of lobe pump. Pressure control
valve, oil filter
bar
Oil pressure
(warm engine)
- idling bar 0.8
- peak rpm bar 3.5
COOLING Liquid
Water pump control
Thermostat Through belt
FILLING
engine sump*
liters 16
15W40 ACEA E3 engine sump + filter*
liters 17
* First filling
NOTE Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78).

Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system;
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.

6-cylinder engines
F4CE9684
Type L*J602 N*J600
Compression ratio 17,5 : 1 17,5 : 1
Max. output kW 86 126
(HP) (117) (170)
rpm 2200 2200

Max. torque Nm 522 720
(kgm) (52,2) (72)
rpm 1250 1250

Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -
Loadless engine 104 x 132
peak rpm rpm 6728

LUBRICATION Forced-circulation by means of lobe pump. Pressure control
valve, oil filter
bar
Oil pressure
(warm engine)
- idling bar 0.8
- peak rpm bar 3.5
COOLING Liquid
Water pump control
Thermostat Through belt
FILLING
engine sump*
liters 16
15W40 ACEA E3 engine sump + filter*
liters 17
* First filling
NOTE Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78).

by FPT.


DIAGNOSI
PART ONE -
MECHANICAL COMPONENTS

DIAGNOSI

OVERHAUL OF THE ENGINE PROVIDED Figure 3

WITH MECHANICAL ROTARY PUMP
Preface

vehicle, depending on the room available for access to the
engine and on the equipment application as well.
NOTE 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.
87712
The following information relate to the engine overhaul

operations only for what concerns the different components - Disassemble the starter;
customising the engine, according to its specific duties. Properly hold the starter (2) and loosen the two fixing
screws (1);
assemble the supporting bracket 99361037 using the
NOTE For specific application exigencies, some units can threaded ports on the basement.
be assembled to the engine in different positions.
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 Figure 4
the part hereby described.
turning stand
Figure 2
88216
On the left hand side:

88215
In order to apply the brackets 99361037 to the engine block - assemble the second bracket 99361037 throughout the
to fix it on to the stand 99322205 for the overhaul, it is screw-threaded ports (1).
necessary to perform the following operations: - Lift the engine using the rocker arm 99360595 and put
On the right hand side: it on the turning stand 99322205.
- disassemble lubrication oil exhaust pipe (2) from the - Drain the oil through the cap underneath the plug.
turbo-blower:
Underneath the turbo-blower loosen the screws (1);;
finally loosen and remove the union (5) from the block;
plug the pipe ends and the exhaust of the turbo-blower.
- oil level rod (4);
- oil filter (3). Warning: avoid contact of engine oil with the skin:
in case of skin contamination, rinse in running water.
Provide for oil recovery and disposal in compliance Engine oil is highly pollutant: provide for disposal in
with the law and regulations in force. compliance with the law and regulations in force.

Disassembly of application components Figure 7

Figure 5
1
75675
Proceed disassembling the supercharger: 70126
- loosen the fixing nut (1) and remove the lubrication pipe
from the supercharger. Analogously carry out the same NOTE To disconnect fuel pipelines (2 and 3, Figure 6), in
operation on the other end of the pipe and remove it low pressure from the relating pipe fittings, it is
from the upper part of the heat exchanger. Necessary to press the locking fastener (1) as
- Loosen the fixing screw (3) and remove the exaust shown in picture B.
lubrication pipe from the supercharger.
After having disconnected the pipeline, reset the
- Hold up the supercharger and after lifting it remove the locking fastener (1) in lock position as shown in.
gasket. picture A, to avoid any possible deformation of the
fastener itself.
Figure 6
4
3
2
Figure 8
1
87404
NOTE In some versions, the fuel filter has the sensor

detecting water on the basis of the filtering
cartridge and/or a heater interposed between filter
support and filtering cartridge.
For the versions requiring it, disconnect the
electrical connections of such electrical
87405
components before removing the fuel filter.
- Disconnect the LDA pipe (1) from the head and from
- Place a container under the fuel filter and screw out the
the feed pump.
condense drain faucet underneath said filter. Carry out
complete drainage of the fuel contained therein. - Pipe the ends of the pipelines as well as the feed pump
- Screw out completely the faucet and, using equipment and the engine head.
99360076 disassemble fuel 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 from the bracket fixed to
the engine head.
Figure 9
88311
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. Bracket fixing screw to injection pump side- -
6. Bracket fixing screw to injection pump side- - 7. Front bracket fixing screw (on suction collector plate) - 8. Injector.
Figure 10 Figure 11
88218 88102
- Disconnect the pipelines (1) and (2) that provide feed - Loosen the two fixing screws (2) and disassemble
and fuel recovery between pump and injectors; screw priming pump (1).
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, 5, 6, and 7, Figure 9); pipe the pipeline ends.
- Disassemble the injectors and remove them from their
slot: remove the gaskets.

Figure 12 Figure 14
2
1
76149 75683
- Disassemble rocker arm bearings; loosen the two fixing
- Remove tappet caps: screws (2) and remove the complete rocker arm bearing;
Loosen the fixing screws (1) and lift the caps (2); withdraw tappet rods. Repeat the operation for all the
remove the gaskets. remaining rocker arm bearings.
- Disassemble water temperature transmitter (1).
NOTE On the central cap there is a blow-by valve for the
lubrication oil vapours. Figure 15 (Demonstration)
All the gaskets shall always be replaced during
assembly.
Figure 13
88305
- Using the square wrench with suitable dimensions, work
on the A point shown in the picture, release the pressure
and withdraw the Poli-V belt (3) from the transmission
and drive pulleys.
- Proceed disconnecting the automatic tightening device
(1) and the relevant support (2).
Figure 16
87409
- Disassemble suction and exhaust manifolds: loosen the

screws (1) fixing the suction manifold plate to the
cylinder head.
- From the exhaust manifold side loosen the (2) fixing
screws; remove the gaskets.
87413
- Duly hold the alternator (2) removing it from its support
by loosening the screw (3) and from the bracket by
loosening the screw (1); recover nuts and washers.
Figure 17 Figure 19
88219
117593
- Disassemble thermostat unit; loosen the three fixing - Loosen the fastening screws (4) and remove the oil filter
screws (1), disassemble the thermostat unit (2). support (5), together with the sheaths (1) and (3) and
Remove the gasket (3) and the thermostat (4). the heat exchanger (2).
- Disassemble the ignition pump (see the specific
procedure) and the power takeoff underneath (if
available).
Figure 18 Figure 20
88231 88306
- Loosen the screws (1) and withdraw the alternator - Loosen the fastening screws (3) and remove the pulley
bearing (2). controlling the fan (2).
- Proceed detaching the support (1).
- Remove the transmission pulley (4).

For 4 cylinder engines Figure 24

Figure 21
1 2
1
2
4 75688
- 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.
- F4HE9484A*J105
For 6 cylinder engines
Figure 22
4 3
75689
- Loosen the screws (1) and withdraw water pump (2).

- Loosen the screws (3) and remove the pulley (4).
76152
Figure 25
- Proceed disconnecting the cylinder head;
loosen the screws (1) and (2) fixing the cylinder head (3);
hoist withdraw cylinder head from the block.
- Remove the gasket (4).
Figure 23
00900t
- Remove the engine drive shaft fixing ring from the front
cover. Use the tool 99340055 (4) to operate on the
87747
front tang (2) of the engine drive shaft. Throughout the
tool guide ports, drill the internal holding ring (1) using
- Use the tool 99360339 to operate on the flywheel cover 3,5 mm drill for a 5mm depth. Fix the tool to the ring
box (1) in order to block flywheel rotation (2).
tightening the screws specially provided.
(Utilise starter holding down studs and fixing screw nuts).
Proceed withdrawing the ring (1) tightening the screw
- Loosen the flywheel fixing screws (3) to engine drive (3).
shaft.
Figure 26 Figure 28
88214 87420
- Using the specially provided tie rod (3) for the tool - Screw out the opposite screws (1) from the ports and
99363204 and the lever (4), withdraw the external introduce the withdrawal pins (see picture following).
holding ring (1) from the front cover (2).
- Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (2).
- Remove the flywheel block tool (2).
Figure 27 Figure 29
87419
- Loosen the screws (2) and remove the front cover (1).
87421
- Remove the gasket.
- Screw up two medium length screws in the ports (4) to
sling the flywheel with a hoist.
NOTE Take note of the screw (2) assembly position, since
the screws have different length. 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.

Figure 30 Figure 32
88307
00903t
- Turn the engine upside-down.
- Remove the flywheel cover box fixing ring using the tool - Loosen the screws (2), remove the oil pan(1) recovering
99340056 (3) to operate on the back tang (5) of the the gasket.
engine drive shaft. Throughout the tool guide ports, drill
the internal holding ring using 3,5 mm drill for a 5mm
depth. Figure 33
- Fix the tool 99340056 (3) to the ring (1) tightening the
screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
Figure 31
87655
- Remove the gear (1) transmitting motion to the ignition

pump and the relevant support.
Figure 34
87422
- Loosen the screws (2) and remove the flywheel cover

box (1).
87424
the screws have different length.
- Remove the screws (1) and disassemble the gears (3)
and (4) from the camshaft (2).
Installation of application components Figure 37

Figure 35
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.
70211
- With a felt-tip pen, highlight the conducting gear tooth

(1) mounted on the engine shaft (2) upon the side Figure 38
surface of which a groove has been created for the
ignition timing.
NOTE Screw up two pins to facilitate operation of engine

drive shaft rotation.
Figure 36
87654
- Fit the screws (1) fastening the gears (2) to the camshaft
(3) and tighten them to the prescribed pair.
Figure 39
116355
- 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).
87655
- Spline the gear (1) transferring motion to the ignition

pump.
Figure 40 Figure 42
87656 87658
- Fit the power take-off gear (2) (if available) into the - Re-assemble the box (1) to the engine basement.
specially provided housing and fasten the screws (1),
- Tighten the fastening screws (2) to the same position
detected before disassembly.
Figure 41
NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt.
Figure 43
87657
DIAGRAM SHOWING SEALING LOCTITE 5205

APPLICATION
NOTE 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 87659
or irregular zones.
Any eventual imperfection shall be correct as soon
as possible. - Apply to the rear tongs hold (3) of the engine drive shaft
the part (6) of the tool 99346253, fix it with the screws
Avoid using material in excess to seal the joint. Too (1) and spline the new tight ring to it (2).
much sealing material would drop out on both
sides of the joint and obstruct lubricant passages. - Place the part (5) on the part (6), tighten the nut (4)
until tight ring assembly (2) into the flywheel box is
After having completed seal application, the joints completed.
must be immediately assembled (10-20 minutes
time).

Figure 44 Figure 47
87663
87660
Tighten the engine flywheel (1) fixing screws (2) in two
- Check the laying surface (1) of the clutch disk: if it is phases:
scratched proceed with facing. - 1st phase; tightening by means of dynamometric wrench
- Check the tooth conditions of the toothed rim (2), to couple 30 4 Nm;
replace it in case of broken tooth or excessive wear. Fit - 2nd phase, 60 5 angle dwell.
the new one, previously heated at the temperature of
150 C for 1520. NOTE Angle dwell shall always be performed using
99395216 tool.
Figure 45 Before assembly, always check that the threads of
Figure 48
87661
- Screw tighten two pins (2) of appropriate length into the

ports of the engine drive shaft (3) and assemble the - Fit the sheath. 87664
engine flywheel (1) using the specially provided sling.
- Assemble the oil pump (1).
Figure 46 - Fit the fastening screws (2) and tighten them.
Figure 49
87662 88307
- Fit the new sheath on the basement.
- Spline the flywheel (1) on the engine drive shaft by - Assemble the oil pan (1).
tightening the screws (2) manually. - Fit the screws (2) and tighten them to the prescribed
- Duly lock the flywheel before proceeding with tightening pair.
the relevant screws to the prescribed pair. - Tighten the exhaust caps to the prescribed pair.
Figure 50 Figure 53
87666
87668
- Assemble the water pump (1).
- Fit part (4) of the tool 99346252 on the front tang (3)
of the engine drive shaft; fasten it with the screws (5) and - Tighten the screws (2) and lock them to the prescribed
spline the new tight ring on it (6). couple.
- Fit part (1) on part (4), screw-tighten the nut (7) until Figure 54
the assembly of the tight ring (6) into the front cover (2)
is completed.
Figure 51
88219
- Assemble the following elements to the block: new

gasket (1), heat exchanger (2), new gasket (3), oil filter
bearing (5).
- Tighten the screws (1) and lock them to the prescribed
couple.
88225
- Spline the pulley (2) on the engine drive shaft and tighten the ports and of the screws have no evidence of
the screws to the prescribed pair and angle (1). tear and wear nor dirt.
Figure 55
Figure 52
70221
88231
- Apply to the water pump (1) a new fixing ring (2). - Fit the alternator support (1) and tighten the screws (2)
fastening them to the prescribed pair.
Figure 56 4-cylinder engine

Figure 58
87676
4 75688
- Fit the bracket (1) back to fix the alternator (2) to the - Place the head (3) over the block and insert screws (1)
engine basement. Tighten the screws (3) fastening the and (2).
alternator to the support.
Figure 57 NOTE If the valves have been removed from the head, it
is necessary to assemble them before assembling
the head itself on the engine block.

D2 diameters:
D2 D1
75703
87670
Figure 59
- Place the gasket (1) over the block.
10 4 1 5 11
NOTE Verify that the engine block stand is clean.
Do not grease the gasket. It is recommended to 13 7 2 8 14
keep the gasket inside packaging until assembly to 9 3 6 12
the cylinder head.
Gasket assembly shall be made following the 76115
direction of wording printed on the gasket itself so - Lubricate cylinder head bolts and install to head.
that this will be readable as indicated in the picture. - 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.
- 1st phase of pre-tightening.
Screws 70 mm: 60 5 N.
- 2nd phase of angle tightening for all screws: 90 5
- 3rd phase of angle tightening solo per le viti da 140 e da
180 mm: 90 5
NOTE If not faulty the gasket can be reused.

6-cylinder engine Figure 62

Figure 60
1
3
2
2
1 3
75705
76152
- Place the head (3) over the block and insert screws (1) ROCKER ARM UNIT COMPONENTS:
and (2). 1. Elastic ring - 2. Spacer- 3. Rocker arms-
4. Support.
NOTE If the valves have been removed from the head, it - Carry out the assembly of the rocker arms after previous
is necessary to assemble them before assembling check of the components.
Figure 63
NOTE Before using the fixing screws again, measure them 18.975
twice as indicated in the picture, checking D1 and 18.963
D2 diameters:
D2 D1
75703
19.000 19.000
19.026 19.026
Figure 61 75704
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.
76214 Figure 64
- Lubricate cylinder head bolts and install to head.
- Bolts must be torqued using stitching pattern starting
90 degrees rotation for all bolts.
- 1st phase of pre-tightening. 13.00
Screws 70 mm: 60 5 N. 11.00
- 2nd phase of angle tightening for all screws: 90 5 116391
- 3rd phase of angle tightening solo per le viti da 140 e da

180 mm: 90 5 ROCKER ARM ADJUSTMENT SCREW
If unscrewed, check adjustment quota.
NOTE If not faulty the gasket can be reused. Tighten the screw-threaded nut (1) to the i 4 - 6 Nm couple.

Figure 65 Figure 68
2 1
75806
32655
Before executing assembly, check the Rocker Arm driving wrench (1), point wrench (3) and feeler gauge (2).
rods: these shall not be deformed; the spherical ends in Correct slack is:
contact with the Rocker Arm adjustment screw and with the
- suction valves 0.25 0.05 mm
tappet (arrows) shall not present evidence of seizure or wear:
in case of detection proceed replacing them. - exhaust valves 0.50 0.05 mm.
The rods driving the suction and exhaust valves are identical
and therefore interchangeable.
Figure 66 NOTE In TIER 3 engines, due to the presence of a
supplementary lobe, as regards the INTERNAL
E.G.R. the procedure of the regulation of the valve
clearance, which foresees the enforcement of the
D2 D1 clearance regulation of all valves by using only 2
movements of the engine shaft, cannot be used.
Each cylinder must be checked by bringing it up to
the U.D.C. (upper dead centre) at the end of
compression and by regulating the clearance of
both valves exclusively on the cylinder in question.
75703
- Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure them twice
as indicated in the picture, checking D1 and D2
diameters:
if D1 - D2 > 0,1 mm the screw must be replaced;
Figure 67
75683
- Tighten the screws (2) to the prescribed couple and

assemble water temperature sensor (1).

Figure 69 Figure 71
1
75707
117588
- Assemble injectors after having replaced the sealing
gasket (1). - Assemble thermostat unit (2) including thermostat (5)
and gasket (4).
NOTE During assembly of injectors, verify that the injector - Tighten the screws to the prescribed couple.
sphere is correctly positioned on the head housing.
NOTE The screws (1) have been have been utilised to fix
the bracket (3) (if available).
Figure 70 The gasket (4) must be new.
Figure 72
87409
- Tighten the fastening screws (2) and assemble the

exhaust collector with new sheaths.
- Apply the sheath to the assembly surface of the
induction collector plate and provide tightening the 76149
screws (1) to the prescribed pair.
- Assemble cylinder covers (2) with the respective gaskets;
- If the duct from the suction collector has been
disassembled, re-assemble it after having fitted the - Fit the seal nods and tighten the screws (1) fixing them
sheaths and the heater. to the prescribed couple.
NOTE 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.

Figure 73 Figure 76
87677
88309
- Assemble the ignition pump unit (1) into the gearbox - Assemble the support (3) of the automatic tightening
housing (2) and fix it, without tightening, throughout the device by fastening the relevant screws.
screws (3). - Tighten the fastening screw (1) and assemble the
automatic tightening device (2).
Figure 74 Figure 77
88308
- Assemble the support (1) of the fan pulley throughout

the screws (2) ) tightening them to the prescribed pair.
Figure 75 88310
- Assemble the Poli-V belt (4) on the pulley of the engine

drive shaft, on the water pump (5), on the alternator (1),
on the fan pulley (2) and on the transmission pulley (3).
NOTE Execute belt tightening operation working on the

belt tightening pulley (5).
In case the previously disassembled belt is going to
be reassembled, it is necessary to examine it
carefully first in order to detect any incision or
evidence of stress decay.
88306
- Assemble the fan pulley (2) to the support (1)

throughout the screws (3) tightening them to the pair.
- Assemble the transmission pulley (4).
Figure 78 Figure 80
88102 88218
- Assemble priming pump (1) providing new gasket and - Assemble the fastening brackets of the fuel pipes.
tighten the screws (2) to the prescribed couple.
- 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 79
88311
4. Connection nut to pumping elements - 5. Bracket fixing screw to injection pump side- -
6. Bracket fixing screw to injection pump side- - 7. Front bracket fixing screw (on suction collector plate) - 8. Injector.

Figure 81 Figure 83
70126
NOTE To connect fuel pipelines (2 and 3, Figure 82) in

87405 low pressure from the relating connection unions
it is necessary to press the locking fastener (1) as
- Fix the LDA pipeline (1) to the engine head and to the shown in picture B.
feed pump.
After having connected the pipeline, reset the
fastener (1) into block position as shown in picture
A.
Figure 82
4 Figure 84
3 1
87404 75675
Proceed assembling the turbocharger:

- Assemble the fuel filter bearing (4) to the bracket fixed
to the engine head. - Hold the turbocharger and place it on the exhaust
manifold after having interposed the gasket.
- Connect the fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one to - Screw up the fixing nuts of the turbocharger to the
feed pump. exhaust manifold tightening them to the prescribed
couple.
- Using 99360076 equipment assemble fuel filter (1).
- Tighten the lubrication pipe fixing ring. Operate in the
same way on the other end of the pipe. Connect it to
NOTE The filter shall be priory filled with fuel to facilitate the upper part of the heat exchanger.
feed system bleed operations. To complete engine assembly it is necessary to remove it
For the versions requiring it, connect the electrical from the turning stand.
connections of the sensor detecting presence of - Using rocker arm 99360595 hold the engine and loosen
water, and of the heater. the screws fixing the brackets to the turning stand
99322205.
- Disassemble the brackets from the engine after having
properly put it on a wooden bearing.

Completion of the engine Figure 86
Figure 85
88215 87712
On the right hand side: - Reassemble the starter;

- reassemble the lubrication oil exhaust pipeline (2) from properly hold the starter (2) and tighten the fixing screws
the turbocharger; (1) to the prescribed couple.
from underneath the turbocharger tighten the screws - Fill up engine oil.
(1).
Tighten the union (5) to the block. - Install the engine on the machine (for installation
operations please apply to specific issue).
- The oil level rod (4).
- Oil filter (3).

Rotary feed pump disassembly and assembly Search for top dead center throughout tool 99360339
procedure
Figure 88
NOTE This procedure prescribes that:
- The fuel pipelines (from pumping elements to
injectors, bleeding recovery pipes from
injectors to pump, LDA pipeline and feed
provided by priming pump) shall all be
disassembled.
- Electrical connection to feed pump shall be
disconnected.
- Accelerator cable shall be disconnected.
In case feed pump replacement is necessary, this shall be

supplied pre-set already as spare part. 88232
On the other hand, in case the pump shall be disassembled - Fit the racket of the tool 99360339 (1) holding the
and reassembled later on without being repaired it will be flywheel provided with the rotation coil (2).
necessary to pr-set it while it is still assembled to the engine - Carefully rotate the flywheel in its rotation director to
and disassemble it only afterwards. annul the gear slacks.
The following procedure analyses this second hypothesis - Rotate the flywheel until the pin (4) provided with the
since it is the more complex. tool 99360339 engages in the notch of the flywheel (3).
Search for top dead center throughout tool 99395097 -

Figure 87 False injector
Figure 89
87712
- Disassemble the starter (2) removing the screws (1).
88101
Remove the first injector, fit the tool 99395097 (2) and the
relevant dial gauge 99395604 (1) and remove the tappet
cover.
Apply tool 99360339 (see Figure 88) in order to make the
engine shaft rotate.
The condition of 1st cylinder to TDC at end of compression
phase is obtained when the dial gauge pointer reaches
maximum value and suction and exhaust valves are both
closed and not balancing.
Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 88).
Figure 90 Figure 93
88102
- After having disconnected fuel pipes of the priming

pump, loosen the fastening screws (2) and remove the
87717
pump (1) from the basement (3).
Figure 91 - On timing system side, take cover off gear box to access
pump control gear securing nut.
- Remove nut securing injection pump gear.
- Remove the three nuts (2), (3), (5) fastening the ignition
pump (1) to the basement (4) and withdraw it from their
own housing.
- Reattach the ignition pump following the same order
followed to execute disassembly, in reverse.
Figure 94
87715
- Check, through the priming pump housing, that the

camshaft (1) is in (TDC) end of compression phase,
throughout the notches (2) on said shaft.
If the notches are not visible, unlock the flywheel and
rotate the engine of 360_ until the notches are visible.
Lock the flywheel.
Figure 92
87718
- At the time of assembling the feed pump to the engine

it is necessary to ensure T.D.C. conditions to the cylinder
no.1 in phase of compression, as described previously
(Figure 84 or 85).
- Assemble the ignition pump unit (1), preset , into the
gearbox housing (2) and fasten it, without tightening it,
throughout the screws (3).
87716
- Loosen the screw (2), remove the L spacer (1) and

lock the screw (2) to keep the pump timed with the NOTE The gasket removed during pump disassembly shall
engine flywheel. not be utilised again.
- Duly keep the L spacer with the pump unit. Always use original spare parts.

Figure 95 Figure 97
2 1
88148 88102
- Loosen screw (1) that prevents pump shaft rotation and - Assemble the priming pump (1) to the basement (3) and
insert spacer (2). Tighten screw (1)so that it locks spacer tighten the fastening screws (2) to the prescribed pair.
(2): in this way the suppl pump shaft will be able to rotate
- Connect all pipelines (from pumping elements to
freely.
injectors, bleeding recovery pipes from injectors to
- Unlock the engine flywheel. pump, LDA pipeline and feed provided by priming
pump).
- Remove the flywheel rotation locking tool 99360339;
place the starter into its housing. - Connect electrical connections to electro-magnets on
the hydraulic head and on KSB.
Ignition pump control and timing

NOTE In case pump removal has been carried out while
Figure 96 the engine was assembled, connect acceleration
cable.
88312
- With the ignition pump fitting into its housing and with
loosened fastening screws, remove the closure cap
placed over the pump cover.
- Fit the dial gauge 99395603 (2) and the relevant tool
99395100 (1), pre-loading the rod by 2,5 mm.
- Rotate the engine derive shaft to shift from the condition
of the first cylinder to TDC end of compression phase.
Reset the dial gauges and rotate the engine drive shaft
into the opposite direction until recovering the
condition of the 1st cylinder to TDC in phase of
compression (see Figure 84 or 85).
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.
Feed system bleed procedure Checks and inspections
Figure 98 NOTE The following tests shall be made after engine

assembly to the vehicle.
Preventively check that the liquid levels have been
correctly restored.
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:
- there is no water bleeding from the manifolds

connecting engine cooling circuit pipelines and cabin
88304
internal heating, eventually providing to further tighten
In case any operation has been executed on the components
the locking rings.
of the feed circuit, it is necessary to execute bleeding of air
within the system. - Carefully check the fuel connection pipes to the
respective unions.
- Disconnect the fuel pipe (1) of the filter and repeat
working on the drain lever (2) of the priming pump. - There is no oil leakage from the lubrication circuit of the
various pipelines connecting cover and.
- Continue the operation until when fuel outflows.
- Cylinder head, oil pan and bearing, oil filter and heat
- Connect the (1) to the filter.
exchanger as well as relating housings.
- There is no fuel leakage from fuel pipelines.
- There is no blow-by from pneumatic pipes (if provided).
Power takeoff - Verify correct working of the lighting leds of the
dashboard containing the tools as well as of the
Figure 99 equipment that was disconnected during engine
disconnection.
- Check and blow by with care the engine cooling system,
carrying out frequent drainage.
88230
For the engines with power takeoff, operate as follows:

- loosen the 2 fastening screws (1) and remove the cover
(2).
- Insert the device utilizing the fastening points available.

PART TWO -


ELECTRICAL COMPONET LAYOUT

Figure 100
88320
The electrical components available on the 6-cylinder NEF

engines are listed here following.
1. Cooling liquid temperature sensor;
2. Starter;
3. Resistor for cold start;
4. KSB Water temperature sensor;
5. Electromagnets assembled to feed pump:
(A) on hydraulic head unit
(B) on KSB;
6. Oil pressure switch;
7. Fuel heater (C) and water detecting sensor (D) (where
available);
8. Speed sensor;
9. Alternator.

Cooling liquid temperature sensor Starter

Figure 101 Figure 102
88314
Starter is usually driven by starting unit placed on the vehicle

dashboard and provides positive tension to the tele-switch
assembled to the starter itself.
C
Specifications:
A B BOSCH 3 kW - 12V
A C
B
75718
Pre-post heating resistor
Figure 103
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 -40 130 C/(+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 75723
-10 C 8.244 10.661 k 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 tensions: 12 V
Maximum possible
Air flow: 2 cc / min
(pressure 138 kPa)

Pre-post heating unit KSB Water temperature sensor
+0 30
F 15 7
4
6 GH F
30 50 5
NTC 10 GHC T
31 8
N31
1 3 FB
1.2W R
75719
88153 It is assembled to the cylinder head on the engine left hand si-
de.
Legend
Specifications:
F= Fuse
R= Pre-post heating resistance Working tensions: 12 24 V
T= Remote control switch
GHC = Pre-post heating unit Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 633C Contact opening
Electrical diagram pin out upon increasing temperatu-
re
533 C Contact closure
upon decreasing tempera-
PIN Description ture
1 Output for cold start warning light
2 Not connected
3 Feedback signal input from pre-post heating
resistance (FB)
4 Started engine signal input (D)
5 Start-up signal input (50)
6 Pre-post heating resistance supply remote
control switch output (GH)
7 Supply positive (15)
8 Supply negative (31)
9 Not connected
10 Temperature analogue signal input (NTC)
This unit operates, by means of the remote control switch, the

pre-post heating resistance according to the engine coolant
temperature.
Features:
Working tensions: 12 V
Operating voltage: 7 V 16V
Operating temperature: -40C 85C
Maximum current in the GH line: 0.3A
Electromagnets assembled to feed pump Fuel filter
88321
1 - Hydraulic head Electro-magnet; 2 - KSB

Electro-magnet
Oil pressure switch

88319
Figure 108
1. Heater - 2. Water detecting sensor.

On the basis of the fuel filter there is a sensor detecting the
presence of water. For the use requiring it ( use in cold climate
conditions) a heater provided with connector for heat
resistance of the fuel filter may be interposed between the
filter support and the filtering cartridge.
75722
It is assembled to the block on the engines left hand side.

Specifications:
Contact closure
upon lower pressure: 0.6 bar
Contact opening
upon higher pressure: 0.9 bar

Speed sensor Alternator

It is an induction type sensor and it is placed on the front part
of the engine. It generates signals obtained from magnetic flow Figure 111
lines.
Figure 109
88315
75725
Figure 110
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
88316
Pin out
PIN Description
1 Signal
2 Signal
3 Screening


PART THREE -
TROUBLESHOOTING


Print P2D32N003 E
F4CE N ENGINES
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine does not start Battery flat or faulty. Check and recharge battery. Replace bat-
tery if necessary.
Connections to battery terminals cor- Clean, examine and tighten the nuts on
roded or loose. the battery terminals. Replace the cable
terminals and the nuts if excessively cor-
roded.
Incorrect timing of injection pump. Check and correctly time the injection See your Iveco dealer.
pump.
Deposits or water in the fuel tank. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air.
Dismantle and clean the injection pump.
Remove water from tank and refuel.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or transfer
pump.
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in
pump. fact present and also check the fuel pump.
Eliminate the air from the injection pump
by unscrewing the cap and working the
fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.

Base - May 2010
43
Base - May 2010
44
The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use

peratures forming due to the use of unsuitable fuel. at low temperatures. Replace the fuel fil-
ters.
K.S.B. device for cold spark advance con- Check or replace the injection pump. See your Iveco dealer.
trol operating incorrectly.
The engine cuts out. Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection pump. Adjust flow. See your Iveco dealer.
Impurities or water in the fuel lines. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air. Dismantle
and clean the injection pump. Remove
water from fuel tank and refuel.
Clogged fuel filter. Dismantle and replace if necessary.
Presence of air in the fuel and injection Check that the hoses are not cracked or
system. the unions loose. Replace worn parts, re-
move the air from the hoses and deaerate
the injection pump and fuel filter by un-
screwing the caps and working the primer
pump by hand.
Broken injection pump controls. Replace the faulty parts.
Abnormal clearance between camshaft Adjust clearance by replacing shims.
cams and tappets.
Burnt, corroded or chalky valves. Replace the valves, rectify or replace the
cylinder head seatings.
F4CE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4CE N ENGINES
The engine overheats Faulty water pump. Check the unit and replace if necessary.
Replace the gasket.
Malfunctioning thermostat. Replace the thermostat.
Fouling in coolant openings in the cylinder Wash following the standards specified
head and cylinder groups. for the type of descaling product used.
Water pump drive belt slack. Check and adjust the tightness of the belt. On applications provided with automatic
tensioner, check corret worching of such
device.
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injection pump. Correct the delivery rate of the pump on See your Iveco dealer.
a bench so that the injection is at the
specified rate.
Dry air cleaner blocked. Clean the air filter or replace if necessary.
Engine operation is irregular and lacks Incorrect timing of injection pump. Check timing and correctly set pump.
power
K.S.B. automatic cold advance device mal- Check or replace injection pump.
functioning.
Excessive piston wear. Check or replace injection pump.
Incorrect calibration of speed regulator. Check and correctly calibrate the regula- See your Iveco dealer.
tor.

Base - May 2010
45
Base - May 2010
46
Engine operation is irregular and lacks Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using

power ation of injectors. the appropriate tools and completely
overhaul the injectors.
Impurities or water in the fuel and injec- Carefully clean the system and refuel. If necessary drain feed system.
tion system.
Incorrect play between camshaft cams Check and correct play
and tappets.
Faulty turbocharger. Replace complete unit.
Air cleaner blocked. Clean or replace air cleaner.
Faulty operation of L.D.A. device Check that the diaphragm is not perfor- See your Iveco dealer.
ated, that the counter spring is suitable
and that it has the correct loading (check
on test bench).
Check that there is adequate air pressure
inside the intake manifold in relation to
the engine rpm under full-load conditions.
Tie rods between accelerator pedal and Adjust the tie-rods so that the command
regulation lever incorrectly adjusted. lever can be moved to the full delivery
position.
Engine running with abnormal knocking Faulty operation of injectors. Replace all injectors.
Fuel lines blocked. Dismantle the hoses, clean them and re-
place those that are seriously dented.
Incorrect set-up of injection pump. Correct the set-up of the pump so that in- See your Iveco dealer.
jection occurs at the specified angle.
F4CE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4CE N ENGINES
Engine running with abnormal knocking Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and in-
play on one or more main or rod bearings stall smaller bearings. Replace the thrust
or excessive play on shoulders. half-rings.
Crankshaft unbalanced. Check alignment of crankshaft.
Loosening of screws securing flywheel. Replace the loosened screws and tighten
all the screws to the specified torque.
Misalignment of rods. Replace the rods.
Noise from piston journals due to excess- Replace the piston journal and/or the pis-
ive play of piston hubs and in the rod ton and rod bushing.
bushing.
Loose bushings in the rod seatings. Replace with new bushings.
Noisy timing. Adjust the play between camshaft cams
and tappets and check that there are no
broken springs, that there is no excessive
play between the valve stems and the
valve guides, tappets and seatings.
The engine smokes abnormally. Black or Excessive maximum pump output. Disconnect the pump and adjust delivery See your Iveco dealer.
dark grey smoke. in accordance with the data given in the
calibration table.
K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust
tioning. correctly as described in the manual.
There is an excessive delay on the injec- Correct the set-up.
tion pump.

Base - May 2010
47
Base - May 2010
48
The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up.

dark grey smoke. vance.
The holes in the atomisers (or some of Replace the injectors with a series of new
them) are partially or entirely blocked. injectors or clean and rectify the original
ones using suitable equipment.
Air cleaner blocked or deteriorated. Clean or replace the filter element.
Loss of compression in the engine due to: Overhaul the engine or limit the interven-
tions to the relative parts.
stuck or worn flexible rings;
worn cylinder liners;
valves deteriorated or badly adjusted.
Unsuitable injectors, different types of in- Replace or calibrate the injectors.
jectors or incorrectly calibrated.
Injection hoses with an unsuitable internal Check conditions of the end or unions
diameter, end of hoses pinched due to re- and where necessary replace the hoses.
peated blocking.
Blue, grey-blue, grey smoke tending to Excessive delay in injection pump. Correct the set-up of the pump. See your Iveco dealer.
white.
K.S.B. automatic cold advance device mal- Check or replace injection pump. See your Iveco dealer.
functioning.
Faulty injector. Replace the injector.
Leaking of oil from the piston rings caused Overhaul the engine.
by glued or worn rings or wearing of cylin-
der liner walls.
Engine oil passing through the intake Recondition the cylinder head.
guides-valves following wearing of guides
or valve stems.
Engine too cold (thermostat blocked or Replace the thermostat.
inefficient).
F4CE N ENGINES
Print P2D32N003 E
PART FOUR -


Recovery
Planning of controls and periodical intervention
Controls and periodical intervention Frequency (hours)

Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
FPT.


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.
MAINTENANCE PROCEDURES Figure 113

Checks and controls
Engine oil level check.
and possibly cool.

rod (1).
Figure 112
87757
To provide filling, operate through the upper top (1) or

through the lateral top (2). During filling operation, the tops
flow easier.
Some applications are equipped with a level transmitter
87756 alerting dashboard instruments in case of insufficient
lubrication oil within the pan.
the etched tags of minimum and maximum level. The engine oil is highly polluting and harmful.
Whether it should be difficult to make the evaluation, proceed and detergent.
cleaning the rod using a clean cloth with no rag grinding and Adequately protect the skin and the eyes, operate
put it back in its slot. Draw it off again and check the level. in full compliance with safety regulations.
In case the level results being close to the tag showing Disposal must be carried out properly, and in full
minimum level, provide filling lubrication of the engines compliance with the law and regulations in force.
components.

Check of fuel system Lubricating system check

The check must be executed both when the engine The check must be executed both when the engine
disconnected and when it is running. disconnected and when it is running.
running from the tank to the pre-filter (if provided in the Verify the presence of any oil leakage or blow-by from the
specific equipment), to the filter, to the injection pump and to head, from the engine pan of from the heat exchanger.
the injectors.
The engine oil is highly polluting and harmful.

Cooling system check
The check must be executed both when the engine In case of contact with the skin, rinse well with water
disconnected and when it is running. and detergent.
Check the pipelines from the engine to the radiator, from the Adequately protect the skin and the eyes, operate in
expansion tank and vice-versa. Find out any blow-by, verify the full compliance with safety regulations.
Verify that the radiator is clean, the correct working of the fan compliance with the law and regulations in force.
Due to the high temperatures achieved by the

system, do not operate immediately after the engines Check of water presence within fuel filter or pre-filter
disconnection, but wait for the time deemed
necessary for the cooling.
Protect the eyes and the skin from any eventual high NOTE The components of the system can be damaged
pressure jet of cooling liquid. 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
The density of the cooling liquid must be checked any how drainage of the water within the feed circuit.
every two year.
Fuel filter is equipped with pump screw-valve to drain the

water eventually mixed with fuel (some applications of 6
NOTE In case of new filling, proceed bleeding system, cylinders engines will be equipped with two fuel filters, both
through the bleeds on the engine. provided with drainage.
Place a container underneath the filter and slightly loosen the
If bleeding of the system is not carried out, serious screw. Drain the water eventually contained in the filters
inconvenience might be caused to the engine due bottom.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.

Check of drive belt tensioning Check and setting of tappet clearance

Some applications are equipped with an automatic tensioner Figure 114
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.
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.
87673

wrench (1), box wrench (3) and feeler gauge (2).
Clearance shall be as follows:
NOTE In TIER 3 engines, due to the presence of a

supplementary lobe, as regards the INTERNAL
E.G.R. the procedure of the regulation of the valve
clearance, which foresees the enforcement of the
clearance regulation of all valves by using only 2
movements of the engine shaft, cannot be used.
Each cylinder must be checked by bringing it up to
the U.D.C. (upper dead centre) at the end of
compression and by regulating the clearance of both
valves exclusively on the cylinder in question.

Oil motor and filter replacement Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in different
Warning: We recommend to wear proper protec- positions: the following procedure is a valid guide for all applica-
tions because of high motor service temperature. tions.
The motor oil reaches very high temperature: you - The filter is composed by a support and a filtering cartridge.
must always wear protection gloves. For the cartridge replacement use the 9936076-tool.
Due to the several applications, the pan shape and the oil
quantity can change slightly. However, the following oper- Warning: the oil filter contains inside a quantity of oil
ations are valid for all applications. of about 1 kg.
We recommend to carry out the oil drainage when the motor Place properly a container for the liquid.
is hot. Warning: avoid the contact of skin with the motor oil:
- Place a proper container for the oil collecting under the in case of contact wash the skin with running water.
pan connected with the drain plug. The motor oil is very pollutant: it must be disposed of
- Unscrew the plug and then take out the control dipsick according to the rules.
and the inserting plug to ease the downflow of the
lubrication oil.
manually until when the gasket is in contact with the
support.
The oil motor is very pollutant and harmful.
- Tigthen by means of the 99360076-tool of three fourth
In case of contact with the skin, wash with much turn.
water and detergent.
- Operate the motor for some minutes and check the level
Protect properly skin and eyes: operate according to through the dipsick again. If it is necessary, carry out a
safety rules. topping up to compensate the quantity of oil used for the
Dispose of the residual properly following the rules. filling of the filtering cartridge.

features.
is next to the maximum level notch indicated on the
dipsick.

Fuel filter replacement Alternator belt - water pump replacement

During this operation dont smoke and dont use free
! flames.
Avoid to breathe the vapors coming from filter.
NOTE After filters replacement the supply equipment

deaeration must be carried out.

tity can change.
88305
- Drain the fuel inside the filter by operating the water
release screw. Collect the fuel in a container without - Using a suitably-sized square-head wrench, work on point
impurities. A indicated in the illustration, lower the pressure and
unthread the Poly-V belt (3) from the control and guide
- Unscrew the cartridge by using the 99360076-tool. pulleys.
- Collect the eventual fuel inside the filtering cartridge. - Assemble the Poly-V belt (3) on the engine shaft pulley,
- Clean the gasket seat on the support and oil slightly the on the water pump, on the alternator (1), on the
gasket on the new filtering cartridge. ventilator and drawback pulleys.


F4CE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1
SECTION 4
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . . 4
INJECTION PUMP PUMPING ELEMENT

PRE-LIFT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE REMOVAL AT THE BENCH . . . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Checking head supporting surface on

cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Checking output shaft shoulder clearance . . . 20
CONNECTING ROD PISTON ASSEMBLY . . . . 20
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4CE N ENGINES
Page Page
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Conditions for proper pin-piston
coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 - Checking cylinder head supporting surface . . . 29
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Removing carbon deposits, checking and
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 23 grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - Checking clearance between valve stem and

valve guide and valve centering . . . . . . . . . . . . 30
- Fitting connecting rod-piston
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Connecting rod-piston coupling . . . . . . . . . . . . 25 VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Fitting connecting rod-piston assembly into
cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . 26 FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . 33
- Finding crankpin clearance . . . . . . . . . . . . . . . . 26 - Refitting the cylinder head . . . . . . . . . . . . . . . . 33
- Checking piston protrusion . . . . . . . . . . . . . . . 27 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . 34


Injection Direct
Number of cylinders 4 6

Bore mm 104
Stroke mm 132
TIMING
start before T.D.C. A 15

end after B.D.C. B 35

Checking timing
mm 0.25 0.05
X X
mm 0.50 0.05
FUEL FEED
Injection
Type: Bosch VE 6/12F
Nozzle type DSLA 145 P
Injection sequence 1-3-4-2 1-5-3-6-2 -4
bar
Injection pressure bar -

CLEARANCE DATA

1
X
1 0.4
Pistons
1
X Size X 55.9
Outside diameter 1 103.714 to 103.732
2 Pin housing 2 38.010 to 38.016
X
3 Piston pin 3 37.994 to 38.000

X1 X 1* 2.705 to 2.735*
Split ring slots X2 2.440 to 2.460
X2
X3 4.030 to 4.050
X3
S 1 S1 2.560 to 2.605
S2 Split rings S2 2.350 to 2.380
S3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110
3 0.040 to 0.080
Split rings 0.4
X1 Split ring end opening
X2 in cylinder barrel:
X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3
Small end bush diameter
S Inside 3 38.019 to 38.033
Big end half bearings S 1.955 to 1.968


X
Size X -
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82,990 to 83,010
Crankpins 2 68,987 to 69,013
S1 S 2 Main half bearings S1 2.456 to 2.464

Big end half bearings S2 1.955 to 1.968
Main bearings
3 No. 1 - 7 / 1 - 5 3 87.982 to 88.008
No. 2-3-4-5-6 / 2-3-4 3 87.977 to 88.013

No. 1-7 / 1-5 0.041 to 0.119
No. 2-3-4-5-6 / 2-3-4 0.041 to 0.103
Main half bearings
0.250 ; 0.500
X1
X2
X3


1

4 Valves:
4 7.960 to 7.980
60
4 7.960 to 7.980
45

Housing on head for
valve seat:
1 46.987 to 47.013
1 1 43.637 to 43.663

head:
2 47.063 to 47.089
60o
2 43.713 to 43.739
45o

X 1 to 1.52
Sinking
X X 1.05 to 1.52
0.050 to 0.102
Between valve seat
and head 0.050 to 0.102
Valve seats -


free spring H 63.50

H H1
H2 under a load equal to:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X not adjustable

X
Camshaft bush
housings No. 1-5 59.222 to 59.248
Camshaft housings
No. 2-3-4-5 / 2-3-4-5-6-7 54.089 to 54.139
1 23 4 5
2
Camshaft journals:
15 53.995 to 54.045
17
1 3
Bush inside

Housings and journals 0.044 to 0.144
Cam lift:
H H 11.02
H 10.74


1
Tappet cap housing
on block 1 16.000 to 16.030
2
diameter: 2 15.929 to 15.959
3 15.965 to 15.980
2
Tappets -
1
Rockers 2 19.000 to 19.026
2

INJECTION PUMP PUMPING ELEMENT PRE-LIFT TABLE
Technical Commercial Pre-lift

Code Code (mm)
4-CYLINDER ENGINES F4CE9484F*J600 N45 MRT.X 0.80 0.05
F4CE9684N*J6.. N67 MRT.X 1 0.05
6-CYLINDER ENGINES
F4CE9684L*J6.. N67 MRT.X 1 0.05
NOTE INJECTION PUMP CALIBRATION

Overhaul and calibration interventions are up to BOSCH assistance network.
The contract technical specification containing the data to calibrate the pump at the bench is identified by the code shown
on injection pump body and is available at BOSCH technical assistance network.
Otherwise, refer to FPT Technical Assistance Service.

ENGINE OVERHAUL Figure 3

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.
70160
The second last main bearing cap (1) and the relevant
Figure 1 support are fitted with shoulder half-bearing (2).

assembling positions since in case of reuse they
shall be fitted in the same position found at
removal.
Figure 4
70158
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.

74774
found at removal.
With tool 99360500 (1) and hoist, remove the engine shaft
from the (2) engine crankcase.
Figure 5
Figure 2
87754
70159 Disassemble the bench half-bearings (1).

Remove the screws (1) and the main bearing caps (2). For the supercharged engines, withdraw the screws (2) and
disassemble the oil sprayers (3).
If present, remove nozzles from the (4) workbench supports.
zs

CYLINDER UNIT
Figure 9
70163

plate (2).
NOTE Take note of plate (2) assembling position. 70166

cylinder-block assembly.
Figure 7 The engine block shall not show cracks.
Inspect cylinder barrel surfaces; they shall be free from seizing,

70164
Figure 10
Figure 8
70167

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
70165
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.

bearings;

unit
107804

oversize (0.4 mm).
TIMING SYSTEM
Camshaft
Figure 12
70512
CAMSHAFT MAIN DATA (6 cyl.)

The data reported refer to standard diameter (dimensions in mm) of pins


Set the camshaft on the tailstock and using a 1/100 gauge set Figure 14
on the central support, check whether the alignment error
Figure 13
70172

Use bore dial gauge (3) to measure camshaft front and rear
bush (2) and intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.
70171

Figure 15
sec. A-A
107268
CAMSHAFT BUSH AND HOUSING MAIN DATA (6 cyl.)

* Value to be obtained after driving the bush (dimensions in mm).

Bush replacement Fitting tappets camshaft

Figure 16 Figure 18
70176
70174
housings on the engine block.
To replace front and rear bushes (1), remove and refit them Figure 19
using the beater 99360362 (2) and the handgrip 99370006
(3).
NOTE When refitting the bushes (1), direct them to make

the lubricating holes (2) coincide with the holes on
the block housings.
Tappets
Figure 17 70164
Lubricate the camshaft bush and fit the camshaft (1) taking
care not to damage the bush or its housing.
Figure 20
84053
70238
MAIN DATA CONCERNING THE TAPPETS AND THE
(dimensions in mm). Set camshaft (3) retaining plate (1) with the slot facing the
then tighten the screws (2) to the specified torque.

Figure 21 OUTPUT SHAFT

Measuring journals and crankpins
Figure 23
70179
70182
It shall be 0.23 0.13 mm. Grind journals and crankpins if seizing, scoring or excessive
Figure 22 them with a micrometer (1) to decide the final diameter to
Undersize classes are: 0.250 - 0.500 mm.

Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
87755 For undersized crankpins: letter M
For supercharged engines: For undersized journals: letter B
Fit nozzles (2) and tighten the fastening screws (1) to the For undersized crankpins and journals: letters MB
specified torque.
Fit (if disassembled) the nozzles (3) into the bench supports.


Figure 24
107269
*Rated value (dimensions in mm)
Figure 25


Figure 26

70237

Roundness
SHAPE
Cilindricity //
Parallelism //
Straightness
OSCILLATION
Total oscillation

CRITICAL
IMPORTANT
SECONDARY


Figure 29
Figure 27
74774
With tool 99360500 (1) and hoist, re-assemble the engine

shaft inside the engine crankcase (2).
Check the backlash between output shaft main journals and
87741 the relevant bearings as follows:
Check that the toothing of the threaded bush (1) splined on
the engine drive shaft (2) has no damage neither wear and
in case it has, provide executing two diametrically opposite
radial grooves on the bush (1) and proceed with extraction Figure 30
using the specially provided grab.
In phase of assembly of the new grooved bush, it is necessary
to heat the latter into an oven, for maximum 60 , at constant
temperature of 160 C, then spline it on the engine drive
shaft.
Figure 28
70186

- position a piece of calibrated wire (3) on the output shaft
- fit caps (1), including the half bearings (2) on the relevant
supports.
70185

replaced, in the same position found at removal. Figure 31
D2 D1
Main bearings (1) are supplied spare with 0.250 0.500 mm
undersize on the internal diameter.
75703
- At final assembly, before re-using the bench support
fastening screws, measure them twice as indicated in the
picture, checking D1 and D2
diameters:
Clean accurately the main half bearings (1) having the if D1 - D2 < 0,1 mm the screw can be utilised again;
lubricating hole and fit them into their housings. if D1 - D2 > 0,1 mm the screw must be replaced;
half rings.

Figure 32 Checking output shaft shoulder clearance
Figure 35
70187

successive stages:
- 1st stage, with dynamometric wrench to 50 6 Nm. 70190
- 2nd stage, with dynamometric wrench to 80 6 Nm. This check is performed by setting a magnetic-base dial gauge
(2) on the output shaft (3) as shown in the figure, standard
Figure 33
value is 0.068 to 0.41.
check between output shaft pins and main half bearings.

70188
- 3rd stage, with tool 99395216 (1) set as shown in the
Figure 36
Figure 34
70191
70189
- Remove caps from supports. COMPONENTS
The backlash between the main bearings and the pins is 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
found by comparing the width of the calibrated wire (2) at 6. Half bearings - 7. Connecting rod - 8. Bush.
Figure 37 Pistons
Figure 39
32613
32615
Using a micrometer (2), measure the diameter of the piston

Remove split rings (1) from piston (2) using pliers 99360183 (1) to determine the assembly clearance.
(3).
NOTE The diameter shall be measured at 55.9 mm from

the piston skirt.
Figure 40
Figure 38
70192
32614

Figure 41
87730
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

(dimensions in mm)
Piston pins Split rings

Figure 42 Figure 44
18857

16552
(2).
Figure 43 Figure 45
32619 32620
Lubricate the pin (1) and its seat on piston hubs with engine Check the clearance between the sealing rings (3) of the 1st
oil; the pin shall be fitted into the piston with a slight finger slot (only for pistons of supercharged engines), of the 2nd and
pressure and shall not be withdrawn by gravity. 3rd slot and the relevant housings on the piston (2), using a
feeler gauge (1).

Figure 48
41104

TRAPEZOIDAL RING
(supercharged engines only)
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X) 88607
between ring and slot: found value shall be the specified one.
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON

Figure 47

knurls.
70194


Figure 49
CONNECTING ROD CAP
YEAR DAY
CONN. ROD BODY
CONN.
WEIGHT
ROD No.
CONNECTING ROD CAP
CONNECTING ROD No.
87742
Bushes
NOTE Every connecting rod is marked as follows: Check that the bush in the connecting rod small end is free
- On body and cap with a number showing their from scoring or seizing and that it is not loosen. Otherwise
coupling and the corresponding cylinder. replace.
In case of replacement it is therefore necessary Removal and refitting shall be performed using the proper
to mark the new connecting rod with the same beater.
numbers of the replaced one.
- On the body and on the top by numbers on the bush with those set on the connecting rod small end.
indicating number of connecting rod and date Grind the bush to obtain the specified diameter.
of production and by a coloured identification
mark.
- On body with a letter showing the weight of
S V, 1600 to 1640 g (yellow marking);
S W, 1641 to 1680 g (green marking);
S X, 1681 to 1720 g (blue marking);
green marking *.

Fitting connecting rod-piston assembly Figure 52

Figure 50
72705
87731 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 piston crown is marked as follows: the split rings (2).
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Marking showing 1st slot insert testing;
4. Manufacturing date.
Fitting split rings
Figure 53
Figure 51
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
other by 120.

87732
sizes:
Connect piston (2) to connecting rod (4) with pin (3) so that - standard;
the reference arrow (1) for fitting the piston (2) into the - 0.4 mm oversize.

Figure 54 Figure 56
87733
DIAGRAM FOR CONNECTING ROD-PISTON

ASSEMBLY FITTING INTO BARREL
70200 120;
Fit half bearings (1) on connecting rod and cap. - connecting rod-piston assemblies shall have the same
weight;
NOTE Refit the main bearings that have not been front side of the engine block or the slot obtained on the
replaced, in the same position found at removal. piston skirt shall be corresponding to the oil nozzle
Do not try to adapt the half bearings. position.

Figure 57

cylinder barrels
Figure 55
70203

(1);
bearings (4).

D2 diameters:
70201
Lubricate accurately the pistons, including the split rings and D2 D1
- the number of each connecting rod shall correspond to 75703

Revi - February 2007
Figure 58 Figure 61
70204
- Lubricate the screws (1) with engine oil and then tighten 70207
them to the specified torque using the dynamometric

wrench (2). (60 to 5 Nm) 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
Figure 59 connecting rod cap fastening screws to the specified torque.
NOTE 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.

70205

tighten screws (2) of 60. Checking piston protrusion
Figure 62
Figure 60
70208
Once connecting rod-piston assemblies refitting is over, use

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

Removing the valves
1 2
Figure 63 3
4
1
2 6
A 75751

75750
Overturn the cylinder head and withdraw the valves (5).
Figure 65
2
A = intake side
75752


Figure 66
A
B
87735
The rated thickness A for the cylinder head is 95 0.25 mm,

116357 max. metal removal shall not exceed thickness B by 0.13 mm.

Use a pump to fill with water heated to approx. 90C and 2
to 3 bar pressure. NOTE After grinding, check valve sinking. Regrind the
Replace the cup plugs (1) if leaks are found, use the proper valve seats, if required, to obtain the specified value.
beater for their removal/refitting.


exceed 0.20 mm.

VALVES Figure 70
Figure 68
EXHAUST INTAKE
VALVE VALVE
18882

116395
7.960 7.980.
Removing carbon deposits, checking and Checking clearance between valve stem and
grinding valves valve guide and valve centering
Figure 69 Figure 71
18625
Remove carbon deposits from valves using the proper metal 87738
brush.
Check that the valves show no signs of seizing, scoring or Use a magnetic base dial gauge (1) set as shown in the figure,
cracking. the assembling clearance shall be 0.052 0.092 mm.
Regrind the valve seat, if required, removing as less material Turn the valve (2) and check that the centering error is not
as possible. exceeding 0.03 mm.


Figure 72
Figure 73
75754
Check the valve seats (2). If slight scoring or burnout is found,

regrind seats using adequate tool (1) according to the angle
values shown in Figure 74.
INTAKE EXHAUST
84046
Use a bore dial gauge to measure the inside diameter of the

Figure 74
88368
VALVE SEAT MAIN DATA (dimensions in mm)

A = exhaust valve
B = intake valve
Figure 75
116356
VALVE SEAT HOUSING MAIN DATA (dimensions in mm)

A = exhaust valve
B = intake valve
them with the spare ones. Use adequate tool to remove as beater, fit the new valve seats, previously cooled, into the
Use adequate tool to regrind the valve seats according to the
VALVE SPRINGS
Figure 77
Figure 76
50676

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.

87740
mm N
H (free) 63,50 no load
After regrinding, check that valve (3) sinking value is the H1 49,02 P1 329
H2 38,20 P2 641
gauge 99395603 (1).
FITTING CYLINDER HEAD Refitting the cylinder head

Figure 78 Figure 80
3 1
1
70335
2
Check cleanness of cylinder head and engine block coupling
surface.
75759 Take care not to foul the cylinder head gasket.
Lubricate the valve stems (1) and fit them into the relevant facing the head.
valve guides according to the position marked at removal. The arrow shows the point where the gasket thickness is
Fit the sealing rings (2 and 3) on the valve guide. given.
Figure 81
Figure 79
1 2
3
4
88775
6
There are two types of head seals for F4AE04.., F4AE06.. and
F4HE06.. engines, for the thickness (1.25 mm Type A and
1.15 mm Type B) take the following measures:
5 - for each piston detect, as indicated on Figure 81, at a
75751 upper plane then calculate the average:
Position on the cylinder head: the protection cap (5), the S cil1 = S1 + S2
spring (4), the upper cap (3); use tool 99360268 (1) to 2
compress the spring (4) and lock the parts to the valve (6) Repeat the operation for pistons 2, 3, 4, 5 and 6 and
by the cotters (2). calculate the average value.
S + S cil2 + S cil3 + S cil4 + S cil5 + S cil6
S = cil1
6

D2 diameters:
D2 D1
75703

TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15 3 1.5 0.3
Main bearing cap 1st stage 50 6 5.0 0.6
2nd stage 80 6 8.0 0.6
3rd stage 90 5
Rear gear housing assembly
(M8x1.25x40) 24 4 2.4 0.4
(M8x1.25x25) 24 4 2.4 0.4
(M10x1.5) 49 5 4.9 0.5
Front cover assembly - Oil pump
(M8x1.25x45) 24 4 2.4 0.4
(M8x1.25x30) 24 4 2.4 0.4
Connecting rod bolts(M11x1.25) 1st stage 30 3 3.0 0.3
2nd stage 60 5 6.0 0.5
3rd stage 60 5
Ladder frame assembly (M10x1.25x25) 43 5 4.3 0.5
Oil rifle plugs
(M10x1) 61 0.6 0.1
(M14x1.5) 11 2 1.1 0.2
Assemble oil suction tube (M8x1.25x20) 24 4 2.4 0.4
Oil pan assembly
(M8x1.25x25) 24 4 2.4 0.4
(M18x1.50) 60 9 6.0 0.9
Set timing pin 51 0.5 0.1
Fuel pump assembly
M8 screw 24 4 2.4 0.4
M6 screw 10 1 1.0 0.1
M6 nut 10 1 1.0 0.1
M10x1.5 flange head nuts pre-torque 10 - 15 1.0 - 1.5
Final torque 50 - 55 5.0 - 5.5
Fuel pump gear (drive gear nut) Snug torque 15 - 20 1.5 - 2.0
Final torque 85 - 90 8.5 - 9.0
Timing pin cap of fuel pump 30 - 35 3.0 - 3.5
Equalizer fastening to cylinder head (M8) 24 4 2.4 0.4
Cylinder head bolts
(M12x70) 50 + 90 5.0 + 90
(M12x140) 40 + 180 4.0 + 180
(M12x180) 70 + 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 2.4 0.4
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) 24 4 2.4 0.4
(M8x1.25x70) 24 4 2.4 0.4
Fan support (M10x1.5x20) 33 5 3.3 0.5
Fan pulley
(M6) 10 2 1.0 0.2
(M10) 43 6 4.3 0.6

TORQUE
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 12 7.7 1.2
Crankshaft pulley (M12x1.75x10.9) 110 5 11 0.5
Flywheel housing
(M12x120) 85 10 8.5 1.0
(M12x80) 85 10 8.5 1.0
(M10x80) 49 5 4.9 0.5
(M10x40) 49 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 60 0.5
Fuel lift pump 24 4 24 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
2nd stage 80 6 8 0.6
3rd stage 90 5
2nd stage 60 5


F4CE N ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS F4CE N ENGINES

TOOLS

99322205 daNm torque)

TOOLS
99360339 Tool for stopping the engine flywheel
99360344 Union to control compression within cylinders (use with 99395682)

99360362 993700069)

TOOLS
99363204 Tool to extract sheaths A

TOOLS
99395097 Tool to control Top Dead Center (use with 99395604)
Dial gauge holding tool for rotating ignition pump timing (use with
99395100 99395603)
99395603 Dial gauge (0 5 mm)
99395604 Dial gauge (0 10 mm)

TOOLS
99395682 Device controlling diesel engine compression cylinders


F4CE N ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . . 3

2 APPENDIX F4CE N ENGINES

F4CE N ENGINES APPENDIX 3

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

4 APPENDIX F4CE N ENGINES
GENERALMANUTENZIONE

- Avoid priming from fuel tanks made out of copper alloys
personnels safety and health shall be adopted.
- Do not modify cable wires: their length shall not be
force regulating use and exhaust of liquids and engine
changed.
exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that personnel
equipment unless specifically approved by Iveco. is fully aware of such law prescriptions and of basic
preventive safety measures.
danger.
- Do not execute electric arc welding without having priory environment and within anti-acid containers. Warning:
removed electronic gearbox. battery exhalation represent serious danger of
requiring heating over 80C temperature.
connections.
compromise engine assistance warranty and furthermore
may affect engine correct working and duration.

F4DE N ENGINES 1
Part 3
F4DE N SERIES
Section
Fuel 2
G-DRIVE applications 3
Tools 5

2 F4DE N ENGINES

F4DE N ENGINES 3
UPDATING

4 F4DE N ENGINES

F4DE N ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
Page
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5
AIR INDUCTION BOOST DIAGRAM . . . . . . . . 6
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) 7

2 SECTION 1 - GENERAL SPECIFICATIONS F4DE N ENGINES


F4DE9684A*J100
F4DE9684Q*J100
F4DE9684W*J100
N67 ERT.X
F4DE9684E*J103
F4DE9684X*J102
F4DE9687B*J100

LUBRICATION Lubrication involves the heat exchanger as well, the turbo--

blower and the eventual compressor for any eventual com-
Lubrication by forced circulation is achieved through oil pump,
pressed air system. All these components may often vary ac-
placed in the front part of the basement.
cording to the specific duty and will therefore be examined in
From the pan, the lubrication oil flows to the driving shaft, to the specific section.
Figure 1
Oil under pressure

Oil return by gravity to sump 116358

COOLING SYSTEM - Viscous pusher fan, having the duty to increase the heat
The engine cooling system, closed circuit forced circulation dissipating power of the radiator. This component as
type, generally incorporates the following components: well will be specifically equipped based on the engines
development.
- Expansion tank; placement, shape and dimensions are
subject to change according to the engines equipment. - Heat exchanger to cool the lubrication oil: even this
component is part of the engines specific equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this - Centrifugal water pump, placed in the front part of the
component will have specific peculiarities based on the engine block.
equipment developed, both for what concerns the - Thermostat regulating the circulation of the cooling
placement and the dimensions. liquid.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.
Figure 2
116359
A = TO RADIATOR
B = FROM RADIATOR

AIR INDUCTION BOOST DIAGRAM

Figure 3
6 Cylinders version
EXHAUST
RADIATOR
74195
Description
The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust
feeding pressure , one main body and one compressor. collector before the turbine and connected by piping to the
induction collector.
During engine working process, the exhaust emissions flow
through the body of the turbine, causing the turbine disk Its funchon is to restrict the exhaust of the emissions ,
wheels rotation. releasing part of them directly to the exhaust tube when the
boost feeding pressure, over the compressor, reaches the
turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air through the air filter. The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
(EGR) electronically controlled elements: the system is always
In the TIER 3 version, the profile of the exhaust cam has been active.
modified in order to allow the partial opening of the relative Its configuration does not need additional elements
valve during the aspiration phase (re-circulation of EGR i.e.checking valves, piping or heat exchangers.
exhaust gas) with the subsequent re-introduction of part of The exhaust cam (B) has another lobe apart from the major
the exhaust gas into the engine cylinders. lobe (see Section. A-A fig.) with respects to the configuration
The exhaust gases can partially be re-directed into the without EGR.
cylinders so as to reduce the maximum combustion The additional lobe, during the aspiration phase in the
temperature values responsible for the production of nitric cylinder in question, allows a brief opening of the exhaust
acid (NOx). valve generating re-circulation due to the intake of the
The exhaust gas re-circulation system (EGR), reducing the exhaust gases caused by depression which is created in the
combustion temperature by means of the diminishing of the aspiration phase inside the cylinder.
emission of NOx .
Figure 4
114789


F4DE N ENGINES SECTION 2 - FUEL 1
SECTION 2
Fuel
Page
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . 3
WORKING PROCESS . . . . . . . . . . . . . . . . . . . . 5
FUEL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . 6
MECHANICAL FEEDING PUMP . . . . . . . . . . . . 7
CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . . 8
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . 13
PRESSURE LIMITER FOR FUEL RETURN . . . . . . 14

2 SECTION 2 - FUEL F4DE N ENGINES

COMMON RAIL
General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 1
116360
11. EDC 7 gearbox.
Through the sensors, present on the engine, the ECU con- The outlet voltage is proportional to the pressure or tem-
trols the engine operation. perature obtained by the sensor.
Air pressure/temperature sensor Engine oil temperature and pressure sensor
It is a component integrating a temperature sensor and a Same as air pressure/temperature sensor, it is fitted on the
pressure sensor. engine oil filter, in a horizontal position.
Fitted on the intake manifold, it measures the max. inlet air It measures engine oil temperature and pressure.
capacity to calculate precisely the fuel quantity to inject at
every cycle.

Fuel pressure sensor Injection control

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

WORKING PROCESS
Figure 2
High Pressure
Low Pressure
116361
1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on
chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter.

FUEL SYSTEM DIAGRAM The pressure relief valve housed on the cylinder head, fitted
The following figure outlines the common rail injection on the return of the electro-injectors (3), limits the fuel
system with pump CP3. return flow from the electro-injectors to a pressure of 1.3 2
bar.
The pressure regulator, located upstream from the
high-pressure pump, governs the necessary flow of fuel on In parallel with the mechanical supply pump there are two
the low-pressure system. Then the high-pressure pump by-pass valves.
supplies the rail correctly. This solution, pressurizing only the The by-pass valve (18) is used to run off the fuel from the
necessary amount of fuel, improves energy efficiency and outlet of the mechanical pump at its inlet when the pressure
limits fuel heating in the system. at the inlet of the fuel filter exceeds the allowed limit.
The pressure relief valve (2), fitted on the high-pressure The by-pass valve (17) is used to fill the fuel system through
pump, has the function of keeping the regulator inlet pressure the manual priming pump (10).
constant at 5 bar, irrespective of the efficiency of the fuel filter
and of the system upstream.
The action of the pressure relief valve (2) causes an increase
in the flow of fuel in the cooling circuit of the high-pressure
pump through the pipe (16) for the intake and exhaust from
the pipe (8).
Figure 3
EXHAUST
INTAKE (LOW PRESSURE)
HIGH-PRESSURE PUMP SUPPLY

(LOW PRESSURE)
HIGH PRESSURE
74786
1. High-pressure pump - 2. Pressure relief valve on the high-pressure pump, 5 bar. - 3. Pressure relief valve fitted on the fuel
return from the electro-injectors, from 1.3 to 2 bar. - 4. Rail pressure relief valve. - 5. Common Rail.- 6. Pressure sensor. -
7. Electro-injector. - 8. Return feed line. - 9. Heat exchanger of the control unit. - 10. Mechanical priming pump. -
11. Prefilter fitted on the chassis (if applicable)- 12. Fuel tank - 13. Mechanical fuel pump. - 14. Fuel filter. - 15. Pressure
regulator. - 16. Pipe for cooling high-pressure pump. - 17. By-pass valve. - 18. By-pass valve.

MECHANICAL FEEDING PUMP Jettison condition

Gear pump, placed on rear part of the high pressure pump,
whose function is to feed the high pressure pump. It is driven Figure 6
by the high pressure pumps shaft.
Ordinary working condition
Figure 4
72594
72592 The dump by-pass valve (2) is activated in case, when the
engine is off, it is necessary to fill the feeding system through
the priming pump. In this condition the by pass valve (I) keeps
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, closed while the dump by-pass valve (2) opens up due to the
I - 2 By-pass valves in close position. pressure effect on the entry unit so the fuel flows to the
exhaust unit B.
Overpressure condition in Exhaust unit
Figure 5 NOTE The mechanical feeding pump cannot be replaced

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

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

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.
NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
Figure 7
72595
1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear - 5. Connector to
fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry flowing from
engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter - 9. Mechanical
feeding pump.

High pressure pump-inside structure

Figure 8
Sec. B-B
Sec. C-C
70498
Every pumping unit is composed of:

- a piston (5) actuated by a three-lobe element (2) floating - cap intake valve (3);
on the pump shaft (6). The element (2), being floating on - ball delivery valve (4).
a misaligned part of the shaft (6), when the shaft rotates,
does not rotate therewith but is only translated in a
circular movement along a wider radius, with the
resulting alternate actuation of the three pumping
elements;

Working principle
Figure 9
Sec. B - B
Sec. D - D 72597
The pumping element (3) is orientated towards the pumps During compression phase of the pumping element, the fuel
camshaft (4). During the intake phase, the pumping element achieves the level of pressure determining the opening of the
is fed through the feeding line (5). The quantity of fuel to flow by-pass valve to common rail (2), feeding it through the
to the pumping element is determined by the pressure exhaust unit (I).
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
Figure 10 Figure 11
72601
72598
Sec. C - C Sec. A - A
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
4. Ball delivery valve. 5. Piston. 6- Pump shaft. exhaust flowing from pump with connector to high
7. Low-pressure fuel inlet. 8. Pumping elements supplying pressure pipe for common rail.
fuel ducts.
Picture 10 shows the fuel runs at low pressure inside the Picture 11 shows the fuel flow under high pressure running
pump; the following elements are clearly visible: the main through the exhaust galleries of the pumping elements.
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.

Operation RAIL
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 12
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 108609
in the rail.
The thereby-generated pressure makes the exhaust valve 1. Rail 2. Fuel inlet from high-pressure pump
open and the compressed fuel reaches the high-pressure 3. Overpressure valve - 4. Pressure sensor.
circuit. The rail volume is comparatively small to allow a quick
The pumping element compresses the fuel till the top dead pressurisation at startup, at idle and in case of high flow-rates.
center (delivery stroke) is reached. Afterwards, the pressure It anyway has enough volume as to minimise system spikes
decreases till the exhaust valve is closed.
and the use of plenum chambers caused by injectors
The pumping element piston goes back towards the bottom openings and closings and by the high-pressure pump
dead center and the remaining fuel is decompressed. operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and A fuel pressure sensor (4) is screwed to the rail. The signal
the cycle is repeated. sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
The delivery valves must always be free in their movements, value is checked and, if necessary, corrected.
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.
RELIEF VALVE
If the pipe between fuel filter and high-pressure pump is to Mounted on the end of the rail, it has the function of
be removed-refitted, be sure that hands and components are protecting the systems components in case the failure of the
absolutely clean. 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 allow the fuel to flow and 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.

ELECTRO-INJECTOR Injection start

As for NEF TIER 3 engines, BOSCH - CRIN2 Figure 14
electro-injectors with different injection tubes are used
working on power developed by the engine.
Powers Pressures
Jet kW bar
DLLA Up to 152 250 1600 bar
DSLA Lower to 152 250 1400 bar
15
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

Figure 13
70506
When coil (4) is energised, it makes shutter (6) move

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

it must not be disassembled.
70505
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.

PRESSURE LIMITER FOR FUEL RETURN

It is housed on the rear of the cylinder head, and adjusts the
pressure of fuel returning from injectors at a pressure 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.
Figure 15
70507
A To tank B From injectors

F4DE N ENGINES SECTION 3 - INDUSTRIAL APPLICATION 1
SECTION 3
Page
- Section pictures of complete engine - common rail

version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PART ONE - MECHANICAL COMPONENTS . 5
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 7
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Engine setting operations for the assembly on turning

stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Assembly of application components . . . . . . . 16
PART TWO - ELECTRICAL EQUIPMENT . . . . 29
LOCATION OF MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 31
- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Connector to injectors (A) . . . . . . . . . . . . . . . 33
- Feed connector (B) to components and to functions

of the specific equipment . . . . . . . . . . . . . . . . 34
- Connector to sensors (C) . . . . . . . . . . . . . . . . 35
- Temperature and air-pressure sensor . . . . . . . 36
- Sensor of engines oil temperature and pressure 36
- Driving shaft sensor . . . . . . . . . . . . . . . . . . . . . 36
- Timing system sensor . . . . . . . . . . . . . . . . . . . 36
- Fuel pressure sensor . . . . . . . . . . . . . . . . . . . . 37

2 SECTION 3 - INDUSTRIAL APPLICATION F4DE N ENGINES
Page Page
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 37

MAINTENANCE PROCEDURES . . . . . . . . . . . . 52
- Resistor pre-post heating . . . . . . . . . . . . . . . . . 37
- Cooling liquid temperature sensor . . . . . . . . . . 37
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 - Engine oil level check . . . . . . . . . . . . . . . . 52
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . . 38 - Combustion system inspection . . . . . . . . 53
PART THREE - TROUBLESHOOTING . . . . . . 39 - Cooling system inspection . . . . . . . . . . . . 53
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 - Lubricating system inspection . . . . . . . . . 53

PT - BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
- Inspection of water presence within fuel filter or
pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 53
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . 43
PART FOUR - MAINTENANCE PLANNING . 49 - Inspection of drive belt tensioning . . . . . . 53
MAINTENANCE PLANNING . . . . . . . . . . . . . . 51 - Inspection and setting of tappet clearance 54
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 - Oil motor and filter replacement . . . . . . . 54

- Regular maintenance and inspection planning . 51
- Fuel filter replacement . . . . . . . . . . . . . . . 55
- Checks not included in maintenance planning-daily
checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 - Alternator belt replacement . . . . . . . . . . . 55

Section pictures of complete engine - common rail version
Figure 1
116362
The and F4DE9684 engines are turbocharged a 4-stroke The section herein described is composed or four sections:
diesel engines with 6 cylinders, with 4 valves per cylinder.
- Section of mechanical overhaul prescribed in accordance
They have high pressure injection fuelling (common rail) and to the engines specific duty, illustrating all necessary
are entirely electronically driven in order to optimise the operation to remove and assembly the external
working process in accordance to the operation, limiting as components of the engine, including cylinder heads,
much as possible the pollution emissions and consumption. gearbox of the timing system and 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.
NOTE 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.

F4DE9684
Type A*J100 Q*J100 W*J100 E*J103 X*J102 B*J100

Max. output kW 154 143 134 123 112 129
(HP) (210) (195) (180) (170) (150) (175)
rpm 2200 2200 2200 2200 2200 2200
Max. torque Nm 950 850 800 747 705 753

(kgm) (95) (85) (80) (74.7) (70.5) (75.3)
rpm 1400 1400 1400 1400 1400 1400

Loadless engine
idling rpm -
Loadless engine
peak rpm -
Displacement 4485

Forced by means of a lobe pump, pressure relief valve,
LUBRICATION
oil filter

bar
- idling bar 0.8
- peak rpm bar 3.5
COOLING By liquid
Thermostat
FILLING
min 12
15W40
engine sump* liters { max 15
engine sump + filter* liters 15 + 1
* first filling

! if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
provided by FPT.

PART ONE - MECHANICAL COMPONENTS



Preface
NOTE 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.
A Connector properly locked

The following information relates to the engine overhaul
70126
operations only for what concerns the different components B Connector released for removal-refitting
In section 4, General overhaul, all the operations of engine NOTE Press clamp (1), as shown in Figure B, to disconnect
block overhaul have been contemplated. Therefore the the low pressure fuel pipes (3 4 5, Figure 2)
above mentioned section is to be considered as following the from the corresponding connections.
part hereby described. After disconnecting the pipe, reset the clamp (1) in
locking position (Figure A) to prevent distortions.

turning stand
Disconnect the high pressure fuel pipeline (7, Figure 2) from
Figure 2 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.
NOTE Because of the high pressure in the pipelines

running from the 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.
116364

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 99360076 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.
On the right side of the engine Figure 5

Figure 4
116366
Disconnect the lubricating pipe (2) from the 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.
116365
Figure 6
Disconnect the oil filling pipe (1).
Unscrew the fixing screws and disconnect the starting motor
(2) from its seat.
116367
Make holes (1) and (2) on both sides of the engine base,
brackets 99361037 and then fix by means of the later, the en-
gine to revolving stand 99322205.
Empty the engine oil by removing the cap of the sump.
Collect and dispose of the engine oil according to

enforced regulations.


Figure 7
116360
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, Disassemble the engine from the engine block removing the
Figure 7) wiring harness to fixing clamps.
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.
Figure 8 Figure 10
116370
116368
Now disassemble the supercharger:

Disconnect from the rail (1): the fuel pipe (3) according to
procedures described in Figure 3. Disconnect fuel pipes (5) Unscrew fixing nuts (3) of the turbo-blower (4) on exhaust
from rail (1) and injector manifolds (4). manifold (4).
Hold up turbo-blower (4) and get the seal.
Remove the screws (2) and disconnect the rail (1). Undo the fastening screws (1) and detach the exhaust mani-
fold (2).
Figure 11
Figure 9
116371
116369 On the opposite side, loosen the fixing screws (2) of the inlet
manifold (1) and disassemble the joint to the air heater for
Disconnect the fuel return pressure limiter (1), the pipeline the cold start.
by acting on the connections as described on Figure 3. Remove the pressure-air temperature sensor from the
induction manifold (1).
Remove the external vent pipe (2).
Loosen the nuts (3) and disconnect the tappet cap (4).

Figure 12 Figure 14
116372
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
116378 (2) including the gasket.
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). NOTE Disassembled fuel manifolds (4) must not be used
Undo the fastening screws on the cylinder head and remove again, but however replaced with other new ones.
the support (6).
Undo the fastening screws and remove the ventilator
support (1).
Figure 13
Figure 15
70132
70133 Loosen tappet adjustment fastening nuts (1) and unscrew the
adjusters.
Remove injector fastening screws. Use tool 99342101 (1) to Remove the screws (2), remove the rocker assembly (3),
remove injectors (2) from the cylinder head. consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves.
Remove rods (8).

Figure 16 Figure 18
116377
Use tool 99360076 to remove the oil filter (1).
116373
Remove the fastening screws (1) from the cylinder head (2).
Figure 19
NOTE The highlighted screws are shorter.
Figure 17
88555
Unscrew the fixing screws (1) and disassemble the pipeline

union (2).
116374
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.

Figure 20 Figure 22
88558
Apply the tool (1) to stop flywheel rotation (2) through the
88556 hole (3) made on the base. Tool (1) positioned in hole (3)
is to be inserted in the groove made on the flywheel blocking
Disconnect connector (1) from the oil temperature pressure its rotation.
sensor. Loosen the engine shaft flywheel fixing screws.
Unscrew screws (2) and disconnect oil temperature pressure
sensor (3).
Unscrew screws(4) and disconnect oil filter support (5) from
the base, and remove the relevant seals.
Remove the heat exchanger from its seat.
Figure 23
Figure 21
116376
Undo the screws (1), disassemble the silencer (2) and the
pulley (3).
The blocking tool of the engine flywheel can facilitate disas-
88557 sembly of dampening flywheel (2) assembled on pulley (3).
Remove nuts (1) and disconnect high pressure pump (2)
along with the fuel pump (3).

Figure 24 Figure 26
88560
00900t
Remove the screws (1) and take out the front cover (2).
Remove the ring sealing the engines driving shaft from the
front cover. Use the tool 99340055 (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 NOTE Take note of screw (1) assembling positions since
way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool they have different lengths.
to the ring tightening the 6 screws provided with the
equipment. Then proceed removing the ring (2) by tightening
the screw (3).
Figure 27
Figure 25
88561
00904t
Using the specific tie rod (3) of the tool 99363204 and the Remove two opposite screws (1) from the area where the
ancillary lever (4), remove the external holding ring (2) from withdrawal pins will be introduced (2, Figure 28).
the front cover (1). Loosen the remaining flywheel fixing screws (3) from the
driving shaft (2).
Remove the flywheel locking tool (4).

Figure 28 Figure 30
88307
88562
Tighten two screws of medium length into the holes (4) to Turn the engine upside down.
sling the flywheel with the hoist. Remove screws (2) and disconnect oil sump (1).
Throughout the two guide pins (2) previously screw into the Disconnect the high pressure pump stroke sensor.
driving shaft holes (3) withdraw the engine flywheel (1) after
Unscrew the screws(3) and remove timing gear distribution
slinging it with the hoist.
box (4) from the base.
Figure 29
Figure 31
00903t
Remove the holding ring of the flywheel cover box using the
tool 99340056 (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 99340056 (3) to the ring (1) tightening the 6
screws provided with the equipment (4). 88564
Then proceed removing the ring (1) by tightening the screw

(2). Undo the screws (1) and remove the bevel gear (3) from the
Using a specific tie rod of the tool 99363204 and an ancillary distribution shaft (2).
lever, remove the external holding ring (2) from the front
cover.

Assembly of application components Figure 34
Figure 32
88567
Tighten the screws (1) fastening gear (2) to camshaft (3) to

the specified torque (36 Nm 4 Nm).
70211
With a felt-tip pen, highlight the conducting gear tooth (1) Figure 35
mounted on the engine shaft (2) on the upright surface
where a groove has been created for the ignition timing.
NOTE Fasten screwing of the two pins to facilitate the

operation of engine driving shaft rotation.
Figure 33 70214
LOCTITE 5205 SEALANT APPLICATION AREAS

Clean accurately the timing gear case and the engine block.
NOTE Perfect seal is only obtained by cleaning accurately

the surface to seal.
bead (1) of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
possible.
Avoid to use excess material to seal the joint.
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).

Figure 36 Figure 38
88569
88571
GEARCASE FIXING SCREW TIGHTENING DIAGRAM Put a new seal ring on the water pump.
Reassemble box (1) on the engine. Assemble water pump (1); tighten the screws (2) up to the
prescribed torque.
Tighten fixing screws (2) on the same position from where
they had been removed up to the tightening torque indicated
Figure 39
below.
Screws M8 20 28 Nm
Screws M10 42 52 Nm
Reconnect stroke sensor (3) of the high pressure pump.

wear or dirt.
Figure 37
88572
Disassemble seal ring (2) from the front cap (1), clean the
coupling surface accurately.
Figure 40
88570
Apply tool 99346253 part (6) to the rear output shaft tang
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into housing. 88573
Accurately clean the contact surface on the engine block and

position seal (1) on the base.

Figure 41 Figure 44
88574
88307
Assemble oil pump (1) on the block and tighten the screws
up to the prescribed torque. Fit the new sheath on the basement.
Assemble the oil pan (1).
Figure 42 Fit the screws (2) and tighten them to the prescribed pair.
Tighten the exhaust caps to the prescribed pair.

wear or dirt.
88575
Apply tool 99346252 part (4) to the front output shaft tang
Position part (2) on part (4), screw nut (3) until completing Figure 45
sealing ring (7) fitting into front cover (1).
Figure 43
88581
Check the contact surface (1) of the clutch plate and if it is

116376
scratched, proceed with turning.
Check ring gear teeth (2), if breakage or excessive wear is
Adjust the pulley (3), and the silencer (1) on the engine shaft. found remove the ring gear from the engine flywheel (1)
Tighten screws (1) up to torque 68 7 Nm. using a suitable hammer and fit the new one, previously
Assemble a new seal ring on the revolution sensor. heated to 150C for 15 to 20 minutes. Chamfering on ring
Assemble the revolution sensor in the front cap and tighten gear inside diameter shall be facing the engine flywheel.
the fixing screws up to the prescribed torque.

Figure 46 Figure 49
88582
80359
Screw two manoeuvring hooks or lunettes on flywheel (1)
using holes (4). Fit on the engine block: a new gasket (1), the heat exchanger
With the help of a hoist bring the flywheel closer to its seat (2) a new gasket (3) and the oil filter support (4).
inside the flywheel housing box. Tighten the screws (5) to the specified torque.
Screw two 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. NOTE Before any assembly operation always verify that
Figure 47 the hole and screw threads have no evidence of
wear or dirt.
Figure 50
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.
Figure 48
88586
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
88584
turn.
Tighten engine flywheel (1) fastening screws (2). Apply a new sealing ring on the oil temperature/pressure
sensor (4) and fit it on the support (1).
NOTE Tightening to angle is performed using tool
99395216. Before any assembly operation always Fit a new sealing ring (6) in the engine block seat.
verify that the hole and screw threads have no
evidence of wear or dirt.

Figure 51 Figure 53
88590
88587
Refit the high pressure pump (2) including the feed pump (3)
and tighten the nuts (1) to the specified torque.
Assemble pipeline union (1) and tighten screws (2) up to the
prescribed torque.

wear or dirt.
Figure 54
Figure 52
116378
Re-attach the ventilator support (1) fastening the screws to

116374 the prescribed torque.
Re-attach the support (6) tightening the fastening screws to
the cylinder head.
Apply a new gasket to the engine block and then place the Re-attach the belt tightener (7) and the drawback pulleys (3
cylinder head (2) slung by the hanger brackets (1). and 5).
Re-assemble the belt tightener (2).

Figure 55 Figure 57

70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
70336 a new sealing washer (3) on injector (1).
Assemble cylinder head (1), tighten the screws (2) in three

following steps, following order and mode shown in the
figure below. Figure 58

D2 diameters:
D2 D1
75703
NOTE The angle tightening is carried out through tool

70339
99395216 (3).
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 56
Figure 59
A
6-cylinder engine
70476
Tightening order layout for cylinder head fastening screws:

- 1st step pre-tightening with dynamometric wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
A Screw 12x1.75 x 150 ( ) 55 5 Nm
- 2nd step tightening with a 90 5 angle 70133
- 3rd step tightening with a 90 5 angle
Use tool 99342101 (1) to fit the injector (2) into its seat.
A = Front side
Screw injector fastening screws without tightening them.

Figure 60 Figure 62
70343
ROCKER ASSEMBLY COMPONENTS:

70341 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
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 Figure 63
positioning ball (5) is coinciding with the relevant housing (4).

again, but however replaced with other new ones.
Screw the fastening nuts (2, Figure 61) without locking them.
NOTE 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). SHAFT-ROCKER MAIN DATA
Check that shaft/rocker coupling surfaces are not showing
excessive wear or damages.
Figure 61
Figure 64
70342
32655
Use the torque wrench to tighten gradually and alternately Rocker control rods shall not be distorted; the ball seats in
the injector fastening screws (1) to 8.5 0.8 Nm torque. touch with the rocker adjusting screw and with tappets
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm (arrows) shall not show seizing or wear; otherwise replace
torque. them. Intake and exhaust valve control rods are identical and
are therefore interchangeable.
Carry out the assembly of the equalisers unit , after previous

Figure 65 Figure 67
70520
70345
Fit the rods (2). wrench (1), box wrench (3) and feeler gauge (2).
Position jumpers (1) on valves with marks () facing the Clearance shall be as follows:
exhaust manifold. - intake valves 0.25 0.05 mm
Figure 66
NOTE 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
T.D.C. (top dead centre) at the end of compression
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.

Figure 68 Figure 70
116371
116379
Apply to the coupling surface of the intake manifold (1)

equipped with heater a sufficient coat of LOCTITE 5999 and Fit the wiring support (2) and tighten the screws (1) to the
provide tightening the screws (2) to the prescribed matching specified torque.
couple.
Fit temperature and air pressure sensor.
wear or dirt.
Connect the electric cables to the electro-injectors (3) and

with dynamometric wrench 99389834, fasten fixing nuts to
the prescribed (4) torque.
Figure 69 Figure 71
70352
70355
Check electrical cable (5) conditions, replace if damaged by Fit a new gasket (2) on the tappet cover (1).
cutting the support (2) clamps and removing the screws (5)
Place the tappet cover on, install the bolts in the correct
that secure it to connections (3).
position and tighten.
Fit a new gasket (1) on the support (2).

Figure 72 Figure 74
116370
116380
Reconnect the exhaust manifold (2) with new gaskets.
Tighten the fastening screws (1) to the specified torque.
Assemble the rail (2) and fasten the fixing screws (1) to the
prescribed torque. Sling the turbocharger (4) and place it over the manifold after
Connect new fuel pipes (6) to the rail (2) and to the manifold having first inserted a new gasket, tighten the fastening screws
for electro-injectors (5). (3) to the specified torque.
NOTE The pipe joints (3) must be fastened to the 20 Nm

torque.
Connect the fuel pipe (4) to the rail based on the procedure
described in the following illustration.
Figure 73 Figure 75
70126
Press the clamp (1) in arrow direction (Figure B) and connect

the pipe to the rail, reset the clamp to the initial locking
position A.
116366
NOTE Check proper fuel pipe connection. 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).

Figure 76 Figure 78
116381
Connect the piping (2) to the fuel return pressure limiting 116364
device (1).
Connect the external vent pipe (3) to the head cover and to Assemble the bracket and the support (1) of the fuel filter (6).
the crankcase. Proceed connecting in sequence the pipelines (9,3,4 and 5)
of the support (1) to the high pressure pump (8).
Completion of the engine
Connect the pipeline (7) from the high pressure pump to the
Properly handle the engine holding it by a lifter, remove it rail diffuser.
from the rotating shaft, remove the brackets 99361037 and
place it on proper suitable support to carry out the
completion.
Figure 77
Figure 79
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.
116365 NOTE 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.
Assemble oil filling pipe (1).
Screw fixing screws and assemble starting motor (2) in place. Reconnect the engine harness to all the sensors, the engine
control module and the rail diffuser.

NOTE The following checking inspections must be carried

out after the engine assembly on the vehicle .
Start the engine and leave it running just above the

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

sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- check carefully the connection between the low
pressure fuel pipes and the relevant connectors;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes (if
fitted);
- check also proper operation of the warning lights set on
the instrument panel and of the equipment
disconnected when engine was removed.
- Carefully check and bleed the engine cooling equipment
by repeated draining operations.


PART TWO - ELECTRICAL EQUIPMENT


LOCATION OF MAIN ELECTRICAL COMPONENTS

Figure 80
116382
The and F4DE9684 engines are fully driven by the electronic The electrical and electronic components of the engine are
engine control module. listed here following:
Through the engine control module it is possible to verify the 1. Temperature sensor of cooling liquid;
correct working of the engine. (See part three of the hereby
2. Electro-injector;
users guide specifically dedicated to diagnostic).
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.

EDC7 ECU
Figure 81
01525t
A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled);
C - Connector to sensors.

Connector to injectors (A)

Figure 82
12 16
6 11
50350
1 5
PIN ECU CABLE COLOUR FUNCTION
1 - -
2 - -
3 MN Injector cylinder 2 (**)
4 MV Injector cylinder 3 (**) / Injector cylinder 4 (*)
5 VB Injector cylinder 4 (**)
6 HR Injector cylinder 2 (**)
7 - Earth
8 - Injector cylinder
9 MB Injector cylinder 1 (*) / (**)
10 VN Injector cylinder 6 (**) / Injector cylinder 2 (*)
11 VG Injector cylinder 5 (**) / Injector cylinder 3 (*)
12 HN Injector cylinder 3 (**) / Injector cylinder 4 (*)
13 HG Injector cylinder 1 (*) / (**)
14 CN Injector cylinder 4 (**)
15 CB Injector cylinder 6 (**) / Injector cylinder 2 (*)
16 CL Injector cylinder 5 (**) / Injector cylinder 3 (*)
(*) Only for 4 cyl. versions

Colour legend (**) Only for 6 cyl. versions
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
Feed connector (B) to components and to functions of the specific equipment

Figure 83 89 72 54 6 1
71 11
53 7
35 18 36 17 12 03210t
1 8150 Positive driven by battery

2 0087 Negative for switch of fuel filter heater/starter
3 0000 Earth
4 8885/0159 Positive for pre-post heating resistor
7 8150 Positive driven by battery
8 7777 Positive for blink-code button/ oil low pressure led/ pre-heating led/
Air conditioner switch (if available) / EDC
9 0000 Earth
12/13 8150 Positive driven by battery
14/15 0000 Earth
16 0094 Negative for post-heating resistor
19 0150 Negative start-stop push buttons from eng./accelerator pressed
20 8153 Positive from change over switch to key in starting phase (+50)
27 0156 Positive from blink-code button
28 5535 Positive for EDC diagnostic led
31 2298 K Line for diagnosis connector, 30 poles (2 pin)
32 - Negative for multi-switch couple-limiter
36 8837 Positive for fuel filter heating switch
37 8888 Positive for starter
39 8051 Positive from key switch/ L line for diagnosis connector 30 poles (pin 11)
44 9905 Negative from starter push button from engine
45 9906 Negative from engine stop push button from engine
46 5553 Negative for pre-heating led in on position
49 5584 Diagnosis connector (pin 28)
50 0158 Negative from accelerator push button pressed
52 6109 CAN Line (whether equipped), diagnosis connector (pin 22)
53 6108 CAN Line (whether equipped), diagnosis connector (pin 22)
55 5158 Positive for sensor of foot accelerator pedal pos. / Earth multi-switch
62 0160 Negative for clutch sensor
63 5503 Negative for engine oil low pressure led
64 0535 Negative for EDC diagnosis led
72 0159 Positive from pressed accelerator push button / multi-switch signal
73 0159 Positive redundant from pressed accelerator push button
78 8162 Positive air conditioner device (whether equipped)
81 0157 Negative sensor of foot accelerator pedal pos. / Earth multi-switch
83 5157 Signal from sensor of foot accelerator pedal pos. / Signal multi-switch
87 - Positive for couple multi-switch limiter

Connector to sensors (C)

Figure 84
Colour legend
6 8 16 9 15 C ORANGE
A SKY BLUE
B WHITE
L BLUE
5 22 G YELLOW
4 H GREY
29 M BROWN
N BLACK
1 W LIGHT BROWN
3 23 30 36 03211t S PINK
R RED
V GREEN
Z PURPLE
5 C Earth for pressure regulator

7 V Pressure regulating drive
9 MN Feed for engine oil temperature/pressure sensor
10 CR Feed for air pressure and temperature sensor
12 HN Feed for rail pressure sensor
17 BL Earth for fuel temperature sensor
18 CV Earth for cooling liquid temperature sensor
19 GV Earth for engine oil temperature pressure
20 BZ Feed for rail pressure sensor
21 GN Feed for air pressure - temperature sensor
23 R Timing system sensor
24 B Driving shaft sensor
25 R Driving shaft sensor
27 RV Signal from rail pressure sensor
28 LN Signal from air pressure sensor
29 BH Signal from air temperature sensor
30 B Earth for timing system sensor
33 GR Signal from engine oil temperature sensor
34 CN Signal from fuel temperature sensor
35 NS Signal from engine oil pressure
36 BG Signal from cooling oil temperature

Temperature and air-pressure sensor Driving shaft sensor

Figure 85 Figure 86
50319
3 2 1
50342
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 flow lines
that close up through the openings of a phonic wheel splined
88438 to the driving shaft. The same signal is utilised to control the
eventual electronic engine speed indicator placed on the
It is a component integrating one temperature sensor and a vehicle instrument board.
pressure one.
It is connected to the engine control module by pin 25C
It is assembled to the suction inlet manifold and measures the (signal) and 24C (signal). The third pin is for screening.
maximum capacity of air introduced, in order to provide to the
The resistance value of the sensor is of about 900 .
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 Timing system sensor
pin (temperature), 10C and 28C (pressure) and has a 5 volt
feeding. Figure 87
21C Earth
29C NTC signal (temperature)
10C +5V feed
28C Signal (pressure)
50320
3 2 1
Sensor of engines oil temperature and

50342
pressure
It is a component integrating one temperature sensor and a
pressure one. It is an inductive type sensor and it is placed on the back left
part of the engine.
It is assembled on the engine oil filter support.
It generates some signals originated by the magnetic flow lines
It measures the temperature and the pressure of the engines that close up through the ports drilled on the gear splined to
oil. the camshaft. The signal generated by this sensor is utilised by
the electronic engine control module as signal of injection
It is connected to the engine control module by 19C and 33C,
phase.
9C and 35C.
Even being equal to the flywheel sensor it is not
19C Earth
interchangeable since the external shape is different.
33C NTC signal (temperature)
9C +5V feed (signal) and 30C (signal). The third pin is for screening.
35C Signal (pressure) The resistance value of the sensor is of about 900 .
Fuel pressure sensor Resistor pre-post heating

Figure 88 Figure 90
116384
116383
It is a resistor placed on the suction inlet manifold and is utilised

1 - Earth; 2- Signal; 3- Feed.
to heat the air during the heating pre-post operations.
It is a sensor assembled to one end of the rail and measures It is fed by a tele-switch usually placed very close to the engine.
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. Cooling liquid temperature sensor
It is connected to the engine control module by pin 20C It is a sensor with variable resistor, able to detect the cooling
(Earth), 27C (signal) and 12C (feed). liquid temperature to provide to the engine control module
an index of the engine thermal status.
It has 5 volt feeding.
Usually, the same signal is driven by the engine control module
to the temperature device placed within the vehicles
Fuel temperature sensor dashboard.
Figure 89 It is connected to the engine control module by pin 18C
(Earth) and 36C (temperature signal).
The resistor to 20 C = 2,5 k.
88440
1 - Fuel temperature sensor

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.

Starter Figure 91
The starter is usually driven by the starting block assembled to
the vehicles dashboard and provides positive voltage to pin
B20 of the EDC.
Electro-injectors
This is a N.A. type solenoid valves
They are individually connected to the EDC gearcase on con-
88314
nector A.
The resistance of each injector coil is 0.56 0.57 .
1. Feeding relay of the starter
6 cylinder engines
REFERENCE DESCRIPTION PIN EDC
1 Injector cylinder 2 3A
CONNECTOR 1
3 Injector cylinder 1 13 A
CONNECTOR 2 3 Injector cylinder 3 12 A
CONNECTOR 3
Figure 92
50343
50349

PART THREE - TROUBLESHOOTING


PREFACE Every time there is a breakdown claim and this breakdown is

actually detected, it is necessary to proceed inquiring the
A successful troubleshooting is carried out with the electronic unit in one of the ways indicated and then proceed
competence acquired by years of experience and attending with the diagnostic research making trials and tests in order to
training courses. have a picture of the working conditions and identify the root
causes of the anomaly.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper In case the electronic device is not providing any indication, it
consideration using them to acquire any useful information to will be necessary to proceed relying on the experience,
focus the intervention. adopting traditional diagnosis procedures.
Using FPT processing instruments, it is also possible to
establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input an
enquiry relying on memory files, in order to achieve any further
necessary information to identify the origin of the anomaly.
NOTE Any kind of operation on the electronic center unit

must be executed by qualified personnel, duly
authorized by FPT.
Any unauthorized tamper will involve decay of
after-sales service in warranty.

PT - BOX
PT - BOX is a test tool to be connected to a Laptop.
Figure 93
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator -

4. Operation indicator - 5. Serial port indicator - 6. Error indicator - 7. CAN line indicator - 8. Line K indicator for automatic
management
PT-BOX functions:
- ECU ID reading;
- Failure memory reading;
- Flight recorder reading;
- Parameters reading;
- Failure memory cleaning;
- Active diagnosis: actuators activation/testing;
- Programming of repalced components and parameters/second level;
- Acquisition/Saving of parameters

FAULT CODES
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


Fuel metering
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.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
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.5 TIMEOUT CAN MESSAGE VM2EDC
1.B.D TIMEOUT CAN MESSAGE CCVS
Interfaces 2 (CAN line timeout messages)
1.C.6 ERROR MESSAGE CAN TSC1-PE


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.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.5 SENSORS POWER SUPPLY FAULT (12V)
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


Print P2D32N003 E
F4DE N ENGINES
Low performance at load request. Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact
that, in case of insufficient fuel feeding, the
Possible exessive smoke. engine control module tries to compen-
sate prolonging the injectors working
Possible blink-code 8.1 time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of over- is working correctly.
heating.
If the pump plunger is permanently de-
pressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter. Replace the air filter. Solve the cause of the filters obstruction.
Excessive fuel blow-by from rail boost Check the O Rings and the correct con- Unless the leakage is significant, no per-
valve. nection of the pipe fittings under the formance failures will be detected.
feeding pump (the lockers must stay out- To verify O-rings integrity, extract from
side and the fittings must be well locked). the tank the fuel recycling pipeline, seal
Visually check the low pressure pipeline the end and activate the priming pump
integrity. driving the low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve. there are any significant blow-by from the
boost gauge valve; in such case replace
the valve.
The engine suddenly stops(with no previ- Obstructed fuel filter. Replace the fuel filter. Solve the cause of the filters obstruction
ous problems) and does not start again. (empty and clean the tank and the part of
SECTION 3 - INDUSTRIAL APPLICATION

the circuit over the filter, refill with clean
fuel).
Base - May 2010
47
Base - May 2010
48
SECTION 3 - INDUSTRIAL APPLICATION

The engine disconnects or does not start. (*) Eliminate the short circuit and replace the Verify that the wire line, close to the
EDC. pedal, is not exposed to.
EDC burned by short circuit on the wir-
ing harness of the friction clutch.
Difficult start and low performance in all Inefficient high pressure pump. After having excluded any other possible
conditions. cause, replace the high pressure pump.
Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recog- In case of low entity blow-by, inficiating
gine running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of the mechanical working of the injector
pulsing within the relevant high pressure but not involving flow limiter activation,
pipe. there is no error memorisation in the en-
gine control module.
If the flow limiter is activated. Check error
code memory.
Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recog- Usually, whether such symptoms appear,
followed by huge white exhaust fumes, no return). nisable detecting by feeling the absence of it is instinctive to give up engine start.
and a fuel smell. pulsing within the relevant high pressure However, by insisting, it is possible to start
pipe. the engine.
As a matter of facts, by insisting, if within
the rail the pressure makes the flow li-
miter close up, the engine starts with one
cylinder less and gradually the grade of
fumes reduces and disappears.
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct
pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the orig-
screws. inal position.
The engine works with one cylinder less, Injector blocked in closed position. Identify the injector that is not working The non-working injector is easily recog-
without memorising failure blink codes in any more and the relating high pressure nisable detecting by feeling the absence of
the engine control module. filler. pulsing within the relevant high pressure
pipe.
F4DE N ENGINES
Print P2D32N003 E
PART FOUR - MAINTENANCE PLANNING


Recovery
Regular maintenance and inspection planning
Checks and periodical inspections Frequency (hours)

Inspection presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . Daily
Inspection of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Inspection and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Replacement of pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
FPT.


It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconven-
iences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
z
MAINTENANCE PROCEDURES
Figure 95
and possibly cool.
The check can be made using the specially provided rod (1).
Figure 94
88543

must be removed in order to make the oil flow easier.
88542
the etched tags of minimum and maximum level. The engine oil is highly polluting and harmful.
Whether it should be difficult to make the evaluation, proceed In case of contact with the skin, rinse well with water
cleaning the rod using a clean cloth with no rag grinding and and detergent.
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 mini- Adequately protect the skin and the eyes, operate in
mum level, provide filling lubrication of the engines compo- full compliance with safety regulations.
nents. Disposal must be carried out properly, and in full com-
pliance with the law and regulations in force.

Combustion system inspection Lubricating system inspection

The check must be executed both when the engine discon- The check must be executed both when the engine discon-
nected and when it is running. nected and when it is running.
running from the tank to the pre-filter (if provided in the spe- Verify the presence of any oil leakage or blow-by from the
cific equipment), to the filter, to the high pressure pump and head, from the engine pan of from the heat exchanger.
to the rail diffuser and from this last one to the head.
Special attention must be paid to the connections on the high

pressure pipelines. The engine oil is highly polluting and harmful.

and detergent.
Due to the high pressure within the pipelines running
from the high-pressure pump to the rail diffuser and Adequately protect the skin and the eyes, operate in
from this last one to the electro-injectors, special full compliance with safety regulations.
attention must be aid also in checking presence of any
leakage or blow-by. Disposal must be carried out properly, and in full com-
pliance with the law and regulations in force.
pressure jet: these may deeply penetrate under the
skin surface provoking serious poisoning.
Inspection of water presence within fuel filter or pre--

filter
NOTE The components of the common rail system can be

Cooling system inspection damaged very quickly in presence of water or im-
The check must be executed both when the engine discon- purity within the fuel.
nected and when it is running.
Timely proceed operating on the pre-filter to carry
Check the pipelines from the engine to the radiator, from the out the drainage of the water within the feed circuit.
expansion tank and vice-versa. Find out any blow-by, verify the
Verify that the radiator is clean, the correct working of the fan Inspection of drive belt tensioning
from the manifold and from the radiating unit. The drive belt tensioning control is made using an automatic
tensioning device therefore no intervention is required apart
from checking the wear status of the belt itself.
Due to the high temperatures achieved by the sys-

tem, do not operate immediately after the engines
disconnection, but wait for the time deemed necess-
ary for the cooling.
pressure jet of cooling liquid.
The density of the cooling liquid must be checked any how

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 in-

convenience might be caused to the engine due to
the presence of air pockets in the engines head.

Inspection and setting of tappet clearance Oil motor and filter replacement
Figure 96
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.
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
70520 pan connected with the drain plug.
Adjust clearance between rockers and valves using setscrew - Unscrew the plug and then take out the control dipsick
wrench (1), box wrench (3) and feeler gauge (2). and the inserting plug to ease the downflow of the lubrica-
Clearance shall be as follows: tion oil.
The oil motor is very pollutant and harmful.

NOTE On TIER 3 engines, due to the additional lobe for In case of contact with the skin, wash with much
the INTERNAL E.G.R., it is not possible to use the water and detergent.
valve clearance adjustment procedure that requires Protect properly skin and eyes: operate according to
adjusting the clearance of all the valves by safety rules.
Each cylinder must be checked by taking it to the Dispose of the residual properly following the rules.

features.
is next to the maximum level notch indicated on the dip-
sick.

Whereas you replace the lubrication oil, it is necessary to re- Alternator belt replacement
place the filter. Due to several applications the belt run can change very much.
According to the application the filter can be located in differ-
ent positions: the following procedure is a valid guide for all ap-
plications.
- The filter is composed by a support and a filtering car- belt can operate without advance notice.
tridge. For the cartridge replacement use the
9936076-tool. Wait for the motor temperature lowering to avoid
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. For applications with automatic belt stretcher, the procedure
is the following:
The motor oil is very pollutant: it must be disposed of
according to the rules. Figure 97 (Demonstration)

port.
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-
Fuel filter replacement

88544
During this operation dont smoke and dont use free - By means of a square wrench of proper size act on point
flames. A, indicated on the figure, of the automatic belt tightener
Avoid to breathe the vapors coming from filter. (1) and release the pressure.
- Remove the control belt (2) from the driven and inter-
mediate pulleys.
- Replace the worn belt with a new one.
tity can change. - Place the belt on the pulleys and the guide rollers.
However the following operations are valid for all applications. - Place the automatic tightener in order to key the belt in
the functioning position.
lease screw. Collect the fuel in a container without impu- - Check proper position in the races of the pulleys.
rities.
- Unscrew the cartridge by using the 99360076-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.


F4DE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1
SECTION 4
Page
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 11
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
- Checking head supporting surface on cylinder unit 13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 16
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Measuring piston diameter . . . . . . . . . . . . . . . 21
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4DE N ENGINES
Page Page

- Conditions for proper pin-piston coupling . . . . 22
- Checking cylinder head supporting surface . . . 29
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 23
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Removing carbon deposits, checking
and grinding valves . . . . . . . . . . . . . . . . . . . . . . 30
- Fitting connecting rod-piston assembly . . . . . . 24
- Checking clearance between valve stem and valve
- Connecting rod-piston coupling . . . . . . . . . . . . 24 guide and valve centering . . . . . . . . . . . . . . . . . 30
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 25 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Fitting connecting rod-piston assembly into cylinder VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Finding crankpin clearance . . . . . . . . . . . . . . . . 26
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Checking piston protrusion . . . . . . . . . . . . . . . 27 FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . 33
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 28 - Refitting the cylinder head . . . . . . . . . . . . . . . . 34
- Removing the valves . . . . . . . . . . . . . . . . . . . . 28 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 35

Type 6 CYLINDERS

Injection Direct
Number of cylinders 6

Bore mm 104
Stroke mm 132
+ + +.. = Total displacement cm3 6728
TIMING
start before T.D.C. A 18.5

end after B.D.C. B 29.5

Checking timing
mm 0.20 to 0.30
X X
mm 0.45 to 0.55
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 ECU
Nozzle type Injectors
Injection sequence 1-5-3-6-2-4
ba
r Injection pressure bar 250 - 1600

CLEARANCE DATA
Type 6 CYLINDERS

1
X
1 0.4
Pistons
1
X Size X 55.9 / 49.5 ()
Outside diameter 1 103.714 to 103.732 / 103.759 to 103.777 ()
2 Pin housing 2 38.010 to 38.016
Piston cylinder barrels 0.252 to 0.294
X
3 Piston pin 3 37.994 to 38.000
() Valid for engines F4DE9684A

Type 6 CYLINDER
X1 X1* 2.705 to 2.735

Split ring slots X2 2.440 to 2.460 / 2.420 to 2.440 ()
X2
X3 4.030 to 4.050
X3
S 1 S1 2.560 to 2.605
S 3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0,.060 to 0,110 / 0.040 to 0.090 ()
3 0.040 to 0.080
Split rings 0.4
X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3
S Inside 3 38.019 to 38.033
() Valid for engines F4DE9684A

Type 6 CYLINDERS

X
Size X -
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82.990 to 83.010
Crankpins 2 68.987 to 69.013

S 1 S 2
Main bearings
3 No. 1 - 7 3 87.982 to 88.008
No. 2-3-4-5-6 3 87.977 to 88.013

No. 1-7 0.041 to 0.119
No. 2-3-4-5-6 0.041 to 0.103
Main half bearings
0.250 ; 0.500
X 1
X 2
X 3

Type 6 CYLINDERS

1

Valve guides and seats on head -

4 Valves:
4 6.970 to 6.990
60 0.25
4 6.970 to 6.990
45 0.25

Housing on head for
valve seat:
1 34.837 to 34.863
1 1 34.837 to 34.863

head:
2 34.917 to 34.931
60
2 34.917 to 34.931

45
X 0.59 to 1.11
Sinking
X X 0.96 to 1.48
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -

Type 6 CYLINDERS

free spring H 47.75

H H1
339.8 19 N H1 35.33
741 39 N H2 25.2
X
Camshaft bush
housings No. 1 59.222 to 59.248
(flywheel side)
Camshaft housings 54.089 to 54.139
No. 2-3-4-5-6-7
1 23 4 5
2
Camshaft journals:
17 53.995 to 54.045
1 3
Bush inside

Cam lift:
H H 6.045
H 7.582

Type 6 CYLINDERS

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



The following instructions assume that the engine has
previously been placed on the rotating bench and that
removal of all specific components of the FPT 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.
Figure 1 70160
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).

assembling positions since in case of reuse they shall
be fitted in the same position found at removal.
Figure 4
70158
and remove them.

found at removal.
74774
Use tool 99360500 (1) and hoist to remove the crankshaft (2)
from the block.
Figure 2
Figure 5
70159
Remove the screws (1) and the main bearing caps (2). 70162
Remove the main half-bearings (1).

zs

CYLINDER UNIT
Figure 9
70163 s

plate (2).
NOTE Take note of plate (2) assembling position.

70166


70164
Figure 10
Figure 8
70167

different heights in the barrel and on two planes perpendicular
with each other: one parallel to the longitudinal axis of the
engine (A), and the other perpendicular (B). Maximum wear
is usually found on plane (B) in correspondence with the first
measurement.
Should ovalisation, taper or wear be found, bore and grind the
70165
cylinder barrels. Cylinder barrel regrinding shall be performed
according to the spare piston diameter oversized by 0.5 mm
and to the specified assembling clearance.

bearings;

unit
Check cylinder unit operating plug (1) conditions, replace
them in case of uncertain seal or if rusted.
107804

oversize (0.4 mm).
TIMING SYSTEM
Camshaft
Figure 12
88595
CAMSHAFT MAIN DATA (6-cyl.)

Camshaft pin and cam surfaces shall be absolutely smooth; if camshaft and the bushes.
they show any traces of seizing or scoring replace the


Set the camshaft on the tailstock and using a 1/100 gauge set Figure 14
on the central support, check whether the alignment error is
not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.
Figure 13
88596

intermediate housing (1) diameter.
70171
Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two
perpendicular axes.
Figure 15
116363
MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING (6-cyl.)

*Height to be obtained after driving the bush.


Figure 16 Figure 18
88600
88599
To replace bush (1), remove and refit it using the beater housings on the engine block.
99360362 (2) and the handgrip 99370006 (3).
Figure 19
NOTE When refitting the bush (1), direct them to make

the lubricating holes (2) coincide with the holes on
the block housing.
88601
Tappets Lubricate the camshaft bush and fit the camshaft (1) taking
care not to damage the bush or the housing.
Figure 17
Figure 20
88602
88612
Set camshaft (3) retaining plate (1) with the slot facing the top
MAIN DATA CONCERNING THE TAPPETS AND THE of the engine block and the marking facing the operator, then
RELEVANT HOUSINGS ON THE ENGINE BLOCK tighten the screws (2) to the specified torque.


Figure 23
88605
70182
It shall be 0.23 0.13 mm.
NOTE It is recommended to insert the found values in the

proper table.
See Figure 24.
Undersize classes are: 0.250; 0.500 mm
NOTE Journals and crankpins shall always be ground to the

same undersize class.
Journals and crankpins undersize shall be marked on
Figure 22 the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized crankpins and journals: letters MB
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.

Figure 24
88604
*Rated value
Figure 25


Figure 26

70237

Roundness
SHAPE
Cilindricity //
Parallelism //
Straightness
OSCILLATION
Total oscillation

CRITICAL
IMPORTANT
SECONDARY


Figure 29
Figure 27
74774
With tool 99360500 (1) and hoist, re-assemble the engine

70184
shaft inside the engine crankcase (2).
Check that gear toothing (1) is not damaged or worn, the relevant bearings as follows:
When fitting the new gear, heat it to 180C for 10 minutes
in an oven and then key it to the output shaft. Figure 30
Figure 28
70186

70185 - position a piece of calibrated wire (3) on the output shaft
NOTE Refit the main bearings that have not been - fit caps (1), including the half bearings (2) on the relevant
replaced, in the same position found at removal. supports.

Main bearings (1) are supplied spare with 0.250 0.500 mm twice as indicated in the picture, checking D1 and
undersize on the internal diameter. D2 diameters:
D2 D1
Clean accurately the main half bearings (1) having the 75703
half rings.

Figure 34
70187

successive stages:
(2) on the output shaft (3) as shown in the figure, standard
Figure 32 value is 0.068 to 0.41.
70188
Figure 35
- 3rd stage, with tool 99395216 (1) set as shown in the
Figure 33
70191

70189
COMPONENTS
- Remove caps from supports. 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2) at
Figure 36 Pistons
Figure 39
32613
Remove split rings (1) from piston (2) using pliers 99360183
32615
(3).
Using a micrometer (2), measure the diameter of the piston

Figure 37
Figure 40
32614
70192
Figure 38
1.5
2.705 2.420
2.560 2.735 2.440
* 2.605
220
2.350
2.380
3.970
3.990 38.010 37.994
38.016 38.000
114797
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
Figure 41
114798
MAIN DATA CONCERNING MONDIAL MAHLE PISTON, PINS AND SPLIT RINGS
Piston pins
Figure 42
Figure 44
18857

16552
(2).
Figure 43 Figure 45
32619
Lubricate the pin (1) and its seat on piston hubs with engine 32620
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 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).

Figure 48
41104

TRAPEZOIDAL RING
the ring (2) protrudes half-way from the cylinder barrel (3). 88607

between ring and slot: found value shall be the specified one. MAIN DATA FOR CONNECTING ROD, BUSH, PISTON

Figure 47

knurls.
70194


Figure 49 Bushes
replace.
beater.

Figure 50
80339

- On body and cap with a number showing their
coupling and the corresponding cylinder. 88608
In case of replacement it is therefore necessary
to mark the new connecting rod with the same The piston crown is marked as follows:
numbers of the replaced one. 1. Part number and design modification number;
- On body with a letter showing the weight of barrel, this arrow shall face the front key of the engine
the connecting rod assembled at production: block;
S V, 1600 to 1640 (yellow marking); 3. Manufacturing date.
S X, 1681 to 1720 (blue marking); Figure 51
green marking *.
88609

Figure 52 Figure 54
72705
Position the piston (1) on the connecting rod according to 70200

the split rings (2). Fit half bearings (1) on connecting rod and cap.

replaced, in the same position found at removal.
Do not try to adapt the half bearings.
Fitting split rings

Figure 53

cylinder barrels
Figure 55
32613
(2).
other by 120.
70201
sizes: Lubricate accurately the pistons, including the split rings and
- standard; Use band 99360605 (2) to fit the connecting rod-piston
- 0.4 mm oversize. assembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to

Figure 56
D2 diameters:
D2 D1
75703
88610
Figure 58
120;
- connecting rod-piston assemblies shall have the same
weight;

front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
70204
- Lubricate the screws (1) with engine oil and then tighten
Figure 57 them to the specified torque using the dynamometric
wrench (2).
Figure 59
70203

(1);
bearings (4).
70205

tighten screws (2) of 60.

Figure 60 Checking piston protrusion
Figure 62
70206
70208
- Remove the cap and find the existing clearance by
comparing the calibrated wire width (1) with the scale Once connecting rod-piston assemblies refitting is over, use
on the wire envelope (2). dial gauge 39395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Figure 61
70207
If a different clearance value is found, replace the half bearings



Removing the valves
Figure 63
70321

70319
Figure 65
70322


Figure 66
70323 70325
Use a pump to fill with water heated to approx. 90C and 2 The rated thickness A for the cylinder head is 105 0.25 mm,
to 3 bar pressure. max. metal removal shall not exceed thickness B by 1 mm.
Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
NOTE After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
Use a rule (2) and a feeler gauge (3) to check the cylinder
head (1) supporting surface.
exceed 0.20 mm.

VALVES Figure 70
Figure 68
EXHAUST INTAKE
VALVE VALVE
18882

6.970 6.990.
107280
Figure 69 Figure 71
18625
Remove carbon deposits from valves using the proper metal

brush. 70327
Check that the valves show no signs of seizing, scoring or

cracking. Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.052 0.092 mm.
Regrind the valve seats, if required, removing as less material
as possible. Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.


Figure 72
Figure 73
INTAKE EXHAUST 70330
70328 Check the valve seats (2). If slight scoring or burnout is found,
regrind seats using adequate tool (1) according to the angle
Use a bore dial gauge to measure the inside diameter of the values shown in Figure 74.
Figure 74
INTAKE EXHAUST
70331
VALVE SEAT MAIN DATA (6 CYL.)

Figure 75
EXHAUST INTAKE
70332
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD (6-CYL.)
Figure 76 After regrinding, check that valve (3) sinking value is the
gauge 99395603 (1).
70333

VALVE SPRINGS FITTING CYLINDER HEAD

Figure 77 Figure 78
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST 70334

VALVE SPRINGS
Before refitting use tool 99305047 to check spring flexibility. Lubricate the valve stems (1) and fit them into the relevant
Compare load and elastic deformation data with those of the valve guides according to the position marked at removal.
sealing rings (3) for exhaust valves are green.
mm kg
H 47,75 Free
H1 35,33 P 339,8 19 N
H2 25,2 P1 741 39 N
Figure 79
770321

Refitting the cylinder head Figure 81

Figure 80
88775
There are two types of head seals, for the thickness (1.25 mm
70335
Check cleanness of cylinder head and engine block coupling distance of 45 mm from the centre of the piston
surface. overhandings S1 and S2 in relation to the engine base
Take care not to foul the cylinder head gasket. upper plane then calculate the average:
facing the head.
The arrow shows the point where the gasket thickness is
given. S cil1 = S1 + S2
2
For 6 cylinder versions:
Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
NOTE Before using the fixing screws again, measure them the average value.
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again; S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6
S=
if D1 - D2 > 0,1 mm the screw must be replaced. 6
D2 D1 If S is > 0,40 mm use seal type A.
75703

TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Bench fixing screws: 1st step 50 6 5 0.6
2nd step 80 6 8 0.6
3rd step 90_ 5_
Connecting rod cap: 1st step 30 3 3 0.3
2nd step 60 5 6 0.5
3rd step 60_ 5_
Engine cover fixing nuts (M8x125) 25 5 2.5 0.5
Engine flywheel fixing screws: 1st step 30 4 3 0.4
2nd step 60_ 5_
Pulleys and dampener fixing screws 110 5 11 0.5
Screws used to fix the injectors on the cylinder heads 110 5 11 0.5
P.A.P. gear fixing nut: 105 7 10.5 0.7
Compressor gear fixing nut: 125 19 12.5 1.9
Distribution gear fixing screws: 36 4 3.6 0.4
Piston lubricating nozzle fixing unions: 15 3 1.5 0.3
Distribution box fixing screws
M8 1.25x40 24 4 2.4 0.4
M10 1.5x30 47 5 4.7 0.5
Front cover fixing screws
M10 1.5x30 24 4 2.4 0.4
Bench cap fixing screws M12x1.50 1st step 50 6 5.0 0.6
2nd step 80 6 8.0 0.6
3rd step + 90_ 5_
Ladder Frame fixing screws M10 1.5x25 43 5 4.3 0.5
Hoisting bracket fixing screws:
M12 1.75x25 70 12 7 1.2
M10 43 5 4.3 0.5
Heat exchanger fixing screws
M8 1.25x35 25 5 2.5 0.5
M8 1.25x100 25 5 2.5 0.5
M12 Connector 25 5 2.5 0.5
M8 valve cap fixing screws 24 4 2.4 0.4

Engine exhaust fixing (Ccv)
M8 1.25x45 24 4 2.4 0.4
M8 1.25x35 24 4 24 0.4
Oil sump fixing screws
Screws No. 26-23 M10 1.5x45 50 5 5 0.5
Screws No. 310; 1320; 24-25 M10 1.5x90 70 5 7 0.5
Screws No. 1-2-21-22 M10 1.5x125 70 5 7 0.5
Screws No. 11-12 M10 15x190 70 5 7 0.5
Screws / Caps on Head
1/2 Nptf 24 4 2.4 0.4
3/4 Nptf 36 5 3.6 0.5
1/4 Inch Nptf 12 2 1.2 0.2
Cylinder head fixing screws
Screws No. 16-15-8-7-1-2-9-10-17-18 M12 1.75x150 55 5 5.5 0.5
Screws No. 12-11-4-3-5-6-13-14 M12 1.75x130 35 5 3.5 0.5
+ 90_ 5_
Angle closure + 180_ 5_
M6 heater grid fixing screws 10 2 1.0 2
Intake manifold fixing screws:
M8 1.25x25 25 5 2.5 0.5
M8 1.25x60 25 5 2.5 0.5

TORQUE
COMPONENT
Nm kgm
Screws used to fix the exhaust manifold on the head:
M8x1.25x25 mm 25 5 2.5 0.5
M8x1.25x14 mm 25 5 2.5 0.5
M11x1.25 connection rod cap fixing screws 1st step 30 3 3.0 0.3
2nd step 60 5 6.0 0.5
3rd step + 90_ 5_
Flywheel fixing screws
M12 85 10 8.5 1.0
M10 49 5 4.9 0.5
M8x1.25x25 distribution shaft should plate fixing screws 24 4 2.4 0.4
M8x1.25x20 distribution shaft gear fixing screws 36 4 3.6 0.4
Rocker arm fixing screws 36 5 3.6 0.5
3/8 rocker arm register fixing screws 24 4 2.4 0.4
Rocker arm box fixing screws 24 4 2.4 0.4
M12x1.25 phonic wheel fixing screws 110 5 11.0 0.5
Head side fuel connector fixing 50 5 5.0 0.5
Common Rail side fuel connector fixing 20 2 2.0 0.2
Common Rail fixing M8 1.25x10
M8 1.25x50 24 4 2.4 0.4
M8 1.25x90
Fixing of high pressure pipe between Common Rail and M14x1.5 cylinder head 20 2 2.0 0.2
Fixing of fuel combustion filter support on M12x1.75x25 base 77 8 7.7 0.8
Fixing of turbine on the M8x1.25 exhaust manifold 25 5 2.5 0.5
M12x1.5 oil delivery and return pipeline fixing 35 5 3.5 0.5
Oil level rod fixing 24 4 2.4 0.4
81 0.8 0.1
M8x1.25x30 oil pump fixing screws 24 4 2.4 0.4
Principal oil delivery screws (caps)
M10 1 61 0.6 0.1
M14 1.5 11 2 1.1 0.2
Fixing between oil cooler with oil filter assembly 24 4 2.4 0.4
Fixing of the water pump on the base: 24 4 2.4 0.4
M8x1.25x25 43 6 4.3 0.6
Belt tightener fixing
M10x1.5x60
M10 fan support fixing 33 5 3.3 0.5
Fan pulley fixing
Fan spacer or accessory pulley fixing (on request)
M6 10 2 1.0 0.2
M10 43 6 4.3 0.6
M12 77 12 7.7 1.2

TORQUE
COMPONENT
Nm kgm
Stud fixing for M8 fuel pump assembly 12 2 1.2 0.2
M8x1.5 injection pump fixing screws 24 4 2.4 0.4
M18x1.5 injection pump gear fixing nut closure 105 5 10.5 0.5
Fixing of the unions between the injection pump and the M12x15 Common Rail 20 2 2.0 0.2
Injector fixing screws 3.5 0.35 0.35 0..35
Injector connector fixing screws 1.5 0.25 0.15 0..25
Oil pressure regulator sensor fixing 82 0.8 0.2
Fixing of distribution shaft sensor in the M6 gear box 82 0.8 0.2
Fixing of engine shaft speed sensor on the M6 front cap 82 0.8 0.2
Fixing of the temperature sensor on the M14x1.5x12 cylinder heads 20 3 2.0 0.3
Fixing of the air temperature sensor on the M6x1x20 intake manifold 31 0.3 0.1
Fixing of the air pressure and temperature sensor on the intake manifold M5 31 0.3 0.1
Fuel pressure sensor fixing 35 5 3.5 0.5
M14x1.5x12 fuel temperature sensor fixing 20 3 2.0 0.3
Fixing of gear on the 5/8 air compressor 125 19 12.5 1.9
Air compressor fixing on the M12 base 81 12 8.1 1.2
2nd stage 80 6 8 0.6
3rd stage 90 5
2nd stage 60 5


F4DE N ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS F4DE N ENGINES

TOOLS
99317915 Set of 3 pin wrenches (14 - 17 - 19 mm)

99327281 Tester PT-BOX
99341001 Double acting puller

TOOLS
99341009 Pair of brackets
99341015 Press

TOOLS
99360339 Tool for rotating/stopping the engine flywheel

99360362 993700069)

TOOLS
99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)

TOOLS
Torque screwdriver for injector solenoid valve connector stop nut

99389834 setting
99395603 Dial gauge (0 5 mm)


F4DE N ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3

2 APPENDIX F4DE N ENGINES

F4DE N ENGINES APPENDIX 3

not sufficient to ensure safety to the personnel in-charge of
maintenance. - In case of test or calibration operations requiring engine
adequate aeration.
- Ensure that working areas are provided with emergency During maintenance
boxes, that must be clearly visible and always provided - Never open filler cap of cooling circuit when the engine
with adequate sanitary equipment. is hot. Operating pressure would provoke high
- Provide for adequate fire extinguishing means, properly temperature with serious danger and risk of burn. Wait
indicated and always having free access. Their efficiency unit the temperature decreases under 50C.
must be checked on regular basis and the personnel must - Never top up an overheated engine with cooler and
be trained on intervention methods and priorities. utilize only appropriate liquids.
- Organize and displace specific exit points to evacuate the - Always operate when the engine is turned off: whether
areas in case of emergency, providing for adequate particular circumstances require maintenance
indications of the emergency exit lines. intervention on running engine, be aware of all risks
- Smoking in working areas subject to fire danger must be involved with such operation.
strictly prohibited. - Be equipped with adequate and safe containers for
- Provide Warnings throughout adequate boards signaling drainage operation of engine liquids and exhaust oil.
danger, prohibitions and indications to ensure easy - Keep the engine clean from oil tangles, diesel fuel and or
comprehension of the instructions even in case of chemical solvents.
emergency.
Prevention of injury originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Disconnect batteries before any intervention on the
- Wear safety helmet when working close to hanging loads electrical system.
or equipment working at head height level.
- Disconnect batteries from system aboard to load them
- Always wear safety shoes when and cloths adhering to the with the battery loader.
body, better if provided with elastics at the ends.
- After every intervention, verify that battery clamp polarity
- Use protection cream for hands. is correct and that the clamps are tight and safe from
- Change wet cloths as soon as possible accidental short circuit and oxidation.
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections in
efficiency of earth and mass electrical connections. Ensure presence of electrical feed.
that hands and feet are dry and execute working - Before proceeding with pipelines disassembly
operations utilizing isolating foot-boards. Do not carry out (pneumatic, hydraulic, fuel pipes) verify presence of liquid
working operations if not trained for. or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
- Put the dirty rags with oil, diesel fuel or solvents in anti-fire injury and poisoning.
specially provided containers.

4 APPENDIX F4DE N ENGINES

changed.
danger.
connections.

F4GE N ENGINES 1
Part 4
F4GE N ENGINES
Sezione
Fuel 2
Duty - Industrial application 3
Tools 5

2 F4GE N ENGINES

F4GE N ENGINES 3
SPECIAL REMARKS
Where possible, the same sequence of procedures has been followed for easy reference.
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.
Example
1 1 = housing for connecting rod small end bush

Tighten to torque
Tighten to torque + angular value

2 2 = housing for connecting rod bearings

4 F4GE N ENGINES
SYMBOLS - ASSISTANCE OPERATIONS
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly
Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Higher than.
Strained assembly
Maximum, peak
Undersized
Thickness
Less than.
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer

F4GE N ENGINES 5
UPDATING
3 Industrial application 25 - 55 Revi-September 2012

6 F4GE N ENGINES

F4GE N ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
Page
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OIL VAPOUR RECIRCULATING SYSTEM . . . . . 6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 7
- Boosting version engines . . . . . . . . . . . . . . . . . 9
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) 11

2 SECTION 1 - GENERAL SPECIFICATIONS F4GE N ENGINES


F4GE9454H*J601
F4GE9454J*J600
F4GE9454H*J600 N45 MSS.X
F4GE9454H*J603
F4GE9454H*J605
F4GE9454H*J602
N45 MNS.X
F4GE9454J*J601
F4GE9484D*J601
N45 MST.X
F4GE9484F*J603
F4GE9484D*J602
F4GE9484D*J609
F4GE9484D*J612
F4GE9484D*J613
F4GE9484D*J610
N45 MNT.X
F4GE9484D*J614
F4GE9484J*J602
F4GE9484F*J604
F4GE9484F*J607
F4GE9484F*J611
F4GE9684P*J601
N67 MST.X
F4GE9684P*J602
F4GE9684A*J602 N67 MNT.X

LUBRICATION Lubrication involves the heat exchanger (2,3), the

Lubrication by forced circulation is achieved through oil rotary turboblower for turbocompressed versions, and for any
expansion pump, placed in the front part of the basement, compressed air system.
driven by the straight-tooth gear splined to the shafts bar hold. All these components may often vary according to the specific
From the pan, the lubrication oil flows to the driving shaft, to duty.
Figure 1
Routing of oil
under pressure
Routing of oil return
by gravity to sump
Introduction of oil
116396
LUBRICATION SYSTEM LAYOUT (4 cylinder engine)

1. Heat exchanger body - 2. Lubrication oil pipe to supercharger - 3. Oil filter - 4. Heat exchanger -
5. Oil rotary expansion pump.

Figure 2
112886
LUBRICATION SYSTEM LAYOUT (6 cylinder engines)

1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger - 4. Oil rotary expansion pump -
5. Oil filter.

OIL VAPOUR RECIRCULATING SYSTEM
Figure 3
003240t
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).

COOLING SYSTEM - Heat exchanger to cool the lubrication oil: even this
The engine cooling system, closed circuit forced circulation component is part of the engines specific equipment.
type, generally incorporates the following components: - Centrifugal water pump, placed in the front part of the
- Expansion tank; placement, shape and dimensions are engine block.
subject to change according to the engines equipment. - Thermostat regulating the circulation of the cooling liquid.
- Radiator, which has the duty to dissipate the heat - The circuit may eventually be extended to the
subtracted to the engine by the cooling liquid. Also this compressor, if this is included in the equipment.
component will have specific peculiarities based on the
equipment developed, both for what concerns the
- Visc pusher fan, having the duty to increase the heat
will be specifically equipped based on the engines
development.
6 cylinders version
Figure 4
TO RADIATOR
FROM RADIATOR
117586
COOLING SYSTEM LAYOUT (4 cyl. engines)

6 cylinders version
Figure 5
TO RADIATOR
FROM RADIATOR
117587
COOLING SYSTEM LAYOUT (6 cyl. engines)


Boosting version engines
Figure 6
AIR FILTER TURBOCHARGER
EXHAUST
4 cylinders version
EXHAUST
6 cylinders version
88208
Description
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust collector
feeding pressure , one main body and one compressor. before the turbine and connected by piping to the induction
During engine working process, the exhaust emission flow collector.
through the body of the turbine, provoking the turbine disk Its duty is to choke the exhaust of the emissions , releasing part
wheels rotation. of them directly to the exhaust tube when the boost feeding
The compressor rotor, being connected by shaft to the pressure, over the compressor, reaches the prescribed bar
turbine disk wheel, rotates as long as this last one rotates, value.
compressing the sucked air through the air filter. The cooling process and the lubrication of the turbocharger
The air coming out of the compressor is sent via the intake and of the bearings is made by the oil of the engine.
manifold directly to the pistons.


Inter-cooled engine version
Figure 7
EXHAUST
RADIATOR
74195
4 cylinders version
EXHAUST
RADIATOR
74195
6 cylinders version
Description
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust collector
feeding pressure , one main body and one compressor. before the turbine and connected by piping to the induction
collector.
During engine working process, the exhaust emission flow
through the body of the turbine, provoking the turbine disk Its duty is to choke the exhaust of the emissions , releasing part
wheels rotation. of them directly to the exhaust tube when the boost feeding
pressure, over the compressor, reaches the prescribed bar
value.
turbine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter. The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
emission of NOx .
Figure 8
114789


F4GE N ENGINES SECTION 2 - FUEL 1
SECTION 2
Fuel
Page
4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTA-

RY MECHANICAL PUMP . . . . . . . . . . . . . . . 3
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Example of identification . . . . . . . . . . . . . . . . . 5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6-CYLINDER ENGINES WITH BOSCH VE 6/12 F ROTA-

RY MECHANICAL PUMP . . . . . . . . . . . . . . . 8
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-CYLINDER ENGINES WITH DELPHI ROTARY

MECHANICAL PUMP . . . . . . . . . . . . . . . . . . 12
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2 SECTION 2 - FUEL F4GE N ENGINES


General information
- Injectors
Figure 1
2
1
4
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.

Figure 2
116385
the camshaft.
The fuel drawing from the injectors is recovered and
with heater).
delivered to the tank again.

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
Figure 3
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
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.

PRIMING PUMP
Figure 4
88209

FUEL FILTER
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.
Figure 5
88210
1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.


General information
- Fuel feed pump
- Injectors
Figure 6
86495
1. Injector fuel pipe 1 - 2. Injector fuel pipe 2 - 3. Injector fuel pipe 3 - 4. Injector fuel pipe 4 - 5. Injector fuel pipe -
6. Injector fuel pipe 5 - 7. Injector fuel pipe 6 - 7. Injector fuel pipe 6 - 8. Injection pump - 9. Injector.

Figure 7
114799
Fuel is sucked from the fuel tank by the priming pump. This
Fuel is delivered to the pressure gauge valve within feed
last one is placed on the engine basement and is driven by
pump.
the camshaft.
Timing plungers further increase the pressure and deliver fuel
Throughout the filter/s, the fuel is piped to the union fitting
to the injectors throughout the delivery pipe fittings.
vacuum chamber of the transfer pump. (For applications to
be equipped in cold climate areas, the fuel filter is provided Fuel bleeding from the injectors is recovered and piped back
with heater). to the pump.

PRIMING PUMP
Figure 8
88209

FUEL FILTER
On the filter cartridge base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the
bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a
temperature sensor (5).
Figure 9
88210
1. Fuel filter bearing - 2. Filter cartridge - 3. Bleender vent screw.

4-CYLINDER ENGINES WITH DELPHI ROTARY MECHANICAL PUMP

General information
- Injectors
Figure 10
127132
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Connector for LDA pressure gauge pipe within suction
collector - 4. Fuel feed rotary pump - 5. Electro-valve - 6. KSB thermal bulb - 7. KSB Sensor - 8. Injector.

Figure 11
127134
the camshaft.
The fuel drawing from the injectors is recovered and delivered
with heater).
to the tank again.

PRIMING PUMP
Figure 12
88209

FUEL FILTER
On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage.
Figure 13
127131
1. Bleed screw - 2. Fuel filter bearing- - 3. Filter cartridge - 4. Water dump screw.


F4GE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 1
SECTION 3
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 5
F4GE ENGINE CHARACTERISTICS . . . . . . . . . . . . 6
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE ENGINE CHARACTERISTICS . . . . . . . . . . . . 7
PART ONE - MECHANICAL COMPONENTS . . . 11
OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Disassembly of application components . . . . . . 14
- Installation of rear components . . . . . . . . . . . . 23
- Installation of rear components with reduced
distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Flywheel installation . . . . . . . . . . . . . . . . . . . . . 28
- Installation of front components . . . . . . . . . . . . 28
- Timing of additional masses . . . . . . . . . . . . . . . 30
- Assembly of additional masses . . . . . . . . . . . . . 30
- Completion of engine re-assembly . . . . . . . . . . 39
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
- Power take-off disassembly and assembly
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Feed system bleed procedure . . . . . . . . . . . . . . 43
- Checks and controls . . . . . . . . . . . . . . . . . . . . . 44
OVERHAUL OF THE 6 CYLINDER ENGINE PROVIDED
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4GE N ENGINES
Page Page
- Removing components from application . . . . . 46 PART TWO -

ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES
- Installation of front components . . . . . . . . . . . . 56 WITH ROTARY PUMP) . . . . . . . . . . . . . . . . . . 105
- Completion of engine re-assembly . . . . . . . . . . 66 - Cooling liquid temperature sensor . . . . . . . . . . 106
- Checks and inspections . . . . . . . . . . . . . . . . . . . 66 - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
- Rotary feed pump disassembly and assembly - KSB Water temperature sensor . . . . . . . . . . . . 106
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
- Electromagnets assembled to feed pump . . . . . 107
- Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . 107
- Power take-off disassembly and assembly
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
- Checks and controls . . . . . . . . . . . . . . . . . . . . . 71 - Pre-post heating resistor . . . . . . . . . . . . . . . . . . 107
REVIEW OF 4-CYLINDER ENGINE WITH ELECTRICAL COMPONENT LAYOUT (6 CYL.
DELPHI PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 72 ENGINES WITH ROTARY PUMP) . . . . . . . . . 108
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 - Cooling liquid temperature sensor . . . . . . . . . . 109
- Engine setting operations for the assembly on turning - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
- KSB Water temperature sensor . . . . . . . . . . . . 109
- Disassembly of application components . . . . . . 73
- Installation of rear components . . . . . . . . . . . . 81
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
- Pre-post heating resistor . . . . . . . . . . . . . . . . . . 110
- Installation of front components . . . . . . . . . . . . 85
ELECTRICAL COMPONENT LAYOUT . . . . . . . . . 111
- Assembly of additional masses . . . . . . . . . . . . . 86
4 CYLINDER ENGINE WITH DELPHI PUMP . . . . 111
- Timing of additional masses . . . . . . . . . . . . . . . 87
- Cooling liquid temperature sensor . . . . . . . . . . 112
- Completion of engine re-assembly . . . . . . . . . . 96
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 - Cooling liquid temperature sensor . . . . . . . . . . 112
- Power take-off disassembly and assembly - Electromagnets assembled to feed pump . . . . . 113
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
PART THREE - TROUBLESHOOTING . . . . . . . . . 115

Page
PART FOUR - MAINTENANCE PLANNING . . . . 123

MAINTENANCE PLANNING . . . . . . . . . . . . . . . . 125
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
- Planning of controls and periodical intervention 125
- Checks not included in maintenance planning-daily
checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
- Engine oil level check . . . . . . . . . . . . . . . . 126
- Check of fuel system . . . . . . . . . . . . . . . . 127
- Cooling system check . . . . . . . . . . . . . . . 127
- Lubricating system check . . . . . . . . . . . . . 127
- Check of water presence within fuel filter

or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . 127
- Check of drive belt tensioning . . . . . . . . . 128
- Check of belts tear and wear status . . . . 128
- Check and setting of tappet clearance . . . 128
- Oil motor and filter replacement . . . . . . . 128
- Fuel filter replacement . . . . . . . . . . . . . . . 129
- Alternator belt replacement . . . . . . . . . . . 130


GENERAL INFORMATION
Figure 1
116390
NOTE Data, technical specifications and performances

NEF engines have been designed and developed by FPT granted shall be valid only if the Setter will follow and
specifically for transportation by land and farming equipment comply with all installation prescriptions provided
in general. by FTP.
They are characteristed by diesel cycle 4 stroke atmospheric Furthermore, the expanders assembled by the
or supercharged 4 and 6 cylinders each with 2 valves. Setter must always comply with couple, power and
number of revolutions based on which the engine
Feed is provided by rotary mechanical pump or on line has been designed.
according to the equipment application.
It differs from other applications because of the provision of
The section herein described is composed or four directories:
different power, power take-off for the different collector
configuration, priming pump, oil pan and boost turbine. - 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;
NOTE The picture shows application designed for 6 - electrical directory, describing the connections of the
cylinders version, 2 valves per cylinder, having fuel different components, of the pre-post heating gearbox
feed mechanical pump. (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.
F4GE ENGINE CHARACTERISTICS

4-cylinder engines
F4GE9454H*
Type
J601 J602 J600 J603 J605
Compression ratio 17.5:1
Max. output kW 74
(HP) (100)
rpm 2000

(kgm) (40) (43)
rpm 1250 1400
Loadless engine
idling rpm - -
Loadless engine
peak rpm rpm - -
Bore x stroke mm 104 X 132
SUPERCHARGING without intercooler

LUBRICATION Forced by gear pump, relief valve single action
oil filter
Oil pressure
bar (warm engine)
- idling bar 0.70

- peak rpm bar 3.50
COOLING By centrifugal pump, regulating thermostat, heat
exchanger, intercooler
Thermostat
FILLING
engine sump* liters 13

15W40 ACEA E3 engine sump
+ filter* liters 14
* First filling operation

by FPT.

F4GE ENGINE CHARACTERISTICS

4-cylinder engines
Type F4GE9454J*J6
Max. output kW 66
(HP) (90)
rpm 2000
Max. torque Nm 375

(kgm) (37,5)
rpm 1250
Loadless engine
idling rpm - -
Loadless engine
peak rpm rpm - -
SUPERCHARGING without intercooler

oil filter
Oil pressure
b (warm engine)
ar
- idling bar 0.70

- peak rpm bar 3.50
Thermostat
FILLING

15W40 ACEA engine sump
E3 + filter* liters 14

by FPT.

Type F4GE9484
J*J602 D*J6
Max. output kW 88 93
(HP) (120) (126)
rpm 2200 2200

(kgm) (52,5) (51,0)
rpm 1250 1250
Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -
SUPERCHARGING
with intercooler

oil filter
Oil pressure
ba (warm engine)
r
- idling bar 0.70

- peak rpm bar 3.50
Thermostat
FILLING
15W40 ACEA engine sump liters -

E3 engine sump
+ filter liters -

by FPT.

6-cylinder engines
F4GE9684
Type
A*J6
Max. output kW 129

(HP) (175)
rpm 2200
Max. torque Nm 770

(kgm) (77)
rpm 1250
Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -

oil filter
Oil pressure
(warm engine)
bar
- idling bar 0.70
- peak rpm bar 3.50
Thermostat
FILLING

15W40 ACEA E3 engine sump
+ filter* liters 16

by FPT.

F4GE9684P*
Type
J601 J602
Max. output kW 98
(HP) (133)
rpm 2200
Max. torque Nm 590

(kgm) (60)
rpm 1250
Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -

oil filter
Oil pressure
(warm engine)
b
a
- idling bar 0.70
r
- peak rpm bar 3.50
Thermostat
FILLING

15W40 ACEA engine sump
E3 + filter* liters 16

by FPT.

PART ONE - MECHANICAL COMPONENTS


OVERHAUL OF THE 4 CYLINDER ENGINE Figure 3

PROVIDED WITH MECHANICAL ROTARY
PUMP
Preface


operations only for what concerns the different components
NOTE For specific application exigencies, some units can


the above mentioned section is to be considered as following
Engine setting operations for the assembly on 164006
turning stand
Figure 2 - disassemble lubrication oil exhaust pipe from the
turbo-blower:
Underneath the turbo-blower loosen the two screws
(1), loosen the screw (2) fixing the pipe throughout the
stop collar (3) fixing the block; finally loosen and remove
the union (5) from the block; plug the pipe ends and the
exhaust of the turbo-blower.
Figure 4
164007

to fix it on to the stand 99322205 for the overhaul, it is 2
necessary to perform the following operations:
On the right hand side:
- disassemble the oil filter (1) from the support using tool 1
99360076; 75672
Warning: the oil filter contains inside aprx. 1 kg. of - Disassemble the starter;
engine oil. Provide for oil recovery and disposal in Properly hold the starter (1) and loosen the fixing screws
compliance with the law and regulations in force. (2);
- assemble the bracket bearing 99361037 using the four
screw threaded ports (3).
Figure 5 Figure 7
75674
From the left-hand side:

- Assemble the second bracket 99361037 throughout the 116387
screw-threaded ports (1).
- Lift the engine using the rocker arm 99360595 and put - Place a container under the fuel filter and screw out the
it on the turning stand 99322205. condense drain faucet underneath said filter. Carry out
- Drain the oil through the cap underneath the plug. complete drainage of the fuel contained therein.
- Screw out completely the faucet and, using equipment
99360076 disassemble oil filter (2).
Warning: avoid contact of engine oil with the skin: - Disconnect fuel pipelines (4 and 3) respectively from
in case of skin contamination, rinse in running water. priming pump to filter bearing and from this last one to
Engine oil is highly pollutant: provide for disposal in the feed pump.
compliance with the law and regulations in force. - Remove the fuel filter bearing (1) from the bracket fixed
to the engine head.

Figure 8
Figure 6
75675
70126
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 NOTE To disconnect fuel pipelines (2 and 3, Figure 7), in
from the upper part of the heat exchanger. low pressure from the relating pipe fittings, it is
- Loosen the screw nuts fixing the supercharger on the Necessary to press the locking fastener (1) as
exhaust manifold. shown in picture B.
- Hold up the supercharger and after lifting it remove the After having disconnected the pipeline, reset the
gasket. locking fastener (1) in lock position as shown in.
picture A, to avoid any possible deformation of the
fastener itself.

BOSCH VE 4/12 F Pump Figure 10

Figure 9
1 1
75679
75677
- Disconnect the pipelines (1) and (2) that provide feed
- Disconnect the LDA pipe (1) from the head and from and fuel recovery between pump and injectors; screw
the feed pump. Pipe the ends of the pipelines as well as out the nuts fixing the pipes to the pumping elements;
the feed pump and the engine head. loosen the fuel recovery pipe collar on the injection
pipelines (1,6, and 7, Figure 11); pipe the pipeline ends.
slot: remove the gaskets.
Figure 11
3
7
4
6 5
75680
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).

Figure 12 Figure 14
87409
88102
- Disassemble suction and exhaust manifolds: loosen the

- Loosen the two fixing screws (2) and disassemble 8 screws (1) fixing the suction manifold plate to the
priming pump (1). 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.
Figure 13
Figure 15
87406
- Remove tappet caps:

Loosen the four fixing screws (1) and lift the caps (2);
remove the gaskets.
1
75683
NOTE On the central cap there is a blow-by valve for the

lubrication oil vapours. - Disassemble rocker arm bearings; loosen the two fixing
All the gaskets shall always be replaced during screws (2) and remove the complete rocker arm bearing;
assembly. withdraw tappet rods. Repeat the operation for all the
remaining rocker arm bearings.

Figure 16 Figure 18
1 2
117588
75686
- 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 - Properly hold the alternator (1) separating it from its
the thermostat (5). bearing by loosening the screw (2); remove screw nut
and washer.
- Assemble the bracket in the original position fixing it with
the screws of the thermostat unit.
Figure 19
Figure 17
88091
88089
- Loosen the screws (1) and withdraw the alternator
- Loosen screw (1) and relevant nut on belt stretcher bearing (2).
bracket (3).
- Loosen screw (2, Figure 18) in order to slide out
POLY-V belt (2). NOTE The shape and the dimensions of the support of
the alternator vary according to the use of the
- Remove the belt stretcher bracket (3). engine. The relevant pictures provide a general
- Disassemble the driven pulleys and the guide rollers. trace of the intervention that is to be carried out.
The procedures described are always applicable.

Figure 20 Figure 22
4 75692
75810
- Loosen the screws (4) and disassemble the oil - Use the tool 99360339 (2) to operate on the flywheel
pressure/temperature sensor (3) (if fitted). cover box (1) in order to block flywheel rotation (3).
- Loosen the screws (1) and disassemble the oil filter/heat (Utilise starter holding down studs and fixing screw nuts).
exchanger bearing (2), interlayer plate (6) and relating - Loosen the flywheel fixing screws (4) to engine drive
gaskets. shaft.
- Disassemble oil level sensor (5) (whether provided).
- Disassemble injection pump (see specific procedure)
and the power take-off underneath. NOTE In some versions there is provided 99360351 tool
checking the flywheel.
Figure 21
3
Figure 23
4
75688

loosen the screws (1) and (2) fixing the cylinder head (3);
90504
- Loosen the screws (1) and disassemble the pulley (2).

Figure 24 Figure 26
116242
- Loosen the screws (1 and 3) and remove the front cover

(2).
78256 NOTE Take note of the screw (1 and 3) assembly position,

since the screws have different length.
tool guide ports, drill the internal holding ring (1) using Figure 27
3,5 mm drill for a 5mm depth. Fix the tool to the ring
tightening the 6 screws specially provided.
(3).
75811
Figure 25 - Loosen the screws (1) and remove oil pump (2).
Figure 28
1 2
3
75691
- Screw out the opposite screws (1) from the ports where
00904t
the withdrawal pins shall be introduced (see picture
following).
holding ring (2) from the front cover (1). - Remove the flywheel block tool (2).
Figure 29 Figure 31
1 4
70153
75690
- Screw up two medium length screws in the ports (4) to box (1).
Throughout two guide pins (2) previously screwed up NOTE Take note of the screw (1) assembly position, since
into the engine drive shaft ports (3) control the engine the screws have different length.
Figure 32
Figure 30
00903t
- Remove the flywheel cover box fixing ring using the

tool 99340056 (3) to operate on the back tang (5) of
the engine drive shaft. Throughout the tool guide ports, 88046
drill the internal holding ring using 3,5 mm drill for

a 5mm depth.
- Loosen the screws (2), disassemble the plate (3) and
remove the oil pan (1).
6 screws specially provided (4).
(2). NOTE The shape and dimensions of the pan and of the
rose pipe may vary according to the engine
- Using the specially provided tie rod (3) for the tool application. The relating illustrations provide
99363204 and the lever (4), withdraw the external general guidelines of the operation to be
holding ring of the flywheel cover box. performed. The procedures described are
applicable anyway.

Version with suction rose type A Figure 36

Figure 33
99222
- Loosen the screws (1) and disassemble the oil suction

rose pipe (3).
- Loosen the screws (2) and remove the stiffening plate
(4).
Version with suction rose type B
Figure 34
90505
- Loosen the screws (1) and disassemble the gear from the
camshaft (2).
86601
Figure 37
- Remove the screws (1) and (4) and disassembled the
suction rose (5).
- Remove the screws (2) and disassemble the stiffening
plate (3)
Version with additional masses
Figure 35
70157
- Loosen the screws (2) and disassemble the timing

gearbox (1).
86578 NOTE Take note of the screw (2) assembly position, since
By means of pin (1) lock the additional masses (2) in the the screws have different length.
P.M.S. Loosen the fixing screws (3) and remove the additional
masses (2).
Version with reduced distribution Figure 40
Figure 38
87424
87422
- Remove the screws (1) and disassemble the gears (3)

and (4) from the camshaft (2).
box (1).

Figure 39
87655
- Remove the gear (1) transmitting motion to the ignition


Installation of rear components Figure 42

1
Figure 41
9 10
6 8
4 3
2
1
7 5
1 75711
75712 DIAGRAM SHOWING SCREW
TIGHTENING TO FIX REAR GEARBOX
APPLICATION WITHIN GEARBOX AREAS - Reassemble to box (1) to the engine block.
- Accurately clean the timing gearbox (1) and the engine - Tighten the fixing screws in the same position as found
block. out during disassembly and fix the screws to the locking
couples listed here below, following the order as shown
in the picture.
It is necessary and essential to clean the surface to Screws M12 65 89 Nm
! be sealed in order to achieve excellent tight seal. Screws M8 20 28 Nm
Screws M10 42 52 Nm
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, the ports and of the screws have no evidence of
thinner or irregular zones. tear and wear nor dirt.
as possible.
Figure 43
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.
70211

(1) mounted on the engine shaft (2) upon the upright
surface on which a groove has been created for the
ignition timing.


Figure 44 Figure 46
90508
90506
- Tighten the screws (1) fixing the gear to the camshaft (3)
- Turn the engine shaft (3) and the distribution shaft (4) and lock them to the prescribed couple.
Figure 47
Figure 45
90507 1
75708
- 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. DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION.
Figure 49
be uniform (no crumbs), with no air blisters, thinner
or irregular zones.
as possible.
sides of the joint and obstruct lubricant passages.
0901t
- Apply to engine drive shaft rear tang (6), the detail (5)
of the tool 99346253, 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).
Figure 48
1
16 15 Figure 50
8 14 7
17
6 1 2
18 13
5
19 12
11
20 1
2
21
4 9 10 3
75709 75696
DIAGRAM SHOWING SCREW

TIGHTENING TO FIX FLYWHEEL COVER BOX. - Check the contact surface (1) of the clutch plate and if
it is scratched, proceed with turning.
- Reassemble the box (1) to the engine block, tighten the
fixing screws in the same position as found out during - Check ring gear teeth (2), if breakage or excessive wear
disassembly and fix the screws to the locking couples is found remove the ring gear from the engine flywheel
listed here below, following the order as shown in the (1) using a suitable hammer and fit the new one,
picture. previously heated to 150C for 15 to 20 minutes.
Chamfering on ring gear inside diameter shall be facing
Screws M12 75 95 Nm the engine flywheel.
Screws M10 44 53 Nm
Before assembly, always check that the threads of

! the ports and of the screws have no evidence of tear
and wear nor dirt.

Installation of rear components with reduced Figure 53

distribution
Figure 51
87653
in the range between 0,076 0,280 mm.
70211
- With a felt-tip pen, highlight the conducting gear tooth Figure 54

surface on which a groove (3) has been created for the
ignition timing.

Figure 52
87654
Figure 55
116375
87655

pump.
Figure 56 Figure 58
87656 87658
Figure 57
Figure 59
87657

APPLICATION

be uniform (no crumbs), with no air blisters, thinner 87659
or irregular zones.
Couplings must be assembled within 10 minutes completed.

Flywheel installation Installation of front components

Figure 60
Figure 63
1 4
75690
- 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. 70220
- Screw up to pins (2) having appropriate length, in the
shaft ports (3) and using them as guide, assemble the - Assemble oil pump (1).
engine flywheel (1) properly placing it inside the flywheel - Tighten fixing screws (2) and lock them to the prescribed
cover box. couple.
Figure 61
2 Figure 64
4 75692
- Tighten the screws (4) fixing the engine flywheel (3) to

the engine shaft. Use tool 99360339 (2) to operate on 70221
the flywheel cover box (1) to block engine flywheel
rotation. - Apply to the water pump (1) a new fixing ring (2).
Figure 62
1
Figure 65
75695

phases:
- 1st phase; tightening by means of dynamometric wrench
to couple 30 4 Nm;
- 2nd phase, 60 5 angle dwell with tool 99395216. 76112
NOTE Before assembly, always check that the threads of - Assemble the water pump (1).
tear and wear nor dirt. - Tighten the screws (2) and lock them to the prescribed
couple.
Figure 66 Figure 69
106549
- Remove the fixing ring (2) from the front cover (1), 00902t
accurately clean the plug surface.
- Apply on engine drive shaft front tang (6) the detail (4)
Figure 67 of the tool 99346252, 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.
Figure 70
87260
- Assemble the plate (1), the rose pipe (2), tighten the
75710
fixing screws (3) and fix them to the prescribed couple.
- Accurately clean the contact surface of engine block and
apply sealing LOCTITE 5205 on it in order to form a Figure 71
uniform and continuous kerbstone with no crumbs.
Figure 68
86601
106550
- Assemble the front cover (2) to the block and tighten - Assemble the plate (3), the suction rose (5) and tighten
the screws (1) fixing them to the prescribed couple. the fixing screws (1, 2 and 4) to the prescribed torque.

Assembly of additional masses Fit the additional masses (2) and tighten the screws (3) on
the engine block.
Figure 72
Remove the lock pin (1) of the additional masses.
86578
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.
Figure 73
86614
1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) -
4. Additional masses.
zs
Figure 74 Figure 76
- Provide for new gasket replacement (1) of the oil pan (2).
3
NOTE 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.
Figure 75 1 2
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
75814

88046 bearing (4).
- Assemble oil pan (1), apply the plate over it (2). Tighten Tighten the screws (5) and lock them to the prescribed
the screws (2) and lock them to the prescribed couple. couple.
NOTE Before assembly, always check that the threads of NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of the ports and of the screws have no evidence of
tear and wear nor dirt. tear and wear nor dirt.

zs
Figure 78 Figure 80
1 2
76113
- Lubricate the fixing ring (2) using engine oil and place it 75686
on the oil filter (3).
- Manually start the oil filter (3) on the bearing union (1) - Connect the alternator (1) to the support.
until counter-boring, further screw up the oil filter (3) by - Tighten the screw without locking it (2).
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.
Figure 79
Figure 81
76114
- Assemble the alternator bearing (1) ensuring that the 87759
pins (3 and 4) are against the engine block.

- Tighten the screws (2) and lock them to the prescribed The choice of the gaskets thickness shall be made in
couple. consideration of the cylinder protrusion measured with
respect to the blocks upper surface.
NOTE 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 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
NOTE Before assembly, always check that the threads of the cylinder head.
the ports and of the screws have no evidence of Gasket assembly shall be made following the
tear and wear nor dirt. direction of wording printed on the gasket itself so
that this will be readable as indicated in the picture.

Figure 82 Figure 84
1 4
2 1
3
3 2
2
1 3
75705
4
75688
- Place the head (3) over the block and insert screws (1) - Carry out the assembly of the rocker arms after previous
and (2). check of the components.
NOTE If the valves have been removed from the head, it ROCKER ARM UNIT COMPONENTS:
is necessary to assemble them before assembling 1. Elastic ring - 2. Spacer- 3. Rocker arms-
the head itself on the engine block. 4. Support.
Figure 85
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again; 18.975
if D1 - D2 > 0,1 mm the screw must be replaced. 18.963
D2 D1
75703
19.000 19.000
Figure 83
19.026 19.026
75704
SHAFT AND ROCKER ARM BASIC DATA

10 4 1 5 11 Check the coupling surfaces of bearing and shaft: no evidence
13 7 2 8 14
9 3 6 12 Figure 86
1
76115

- Bolts must be torqued using stitching pattern starting 19.00
with the centre bolts and moving out. Bolts to be 16.00
75702
90 degrees rotation for all bolts. Then a further 90
degrees for the M12 x 140 and M12 x 180. ROCKER ARM ADJUSTMENT SCREW
M12 x 70 50 Nm + 90 degs If unscrewed, check adjustment quota.

M12 x 140 40 Nm + 180 degs Tighten the screw-threaded nut (1) to the i 0.4 - 0.6 Nm
M12 x 180 70 Nm + 180 degs couple.

Figure 87 Figure 89
2
1
32655
75683
Before executing assembly, check the Rocker Arm driving
rods: these shall not be deformed; the spherical ends in - Tighten the screws (2) to the prescribed couple and
contact with the Rocker Arm adjustment screw and with the assemble water temperature sensor (1).
tappet (arrows) shall not present evidence of seizure or wear: Figure 90
in case of detection proceed replacing them.
and therefore interchangeable. 2 1
3
Figure 88
D2 D1
75703 75806
- Insert the tappet driving rods and the Rocker Arm unit. wrench (1), point wrench (3) and feeler gauge (2).
Before using the fixing screws again, measure them twice Correct slack is:
as indicated in the picture, checking D1 and D2 - suction valves 0.25 0.05 mm
diameters: - exhaust valves 0.50 0.05 mm.

Figure 91 Figure 93
2
1
75808
75707
- Assemble exhaust manifold (1) providing new gaskets

- Assemble injectors after having replaced the sealing (2).
gasket (1).
NOTE The illustration of exhaust manifold may be not
NOTE During assembly of injectors, verify that the injector matching your model. Anyhow, described
sphere is correctly positioned on the head housing. procedure is applicable.
Figure 92
Figure 94
117588
87406
- Assemble cylinder covers (2) with the respective gaskets; - Assemble thermostat unit (2) including thermostat (5)
and gasket (4).
- Fit the seal nods and tighten the screws fixing them to
the prescribed couple. - Tighten the screws to the prescribed couple.
NOTE Always replace the gaskets using new ones. the bracket (3).
Check the threads of the fixing screws: there shall Disassemble the bracket and reassemble
be no evidence of wear or dirt deposit. components from 1 to 5 as shown in the picture.
Seal nods shall have no visible deformation. In such The gasket must be new.

Figure 95 Figure 96
88090
1
- Tighten the control belt turning the alternator as
illustrated.
- Tighten the screws (1) and the alternator fixing bolt to
the support.
75687
Figure 97
- Assemble the pulley fan bearing tightening the screws to

the prescribed couple. 1 7
- Assemble the alternator tensioning bracket. 2
- Mount pulley (3) and secure it to support through 6
screws (2).
- Assemble the transmission pulley (1). 5
- Fit the new belt onto the pulleys and guide rollers.
4
3
NOTE If the old belt is to be reassembled examine it
carefully in order to see if there may be incisions or 75701
evident signs of yielding.

- 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.
NOTE For the versions provided with heater, also

assemble components (3) and (4).

Figure 98 Figure 99
1 88102
- Assemble priming pump (1) providing new gasket and

- Also assemble feed pump (see specific procedure) and
the power take-off underneath.
NOTE Pump mounting requires specific procedure

contained in this section.
75700
- 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.
BOSCH VE 4/12 F pump

Figure 100
3
7
4
6 5
75680
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).

1 1
75679 116387

to the engine head.
Screw up the locking nuts and tighten the screws fixing - Connect the fuel pipelines (4 and 3) respectively from
the fuel recovery manifold; fix the pipes to the injectors priming pump to filter bearing and from this last one to
throughout the brackets previously assembled. feed pump.
NOTE The filter shall be priory filled with fuel to facilitate

feed system bleed operations.
Figure 104
Figure 102
70126
75677
low pressure from the relating connection unions
shown in picture B.
- Fix the LDA pipeline (1) to the engine head and to the
feed pump. After having connected the pipeline, reset the
A.

Figure 105 Completion of engine re-assembly
1 Figure 106
75675

- Hold the turbocharger and place it on the exhaust
- Screw up the fixing nuts of the turbocharger to the
exhaust manifold tightening them to the prescribed
couple.
the upper part of the heat exchanger.
To complete engine assembly it is necessary to remove it
from the turning stand. 164004
From the right-hand side:

- Using rocker arm 99360595 hold the engine and loosen
the screws fixing the brackets to the turning stand - Re-assemble the lubrifying oil discharge pipe (6) from the
99322205. turbo-blower by inserting the joint (5) into the engine
crankcase and tightening the two fastening (1) screws
- Disassemble the brackets 99361037 from the engine
underneath the turbo blower;
after having properly put it on a wooden bearing.
- Tighten the screw (2) which holds the piping to the (6)
monoblock by means of the cylinder bracket (3);
- Re-assemble the oil filter (4) onto the heat exchanger
with tool 99360076;
Figure 107
1
75717
- re-assemble the starting engine (1); opportunely support

the starting engine (1) and tighten the two fastening
screws to the prescribed torque.

Rotary feed pump disassembly and assembly In case feed pump replacement is necessary, this shall be
procedure supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
NOTE This procedure prescribes that: and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the engine
- the fuel pipes (from the pumping elements to and disassemble it only afterwards.
the injectors, recovering blow-by from the
injectors to the pump and the supply from the The following procedure analyses this second hypothesis
priming pump) have all been removed; since it is the more complex.
- the electrical connections have been Find the top dead centre with the tool (99395097) - False
disconnected. injector
- Accelerator cable shall be disconnected. Figure 110
Engine versions with tool (99360330)

Figure 108
88141
Remove the rocker covers of the 1st cylinder; remove the 1st
injector and place the tool (1) to set the 1st cylinder top dead
1 centre position (end-of-compression phase). Pre-load the
gauge.
88140
Disassemble the starter from the flywheel box and use tool valves are both closed.
99360330 to rotate the flywheel. Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 109).
Searching for the top dead centre with timing gear blocking
Figure 109 pin
Figure 111
75714
84071
Disassemble the starter from the flywheel box (1) and use Turn the flywheel until, when pushing the pin 99360616 (1),
tool 99360339 (2) to rotate the flywheel. it blocks the gear (2) obtaining the TDC of the 1 cylinder.

zs

Figure 112
1
2 1
75694
75721
- From the pump side, loosen the fixing nuts (1) without
- Unscrew the side screw that locks the pump shaft removing them in order to enable moving the pump
partially (1) and remove spacer (2). This must be kept on backwards using 99340035 extractor.
a side (we recommend to fix it on the pump with a wire - Assemble the 99340035 extractor throughout the two
or a clip). threaded ports (4, Figure 113) and withdraw the gear
- Tighten the lateral screw (1) blocking rotation of the from the pump shaft.
pump shaft. - Properly hold the feed pump and loosen completely the
fixing nuts.
Figure 113
- Withdraw the pump from the studs, together with the
gasket.
1 4
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.
NOTE Hold the pump driving gear to avoid interference

or crawling during timing gear rotation.
2 3
75693
- From timing side, remove the cover (2) loosening the

screws (1) in order to have access to the union fixing nut
(3) to the pump driving gear.
- Loosen the fixing nut (3) and remove the relating
washer.

zs
1 2
75721
- Loosen screw (1) that prevents pump shaft rotation and

75694 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 116) including gasket and
- Assemble the pump pre-set in its housing on the engine, tighten the screws (1, Figure 116).
fitting the shaft into the gear port (not provided with - Disassemble the flywheel rotation/locking tool 99360339
or 99360330; arrange the starting motor in its seat.
wrench). - Connect all pipelines (from pumping elements to injectors,
- Tighten the fixing nuts (1) locking the pump flange in the bleeding recovery pipes from injectors to pump, LDA
slot centre. pipeline and feed provided by priming pump).
- Connect electrical connections to electro-magnets on the
hydraulic head and on KSB.
NOTE The gasket removed during pump disassembly shall

not be utilised again. NOTE If the pump has been removed with the engine
Always use original spare parts. mounted, connect the accelerator cable, if present
in the application.

Figure 116
1 4
2 3 87720
75715
- With the injection pump inserted in relating seat and
securing screws loosened, mount comparator
99395603 (2) and 99395100 gauge tool (1), preloading
- On the timing side, throughout the specially appointed the rod by 2.5 mm.
- Rotate the engine derive shaft to shift from the condition
port, fit the washer and screw up the fixing nut (3) to the of the first cylinder to TDC end of compression phase.
pump shaft. Lock the nut to the 90-95 Nm couple. Reset the dial gauges and rotate the engine drive shaft
compression (see Figure 111).

Feed system bleed procedure Power take-off disassembly and assembly

procedure
Version with B type fuel filter
Figure 119 (Demonstration) Figure 120
1 4 3
2 75720
87751
Where designed, there is a power take-off able to transmit
motion to different auxiliary parts.
- Disconnect the fuel pipe (1) of the filter and repeat Disassembly of such mechanism shall be executed as
working on the drain lever (2) of the priming pump. following:
- Continue the operation until when fuel outflows. - Loosen the two screws (3) and after having removed the
- Connect the (1) to the filter. 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 new gasket and checking the sprocket
gear meshing.
- Assemble cover and gasket and tighten the screws to the
prescribed couple.

Checks and controls
The following tests shall be made after engine

! assembly to the vehicle.
correctly restored.

- There is no water bleeding from the manifolds

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.
- Verify correct working of the lighting leds of the
equipment that was disconnected during engine
disconnection.

OVERHAUL OF THE 6 CYLINDER ENGINE Figure 122

PROVIDED WITH MECHANICAL ROTARY
PUMP
Preface
76147
- Assemble the bracket bearing 99361037 using the four

NOTE For specific application exigencies, some units can screw threaded ports (1).
Figure 123

turning stand
Figure 121
76145
- Assemble the second bracket 99361037 throughout the

screw-threaded ports (1).
- Lift the engine using the rocker arm 99360595 and put
it on the turning stand 99322205.
76146 - Drain the oil through the cap underneath the plug.
In order to apply to the engine crankcase, the engine fixing

brackets 99361037 to trestle 99322205 and to carry out an Warning: avoid contact of engine oil with the skin:
adequate revision, proceed in the following manner. in case of skin contamination, rinse in running water.
From the left-hand side: Engine oil is highly pollutant: provide for disposal in
- Disassemble the starting engine (1); opportunely compliance with the law and regulations in force.
support the starting engine (1) and unscrew the
fastening screws (2).

Removing components from application Figure 125

Figure 124
116389
- 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 (2) fixing the supercharger on the
exhaust manifold.
- Hold up the supercharger and after lifting it remove the
gasket.
164004
- Undo the screw (2) which holds the lubrifying oil

discharge pipe (6) from the turbo-blower to the
monoblock by means of the cylinder bracket (3). Figure 126
- Undo the two fastening screws (1) of the piping (6)

leading to the turbo-blower.
- Remove the lubrifying (6) oil discharge pipe from the
turbo-blower by undoing the junction from the (5)
engine crankcase and blocking the tube ends and the
turbo-blower exhaust.
- Remove the oil filter by (4) using tool 99360076.
116387
Warning: the oil filter contains inside aprx. 1 kg. of - Place a container under the fuel filter and screw out the
engine oil. condense drain faucet underneath said filter. Carry out
Provide tank with sufficient capacity to contain the complete drainage of the fuel contained therein.
liquid.
- Screw out completely the faucet and, using equipment
Warning: avoid contact of engine oil with the skin: 99360076 disassemble oil filter (2).
in case of skin contamination rinse in running water.
- Disconnect fuel pipelines (4 and 3) respectively from
Engine oil is highly pollutant: provide for disposal in priming pump to filter bearing and from this last one to
compliance with the law and regulations in force. the feed pump.
- Remove the fuel filter bearing (1) from the bracket fixed
to the engine head.

70126
88143
- Disconnect the supply pipe unit from the injectors (1).

NOTE To disconnect fuel pipelines (3 and 4, Figure 126),
in low pressure from the relating pipe fittings, it is - Remove fuel exhaust pipe (2) from the injectors by
Necessary to press the locking fastener (1) as removing screw (4) and seal (3).
shown in picture B.
After having disconnected the pipeline, reset the Figure 130
locking fastener (1) in lock position as shown in.
picture A, to avoid any possible deformation of the
fastener itself.
BOSCH VE 6/12 F Pump

Figure 128
76148
Figure 131
88142
- 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.
- Disassemble the pipes (2) that constitute the fuel
recovery and supply between the pump and the
injectors. 76150
- Loosen the screws (1, Figure 130 and Figure 131)

holding the fixing brackets of such pipelines; pipe the
pipeline ends.

76149
76151
- Remove tappet caps:
Loosen the fixing screws (1) and lift the caps (2);
remove the gaskets. - Disassemble suction and exhaust manifolds: loosen the
screws (1) fixing the suction manifold plate to the
cylinder head (some of them have already been
NOTE On the tappet cap there is a blow-by valve for the screwed-out since fixing the pipe brackets to the
lubrication oil vapours. injectors); from the exhaust manifold side loosen the (2)
All the gaskets shall always be replaced during fixing screws; remove the gaskets.
assembly.
Figure 135
2
Figure 133
75683

screws (2) and remove the complete rocker arm bearing;
84082
withdraw tappet rods. Repeat the operation for all the
- Remove injectors (2) with tool 99340205 (1) and take
out the cylinder head.

1 2
75686
88089
- Properly hold the alternator (1) separating it from its

- Loosen screw (1) and relevant nut on belt stretcher bearing by loosening the screw (2); remove screw nut
bracket (3). and washer.
- Loosen screw (2, Figure 138 page 45) in order to slide
out POLY-V belt (2).
- Remove belt stretcher bracket (3).
- Disassemble the control pipe pulleys and the guide
rollers.
Figure 139
Figure 137
117588
88091
- Disassemble thermostat unit; loosen the three fixing

screws (1) and disassemble the thermostat unit (2) - Loosen the screws (1) and withdraw the alternator
together with the bracket (3); remove the gasket (4) and bearing (2).
the thermostat (5).
- In order to facilitate head overhauling operations at the NOTE The shape and the dimensions of the support of
test bench keep bracket (3) assembled on it by fixing it the alternator vary according to the use of the
with the thermostat unit screws. engine. The relevant pictures provide a general
trace of the intervention that is to be carried out.
The procedures described are always applicable.

70141 4 75692
- Loosen the screws (4) and disassemble the oil - Apply the suitable tool (2) on the flywheel covering box
pressure/temperature sensor (3) (if fitted). (1) in order to lock flywheel (3) rotation. (use the starting
motor fixing nuts and studs).
- Loosen the screws (1) and disassemble the oil filter/heat
exchanger bearing (2), interlayer plate (6) and relating - Loosen the flywheel fixing screws (4) to engine drive
gaskets. shaft.
- Disassemble oil level sensor (5) (whether provided).
- Disassemble injection pump (see specific procedure).
Figure 143
Figure 141
3 74175
- Unloose the screws (3) and disassemble the damping

flywheel (2) and the pulley (1).
76152

loosen the screws (1) and (2) fixing the cylinder head (3); NOTE In some versions, the phonic wheel mounted on
hook the brackets with metal ropes and, throughout a pulley (1) may be not present and pulley (1) can
hoist withdraw cylinder head from the block. be different from the pulley shown in Figure 143.

70148
- Remove the screws (1) and disconnect the water pump 00904t
(2).
- Remove the screw (3) and the roller (4). 99363204 and the lever (4), withdraw the external
- Remove the screw (5) and disconnect the engine speed holding ring (2) from the front cover (1).
sensor (6).
116242
00900t - Loosen the screws (1 and 3) and remove the front cover
(2).
front tang (2) of the engine drive shaft. Throughout the NOTE Take note of the screw (1 and 3) assembly position,
tool guide ports, drill the internal holding ring (1) using since the screws have different length.
(3).

1 4
3
75811
75690
- Loosen the screws (1) and remove oil pump (2).

Throughout two guide pins (2) previously screwed up
Figure 149
1 2
Figure 151
75691
- Screw out the opposite screws (1) from the ports where
the withdrawal pins shall be introduced (see picture
following).
- Remove the flywheel block tool (2). 00903t
- Remove the flywheel cover box fixing ring using the tool
99340056 (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.
(2).


1
9 10
6 8
4 3
2
1
7 5
75711
- 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

tear and wear nor dirt. 90506
- Orient engine drive shaft (3) and camshaft (4) taking care
that in phase of assembly of the driving gear (2) to the
Figure 153 camshaft, the notches marked on the gears (1 and 2)
shall match.
Figure 155
70211

surface on which a groove (3) has been created for the
ignition timing. 90507
- Position comparator (1) on timing system gear (2) and

NOTE Screw up two pins to facilitate operation of engine check that the clearance between gears (2) and (3) is
drive shaft rotation. within 0.076 0.280 mm range.

Figure 156
be uniform (no crumbs), with no air blisters,
thinner or irregular zones.
as possible.
sides of the joint and obstruct lubricant passages.
Figure 158
90508
1
16 15
8 14 7
- Tighten the screws (1) fixing the gear to the camshaft (3) 17
and lock them to the prescribed couple.
6
18 13
5
19 12
11
Figure 157 20 1
2
21
4 9 10 3
75709

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
1
75708
DIAGRAM SHOWING SEALING LOCTITE 5205 tear and wear nor dirt.
APPLICATION.
Figure 159 Flywheel installation

Figure 161
1 4
75690
0901t
- Apply to engine drive shaft rear tang (6), the detail (5) threaded ports (4) for handling .
of the tool 99346253, fix it tightening the screws (4) and
- Using a hoist, handle the flywheel to place it in its housing
key the new holding ring on it (3).
inside the flywheel cover box.
- Place detail (1) on detail (5), tighten the screw nut (2)
until complete assembly of the fixing ring (3) into the
shaft ports (3) and using them as guide, assemble the
flywheel cover box (7).
engine flywheel (1) properly placing it inside the flywheel
cover box.
Figure 160
1 2
Figure 162
75696 1
- Check the contact surface (1) of the clutch plate and if

it is scratched, proceed with turning.
3
- Check ring gear teeth (2), if breakage or excessive wear
is found remove the ring gear from the engine flywheel
4
(1) using a suitable hammer and fit the new one, 75692
previously heated to 150C for 15 to 20 minutes.

Chamfering on ring gear inside diameter shall be facing
the engine flywheel. - Tighten the screws (4) fixing the engine flywheel (3) to
the engine shaft. Use tool 99360339 (2) to operate on
the flywheel cover box (1) to block engine flywheel
rotation.

75695
70221
- Apply to the water pump (1) a new fixing ring (2).

phases:
Figure 166
- 1st phase; tightening by means of dynamometric wrench
to couple 30 4 Nm;
- 2nd phase, 60 5 angle dwell.
NOTE Angle dwell shall always be performed using

99395216 tool.
Before assembly, always check that the threads of
76112
Installation of front components
Figure 164 - Tighten the screws (2) and lock them to the prescribed
couple.
Figure 167
70220
106549
- Assemble oil pump (1).

- Tighten fixing screws (2) and lock them to the prescribed - Remove the fixing ring (2) from the front cover (1),
couple. accurately clean the plug surface.

00902t
of the tool 99346252, fix it with the screws (5) and key
of the holding ring (7) to the front cover.
75710

apply sealing LOCTITE 5205 on it in order to form a
Figure 171
Figure 169
106550
86516
- Assemble the front cover (2) to the block and tighten - Assemble the plate (3), the rose pipe (5), tighten the
the screws (1) fixing them to the prescribed couple. fixing screws (1, 2 and 4) and fix them to the prescribed
couple.
3 74175
- Assemble the pulley (1) and the dumping flywheel (2) to

the driving shaft.
88075
- Tighten the fixing screws (3) and clamp them to the
couple 68 7 Nm.
Figure 175
NOTE 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.
70230
- Fit a new sealing ring on the speed sensor (3) (if fitted).
- Fit the speed sensor (3) on the front cover (1) and
Figure 173 tighten the screw (2) to the specified torque (if fitted).
Figure 176
70231
88076
- Assemble oil pan (1), apply the plate over it (2). Tighten bearing (4).
the screws (2) and lock them to the prescribed couple. Tighten the screws (5) and lock them to the prescribed
couple.
NOTE Before assembly, always check that the threads of NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of the ports and of the screws have no evidence of
tear and wear nor dirt. tear and wear nor dirt.

1 2
76113 75686
- Lubricate the fixing ring (2) using engine oil and place it
- Connect the alternator (1) to the support.
- Manually start the oil filter (3) on the bearing union (1)
until counter-boring, further screw up the oil filter (3) by - Tighten without locking the screw (2).
3/4 turn.
- 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.
- Tighten the screw (5) and lock it to the prescribed
couple.
Figure 180
Figure 178
70234 88090
- Assemble the alternator bearing (1) ensuring that the - Fit the new belt onto pulleys and guide rollers.
pins (3 and 4) are against the engine block.
- Tighten the control belt by turning the alternator as
- Tighten the screws (2) and lock them to the prescribed illustrated.
couple.
- Fix the screw (1) and the alternator fixing bolt (2,
Figure 179) to the support.
tear and wear nor dirt. NOTE In case the same belt priory removed is assembled
again, proceed examining it carefully to check there

Figure 181
1
D2 diameters:
D2 D1
75703
88092 Figure 183

The choice of the gaskets thickness shall be made in
consideration of the cylinder protrusion measured with
respect to the blocks upper surface.
NOTE Verify that the engine block stand is clean.

Do not grease the gasket. It is recommended to
76214
keep the gasket inside packaging until assembly to
the cylinder head.
- Bolts must be torqued using stitching pattern starting
degrees for the M12 x 140 and M12 x 180.
M12 x 70 50 Nm + 90 degs
Figure 182 M12 x 140 40 Nm + 180 degs
M12 x 180 70 Nm + 180 degs
Figure 184
1
3
2
76152 2
- Place the head (3) over the block and insert screws (1)
and (2). 1 3
75705
NOTE If the valves have been removed from the head, it
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms-
4. Support.
- Carry out the assembly of the rocker arms after previous
18.975
18.963
D2 D1
75703
19.000 - Insert the tappet driving rods and the Rocker Arm unit.
19.000 Before using the fixing screws again, measure them twice
19.026 19.026 as indicated in the picture, checking D1 and D2
75704 diameters:
SHAFT AND ROCKER ARM BASIC DATA if D1 - D2 > 0,1 mm the screw must be replaced;
Figure 186
Figure 189
13.00
11.00
2
116391
ROCKER ARM ADJUSTMENT SCREW

If unscrewed, check adjustment quota.
Tighten the screw-threaded nut (1) to the i 4 - 6 Nm couple.
Figure 187
75683

32655

rods: these shall not be deformed; the spherical ends in
contact with the Rocker Arm adjustment screw and with the
and therefore interchangeable.

2 1
75806
1
wrench (1), point wrench (3) and feeler gauge (2). 75707
Correct slack is:

- suction valves 0.25 0.05 mm - Assemble injectors after having replaced the sealing
- exhaust valves 0.50 0.05 mm. gasket (1).
NOTE During assembly of injectors, verify that the injector

NOTE On TIER 3 engines, due to the additional lobe for sphere is correctly positioned on the head housing.
and adjusting the clearance of both valves on the Figure 192
76149
- Assemble cylinder covers (2) with the respective gaskets;

- Fit the seal nods and tighten the screws (1) fixing them
to the prescribed couple.

Seal nods shall have no visible deformation. In such

76207
76206
- Assemble exhaust manifold (1) providing new gaskets (1) the gasket (3) and provide. Fixing the screws (2) to
(2). the prescribed couple.
- If the pipe (7) of the suction manifold plate (1) has been
removed, reassemble it after having fit a new gasket (6).
NOTE The illustration of exhaust manifold may be not
matching your model. Anyhow, described - Tighten the screws (8) to the prescribed couple.
procedure is applicable.
NOTE For the versions provided with heater, also

assemble components (4) and (5).
Figure 194
Figure 196
117588
76208
- Assemble thermostat unit (2) including thermostat (5)
and gasket (4). - Also assemble the brackets (1) fixing the fuel pipelines
to the injectors: use the same screws (2) fixing the
- Tighten the screws to the prescribed couple. manifold plate as shown in the picture.
- Also assemble feed pump (see specific procedure).
the bracket (3).
Disassemble the bracket (3) and reassemble
components from 1 to 5 as shown in the picture. NOTE Pump mounting requires specific procedure
The gasket (4) must be new. contained in this section.

Figure 197
88144
- Assemble the supply pump supply pipes (1).

Screw up the locking nuts and tighten the screws fixing 88146
the fuel recovery manifold.

- Assemble the supply pump pipes (1).
Figure 201
Figure 198
76148
88145
Figure 199
feed pump.
76150
- Fix the pipes to the injectors throughout the brackets

previously assembled (1).

116389
116387 - Hold the turbocharger and place it on the exhaust
- Assemble the fuel filter bearing (1) to the bracket fixed manifold after having interposed the gasket.
to the engine head. - Screw up the fixing nuts (2) of the turbocharger to the
- Connect the fuel pipelines (4 and 3) respectively from exhaust manifold tightening them to the prescribed
priming pump to filter bearing and from this last one to couple.
feed pump. - Tighten the lubrication pipe fixing ring (1). Operate in the
- Using 99360076 equipment assemble fuel filter (2). same way on the other end of the pipe. Connect it to
Figure 205
NOTE The filter shall be priory filled with fuel to facilitate
feed system bleed operations.
Figure 203
70126
164006
Assemble the lubrifying oil discharge pipe (6) coming from

NOTE To connect fuel pipelines (3 and 4, Figure 202) in the turbo-blower:
low pressure from the relating connection unions - Insert the junction (5) into the engine crankcase;
shown in picture B. - Tighten the two screws (1) underneath the
turbo-blower;
After having connected the pipeline, reset the
fastener (1) into block position as shown in picture - Tighten the screw (2) which holds the piping to the
A. monoblock by means of the cylinder bracket (3).
- Assemble the oil filter using tool 99360076 (4).

Completion of engine re-assembly Checks and inspections

In order to complete the re-assembly of the engine, it is
necessary to remove it from the rotating trestle. NOTE The following tests shall be made after engine
- With the aid of lifting beam 99360595, hold the engine assembly to the vehicle.
and undo the screws which limit the brackets to the Preventively check that the liquid levels have been
rotating trestle 99322205. correctly restored.
- Dissemble the brackets from the engine after having
opportunely placed them on a wooden support.

Figure 206

the locking rings.
respective unions.
various pipelines connecting cover and.
1 - Cylinder head, oil pan and bearing, oil filter and heat
75717
exchanger as well as relating housings.
From the right:
- Assemble the starting engine (1); opportunely support dashboard containing the tools as well as of the
the starting engine (1) and tighten the fastening screws equipment that was disconnected during engine
to the prescribed torque. disconnection.
Finally: - Check and blow by with care the engine cooling system,
- carry out the loading of engine oil.
- Install onto the car (for installation procedures, please
refer to specific literature).

Rotary feed pump disassembly and assembly In case feed pump replacement is necessary, this shall be
procedure supplied pre-set already as spare part.
NOTE This procedure prescribes that: and reassembled later on without being repaired it will be
- the fuel pipes (from the pumping elements to and disassemble it only afterwards.
injectors to the pump and the supply from the The following procedure analyses this second hypothesis
priming pump) have all been removed; since it is the more complex.
- the electrical connections have been Find the top dead centre with the tool (99395097) - False
disconnected. injector
- Accelerator cable shall be disconnected. Figure 209

Figure 207
88141
1 centre position (end-of-compression phase). Pre-load the
gauge.
88140
Disassemble the starter from the flywheel box and use tool valves are both closed.
99360330 to rotate the flywheel. Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 208).
Searching for the top dead centre with timing gear blocking
Figure 208 pin
Figure 210
75714
84071
Disassemble the starter from the flywheel box (1) and use Turn the flywheel until, when pushing the pin 99360616 (1),
tool 99360339 (2) to rotate the flywheel. it blocks the gear (2) obtaining the TDC of the 1 cylinder.

zs

Figure 211
2 1
88149
removing them in order to enable moving the pump
88148 backwards using 99340035 extractor.
- Assemble the 99340035 extractor throughout the two
- Unscrew the side screw that locks the pump shaft threaded ports (4, Figure 212) and withdraw the gear
partially (1) and remove spacer (2). This must be kept on from the pump shaft.
a side (we recommend to fix it on the pump with a wire
or a clip). - Properly hold the feed pump and loosen completely the
fixing nuts.
- Tighten the lateral screw (1) blocking rotation of the
pump shaft. - Withdraw the pump from the studs, together with the
gasket.
Figure 212 must be carried out.
1 4 NOTE Hold the pump driving gear to avoid interference

2 3
75693

washer.

zs
2 1
88148
- Loosen screw (1) that prevents pump shaft rotation and

88149 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 pump pre-set in its housing on the engine, tighten the screws (1, Figure 215).
fitting the shaft into the gear port (not provided with - Disassemble the flywheel rotation/locking tool 99360339
wrench). or 99360330; arrange the starting motor in its seat.
- Connect all pipelines (from pumping elements to injectors,
- Tighten the fixing nuts (1) locking the pump flange in the bleeding recovery pipes from injectors to pump, LDA
slot centre. pipeline and feed provided by priming pump).
NOTE The gasket removed during pump disassembly shall
not be utilised again. NOTE If the pump has been removed with the engine
Always use original spare parts. mounted, connect the accelerator cable, if present
in the application.
Figure 215
1 4
2 3 87720
75715
- With the injection pump inserted in relating seat and
securing screws loosened, mount comparator
99395605 (2) and 99395100 gauge tool (1), preloading
- On the timing side, throughout the specially appointed the rod by 2.5 mm.
port, fit the washer and screw up the fixing nut (3) to the - Rotate the engine derive shaft to shift from the condition
of the first cylinder to TDC end of compression phase.
pump shaft. Lock the nut to the 90-95 Nm couple. Reset the dial gauges and rotate the engine drive shaft
compression (see Figure 209).

procedure
Version with B type fuel filter
Figure 219
87751 76137
- Disconnect the fuel pipe (1) of the filter and repeat Where designed, there is a power take-off able to transmit
working on the drain lever (2) of the priming pump. motion to different auxiliary parts.
- Continue the operation until when fuel outflows. 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
reassemble.
gear meshing.
prescribed couple.

Checks and controls
NOTE The following tests shall be made after engine

correctly restored.


the locking rings.
respective unions.
relating housings.
disconnection.

REVIEW OF 4-CYLINDER ENGINE WITH Figure 221

DELPHI PUMP
Preface


NOTE For specific application exigencies, some units can


164006
turning stand - disassemble lubrication oil exhaust pipe from the
- Remove the wiring harness from all components turbo-blower:
indicated in part II, electrical equipment. Underneath the turbo-blower loosen the two screws
(1), loosen the screw (2) fixing the pipe throughout the
Figure 220 stop collar (3) fixing the block; finally loosen and remove
the union (5) from the block; plug the pipe ends and the
exhaust of the turbo-blower.
Figure 222
164007

to fix it on to the stand 99322205 for the overhaul, it is
necessary to perform the following operations:
On the right hand side:
- disassemble the oil filter (1) from the support using tool
99360076; 87712
Warning: the oil filter contains inside aprx. 1 kg. of - Disassemble the starter;
engine oil. Provide for oil recovery and disposal in Properly hold the starter (1) and loosen the fixing screws
compliance with the law and regulations in force. (2);
- assemble the supporting bracket 99361037 using the
threaded ports on the basement.

Figure 223 Disassembly of application components
1 Figure 225
75674
From the left-hand side:

- Assemble the second bracket 99361037 throughout the
screw-threaded ports (1). 116389
- Lift the engine using the rocker arm 99360595 and put
it on the turning stand 99322205. Proceed disassembling the supercharger:
- Drain the oil through the cap underneath the plug. - 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.
Warning: avoid contact of engine oil with the skin:
in case of skin contamination, rinse in running water. - Loosen the screw nuts fixing (2) the supercharger on the
exhaust manifold.
Engine oil is highly pollutant: provide for disposal in
compliance with the law and regulations in force. - Hold up the supercharger and after lifting it remove the
gasket.
Figure 226
Figure 224
116387
- Place a container under the fuel filter and screw out

127121
the condense drain faucet underneath said filter.
Loosen the screws (2), remove the duct (3) and the heater Carry out complete drainage of the fuel contained
(1) therein.
- Screw out completely the faucet and, using
equipment 99360076 disassemble oil filter (2).
- Disconnect fuel pipelines (4 and 3) respectively
from priming pump to filter bearing and from this
last one to the feed pump.
- Remove the fuel filter bearing (1) from the bracket
fixed to the engine head.

Figure 227 DELPHI Pump
Figure 229
70126
NOTE To disconnect fuel pipelines (3 and 4, Figure 226),

in low pressure from the relating pipe fittings, it is
Necessary to press the locking fastener (1) as
shown in picture B. 127119
After having disconnected the pipeline, reset the - Disconnect the LDA pipe (1) from the head and from
locking fastener (1) in lock position as shown in. the feed pump. Pipe the ends of the pipelines as well as
picture A, to avoid any possible deformation of the the feed pump and the engine head.
fastener itself.
Figure 230
Figure 228
127133
87406
- Disconnect the pipelines (1) and (3) that provide feed

- Remove tappet caps: and fuel recovery between pump and injectors; screw
Loosen the four fixing screws (1) and lift the caps (2); out the nuts fixing the pipes to the pumping elements;
remove the gaskets. loosen the fuel recovery pipe collar on the injection
NOTE On the cap there is a blow-by valve for the pipelines (2); pipe the pipeline ends.
lubrication oil vapours.
All the gaskets shall always be replaced during slot: remove the gaskets.
assembly.

125114
88102
- Loosen the two fixing screws (2) and disassemble screws (2) and remove the complete rocker arm bearing;
priming pump (1). withdraw tappet rods. Repeat the operation for all the
87409
- Disassemble suction and exhaust manifolds: loosen the 127122

8 screws (1) fixing the suction manifold plate to the
cylinder head (two of them have already been - Disassemble thermostat unit; loosen the three fixing
screwed-out since fixing the pipe brackets to the screws (1) and disassemble the thermostat unit (2)
injectors); from the exhaust manifold side; together with the bracket (4); remove the gasket (3) and
loosen the (2) fixing screws; remove the gaskets. the thermostat (5).
- Assemble the bracket in the original position fixing it with
the screws of the thermostat unit.

88555
Unscrew the fixing screws (1) and disassemble the pipeline

union (2).
127123 Figure 238
- Loosen the screw nut (5) and the screw (2)

- Loosen the screw (2, figure 18)
- Reduce belt tension operating on the screw (4)
- Loosen the screw (2) on the belt tensioning bracket (3)
- Withdraw the POLY-V belt
- Remove the belt tensioning bracket loosening the screw
(1)
- Disassemble the pulleys and the guide rollers.
Figure 236 107275
- Loosen the screws (5) and disassemble the oil (2)

1 2 filter/heat exchanger bearing (4), interlayer plate (3) and
relating gaskets (1).
- Disassemble injection pump (see specific procedure)
and the power take-off underneath.
88089
- Properly hold the alternator (1) separating it from its

bearing by loosening the screw (2); remove screw nut
and washer.

4
90504
75688
loosen the screws (1) and (2) fixing the cylinder head (3); - Loosen the screws (1) and disassemble the pulley (2).
Figure 240
Figure 243
88140
Fit tool 99360330 (2) in the starter motor housing to be able

to rotate the flywheel.
Figure 241 78256
tool guide ports, drill the internal holding ring (1) using
(3).
84071
Turn the flywheel until, when pushing the pin 99360616 (1),
it blocks the gear (2).

75811
00904t
(2).
holding ring (2) from the front cover (1).
75695
116242 - Screw out the opposite screws from the ports where the
withdrawal pins shall be introduced (see picture
following).
(2). - Loosen remaining (2) flywheel fixing screws (1) to the
engine drive shaft.
- Remove the flywheel block tool (2).
NOTE Take note of the screw (1 and 3) assembly position,
since the screws have different length.

1 4
75690

84077
Throughout two guide pins (2) previously screwed up
box (1).
127124
00903t
- Remove the flywheel cover box fixing ring using the
tool 99340056 (3) to operate on the back tang (5) of - Loosen the screws (2) and remove the oil pan (1).
the engine drive shaft. Throughout the tool guide ports,
drill the internal holding ring using 3,5 mm drill for
a 5mm depth.
(2).

127125 87656
- Loosen the screws (1) and remove the power take-off

- Loosen the screws (1) e (3) and disassemble the oil gear (2) (if available).
suction rose pipe (2).
88221
87655
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). - Remove the gear (1) transmitting motion to the ignition

Figure 256 Installation of rear components

87424
70210

- 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
Figure 257 couples listed here below, following the order as shown
in the picture.
Screws M8 20 28 Nm
Screws M10 44 54 Nm
It is necessary and essential to clean the surface to

! be sealed in order to achieve excellent tight seal.
70157
- Loosen the screws (2) and disassemble the timing
gearbox (1). tear and wear nor dirt.


87653
70211
- With a felt-tip pen, highlight the conducting gear tooth in the range between 0,076 0,280 mm.
surface on which a groove (3) has been created for the Figure 262
ignition timing.

Figure 260
87654
Figure 263
116355
87655

pump.

87656
84077
Figure 265
Figure 267
122588

APPLICATION

be uniform (no crumbs), with no air blisters, thinner
87659
or irregular zones.
Couplings must be assembled within 10 minutes completed.

Flywheel installation Figure 270

Figure 268
1 4
75690

84071
threaded ports (4) for handling .
- Using a hoist, handle the flywheel to place it in its housing Turn the flywheel until, when pushing the pin 99360616 (1),
inside the flywheel cover box. it blocks the gear (2).
shaft ports (3) and using them as guide, assemble the
engine flywheel (1) properly placing it inside the flywheel
cover box.
- Tighten the screws (4) fixing the engine flywheel (3) to
the engine shaft.
Figure 271
Figure 269
75695
1 Tighten the engine flywheel (1) fixing screws (2) in two

phases:
88140 - 1st phase; tightening by means of dynamometric wrench
to couple 30 4 Nm;
Fit tool 99360330 (2) in the starter motor housing to be able
to rotate the flywheel. - 2nd phase, 60 5 angle dwell with tool 99395216.


Installation of front components Figure 274

Figure 272
76112

70220
- Assemble oil pump (1). - Tighten the screws (2) and lock them to the prescribed
couple.
- Tighten fixing screws (2) and lock them to the prescribed
couple.
70221 106549
- Apply to the water pump (1) a new fixing ring (2). - Remove the fixing ring (2) from the front cover (1),
Apply a new sealing ring (2) to the water pump (1). accurately clean the plug surface.

00902t
of the tool 99346252, fix it with the screws (5) and key
75710 of the holding ring (7) to the front cover.
apply sealing LOCTITE 5205 on it in order to form a
Assembly of additional masses

Figure 279
Figure 277
88221
Fit the additional masses (2) and tighten the screws (3) on
the engine block.
Remove the lock pin (1) of the additional masses.
106550
- Assemble the front cover (2) to the block and tighten

the screws (1) fixing them to the prescribed couple.

Timing of additional masses

Match the signs (A) engraved on the gears for timing, insert the pin in the hole (B) on the balancing mass.
Figure 280
86614
1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) -
4. Additional masses.
Figure 281 - Assemble, the suction rose (2) and tighten the fixing
screws (1 and 3) to the prescribed torque.
127125

119123
3
1 2
75697
Figure 283
- 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 285
127124
- Assemble oil pan (1). Tighten the screws (2) and lock
them to the prescribed couple.

the ports and of the screws have no evidence of 107275
bearing (4).
Tighten the screws (5) and lock them to the prescribed
couple.


1 2
122589 75686
- Lubricate the fixing ring (4) using engine oil and place it
- Connect the alternator (1) to the support.
- Tighten the screw without locking it (2).
- Manually start the oil filter (2) on the bearing union (1)
until counter-boring, further screw up the oil filter (2) by
3/4 turn.
Figure 289
Figure 287
87759
88587 - Place the gasket (1) over the block.

The choice of the gaskets thickness shall be made in
Assemble pipeline union (1) and tighten screws (2) up to the consideration of the cylinder protrusion measured with
prescribed torque. respect to the blocks upper surface.
NOTE Before any assembly operation always verify that NOTE Verify that the engine block stand is clean.
the hole and screw threads have no evidence of Do not grease the gasket. It is recommended to
wear or dirt. 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.


1
4
2
1
3
3
2
2
1 3
4 75705
75688
- Place the head (3) over the block and insert screws (1) - Carry out the assembly of the rocker arms after previous
and (2). check of the components.
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms-
NOTE If the valves have been removed from the head, it 4. Support.
Figure 293
18.975
NOTE Before using the fixing screws again, measure them 18.963
D2 diameters:
D2 D1
19.000 19.000
19.026 19.026
75703
75704
Figure 291 SHAFT AND ROCKER ARM BASIC DATA

10 4 1 5 11
Figure 294
13 7 2 8 14
9 3 6 12
76115
- Lubricate cylinder head bolts and install to head. 13.00
- Bolts must be torqued using stitching pattern starting 11.00
116391
degrees for the M12 x 140 and M12 x 180.
ROCKER ARM ADJUSTMENT SCREW
M12 x 70 50 Nm + 90 degs
M12 x 140 40 Nm + 180 degs If unscrewed, check adjustment quota.
M12 x 180 70 Nm + 180 degs Tighten the screw-threaded nut (1) to the i 4 6 Nm couple.


2 1
122587

rods: these shall not be deformed; the spherical ends in
contact with the Rocker Arm adjustment screw and with the 75806
The rods driving the suction and exhaust valves are identical On TIER 3 engines, due to the additional lobe for the
and therefore interchangeable. 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
Figure 296 clearance of both valves on the cylinder in question.
Place the tool 99395097(see Figure 98) to set the cylinder
top dead centre position (end-of-compression phase).
D2 D1 Pre-load the gauge.
75703
wrench (1), point wrench (3) and feeler gauge (2).
Correct slack is:
- Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure them twice - suction valves 0.25 0.05 mm
as indicated in the picture, checking D1 and D2 - exhaust valves 0.50 0.05 mm.
diameters:
IGNITION SEQUENCE: 1 3 4 - 2
Engine shaft Bilance Adjust intake and

starting and valves exhaust valves
Figure 297 rotation cylinder n clearance cylinder
n
1 al PMS 1 1
180 3 3
180 4 4
180 2 2
125114


1
75707
127122
- Assemble injectors after having replaced the sealing

- Assemble thermostat unit (2) including thermostat (5)
gasket (1).
and gasket (3).
- Tighten the screws to the prescribed couple.
NOTE During assembly of injectors, verify that the injector
sphere is correctly positioned on the head housing.
the bracket (4).
Disassemble the bracket and reassemble
components from 1 to 5 as shown in the picture.
The gasket (3) must be new.
Figure 300
123025
- Assemble exhaust manifold (1) providing new gaskets

(2).

127123
- Tighten the screw (2), the screwnut (5) and the

screwnut fastening the alternator to the support.
- Assemble the alternator tensioning bracket (3) and
secure it through screw (1)
75687 - Tighten the screw (2) without locking it
- Tension drive belt operating on the screw (4)
- Assemble the pulley fan bearing tightening the screws to
the prescribed couple.
- Mount pulley (3) and secure it to support through Figure 304
screws (2).
- Assemble the transmission pulley (1).
- Fit the new belt onto the pulleys and guide rollers.
NOTE If not faulty the gasket can be reused.
127127

(1) a sufficient coat of Loctite 5999 and provide. fixing
the screws (2) to the prescribed couple.

127120
Screw up the locking nuts and tighten the screws fixing
75700
the fuel recovery manifold; fix the pipes to the injectors
- Assemble the brackets (1) fixing the fuel pipelines to the throughout the brackets previously assembled.
injectors: use the same screws (2) fixing the manifold
plate as shown in the picture.
Figure 306
Figure 308
88102
87406
- Assemble priming pump (1) providing new gasket and - Assemble cylinder covers (2) with the respective gaskets;
- Fit the seal nods and tighten the screws fixing them to
- Also assemble feed pump (see specific procedure) and the prescribed couple.
the power take-off underneath.

NOTE Pump mounting requires specific procedure
contained in this section. Seal nods shall have no visible deformation. In such
If not faulty the gasket can be reused.

116387

to the engine head.
- Connect the fuel pipelines (4 and 3) respectively from
priming pump to filter bearing and from this last one to
feed pump.
127119
feed pump. NOTE Pump mounting requires specific procedure
contained in this section.
Figure 312
Figure 310
70126

low pressure from the relating connection unions
127121
- Refit the duct (3) and thje heater (1), after having fitted shown in picture B.
new gaskets, and thighten the screws (2). After having connected the pipeline, reset the
A.

Figure 313 Completion of engine re-assembly

Figure 314
116389

- Hold the turbocharger and place it on the exhaust
- Screw up the fixing (2) nuts of the turbocharger to the
exhaust manifold tightening them to the prescribed
couple.
To complete engine assembly it is necessary to remove it
from the turning stand. 164004
- Using rocker arm 99360595 hold the engine and loosen From the right-hand side:
the screws fixing the brackets to the turning stand
99322205. - Re-assemble the lubrifying oil discharge pipe (6) from the
turbo-blower by inserting the joint (5) into the engine
- Disassemble the brackets 99361037 from the engine crankcase and tightening the two fastening (1) screws
after having properly put it on a wooden bearing. underneath the turbo blower;
- Tighten the screw (2) which holds the piping to the (6)
monoblock by means of the cylinder bracket (3);
- Re-assemble the oil filter (4) onto the heat exchanger
with tool 99360076;
Figure 315
87712
- re-assemble the starting engine (2); opportunely support

the starting engine (2) and tighten the fastening screws
to the prescribed torque.
- Refit and connect the wiring harness

Rotary feed pump disassembly and assembly Find the top dead centre with the tool (99395097) - False
procedure injector
Figure 317
NOTE This procedure prescribes that:
- the fuel pipes (from the pumping elements to
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.
1
Figure 316
88141
centre position (end-of-compression phase). Pre-load the
gauge.
1 Figure 318
88140
Disassemble the starter from the flywheel box and use tool
99360330 to rotate the flywheel.
In case feed pump replacement is necessary, this shall be
supplied pre-set already as spare part.
and reassembled later on without being repaired it will be
and disassemble it only afterwards.
The following procedure analyses this second hypothesis
since it is the more complex.
84071
Turn the flywheel until, when pushing the pin 99360616 (1),
it blocks the gear (2) obtaining the TDC of the 1 cylinder.

Pump DELPHI Figure 321

Figure 319
1
75694
127693 removing them in order to enable moving the pump
backwards using 99340035 extractor.
- Unscrew the side screw that locks the pump shaft
partially (1) and move spacer (2) from position (A) to - Assemble the 99340035 extractor throughout the two
position (B) threaded ports (4, Figure 320) and withdraw the gear
from the pump shaft.
- Tighten the lateral screw (1) blocking rotation of the
pump shaft. - Properly hold the feed pump and loosen completely the
fixing nuts.
- Withdraw the pump from the studs, together with the
gasket.
must be carried out.
Figure 320
1 4 NOTE Hold the pump driving gear to avoid interference

2 3
75693

washer.

75694
- Assemble the pump pre-set in its housing on the engine, 127693

fitting the shaft into the gear port (not provided with
wrench). - Loosen screw (1) that prevents pump shaft rotation and
- Tighten the fixing nuts (1) locking the pump flange in the move spacer (2) from position (B) to position (A).
slot centre, to the pair 24 Nn. Tighten screw (1) so that it locks spacer (2): in this way
the supply pump shaft will be able to rotate freely.
tighten the screws (1, Figure 323).
NOTE The gasket removed during pump disassembly shall - Disassemble the flywheel rotation/locking tool 99360339
not be utilised again. or 99360330; arrange the starting motor in its seat.
Always use original spare parts. - Connect all pipelines (from pumping elements to injectors,
bleeding recovery pipes from injectors to pump, LDA
pipeline and feed provided by priming pump).
Figure 323
1 4
NOTE If the pump has been removed with the engine
mounted, connect the accelerator cable, if present
in the application.
2 3
75693
- On the timing side, throughout the specially appointed

port, fit the washer and screw up the fixing nut (3) to the
pump shaft. Lock the nut to the prescribed pair.


procedure
1 4 3
2 75720
127694
Where designed, there is a power take-off able to transmit
motion to different auxiliary parts.
- Disconnect the fuel pipe (1) of the filter and repeat
working on the drain lever (2) of the priming pump. Disassembly of such mechanism shall be executed as
following:
- Continue the operation until when fuel outflows.
- Loosen the two screws (3) and after having removed the
cover (1) with a specially provided extractor, withdraw
reassemble.
gear meshing.
prescribed couple.

Checks and controls
NOTE The following tests shall be made after engine

correctly restored.


the locking rings.
respective unions.
relating housings.
disconnection.


PART TWO -


ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES WITH ROTARY PUMP)

Figure 327
116392
Below there are listed the electric components which are

present on F4GE94--- engines*.
2. Starter;
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;
* Excluding motor F4GE9454H*J600, F4GE9454H*J603
and F4GE9454H*J605.


1
75717

C assembled to the starter itself.
Specifications:
A B
BOSCH 3 kW - 12V
A C
B
KSB Water temperature sensor
75718
Figure 330
Specifications:
Connection side -40 +150 C for < 10 min.
Bulb side on engine: -40 +140 C
Settings:
80 C 0.304 0.342 k
20 C 2.262 2.760 k
-10 C 8.244 10.661 k
75719
It is assembled to the cylinder head on the engine left hand

side.
Specifications:
Working tensions:12 24 V
Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 633 C Contact opening
upon increasing temperature
upon decreasing temperature

Electromagnets assembled to feed pump Alternator
2
75724a
75725
1 - Hydraulic head Electro-magnet; 2 - KSB

Electro-magnet It is place front view on the right hand side of the engine, and
Specifications:
Oil pressure sensor Current delivered: 90A (at 6000 rpm)
Figure 332 Absorption in stand-by: 1mA

Pre-post heating resistor

Figure 334
75722

Specifications: 75723
Contact closure
Contact opening It is a resistor assembled to the suction collector and is utilised
upon higher pressure: 0.9 bar to heat the air during pre-post heating operations.
It is fed by a tele-switch usually placed very close to the engine.
Specifications:
Maximum possible
air flow: 2 cc / min
(pressure 138 kPa)

ELECTRICAL COMPONENT LAYOUT (6 CYL. ENGINES WITH ROTARY PUMP)

Figure 335
B 116393

present on F4GE06--- engines.
2. Alternator;
3. Starter;
4. Magnets mounted on feed pump:
(A) on hydraulic head body;
(B) on KSB;
5. Oil pressure sensor;
7. Resistance for cold start up (where provided for).


1
75717

C assembled to the starter itself.
Specifications:
A B
BOSCH 4 kW - 24V
A C
B
KSB Water temperature sensor
75718
Figure 338
Specifications:
Settings:
80 C 0.304 0.342 k
20 C 2.262 2.760 k
-10 C 8.244 10.661 k
75719

side.
Specifications:
5.0 A (resistance)

Oil pressure sensor Pre-post heating resistor

75723
75722

It is a resistor assembled to the suction collector and is utilised
Specifications: to heat the air during pre-post heating operations.
Working tensions:12 24 V It is fed by a tele-switch usually placed very close to the engine.
Contact closure Specifications:
Contact opening Maximum possible
upon higher pressure: 0.9 bar air flow: 2 cc / min
(pressure 138 kPa)
Alternator
Figure 340
75725
Specifications:
Rated tensions: 24 V
Current delivered: 90A (at 6000 rpm)

ELECTRICAL COMPONENT LAYOUT

4 CYLINDER ENGINE WITH DELPHI PUMP
Figure 342
127135

present on F4GE9454H*J600, F4GE9454H*J603,
F4GE9454H*J605 engine.
1A. KSB Water temperature sensor;
1B. KSB Electro-magnet;
1C. Pump stop connection;
1D. Engine stop solenoid;
3. Alternator;
4. Starter;
5. Oil pressure sensor.
1
75717

C dashboard and provides positive tension to the tele-switch
assembled to the starter itself.
A Specifications:
B
BOSCH 3 kW - 12V
A C
B
Cooling liquid temperature sensor
75718
Figure 345

Specifications:
Settings:
80 C 0.304 0.342 k
20 C 2.262 2.760 k
75719
-10 C 8.244 10.661 k

side.
Specifications:
5.0 A (resistance)

Electromagnets assembled to feed pump Alternator

75725
4 3
127136
Specifications:
1. KSB Water temperature sensor - 2. KSB Working tension: 12 V
Electro-magnet - 3. Pump stop connection - Current delivered: 90A (at 6000 rpm)
4. 1D. Engine stop solenoid;
Oil pressure sensor
Figure 347
75722

Specifications:
Contact closure
Contact opening
upon higher pressure: 0.9 bar


PART THREE - TROUBLESHOOTING


Print P2D32N003 E
F4GE N ENGINES
The engine does not start Battery flat or faulty. Check and recharge battery. Replace bat-
tery if necessary.
Connections to battery terminals cor- Clean, examine and tighten the nuts on
roded or loose. the battery terminals. Replace the cable
terminals and the nuts if excessively cor-
roded.
Incorrect timing of injection pump. Check and correctly time the injection See your Iveco dealer.
pump.
Deposits or water in the fuel tank. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air.
Dismantle and clean the injection pump.
Remove water from tank and refuel.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or transfer
pump.
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in
pump. fact present and also check the fuel pump.
Eliminate the air from the injection pump
by unscrewing the cap and working the
fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.

Base - May 2010
117
Base - May 2010
118
The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use

peratures forming due to the use of unsuitable fuel. at low temperatures. Replace the fuel fil-
ters.
K.S.B. device for cold spark advance con- Check or replace the injection pump. See your Iveco dealer.
trol operating incorrectly.
The engine cuts out. Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection pump. Adjust flow. See your Iveco dealer.
Impurities or water in the fuel lines. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air. Dismantle
and clean the injection pump. Remove
water from fuel tank and refuel.
Clogged fuel filter. Dismantle and replace if necessary.
Presence of air in the fuel and injection Check that the hoses are not cracked or
system. the unions loose. Replace worn parts, re-
move the air from the hoses and deaerate
the injection pump and fuel filter by un-
screwing the caps and working the primer
pump by hand.
Broken injection pump controls. Replace the faulty parts.
Abnormal clearance between camshaft Adjust clearance by replacing shims.
cams and tappets.
Burnt, corroded or chalky valves. Replace the valves, rectify or replace the
cylinder head seatings.
F4GE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4GE N ENGINES
The engine overheats Faulty water pump. Check the unit and replace if necessary.
Replace the gasket.
Malfunctioning thermostat. Replace the thermostat.
Fouling in coolant openings in the cylinder Wash following the standards specified
head and cylinder groups. for the type of descaling product used.
Water pump drive belt slack. Check and adjust the tightness of the belt. On applications provided with automatic
tensioner, check corret worching of such
device.
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injection pump. Correct the delivery rate of the pump on See your Iveco dealer.
a bench so that the injection is at the
specified rate.
Dry air cleaner blocked. Clean the air filter or replace if necessary.
Engine operation is irregular and lacks Incorrect timing of injection pump. Check timing and correctly set pump.
power
K.S.B. automatic cold advance device mal- Check or replace injection pump.
functioning.
Excessive piston wear. Check or replace injection pump.
Incorrect calibration of speed regulator. Check and correctly calibrate the regula- See your Iveco dealer.
tor.

Base - May 2010
119
Base - May 2010
120
Engine operation is irregular and lacks Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using

power ation of injectors. the appropriate tools and completely
overhaul the injectors.
Impurities or water in the fuel and injec- Carefully clean the system and refuel. If necessary drain feed system.
tion system.
Incorrect play between camshaft cams Check and correct play
and tappets.
Faulty turbocharger. Replace complete unit.
Air cleaner blocked. Clean or replace air cleaner.
Faulty operation of L.D.A. device Check that the diaphragm is not perfor- See your Iveco dealer.
ated, that the counter spring is suitable
and that it has the correct loading (check
on test bench).
Check that there is adequate air pressure
inside the intake manifold in relation to
the engine rpm under full-load conditions.
Tie rods between accelerator pedal and Adjust the tie-rods so that the command
regulation lever incorrectly adjusted. lever can be moved to the full delivery
position.
Engine running with abnormal knocking Faulty operation of injectors. Replace all injectors.
Fuel lines blocked. Dismantle the hoses, clean them and re-
place those that are seriously dented.
Incorrect set-up of injection pump. Correct the set-up of the pump so that in- See your Iveco dealer.
jection occurs at the specified angle.
F4GE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4GE N ENGINES
Engine running with abnormal knocking Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and in-
play on one or more main or rod bearings stall smaller bearings. Replace the thrust
or excessive play on shoulders. half-rings.
Crankshaft unbalanced. Check alignment of crankshaft.
Loosening of screws securing flywheel. Replace the loosened screws and tighten
all the screws to the specified torque.
Misalignment of rods. Replace the rods.
Noise from piston journals due to excess- Replace the piston journal and/or the pis-
ive play of piston hubs and in the rod ton and rod bushing.
bushing.
Loose bushings in the rod seatings. Replace with new bushings.
Noisy timing. Adjust the play between camshaft cams
and tappets and check that there are no
broken springs, that there is no excessive
play between the valve stems and the
valve guides, tappets and seatings.
The engine smokes abnormally. Black or Excessive maximum pump output. Disconnect the pump and adjust delivery See your Iveco dealer.
dark grey smoke. in accordance with the data given in the
calibration table.
K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust
tioning. correctly as described in the manual.
There is an excessive delay on the injec- Correct the set-up.
tion pump.

Base - May 2010
121
Base - May 2010
122
The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up.

dark grey smoke. vance.
The holes in the atomisers (or some of Replace the injectors with a series of new
them) are partially or entirely blocked. injectors or clean and rectify the original
ones using suitable equipment.
Air cleaner blocked or deteriorated. Clean or replace the filter element.
Loss of compression in the engine due to: Overhaul the engine or limit the interven-
tions to the relative parts.
stuck or worn flexible rings;
worn cylinder liners;
valves deteriorated or badly adjusted.
Unsuitable injectors, different types of in- Replace or calibrate the injectors.
jectors or incorrectly calibrated.
Injection hoses with an unsuitable internal Check conditions of the end or unions
diameter, end of hoses pinched due to re- and where necessary replace the hoses.
peated blocking.
Blue, grey-blue, grey smoke tending to Excessive delay in injection pump. Correct the set-up of the pump. See your Iveco dealer.
white.
K.S.B. automatic cold advance device mal- Check or replace injection pump. See your Iveco dealer.
functioning.
Faulty injector. Replace the injector.
Leaking of oil from the piston rings caused Overhaul the engine.
by glued or worn rings or wearing of cylin-
der liner walls.
Engine oil passing through the intake Recondition the cylinder head.
guides-valves following wearing of guides
or valve stems.
Engine too cold (thermostat blocked or Replace the thermostat.
inefficient).
F4GE N ENGINES
Print P2D32N003 E
PART FOUR - MAINTENANCE PLANNING


Recovery
Planning of controls and periodical intervention
Controls and periodical intervention Frequency (hours)

Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
Replacement of engines oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500*
Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
* 600 hours for engines F4GE9454H*J600, F4GE9454H*J603 and F4GE9454H*J605
FPT.


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.
MAINTENANCE PROCEDURES Figure 350 (Demonstration)

Checks and controls

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

rod (1).
MAX
2
75749
MIN
1 flow easier.
Some applications are equipped with a level transmitter
alerting dashboard instruments in case of insufficient
lubrication oil within the pan.
75748
Draw off the rod from its slot and check that the level is within In case of contact with the skin, rinse well with water
the etched tags of minimum and maximum level. and detergent.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and Adequately protect the skin and the eyes, operate in
put it back in its slot. Draw it off again and check the level. full compliance with safety regulations.
In case the level results being close to the tag showing Disposal must be carried out properly, and in full
minimum level, provide filling lubrication of the engines compliance with the law and regulations in force.
components.
Check of fuel system Lubricating system check

The check must be executed both when the engine The check must be executed both when the engine
disconnected and when it is running. disconnected and when it is running.
running from the tank to the pre-filter (if provided in the Verify the presence of any oil leakage or blow-by from the
specific equipment), to the filter, to the injection pump and to head, from the engine pan of from the heat exchanger.
the injectors.

Cooling system check
The check must be executed both when the engine In case of contact with the skin, rinse well with water
disconnected and when it is running. and detergent.
Check the pipelines from the engine to the radiator, from the Adequately protect the skin and the eyes, operate in
expansion tank and vice-versa. Find out any blow-by, verify the full compliance with safety regulations.
Verify that the radiator is clean, the correct working of the fan compliance with the law and regulations in force.
Check of water presence within fuel filter or pre-filter

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 NOTE The components of the system can be damaged
pressure jet of cooling liquid. 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
The density of the cooling liquid must be checked any how drainage of the water within the feed circuit.
every two year.
Fuel filter is equipped with pump screw-valve to drain the

water eventually mixed with fuel (some applications of 6
NOTE In case of new filling, proceed bleeding system, cylinders engines will be equipped with two fuel filters, both
through the bleeds on the engine. provided with drainage.
Place a container underneath the filter and slightly loosen the
If bleeding of the system is not carried out, serious screw. Drain the water eventually contained in the filters
inconvenience might be caused to the engine due bottom.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.

Check of drive belt tensioning Oil motor and filter replacement

Some applications are equipped with an automatic tensioner
that provides correcting belt tensioning.
Warning: We recommend to wear proper protec-
tions because of high motor service temperature.
Check of belts tear and wear status
The motor oil reaches very high temperature: you
Carefully verify the belts surface in order to detect any sign of must always wear protection gloves.
incision, crack, excessive wear in correspondence of toothing;
check end and surface grinding.
ations are valid for all applications.
Danger: if the engine is switched off but is still hot,
unexpected motion of the belt may occur. We recommend to carry out the oil drainage when the motor
is hot.
Wait for engine temperature cooling as a precaution
in order to avoid serious danger injury. - 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
and the inserting plug to ease the downflow of the lubrica-
tion oil.
Check and setting of tappet clearance

Figure 351 The oil motor is very pollutant and harmful.
In case of contact with the skin, wash with much
2 1 water and detergent.
Protect properly skin and eyes: operate according to
3 safety rules.
Dispose of the residual properly following the rules.
75806
Adjust clearance between rockers and valves using setscrew Use only the recommended oil or oil having the re-
wrench (1), box wrench (3) and feeler gauge (2). ! quested features for the corrrect motor functioning.
Clearance shall be as follows: In case of topping up, dont mix oils having different
- intake valves 0.25 0.05 mm features.
- exhaust valves 0.50 0.05 mm. If you dont comply with theses rules, the service war-
valve clearance adjustment procedure that requires - Check the level through the dipsick until when the filling
adjusting the clearance of all the valves by is next to the maximum level notch indicated on the dip-
positioning the crankshaft 2 times only. sick.

Whereas you replace the lubrication oil, it is necessary to re- Fuel filter replacement
place the filter.
According to the application the filter can be located in different
positions: the following procedure is a valid guide for all applica- During this operation dont smoke and dont use free
tions. flames.
- The filter is composed by a support and a filtering cartridge. Avoid to breathe the vapors coming from filter.
For the cartridge replacement use the 9936076-tool.

After filters replacement the supply equipment
of about 1 kg.
! deaeration must be carried out.
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 applications the filters position and the quan-
according to the rules. tity can change.
lease screw. Collect the fuel in a container without impu-
rities.
port.
- Unscrew the cartridge by using the 99360076-tool.
turn. - Collect the eventual fuel inside the filtering cartridge.
- Operate the motor for some minutes and check the level - Clean the gasket seat on the support and oil slightly the
through the dipsick again. If it is necessary, carry out a top- gasket on the new filtering cartridge.
ping up to compensate the quantity of oil used for the fill-

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.

belt can operate without advance notice.
Wait for the motor temperature lowering to avoid
For applications with traditional belt stretcher

Figure 352
88089
- 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 to the
support
- Run the engine for a few hours and check proper belt
stretching.

F4GE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1
SECTION 4
Page
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
TABLE OF PRE-DELIVERY VALUES FOR BOSCH

INJECTION PUMPS VE 4/12 F - VE 6/12 F . . 10
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 11
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
- Checking head supporting surface on cylinder unit 13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 18
- Measuring journals and crankpins (4 cylinders) 18
- Measuring journals and crankpins (6 cylinders) 20
CONNECTING ROD PISTON ASSEMBLY . . 23

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N ENGINES
Page Page
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 30
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Checking cylinder head supporting surface . . . 31
- Conditions for proper pin-piston coupling . . . . 25
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - Removing carbon deposits, checking and grinding val-
ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 26
- Checking clearance between valve stem and valve
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 guide and valve centering . . . . . . . . . . . . . . . . . 32
- Fitting connecting rod-piston assembly . . . . . . 27 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Connecting rod-piston coupling . . . . . . . . . . . . 27
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Fitting connecting rod-piston assembly into cylinder
barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . 34
- Finding crankpin clearance . . . . . . . . . . . . . . . . 28 - Refitting the cylinder head . . . . . . . . . . . . . . . . 35
- Checking piston protrusion . . . . . . . . . . . . . . . 29 TIGHTENING TORQUE (FOR 4 AND 6 CYL.) 36


Power See properties described in Section 3
Injection Direct
Number of cylinders 4 in-line 6 in-line

Bore mm 104
Stroke mm 132
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 -
Checking timing
mm 0.25 0.05
X X
mm 0.50 0.05
FUEL FEED
Bosch* Bosch
Type: rotary VE 4/12 F VE 6/12 F
Nozzle type -
Injection sequence 1-3-4-2 1-5-3-6-2-4
bar
Injection pressure bar
-
* Excluding motor F4GE9454H*J600, F4GE9454H*J603 and F4GE9454H*J605.

CLEARANCE DATA

1
X
1 0.4
Pistons
1
X Size X 55.9
Outside diameter 1 103.714 to 103.732
2 Pin housing 2 38.010 to 38.016
Piston cylinder barrels 0.252 to 0.294
X
3 Piston pin 3 37.994 to 38.000

Type 4 CYLINDERS 6 CYLINDER

X1 2,705 to 2,735
X1 Split ring slots X2 2,440 to 2,460
X2 X3 4,030 to 4,050
X3 * measured on a of
99.00 mm
S 1 S1 2.560 to 2.605
S 3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110
3 0.040 to 0.080
Split rings 0.4
X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3
S Inside 3 38.019 to 38.033


X
Size X -
Max. tolerance
on connecting rod
axis alignment -
Journals 1 82.99 to 83.01

Crankpins 2 68.987 to 69.013
1 2

S 1 S 2
Main bearings
3 No. 1 5 3 87.982 to 88.008
No. 2 3 4 3 87.977 to 88.013

No. 15 / 1-7 0.064 to 0.095
No. 234 / 2-3-4-5-6 0.059 to 0.100
Main half bearings
0.250 to 0.500
Shoulder journal X1 37.475 to 37.550 37.475 to 37.545
X 1
X 2
X 3
Output shaft shoulder 0.095 to 0.270 0.095 to 0.265


1

4 Valves:
4 7.960 to 7.980
60
4 7.960 to 7.980
45

Housing on head for
valve seat:
1 46.987 to 47.013
1 1 43.637 to 43.663

head:
2 47.063 to 47.089
60
2 43.713 to 43.739

45
X 1 to 1.52
X Sinking X 1 to 1.52
0.050 to 0.102
Between valve seat
and head 0.050 to 0.102
Valve seats -


free spring H 63.50

H H1
329 N H1 49.02
641 N H2 38.20
X
Camshaft bush
housings No. 1 59.222 to 59.248
(flywheel side)
Camshaft housings 54.089 to 54.139

No. 2-3-4-5 / 2-3-4-5-6-7
1 23 4 5
2
Camshaft journals:
15
53.995 to 54.045
17
1 3
Bush inside

Cam lift:
H H -
H -


1
Tappet cap housing
on block 1 16.000 to 16.030
2
diameter: 2 15.924 to 15.954
3 15.965 to 15.980
2
Between tappets and housings -
Tappets -
1
Rockers 2 19.000 to 19.026
2

TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F - VE 6/12 F
Technical Commercial Pre-lift

Code Code (mm)
F4GE9454H*J601 1.00 0.05
N45 MSS.X
F4GE9454J*J600 0.70 0.05
F4GE9454H*J602 1.00 0.05
N45 MNS.X
F4GE9454J*J601 0.70 0.05
F4GE9484D*J601 0.75 0.05
N45 MST.X
F4GE9484F*J603 0.80 0.05
F4GE9484F*J611 0.80 0.05
4-CYLINDER F4GE9484J*J602 0.80 0.05
ENGINES F4GE9484F*J604 0.80 0.05
F4GE9484F*J607 0.80 0.05
F4GE9484D*J602 0.75 0.05
F4GE9484D*J612 N45 MNT.X 0.75 0.05
F4GE9484D*J613 0.75 0.05
F4GE9484D*J614 0.75 0.05
F4GE9484D*J610 0.75 0.05
F4GE9484D*J609 0.75 0.05
F4GE9484D*J602 1.00 0.05
F4GE9684A*J602
6-CYLINDER
ENGINES F4GE9684P*J601 0.70 0.05
N67 MST.X
F4GE9684P*J602 0.70 0.05
NOTE INJECTION PUMP CALIBRATION

Overhaul and calibration interventions are up to BOSCH assistance network.
The contract technical specification containing the data to calibrate the pump at the bench is identified by the code shown
on injection pump body and is available at BOSCH technical assistance network.
Otherwise, refer to FPT Technical Assistance Service.


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.
70160
The second last main bearing cap (1) and the relevant
Figure 1 support are fitted with shoulder half-bearing (2).

assembling positions since in case of reuse they
shall be fitted in the same position found at
removal.
Figure 4
70158
and remove them.

found at removal. 70161
Use tool 99360500 (1) and hoist to remove the output shaft
(2) from the block.
Figure 2
Figure 5
70159
Remove the screws (1) and the main bearing caps (2). 70162
Remove the main half-bearings (1).

zs

CYLINDER UNIT
Figure 9
70163 s

plate (2).
NOTE Take note of plate (2) assembling position. 70166


70164
Figure 10
Figure 8
70167

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
70165
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.

bearings;


unit
107804

oversize (0.4 mm).

TIMING SYSTEM
Camshaft
Figure 12
70169
CAMSHAFT MAIN DATA (4 CYL.)

Figure 13
70512
MAIN DATA ABOUT CAMSHAFT PINS (6 CYL.)
Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bushes.
if they show any traces of seizing or scoring replace the


Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error Figure 15
Figure 14
70172

70171 intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.

Figure 16
sec. A-A
107399
MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (4-cylinder engines)
* Dimension to be measured after inserting the bearing bush.
Figure 17
sec. A-A
107268
MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (6-cylinder engines)
* Dimension to be measured after inserting the bearing bush.


Figure 18 Figure 20
70176
70174
To replace the bearing (1) use tool 99360362 (2) and handle housings on the engine block.
99370006 (3) to remove and install it.
Figure 21
NOTE When installing the bearing (1) it must be oriented

so that the lubrication holes are aligned with those
on the seats of the crankcase.
70164
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.
Tappets
Figure 22
Figure 19
70238
84053
Set camshaft (3) retaining plate (1) with the slot facing the
MAIN DATA CONCERNING THE TAPPETS AND THE then tighten the screws (2) to the specified torque.

Measuring journals and crankpins (4 cylinders)
Figure 25
70179

It shall be 0.23 0.13 mm. 70182
Figure 24 ovalisation are found. Before grinding the pins (2) measure
NOTE It is recommended to insert the found values in the

proper table.
See Figure 26.
Undersize classes are:

70180 Journals and crankpins undersize shall be marked
Fit nozzles (2) and tighten the fastening screws (1) to the on the side of the crank arm No.1.
specified torque. For undersized crankpins: letter M
For undersized crankpins and journals: letters MB
Figure 26
108487
*Rated value
Figure 27
measured on > 45.5 mm radius

between adjacent journals 70183
OUTPUT SHAFT MAIN TOLERANCES

Roundness
SHAPE
Cilindricity //
Parallelism //
Straightness
OSCILLATION
Total oscillation

CRITICAL
IMPORTANT
SECONDARY
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237

Measuring journals and crankpins (6 cylinders)

Figure 28
107269
*Rated value
Figure 29


Figure 30

70237

Roundness
SHAPE
Cilindricity //
Parallelism //
Straightness
OSCILLATION
Total oscillation

CRITICAL
IMPORTANT
SECONDARY


Figure 33
Figure 31
70161
Refit the output shaft (2).
the relevant bearings as follows:
70184
Check that gear toothing (1) is not damaged or worn,

When fitting the new gear, heat it to 180C for 10 minutes
in an oven and then key it to the output shaft.
Figure 34
Figure 32
70186

70185
- position a piece of calibrated wire (3) on the output shaft
NOTE Refit the main bearings that have not been - fit caps (1), including the half bearings (2) on the relevant
replaced, in the same position found at removal. supports.

Main bearings (1) are supplied spare with 0.250 0.500 mm twice as indicated in the picture, checking D1 and
undersize on the internal diameter. D2 diameters:
D2 D1
Clean accurately the main half bearings (1) having the

75703
half rings.

Figure 38
70187
successive stages:
Figure 36 (2) on the output shaft (3) as shown in the figure, standard
value is 0.068 to 0.41.


70188
- 3rd stage, with tool 99395216 (1) set as shown in the Figure 39
Figure 37
70191
70189
- Remove caps from supports. COMPONENTS
The backlash between the main bearings and the pins is 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
found by comparing the width of the calibrated wire (2) at 6. Half bearings - 7. Connecting rod - 8. Bush.
Figure 40 Pistons
Figure 43
32613
Remove split rings (1) from piston (2) using pliers 99360183 32615
(3). Using a micrometer (2), measure the diameter of the piston
Figure 41 NOTE The diameter shall be measured at 55.9 mm from

the piston skirt.
Figure 44
32614
70192
Figure 42
87760
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

Piston pins Figure 48

Figure 45
18857 32620
To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2nd
(2). and 3rd slot and the relevant housings on the piston (2), using
Conditions for proper pin-piston coupling a feeler gauge (1).
Figure 46 Figure 49
32619 41104
Lubricate the pin (1) and its seat on piston hubs with engine DIAGRAM FOR MEASURING THE CLEARANCE X
oil; the pin shall be fitted into the piston with a slight finger BETWEEN THE FIRST PISTON SLOT AND THE
pressure and shall not be withdrawn by gravity. TRAPEZOIDAL RING
Split rings between the slot and the ring shall be measured as follows:
Figure 47 the ring (2) protrudes half-way from the cylinder barrel (3).
between ring and slot: found value shall be the specified one.
16552

Figure 50 Figure 52
70194

Connecting rods
Figure 51 80339

- 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 new connecting rod with the same
numbers of the replaced one.
- On body with a letter showing the weight of
S V, 1820 to 1860 (yellow marking);
S X, 1901 to 1940 (blue marking);
green marking *.

88607

knurls.

Bushes Figure 55
replace.
beater.

72705
Figure 53
Position the piston (1) on the connecting rod according to
the split rings (2).
Fitting split rings

Figure 56
70198
The piston crown is marked as follows:

1. Part number and design modification number;
barrel, this arrow shall face the front key of the engine
block;
4. Manufacturing date.
32613
Figure 54 (2).
other by 120.

sizes:
- standard;
- 0.4 mm oversize.
70199
Figure 57 Figure 59
70202

70200 - Split ring openings shall be displaced with each other by
120;
Fit half bearings (1) on connecting rod and cap. - connecting rod-piston assemblies shall have the same
weight;
NOTE Refit the main bearings that have not been front side of the engine block or the slot obtained on the
replaced, in the same position found at removal. piston skirt shall be corresponding to the oil nozzle
Do not try to adapt the half bearings. position.
Figure 60

cylinder barrels
Figure 58
70203

(1);
bearings (4).

D2 diameters:
70201
Lubricate accurately the pistons, including the split rings and D2 D1
- the number of each connecting rod shall correspond to 75703

Figure 61 Figure 64
70204
70207
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2). If a different clearance value is found, replace the half bearings
Figure 62
70205

tighten screws (2) of 60. Checking piston protrusion
Figure 65
Figure 63
70208
Once connecting rod-piston assemblies refitting is over, use

70206
- Remove the cap and find the existing clearance by check piston (3) protrusion at T.D.C. with respect to the top
comparing the calibrated wire width (1) with the scale of the engine block.
on the wire envelope (2).


Removing the valves
1 2
Figure 66 3
4
1
2 6
A 75751

75750
Figure 68
them in the same position. 2
75752



Figure 69
D
1 0,4 C
0,025 / 25,4
A B
0,4 TOTAL C
0,01 / 50
75753 75756
This check shall be performed using the proper tools. The rated thickness A for the cylinder head is 95 0.25 mm,
max. metal removal shall not exceed thickness B by 1 mm.
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 NOTE After grinding, check valve sinking. Regrind the
beater for their removal/refitting. valve seats, if required, to obtain the specified value.


exceed 0.20 mm.

VALVES Figure 73
Figure 71
EXHAUST INTAKE
VALVE VALVE
18882

7.943 to 7.963.
116395
Figure 72
Figure 74
18625
Remove carbon deposits from valves using the proper metal 75757
brush.
Use a magnetic base dial gauge (1) set as shown in the figure,
Check that the valves show no signs of seizing, scoring or the assembling clearance shall be 0.056 0.096 mm.
cracking.
Turn the valve (2) and check that the centering error is not
Regrind the valve seats, if required, removing as less material
exceeding 0.03 mm.
as possible.

Figure 75 Figure 76
75754
Check the valve seats (2). If slight scoring or burnout is found,

INTAKE EXHAUST regrind seats using adequate tool (1) according to the angle
84046 values shown in Figure 77.
Use a bore dial gauge to measure the inside diameter of the
Figure 77
116356
INTAKE EXHAUST
VALVE SEAT MAIN DATA

Figure 78 FITTING CYLINDER HEAD
Figure 80
1
3 1
2
2
75758
75759
After regrinding, check that valve (3) sinking value is the

specified one by using the base 99370415 (2) and the dial Lubricate the valve stems (1) and fit them into the relevant
gauge 99395603 (1). valve guides according to the position marked at removal.
VALVE SPRINGS sealing rings (3) for exhaust valves are green.
Figure 79
50676 Figure 81
1 2
VALVE SPRINGS 3
Before refitting use adequate tool to check spring flexibility. 4
Compare load and elastic deformation data with those of the
6
mm N
H (free) 63.50 0 5
H1 49.02 329
H2 38.20 641 75751

Refitting the cylinder head For 6 cylinder versions:

Figure 82 Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
the average value.
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6

S=
6


87759
D2 diameters:
Check cleanness of cylinder head and engine block coupling if D1 - D2 < 0,1 mm the screw can be utilised again;
surface. if D1 - D2 > 0,1 mm the screw must be replaced.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking N. of D2 D1
component (1) facing the head.
The arrow shows the point where the gasket thickness is
given.
Figure 83
75703
88775
There are two types of head seals, for the thickness (1.25 mm
upper plane then calculate the average:
S cil1 = S1 + S2
2
For 4 cylinder versions:
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
S cil1 + S cil2 + S cil3 + S cil4
S=
4

TIGHTENING TORQUE (FOR 4 AND 6 CYL.)

TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15 3 1.5 0.3
Main bearing cap 1st stage 50 6 5.0 0.6
2nd stage 80 6 8.0 0.6
3rd stage 90 5
Rear gear housing assembly
2.4 0.4
(M8x1.25x40) 24 4
2.4 0.4
(M8x1.25x25) 24 4
4.9 0.5
(M10x1.5) 49 5
Oil pump (M8x1.25x30) 81 0.8 0.1
Front cover assembly
(M8x1.25x45) 24 4 2.4 0.4
(M8x1.25x30) 24 4 2.4 0.4
Connecting rod bolts (M11x1.25) 1st stage 30 3 3.0 0.3
2nd stage 60 5 6.0 0.5
3rd stage 60 5
Ladder frame assembly (M10x1.25x25) 43 5 4.3 0.5
Oil rifle plugs
(M10x1) 61 0.6 0.1
(M14x1.5) 11 2 1.1 0.2
Assemble oil suction tube (M8x1.25x20) 24 4 2.4 0.4
Oil pan assembly
(M8x1.25x25) 24 4 2.4 0.4
(M18x1.50) 60 9 6.0 0.9
Set timing pin 51 0.5 0.1
Fuel pump assembly
M8 screw 24 4 2.4 0.4
M6 screw 10 1 1.0 0.1
M6 nut 10 1 1.0 0.1
M10x1.5 flange head nuts pre-torque 10 - 15 1.0 - 1.5
Final torque 50 - 55 5.0 - 5.5
Fuel pump gear (drive gear nut) Snug torque 15 - 20 1.5 - 2.0
Final torque 85 - 90 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) 50 + 90 5.0 + 90
(M12x140) 40 + 180 4.0 + 180
(M12x180) 70 + 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) 24 4 2.4 0.4
(M8x1.25x70) 24 4 2.4 0.4
Fan support (M10x1.5x20) 33 5 3.3 0.5
Fan pulley
(M6) 10 2 1.0 0.2
(M10) 43 6 4.3 0.6

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) 85 10 8.5 1.0
(M12x80) 85 10 8.5 1.0
(M10x80) 49 5 4.9 0.5
(M10x40) 49 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
2nd stage 80 6 8 0.6
3rd stage 90 5
2nd stage 60 5


F4GE N ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS F4GE N ENGINES

TOOLS

99340035 Injection pump gear extractor.

TOOLS
99360330 Flywheel crank handle
99360339 Tool for stopping the engine flywheel

TOOLS
99360344 Adapter, cylinder compression test (use with 99395682)
99360351 Tool for flywheel holding

99360362 993700069)

TOOLS
99360616 Engine TDC positioning tool
99370006 Interchangeable willow handgrip
99395097 Tool to check top dead centre (use with 99395604)

TOOLS
Dial gauge holder for rotary injection pump timing (use with
99395100 99395603)
99395603 Dial gauge (0 5 mm)
99395604 Dial gauge (0 10 mm)
99395682 Diesel fuel engine cylinder compression control device


PT-BOX ISTRUCTIONS 1
Part 5
PT-BOX ISTRUCTIONS
Section
PT-BOX istructions 1

2 PT-BOX ISTRUCTIONS

PT-BOX INSTRUCTIONS Select your user configuration type and then follow the
relevant information.
Hardware installation
1. PT-PLUS configuration
- PC Panasonic user
This Sw may cause engine start-up. Be extremely - PT-BOX module
! careful. - PT-DIAGNOSIS sw
The user is responsible for the correct use of the 2. PT-DIAGNOSIS configuration
PT-DIAGNOSIS software so as not to any cause
injury to people or damage to items. - user with own PC
- PT-BOX module
The user is also responsible for complying with all - PT-DIAGNOSIS sw
the rules relating to security for activities on the
industrial applications (engine, pump, generating The PT-BOX module (Electronic Communication Interface)
set) carried out in the workshop.
Carefully read the user manual before using the PT-BOX is an interface module allowing the communication
diagnostic tool and follow the instructions displayed between the engine ecus and the PC.
on the screen. - Weight: 500 g;
- Dimension: 175x75x30mm;
General rules for use - Flash memory: 4Mb - RAM 1Mb;
The following instructions should always be strictly followed: - Thermal tolerance: 0-50C;
- all instruments ensuring the security must be applied as - Power supply: 6-32V;
indicated in the application; - Connection interfaces: USB and RS232 standard
- ensure that the PT-BOX module is connected to the Bluetooth optional;
diagnostic socket of the engine on which work is to be - Interface for engine electronic systems: 9 KL ISO 9141
carried out; lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O
- in case of emergency, disconnect the PT-BOX module PWM.
from the engine or disconnect the USB cable; The led indicators on the front view allow to check the
- ensure that while using the software, there is nobody communication lines activity with the engine and with the PC
near the engine/vehicle you are working on; to which the instrument is connected.
- if it is necessary for more than one person to be working
on or near the engine/vehicle, they are all responsible for Figure 1
complying with security regulations of the workshop;
- we strongly suggest that the PT-BOX modules be visibly
and uniquely identified (for example by using coloured
adhesive tape, labels with names, etc).
By only accepting the use disposal it is possible to

! access PT-DIAGNOSIS (the green tick icon
becomes active). 156133
1. Led indicators to display the activity of the

The diagnosis system consists of: communication lines K/L. - 2. The upper led display the
ECUs communication activity. - 3. The lower led indicators
- a PC (Panasonic / your PC + Microsoft Windows 2000 display the CAN lines activity. - 4. The three upper led
or Windows XP Professional); indicators show the activity of the K/L communication lines.
- 5. The lower led indicator (fault) shows the presence of
- an instrument used as interface between engines/vehicles errors on the K/L lines. - 6. The upper led indicator shows
and PC (PT-BOX tester); that the PT-BOX is power-supplied. - 7. When blinking the
- a SW program (PT-DIAGNOSIS) to process data. lower led indicator (run) shows that the PT-BOX module is
correctly working. - 8. Led indicators to display the USB
By combinating the above indicated components 2 different ports (upper led). - 9. Led indicators to display the serial
configuration are possible. ports (lower led).

Connect the pt-box module Pt-box - engine/vehicle connection

On the PT-BOX module there are the communication ports
for the connection to the PC and to the engine / vehicle. Figure 5
Communication ports for the connection to the PC

Figure 2
156138
- connect the module to the engine/vehicle by using the

specific connection cable.
156135
1. serial port - 2. USB port NOTE The module is power-supplied by the diagnostic
cable; for this reason to work correctly it must be
Figure 3 connected to the engine.
System requirements
Minimum
- Processor: 300 MHz Pentium-II CPU;
- Hard disk space: 3 GB available;
- Ram: 256 MB;
156136
- Display: 800 x 600 video adapter and monitor;
Connector for the connection of the engine communication
cable. - Internet connection only needed for rss and pt-diagnosis
software update (eaus): modem;
- External ports: USB connector;
Pt-box - pc connection
- External reader: DVD-ROM reader;
Figure 4
- Os: Microsoft WindowsTM XP Professional Service Pack
2 - Microsoft Windows 2000 Service Pack 4 plus -
Windows 2000-KB835732-x86-ENU.EXE (login with
administrator privileges);
- Browser: Internet Explorer 5.5.
Recommended
- Processor: 1 GHz Pentium IV - Centrino CPU;
- Hard disk space: 5 GB available;
- Ram: 512 MB;
- Display: 1024 x 768 high colour video adapter and
156137 monitor;
- Internet connection only needed for rss and pt-diagnosis
software update (eaus): high-speed e.g. ADSL;
- connect the USB cable (PT-BOX side marked) to the - External ports: 2 USB 2.0 connectors, Bluetooth;
PT-BOX module (remove the holding screws from the
PT-BOX module, where present); - External reader: DVD-ROM reader;
- connect the USB cable to the PC; - Os: Microsoft WindowsTM XP Professional - Service Pack
3 (login with administrator privileges);
- turn the PC on.
- Browser: Internet Explorer 6.0.

Software installation
Registration
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
The registration procedure is carried out on-line and it is
different according to the user type:
- OEM users
- Dealer users
NOTE For both configurations (PT-PLUS and

PT-DIAGNOSIS) the SW installation is the same.
- A fill-in form is displayed.
Registration>OEM users The activation code received will be requested the

! first time you run the PT-DIAGNOSIS software.
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
Registration form (OEM user)
For this reason:
- Check that the registration card has been delivered The Registration allows you to download the EVCA SYNC
together with the kit. WEB application which allows you to obtain the activation
code:
- Select www.eltrac.it/ivecomotors/default.asp.
- From the starting page, select the language.
- Select pt users registration.
In the registration form:
1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
the identification data and the Network characteristics
areautomatically entered.
3. Enter the serial number of the PT-BOX instrument.

Figure 6
NOTE Before carrying out the registration we suggest to
install the PT-Diagnosis SW.
Installing the EVCA SYNC WEB (OEM users) application

To obtain the activation code it is necessary to install the
EVCA SYNC WEW application, after saving it on the desired
directory:
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module
4. Read the note in compliance with art. 13 of Italian
Legislative Degree 196 dated 30 June 2003 about the
processing of personal data Informative
5. Select the send key (only once!) wait
After sending a summary window is displayed waiting for the
end of the registration procedure.
1. Unzip the evcasyncweb1.2.6.zip (for example using

WinZip: www.winzip.com/downwz.htm).
2. Open the EVCASyncWeb1.2.6 and then
EVCASyncWeb15-09-10 (Rel1.2.6).
3. Run setup.exe and continue with the installation of the
guided application.
NOTE For further information about the installation of

EVCASyncWeb it is possible to read the detailed
guide EVCASyncWeb Setup.pdf in the directory
EVCASyncWeb1.2.6.
Then a link is available to download the EVCA SYNC WEB
application. It will be used to obtain the activation code:
6. Select the print key for printing a summary report 4. At the end of the installation, the icon of the
(registration data and number of registered instrument). EVCASyncWeb application is displayed on the desktop
of the PC.
7. Select the link to download and then select the save key,
to save the application on the PC.

Running the EVCA SYNC WEB (OEM user) application
3. Enter the PT-BOX serial number of and the Customer

PIN.
4. To continue, select the confirm key.
1. Double click on the icon EVCASyncWeb application.

At the start up of the application choose the Internet
connection mode:
- by means of the Proxy Server;
it is necessary to enter the connection parameters; at the
end select the okey. It is possible to pre-set the
connection parameters: read the EVCASyncWeb
manual;
- without Proxy Server;
select the okey.
5. Enter the alpha code supplied with the Registration Card

(scrap the card).
The starting page EVCASyncWeb is displayed; some

functions are available (for more information read the manual
EVCASyncWeb).
2. Select the applications key for pc.

Summary of the selected choices (OEM user)

At the end of the activation procedure, the summary of the
selected choices is available. The following data are displayed:
Contract Activation (OEM User)

7. Select a contract type.
The contract types available for the OEM users are indicated
below:
- Fee (annually):
the duration of the contract is for one year, starting from - The type of selected contract.
the activation date of the contract. During this phase it is
- The list of instruments (PT/PB) associated to the contract
only possible to associate one instrument to the contract.
with the generated activation codes
- Token (to be deducted):
- The expire date of the contract (in case of yearly fee) or
it is the payment for a single download of an application;
residual credit (coins):
it is possible to associate to the contract to 4 instruments.
1. We suggest you to print and keep the summary data:
select the key print selections recap.
2. Show and download the list of the available
applications belonging to your profile (FPT
activation): select the applications download key.
The window containing the activation codes is displayed.

9. Print/copy the activation codes and keep them together
with the instruments they are associated to.
10. Select the okey to end.

Download the applications Registration>Dealer users

Before using the PT-DIAGNOSIS diagnosis system you must
register on the FPT web site.
1. Connect to
http://www.fptpowertrain.com/index_main.htm.
The following information for each one of the available
2. Select the language.
applications for downloading is displayed: ECU, license, file
name, Release Date, Release Type and short description.
Each option can be used to sort the list: to sort the list in
ascending/descending order according to a given key, select
the title of the corresponding column.
1. Select the application to be downloaded; the selected line
is highlighted in red.
2. Select the download the selected application key and follow
the system instructions.
3. Identify the path where the packets have been
downloaded.
4. At the end of the download install the packets (double
click) one by one.
3. Select Fiat Powertrain Technologies and then Partner Area.
NOTE The packets must be downloaded/installed one by

one.
4. Connect to the web site by selecting Click here.

5. Fill in the fields for the login procedure.
7. Go to the registration web page; select pt users registration

a fill-in form is displayed (on-line registration form).
NOTE For the new customers:
request username and password to
areapartner@fptpowertrain.com.
For the customers already registered:
use username and password received by e-mail.
Registration form (Dealer user)

The Registration allows you to download the EVCA SYNC
WEB application which allows you to obtain the activation
code.
In the registration form:

1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
6. Please follow the indicated instructions the identification data and the Network characteristics are
automatically entered.
After Sales>Various>Diagnostic Instruments>Diagnostic
Tools

3. Fill in the yellow field by entering the alpha code supplied 6. Select the send key (only once!) wait
with the Registration Card (scrap the area on the card).
After sending a summary window is displayed waiting for the
4. Enter the serial number of the pt-box instrument. end of the registration procedure.
Wait for the following window:
- the activation code;
- the link to download the EAUS application (EAsy Update
Software).
7. Print the activation codes (print key) and keep them
together.
8. Select the link to download the EAUS application.
Installation of EAUS application (Dealer user)

The EAUS application is an update utility to automatically
download all SW Updates for all ECUs activated for FPT.
After having selected the link for downloading the EAUS
Figure 7 application, the system asks you to select the file or to directly
run it.
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module.
1. Select the run key:
5. Read the note in compliance with art. 13 of Italian the system automatically downloads first and then installs
Legislative Degree 196 dated 30 June 2003 about the the EAUS application; run the operation required by the
processing of personal data Informative. system and wait for the end of operation.

Connection
Figure 8
156138
1. Connect the PT-BOX module to the engine/vehicle using

the diagnosis cable.
2. Connect the PT-BOX module to the PC, using one of the
2. Select the end key to exit the installation. two USB cables provided with the module.
NOTE Before carrying out the registration we suggest to The PT-BOX module is supplied by the diagnosis
install the PT-Diagnosis SW. ! cable; therefore it must be connected to the
engine/vehicle to be able to work.
Figure 9
Run the EAUS (Dealer user) application
156140
3. Switch the PC on.
PT-BOX module USB driver set-up

(only for the PT-DIAGNOSIS configuration)
This operation is required only if the PC in use has never been
connected to an PT-BOX module:
1. It is now possible to download the update by using the

Automatic Update Function (tools>software update key).
1. Check that the PT-BOX module is correctly connected to
the PC via the USB cable.
2. The PC acknowledges the presence of a new hardware
component; press the cross button to continue.

5. Select the have disk> button to continue.

3. Automatically (Windows XP) the procedure starts to
set-up the driver; select the Install from a list or specific
location option; select the next> button to continue.
6. Enter the path:

ProgramFiles\EltracECI\Driver\PT-BOX.sys;
select the ok button.
4. Select the Dont search. I will choose the driver to install;

select the next> button to continue.
7. Select the next> button to continue.

4. The system asks you to enter the activation code received

from Field Service; select the tick button.
8. Driver set-up begins wait.

9. The procedure is completed; press the finish button.
5. Enter the activation code sent via Web.

6. Select the register button; a message confirms that
registration has taken place.
7. Select the cross button to close the Activation Code
window and go back to the PT-DIAGNOSIS screen.
10. The system informs that the new hardware has been
correctly installed; select the cross button to continue.
11. Re-start the PC.
Activation - first time of use of PT-DIAGNOSIS sw +

PT-BOX module
The first time the PT-DIAGNOSIS Diagnosis System is used,

it is necessary to follow the procedure described below:
1. Make sure you possess the activation codes (Web
access).
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB/BT module.
3. Start the Panasonic PC.
8. Select the stop button and restart PT-DIAGNOSIS.
Now all the software functions are available.

Activating - new PT-BOX module

The activation procedure is necessary every time you want to
use an PT-BOX module that has not yet been paired to the
PT-DIAGNOSIS diagnosis system in use; follow the
operations described below:
6. Enter the activation code received from Field Service.

7. Select the register button; a message confirms that
registration has taken place.
8. Select the cross button to end activation.
9. Re-start the PT-DIAGNOSIS (E.A.SY. icon).
1. Make sure you have requested and obtained the
activating code for the PT-BOX module.
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB cable.
3. Start the PT-DIAGNOSIS software: double click on the
EASY icon (PT-DIAGNOSIS) placed on the desktop of
PC.
4. Select the tools>activations button.
5. Select the entry button.

Software Interface
The PT-DIAGNOSIS software interface is designed to facilitate access to tools, view functions and make diagnostic procedures clear
and adaptable to various needs.
All windows follow the same design with additional features which depend on the specific working environments.
Each window presents three main areas to which specific functions are univocally associated:
- Keys Area
- Title Area
- Operative Area
The Title area shows the selected function under test and previous choices by which you arrived.
The Keys The Operative

area contains Keys area contains available
for accessing the system and function
operative list referred to the
environments and intervention area.
the functions to
which they are
associated.

To go from one environment to another
3. Select the Class and the System under test to which the
engine/ vehicle belongs; then press the navigation key (is
active - green) to continue.
1. The Start Window shows the family.
Start Window
- It is possible to select a new family or to choose a family
from the database;
- green identifies a pull-down menu.
4. The window Choose Activity appears; it is here possible

to choose from four lists.
Window Choose Activity
It is now possible to choose:
- diagnosis;
- test;
- programming;
- specific functions.
Navigation keys
2. Select the fami ly of the engine/vehicle under diagnosis; They allow you to go from one environment to another.
then press the navigation key (is active - green) to Enabled keys are displayed in green and disabled keys are
continue. displayed in grey.
Family Choice Window navigation key forward disabled
- Yellow identifies a selected item in a pull-down menu;
- a paged list is used to display a large amount of navigation key forward enabled
information one page at a time; navigation tools are
available to navigate from page to page. navigation key back enabled
Database key
It allows you to access the Database

environment.
Browse key
To scroll long lists which cannot

be contained in a single window. ignition key
For the equipped engines, it allows you to operate engine

Detail of Keys area ignition directly via the diagnostic tool. Two positions (stop
In the Start Window the Keys area contains the Keys for and mar) and three states (enabled stop, disabled stop,
accessing the functions which are always available: enabled mar) are possible.
communication panel
It indicates that the communication with the ECU is active or
that the ECU is not present (no ecu).
The lower leds indicate the communication state of the
electronic system as shown below:
Square LEDs: two states (green/red); green indicates that
communication with the electronic system has been initialised;
if red indicates the communication has been interrupted.
Rectangular LEDs: blinking indicate that data exchange
between electronic system and diagnostic system is in
progress.
Utilities key
stop key
To quit PT-DIAGNOSIS application at any time.
engine/vehicle key
It allows you to return to the Family Choice Window.
utilities key
When selected the Key background will be yellow and allows
you to access a menu.
guide to diagnosis key

It allows you to access the environment Guide to Diagnosis
(only available for some ranges). It is available in the Electrical
Control Units environment.

Teleservices key
It allows you to access the remote connections services. Electronic control units key
Activations key
It allows you to access the Electronic Ecus environment.
It allows you to access the management function of the The key appears on a yellow background (default status,
activation codes. environment Electronic Control Units enabled) or on a grey
Select the measure unit key background (environment Electronic Control Units disabled).
If you want to work at the same time with more Ecus, select
It allows you to choose the measure unit system. the key environment electronic ecus>add ecu.
Electrical diagrams key

It refers to a CLASSES list for which an electrical diagram is
The Metric System (SI), the international standard one, is available. The key appears on a yellow background
based on the meter, kilogram and second. The British System (environment Electrical Diagrams enabled) or on a grey
(fps) is based on the foot, pound and second. background (environment Electrical Diagrams disabled).
Select language key To enter the Electrical Diagrams environment select the key
electrical diagrams area.
To change the language; restart the application to make the
setting operational.
Software update key Report key
It allows you to carry out the automatic update of the It allows you to access the Report environment.
PT-DIAGNOSIS software. The key appears on a yellow background (environment
Eci management key Report enabled) or on a grey background (environment
Report disabled). To access the Report environment select
It allows you to manage the connection (usb or Bluetooth) the report key.
PT-DIAGNOSIS - PT-BOX module.
On/Off-line key
It can be on-line or off-line.
The on-line key indicates that the PT-Diagnosis SW uses the
In the Start Window select the fami ly; by pressing the PT-BOX/PC module connection.
navigation key forward it is possible to access the next The off-line key indicates the PT-Diagnosis SW is working in
window. New icons appear in the Keys area for accessing simulated mode. To change the status select the key.
specific functions:

Acceptance
Environment DataBase key search
From the PT-DIAGNOSIS start window it is possible to select It allows you to search an engine by applying a filter (DATE,
a new engine or to select one from the database. engine mode l, CUSTOMER or NUMBER PLATE).
key delete search

It cancel the filter; it is active only after a search.
key order
It orders the list according to the selected ordering criterion.
key report
It gives access to the summary environment; enabled after
selecting an engine.
key delete
1. Select the database button: you access the DataBase
environment (it contains the list of accepted engines). It deletes the selected engine from the database; it is active
only after selecting an engine.
2. The list of accepted engines is available.

They can be search by means of the following keys:
3. Select an engine from the list (the background is yellow);
- DATE it is possible:
- ENGINE MODEL - to analyse engine data (report button);
- CUSTOMER - to start again the diagnosis procedure on the engine
(navigation button forward);
- NUMBER PLATE
- to return to the start window (navigation button
back).

How to order the engines list 3. If required, enter the word or the code to be searched
and confirm by selecting the tick icon.
To cancel the search and display all elements from the archive
select the cancel search key.
For the selection of a new engine see ECU Diagnosis.

!
1. Select the order key.

2. Select the order method.
- DATE
- ENGINE MODEL
- CUSTOMER
- NUMBER PLATE
Environment Report
How to search for an engine from the database
When the engine sheet of the engine under test has been
saved in the Report Environment, the engine has been
accepted.
You access the Report environment in the following ways:
1. Select the search key.

2. Select the search method.
- DATE
- from the Buttons area at any time by selecting the
- ENGINE MODEL corresponding button;
- CUSTOMER - from the DataBase environment by selecting the
required engine and the report button.
- NUMBER PLATE

Environment Report
DIAGNOSIS REPORT LIST

KEY:
summary of all performed
ENGINE DATA KEY: diagnosis operations
engine identification data;
the fields can be always
changed (with the
exception of the engine
model and the date) can be PROGRAMMING
always changed REPORT LIST KEY:
summary of all performed
programming operations
SAVE KEY: AUTOMATIC

it allows you to save the ACCEPTANCE KEY:
engine sheet (to accept it) (enabled only if the
communication is active)

Acceptance When you read or cancel the faults memory or carry out a
programming it is not possible to return directly to the window
The acceptance (sheet saving) is mandatory when important Family Choice; by selecting the engine button the following
operations are performed on the engine (read or cancel faults windows are displayed:
memory, programming).
1. Read or cancel the faults memory or carry out a 1. Before continuing it is necessary to save the data of the
programming and then select from the corresponding performed activity; select the tick icon; the Report
environment the report button; you enter the Report environment appears.
environment.
2. Enter data.
2. Enter data.
3. Save the sheet by selecting the save button.
3. Save the sheet by selecting the save button.

4. From the Buttons area select the button of the operation
you want to perform. It is now possible to return to the Family Choice window.

Automatic acceptance
From the Report environment it is also possible to accept the
engine automatically.
This operation is only possible if the communication

! with the system has been activated.
1. Read or cancel the faults memory or carry out a

programming and then select from the corresponding
environment the report button.
5. The automatic acceptance reads the following

information:
- Engine Model (engine type + engine serial number)
- PIC
- Engine type
- Engine Serial Number
6. At the select the save key.
2. You enter the Report environment. ECU diagnosis

3. Select the button automatic acceptance.
1. Sselect the Family, the Class and then the System of engine
under diagnosis.
2. Press the navigation button forward (enabled - green) to
continue.
4. By means of the automatic acceptance the system tries to
communicate with the engine ECU: confirm the displayed
message by pressing the tick icon; wait until the ECU is
ready.

3. The window Choose Activity appears; it is here possible 2. PT-DIAGNOSIS system presents a pop-up window
to choose from four lists: where to select the automatic or the manual activation of
Window Choose Activity the ignition key; select the required mode; the key button
is disabled.
- diagnosis
Under the automatic mode all activation of the ignition key are
- test controlled by the diagnosis instrument (key button working).
- programming Under the manual mode all activation of the ignition key are
- specific functions controlled by the operator on the engine.
4. The present Repair Guide describes the diagnosis

environment and the specific functions to which it is
associated:
- Identification Code Reading
- Faults Memory Reading
- Parameters Reading
Identification code reading

3. Confirm the new message by pressing the tick icon.
1. To access the Read Identification environment select the

item Identification Code Reading from the Diagnosis list
and then press the navigation button forward.

Multitasking option
report key
PT-DIAGNOSIS introduces a very important news: it is
Shows the Diagnosis Report List (and allows you to print each
possible to associate more ECUs to the family of engine under
report).
test.
Add an ecu
print key
It is possible to interrupt the diagnosis with an ECU and to start
Prints the summary page of Identification Parameters. the procedure with another one.
4. Wait until the ECU is ready; the general information

about the electronic system under test is read:
- identification code
- HW version
- SW version 1. Select the button ecus area>add ecu; the Choose Vehicle
- production date window will appear, where you can select the desired
ECU.
-
Managing more ecus
After identification code reading it is possible to carry out
other activities (step 5) or to return to the window Choose It is possible to operate with two or more connected ECUs
engine (step 6). at the same time.
1. Select the button ecus area>desired ecu.

The activity remains interrupted for the not selected ECUs
and can be started again at any time.
Cancel an ecu
5. To access the other activities from the environment It is possible to stop the activity on one of the connected
Identification Code Reading, select the choose activities ECUs.
buttons: choose an activity; the system automatically access
the selected activity.
The choose activities buttons are shown in yellow when
selected.
6. To exit the diagnosis of the engine under test select the 1. Slect the button ecus area>required ecu>cancel.
button ecus area>ecu under test>cancel.
2. Select the required ECU.

Ignition Key Button Modes - on line/off line Read faults memory

At the system start up the on/off button is on-line if the
PT-BOX module is activated and connected to the PC,
otherwise is disabled (off-line).
On line mode
The function Ignition Key is active; it can be managed in
automatic or manual mode; the ignition key screen appears
only after the selection of a function that requires it (e.g.
diagnosis functions).
In automatic mode all ignition key activations are managed by
the diagnosis instrument.
In manual mode all ignition key activations are managed by the
operator on the engine.
The automatic activation depends on the type of engine; make
sure the engine supports the function before selecting 1. To access the Read Faults Memory environment select the
automatic mode. item Faults Memory Reading from the list Diagnosis and
then press the navigation button forward.
1. After selecting the automatic mode a test procedure is

carried out.
2. Switch the ignition off. 2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation of
3. The engine chassis may move. the ignition key; select the required mode; the key button
The PT-DIAGNOSIS SW activates the ignition key and is disabled.
displays a screen page in which it asks to check the dashboard;
if it is turned on the diagnosis procedure can be continued;
otherwise the system asks for position of the key to ON in
manual mode.
Both in manual and in automatic mode:
1. Before ignition key activation a message is always
displayed: request (manual mode) or warning
(automatic).
2. When the ECU is cancelled a message indicates that it is
necessary to interrupt the communication and then to
confirm the operation.
3. The chosen mode remains until the engine under test is
changed.
Off line mode
The basis diagnosis is simulated and it is possible to read some
information about the electronic system under test.
3. Confirm the new message by pressing the tick icon.

cancel faults memory key

It cancels the faults selected in the list; it is possible to cancel
a fault at a time; the cancel operation will be effective when you
confirm it by pressing the tick icon displayed in the next
pop-up-window.
faults key
It allows you to access the Faults environment; it can be yellow
(the faults list is displayed) or gray (environment Faults
disabled).
4. Wait until the ECU is ready; the list and faults type
occurred during the working are displayed.
There are two types of failures:
- failures present during the reading procedure (red);
- intermittent failures not present during the reading
operation but which occurred at least once before
(black).
Detail of Buttons area of the Faults Memory area

New icons appear in the window Read Faults Memory for
accessing specific functions:
On line Mode
Faults Memory Reading Icons
environmental condi tions key

Active when the communication with the ECU has been
interrupted this is used to examine environmental conditions
when the failure occurred. It can be gray (default status) or
yellow (when selected).
repair guide key

Active when the communication with the ECU has been
interrupted it gives an analysis of the fault selected from the list;
On line Mode in particular other information (blink code, failure code and
Faults Memory Reading Icons fault mode) is available it can be gray (default status) or yellow
(when selected).
on key
The communication between the system and the ECU is report key
active: it performs again the Faults Reading; it updates the ECU
communication. It allows you to save the report of carried out operations see
Select the button to interrupt the reading. Report environment > button diagnosis report.
off key
The communication with the ECU has been interrupted. print key
Select the button to start again the electronic system reading. It allows you to print the displayed window.

Off line Mode 2. Select the button environmental conditions.

Faults Memory Reading Icons It examines the present environmental conditions at time of
the fault.
blink code search key
Appears only if the communication with the ECU interrupted
is (under OFF LINE Mode) recognize the fault where blink
code or required word appear.
To go from one function to another (faults, environmental
conditions, troubleshooting) select the corresponding button.
Operations like Read and Cancel Faults Memory are very
important: they are automatically stored and need the engine
acceptance.
How to get information about a fault

1. Interrupt the communication with the ECU (button
on/off) and select an item from the faults list: the fault is
described in the below blank area; in particular the
following information is available:
3. Select the repair guide button; the following information
is available:
- the blink code
- the failure code (DTC)
- the failure mode (FMI)
Appears a new icon, the measures key
measures key
The Measurements pop-up window opens with a list of

possible measurements and the relevant operating
suggestions.
- the fault
- the signal type
- the repetition type
The button faults appears on yellow background because it
is selected.

Parameters reading 3. The read parameters are shown and the values assumed
4. Select the groups key.
The groups key allows you to access the groups management
functions (see group Management).
Detail of parameters buttons area

New icons appears on the window Parameters Reading for
accessing specific functions:
1. To access the Parameters Reading environment select

the item Parameters Reading from the Diagnosis List and
then press the navigation button forward.
on key
The communication between the system and the ECU is
active: select the button to interrupt the reading.
off key
The communication with the ECU has been interrupted; select
the button to start again the electronic system reading.
groups key
2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation It opens the GROUPS window showing the list of created
of the ignition key; select the required mode; the key group (A) and the keys to create/modify the groups (B).
button is disabled.
Pay close attention to the displayed messages and wait until
the ECU is ready.
parameters acquisition key

It allows to record the trend in time of the measurable
parameters.
report key
It allows you to save the report of carried out operations.
print key
It allows you to print the displayed window.

Groups Management 9. From the drop down menu (above on the left), select one
of the available parameter groups, excluding the
parameter you are changing.
10. On the left-hand list the parameters of the selected group
are shown; on the right-hand list the parameter of the
group you are changing are shown.
The parameters with a gray background on the left-hand list
are parameters that have already been added and can not be
selected.
5. The Groups window opens.

The pre-defined parameter groups are first displayed then
the customized ones; the pre-defined parameters
(measurable and status) can not be modified.
11. To a parameter to the right-hand group, select it and

confirm by pressing the right arrow key ( ).
12. To remove a parameter (from the right-hand list select it
and confirm by pressing the left hand arrow key ( ).
Select the save key to save and exit the groups management
environment.
Modify a parameters group

Create a new parameters group
6. Select create.
7. Enter the name of the group you want to create.
8. Confirm by selecting the green tick icon.
1. Select a customized parameters group.

2. Select modify; the window for parameters groups
management opens.
3. Select the group you want to change and continue with
step 9 (link).

Cancel a parameters group Window Store Parameter
2. Select the sample time by using the arrows on the

Sampling active area.
3. Select the duration of registration by using the arrows key
1. Select a group of customized parameters on the active area Duration.
2. Select delete; confirm or cancel the request.
Appendix parameter acquisition key
4. Select the key start/stop to start the registration (a new

window open Notes where you can add a comment).
5. Close the Notes window, the registration starts.
6. Wait for the end of registration procedure (it is also
possible to interrupt the registration, by using the stop
key).
1. Select the parameters acquisition key; the window Store

Parameter opens.
The key is only active under on line mode.
7. Select the archive key: the Archive window open showing
the list of available registration in the archive.
Parameters reading

Archive window
- To display tables (horizontal or vertical).
- To colour display the area indicated by the diagram.
- Print.
- To go back
Programming
The consultation can be started
To access the programming area of the ECU under test
proceed as follows:
1. From the Archive windows, select a registration; it is

possible:
- to cancel it (cancel key)
- to read data (report key)
- to show data (show key, opens the Data Reading
window)
- to print data (print key)
- to save data in text format (save as key)
- to go back (cross key)
Data Reading window
1. Select the Engine Family under diagnosis.

continue.
2. From the Archive window, select a registration and the

show key; the Data Reading window opens; it is possible:
- To select all parameters (fast selection key).
- Deselect all parameters (fast deselection key).
- To show the diagram with full-screen.
- Increase, reduce or to bring back to the original 3. Select the Class and the System under test to which the
display the time range (x-axle, seconds). engine belongs; select the forward navigation key
(enabled - green) to continue.

4. Select the programming option from the Programming 7. Read the displayed messages and select the green tick
list; select the forward navigation key (enabled - green). icon to continue.
5. If required, enter the required data, by following the 8. At the end the system permits access to the
indicated procedure. Programming environment; the components list is
displayed, on which tests can be carried out.
It is possible to carry out a programming only in During the programming do not disconnect the
! online mode. In case of error check the connections ! USB cable. Before carrying out the ECU
ECU/PT-BOX/PT-DIAGNOSIS. programming verify the charge left in the
computers battery.
It is recommended to plug the PC in (connect it to
the engine/vehicle or to the mains supply).
Programming environment
It is possible to use specific functions, by selecting the
corresponding key:
6. Select the ignition key management (automatic/manual): - Data Reading

if the electronic system engine under test is fitted with this
function, select the automatic key. - Change the configuration
- PT-DIAGNOSIS shows the running activities. - Programming
- The ignition key ON is automatically activated. - PTO (only for the PT-DIAGNOSIS full version SW)
- The connection to the ECU starts.

The available function types are determined according to the Data Reading
type of ECU under test. The Keys area contains the buttons
for accessing the functions specific for the Programming This is used to view the data concerning the ECU and the
environment. respective programming state; tampering attempts are shown.
The following are indicated:

print key
- station type and number;
If enabled, select to print a report. - programming date;
- ECU software release.
cancel key
If enabled, select to re-establish a configuration.
navigation keys
If enabled, select to move between different environments.
cross key
If enabled, select to cancel an operation.

The system views the following data classes:
- supplying data;
- factory data (never updated);
- service data (updated after each programming
event).
scroll keys
If enabled, select to scroll the list step by step.
fast scroll keys

If enabled, select to scroll the list step by step.

Active diagnosis
It is possible to carry out an active diagnosis only in
To start the Active Diagnosis online mode. In case of error check the following
!
connections ECU/PT-BOX/PT-DIAGNOSIS.
1. Select the Engine Family under diagnosis.

continue.
5. Select the ignition key management (automatic/manual):
if the electronic system engine under test is fitted with
this function, select the automatic key.
- PT-DIAGNOSIS displays some information about
the activity in progress.
- The ignition key ON is automatically activated.
- The ECU connection starts.
6. Read the displayed messages and select the green tick

icon to continue.
3. Select the Class and the System under test to which the
engine belongs; select the forward navigation key (enabled
- green) to continue.
7. At the end the system permits access to the Active

Diagnosis environment; the components list is displayed,
on which tests can be carried out.
4. From the Test list select the option acti ve diagnosis;

select the forward navigation key (it is active, in green
displayed).

Active Diagnosis environment

The components of the selected electronic system are indicated in a list; use the browse keys to display all the elements of the list.
1. Select the component on which the test will be carried out.
2. Select the forward navigation key to continue and carry out the test.
Help key Components:

if selected it shows selectable list
information about
the electronic system
under test;
information about Browse key
the guide to the
diagnosis are not
provided.
Forward navigation
key
Back navigation key

It allows you to move one
step back; if selected at
this level it allows you to
exit the Active Diagnosis
environment.


APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3

2 APPENDIX

APPENDIX 3

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

4 APPENDIX
GENERALMANUTENZIONE

changed.
danger.
connections.

F4ce de Ge He9684 87 9454

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

F4ce de Ge He9684 87 9454

Transféré par

Droits d'auteur :

Formats disponibles

N TIER

Technical and Repair manual

Print P2D32N003 E - 3a Ed. 05.2010

N F4HE engines Part 1

N F4CE engines Part 2

N F4DE engines Part 3

N F4GE engines Part 4

PT-BOX Instructions Part 5

Print P2D32N003 E Base - May 2010

Base - May 2010 Print P2D32N003 E

PREFACE TO USERS GUIDELINE MANUAL . . . . 3

- Bonding and screening . . . . . . . . . . . . . . . . . . . 8

CONVERSIONS BETWEEN THE MAIN UNITS

KEY OF LECTURE OF THE HEADINGS

Print P2D32N003 E Base - May 2010

Base - May 2010 Print P2D32N003 E

PREFACE TO USERS GUIDELINE MANUAL

Danger for persons

Danger of serious damage for the assembly

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

1 1 = housing for connecting rod small end bush

Print P2D32N003 E Base - May 2010

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Base - May 2010 Print P2D32N003 E

Print P2D32N003 E Base - May 2010

Base - May 2010 Print P2D32N003 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Print P2D32N003 E Base - May 2010

Bonding and screening

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

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

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

Base - May 2010 Print P2D32N003 E

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Print P2D32N003 E Base - May 2010

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Language Basic edition referred to When month - year

Base - May 2010 Print P2D32N003 E

Overhaul and technical specifications 4

Safety prescriptions Appendix

Print P2D32N003 E Base - May 2010

Base - May 2010 Print P2D32N003 E

Section Description Page Date of revision

3 Industrial application 19 Revi-September 2012

Print P2D32N003 E Base - May 2010

Base - May 2010 Print P2D32N003 E

CORRESPONDENCE BETWEEN TECHNICAL

- 4-cylinder engine version . . . . . . . . . . . . . . . . . 4

- 6-cylinder engine version . . . . . . . . . . . . . . . . . 5

OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 6

- Version with blow-by filter . . . . . . . . . . . . . . . . 6

- Version without blow-by filter . . . . . . . . . . . . . 7

- 4-cylinder engine version . . . . . . . . . . . . . . . . . 8

- 6-cylinder engine version . . . . . . . . . . . . . . . . . 9

AIR INDUCTION - BOOST DIAGRAM . . . . . . . 10

EXHAUST GAS RE-CIRCULATION

Print P2D32N003 E Base - May 2010

Base - May 2010 Print P2D32N003 E

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

Technical Code Commercial Code

Print P2D32N003 E Base - May 2010