Iveco workshop manual

NEF TIER 2 SERIES
Power generation application
NEF 45
GE NEF 45M
GE NEF 60M
GE NEF 75M
GE NEF 85M
GE NEF 100M
GS NEF 45M
GS NEF 60M
GS NEF 75M
GS NEF 85M
GS NEF 100M
NEF 60
GE NEF 200E
GS NEF 200E
NEF 67
GE NEF 125M
GE NEF 130M
GE NEF 160M
GS NEF 125M
GS NEF 130M
GS NEF 160M
Technical and Repair manual

Publication edited by
Iveco Motors
Iveco SpA
PowerTrain
Mkt. Advertising & Promotion
Viale dell’Industria, 15/17
20010 Pregnana Milanese
Milano (Italy)
Print P4D32N001 E - 2nd Ed. 04.2007
This publication describes the characteristics, data and correct
methods for repair operations on each component of the ve-
hicle.
If the instructions provided are followed and the specified
equipment is used, correct repair operations in the pro-
grammed time will be ensured, safeguarding against possible
accidents.
Before starting to perform whatever type of repair, ensure that
all accident prevention equipment is available and efficient.
All protections specified by safety regulations, i.e.: goggles,
helmet, gloves, boot, etc. must be checked and worn.
All machining, lifting and conveying equipment should be in-
spected before use.
The data contained in this publication was correct at the time
of going to press but due to possible modifications made by
the Manufacturer for reasons of a technical or commercial na-
ture or for adaptation to the legal requirements of the differ-
ent countries, some changes may have occurred.
No part of this publication, including the pictures, may be re-
produced in any form or by any means.
B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15/19
10156 Turin - Italy
Produced by:

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
PRELIMINARY REMARKS
General danger
It includes the dangers of above described signals.
Danger of serious damage for the assembly
Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may
sometimes cause the warranty to become null and void.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
SYMBOLS - WARNINGS
It indicates an additional explanation for a piece of information.
!
NOTE
3NEF POWER GENERATION ENGINES
Print P4D32N001 E Base - April 2007

GENERAL WARNINGS
Warnings shown cannot be representative of all dangersituations possiblyoccurring. Therefore,it issuggested tocontact
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 onharmful
materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by IVECO Motors original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
!
4 NEF POWER GENERATION ENGINES
Base - April 2007 Print P4D32N001 E

GENERAL WARNINGS
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO Motors commercial and assistance
network is available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
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.

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

Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR
d. DISTANCE ! 0
88039
Figure 1
Figure 2

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

F4GE NEF engines Part 1
F4AE NEF engines Part 2
Main electrical power and Troubleshooting Part 3
NEF POWER GENERATION
ENGINES
NEF POWER GENERATION ENGINES 1

Section
General specifications 1
Fuel 2
Power Generation application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the NEF engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty andis dividedin foursepa-
rate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
Part 1
F4GE NEF ENGINES
1F4GE NEF ENGINES

2 F4GE NEF ENGINES F4GE NEF ENGINES

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
Ø 1 = housing for connecting rod small end bush
Ø 2 = housing for connecting rod bearings
α
Tighten to torque
Tighten to torque + angular value
1∅
∅ 2
3F4GE NEF ENGINES
SPECIAL REMARKS

SYMBOLS - ASSISTANCE OPERATIONS
Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
ρ Compression ratio
Tighten to torque
Tolerance
Weight difference
α
Tighten to torque + angle value Rolling torque
Press or caulk Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fitting position check
Preload
Measurement
Value to find
Check
Number of revolutions
Equipment Temperature
Surface for machining
Machine finish bar
Pressure
Interference
Strained assembly
Oversized
Higher than….
Maximum, peak
Thickness
Clearance
Undersized
Less than….
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 °C
Cold
Winter
Air bleeding
Temperature > 0 °C
Hot
Summer
Replacement
Original spare parts

5F4GE NEF ENGINES
UPDATING
Section Description Page Date of revision

SECTION 1 - GENERAL SPECIFICATIONS 1F4GE NEF ENGINES
SECTION 1
General specifications
Page
ELECTRICAL SPECIFICATIONS
OF THE GENERATING SETS 3. . . . . . . . . . . .
CORRESPONDENCE BETWEEN TECHNICAL
CODE AND COMMERCIAL CODE 4. . . . . . .
LUBRICATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .
OIL VAPOUR RECIRCULATING SYSTEM 6. . . . .
COOLING SYSTEM 7. . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION BOOST DIAGRAM 8. . . . . . . .
- Description 8. . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 1 - GENERAL SPECIFICATIONS F4GE NEF ENGINES

ELECTRICAL SPECIFICATIONS OF THE GENERATING SETS
Prime Power
The Prime Power is the maximum power available with varying loads for an unlimited number of hours. The average power output
during a 24 h period of operation must not exceed 80% of the declared prime power between the prescribed maintenance intervals
and at standard environmental conditions. A 10% overload is permissible for 1 hour every 12 hours of operation.
Stand-by Power
This is the maximum power available for a period of 500 hours/year with a mean load factor of 90% of the declared stand-by power.
No kind of overload is permissible for this use.
(*) Power factor 0.8.
Electrical specifications
Generating set Assembled Engine
Ratings
50 Hz 60 Hzg g
Ratings
kVA kW (*) kVA kW (*)
GE NEF 45M NEF 45 AM1
Prime 45 36 50 40
GE NEF 45M NEF 45 AM1 Stand By 50 40 55 44
GE NEF 60M NEF 45 SM1
Prime 60 48 66 53
GE NEF 60M NEF 45 SM1 Stand By 66 53 73 58
Prime 75 60 75 60
GE NEF 85M NEF 45 TM1
Prime 85 68 100 80
GE NEF 85M NEF 45 TM1 Stand By 94 75 110 88
Prime 100 80 110 88
Prime 125 100 145 116
Prime 130 104 145 116
Prime 160 128 170 136
GS NEF 45M NEF 45 AM1
Prime 45 36 50 40
GS NEF 45M NEF 45 AM1 Stand By 50 40 55 44
GS NEF 60M NEF 45 SM1
Prime 60 48 66 53
GS NEF 60M NEF 45 SM1 Stand By 66 53 73 58
Prime 75 60 75 60
GS NEF 85M NEF 45 TM1
Prime 85 68 100 80
GS NEF 85M NEF 45 TM1 Stand By 94 75 110 88
Prime 100 80 110 88
Prime 125 100 145 116
Prime 130 104 145 116
Prime 160 128 170 136

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code
F4GE0405A*F600 GE NEF 45M
F4GE0405B*F600 GE NEF 45M
F4GE0455C*F600 GE NEF 60M
F4GE0485C*F600 GE NEF 85M
F4GE0655B*B600 GE NEF 125M
F4GE0685D*F601 GE NEF 130M
F4GE0405A*F600 GS NEF 45M
F4GE0405B*F600 GS NEF 45M
F4GE0455C*F600 GS NEF 60M
F4GE0485C*F600 GS NEF 85M
F4GE0655B*B600 GS NEF 125M
F4GE0685D*F601 GS NEF 130M

Figure 1
LUBRICATION
Lubrication by forced circulation is achieved through oil
rotary expansion pump, placed in the front part of the
basement, driven by the straight-tooth gear splined to the
shaft’s bar hold.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Lubrication involves the heat exchanger (2,3), the
turboblower for turbocompressed versions, and for any
compressed air system.
All these components may often vary according to the
specific duty.
Lubrication delivery oil
Oil returning to sump
LUBRICATION SYSTEM LAYOUT (6 cyl. engines)
106533

3240t
Figure 2
OIL VAPOUR RECIRCULATING SYSTEM
1. Valve - 2. Breather pipe - 3. Tappet Cap.
On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity,
to the Tappet cap underneath.
The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example (con-
nection towards these vapours shall be designed by the Engineer).
1
2
3

Figure 3
COOLING SYSTEM
The engine cooling system, closed circuit forced circulation
type, generally incorporates the following components:
- expansion tank; placement, shape and dimensions are
subject to change according to the engine’s equipment;
- radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions;
- visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as
well will be specifically equipped based on the engine’s
development;
- heat exchanger to cool the lubrication oil: even this
component is part of the engine’s specific equipment;
- centrifugal water pump, placed in the front part of the
engine block;
- thermostat regulating the circulation of the cooling
liquid;
- the circuit may eventually be extended to the
compressor, if this is included in the equipment.
117585
COOLING SYSTEM LAYOUT (6 cyl. engines)

74195
Figure 4
The turbocharger is composed by the following main parts:
one turbine, one transforming valve to regulate the boost
feeding pressure , one main body and one compressor.
During engine working process, the exhaust emission flow
through the body of the turbine, provoking the turbine disk
wheel’s rotation.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
The turbocharger is equipped with a transforming valve to
regulate the pressure , that is located on the exhaust
collector before the turbine and connected by piping to the
induction collector.
It’s duty is to choke the exhaust of the emissions , releasing
part of them directly to the exhaust tube when the boost
feeding pressure, over the compressor, reaches the
prescribed bar value.
The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
Description
RADIATOR
AIR FILTER TURBOCHARGER
EXHAUST
74195
RADIATOR
AIR FILTER TURBOCHARGER
EXHAUST
4 cylinders version
6 cylinders version
AIR INDUCTION BOOST DIAGRAM

SECTION 2 - FUEL 1F4GE NEF ENGINES
SECTION 2
Fuel
Page
INJECTION FEED SYSTEM BY MECHANICAL
ROTARY PUMP 3. . . . . . . . . . . . . . . . . . . . . . .
- General information 3. . . . . . . . . . . . . . . . . . . . .
- Description of working principles 3. . . . . . . . . . .
FEED PUMP 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- STANADYNE DB4 pump 4. . . . . . . . . . . . . . . .
- Description of operation 4. . . . . . . . . . . . . . . . .
PRIMING PUMP 5. . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FILTER 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 2 - FUEL F4GE NEF ENGINES

INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP
General information
Fuel feed system is composed by:
- Fuel tank
- Fuel delivery and back-flow to tank
- Fuel pre-filter
- Priming pump, assembled to the engine and driven by the camshaft
- Fuel filter
- Fuel feed rotary pump
- Injector feed pipeline
- Injectors
Figure 1
106534
Description of working principles
Fuel is sucked from the fuel tank by the priming pump. This
last one is placed on the engine basement and is driven by
the camshaft.
Throughout the filter, the fuel is piped to the union fitting
vacuum chamber of the transfer pump.
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
The fuel arrives therefore to the valve gauging the pressure
inside feed pump.
The distribution plunger further increases this pressure and
delivers fuel throughout the delivery pipe fitting to the
injectors.
The fuel drawing from the injectors is recovered and
delivered to the tank again.
(6-cylinder version)

1. Camshaft - 2. Distributor rotor - 3. Transfer pump vanes - 4. Pump element pistons (4) -
5. Cam - 6. Hydraulic head - 7. Pressure regulator unit - 8. Regulator - 9. Automatic advance - 10. Casing -
11. Metering valve- 12. Delivery valve - 13. Electrical power cut-off solenoid.
Figure 2
FEED PUMP
The rotary type pump is driven by a gear mating the camshaft’s one.
STANADYNE DB4 pump
106514
Description of operation
The main rotating components are propeller shaft (1),
distributor rotor (2), transfer pump vanes (3) and regulator
(8). With reference to the Figure 2, the propeller shaft
engages the distributor rotor inside the hydraulic head.
The four pistons are driven simultaneously, one towards the
other, by a cam by means of rollers and pads positioned on
the peripheral part of the rotor. There is one cam lobe for
each engine cylinder.
The transfer pump, positioned on the rear part of the rotor,
is sealed inside by the end cap. This also contains the filter
mesh and the transfer pump pressure regulator.
The upper part of the regulator unit is pressed against the
distributor rotor and acts as a seal for the transfer pump.
The distributor rotor incorporates two fuel inputs, an axial
hole and an exhaust that serves all the outputs to the
injection ports.
The hydraulic head contains the head in which the rotor
turns, the metering valve seat, the fuel inputs and the
connectors to the injectors. The high pressure injection
pumps, connected to the injectors, are fastened to the above
connectors.

3246t
Figure 3
1. Priming pump - 2. Camshaft.
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.
1
2
Figure 4
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.

Figure 5
1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.
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.
106515

SECTION 3 - POWER GENERATION APPLICATION 1F4GE NEF ENGINES
SECTION 3
Power Generation application
Page
GENERAL INFORMATION 3. . . . . . . . . . . . . . . .
- Clearance data - 4 cyl. 4. . . . . . . . . . . . . . . . . . .
PART ONE - MECHANICAL COMPONENTS 9
REMOVING AND REFITTING
THE SOUND-PROOFING UNIT 11. . . . . . . . .
- Removal 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING AND REFITTING THE ENGINE/
GENERATOR 13. . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEPARATING THE GENERATOR FROM
THE ENGINE 14. . . . . . . . . . . . . . . . . . . . . . . . .
DETACHING THE TANK FROM THE BASE 15. .
OVERHAULING THE 6-CYLINDER ENGINE 16. .
- Introduction 16. . . . . . . . . . . . . . . . . . . . . . . . . .
- Operations of preparing the engine for assembly
on the rotary stand 16. . . . . . . . . . . . . . . . . . . . .
- Installation of rear components 25. . . . . . . . . . . .
- Flywheel installation 28. . . . . . . . . . . . . . . . . . . . .
- Installation of front components 28. . . . . . . . . . .
- Completing the engine 37. . . . . . . . . . . . . . . . . .
- Rotary feed pump disassembly and assembly
procedure 39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Disassembly 40. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Rotary feed pump setting check 41. . . . . . . . . . .
- Assembly 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 3 - POWER GENERATION APPLICATION F4GE NEF ENGINES
Page
ASSEMBLY PROCEDURE OF THE ”ADC100” ELEC-
TRONIC ACTIVATOR ON STANADYNE SERIES ”D”
INJECTION PUMPS 43. . . . . . . . . . . . . . . . . . . .
- Assembly of the actuator 44. . . . . . . . . . . . . . . .
PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS
WITH STANADYNE PUMP 45. . . . . . . . . . . . . .
- Passage from 50 Hz to 60 Hz 45. . . . . . . . . . . . .
- Passage from 60 Hz to 50 Hz 47. . . . . . . . . . . . .
- Stabilization of the rotation regime 47. . . . . . . . .
- Identification tag 47. . . . . . . . . . . . . . . . . . . . . . . .
REPLACEMENT OF THE ELECTRO-VALVE AND THE
SOLENOID VALVE THROTTLE ON STANADYNE
PUMPS 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electro-valve replacement 49. . . . . . . . . . . . . . . .
- Replacement of the solenoid valve throttle 51. . .
- Checks and controls 52. . . . . . . . . . . . . . . . . . . .
PART FOUR -
MAINTENANCE PLANNING 53. . . . . . . . . . .
MAINTENANCE PLANNING 55. . . . . . . . . . . . . .
- Recovery 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Planning of controls and periodical intervention 55
- Checks not included in maintenance
planning-daily checks 56. . . . . . . . . . . . . . . . . . . .
MAINTENANCE PROCEDURES 56. . . . . . . . . . . .
- Checks and controls 56. . . . . . . . . . . . . . . . . . . .
- Engine oil level check. 56. . . . . . . . . . . . . . .
- Check of fuel system 57. . . . . . . . . . . . . . . .
- Cooling system check 57. . . . . . . . . . . . . . .
- Lubricating system check 57. . . . . . . . . . . . .
- Check for any water in the fuel filter 57. . . .
- Check of drive belt tensioning 58. . . . . . . . .
- Check of belt’s tear and wear status 58. . . .
- Check and setting of tappet clearance 58. . .
- Oil motor and filter replacement 59. . . . . . .
- Changing the coolant 59. . . . . . . . . . . . . . . .
- Fuel filter replacement 60. . . . . . . . . . . . . . .
- Alternator belt replacement 60. . . . . . . . . . .

Figure 1
GENERAL INFORMATION
The NEF engines have been specifically designed by Iveco
Motors for the power generation application.
They are internal combustion engines, with a 4-stroke Diesel
cycle, 4 or 6 cylinders and 2 valves per cylinder.
They are fueled by a rotary mechanical pump.
The section herein described is composed or four directories:
- directory of mechanical overhaul prescribed in
accordance to the engine’s specific duty, illustrating all
necessary operations to remove and assembly the
external components of the engine, including cylinder
heads, gearbox of the timing system and of the front part
cover;
- electrical directory, describing the connections of the
different components, of the pre-post heating gearbox
(only for some versions) and of the sensors assembled to
the engine;
- troubleshooting directory;
- directory of preventive and regular maintenance
operations, providing instructions for the execution of the
main operations.
!
Data, technical specifications and performances
granted shall be valid only if the Setter will follow and
comply with all installation prescriptions provided by
Iveco Motors.
Furthermore, the expanders assembled by the Setter
must always comply with couple, power and number
of revolutions based on which the engine has been
designed.
106522
ENGINE WITH 6 CYLINDERS

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
NOTE
Clearance data - 4 cyl.
Type F4GE0405A*F600 F4GE0405B*F600
ρ Compression ratio 17.5:1
Working power kW
rpm
50
1500
52
1800
Working torque Nm
rpm
318
1500
-
-
Loadless engine
idling rpm . -
Loadless engine
peak rpm rpm - -
Bore x stroke mm
Displacement cm3
104 x 132
4485
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
Forced by gear pump, relief valve single action
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
- start of opening ºC
By centrifugal pump, regulating thermostat, heat
exchanger, intercooler
Through belt
81 ± 2
15W40 ACEA E3
FILLING
engine sump liters
engine sump
+ filter liters
-
-

by Iveco Motors.
NOTE
Type F4GE0455A*F600 F4GE0455B*F600 F4GE0455C*F600
Working power kW
rpm
74
1500
74
1800
60
1500
Working torque Nm
rpm
471
1500
393
1800
382
1500
Loadless engine
idling rpm . - -
Loadless engine
peak rpm rpm - - -
Bore x stroke mm
Displacement cm3
104 x 132
4485
SUPERCHARGING
Without intercooler
direct injection
Turbocharger type HOLSET HX25 HOLSET HX25W HOLSET HX25
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Through belt
81 ± 2
15W40 ACEA E3
FILLING
engine sump liters
engine sump
+ filter liters
-
-

by Iveco Motors.
NOTE
Type F4GE0485A*F600 F4GE0485C*F600
Working power kW
rpm
98
1500
87
1500
Working torque Nm
rpm
471
1500
554
1500
Loadless engine
idling rpm . -
Loadless engine
peak rpm rpm - -
Bore x stroke mm
Displacement cm3
104 x 132
4485
SUPERCHARGING
With intercooler
direct injection
Turbocharger type HOLSET HX27W
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Through belt
81 ± 2
15W40 ACEA E3
FILLING
engine sump liters
engine sump
+ filter liters
-
-

by Iveco Motors.
NOTE
Type F4GE0655 F4GE0685
Type F4GE0655
B*B600 D*F601 B*F601
Working power kW
rpm
125
1500
130
1500
156
1500
Working torque Nm
rpm
796
1500
815
1500
969
1500
Loadless engine
idling rpm - - -
Loadless engine
peak rpm - - -
Bore x stroke mm
Displacement cm3
104 x 132
6728
SUPERCHARGING
Without
intercooler
direct injection
With intercooler
direct injection
Turbocharger type HOLSET HX35W
bar
LUBRICATION
Oil pressure
(warm engine)
- idling bar
- peak rpm bar
oil filter
0.70
3.50
COOLING
Water pump control
Thermostat
Liquid
Through belt
81 ± 2
15W40 ACEA E3
FILLING
engine sump* liters
engine sump + filter* liters
* First filling operation
15
16

PART ONE - MECHANICAL COMPONENTS

Figure 2
Figure 3
Figure 4
REMOVING AND REFITTING THE
SOUND-PROOFING UNIT
Removal
114332
Operate from the control board side and disconnect the
electric connection (1) from the stop button.
Operate inside the soundproofing unit and move back the
exhaust pipe cover (1) in order to reach the stop collar (2),
then loosen the fastening screw (3).
Operate from the exhaust pipes side and loosen the covering
panel (2) fastening nuts (1) and remove it.
115047
114334

Figure 5
Figure 6
Figure 7
114335
Remove pipe (1) from its seat.
Operate along the perimeter and loosen the soundproofing
unit (2) fastening screws (1).
Secure hooks with chain catches (1) into the slots (2)
provided for the purpose and, by means of a proper hoisting
device, lift the soundproofing unit (3) and remove it with the
aid of another operator.
114336
114337
When removing pipe (1), pay attention not to
damage the cooling unit air ducts (2).
NOTE
Make sure that the rods have all the same length
in order to lift the soundproofing unit along the
vertical axis, thus reducing interferences.
NOTE
Refitting
To refit, reverse the removal instructions.

Figure 8
Removal
Disconnect the electrical system by detaching the cables
from the battery.
Disconnect the positive and negative cables from any clamps,
detach them from their attachments on the starter motor,
then remove them.
Remove the fan safety grilles (4) by undoing the relevant
fasteners.
Place a container under the cock (10) to collect the coolant.
Disconnect and remove the pipes (1) and (16) together with
the sleeves by undoing the clamps. Block the radiator suitably
and remove it from its seat after disconnecting the brackets
(3) from the engine and the nuts (12) from the support (11).
Disconnect the diesel pipes (6) from the engine and from the
tank, taking care to collect any diesel coming down, then
remove them from their seat.
Disconnect the electrical connection (7) of the diesel level
signal (8) and earth (9).
107479
Check the integrity of the rubber-type blocks in
the supports (5) of the pipes and electrical
connections.
REMOVING AND REFITTING THE ENGINE/GENERATOR
Disconnect the air hose (19) from the turbocharger of the
turbine and the oil vapour recovery pipe from the cover of
the cylinder head. Remove the air cleaner (18) by undoing
the fasteners (← ) and remove it from its seat together with
the support (17).
Fit a lifting tool onto the specific hooks on the engine and
keep it under tension.
Remove the fixing nuts from the four supports (5) of the
engine/generator assembly.
Separate the engine/generator assembly from the crankcase.
Refitting
To refit, reverse the removal instructions; restore the coolant
system as described in the procedure on page 49.
NOTE

Figure 9
Remove the fan (1), the brackets of the supports (4) and the
support (3).
Separate the generator from the engine as follows:
- disconnect the wiring (10) from the engine at each of its
points of connection with the parts of the engine: starter
motor, alternator, various sensors, etc. Then fasten it
appropriately to the control panel (9) so as not to hinder
operations when separating the two assemblies;
107480
SEPARATING THE GENERATOR FROM THE ENGINE
- remove the safety grilles (5) by undoing the fasteners (7),
unscrew all the nuts (6) connecting the generator (8) to
the housing of the engine flywheel;
- block the generator suitably and separate it from the
engine.

Figure 10
The tank is blocked inside the base (1) with angular brackets
(3).
To remove the tank (2) from its seat, remove the brackets
(3) by undoing the relevant fasteners.
At the time of assembly, check that the adhesive rubber
blocks (4) are sound and positioned by the brackets (3).
107477
DETACHING THE TANK FROM THE BASE
At the time of assembly, check that the adhesive
rubber blocks (4) are sound and positioned by the
brackets (3).
NOTE

OVERHAULING THE 6-CYLINDER ENGINE
Introduction
The following description concerns the operations of overhauling the engine restricted to the components that differentiate
it according to its specific use.
The operations of removing the engine, as those for overhauling, must be performed by skilled personnel with specific
tools.
Figure 11
Operations of preparing the engine for assembly on the rotary stand
The “General Overhaul” section contains all the operations of overhauling the engine block and this section is therefore to be
considered as following this topic.
Due to requirements dictated by the application, some assemblies may be located on the engine in different positions.
108987
- Remove the intake manifold (1) and the sleeve (6).
- Remove the fuel hoses (2).
- Place a container under the diesel filter and unscrew the
condensation bleed cock located under the filter; drain
off all the diesel it contains.
- Fully unscrew the cock and, using tool 99360076,
remove the diesel filter (4).
- Remove the fuel filter mounting (4) from the bracket
secured to the cylinder head.
- Remove the priming pump (5).
- Disconnect the pipes (3) from the injection pump.
Removing the injection pump requires a specific
procedure described in this section.
NOTE
NOTE
NOTE

Figure 12
108988
- Disconnect the pipe (1) delivering oil to the turbine (3).
- Disconnect the pipe (4) returning oil to the turbine (3).
- Remove the turbine (3).
- Remove the oil filter (6) with tool 99360076.
- Remove the starter motor (5).
- Remove the exhaust manifold (2).
Warning: the oil filter contains inside aprx. 1 kg. of
engine oil.
Provide tank with sufficient capacity to contain the
liquid.
Warning: avoid contact of engine oil with the skin:
in case of skin contamination rinse in running
water.
Engine oil is highly pollutant: provide for disposal
in compliance with the law and regulations in force.
NOTE
Figure 13
70126
To disconnect fuel pipelines (2, Figure 11), in low
pressure from the relating pipe fittings, it is
Necessary to press the locking fastener (1) as
shown in picture B.
After having disconnected the pipeline, reset the
locking fastener (1) in lock position as shown in.
picture A, to avoid any possible deformation of the
fastener itself.
NOTE

- 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.
- Remove the oil level rod together with guide pipe;
(loosen the guide pipe disassembling from the block);
properly pipe the screw-threaded port to avoid inlet of
foreign matters.
- Drain the oil through the cap underneath the plug.
Figure 14
Figure 15
- Assemble the bracket bearing 99361037 using the four
screw threaded ports (1).
76147
106554
Figure 16
- Disconnect the supply pipe unit from the injectors (1).
- Remove fuel exhaust pipe (2) from the injectors by
removing screw (4) and seal (3).
Figure 17
88143
- Loosen the screws (1) holding the fixing brackets of such
pipelines; pipe the pipeline ends.
76150
(Demonstration)

Figure 18
- Remove tappet caps: loosen the fixing screws (1) and lift
the caps (2); remove the gaskets.
On the tappet cap there is a blow-by valve for the
lubrication oil vapours.
All the gaskets shall always be replaced during
assembly.
76149
Figure 19
- Remove injectors (2) with tool 99340205 (1) and take
out the cylinder head.
84082
(Demonstration)
NOTE
Figure 20
- Disassemble suction and exhaust manifolds: loosen the
screws (1) fixing the suction manifold plate to the
cylinder head (some 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 21
- Disassemble rocker arm bearings; loosen the two fixing
screws (2) and remove the completerocker armbearing;
withdraw tappet rods. Repeat the operation for all the
remaining rocker arm bearings.
- Disassemble water temperature transmitter (1).
75683
76151
1
2
(Demonstration)

88089
- Loosen screw (1) and relevant nut on belt stretcher
bracket (3).
- Loosen screw (2) in order to slide out POLY-V belt (2).
- Remove belt stretcher bracket (3).
- Remove the cooling fan.
- Disassemble the control pipe pulleys and the guide
rollers.
Figure 22
Figure 23
117588
- Disassemble thermostat unit; loosen the three fixing
screws (1) and disassemble the thermostat unit (2)
together with the bracket (3); remove the gasket (4) and
the thermostat (5).
- In order to facilitate head overhauling operations at the
test bench keep bracket (3) assembled on it by fixing it
with the thermostat unit screws.
- Loosen the screws (1) and withdraw the alternator
bearing (2).
75686
- Properly hold the alternator (1) separating it from its
bearing by loosening the screw (2); remove screw nut
and washer.
Figure 24
Figure 25
1 2
106544
The shape and the dimensions of the support of
the alternator vary according to the use of the
engine. The relevant pictures provide a general
trace of the intervention that is to be carried out.
The procedures described are always applicable.
NOTE

- Loosen the screws (4) and disassemble the oil
pressure/temperature sensor (3) (if fitted).
- Disassemble injection pump (see specific procedure).
76152
Figure 26
Figure 27
- 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.
106545
Figure 28
Figure 29
- Apply the suitable tool (2) on the flywheel covering box
(1) in order to lock flywheel (3) rotation.(use thestarting
motor fixing nuts and studs).
- Loosen the flywheel fixing screws (4) to engine drive
shaft.
75692
3
4
1
2
- Unloose the screws (3) and disassemble the damping
flywheel (2) and the pulley (1).
- The engine flywheel lock tool can facilitate the removal
of damper flywheel (2) installed on pulley (1).
106546

Figure 30
Figure 31
- Remove the engine drive shaft fixing ring from the front
cover. Use the tool 99340055 (4) to operate on the
front tang (2) of the engine drive shaft. Throughout the
tool guide ports, drill the internal holding ring (1) using
Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring
tightening the 6 screws specially provided.
Proceed withdrawing the ring (1) tightening the screw
(3).
00900t
- Remove the screws (1) and disconnect the water pump
(2).
- Remove the screw (3) and the roller (4).
- Remove the screw (5) and disconnect the engine speed
sensor (6).
106547
Figure 32
00904t
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring (2) from the front cover (1).
70149
- Loosen the screws (1) and remove the front cover (2).
Take note of the screw (1) assembly position, since
the screws have different length.
Figure 33
NOTE
Figure 34
- Loosen the screws (1) and remove oil pump (2).
75811

Figure 35
- Screw out the opposite screws (1) from the ports where
the withdrawal pins shall be introduced (see picture
following).
- Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (4).
- Remove the flywheel block tool (2).
75691
1 2
3
4
Figure 36
75690
- Screw up two medium length screws in the ports (4) to
sling the flywheel with a hoist.
Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine
flywheel withdrawal by means of a hoist.
1
2
3
4
00903t
Figure 37
- 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 Ø 3,5 mm drill for a 5mm
depth.
- Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
Figure 38
70153
- Loosen the screws (2) and remove the flywheel cover
box (1).
NOTE

Figure 39
- Turn the engine upside-down.
- Loosen the screws (2), disassemble the plate (3) and
remove the oil pan (1).
88076
The shape and dimensions of the pan and of the
rose pipe may vary according to the engine
application. The relating illustrations provide
general guidelines of the operation to be
performed. The procedures described are
applicable anyway.
NOTE
- Loosen the screws (1) and disassemble the oil suction
rose pipe (3).
- Loosen the screws (2) and remove the stiffening plate
(4).
Figure 40
87261
- Loosen the screws (2) and disassemble the timing
gearbox (1).
Figure 41
Figure 42
- Loosen the screws (1) and disassemble the gear fromthe
camshaft (2).
106540
70156
NOTE

Figure 43
Installation of rear components
DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION WITHIN GEARBOX AREAS
- Accurately clean the timing gearbox (1) and the engine
block.
75712
It is necessary and essential to clean the surface to
be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order
to form a kerbstone of a few mm. Diameter.
It must be uniform (no crumbs), with no air blisters,
thinner or irregular zones.
Any eventual imperfection shall be correct as soon
as possible.
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both
sides of the joint and obstruct lubricant passages.
Couplings must be assembled within 10 minutes
after completing the sealing operation.
DIAGRAM SHOWING SCREW
TIGHTENING TO FIX REAR GEARBOX
- 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
75711
Figure 44
Figure 45
70211
- With a pen marker, mark the tooth (1) of the driving gear
assembled to the engine drive shaft with (2) (→) timing
notch.
Screw up two pins to facilitate operation of engine
drive shaft rotation.
Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt.
1
1
2
34
5
6
7
8
9 10
1
NOTE
NOTE
NOTE

Figure 46
- Orient engine drive shaft (3) and camshaft (4) taking care
that in phase of assembly of the driving gear (2) to the
camshaft, the notches marked on the gears (1 and 2)
shall match.
Figure 47
- Tighten the screws (1) fixing the gear to the camshaft (3)
and lock them to the prescribed couple.
Figure 48
75708
DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION.
1
Figure 49
- 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.
106541
106543
106542

It is necessary and essential to clean the surface to
be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order
to form a kerbstone of a few mm. Diameter. It must
be uniform (no crumbs), with no air blisters,
thinner or irregular zones.
Any eventual imperfection shall be correct as soon
as possible.
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both
sides of the joint and obstruct lubricant passages.
Couplings must be assembled within 10 minutes
after completing the sealing operation.
Figure 50
75709
DIAGRAM SHOWING SCREW
TIGHTENING TO FIX FLYWHEEL COVER BOX.
- Reassemble the box (1) to the engine block, tighten the
fixing screws in the same position as found out during
disassembly and fix the screws to the locking couples
listed here below, following the order as shown in the
picture.
Tightening to angle is performed using tool
99395216.
1
2
34
5
6
78
9 10
11
12
13
14
1516
17
18
19
20
21
1
Figure 51
75696
- Check the conditions of the rim tooth (2). Whether
tooth break or excessive wear is detected, disassemble
the rim from the engine flywheel using a common willow
and replace with a new one, previously heated to
150º C degrees for 15’ ÷ 20’; seconds; bevelling must
be made towards engine flywheel direction.
Figure 52
- Apply to engine drive shaft rear tang (6), the detail (5)
of the tool 99346252, 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).
0901t
1 2
NOTE
NOTE

- Screw up two hooks or trail rings in the flywheel (1)
threaded ports (4) for handling .
- Using a hoist, handle the flywheel to place it in its housing
inside the flywheel cover box.
- Screw up to pins (2) having appropriate length, in the
shaft ports (3) and using them as guide, assemble the
engine flywheel (1) properly placing it inside the flywheel
cover box.
Figure 53
- 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.
75690
Figure 54
75692
1
2
3
4
2
1
3
4
Figure 55
Tighten the engine flywheel (1) fixing screws (2) in two
phases:
- 1st phase; tightening by means of dynamometric wrench
to couple 30 ± 4 Nm;
- 2nd phase, 60º ± 5º angle dwell.
Angle dwell shall always be performed using
99395216 tool.
α 1
2
75695
70220
- Assemble oil pump (1).
- Tighten fixing screws (2) and lock them to the prescribed
couple.
Figure 56
Flywheel installation
Installation of front components
NOTE

70221
- Apply to the water pump (1) a new fixing ring (2).
- Assemble the water pump (1).
- Tighten the screws (2) and lock them to the prescribed
couple.
Figure 57
Figure 58
- Remove the fixing ring (2) from the front cover (1),
accurately clean the plug surface.
Figure 59
76112
Figure 60
Figure 61
- Assemble the front cover (2) to the block and tighten
the screws (1) fixing 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
uniform and continuous kerbstone with no crumbs.
75710
106549
106550

- Apply on engine drive shaft front tang (6) the detail (4)
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.
00902t
Figure 62
Figure 63
88074
- Assemble plate (4), suction rose (3) andtighten thefixing
screws (2 and 1) locking them on the prescribed torque.
Figure 64
Figure 65
- Provide for new gasket replacement (1) of theoil pan (2).
The pictures illustrating the pan and of the rose
pipe may not correspond to the ones of your
model.
However the procedures described are applicable
anyway.
- Assemble oil pan (1), apply the plate over it (2). Tighten
the screws (2) and lock them to the prescribed couple.
88076
88075
NOTE
NOTE

- Assemble the following elements to the block: new
gasket (1), heat exchanger (2), new gasket (3), oil filter
bearing (4).
Tighten the screws (5) and lock them to the prescribed
couple.
Figure 66
- Assemble the pulley (1) and the dumping flywheel (2) to
the driving shaft.
- Tighten the fixing screws (3) and clamp them to the
couple 68 ± 7 Nm.
Figure 67
Figure 68
- Lubricate the fixing ring (2) using engine oil and place it
on the oil filter (3).
- Manually start the oil filter (3) on the bearing union (1)
until counter-boring, further screw up the oil filter (3) by
3/4 turn.
- Place a new fixing ring on the block housing (4).
In some applications, the bearing of the exchanger
shall be assembled to a screw threaded union
connected to the filter on the opposite side of the
engine, throughout two pipelines.
Figure 69
- Assemble the alternator bearing (1) ensuring that the
pins (3 and 4) are against the engine block.
- Tighten the screws (2) and lock them to the prescribed
couple.
106546
106551
106552
106553
NOTE
NOTE
NOTE

75686
- Connect the alternator (1) to the support.
- Tighten without locking the screw (2).
Figure 70
1 2
Figure 71
To refit the POLY-V belt, perform the steps described in
Figure 22 in reverse order.
88090
For belt stretching rotate the alternator as
indicated in the figure, lock screw (1) and screw (2,
Figure 70).
In case the same belt priory removed is assembled
again, proceed examining it carefully to check
there
Figure 72
- Place the gasket (1) over the block.
The choice of the gasket’s thickness shall be made in
consideration of the cylinder protrusion measured with
respect to the block’s upper surface.
Verify that the engine block stand is clean.
Do not grease the gasket. It is recommended to
keep the gasket inside packaging until assembly to
the cylinder head.
88092
1
NOTE
NOTE
NOTE

76214
Figure 74
- Lubricate cylinder head bolts and install to head.
- Bolts must be torqued using stitching pattern starting
with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque, then
90 degrees rotation for all bolts. Then a further 90
degrees for the M12 x 140 and M12 x 180.
M12 x 70 50 Nm + 90 deg’s
M12 x 140 40 Nm + 180 deg’s
M12 x 180 70 Nm + 180 deg’s
α
Figure 73
76152
- Place the head (3) over the block and insert screws (1)
and (2).
If the valves have been removed from the head, it
is necessary to assemble them before assembling
the head itself on the engine block.
Figure 75
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms-
4. Support.
- Carry out the assembly of the rocker arms after previous
check of the components.
75705
1
2
3
4
1
2
3
NOTE
76115
1
2
3
4 5
6
7 8
9
10 11
12
13 14
4 cylinder engine
6 cylinder engine
75703
D1D2
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;
if D1 - D2 > 0,1 mm the screw must be replaced.

Figure 76
Figure 77
116391
ROCKER ARM ADJUSTMENT SCREW
If the adjuster screw has been removed, check the
adjustment distance.
Tighten the screw-threaded nut (1) to the 4 - 6 Nm couple.
32655
Before executing assembly, check the Rocker Arm driving
rods: these shall not be deformed; the spherical ends in
contact with the Rocker Arm adjustment screw and with the
tappet (arrows) shall not present evidence ofseizure orwear:
in case of detection proceed replacing them.
The rods driving the suction and exhaust valves are identical
and therefore interchangeable.
Figure 78
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 can be utilised again;
- if D1 - D2 > 0,1 mm the screw must be replaced.
Figure 79
75683
- Tighten the screws (2) to the prescribed couple and
assemble water temperature sensor (1).
1
2
D1D2
13.00
11.00
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.
75704
18.975
18.963
19.000
19.026
19.000
19.026
Figure 80

Figure 81
75806
Adjust the slack between rocker arms and valves using socket
wrench (1), point wrench (3) and feeler gauge (2).
Correct slack is:
- suction valves 0.25  0.05 mm
- exhaust valves 0.50  0.05 mm.
In order carry out a quicker adjustment of the
working slack between rocker arms and valves,
proceed as following:
6 cylinder engine
Rotate the engine drive shaft, balance the valves of
cylinder 1 and adjust the valves identified by star
symbol, as indicated in the following table:
Cylinder n.
Suction
Exhaust
1 2 3 4
-
-
-
-
-
*
*
*
2 1
3
5 6
*
*
Cylinder n.
Suction
Exhaust
1 2 3 4
*
* - *
* * -
-
5 6
-
-
-
*
-
*
- Assemble injectors after having replaced the sealing
gasket (1).
Figure 82
75707
1
During assembly of injectors, verify that the
injector sphere is correctly positioned on the head
housing.
Figure 83
- Assemble cylinder covers (2) with the respectivegaskets;
- Fit the seal nods and tighten the screws (1) fixing them
to the prescribed couple.
76149
(Demonstration)
NOTE
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.
NOTE
4 cylinder engine
Cylinder n.
Suction
Exhaust
1 2 3 4
* * - -
-* - *
Cylinder n.
Suction
Exhaust
1 2 3 4
*
- * -
- - *
*

117588
- Assemble thermostat unit (2) including thermostat (5)
and gasket (4).
- Tighten the screws to the prescribed couple.
Figure 84
The screws (1) have been have been utilised to fix
the bracket (3).
Disassemble the bracket (3) and reassemble
components from 1 to 5 as shown in the picture.
The gasket (4) must be new.
- Apply on the surface joining the suction manifold plate
(1) the gasket (3) and provide. Fixing the screws (2) to
the prescribed couple.
- If you have removed the pipe (7) and the spacer (5) from
the intake manifold plate (1) fit it back on after inserting
two new gaskets (4-6).
- Tighten the screws (8) to the prescribed couple.
Figure 85
Figure 86
- 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.
76208
1
2
(Demonstration) (Demonstration)
106555
Figure 87
- Fix the fuel pipes (1) to the injectors (2) and to the
connectors (3) previously fitted.
107
NOTE

Figure 88
- Fit the starter motor (5).
- Fit the oil filter (6) with tool 99360076.
- Fit the exhaust manifold (2).
- Fit the turbine (3).
- Fit the pipe (4) returning oil from the turbine (3).
- Fit the pipe (1) delivering oil to the turbine (3).
108988
Completing the engine

Figure 89
- Fit the fuel pipes (2).
- Fit the intake manifold (1) and the sleeve (6).
Figure 90- Fit the pipes (3) to the injection pump.
- Fit the priming pump (5).
- Fit the fuel filter mounting (4).
- Fit the diesel filter (4) with tool 99360076.
108987
70126
To connect fuel pipelines (3, Figure 89) in low
pressure from the relating connection unions it is
necessary to press the locking fastener (1) as
shown in picture B.
After having connected the pipeline, reset the
fastener (1) into block position as shown in picture
A.
The filter shall be priory filled with fuel to facilitate
feed system bleed operations.
Fitting the injection pump requires a specific procedure described in this section.NOTE
NOTE
NOTE

Figure 91
Rotary feed pump disassembly and assembly
procedure
!
This procedure prescribes that:
- the fuel pipes (from the pumping elements to
the injectors, recovering blow-by from the
injectors to the pump and the supply from the
priming pump) have all been removed;
- the electrical connections have been
disconnected.
- Accelerator cable shall be disconnected.
In case feed pump replacement is necessary, this shall be
supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the engine
and disassemble it only afterwards.
The following procedure analyses this second hypothesis
since it is the more complex.
Disassemble the starter from the flywheel box and use tool
99360330 to rotate the flywheel.
75714
Figure 92
Engine versions with tool (99360330)
Engine versions with tool (99360339)
88140
1
1
2
Disassemble the starter from the flywheel box (1) and use
tool 99360339 (2) to rotate the flywheel.
Figure 93
88141
Find the top dead centre with the tool (99395097) - False
injector
1
Remove the rocker covers of the 1st cylinder; remove the 1st
injector and place the tool (1) to set the 1st cylinder top dead
centre position (end-of-compression phase). Pre-load the
gauge.
The searched condition is obtained by rotating the engine
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
valves are both closed.
Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 93).
Figure 94
84071
Searching for the top dead centre with timing gear blocking
pin
Turn the flywheel until, when pushing the pin (1), it blocks the
gear (2) obtaining the TDC of the 1° cylinder.

- From the pump side, loosen the fixing nuts (1) without
removing them in order to enable moving the pump
backwards using 99340035 extractor.
- Assemble the 99340035 extractor throughout the two
threaded ports (4, Figure 96) and withdraw the gear from
the pump shaft.
- Properly hold the feed pump and loosen completely the
fixing nuts.
- Withdraw the pump from the studs, together with the
gasket.
Figure 95
- Partially unlock pump shaft retaining screw (1) and move
spacer with slot (2) in area with lager size hole for
complete screw passage.
- Lock applying a torque ranging between 11,9 and 12,4
Nm retaining screw (1) till reaching spacer, thus locking
pump shaft rotation.
- From timing side, remove the cover (2) loosening the
screws (1) in order to have access to the union fixing nut
(3) to the pump driving gear.
- Loosen the fixing nut (3) and remove the relating
washer.
Figure 96
Figure 97
75693
Hold the pump driving gear to avoid interference
or crawling during timing gear rotation.
1
2 3
4
Disassembly
106659
106658
NOTE

Figure 98
Support the pump gear to prevent interference or
sticking when the timing system gears turn.
Rotary feed pump setting check
106660
1. Slot on the hub of the hydraulic rotor -
2. Synchronization pin 99365196 - 3. Plate.
The synchronization pin 99365196 (2) has been designed for
use in the event of the rotor shaft being inadvertently
released.
The correct synchronization of the pump with the engine is
obtained when the synchronization pin 99365196 (2), fitted
in the hole on the plate (3), enters the slot (1) on the exterior
of the hydraulic rotor hub.
NOTE
Therefore:
- Remove the screw cap (3) at the centre of the plate.
- Insert the synchronization pin (1) 99365196 in the hole
on the plate (3). The synchronization position is
obtained when the synchronization pin (2) enters the
slot on the hydraulic rotor hub.
- Lock the control shaft in the correct position by means
of the screw (1, Figure 95).
- Remove the synchronization pin and fit the screw cap of
the plate (3). Tighten the cap using a torque of 2.3 ÷ 3.4
Nm.
Figure 99
When installing supplì pump on engine, cylinder no.1 must
be at TDC, end of compression phase.
- Assemble the pump pre-set in its housing on the engine,
fitting the shaft into the gear port (not provided with
wrench).
- Tighten the fixing nuts (1) locking the pump flange in the
slot centre.
- On the timing side, throughout the specially appointed
port, fit the washer and screw up the fixing nut (3) to the
pump shaft. Lock the nut to the 190-203 Nm couple.
- Assemble the cover (2) including gasket and tighten the
screws (1).
Figure 100
75693
The gasket removed during pump disassembly shall
not be utilised again.
Always use original spare parts.
1
2 3
4
106658
Assembly
NOTE

Figure 101
- - Svitare, senza rimuovere, la vite (1) di bloccaggio
rotazione dell’alberino della pompa e spostare il
distanziale con asola nella zona del foro di dimensioni
minori. Avvitare fino a battuta la vite bloccando il
suddetto distanziale: in questo modo l’alberino della
pompa di alimentazione è libero di ruotare.
- Disassemble the flywheel rotation/locking tool
99360339 or 99360330; arrange the starting motor in its
seat.
- Connect all the pipes (from the pumping elements to the
injectors, recovering blow-by from the injectors to the
pump and the supply from the priming pump).
- Connect the electrical connections.
In case pump removal has been carried out while
the engine was assembled, connect acceleration
cable.
106659
NOTE

ASSEMBLY PROCEDURE OF THE ”ADC100” ELECTRONIC ACTIVATOR ON STANADYNE
SERIES ”D” INJECTION PUMPS
116978
Figure 102
Before proceeding in the removal of the Injection Pump
cover and then to the replacement with the electronic
actuator, it is important to clean the external part of the
pump, if necessary, using solvents. This prevents
contamination of the internal part of the pump.
- Disconnect the wire of the stop electro-valve from the
clamp (I) positioned on the pump cover, being careful to
isolate it.
- Remove the fuel return pipe from the connection (2).
- Remove the three screws (3) of the pump cover. The
screws will then be replaced assembling the screws
supplied with the ADC100 actuator.
- Remove the cover of the injection pump very carefully
so that the dirt won’t penetrate inside the pump.
- Remove the connection (2) of the fuel return pipe and
the sealing from the injection pump cover. Keep the
connection (2) and the sealing that will have to be
assembled on the electronic actuator.

116979
Figure 103
Assembly of the actuator
- Reassemble the connection forthe fuel return pipe and
the pump cover’s original dealing, on the ADC 100
electronic actuator.
- Position the electronic actuator on the injection pump
with the highest part slightly titled upwards.
- Slide the electronic actuator towards the rear part of the
pump (injectors’ side) until the ”U” shape hook (I) of the
actuator engages the lever of the injection pump
(2).Once engaged, align the holes of the pump and the
electronic actuator.
- Tighten the ADC 100 actuator to the injection pump,
using the screws supplied with the actuator.
- Reconnect the fuel return pipe to the connection placed
on the actuator.
A. The injection pump open seen from above - B. Front (carter side) - C Rear (injector side)
I. The ”U” shaped hook of the electronic actuator- 2. Injection pump lever- 3. Droop adjustment screws
Couplings mistakes between the actuator’s hook
(I) and the lever (2) of the injection pump cancause
motor over speed conditions.
NOTE

116400
Figure 104
According to the specific needs of the motor employment
it is possible that a request to vary the adjustment of the
Stanadyne pump be made to obtain adifferent use frequency:
- 1500 rpm / 50 Hz
- 1800 rpm / 60 Hz
The necessary procedures will be described in order to
execute the following adjustments:
- passage from 50 Hz to 60 Hz and vice versa.
- stabilizing of the rotation regime.
On the Iveco Motors tag (I) reported are:
- the model of the injection pump (4);
- an identification code (3) of the specific application of
the setting ofthe injection pump, forexample: A.S. 7.54
identifies the setting at 1800 rpm of 60 Hz.
If only the Stanadyne identification tag (2) is
present, this means that the injection pump
presents a setting of 50 Hz.
In case of modification of the setting from 50 Hz
to 60 Hz done in the factory, an identification tag
(1) is applied by Iveco Motors.
NOTE Passage from 50 Hz to 60 Hz
To carry out the passage from 50 Hz to 60 Hz you must, first
of all:
- identify the code of the injection pump from the
Stanadyne tag (2).
PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS WITH STANADYNE PUMP

116975
Figure 105
- Act on the droop setting adjustment screw (2), rotating
it clockwise the number of rotations indicated in the
chart figure, starting from the position in which the screw
is.
- After starting the motor you must operate the maximum
(I) and minimum (4) register screws in order to block the
accelerator lever (3) in the position to obtain the desired
regime, considering the frequency fall in the passagefrom
empty to full of the motor (about 2 Hz).
If, for example, for a motor with an injection pump with code
DB 4429 - 5945, originally set at 50 Hz, you want to pass to
60 Hz, it is sufficient to act on the droop setting adjustment
screw (2) rotating it 3 times clockwise from the position in
which it is, start the motor, loosen the adjustment screw of
the maximum regime and accelerate with the accelerator
lever, till you obtain the empty rotation regime equal to 62
Hz (l860 rpm),
- Then regulate the screw of the minimum regime (4) so
to block the accelerator lever in the newly obtained
position and finally block both adjustment screws (I and
4) using the appropriate lock nuts (tightening torque 3,5
- 4 Nm).
In case of doubt you can always unscrew the
droop setting register screw (2) counter clockwise
till you get to the final position - do not force it
further in order to not damage the adjustment
system. At this point, always referring to the chart
figure, rotate the droop setting screw clockwise
(2), the number of rotations indicated for the
regime of 60 Hz from the final position.
NOTE
The adjustment screw of the minimum regime (4)
does not allow the attainment of the minimum
intended in the ”classical” meaning of the term
because the injection pump regulator imposes a
superior rotation regime since it is about an
injection pump for the application of a generator.
NOTE
Type of injection pump
(Stanadyne tag)
Screw rotations at 50 Hz
from the final position
(clockwise)
Screw rotations at 60 Hz
from the final position
(clockwise)
Difference of rotations
from 50 Hz to 60 Hz
(clockwise)
DB 4629 - 5927 2 6 4
DB 4629 - 5932 2 9 7
DB 4629 - 5944 2.5 8.5 6
DB 4429 - 5945 3 6 3
DB 4429 - 5954 2 8.5 6.5
DB 4427 - 5955 3 9 6

116976
116977
Figure 106
Figure 107
If the Iveco Motors tag is already on the injection pump, you
must proceed stamping the new identification suffix of the
newly obtained setting and strikethrough the identification of
the preceding setting, as illustrated in the figure example.
Passage from 60 Hz to 50 Hz
To pass from a 60 Hz regime to the 50 Hz regime, operate
analogously to what seen above, remembering to act on the
droop setting adjustment screw (2, Figure 105), rotating the
same of 3 counter clockwise rotations from the position in
which it is for the functioning at 60 Hz.
Stabilization of the rotation regime
In case of instability of the rotation regime, act on the droop
setting adjustment screw (2, Figure 105) rotating lightly the
same clockwise/counter clockwise till the stabilization of the
motor rotation regime.
Attention! Some motors cannot undergo the
passage from 50 Hz to 60 Hz and vice versa, asthey
need a specific injection pump to work at the
required regimes.
Make reference to the SI 191 1 ”Service
Information” to verify which motors cannot
undergo the passage from 50 Hz to 60 Hz and vice
versa.
NOTE
Identification tag
In case the Iveco Motors tag is not present because it is a
motor with an injection pump that has a setting of 50 Hz, it
is necessary to proceed in the application of a tag in the
illustrated area as in Figure 4 stamping it as the figure example.
The blank tag can be ordered at the Part Replacement
Service.

116980
Figure 108
A. Position of the electro-valve arm - I. Encapsulated coil - 2. Mobile nucleus of the electro-valve -3. Electro-valve arm -
4. Isolator - 5. Solenoid valve ends
Two types of electro-valves can be used on Stanadyne injection pumps:
- ETR (Energize To Run)
- ETSO (Energize To Stop).
Please note, in the figure, the different assembling position of the electro-valve according to the ETR - ETSO functions.
REPLACEMENT OF THE ELECTRO-VALVE AND THE SOLENOID VALVE THROTTLE ON
STANADYNE PUMPS
A. Position of the electro-valve arm - I. Encapsulated coil - 2. Mobile nucleus of the electro-valve -3. Electro-valve arm -
4. Isolator - 5. Solenoid valve ends
116981

116982
116983
116985
Figure 109
Figure 110
Figure 111
To replace the electro-valve remove the cover of the
injection pump loosening and removing the three fixing
screws (I and 2) of the cover and the relative washers.
Remove the entire cover of the electro-valve (I), pulling it
upwards perpendicularly to the injection pump.
Assemble of the new electro-valve on the injection pump’s
cover, using the appropriate kits:
- I2 V-ETR
- 24 V-ETR
- I2 V-ETSO
- 24 V-ETSO
The kits contain the indicated type Check the state of wear
of the rubber couplings. of electro-valve and all that is needed
for its assembling.
The nuts fixing the electro-valve (3) to the cover (2) must be
tightened to a I, I ÷ 1,7 Nm torque.
Electro-valve replacement
Check the state of wear of the rubber couplings.NOTE
Be careful that nothing falls into the injection pump.
Since the ends of the component are electrically
isolated from the cover, make sure to remember
the assembling order of the nuts, of the washers
and of the components, for the electrical
connection of the electro-valve ends; one end is
earthed through an appropriate element (I). Pay
attention to the position of the isolating element
(4).
NOTE
Remove the electro-valve (3) from the cover (2).

116986
116987
116998
Figure 112 Figure 113
Figure 114
In the electro-valve ETR kit there is the joint tool (I) which
must be used to position the electro-valve’s arm (2) and to
reassemble the cover on the injection pump.
In case the original electro-valve should be replaced and its
characteristics modified (different voltage, ETR instead of
ETSO, eco), it is necessary the application of an identification
tag (I) in the indicated place.
The tag must be stamped (I) as shown in details in the figure.
This tool (I) allows to keep in the excitation
position the arm of the electro-valve (2), allowing
the correct assembling of the cover and avoiding
dangerous over rotations at the starting of the
motor.
NOTE
Once the cover is put on the assembling seat and the relative
screws are pointed on the injection pump, rotate the joint
tool (I) and then pull it carefully from underneath the cover
(3), making sure not to move or damage its sealing.
Then tighten the screws with a 4,0 ÷ 5,1 Nm tightening
torque, making sure not to damage the connection earthed
element of the electro-valve end.
The repositioning of the cover (2) must be done proceeding
in reverse to what described for its disassembling, making
sure that it corresponds perfectly to the assembling seat
without forcing it (for the ETR version the cover of the pump
will correspond to the assembling seat only after the joint
tool has been removed).
A blue seal is included in the kit and it has to be
positioned on the screw (I), after the cover
reassembling operations (2): when new, the seal is
not blue.
NOTE

116989
116990
116991
Figure 115
Figure 116
Figure 117
In some cases the tag may already be present. If the tag is
already present, it is necessary to strikethrough the old
identification elements and stamping the new ones, as shown
in the example in the figure.
Disconnect the linkage connector from the temperature
sensor on the motor, and then remove the fixing nut of the
socket clamp (2) and the nut (I) of the cable group end, so
to release the electrical lead assembly of the solenoid valve
throttle.
Remove the fixing nut (3) from the magnet and remove the
component from its seat.
Insert the connection cable socket (I) in the cable group end
and screw the nut (I, Figure 116) tightening it to a 5, 7 ÷ 6,8
Nm torque.
Position the socket clamp (2, Figure 116) and screw the fixing
nut tightening it to a 7, 9 ÷ 9, 0 Nm torque.
Position the magnet in its seat and screw the self-blocking
fixing nut, supplied with the replacement kit, tightening it to
a 5, 1 ÷ 5, 7 Nm torque.
The electro-valve and the solenoid valve throttle on
the same injection pump, must have the same
operating voltage, so in case of a change in the
motor’s operating voltage, both must be replaced.
Replacement of the solenoid valve throttle
The operating voltage of the device is easy to find
looking at the colors of the supply wires of the
solenoid:
- BLACK: forthe I2V device
- RED: for the 24V device
NOTE
The electro-valve and the solenoid valve throttle on
the same injection pump, must have the same
operating voltage, so in case of a change in the
motor’s operating voltage, both must be replaced.

Checks and controls
!
The following tests shall be made after engine
assembly.
Preventively check that the liquid levels have been
correctly restored.
- no coolant leaks from the coupling sleeves of the cooling
circuit piping, tightening the collars further if necessary.
- Carefully check the fuel connection pipes to the
respective unions.
- There is no oil leakage from the lubrication circuit of the
various pipelines connecting cover and.
- Cylinder head, oil pan and bearing, oil filter and heat
exchanger as well as relating housings.
- There is no fuel leakage from fuel pipelines.
- Verify correct working of the lighting leds of the
dashboard containing the tools as well as of the
equipment that was disconnected during engine
disconnection.
- Check and blow by with care the engine cooling system,
carrying out frequent drainage.
Start the engine, let it run at revolution regimen
slightly higher than idling and wait that the cooling
liquid temperature reaches the value enabling
thermostat opening, then check that:

PART FOUR - MAINTENANCE PLANNING

MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
Planning of controls and periodical intervention
Controls and periodical intervention
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . .
Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency (hours)
Daily
Daily
-
4000
500
500
1500
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.
NOTE

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Checking the coolant level.
Checks not included in maintenance planning-daily checks
MAINTENANCE PROCEDURES
Checks and controls
Engine oil level check.
Figure 118
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).
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
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing
minimum level, provide filling lubrication of the engine’s
components.
To provide filling, operate through the upper top (1) or
through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier”.
Figure 119
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Adequately protect the skin and the eyes, operate
in full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.
106668
106669

Check of fuel system
The check must be executed both when the engine
disconnected and when it is running.
The check is made by observing the fuel pipes from the tank
to the fuel pump and to the injectors.
Cooling system check
Check the pipes from the engine to the radiator and vice versa;
note any seepage and the state of the pipes especially near the
coupling clamps.
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.
Due to the high temperatures achieved by the
system, do not operate immediately after the engine’s
disconnection, but wait for the time deemed
necessary for the cooling.
Protect the eyes and the skin from any eventual high
pressure jet of cooling liquid.
Lubricating system check
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan of from the heat exchanger.
and detergent.
Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Check for any water in the fuel filter
The components of the system can be damaged
very quickly in presence of water or impurity within
the fuel.
Take prompt action on the filter to drain off the
water in the fuel circuit.
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any case
every two year.
If refilled, bleed the system as described on page 49.
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 engine’s head.
Fuel filter is equipped with pump screw-valve to drain the
water eventually mixed with fuel.
Place a container underneath the filter and slightly loosen the
screw. Drain the water eventually contained in the filter’s
bottom.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.
NOTE
NOTE

Check of drive belt tensioning
Some applications are equipped with an automatic tensioner
that provides correcting belt tensioning.
Check of belt’s tear and wear status
Carefully verify the belt’s surface in order to detect any sign of
incision, crack, excessive wear in correspondence of toothing;
check end and surface grinding.
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.
In order to more quickly perform the operating
clearance adjustment for rocker arms — valves,
proceed as follows:
rotate the drive shaft, balance cylinder 1 valves and
adjust the valves marked by the asterisk as shown
in the table:
Check and setting of tappet clearance
Figure 120
2 1
3
75806
Danger: if the engine is switched off but is still hot,
unexpected motion of the belt may occur.
Wait for engine temperature cooling as a precaution
in order to avoid serious danger injury.
6 cylinder engine
Rotate the drive shaft, balance cylinder 1 valves and
in the table:
in the table:
NOTE
4 cylinder engine
in the table:
Cylinder n.
Suction
Exhaust
1 2 3 4
* * - -
-* - *
Cylinder n.
Suction
Exhaust
1 2 3 4
*
- * -
- - *
*
in the table:
Cylinder n.
Suction
Exhaust
1 2 3 4
-
-
-
-
-
*
*
*
5 6
*
*
Cylinder n.
Suction
Exhaust
1 2 3 4
*
* - *
* * -
-
5 6
-
-
-
*
-
*

Oil motor and filter replacement
We recommend to carry out the oil drainage when the motor
is hot.
- Place a proper container for the oil collecting under the
pan connected with the drain plug.
- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the lubrica-
tion oil.
Warning: We recommend to wear proper protec-
tions because of high motor service temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves.
The oil motor is very pollutant and harmful.
In case of contact with the skin, wash with much water
and detergent.
Protect properly skin and eyes: operate according to
safety rules.
Dispose of the residual properly following the rules.
- After the complete drainage, 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, don’t mix oils having different
features.
If you don’t 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.
Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
- The filter is composed by a support and a filtering car-
tridge. For the cartridge replacement use the
9936076-tool.
Warning: the oil filter contains inside a quantity of oil
of about 1 kg.
Place properly a container for the liquid.
Warning: avoid the contact of skin with the motor oil:
in case of contact wash the skin with running water.
The motor oil is very pollutant: it must be disposed
of according to the rules.
- Replace the filtering cartidge with a new one and screw
manually until when the gasket is in contact with the sup-
port.
- Tigthen by means of the 99360076-tool of three fourth
turn.
- Operate the motor for some minutes and check the level
through the dipsick again. If it is necessary, carry out a top-
ping up to compensate the quantity of oil used for the fill-
ing of the filtering cartridge.
!
Changing the coolant
- Position a container beneath the radiator tap to recover
the coolant.
- Open the tap and allow all the coolant in the radiator to
flow out.
- Charge the coolant for the first time.
- Leave the radiator cap open.
- Start the engine and leave it running for at least a minute
so that all the air in the circuit is completely removed.
- Stop the engine.
- Top up.
If the procedure described is not followed, the
radiator fluid level will be incorrect.
NOTE

Fuel filter replacement
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.
- Collect the eventual fuel inside the filtering cartridge.
- Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 10-5 Nm torque.
During this operation don’t smoke and don’t use free
flames.
Avoid to breathe the vapors coming from filter.
After filters replacement the supply equipment
deaeration must be carried out.
Alternator belt replacement
Warning: with switched off motor (but still hot) the
belt can operate without advance notice.
Wait for the motor temperature lowering to avoid
very serious accidents.
Figure 121
- Loosen screw (1) and the relevant nut on belt stretching
bracket (3).
- Loosen the bolt that fixes the alternator to the support.
- Remove the worn Poly-V belt (2) from the pulleys and
driving rollers.
- Fit the new Poly-V belt (2) onto the pulleys and driving
rollers.
- Fit the new POLY-V belt (2) 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.
88089
NOTE

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1F4GE NEF ENGINES
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS 3. . . . . . . . . . . . . . .
CLEARANCE DATA 4. . . . . . . . . . . . . . . . . . . . .
ENGINE OVERHAUL 10. . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL AT THE BENCH 10. . . . . . . .
REPAIR OPERATIONS 11. . . . . . . . . . . . . . . . . . . .
CYLINDER UNIT 11. . . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurements 11. . . . . . . . . . . . . . .
- Checking head supporting surface
on cylinder unit 12. . . . . . . . . . . . . . . . . . . . . . . .
TIMING SYSTEM 13. . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and pin alignment 14. . . . . . . .
BUSHES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Bush replacement 16. . . . . . . . . . . . . . . . . . . . . .
- Tappets 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting tappets — camshaft 16. . . . . . . . . . . . . . . .
OUTPUT SHAFT 17. . . . . . . . . . . . . . . . . . . . . . . .
- Measuring journals and crankpins 17. . . . . . . . . .
- Replacing oil pump control gear 21. . . . . . . . . . .
- Fitting main bearings 21. . . . . . . . . . . . . . . . . . . .
- Finding journal clearance 21. . . . . . . . . . . . . . . . .
- Checking output shaft shoulder clearance 22. . .
CONNECTING ROD — PISTON ASSEMBLY 22. .
- Pistons 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring piston diameter 23. . . . . . . . . . . . . . .
- Piston pins 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE NEF ENGINES
Page
- Conditions for proper pin-piston coupling 24. . . .
- Split rings 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods 25. . . . . . . . . . . . . . . . . . . . . . .
- Bushes 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking connecting rods 26. . . . . . . . . . . . . . . .
- Checking torsion 26. . . . . . . . . . . . . . . . . . . . . . .
- Checking bending 27. . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly 27. . . . . .
- Connecting rod-piston coupling 27. . . . . . . . . . . .
- Fitting split rings 28. . . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly
into cylinder barrels 28. . . . . . . . . . . . . . . . . . . . .
- Finding crankpin clearance 29. . . . . . . . . . . . . . . .
Page
- Checking piston protrusion 30. . . . . . . . . . . . . . .
CYLINDER HEAD 31. . . . . . . . . . . . . . . . . . . . . . . .
- Removing the valves 31. . . . . . . . . . . . . . . . . . . .
- Checking cylinder head wet seal 32. . . . . . . . . . .
- Checking cylinder head supporting surface 32. . .
VALVES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing carbon deposits, checking
and grinding valves 33. . . . . . . . . . . . . . . . . . . . . .
- Checking clearance between valve stem
and valve guide and valve centering 33. . . . . . . . .
VALVE GUIDE 34. . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS 34. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regrinding — replacing the valve seats 34. . . . . . .
VALVE SPRINGS 35. . . . . . . . . . . . . . . . . . . . . . . . .
FITTING CYLINDER HEAD 35. . . . . . . . . . . . . . . .
- Refitting the cylinder head 36. . . . . . . . . . . . . . . .
TIGHTENING TORQUE 37. . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS
Type 4 CYLINDERS 6 CYLINDERS
Cycle Four-stroke diesel engine
Power Supercharged with intercooler
Injection Direct
Number of cylinders 4 in-line 6 in-line
∅
Bore mm 104
Stroke mm 132
+ + +.. = Total displacement cm3 4553 6728
TIMING
start before T.D.C. A
end after B.D.C. B
15°
35°
start before B.D.C. D
end after T.D.C. C
69°
21°
X
Checking timing
mm
X
mm
Checking operation
mm
X
mm
-
-
0.25 to 0.05
0.50 to 0.05
FUEL FEED
Injection
Type: rotary
STANADYNE DB 4
Nozzle type DSLA 145 P
Injection sequence 1 - 3 - 4 - 2 1 - 5 - 3 - 6 - 2 - 4

CLEARANCE DATA
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm
∅1
X
Cylinder barrels ∅1
∅1
104.000 to 104.024
0.4
∅1
X
∅ 2
Pistons:
Size X
Outside diameter ∅ 1
Pin housing ∅ 2
55.9 / 52.4 (•)
103.714 ÷ 103.732 / 103.755 ÷ 103.733 (•)
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 0.010 to 0.022
(•) Applicable to F4GE0405 engines only

X
1
3
2
X
X
X1*
Split ring slots X 2
X 3
* measured on a ∅ of
99.00 mm
2.705 to 2.735* / 2.600 to 2.620 (•)
2.440 to 2.460 / 2.550 to 2.570 (•)
4.030 to 4.050
1
3
2
S
S
S
S 1*
Split rings S 2
S 3
3.000 (••) / 2.470 to 2.500 (•)
2.350 to 2.380 / 2.478 to 2.490 (•)
3.970 to 3.990
1
Split rings - slots 2
3
- / 0.100 to 0.150 (•)
0.060 to 0.110 / 0.060 to 0.092 (•)
0.040 to 0.080
Split rings 0.4
X 1
3
2X
X
Split ring end opening
in cylinder barrel:
X 1
X 2
X 3
0.30 to 0.45 / 0.25 to 0.55 (•)
0.60 to 0.80 / 0.30 to 0.55 (•)
0.30 to 0.55
1∅
∅ 2
Small end bush
housing ∅ 1
Big end bearing
housing ∅ 2
40.987 to 41.013
72.987 to 73.013
∅
S
3
Small end bush diameter
Inside ∅ 3
Spare big end half
bearings S
38.019 to 38.033
2.205 to 2.218
Piston pin — bush 0.019 to 0.039
Big end half bearings 0.250; 0.500
(•) Applicable to F4GE0405 engines only
(••) Nominal dimension

Journals ∅ 1
Crankpins ∅ 2
82.99 to 83.01
68.987 to 69.013
1 2∅∅
S 1 S 2
Main half bearings S 1
Big end half bearings S 2
2.456 to 2.464
1.955 to 1.968
3∅
Main bearings
No. 1—5 / 1-7 ∅ 3
No. 2—3—4 / 2-3-4-5-6 ∅ 3
87.982 to 88.008
87.977 to 88.013
Half bearings — Journals
No. 1—5 / 1-7
No. 2—3—4 / 2-3-4-5-6
0.064 to 0.095
0.059 to 0.100
Half bearings - Crankpins 0.033 to 0.041
Main half bearings
Big end half bearings
0.250; 0.500
1X
Shoulder journal X 1 37.475 to 37.545
X 2
Shoulder main bearing X 2 32.180 to 32.280
X 3
Shoulder half-rings X 3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.265

CYLINDER HEAD — TIMING SYSTEM mm
∅ 1
Valve guide seats on
cylinder head ∅ 1 8.019 to 8.039
∅
α
4 Valves:
∅ 4
α
∅ 4
α
7.960 to 7.980
60º
7.960 to 7.980
45º
Valve stem and guide 0.039 to 0.076
∅ 1
Housing on head for
valve seat:
∅1
∅1
46.987 to 47.013
43.637 to 43.663
α
2∅
Valve seat outside diameter;
valve seat angle on cylinder
head:
∅ 2
α
∅ 2
α
47.063 to 47.089
60º
43.713 to 43.739
45º
X
X
Sinking X
0.356 to 1.102
0.104 to 0.840
Between valve seat
and head
0.050 to 0.102
0.050 to 0.102
Valve seats -

H H 1
H 2
Valve spring height:
free spring H
under a load equal to:
329 N H1
641 N H2
63.50
49.02
38.20
X
Injector protrusion X
∅∅∅
1 2 3 4 5
Camshaft bush
housings No. 1
(flywheel side)
Camshaft housings
No. 2-3-4-5/2-3-4-5-6-7
59.222 to 59.248
54.089 to 54.139
∅
∅
∅1
2
3
Camshaft journals:
1 ⇒ 5 ∅
1 ⇒ 7 ∅
53.995 to 54.045
∅
Bush inside
diameter ∅ 54.083 to 54.147
Bushes and journals 0.038 to 0.162
H
Cam lift:
H
H
11.02
10.74

∅ 1
Tappet cap housing
on block ∅ 1 16.000 to 16.030
∅ 2
3
∅
∅
2
Tappet cap outside
diameter: ∅ 2
∅ 3
15.929 to 15.959
15.965 to 15.980
Between tappets and housings -
Tappets -
∅ 1
Rocker shaft ∅ 1 18.963 to 18.975
∅ 2
Rockers ∅ 2 19.000 to 19.026
Between rockers and shaft 0.025 to 0.063

70159
70158
70160
74774
70162
Figure 1
Figure 2
Figure 3
Figure 4
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 6 cylinders engine
but are analogously applicable for the 4 cylinders.
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdraw the pistons including the connecting rods from the
top of the engine block.
Remove the screws (1) and the main bearing caps (2).
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
Use tool 99360500 (1) and hoist to remove the output shaft
(2) from the block.
Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
Keep the half-bearings into their housings since in
case of use they shall be fitted in the same position
found at removal.
Take note of lower and upper half-bearing
assembling positions since in case of reuse they shall
be fitted in the same position found at removal.
Figure 5
ENGINE OVERHAUL
ENGINE REMOVAL AT THE BENCH
NOTE
NOTE

70163
70165
70164
75386
70167
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Remove the screws (1) and disconnect camshaft (3)retaining
plate (2).
Withdraw carefully the camshaft (1) from the engine block.
Withdraw the tappets (1) from the engine block.
Once engine is disassembled, clean accurately the
cylinder-block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free fromseizing,
scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation, taper
and wear shall be performed using the bore dial gauge (1)
fitted with the dial gauge previously set to zero on the ring
gauge (2) of the cylinder barrel diameter.
Measurements shall be performed on each cylinder, at three
different heights in the barrel and on two planes
perpendicular with each other: one parallel to the
longitudinal axis of the engine (A), and the other
perpendicular (B). Maximum wear is usually found on plane
(B) in correspondence with the first measurement.
Should ovalisation, taper or wear be found, bore and grind
the cylinder barrels. Cylinder barrel regrinding shall be
performed according to the spare piston diameter oversized
by 0.5 mm and to the specified assembling clearance.
Take note of plate (2) assembling position.
REPAIR OPERATIONS
CYLINDER UNIT
Checks and measurements
Should the ring gauge be not available, use a
micrometer for zero-setting.
NOTE
NOTE
zs

Figure 11
In case of regrinding, all barrels shall have the same
oversize (0.4 mm).
Checking head supporting surface on cylinder
unit
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them
in case of uncertain seal or if rusted.
Check main bearing housings as follows:
- fit the main bearings caps on the supports without
bearings;
- tighten the fastening screws to the specified torque;
- use the proper internal gauge to check whether the
housing diameter is falling within the specified value.
Replace if higher value is found.
α
NOTE
107804

70169
Figure 12
TIMING SYSTEM
Camshaft
CAMSHAFT MAIN DATA
Specified data refer to pin standard diameter
70512
Figure 13
MAIN DATA ABOUT CAMSHAFT PINS
Camshaft pin and cam surfaces shall be absolutely smooth;
if they show any traces of seizing or scoring replace the
camshaft and the bushes.

70171
70172
Figure 14
Figure 15
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
The camshaft bushing (2) must be forced into its seat.
Internal surfaces must not show seizing or wear.
Using a bore gauge (3), measure the diameter of the bushing
(2) and of the intermediate seats (1) for the camshaft.
Measurements shall be performed on two perpendicular
axes.
BUSHESChecking cam lift and pin alignment
Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.

Figure 16
MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT (4 cylinders)
* Measurement to make after fitting the bushing.
Figure 17
MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT (6 cylinders)
* Measurement to make after fitting the bushing.
107399
107268
sec. A-A
sec. A-A

70174
84053
70176
70164
70238
Figure 18
To change the bushing (1), use the drift 99360362 (2) and
grip 99370006 (3) for its disassembly and assembly.
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Lubricate the bushing supporting the camshaft and install the
camshaft (1) taking care that, during this process, the bushing
or the supporting seats do not get damaged.
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
Bush replacement Fitting tappets — camshaft
Upon assembly, the bushing (1) must be directed
so that the lubrication holes coincide with the
holes in the seats in the crankcase.
Tappets
Figure 19
Figure 20
Figure 21
Figure 22
NOTE

70179
70180
70182
Figure 23
Figure 24
Figure 25
Check camshaft end float (1).
It shall be 0.23 ± 0.13 mm.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Grind journals and crankpins if seizing, scoring or excessive
ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
It is recommended to insert the found values in the
proper table.
See Figure 24 and 28.
Undersize classes are: 0250 - 0.500 mm.
Journals and crankpins shall always be ground to
the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
OUTPUT SHAFT
Measuring journals and crankpins
NOTE
NOTE

Figure 26
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYLINDERS)
*Rated value
Figure 27
MAIN OUTPUT SHAFT TOLERANCES
* Measured on a radius greater than 45.5 mm
** ↗ 0.500 between adjacent main journals
107805
107481

Figure 28
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (6 CYLINDERS)
*Rated value
Figure 29
MAIN OUTPUT SHAFT TOLERANCES (6 CYLINDERS)
** ↗ 0.500 between adjacent main journals
107269
107482

TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL
SHAPE
Roundness ○
SHAPE
Cilindricity /○/
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
OSCILLATION
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL ©
IMPORTANT ⊕
SECONDARY ⊝
70237
MAIN BEARING ON TIMING
SYSTEM CONTROL SIDE
INTERMEDIATE MAIN
BEARINGS
FIRST MAIN BEARING ON
FRONT SIDE
Figure 30

70184
70185
Figure 31
Figure 32
Figure 33
Figure 34
Refit the output shaft (2).
Check the backlash between output shaft main journals and
the relevant bearings as follows:
Refit the main bearings that have not been
replaced, in the same position found at removal.
Fitting main bearings
Do not try to adapt the bearings.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm
undersize on the internal diameter.
Clean accurately the main half bearings (1) having the
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
Check that gear toothing (1) is not damaged or worn,
otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180°C for 10 minutes
in an oven and then key it to the output shaft.
Finding journal clearance
- clean accurately the parts and remove any trace of oil;
- position a piece of calibrated wire (3) on the output shaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
supports.
70186
74774
Replacing oil pump control gear
NOTE
NOTE
75703
D1D2
D2 diameters:

This check is performed by setting a magnetic-base dial gauge
(2) on the output shaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.
70188
70189
70190
70191
Figure 35
Figure 36
Figure 37
Figure 38
- 3rd stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90° ± 5° angle.
- Remove caps from supports.
The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2) at
the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
The numbers on the scale indicate the backlash in mm.
CONNECTING ROD — PISTON ASSEMBLY
COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
α
Checking output shaft shoulder clearance
Pistons are supplied as spare parts in standard sizes
or 0,4 mm oversize.
NOTE
70187
Tighten the pre-lubricated screws (1) in the following three
successive stages:
- 1st stage, with dynamometric wrench to 50 ± 6 Nm.
- 2nd stage, with dynamometric wrench to 80 ± 6 Nm.
Figure 39
Replace the half bearings and repeat the check if a different
backlash value is found. Once the specified backlash is
obtained, lubricate the main bearings and fit the supports by
tightening the fastening screws as previously described.

32615
32614
32613
70192
87760
Figure 40
Figure 41
Figure 42
Figure 43
Figure 44
Remove split rings (1) from piston (2) using pliers 99360183
(3).
Piston pin (1) split rings (2) are removed using a scriber (3).
Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in thefigure.
The diameter shall be measured at 55.9 mm from
the piston skirt.
MAIN DATA OF THE PISTON RINGS AND PINS
Pistons
Measuring piston diameter
NOTE

32620
16552
32619
18857
41104
Figure 45
Figure 46
Figure 47
Figure 48
Figure 49
To measure the piston pin (1) diameter use the micrometer
(2).
Conditions for proper pin-piston coupling
Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.
Use a micrometer (1) to check split ring (2) thickness.
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
Piston pins
Split rings

70194
88607
Figure 50
Use feeler gauge (1) to measure the clearance between the
ends of the split rings (2) fitted into the cylinder barrel (3).
The surface of connecting rod and rod cap are
knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.
Connecting rods
Figure 51
NOTE

80339
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
Every connecting rod is marked as follows:
- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore
necessary to mark the new connecting rod
with the same numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
S X, 1901 to 1940 (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
Figure 52
61696
Figure 53
Check that the axes of the connecting rods (1) are parallel
using tool 99395363 (5) as follows:
- fit the connecting rod (1) on tool 99395363 (5) spindle
and lock it with screw (4);
- set the spindle (3) on V-blocks by resting the connecting
rod (1) on the stop bar (2).
Checking connecting rods
Checking torsion
61694
Figure 54
Check connecting rod (5) torsion by comparing two points
(A and B) of pin (3) on the horizontal plane of the connecting
rod axis.
Position the dial gauge (2) support (1) to obtain a preload of
approx. 0.5 mm on the pin (3) in point A and then set the
dial gauge (2) to zero. Move the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A and
B shall not exceed 0.08 mm.
NOTE

61695
70198
Figure 55
Figure 56
Check connecting rod (5) bending by comparing two points
C and D of the pin (3) on the vertical plane of the connecting
rod axis.
Position the vertical support (1) of the dial gauge (2) to rest
the latter on pin (3), point C.
Move the connecting rod forwards and backwards to find pin
top position, then in this condition reset the dial gauge (2).
Move the spindle with the connecting rod (5) and repeat the
check of the top point on the opposite side D of the pin (3).
The difference between point C and point D shall not exceed
0.08 mm.
Fitting connecting rod-piston assembly
Connecting rod-piston coupling
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Marking showing 1st slot insert testing;
4. Manufacturing date.
Checking bending Figure 57
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
70199

72705
32613
70200
70201
Figure 58
Figure 59
Figure 60
Figure 61
Position the piston (1) on the connecting rod according to
the diagram shown in the figure, fit the pin (3) and stop it by
the split rings (2).
Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
Split rings shall be fitted with the marking “TOP” facing
upwards and their openings shall be displaced with each
other by 120°.
Fit half bearings (1) on connecting rod and cap.
Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
Use band 99360605 (2) to fit the connecting rod-piston
assembly (1) into the cylinder barrels and check thefollowing:
- the number of each connecting rod shall correspond to
the cap coupling number.
Split rings are supplied spare with the following
sizes:
- standard;
- 0.4 mm oversize.
Fitting connecting rod-piston assembly into
cylinder barrels
Do not try to adapt the half bearings.
Fitting split rings
NOTE
NOTE

70203
70204
70205
Figure 62
Figure 63
Figure 64
Figure 65
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120°;
- connecting rod-piston assemblies shall have the same
weight;
- the 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
To measure the clearance proceed as follows:
- clean the parts accurately and remove any trace of oil;
- set a piece of calibrated wire (2) on the output shaft pins
(1);
- fit the connecting rod caps (3) with the relevant half
bearings (4).
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2).
- Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60°.
α
α
107487
75703
D1D2
D2 diameters:

70207
70208
Figure 66
Figure 67
If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
Once connecting rod-piston assemblies refitting is over, use
dial gauge 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.
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 0.250 to 0.275 mm.
Checking piston protrusion
70206
Figure 68
- Remove the cap and find the existing clearance by
comparing the calibrated wire width (1) with the scale
on the wire envelope (2).

75750
Figure 69
Intake (1) and exhaust (2) valves have heads with the same
diameter.
Should cylinder head valves be not replaced,
number them before removing in order to refit
them in the same position.
A = intake side
CYLINDER HEAD
Removing the valves
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
cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (5).
75751
75752
Figure 70
Figure 71
Remove sealing rings (1 and 2) from the valve guide.
Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
1
2
A
1 2
3
4
5
6
2
1
NOTE
NOTE

Figure 72
Figure 73
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90°C and 2
to 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
Replace the cylinder head if leaks are found.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.
Checking cylinder head wet seal
Before refitting, smear the plug surfaces with
water-repellent sealant.
Checking cylinder head supporting surface
75756
The rated thickness A for the cylinder head is 95 ± 0.25 mm,
max. metal removal shall not exceed thickness B by 1 mm.
After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified
value.
75753
1
0,4 C
D
0,025 / ¯ 25,4
0,4 TOTAL C
0,01 / ¯ 50
A B
NOTE
NOTE

INTAKE
VALVE
EXHAUST
VALVE
18625
18882
75757
Figure 74
Figure 75
Figure 76
Figure 77
VALVES
INTAKE AND EXHAUST VALVE MAIN DATA
Remove carbon deposits from valves using the proper metal
brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, using tool 99305018 and
removing as less material as possible.
Check the valve stem (1) using a micrometer (2), it shall be
7.960 to 7.980.
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.056 ± 0.096 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
Removing carbon deposits, checking and
grinding valves
Checking clearance between valve stem and
valve guide and valve centering
2
1
116395

EXHAUST
70328
75754
75755
Figure 78
Figure 79
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.
Check the valve seats (2). If slight scoring or burnout is found,
regrind seats using tool 99305014 (1) according to the angle
values shown in Figure 80.
VALVE SEATS
Regrinding — replacing the valve seats
VALVE SEAT MAIN DATA
INTAKE EXHAUST
INTAKE
Figure 80
Should valve seats be not reset just by regrinding, replace
them with the spare ones. Use tool 99305019 (Figure 79) to
remove as much material as possible from the valve seats
(take care not to damage the cylinder head) until they can
be extracted from the cylinder head using a punch.
Heat the cylinder head to 80° - 100°C and using the proper
beater, fit the new valve seats, previously cooled, into the
cylinder head.
Use tool 99305019 to regrind the valve seats according to
the values shown in Figure 80.
1
2
36.5º
37.5º
60º
29.5º
30.5º
4.06
4.32
4.64
4.38
59.5º
60.5º
45º
74.5º
75.5º
VALVE GUIDE

Height Under a load of
mm N
H (free) 63.50 -
H1 49.02 329
H2 38.20 641
50676
75759
75751
Figure 81
Figure 82
Figure 83
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
Before refitting use tool 99305047 to check spring flexibility.
Compare load and elastic deformation data with those of the
new springs shown in the following table.
FITTING CYLINDER HEAD
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.VALVE SPRINGS
75758
Figure 84
After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).
1
2
3
3 1
1
2
1 2
3
4
5
6
NOTE

Check cleanness of cylinder head and engine block coupling
surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking “N. of
component” (1) facing the head.
The arrow shows the point where the gasket thickness is
given.
87759
Figure 85
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:
- for each piston detect, as indicated on Figure 86, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:
For 4 cylinder versions:
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
For 6 cylinder versions:
Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
the average value.
If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.
88775
Figure 86
S =
Scil1 + Scil2 + Scil3 + Scil4 + Scil5 + Scil6
6
Scil1 = S1 + S2
2
S =
Scil1 + Scil2 + Scil3 + Scil4
4
75703
D1D2
D2 diameters:

TIGHTENING TORQUE
COMPONENT
TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15 ± 3 1.5 ± 0.3
Main bearing cap 1st stage
2nd stage
50 ± 6
80 ± 6
5.0 ± 0.6
8.0 ± 0.6
3rd stage 90º ± 5º
Rear gear housing assembly
(M8x1.25x40)
(M8x1.25x25)
(M10x1.5)
24 ± 4
24 ± 4
49 ± 5
2.4 ± 0.4
2.4 ± 0.4
4.9 ± 0.5
Oil pump (M8x1.25x30) 8 ± 1 0.8 ± 0.1
Front cover assembly
(M8x1.25x45)
(M8x1.25x30)
24 ± 4
24 ± 4
2.4 ± 0.4
2.4 ± 0.4
Connecting rod bolts (M11x1.25) 1st stage
2nd stage
30 ± 3
60 ± 5
3.0 ± 0.3
6.0 ± 0.5
60º ± 5º
Ladder frame assembly (M10x1.25x25) 43 ± 5 4.3 ± 0.5
Oil rifle plugs
(M10x1)
(M14x1.5)
6 ± 1
11 ± 2
0.6 ± 0.1
1.1 ± 0.2
Assemble oil suction tube (M8x1.25x20) 24 ± 4 2.4 ± 0.4
Oil pan assembly
(M8x1.25x25)
(M18x1.50)
24 ± 4
60 ± 9
2.4 ± 0.4
6.0 ± 0.9
Set timing pin 5 ± 1 0.5 ± 0.1
Fuel pump assembly
M8 screw
M6 screw
M6 nut
24 ± 4
10 ± 1
10 ± 1
2.4 ± 0.4
1.0 ± 0.1
1.0 ± 0.1
M10x1.5 flange head nuts pre-torque
Final torque
10 - 15
50 - 55
1.0 - 1.5
5.0 - 5.5
Fuel pump gear (drive gear nut) Snug torque
Final torque
15 - 20
85 - 90
1.5 - 2.0
8.5 - 9.0
Timing pin cap of fuel pump 30 - 35 3.0 - 3.5
Rocker assys (M8) 24 ± 4 2.4 ± 0.4
Cylinder head bolts
(M12x70)
(M12x140)
(M12x180)
50 + 90º
40 + 180º
70 + 180º
5.0 + 90º
4.0 + 180º
7.0 + 180º
Assy rocker covers (M8x1.25x25) 24 ± 4 2.4 ± 0.4
Intake manifold (M8x1.25) 24 ± 4 2.4 ± 0.4
Assy air intake connection (M8x1.25) 24 ± 4 2.4 ± 0.4
Oil bypass valve into lube filter head (M22x1.5x10) 80 ± 8 8.0 ± 0.8
Plug (M12x1.5x12) 10 ± 1 1.0 ± 0.1
Exhaust manifold (M10x1.5x65) 43 ± 6 4.3 ± 0.6
Water pump (M8x1.25x25) 24 ± 4 2.4 ± 0.4
Water outlet connection
(M8x1.25x35)
(M8x1.25x70)
24 ± 4
24 ± 4
2.4 ± 0.4
2.4 ± 0.4
Fan support (M10x1.5x20) 33 ± 5 3.3 ± 0.5
Fan pulley
(M6)
(M10)
10 ± 2
43 ± 6
1.0 ± 0.2
4.3 ± 0.6

COMPONENT
TORQUE
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 ± 12 7.7 ± 1.2
Crankshaft pulley (M12x1.75x10.9) 110 ± 5 11.0 ± 0.5
Flywheel housing
(M12x120)
(M12x80)
(M10x80)
(M10x40)
85 ± 10
85 ± 10
49 ± 5
49 ± 5
8.5 ± 1.0
8.5 ± 1.0
4.9 ± 0.5
4.9 ± 0.5
Flywheel housing (M12x1.25) 1st stage 30 ± 4 3.0 ± 0.4
2nd stage 60º ± 5º
Assy rear cover plate to flywheel housing (M8x1.25x16) 24 ± 4 2.4 ± 0.4
Fuel injectors 60 ± 5 6.0 ± 0.5
Fuel lift pump 24 ± 4 2.4 ± 0.4
Turbocharger to exhaust manifold (M10) 43 ± 6 4.3 ± 0.6
Oil feed to oil filter head 24 ± 4 2.4 ± 0.4
Oil feed to turbocharger (M12x1.5) 35 ± 5 3.5 ± 0.5
Oil drain (M8x1.25x16) 24 ± 4 2.4 ± 0.4
Alternator to alternator support (M8x1.25x30) 24 ± 4 2.4 ± 0.4
Alternator to water inlet conn. assy (M8x1.25x30) 24 ± 4 2.4 ± 0.4
Lower alternator mounting (M10x1.25x25) 24 ± 4 2.4 ± 0.4
Alternator upper pivot to support (M10) 49 ± 5 4.9 ± 0.5
Alternator mounting hardware (M12x1.75x120) 43 ± 6 4.3 ± 0.6
Alternator wiring (M6x1.0 nut) 10 ± 2 1.0 ± 0.2
Starter motor to gear case (M10) 49 ± 5 4.9 ± 0.5
Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3
Screw M12 for fastening output shaft caps 1st stage
2nd stage
d
50 ± 6
80 ± 6
5 ± 0.6
8 ± 0.62 stage
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 M110 for fastening connecting rod caps 1st stage 60 ± 5 6 ± 0.5Screw M110 for fastening connecting rod caps 1 stage

SECTION 5 - TOOLS 1F4GE NEF ENGINES
SECTION 5
Tools
Page
TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 5 - TOOLS F4GE NEF ENGINES

TOOLS
TOOL NO. DESCRIPTION
99305019 Kit for valve seat regrinding
99305047 Spring load tester
99322205
Revolving stand for overhauling units (700 daN/m capacity, 120
daN/m torque)
99340035 Injection pump gear extractor.
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket

v
TOOLS
99340205 Tool to remove injectors
99346252 Tool for fitting output shaft rear gasket
99360076 Tool to remove oil filter (engine)
99360183 Pliers for removing/refitting piston rings (65 — 110 mm)
99360268 Tool for removing/refitting engine valves

TOOLS
99360330 Flywheel crank handle
99360339 Tool for stopping the engine flywheel
99360344 Adapter, cylinder compression test (use with 99395682)
99360351 Tool for flywheel holding
99360362
Beater for removing/refitting camshaft bushes (to be used with
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
99365196 Tool for positioning the injection pump at the start of delivery
99370006 Interchangeable willow handgrip

TOOLS
99370415 Gauge base for different measurements (to be used with 99395603)
99395097 Tool to check top dead centre (use with 99395604)
99395216 Pair of gauges with ½” and ¾” square head for angle tightening
99395220 All-purpose goniometer/Inclinometer
99395363 Complete bush testing square
99395603 Dial gauge (0 — 5 mm)

TOOLS
99395604 Dial gauge (0 — 10 mm)
99395682 Diesel fuel engine cylinder compression control device

APPENDIX 1F4GE NEF ENGINES
Appendix
Page
SAFETY PRESCRIPTIONS 3. . . . . . . . . . . . . . . . .

2 APPENDIX F4GE NEF ENGINES

Particular attention shall be drawn on some precautions that
must be followed absolutely in a standard working area and
whose non fulfillment will make any other measure useless
or not sufficient to ensure safety to the personnel in-charge
of maintenance.
Be informed and inform personnel as well of the laws in force
regulating safety, providing information documentation
available for consultation.
- Keep working areas as clean as possible, ensuring
adequate aeration.
- Ensure that working areas are provided with emergency
boxes, that must be clearly visible and always provided
with adequate sanitary equipment.
- Provide for adequate fire extinguishing means, properly
indicated and always having free access. Their efficiency
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities.
- Organize and displace specific exit points to evacuate
the areas in case of emergency, providing for adequate
indications of the emergency exit lines.
- Smoking in working areas subject to fire danger must be
strictly prohibited.
- Provide Warnings throughout adequate boards signaling
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of
emergency.
- Do not execute any intervention if not provided with
necessary instructions.
- Do not use any tool or equipment for any different
operation from the ones they’ve been designed and
provided for: serious injury may occur.
- In case of test or calibration operations requiring engine
running, ensure that the area is sufficiently aerated or
utilize specific vacuum equipment to eliminate exhaust
gas. Danger: poisoning and death.
SAFETY PRESCRIPTIONS
Standard safety prescriptions
Prevention of injury
- Do not wear unsuitable cloths for work, with fluttering
ends, nor jewels such as rings and chains when working
close to engines and equipment in motion.
- Wear safety gloves and goggles when performing the
following operations:
- filling inhibitors or anti-frost
- lubrication oil topping or replacement
- utilization of compressed air or liquids under pressure
(pressure allowed: ≤ 2 bar)
- Wear safety helmet when working close to hanging
loads or equipment working at head height level.
- Always wear safety shoes when and cloths adhering to
the body, better if provided with elastics at the ends.
- Use protection cream for hands.
- Change wet cloths as soon as possible
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry
out working operations if not trained for.
- Do not smoke nor light up flames close to batteries and
to any fuel material.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.
During maintenance
- Never open filler cap of cooling circuit when the engine
is hot. Operating pressure would provoke high
temperature with serious danger and risk of burn. Wait
unit the temperature decreases under 50ºC.
- Never top up an overheated engine with cooler and
utilize only appropriate liquids.
- Always operate when the engine is turned off: whether
particular circumstances require maintenance
intervention on running engine, be aware of all risks
involved with such operation.
- Be equipped with adequate and safe containers for
drainage operation of engine liquids and exhaust oil.
- Keep the engine clean from oil tangles, diesel fuel and or
chemical solvents.
- Use of solvents or detergents during maintenance may
originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Do not leave rags impregnated with flammable
substances close to the engine.
- Upon engine start after maintenance, undertake proper
preventing actions to stop air suction in case of runaway
speed rate.
- Do not utilize fast screw-tightening tools.
- Never disconnect batteries when the engine is running.
- Disconnect batteries before any intervention on the
electrical system.
- Disconnect batteries from system aboard to load them
with the battery loader.
- After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
from accidental short circuit and oxidation.
- Do not disconnect and connect electrical connections
in presence of electrical feed.
- Before proceeding with pipelines disassembly
(pneumatic, hydraulic, fuel pipes) verify presence ofliquid
or air under pressure. Take all necessary precautions
bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
injury and poisoning.
APPENDIX 3F4GE NEF ENGINES

- Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
personnel’s safety and health shall be adopted.
- Be informed and inform the personnel as well of laws in
force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate board indications and
organize specific training courses to ensure that
personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Collect exhaust oils in adequate specially provided
containers with hermetic sealing ensuring that storage is
made in specific, properly identified areas that shall be
aerated, far from heat sources and not exposed to fire
danger.
- Handle the batteries with care, storing them in aerated
environment and within anti-acid containers. Warning:
battery exhalation represent serious danger of
intoxication and environment contamination.
Respect of the Environment- Avoid incorrect tightening or out of couple. Danger:
incorrect tightening may seriously damage engine’s
components, affecting engine’s duration.
- Avoid priming from fuel tanks made out of copper alloys
and/or with ducts not being provided with filters.
- Do not modify cable wires: their length shall not be
changed.
- Do not connect any user to the engine electrical
equipment unless specifically approved by Iveco Motors.
- Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any
unauthorized modification will compromise warranty
assistance and furthermore may affect engine correct
working and duration.
For engines equipped with electronic gearbox:
- Do not execute electric arc welding without having
priory removed electronic gearbox.
- Remove electronic gearbox in case of any intervention
requiring heating over 80ºC temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.
4 APPENDIX F4GE NEF ENGINES

Sezione
General specifications 1
Fuel 2
Power Generation application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
Section 1 describes the NEF engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty andis dividedin foursepa-
rate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
Part 2
F4AE NEF ENGINES
1F4AE NEF ENGINES

2 F4AE NEF ENGINES

Example
α
Tighten to torque
1∅
∅ 2
3F4AE NEF ENGINES
SPECIAL REMARKS

4 F4AE NEF ENGINES
Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
Tighten to torque
Tolerance
Weight difference
α
Regulation
Adjustment
Angle
Angular value
Visual inspection
Preload
Measurement
Value to find
Check
Machine finish bar
Pressure
Interference
Strained assembly
Oversized
Higher than….
Maximum, peak
Thickness
Clearance
Undersized
Less than….
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 °C
Cold
Winter
Air bleeding
Temperature > 0 °C
Hot
Summer
Replacement

5F4AE NEF ENGINES
UPDATING

6 F4AE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS 1F4AE NEF ENGINES
SECTION 1
Page
ELECTRICAL SPECIFICATIONS
OF THE GENERATING SETS 3. . . . . . . . . . . .
CORRESPONDENCE BETWEEN TECHNICAL
CODE AND COMMERCIAL CODE 4. . . . . . .
LUBRICATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .
OIL VAPOUR RECYCLING 6. . . . . . . . . . . . . . . .
COOLING SYSTEM 7. . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION - BOOST DIAGRAM 8. . . . . . .
- Description 8. . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 1 - GENERAL SPECIFICATIONS F4AE NEF ENGINES

ELECTRICAL SPECIFICATIONS OF THE GENERATING SETS
Prime Power
The Prime Power is the maximum power available with varying loads for an unlimited number of hours. The average power output
during a 24 h period of operation must not exceed 80% of the declared prime power between the prescribed maintenance intervals
and at standard environmental conditions. A 10% overload is permissible for 1 hour every 12 hours of operation.
Stand-by Power
This is the maximum power available for a period of 500 hours/year with a mean load factor of 90% of the declared stand-by power.
No kind of overload is permissible for this use.
(*) Power factor 0.8.
Electrical specifications
Generating set Assembled engine
Ratings
50 Hz 60 Hzg g
Ratings
kVA kW (*) kVA kW (*)
GE NEF 200E NEF 60 TE2
Prime 200 160 225 180
GE NEF 200E NEF 60 TE2 Stand By 220 176 248 198
GS NEF 200E NEF 60TE2
Prime 200 160 225 180
GS NEF 200E NEF 60TE2 Stand By 220 176 248 198

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
F4AE0685A*F101 GE NEF 200E
F4AE0685A*F100 GE NEF 200E
F4AE0685A*F101 GS NEF 200E
F4AE0685A*F100 GS NEF 200E

Figure 1
LUBRICATION SYSTEM LAYOUT
Routing of oil under pressure
Routing of oil return by gravity to sump
Introduction of oil
Oil recover from the
turbo-blower
To the exchanger
and to the
turbo-blower
LUBRICATION
Lubrication by forced circulation is achieved through oil rotary
expansion pump, placed in the front part of the basement,
driven by the straight-tooth gear splined to the shaft’s bar hold.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Lubrication involves the heat exchanger (2,3), the
turboblower for turbocompressed versions, and for any
compressed air system.
All these components may often vary according to the specific
duty.
(Demonstration)

Figure 2
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).
Oil condensate
Oil vapours
OIL VAPOUR RECYCLING
106673

Figure 3
106529
Water leaving the thermostat
Coolant recirculating in the engine
Water entering the pump
DIAGRAM OF THE COOLING SYSTEM
COOLING SYSTEM
The engine cooling system, closed circuit forced circulation
type, generally incorporates the following components:
- expansion tank; placement, shape and dimensions are
subject to change according to the engine’s equipment;
- radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions;
- visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engine’s
development;
- heat exchanger to cool the lubrication oil: even this
component is part of the engine’s specific equipment;
- centrifugal water pump, placed in the front part of the
engine block;
- thermostat regulating the circulation of the cooling liquid;
- the circuit may eventually be extended to the
compressor, if this is included in the equipment.

Figure 4
AIR INDUCTION - BOOST DIAGRAM
Description
The turbocharger is composed by the following main parts:
one turbine, one transforming valve to regulate the boost
feeding pressure , one main body and one compressor.
During engine working process, the exhaust emissions flow
through the body of the turbine, causing the turbine disk
wheel’s rotation.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air through the air filter.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
The turbocharger is equipped with a transforming valve to
regulate the pressure , that is located on the exhaust collector
before the turbine and connected by piping to the induction
collector.
It’s funchon isto restrictthe exhaustof theemissions ,releasing
part of them directly to the exhaust tube when the boost
feeding pressure, over the compressor, reaches the
prescribed bar value.
The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
106548
Compressed air to the heat exchanger
Refrigerated compressed air to the pistons
Exhaust gas
Intake air
TURBOCHARGING DIAGRAM

SECTION 2 - FUEL 1F4AE NEF ENGINES
SECTION 2
Fuel
Page
COMMON RAIL 3. . . . . . . . . . . . . . . . . . . . . . . . .
- General specifications 3. . . . . . . . . . . . . . . . . . .
- Electric system description 3. . . . . . . . . . . . . . . .
WORKING PROCESS 5. . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM LAYOUT 6. . . . . . . . . . . . . . . . . . .
MECHANICAL FEEDING PUMP 7. . . . . . . . . . . .
CP3.3 HIGH PRESSURE PUMP 8. . . . . . . . . . . . . .
RAIL 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE LIMITER FOR FUEL RETURN 12. . . . . .
BOOST GAUGE VALVE 13. . . . . . . . . . . . . . . . . . .
ELECTRO-INJECTOR 14. . . . . . . . . . . . . . . . . . . . .

2 SECTION 2 - FUEL F4AE NEF ENGINES

74168
Figure 1
Through the sensors, present on the engine, the ECU con-
trols the engine operation.
Air pressure/temperature sensor
It is a component integrating a temperature sensor and a
pressure sensor.
Fitted on the intake manifold, it measures the max. inlet air
capacity to calculate precisely the fuel quantity to inject at
every cycle.
The outlet voltage is proportional to the pressure or tem-
perature obtained by the sensor.
Engine oil temperature and pressure sensor
Same as air pressure/temperature sensor, it is fitted on the
engine oil filter, in a horizontal position.
It measures engine oil temperature and pressure.
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engine’s cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engine’s 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 cable - 11. EDC 7 gearbox.
COMMON RAIL
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1400 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
Electric system description
1
2
3
4
5
6
7
8
9
10
11

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

Figure 2
1. Injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical rotor pump - 5. High-pressure pump -
6. Prefilter assembled on chassis - 7. Rail overpressure valve - 8. Pressure limiter for fuel return.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
WORKING PROCESS
High Pressure
Low Pressure
106531

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.
FUEL SYSTEM DIAGRAM
The following figure outlines the common rail injection
system with pump CP3.3.
The pressure regulator, located upstream from the
high-pressure pump, governs the necessary flow of fuel on
the low-pressure system. Then the high-pressure pump
supplies the rail correctly. This solution, pressurizing only the
necessary amount of fuel, improves energy efficiency and
limits fuel heating in the system.
The pressure relief valve (2), fitted on the high-pressure
pump, has the function of keeping the regulator inlet pressure
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).
The pressure relief valve housed on the cylinder head, fitted
on the return of the electro-injectors (3), limits the fuel
return flow from the electro-injectors to a pressure of 1.3 ÷2
bar.
In parallel with the mechanical supply pump there are two
by-pass valves.
The by-pass valve (18) is used to run off the fuel from the
outlet of the mechanical pump at its inlet when the pressure
at the inlet of the fuel filter exceeds the allowed limit.
The by-pass valve (17) is used to fill the fuel system through
the manual priming pump (10).
74786
Figure 3
INTAKE (LOW PRESSURE)
HIGH PRESSURE
HIGH-PRESSURE PUMP SUPPLY
(LOW PRESSURE)
EXHAUST

MECHANICAL FEEDING PUMP
The gear pump is fitted on the back of the high-pressure
pump and feeds it. It is driven by the shaft of the high-pressure
pump.
Figure 4
72592
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter,
I - 2 By-pass valves in close position.
Overpressure condition in exhaust unit
Figure 5
72593
The by-pass valve (I) is activated in case of overpressure on
B Exhaust unit. The actual pressure, overcoming the
resistance of the valve’s spring (I), connects the exhaust with
the entry through the gallery (2).
Figure 6
Jettison condition
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
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
pressure effect on the entry unit so the fuel flows to the
exhaust unit B.
The mechanical feeding pump cannot be replaced
separately, therefore it must not be disassembled
from the high pressure pump.
NOTE
Ordinary working condition

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.
CP3.3 HIGH PRESSURE PUMP
It is a pump with 3 radial pumping elements driven by the
timing gear and needs no timing. The mechanical feeding
pump driven by the high pressure pump’s shaft is assembled
to the rear side of the high pressure pump.
The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
NOTE

70498
Figure 8
Every pumping unit is composed of:
- a piston (5) actuated by a three-lobe element (2) floating
on the pump shaft (6). The element (2), being floating on
a misaligned part of the shaft (6), when the shaft rotates,
does not rotate therewith but is only translated in a
circular movement along a wider radius, with the
resulting alternate actuation of the three pumping
elements;
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.
Sec. B-B
Sec. C-C
- cap intake valve (3);
- ball delivery valve (4).
High pressure pump-inside structure

Figure 9
Working principle
72597
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.
Sec. D - D
The pumping element (3) is orientated towards the pump’s
camshaft (4). During the intake phase, the pumping element
is fed through the feeding line (5). The quantity of fuel to flow
to the pumping element is determined by the pressure
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
During compression phase of the pumping element, the fuel
achieves the level of pressure determining the opening of the
by-pass valve to common rail (2), feeding it through the
exhaust unit (I).
Sec. B - B

Figure 10
72601
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve.
— 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying
fuel ducts.
Sec. C - C 72598
Picture 10 shows the fuel runs at low pressure inside the
pump; the following elements are clearly visible: the main
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.
Figure 11
Sec. A - A
1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
exhaust flowing from pump with connector to high
pressure pipe for common rail.
Figure 11 shows the fuel flow under high pressure running
through the exhaust galleries of the pumping elements.

Figure 12
Operation
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing
in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure
circuit.
The pumping element compresses the fuel till the top dead
center (delivery stroke) is reached. Afterwards, the pressure
decreases till the exhaust valve is closed.
The pumping element piston goes back towards the bottom
dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and
the cycle is repeated.
The delivery valves must always be free in their movements,
free from impurities and oxidation.
The rail delivery pressure is modulated between 250 and
1400 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection — reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
1. Rail. — 2. Pressure sensor - 3. Fuel inlet from
high-pressure pump. — 4. Overpressure valve.
The rail volume is comparatively small to allow a quick
pressurisation at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise system spikes
and the use of plenum chambers caused by injectors
openings and closings and by the high-pressure pump
operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
A fuel pressure sensor (4) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
value is checked and, if necessary, corrected.
RAIL
101638
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.
70507
A To tank — B From injectors
Figure 13

70502
Figure 14
70500
BOOST GAUGE VALVE
The boost valve (1750 bars) is assembled to the rail with the purpose to protect the system’s components in case of excessive
increase of pressure within the high pressure system. Pressure limiter.
The valve can be single-stage (as the one showed in the picture) or double-stage with double working limit (1750 bars and 800
bars).
In the second case, when the pressure within the high pressure system reaches 1750 bars, the valve is activated as a single-stage
one to exhaust the fuel and consequently reduce the pressure until reaching safety parameters. Then it provides mechanically
gauging the pressure into rail to aprx. 800 bars. This way the valve enables working of the engine for extended timing at limited
performances, avoiding the fuel’s overheating and preserving the exhaust galleries.
If the above mentioned valve is activated, the engine control module excludes by isolation the pressure gauge and records the
errore code 8.4.
The pump will flow the maximum delivery to the rail.
A Normally, the tapered piston end keeps closed the
discharge towards the tank.
B If the 1750 bar fuel pressure is exceeded in rail, the small
piston is displaced and the excess pressure is discharged
into the tank.
1. Body — 2. Small piston — 3. Stop — 4. Spring — 5. Direct tank discharge — 6. Seat on rail.
A B

117529
70506
Figure 15
Figure 16
ELECTRO-INJECTOR
The injector is similar as construction to the traditional ones,
apart from the absence of plunger return springs.
1. Electric connection - 2. Coil - 3.High-pressure fuel inlet
- 4. Nozzle - 5. Control fuel outlet - 6. Mount bracket .
When coil (4) is energised, it makes shutter (6) move
upwards. The control volume (9) fuel flows towards flow
duct (12) making a pressure drop occur in control volume
(9). Simultaneously the fuel pressure into pressure chamber
(8) makes plunger (2) lift, with following fuel injection into the
cylinder.
Injection end
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
Injection start
The injector cannot be overhauled and therefore
it must not be disassembled.
15
NOTE
(Demonstration)

SECTION 3 - POWER GENERATION APPLICATION 1F4AE NEF ENGINES
SECTION 3
Power Generation application
Page
PART ONE - MECHANICAL COMPONENTS 5
REMOVING AND REFITTING
THE SOUND-PROOFING UNIT 7. . . . . . . . .
- Removal 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING AND REFITTING THE RADIATOR
ASSEMBLY AND ENGINE AIR CLEANER 9. .
- Removal 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING AND REFITTING THE ENGINE/
GENERATOR 10. . . . . . . . . . . . . . . . . . . . . . . . .
- Removal 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEPARATING THE GENERATOR FROM THE ENGINE 11
DETACHING THE TANK FROM THE BASE 12. .
ENGINE OVERHAUL 13. . . . . . . . . . . . . . . . . . . . .
- Preface 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Engine setting operations for the assembly
on turning stand 13. . . . . . . . . . . . . . . . . . . . . . .
- Disassembly of application components 14. . . . .
- Assembly of application components 21. . . . . . .
- Completion of the engine 32. . . . . . . . . . . . . . . .
- Checks and inspections 34. . . . . . . . . . . . . . . . . .
PART TWO -
MAINTENANCE PLANNING 35. . . . . . . . . . .
MAINTENANCE PLANNING 37. . . . . . . . . . . . . .

2 SECTION 3 - POWER GENERATION APPLICATION F4AE NEF ENGINES
Page
- Recovery 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regular maintenance and
inspection planning 37. . . . . . . . . . . . . . . . . . . . .
- Checks not included in maintenance
planning-daily checks 38. . . . . . . . . . . . . . . . . . . .
MAINTENANCE PROCEDURES 38. . . . . . . . . . . .
- Checks and inspections 38. . . . . . . . . . . . . . . . . .
- Engine oil level check 38. . . . . . . . . . . . . . . .
- Combustion system inspection 39. . . . . . . .
- Cooling system inspection 39. . . . . . . . . . . .
- Lubricating system inspection 39. . . . . . . . .
- Inspection of water presence within
fuel filter or pre-filter 39. . . . . . . . . . . . . . . .
- Inspection/replacement of blow-by filter 40.
- Inspection of drive belt tensioning 40. . . . . .
- Inspection and setting of tappet clearance 40
- Oil motor and filter replacement 41. . . . . . .
- Changing the coolant 41. . . . . . . . . . . . . . . .
- Fuel filter replacement 42. . . . . . . . . . . . . . .
- Alternator belt replacement 42. . . . . . . . . . .

Figure 1
The NEF F4AE0685 engines have a 4-stroke Diesel cycle,
turbocharged with 6 cylinders and 4 valves per cylinder.
They have high pressure injection fuelling (common rail) and
are entirely electronically driven in order to optimise the
working process in accordance to the operation, limiting as
much as possible the pollution emissions and consumption.
The section herein described is composed or four sections:
- Section of mechanical overhaul prescribed in accordance
to the engine’s specific duty, illustrating all necessary
operation to remove and assembly the external
components of the engine, including cylinder heads,
gearbox of the timing system and of the front part cover;
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.
Data, features and performances are valid only if the
setter fully complies with all the installation
prescriptions provided by Iveco Motors.
Furthermore, the users assembled by the setter
shall always be in conformance to couple, power
and number of turns based on which the engine has
been designed.
74190
(Demonstration)
NOTE

Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by Iveco Motors.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.
NOTE
F4AE0685A
Type *F100 *F101
ρ Compression ratio 17 : 1
Max. output kW
(HP)
rpm
193
1500
215
1800
Max. torque Nm
(kgm)
rpm
-
-
1140
(114)
1800
Loadless engine
idling rpm
-
Loadless engine
peak rpm
-
Bore x stroke
Displacement cm3
102 x 120
5880
TURBOCHARGING
Turbocharger type
with aftercooler
HOLSET HX35W
LUBRICATION Forced by gear pump, relief valve single action
oil filter
bar
Pump characteristics
Oil pressure with engine hot:
- a 750 rpm bars
- a 4200 rpm bars
2
4
COOLING
Water pump control
Thermostat
Through belt
81 ± 2
15W40 ACEA E3-E5
FILLING
engine sump liters
engine sump + filter liters
15
~ 17

PART ONE - MECHANICAL COMPONENTS
DIAGNOSI

Figure 2
Figure 3
Figure 4
REMOVING AND REFITTING THE
SOUND-PROOFING UNIT
Removal
114332
Operate from the control board side and disconnect the
electric connection (1) from the stop button.
Operate inside the soundproofing unit and move back the
exhaust pipe cover (1) in order to reach the stop collar (2),
then loosen the fastening screw (3).
Operate from the exhaust pipes side and loosen the covering
panel (2) fastening nuts (1) and remove it.
115047
114334

Figure 5
Figure 6
Figure 7
114335
Remove pipe (1) from its seat.
Operate along the perimeter and loosen the soundproofing
unit (2) fastening screws (1).
Secure hooks with chain catches (1) into the slots (2)
provided for the purpose and, by means of a proper hoisting
device, lift the soundproofing unit (3) and remove it with the
aid of another operator.
114336
114337
When removing pipe (1), pay attention not to
damage the cooling unit air ducts (2).
NOTE
Make sure that the rods have all the same length
in order to lift the soundproofing unit along the
vertical axis, thus reducing interferences.
NOTE
Refitting
To refit, reverse the removal instructions.

Figure 8
Removal
Remove the fan safety grilles (5) by undoing the relevant
fasteners.
Place a container under the pipe (13) to collect the coolant.
Disconnect and remove the pipe (13) together with the
sleeves by undoing the clamps.
Disconnect the air pipes (4) and (14) from the air exchanger
and from the engine, then remove it from its seat. Disconnect
the exhaust pipe (15) from the system.
Disconnect and remove the coolant pipes (1) and (2).
Block the radiator assembly (3) appropriately, then detach it
from the crankcase (6) by undoing the fasteners (7) on both
sides.
Remove the radiator assembly from its seat, taking care over
any interference with the fan.
107475
Check the state of wear of the rubber couplings.
REMOVING AND REFITTING THE RADIATOR ASSEMBLY AND ENGINE AIR CLEANER
Disconnect the air hose (10) from the turbocharger of the
turbine (9).
Remove the air cleaner (11) by undoing the fasteners (8) and
remove it from its seat together with the support (12).
Refitting
Reverse the removal instructions; restore the coolant system
as described in the procedure on page 39.
NOTE

Figure 9
Removal
Disconnect the electrical system by detaching the cables
from the battery.
Disconnect the positive and negative cables from any clamps,
detach them from their attachments on the starter motor
(4), then remove them.
Block the control panel (7) suitably for subsequently
removing it from its seat.
Take the cover off the interface box (2) and disconnect the
connections of the wiring (3).
Disconnect the wiring (3) from the clamps along its route,
then fasten it appropriately to the control panel (7).
Remove the fasteners (6) and (8) from both sides of the
control panel.
Extract the control panel from its seat.
Disconnect the diesel pipes (13) and (14) from the engine,
taking care to collect any diesel coming down.
107476
REMOVING AND REFITTING THE ENGINE/GENERATOR
Disconnect the electrical connections of the diesel level
signal (5) and earth (10).
Fit a lifting tool onto the specific hooks on the engine and
keep it under tension.
Remove the fixing nuts (11) and (12) from the four supports
of the engine/generator assembly.
Separate the engine/generator assembly from the crankcase
(9).
Refitting
For refitting, reverse the steps described for removal.
Check the integrity of the rubber-type blocks in
the supports (11) and (12) of the pipes and
electrical connections.
NOTE

Figure 10
Remove the fan (1).
Remove the brackets of the supports (2).
Separate the generator from the engine as follows:
- remove the safety grilles (3) by undoing the fasteners (5),
unscrew all the nuts (4) connecting the generator (6) to
the housing of the engine flywheel (7);
- block the generator suitably and separate it from the
engine.
106478
SEPARATING THE GENERATOR FROM THE ENGINE

Figure 11
The tank is blocked inside the base (1) with angular brackets
(3).
To remove the tank (2) from its seat, remove the brackets
(3) by undoing the relevant fasteners.
At the time of assembly, check that the adhesive rubber
blocks (4) are sound and positioned by the brackets (3).
107477
DETACHING THE TANK FROM THE BASE
At the time of assembly, check that the adhesive
rubber blocks (4) are sound and positioned by the
brackets (3).
NOTE

The following information relates to the engine overhaul
operations only for what concerns the different components
customising the engine, according to its specific duties.
In section ”General overhaul”, all the operations of engine
block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the
part hereby described.
All operations of Engine disassembly operations as
well as overhaul operations must be executed by
qualified technicians provided with the specific
tooling and equipment required.
Figure 12
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 (6)
and remove it from the support (1);
- Disconnect the electrical connection (2) from the
support (1) and the heater’s 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.
70126
Figure 13
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.
Engine setting operations for the assembly on
turning stand
ENGINE OVERHAUL
Preface
Some of the operations described in this section can be
carried out directly with the engine connected to the
generator.
NOTE
Press clamp (1), as shown in Figure B, to disconnect the low
pressure fuel pipes from the corresponding connections.
After disconnecting the pipe, reset the clamp (1) in locking
position (Figure A) to prevent distortions.
NOTE
107484

Figure 14
On the right hand side of the engine:
Remove the screws and remove the oil pipe (2) from the
turbocharger pipe (1) and from the engine block.
Disconnect the oil feed pipeline unlocking the three screws
M12x25. Remove the O-ring from the pipe.
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
sump cap and drain out oil.
Remove the fan from the output shaft pulley.
74166
Figure 15
Figure 16
Disassembly of application components
1. Connections for Electro-injectors - 2. Engine cooling liquid temperature’s sensor - 2. Cable of the fuel pressure sensor -
4. Sensor of engine’s 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 temperature’s sensor - 10. Cable of pressure
regulating gauge - 11. EDC 7 gearbox.
Disconnect the engine cable by disconnecting the connectors: (1) from injector wiring (6); (7) air pressure/temperature sensor;
(3) fuel pressure sensor; (11) ECU; (10) high pressure pump sensor; (8) timing sensor; (2) engine coolant temperature sensor
on thermostat; (5) engine speed sensor.
1
2
1
2
3
4
5
6
7
8
9
10
11
107486
(Demonstrative)
74166

Figure 17
91576
Disconnect from the rail (2): the fuel pipe (4) according to
procedures described in Figure 12. Disconnect fuel pipes (5)
from rail (2) and injector manifolds (3).
Remove the screws (1) and disconnect the rail (2).
74170
Disconnect the pipeline (2) from the fuel recover
pressure-limiter, working on the connections as described in
Figure 13.
Unscrew the nut and loosen the clamp tightening the oil
vapour pipe.
Remove the pipe (6).
Loosen the screws (3) and disassemble the blow-by filter (4).
Remove on the nuts and tappet cover.
Figure 18
Figure 19
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).
Disassembled fuel manifolds (4) must not be used
again, but however replaced with other new ones.
1
2
3
4
5
6
NOTE
Figure 20
70132
Loosen tappet adjustment fastening nuts (1)and unscrewthe
adjusters.
Remove the screws (2), remove the rocker assembly (3),
consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves.
Remove rods (8).

Figure 21
70133
Remove injector fastening screws. Use tool 99342101 (1) to
remove injectors (2) from the cylinder head.
Figure 22
Figure 23
Figure 24
74779
Hook brackets (1) with suitable lifting chains and remove
cylinder head (2) from block using hoist.
(Demonstrative)
107485
Remove the pipe (1) returning oil from the turboblower.
Remove the nuts and detach the turbocharger (2) from the
exhaust manifold.
108482
Remove screws (1) and disconnect air conveyor (2)
complete with heater. Remove screws (4), remove cover (3)
and thermostat below.
Remove screws (5) retaining cylinder head (6).
The external highlighted screws are shorter.NOTE

70140
Remove the screws (2) and disconnect the alternator
support (3).
Use tool 99360076 to remove the oil filter (1).
Figure 25
Figure 26
70141
Remove the screws (4) and disconnect the oil
temperature/pressure sensor (3).
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 27
Remove the screws (1) and disconnect the ECU (2) including
the heat exchanger.
74174
Figure 28
Unloose the screws (3) and remove the cap (1). Keep the
gasket (4), the power take-off (2) and the second gasket (4).
74176
1
2
1
2
34
(Demonstrative)
(Demonstrative)
Figure 29
70145
Remove the nut (1) and disconnect the timing sensor (2).
Remove the nuts (3) and disconnect the high pressure pump
(4) including the feed pump (5).

Figure 30
Remove the screws (3) and disassemble the damping
flywheel (2) and the pulley (1).
74175
Figure 31
Figure 32
116241
Remove the screws (1) and disconnect the water pump (2).
Remove the screw (3) and the roller (4).
Remove the screw (5) and disconnect the engine speed
sensor (6).
Remove the ring sealing the engine’s 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
way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool
to the ring tightening the 6 screws provided with the
equipment. Then proceed removing the ring (2) by tightening
the screw (3).
00900t
Figure 33
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).
1
2
3
70146
Fit tool 99360339 (2) to the flywheel housing (1) to stop
flywheel (3) rotation.
Loosen the screws (4).
Figure 34
Figure 35
116242
Remove the screws (1 and 3) and take out the front cover
(2).
Take note of screw (1) assembling positions since
they have different lengths.
NOTE

70151
Remove two opposite screws (1) from the area where the
withdrawal pins will be introduced (2, Figure 37).
Loosen the remaining flywheel fixing screws (3) from the
driving shaft (4).
Remove the flywheel locking tool 99360351.
Figure 36
Remove the screws (1) and disconnect the oil pump (2).
Figure 37
Figure 38
70152
Tighten two screws of medium length into the holes (4) to
sling the flywheel with the hoist.
Throughout the two guide pins (2) previously screw into the
driving shaft holes (3) withdraw the engine flywheel (1) after
slinging it with the hoist.
00903t
Figure 39
Remove the holding ring of the flywheel cover box using the
tool 99340056 (3) to operate on the driving shaft’s 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.

70153
Remove the screws (2) and take out the rear cover (1).
they have different sizes.
88076
Figure 40
Overturn the engine.
Remove the screws (2), disassemble the plate (3) and
disconnect the oil sump (1).
87261
Figure 41
Remove the screws (1) and disassemble the oil suction tube
(3).
Remove the screws (2) and disassemble the stiffening plate
(4).
70156
Figure 42
Remove the screws (1) and remove the gear (3) from the
camshaft (2).
70157
Figure 43
Remove the screws (2) and disconnect the timing gear case
(1).
they have different sizes.
Figure 44
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.
NOTE
NOTE
NOTE
(Demonstrative)

DIAGRAM FOR TIGHTENING THE REAR TIMING
GEAR CASE FASTENING SCREWS
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
Figure 45
Assembly of application components
LOCTITE 5205 SEALANT APPLICATION AREAS
Clean accurately the timing gear case (1) and the engine
block.
70209
Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 to 20 minutes).
70210
Figure 46
Figure 47
70211
Use a felt pen to mark the driving gear (1) tooth fitted on the
output shaft (2) having the mark (→) for timing on the side
surface.
Fasten screwing of the two pins to facilitate the
operation of engine driving shaft rotation.
Before any assembly operation always verify that
the hole and screw threads have no evidence of
wear or dirt.
NOTE
NOTE
NOTE

Figure 48
70212
Rotate the output shaft (4) and thecamshaft (2)so thatwhen
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding.
Figure 49
70213
Tighten the screws (1) fastening gear (2) to camshaft (3) to
the specified torque.
Figure 50
70214
LOCTITE 5205 SEALANT APPLICATION AREAS
Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 to 20 minutes).
Figure 51
70215
SEQUENCE FOR TIGHTENING THE FLYWHEEL
HOUSING FASTENING SCREWS
Refit the housing (1) to the engine block and 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:
wear or dirt.
NOTE
NOTE

Figure 52
70217
Check ring gear teeth (2), if breakage or excessive wear is
found remove the ring gear from the engine flywheel (1)
using a suitable hammer and fit the new one, previously
heated to 150°C for 15 to 20 minutes. Chamfering on ring
gear inside diameter shall be facing the engine flywheel.
Figure 53
Figure 54
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 55
70219
α
Tightening to angle is performed using tool
99395216.
wear or dirt.
Apply tool 99346252 part (6) to the rear output shaft tang
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
hoister.
70152
Figure 56
0901t
Tighten engine flywheel (2) fastening screws (1) in two
stages:
- 1st stage, tightening to 30 ± 4 Nm torque with
dynamometric wrench;
- 2nd stage, tightening to 60 ± 5° angle.
(Demonstrative)
NOTE

Figure 57
70220
Fit the oil pump (1).
Tighten the fastening screws (2) to the specified torque.
Figure 58
70221
Apply a new sealing ring (2) to the water pump (1).
Figure 59
Fit the water pump (1).
Tighten the screws (2) to the specified torque.
Figure 60
106549
Remove the sealing ring (2) from the front cover (1), clean
accurately the coupling surfaces and smear them with
LOCTITE 5205.
Clean accurately the front cover (2) surface and refit it.
Figure 61
Apply tool 99346252 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Position part (2) on part (4), screw nut (3) until completing
sealing ring (7) fitting into front cover (1).
00902t
Figure 62
106550

Figure 63
Fit the plate (4), the oil pick up tube (3) and tighten the
fastening screws (2 and 1) to the specified torque.
Figure 64
Set the gasket (1) on the oil sump (2).
The pictures of the instructions relating to the oil
pan and to thesuction rose may not reflect the
actual shape and dimensions of your engine equip-
ment. However the procedures described are still
applicable.
Figure 65
Fit the oil sump (1) and apply the plate (3) to it.
88076
Figure 66
74175
Assemble the pulley (1) and the damping flywheel (2) to the
driving shaft.
Tighten the fixing screws (3) and clamp them to the couple
68 ± 7 Nm.
70230
Fit a new sealing ring on the speed sensor (3).
Fit the speed sensor (3) on the front cover (1) and tighten
the screw (2) to the specified torque.
Figure 67
Figure 68
70231
Fit on the engine block: a new gasket (1), the heat exchanger
(2) a new gasket (3) and the oil filter support (4).
1
2
3
wear or dirt.
wear or dirt.
(Demonstrative)
88074
88075
NOTE
NOTE NOTE
(Demonstrative)(Demonstrative)

Figure 69
Figure 70
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 ¾
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.
70234
Position the alternator support (1) so that pins (3 and 4) are
set against the engine block.
74781
Reconnect the alternator (1).
Tighten the screw (2) to the specified torque.
Figure 71
70145
Refit the high pressure pump (6) including the feed pump (5)
and tighten the nuts (3) to the specified torque. Fit the
support (4) with a new sealing ring, the timing sensor (2) with
a new sealing ring and tighten the relevant fastening nut (1)
to the specified torque.
Figure 72
wear or dirt.
(Demonstrative)
(Demonstrative)
NOTE

Figure 73
Assemble the electronic gearbox (2) equipped with the
exchanger to the engine, fixing it with the screws (1).
In case the rubber buffers are cracked or excessively
deformed, provide replacing them.
74174
Figure 74
Apply a new gasket to the engine block and then place the
cylinder head (2) slung by the hanger brackets (1).
Figure 75
Assemble cylinder head (1), tighten the screws (2) in three
following steps, following order and mode shown in the
figure below.
The angle tightening is carried out through tool
99395216 (3).
α
70336
Tightening order layout for cylinder head fastening screws:
- 1st step pre-tightening with a torque wrench:
• Screw 12x1.75x130 ( ) 35 ± 5 Nm
A • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm
- 2nd step tightening with a 90 ± 5° angle
- 3rd step tightening with a 90 ± 5° angle
A = Front side
70476
α
Figure 77
A
74779
1
2
wear or dirt.
NOTE
NOTE
Figure 76
r
70235
Reconnect automatic belt tensioner (2).
Lock screw (3) at predefined torque by means of specific
spanner, rotate automatic belt tensioner (2) to fix belt (1) on
drive pulleys and rollers.
75703
D1D2
D2 diameters:

Figure 78
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).
70339
Fit injectors (1) on the cylinder head seats, directed so that
the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
Figure 79
70133
Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.
Figure 80
Figure 81
Figure 82
70341
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
housing (4).
Disassembled fuel manifolds (2) must not be used
again. Replace with new items.
During this operation, the injector (1) shall be
moved so that the manifold (2, Figure 79) is
properly inserted into the fuel inlet hole (2,
Figure 81).
70342
Use the torque wrench to tighten gradually and alternately
the injector fastening screws (1) to 8.5 ± 0.8 Nm torque.
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm
torque.
Carry out the assembly of the equalisers’ unit , after previous
check of the components.
NOTE
NOTE
Screw the fastening nuts (2, Figure 82) without locking them.

Figure 83
Figure 84
70343
ROCKER ASSEMBLY COMPONENTS:
1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
SHAFT-ROCKER MAIN DATA
Check that shaft/rocker coupling surfaces are not showing
excessive wear or damages.
Rocker control rods shall not be distorted; the ball seats in
touch with the rocker adjusting screw and with tappets
(arrows) shall not show seizing or wear; otherwise replace
them. Intake and exhaust valve control rods are identical and
are therefore interchangeable.
32655
Figure 85
Figure 86
Figure 87
70345
Fit the rods (2).
Position jumpers (1) on valves with marks (→) facing the
exhaust manifold.
70346
Check that tappet adjusters (1) are loose to prevent their
balking on the rods (2, Figure 86) 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 88
70520
clearance adjustment for rocker arms — valves,
proceed as follows:
in the table:
NOTE
Figure 89
Figure 90
Figure 91
Apply to the coupling surface of the intake manifold (1)
equipped with heater (2) a sufficient coat of LOCTITE 5999
and provide tightening the screws to the prescribed matching
couple.
74173
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.
z 74179
74180
Connect new fuel pipes (1) to rail (3) and injector manifolds
(2).
1
2
3
(Demonstrative)
Rotate the drive shaft, balance cylinder 6 valvesand
in the table:
cylinder n. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *
cylinder n. 1 2 3 4 5 6
intake * * - * - -
exhaust * - * - * -

Figure 92
74181
Pipe (7) connections shall be tightened to 20 Nm
torque, using the proper wrench (5) and the
torque wrench 99389833 (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.
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”.
Check proper fuel pipe connection.
Figure 93
NOTE
NOTE
70352
70353
Figure 94
Figure 95
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).
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.
wear or dirt.
NOTE

Completion of the engine
Properly handle the engine holding it by a lifter, remove it
from the rotating shaft, remove the brackets 99341009 and
place it on proper suitable support to carry out the
completion.
Proceed assembling the oil filter.
Figure 96
1
2
Assemble the starter (2) to the internal part of the flywheel
cover.
Assemble the oil feeding pipe using a new O-ring. Fix with
three M12x25 screws.
Assemble the bracket and the support (1) of the fuel filter (6).
Proceed connecting in sequence the pipelines (9,3,4 and 5)
of the support (1) to the high pressure pump (8).
Connect the pipeline (7) from the high pressure pump to the
engine control module heat exchanger.
Connect the pipeline (10) from the high pressure pump to
the rail diffuser.
Figure 97
1
2
3
4
5
6
7
8
9
10
74165
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 arrow’s direction (Figure B) and connect the pipe to the
clamp on the high pressure pump or on the support of the
fuel filter.
Reset the clamp in the initial locking ”A” position.
In case the pipes are re-employed, they must keep
the sealing tops at the edges.
Make sure that the fuel pipeline is correctly
connected.
Reconnect the engine harness to all the sensors, the engine
control module and the rail diffuser.
Figure 98
NOTE

70354
Figure 99
Figure 100
Fit a new gasket (2) on the tappet cover (1).
Place the tappet cover on, install the bolts in the correct
position and tighten.
70355
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 through the clamp (4) and the screw locking to
the block.
74172
2
1
3
4
5
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 101
74170
Figure 102
Insert the blow-by filter (4) tightening the screws.
Connect the pipeline (6) and fix the oil vapour recover pipe
through the clamp (5); lock up the nut fixing it to the upper
edge.
Connect the pipeline (2) to the pressure- limiter (1).
1
2
3
4
5
6

- 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;
- 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);
Carefully check and bleed the engine cooling equipment by
repeated draining operations.
Checks and inspections
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:
!
The following checking inspections must be carried
out after the engine assembly on the vehicle .

PART TWO - MAINTENANCE PLANNING

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
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . .
Inspection blow-by filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of blow by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency (hours)
Daily
Daily
-
-
4000
500
-
1000
500
500
1500
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.
NOTE

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.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
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.
- 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.
MAINTENANCE PROCEDURES
Checks and inspections
Engine oil level check
The check must be made with the engine switched off and
preferably cold.
The check can be made using the specially provided flexible
rod (1) placed on the right hand side of the EDC.
Figure 103
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
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing mini-
mum level, provide filling lubrication of the engine’s compo-
nents.
To provide filling, operate through the upper top (1) or
through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier”.
Figure 104
and detergent.
Adequately protect the skin and the eyes, operate
in full compliance with safety regulations.
74174
1
2
74184

Combustion system inspection
The check must be executed both when the engine discon-
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-
cific equipment), to the filter, to the high pressure pump and
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.
Due to the high pressure within the pipelines running
from the high-pressure pump to the rail diffuser and
from this last one to the electro-injectors, special
attention must be aid also in checking presence of any
leakage or blow-by.
pressure jet: these may deeply penetrate under the
skin surface provoking serious poisoning.
Cooling system inspection
Check the pipelines from the engine to the radiator, from the
expansion tank and vice-versa. Find out any blow-by, verify the
status of the pipes specially close to the holding strips.
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.
Due to the high temperatures achieved by the sys-
tem, do not operate immediately after the engine’s
disconnection, but wait for the time deemed necess-
ary for the cooling.
pressure jet of cooling liquid.
Lubricating system inspection
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan of from the heat exchanger.
and detergent.
Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Inspection of water presence within fuel filter or pre-filter
The components of the common rail system can be
damaged very quickly in presence of water or im-
purity within the fuel.
Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the drain-
age of the water within the feed circuit.
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any case
every two year.
If refilled, bleed the system as described on page 49.
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 engine’s head.
NOTE
NOTE

Inspection/replacement of blow-by filter
The filter in subject has been developed and equipped for the
collection, filtering and condense of the lubricating oil vapours.
Within the filter unit (1) two cartridge filters are included (2).
Figure 105
Figure 106
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.
70520
clearance adjustment for rocker arms — valves, pro-
ceed as follows:
in the table:
in the table:
Inspection and setting of tappet clearance
74188
21
NOTE
cylinder n. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *
cylinder n. 1 2 3 4 5 6
intake * * - * - -
exhaust * - * - * -

Oil motor and filter replacement
Due to the several applications, the pan shape and the oil
quantity can change slightly. However, the following oper-
ations are valid for all applications.
We recommend to carry out the oil drainage when the motor
is hot.
- Place a proper container for the oil collecting under the
pan connected with the drain plug.
- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the lubrica-
tion oil.
Warning: We recommend to wear proper protec-
tions because of high motor service temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves.
The oil motor is very pollutant and harmful.
In case of contact with the skin, wash with much water
and detergent.
Protect properly skin and eyes: operate according to
safety rules.
Dispose of the residual properly following the rules.
- After the complete drainage, 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 function-
ing.
In case of topping up, don’t mix oils having different
features.
If you don’t comply with theses rules, the service
warranty 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.
Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in differ-
ent positions: the following procedure is a valid guide for all ap-
plications.
- The filter is composed by a support and a filtering car-
tridge. For the cartridge replacement use the
9936076-tool.
Warning: the oil filter contains inside a quantity of oil
of about 1 kg.
Place properly a container for the liquid.
Warning: avoid the contact of skin with the motor oil:
in case of contact wash the skin with running water.
The motor oil is very pollutant: it must be disposed
of according to the rules.
- Replace the filtering cartidge with a new one and screw
manually until when the gasket is in contact with the sup-
port.
- Tigthen by means of the 99360076-tool of three fourth
turn.
- Operate the motor for some minutes and check the level
through the dipsick again. If it is necessary, carry out a top-
ping up to compensate the quantity of oil used for the fill-
ing of the filtering cartridge.
NOTE
Changing the coolant
- Position a container beneath the radiator tap to recover
the coolant.
- Open the tap and allow all the coolant in the radiator to
flow out.
- Charge the coolant for the first time.
- Leave the radiator cap open.
- Start the engine and leave it running for at least a minute
so that all the air in the circuit is completely removed.
- Stop the engine.
- Top up.
If the procedure described is not followed, the
radiator fluid level will be incorrect.
NOTE

Fuel filter replacement
According to the applications the filters position and the quan-
tity can change.
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.
- Collect the eventual fuel inside the filtering cartridge.
- Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 10 to 15 Nm
torque.
During this operation don’t smoke and don’t use free
flames.
Do not breathe the vapours generated in the filter.
Alternator belt replacement
Due to several applications the belt run can change very much.
Warning: with switched off motor (but still hot) the
belt can operate without advance notice.
Wait for the motor temperature lowering to avoid
very serious accidents.
For applications with automatic belt stretcher, the procedure
is the following:
Figure 107
74171
2 3
1
- Unscrew the screws which fix the belt guard (2) to the
support and dismount it.
- Operate on the tightener (1) and withdraw the belt (3)
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.

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1F4AE NEF ENGINES
SECTION 4
Overhaul and technical specifications
Page
CLEARANCE DATA 4. . . . . . . . . . . . . . . . . . . . .
ENGINE OVERHAUL 11. . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL AT THE BENCH 11. . . . . . . .
REPAIR OPERATIONS 12. . . . . . . . . . . . . . . . . . . .
CYLINDER UNIT 12. . . . . . . . . . . . . . . . . . . . . . . .
- Checks and measurement 12. . . . . . . . . . . . . . . .
- Checking head supporting surface
on cylinder unit 13. . . . . . . . . . . . . . . . . . . . . . . .
TIMING SYSTEM 14. . . . . . . . . . . . . . . . . . . . . . . .
- Camshaft 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking cam lift and pin alignment 14. . . . . . . .
BUSHES 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Bush replacement 15. . . . . . . . . . . . . . . . . . . . . .
- Tappets 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fitting tappets — camshaft 16. . . . . . . . . . . . . . . .
OUTPUT SHAFT 17. . . . . . . . . . . . . . . . . . . . . . . .
- Measuring journals and crankpins 17. . . . . . . . . .
- Replacing oil pump control gear 19. . . . . . . . . . .
- Fitting main bearings 19. . . . . . . . . . . . . . . . . . . .
- Finding journal clearance 19. . . . . . . . . . . . . . . . .
- Checking crankshaft shoulder clearance 20. . . . .
CONNECTING ROD — PISTON ASSEMBLY 20. .
- Pistons 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Measuring piston diameter 21. . . . . . . . . . . . . . .
- Piston pins 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4AE NEF ENGINES
Page
- Conditions for proper pin-piston coupling 22. . . .
- Piston rings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Connecting rods 23. . . . . . . . . . . . . . . . . . . . . . .
- Bushes 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Checking connecting rods 24. . . . . . . . . . . . . . . .
- Checking torsion 24. . . . . . . . . . . . . . . . . . . . . . .
- Checking bending 24. . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly 24. . . . . .
- Connecting rod-piston coupling 24. . . . . . . . . . . .
- Fitting split rings 25. . . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly
into cylinder barrels 25. . . . . . . . . . . . . . . . . . . . .
- Finding crankpin clearance 26. . . . . . . . . . . . . . . .
- Checking piston protrusion 27. . . . . . . . . . . . . . .
CYLINDER HEAD 28. . . . . . . . . . . . . . . . . . . . . . . .
Page
- Removing the valves 28. . . . . . . . . . . . . . . . . . . .
- Checking cylinder head supporting surface 29. . .
- Checking cylinder head wet seal 29. . . . . . . . . . .
VALVES 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing carbon deposits, checking
and grinding valves 30. . . . . . . . . . . . . . . . . . . . . .
- Checking clearance between valve stem
and valve guide and valve centering 30. . . . . . . . .
VALVE GUIDE 31. . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE SEATS 31. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Regrinding — replacing the valve seats 31. . . . . . .
CYLINDER HEAD VALVE SEATS 31. . . . . . . . . . .
VALVE SPRINGS 33. . . . . . . . . . . . . . . . . . . . . . . . .
FITTING CYLINDER HEAD 33. . . . . . . . . . . . . . . .
- Refitting the cylinder head 34. . . . . . . . . . . . . . . .
TIGHTENING TORQUE 35. . . . . . . . . . . . . . . . . .

Type 6 CYLINDERS
Cycle Four-stroke diesel engine
Power Supercharged with aftercooler
Injection Direct
Number of cylinders 6
∅
Bore mm 102
Stroke mm 120
+ + +.. = Total displacement cm3 5880
TIMING
start before T.D.C. A
end after B.D.C. B
18.5º
29.5º
start before B.D.C. D
end after T.D.C. C
67º
35º
X
Checking timing
mm
X
mm
Checking operation
mm
X
mm
-
-
0.20 to 0.30
0.45 to 0.55
FUEL FEED
Injection
Type: Bosch
high pressure common rail
EDC7 ECU
Nozzle type Injectors
Injection sequence 1 - 5 - 3 - 6 - 2 - 4
bar
Injection pressure bar 250 ÷ 1400

CLEARANCE DATA
Type 6 CYLINDERS
∅1
X
Cylinder barrels ∅1
∅1
102.01 to 102.03
0.5
∅1
X
∅ 2
Spare pistons
type:
Size X
Outside diameter ∅ 1
Pin housing ∅ 2
60.5
102.226 to 102.244
40.008 to 40.014
Piston diameter ∅ 1 0.5
X
Piston protrusion X
0.28 to 0.52
0.28 to 0.52
3∅ Piston pin ∅ 3 39.9938 to 40.0002
Piston pin — pin housing 0.0006 to 0.0202

Type 6 CYLINDERS
X
1
3
2
X
X
X1*
Split ring slots X 2
X 3
* measured on 99 mm ∅
2.705 to 2.735
2.420 to 2.440
4.020 to 4.040
1
3
2
S
S
S
S 1*
Split rings S 2
S 3
2.560 to 2.605
2.350 to 2.380
3.975 to 4.000
1
Split rings - slots 2
3
0.100 to 0.175
0.040 to 0.90
0.020 to 0.065
Split rings 0.5
X 1
3
2X
X
Split ring end opening
in cylinder barrel:
X 1
X 2
X 3
0.30 to 0.40
0.60 to 0.80
0.25 to 0.55
1∅
∅ 2
Small end bush
housing ∅ 1
Big end bearing
housing ∅ 2
42.987 to 43.013
72.987 to 73.013
∅
S
∅ 4
3 Small end bush diameter
Inside ∅ 3
Big end half-bearings
Supplied as spare parts S
40.019 to 40.033
1.955 to 1.968
Piston pin — bush 0.0188 to 0.0372
Big end half bearings 0.250; 0.500

Type 6 CYLINDERS
1 2∅∅
S 1 S 2
Journals ∅ 1
Crankpins ∅ 2
Main half bearings S 1
Big end half bearings S 2
*provided as spare part
82.99 to 83.01
68.987 to 69.013
2.456 to 2.464
1.955 to 1.968
3∅
Main bearings
No. 1—7 ∅ 3
No. 2—3—4—5—6 ∅ 3
87.982 to 88.008
87.977 to 88.013
Half bearings — Journals
No. 1—7
No. 2—3—4—5—6
0.044 to 0.106
0.039 to 0.111
Half bearings - Crankpins 0.038 to 0.116
Main half bearings
Big end half bearings
0.250; 0.500
1X
Shoulder journal X 1 37.475 to 37.545
X 2
Shoulder main bearing X 2 32.180 to 32.280
X 3
Shoulder half-rings X 3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.265

Type 6 CYLINDERS
∅ 1
Valve guide seats on
cylinder head ∅ 1 8.019 to 8.039
Valve guides -
∅
α
4 Valves:
∅ 4
α
∅ 4
α
6.970 to 6.999
60 ± 0.25°
6.970 to 6.999
45 ± 0.25°
Valve stem and guide 0.052 to 0.092
∅ 1
Housing on head for
valve seat:
∅1
∅1
34.837 to 34.863
34.837 to 34.863
α
2∅
Valve seat outside diameter;
valve seat angle on cylinder
head:
∅ 2
α
∅ 2
α
34.917 to 34.931
59.5°
34.917 to 34.931
44.5°
X
X
Sinking X
0.59 to 1.11
0.96 to 1.48
Between valve seat
and head
0.054 to 0.094
0.054 to 0.094
Valve seats -

Type 6 CYLINDERS
H H 1
H 2
Valve spring height:
free spring H
under a load equal to:
339.8 ± 9 N H1
741 ± 39 N H2
47.75
35.33
25.2
X
Injector protrusion X -
∅∅∅
1 2 3 4 5
Camshaft bush
housings No. 1
Camshaft housings
No. 2-3-4-5-6-7
59.222 to 59.248
54.089 to 54.139
∅
∅
∅1
2
3
Camshaft journals:
1 ⇒ 7 ∅ 53.995 to 54.045
∅
Bush inside
diameter ∅ 54.083 to 54.147
Bushes and journals 0.038 to 0.162
H
Cam lift:
H
H
6.045
7.582

Type 6 CYLINDERS
∅ 1
Tappet cap housing
on block ∅ 1 16.000 to 16.030
∅ 2
3
∅
∅
2
Tappet cap outside
diameter: ∅ 2
∅ 3
15.924 to 15.954
15.960 to 15.975
Between tappets and housings 0.025 to 0.070
Tappets -
∅ 1
Rocker shaft ∅ 1 21.965 to 21.977
∅ 2
Rockers ∅ 2 22.001 to 22.027
Between rockers and shaft 0.024 to 0.162

70159
70158
70160
74774
70162
Figure 1
Figure 2
Figure 3
Figure 4
The following instructions assume that the engine has
previously been placed on the rotating bench and that
removal of all specific components of the Iveco Motors
equipment have been already removed as well. (See Section
3 of the manual herein).
The section illustrates therefore all the most important engine
overhaul procedures.
Loosen the fixing screws (1) and remove the rod caps (2).
Withdraw the pistons including the connecting rods from the
top of the engine block.
Remove the screws (1) and the main bearing caps (2).
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
Use tool 99360500 (1) and hoist to remove the crankshaft (2)
from the block.
Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
Keep the half-bearings into their housings since in
case of use they shall be fitted in the same position
found at removal.
Take note of lower and upper half-bearing
assembling positions since in case of reuse they shall
be fitted in the same position found at removal.
Figure 5
ENGINE OVERHAUL
ENGINE REMOVAL AT THE BENCH
NOTE
NOTE

70163
70165
70164
70166
70167
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Remove the screws (1) and disconnect camshaft (3) retaining
plate (2).
Withdraw carefully the camshaft (1) from the engine block.
Withdraw the tappets (1) from the engine block.
Once engine is disassembled, clean accurately the
cylinder-block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free 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.
Measurements shall be performed on each cylinder, at three
different heights in the barrel and on two planes perpendicular
with each other: one parallel to the longitudinal axis of the
engine (A), and the other perpendicular (B). Maximum wear
is usually found on plane (B) in correspondence with the first
measurement.
Should ovalisation, taper or wear be found, bore and grind the
cylinder barrels. Cylinder barrel regrinding shall be performed
according to the spare piston diameter oversized by 0.5 mm
and to the specified assembling clearance.
Take note of plate (2) assembling position.
REPAIR OPERATIONS
CYLINDER UNIT
Checks and measurement
Should the ring gauge be not available, use a
micrometer for zero-setting.
s
NOTE
NOTE
zs

Figure 11
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them
in case of uncertain seal or if rusted.
In case of regrinding, all barrels shall have the same
oversize (0.5 mm).
Checking head supporting surface on cylinder
unit
α
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.
107267
NOTE

Figure 12
TIMING SYSTEM
Camshaft
70512
CAMSHAFT MAIN DATA (6 F4AE0685 engine cylinders)
Specified data refer to pin standard diameter
Camshaft pin and cam surfaces shall be absolutely smooth;
if they show any traces of seizing or scoring replace the
camshaft and the bushes.
70171
70172
Figure 13
Figure 14
Check camshaft (2) pin diameter using micrometer (1) on
two perpendicular axes.
The camshaft bushing (2) must be forced into its seat.
Internal surfaces must not show seizing or wear.
Using a bore gauge (3), measure the diameter of the bushing
(2) and of the intermediate seats (1) for the camshaft.
Measurements shall be performed on two perpendicular
axes.
BUSHES
Checking cam lift and pin alignment
Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.

Figure 15
Figure 16
MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS
*Height to be obtained after driving the bushes.
70174
Bush replacement
70175
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
Tappets
Figure 17
107268
sec. A-A
To change the bushing (1), use the drift 99360362 (2) and
grip 99370006 (3) for its disassembly and assembly.
Upon assembly, the bushing (1) must be directed
so that the lubrication holes coincide with the
holes in the seats in the crankcase.
NOTE

70176
70164
70238
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
Fitting tappets — camshaft
Figure 18
Figure 19
Figure 20
Figure 21
70179
70180
Check camshaft end float (1).
It shall be 0.23 ± 0.13 mm.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Figure 22

70182
Figure 23
Figure 24
Grind journals and crankpins if seizing, scoring or excessive
ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
It is recommended to insert the found values in the
proper table.
See Figure 24.
Undersize classes are:
Journals and crankpins shall always be ground to
the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M.
For undersized journals: letter B.
For undersized crankpins and journals: letters MB.
OUTPUT SHAFT
Measuring journals and crankpins NOTE
NOTE
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Measuring journals and crankpins (6 cyl.)
107269

Figure 25
MAIN OUTPUT SHAFT TOLERANCES
** ↗ 0.500 between adjacent main journals 70577
70237
MAIN BEARING ON TIMING
SYSTEM CONTROL SIDE
INTERMEDIATE MAIN
BEARINGS
FIRST MAIN BEARING
ON FRONT SIDE
Figure 26
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL
SHAPE
Roundness ○
SHAPE
Cilindricity /○/
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
OSCILLATION
Circular oscillation
OSCILLATION
Total oscillation

70184
70185
Figure 27
Figure 28
Figure 29
Figure 30
Refit the output shaft (2).
Check the backlash between crankshaf main journals and the
relevant bearings as follows:
Fitting main bearings
Do not try to adapt the bearings.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm
undersize on the internal diameter.
Clean accurately the main half bearings (1) having the
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
Check that gear toothing (1) is not damaged or worn,
otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180°C for 10 minutes
in an oven and then key it to the crankshaft.
Finding journal clearance
- clean accurately the parts and remove any trace of oil;
- position a piece of calibrated wire (3) on the crankshaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
supports.
70186
74774
Replacing oil pump control gear
NOTE
NOTE
75703
D1D2
D2 diameters:

This check is performed by setting a magnetic-base dial gauge
(2) on the crankshaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between crankshaft pins and main half bearings.
70188
70189
70190
70191
Figure 31
Figure 32
Figure 33
Figure 34
- 3rd stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90 ± 5° angle.
- Remove caps from supports.
The backlash between the main bearings and the pins is
found by comparing the width of the calibrated wire (2) at
the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
The numbers on the scale indicate the backlash in mm.
COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
α
Checking crankshaft shoulder clearance
Pistons are supplied spare with 0.5 mm oversize.
NOTE
Replace the half bearings and repeat the check if a different
backlash value is found. Once the specified backlash is
obtained, lubricate the main bearings and fit the supports by
tightening the fastening screws as previously described.
70187
Tighten the pre-lubricated screws (1) in the following three
successive stages:
- 1st stage, with torque wrench to 50 ± 6 Nm.
- 2nd stage, with torque wrench to 80 ± 6 Nm.
Figure 35

32615
32614
32613
70192
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
Remove split rings (1) from piston (2) using pliers 99360183
(3).
Piston pin (1) split rings (2) are removed using a scriber (3).
Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in thefigure.
The diameter shall be measured at 60.5 mm from
the piston skirt.
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS
* Value measured on 99 mm diameter
Pistons
Measuring piston diameter
NOTE
107270

32620
16552
32619
18857
Figure 41
Figure 42
Figure 43
To measure the piston pin (1) diameter use the micrometer
(2).
Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Piston pins Figure 44
Conditions for proper pin-piston coupling
Piston rings
41104
Figure 45
DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.

Figure 46
Figure 47
70194
Use feeler gauge (1) to measure the clearance between the
ends of the split rings (2) fitted into the cylinder barrel (3).
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
Connecting rods
* Value for inside diameter to be obtained after driving in
connecting rod small end and grinding.
** Value not measurable in released condition.
The surface of connecting rod and rod cap are
knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.
107271
NOTE
70196
Figure 48
*
CONNECTING ROD BODY
CONNECTING
ROD No.
WEIGHT
YEAR DAYCONN. ROD No.
CONNECTING ROD CAP
Every connecting rod is marked as follows:
- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore
necessary to mark the new connecting rod
with the same numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
S X, 1901 to 1940 (blue marking);
NOTE
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.

61696
61694
61695
70198
Figure 49
Figure 50
Figure 51
Figure 52
Check parallelism of conrod axes (1) by means of specific
tool (5) as follows:
- fit the connecting rod (1) on tool (5) spindle and lock it
with screw (4);
- set the spindle (3) on V-blocks by resting the connecting
rod (1) on the stop bar (2).
Check connecting rod (5) torsion by comparing two points
(A and B) of pin (3) on the horizontal plane of the connecting
rod axis.
Position the dial gauge (2) support (1) to obtain a preload of
approx. 0.5 mm on the pin (3) in point A and then set the
dial gauge (2) to zero. Move the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side (B) of the pin (3): the difference between A and
B shall not exceed 0.08 mm.
Check connecting rod (5) bending by comparing two points
C and D of the pin (3) on the vertical plane of the connecting
rod axis.
Position the vertical support (1) of the dial gauge (2) to rest
the latter on pin (3), point C.
Move the connecting rod forwards and backwards to find pin
top position, then in this condition reset the dial gauge (2).
Move the spindle with the connecting rod (5) and repeat the
check of the top point on the opposite side D of the pin (3).
The difference between point C and point D shall not exceed
0.08 mm.
Fitting connecting rod-piston assembly
Connecting rod-piston coupling
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Marking showing 1st slot insert testing;
4. Manufacturing date.
Checking connecting rods Checking bending
Checking torsion

72705
70199
32613
70200
70201
Figure 53
Figure 54
Figure 55
Figure 56
Figure 57
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.
Position the piston (1) on the connecting rod according to
the diagram shown in the figure, fit the pin (3) and stop it by
the split rings (2).
Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
Split rings shall be fitted with the marking “TOP” facing
upwards and their openings shall be displaced with each
other by 120°.
Fit half bearings (1) on connecting rod and cap.
Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
Use band 99360605 (2) to fit the connecting rod-piston
assembly (1) into the cylinder barrels and check thefollowing:
- the number of each connecting rod shall correspond to
the cap coupling number.
Split rings are supplied spare with the following
sizes:
- standard;
- 0.5 mm oversize, yellow/green marking;
Fitting connecting rod-piston assembly into
cylinder barrels
Do not try to adapt the half bearings.
Fitting split rings
NOTE
NOTE

107487
70203
70204
70205
70206
Figure 58
Figure 59
Figure 60
Figure 61
Figure 62
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120°;
- connecting rod-piston assemblies shall have the same
weight;
- the 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
To measure the clearance proceed as follows:
- clean the parts accurately and remove any trace of oil;
- set a piece of calibrated wire (2) on the output shaft pins
(1);
- fit the connecting rod caps (3) with the relevant half
bearings (4).
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the torque wrench
(2).
- Apply tool 99395216 (1) to the socket wrench and
tighten screws (2) of 60°.
- Remove the cap and find the existing clearance by
comparing the calibrated wire width (1) with the scale
on the wire envelope (2).
α
α
The M11 screws of the connecting rods cups, must
be replaced if the nominal diameter of the of the
threaded part that does not work, presents a
diameter of < 0,1 mm compared to the nominal
value.
NOTE

70207
70208
Figure 63
If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
Once connecting rod-piston assemblies refitting is over, use
dial gauge 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.
Protrusion shall be 0.28 to 0.52 mm.
Before the final fitting of the connecting rod cap
fastening screws, check that their diameter
measured at the centre of the thread length is not
< 0.1 mm than the diameter measured at approx.
10 mm from screw end.
Check manually that the connecting rods (1) are sliding
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.10 to 0.33 mm.
Checking piston protrusion
Figure 64
NOTE

70319
Figure 65
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch (→) of the exhaust valve (2) head
distinguishes it from the intake valve.
Should cylinder head valves be not replaced,
number them before removing in order to refit
them in the same position.
A = intake side — S = exhaust side
CYLINDER HEAD
Removing the valves
Valve removal shall be performed using tool 99360268 (1)
and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves (5).
70321
70322
Figure 66
Figure 67
Remove sealing rings (1 and 2) from the valve guide.
Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
NOTE
NOTE

70323
Figure 68
Figure 69
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90°C and 2
to 3 bar pressure.
Replace the core plugs (1) if leaks are found, use the proper
punch for their removal/refitting.
Replace the cylinder head if leaks are found.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.
Checking cylinder head wet seal
Before refitting, smear the plug surfaces with
water-repellent sealant.
Checking cylinder head supporting surface
70325
The rated thickness A for the cylinder head is 105 ± 0.25 mm,
max. metal removal shall not exceed thickness B by 1 mm.
After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified
value.NOTE
NOTE

18625
18882
70327
Figure 70
Figure 71
Figure 72
Figure 73
VALVES
INTAKE AND EXHAUST VALVE MAIN DATA
Remove carbon deposits from valves using the proper metal
brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, using tool 99305018 and
removing as less material as possible.
Check the valve stem (1) using a micrometer (2), it shall be
6.970 ± 6.990 mm.
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.052 ± 0.092 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
Removing carbon deposits, checking and
grinding valves Checking clearance between valve stem and
valve guide and valve centering
107280
INTAKE
VALVE
EXHAUST
VALVE

EXHAUST
70328
70330
Figure 74
Figure 75
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value
shown in the figure.
Check valve seats (2). In case slight burns or scratches are
found, regrind using specific tool (1) with inclination values
shown in Figure 76.
VALVE SEATS
Regrinding — replacing the valve seats
MAIN DATA ABOUT ENGINE VALVE SEATS
INTAKEEXHAUST
INTAKE
Figure 76
VALVE GUIDE
CYLINDER HEAD VALVE SEATS
107281
Valve seats are installed by cooling onto the cylinder head
and machining to the correct dimension.

70332
70331
Figure 77
Figure 78
If valve seats cannot be restored just by regrinding, it is
possible to assemble the spare inserts provided.
In this case, it is necessary to install seats into the cylinder
head sized as shown in the figure and to assemble the valve
seats.
VALVE SEAT MAIN DATA
In order to assemble the valve seats into the cylinder head,
it is necessary to heat the cylinder head to 80° to 100°C and,
through a suitable punch, to assemble the new, previously
cooled valve seats (2) into the head.
Therefore, use specific tool to regrind valve seats as per
values shown in Figure 78.
EXHAUST INTAKE
EXHAUSTINTAKE

50676
70334
770321
Figure 79
Figure 80
Figure 81
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS
Before refitting, check valve spring flexibility using a specific
tool. Compare load and elastic deformation data with those
of new springs shown in table below.
FITTING CYLINDER HEAD
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
VALVE SPRINGS
70333
Figure 82
After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).
NOTE
Height Under a load of
mm N
H 47.75 Free
H1 35.33 P1 339.8 ± 19 N
H2 25.2 P2 741 ± 39 N

Check cleanness of cylinder head and engine block coupling
surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking “TOP” (1)
facing the head.
The arrow shows the point where the gasket thickness is
given.
70335
Figure 83
Refitting the cylinder head
88775
Figure 84
There are two types of head seals for F4AE06..,engines, for
the thickness (1.25 mm Type A and 1.15 mm Type B) take
the following measures:
- for each piston detect, as indicated on Figure 84, 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 =
Scil1 + Scil2 + Scil3 + Scil4 + Scil5 + Scil6
6
Scil1 = S1 + S2
2
Repeat the operation for pistons 2, 3, 4, 5 and 6 and
calculate the average value.
If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.
75703
D1D2
D2 diameters:

TIGHTENING TORQUE
COMPONENT
TORQUE
COMPONENT
Nm kgm
Studs M6 for camshaft sensors 8 ± 2 0.8 ± 0.2
Studs M8 for feed pump 12 ± 2 1.2 ± 0.2
Screw M12 for fastening rear gear case
77 ± 12
47 ± 5
24 ± 4
7.7 ± 1.2
4.7 ± 0.5
2.4 ± 0.4
Nut M6 for fastening camshaft sensor 10 ± 2 1 ± 0.2
Screw M8 for fastening oil pump
1st stage
2nd stage
8 ± 1
24 ± 4
0.8 ± 0.1
2.4 ± 0.4
Screw M8 for fastening front cover 24 ± 4 2.4 ± 0.4
Screw M10 for fastening crankcase plate 43 ± 5 4.3 ± 0.4
Nut M18 for fastening high pressure pump gear 105 ± 5 10.5 ± 0.5
Nuts M8 for fastening fuel pump 24 ± 4 2.4 ± 0.4
½ inch plug on cylinder head
¼ inch plug on cylinder head
¾ inch plug on cylinder head
24 ± 4
36 ± 5
12 ± 2
2.4 ± 0.4
3.6 ± 0.5
1.2 ± 0.2
Screw M6 for fastening injectors
1st stage
d
8,5 ± 0,35 0.85 ± 0.035
Screw M6 for fastening injectors
1 stage
Nut fastening for injector feed connector 50 ± 5 5 ± 0.5
Nut M6 for flame start grille on intake manifold 8 ± 2 0.8 ± 0.2
Screw M8 for fastening intake manifold 24 ± 4 2.4 ± 0.4
Screw M12 for fastening rear brackets for engine lifting 77 ± 12 7.7 ± 1.2
Screws M8 for fastening Common Rail 24 ± 4 2.4 ± 0.4
Connectors M14 for high pressure fuel pipes 20 ± 2 2 ± 0.2
Screw M12 (12 x 1.75 x 130) for fastening cylinder head
1st stage} 35 ± 5 3.5 ± 0.5
Screw M12 (12 x 1.75 x 150) for fastening cylinder head
1st stage} 55 ± 5 5.5 ± 0.5
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 + ¾ 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 + ¾ 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 ± 06
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

COMPONENT
TORQUE
COMPONENT
Nm kgm
Screw M6 for fastening engine coolant drain connector 10 ± 2 1 ± 0.2
Pin fastening on engine block for exhaust manifold 10 ± 2 1 ± 0.2
Screw M10 for fastening exhaust manifold on cylinder head 53 ± 5 5.3 ± 0.5
Screw M12 for fastening damper adapter 1st stage 50 ± 5 5 ± 0.5Screw M12 for fastening damper adapter 1 stage
and damper on output shaft 2nd stage 90º
Screw M10 for fastening pulley on output shaft 68 ± 7 6.8 ± 0.7
Screw M8 for fastening water pump 24 ± 4 2.4 ± 0.4
Screw M10 for fastening auxiliary component control belt tensioners 43 ± 6 4.3 ± 0.6
Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 ± 6 4.3 ± 0.6
Screw M10 for fastening flywheel housing
Screw M12 for fastening flywheel housing
85 ± 10
49 ± 5
8.5 ± 1
4.9 ± 0.5
Screw M6 for fastening heat exchanger for control unit
Screw M8 for fastening heat exchanger for control unit
10 ± 2
24 ± 4
1 ± 0.2
2.4 ± 0.4
Connection M12 for fuel inlet-outlet on heat exchanger 12 ± 2 1.2 ± 0.2
Nut M8 for fastening valve cover 24 ± 4 2.4 ± 0.4
Screw M6 for fastening camshaft sensor 8 ± 2 0.8 ± 0.2
Screw M6 for fastening output shaft sensor 8 ± 2 0.8 ± 0.2
Screw M14 for fastening coolant temperature sensor 20 ± 3 2 ± 0.3
Screw M5 for fastening oil pressure/temperature sensor 6 ± 1 0.6 ± 0.1
Screw for fastening fuel pressure sensor 35 ± 5 3.5 ± 0.5
Screw M14 for fastening fuel temperature sensor 20 ± 3 2 ± 0.3
Screw for fastening air temperature/pressure sensor on intake manifold 6 ± 1 0.6 ± 0.1
Screw M12 for fastening engine oil level sensor 12 ± 2 1.2 ± 0.2
Turbine fixing to exhaust manifold {pins M10
nuts M10
7 ± 1
43 ± 6
0.7 ± 0.1
4.3 ± 0.6
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
d
30 ± 4 3 ± 0.4Screw M12 for fastening engine flywheel 1 stage
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
2nd stage
d
50 ± 6
80 ± 6
5 ± 0.6
8 ± 0.62 stage
Screw M101 for fastening connecting rod caps 1st stage 60 ± 5 6 ± 0.5Screw M101 for fastening connecting rod caps 1 stage
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

SECTION 5 - TOOLS 1F4AE NEF ENGINES
SECTION 5
Tools
Page
TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 5 - TOOLS F4AE NEF ENGINES

TOOLS
99317915 Set of 3 pin wrenches (14 - 17 - 19 mm)
99322205
Revolving stand for overhauling units (700 daN/m capacity, 120
daN/m torque)
99331043 Adapter from 38 pin to 30 pin (component of 99368554)
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
99360076 Tool to remove oil filter (engine)

TOOLS
99360183 Pliers for removing/refitting piston rings (65 to 110 mm)
99360268 Tool for removing/refitting engine valves
99360339 Tool for rotating/stopping the engine flywheel
99360351 Equipment for flywheel holding
99360362
Beater for removing/refitting camshaft bushes (to be used with
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 to 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99367121 Manual pump for pressure and depression measures
99368554
PT01 Hand-held tester for electronic controlled engine testing
(includes also 99331043 - 99368555 - 99368556)

TOOLS
99368555 Adapter from 30 to 19 pins (component of 99368554)
99368556
Adapter (5 m) for connecting PT01 tester to 30-pin test socket
(component of 99368554)
99370006 Handgrip for interchangeable beaters
99370415 Gauge base for different measurements (to be used with 99395603)
99389829 Dog type dynamometric wrench 9x12 (5 to 60 Nm)
99389834
Torque screwdriver for injector solenoid valve connector stop nut
setting

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

APPENDIX 1F4AE NEF ENGINES
Appendix
Page
SAFETY PRESCRIPTIONS 3. . . . . . . . . . . . . . . . . .
- Standard safety prescriptions 3. . . . . . . . . . . . . .
- Prevention of injury 3. . . . . . . . . . . . . . . . . . . . .
- During maintenance 3. . . . . . . . . . . . . . . . . . . . .
- Respect of the Environment 4. . . . . . . . . . . . . .

2 APPENDIX F4AE NEF ENGINES

Particular attention shall be drawn on some precautions that
must be followed absolutely in a standard working area and
whose non fulfillment will make any other measure useless
or not sufficient to ensure safety to the personnel in-charge
of maintenance.
Be informed and inform personnel as well of the laws in force
regulating safety, providing information documentation
available for consultation.
- Keep working areas as clean as possible, ensuring
adequate aeration.
- Ensure that working areas are provided with emergency
boxes, that must be clearly visible and always provided
with adequate sanitary equipment.
- Provide for adequate fire extinguishing means, properly
indicated and always having free access. Their efficiency
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities.
- Organize and displace specific exit points to evacuate
the areas in case of emergency, providing for adequate
indications of the emergency exit lines.
- Smoking in working areas subject to fire danger must be
strictly prohibited.
- Provide Warnings throughout adequate boards signaling
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of
emergency.
- Do not execute any intervention if not provided with
necessary instructions.
- Do not use any tool or equipment for any different
operation from the ones they’ve been designed and
provided for: serious injury may occur.
- In case of test or calibration operations requiring engine
running, ensure that the area is sufficiently aerated or
utilize specific vacuum equipment to eliminate exhaust
gas. Danger: poisoning and death.
SAFETY PRESCRIPTIONS
Standard safety prescriptions
Prevention of injury
- Do not wear unsuitable cloths for work, with fluttering
ends, nor jewels such as rings and chains when working
close to engines and equipment in motion.
- Wear safety gloves and goggles when performing the
following operations:
- filling inhibitors or anti-frost
- lubrication oil topping or replacement
- utilization of compressed air or liquids under pressure
(pressure allowed: ≤ 2 bar)
- Wear safety helmet when working close to hanging
loads or equipment working at head height level.
- Always wear safety shoes when and cloths adhering to
the body, better if provided with elastics at the ends.
- Use protection cream for hands.
- Change wet cloths as soon as possible
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry
out working operations if not trained for.
- Do not smoke nor light up flames close to batteries and
to any fuel material.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.
During maintenance
- Never open filler cap of cooling circuit when the engine
is hot. Operating pressure would provoke high
temperature with serious danger and risk of burn. Wait
unit the temperature decreases under 50ºC.
- Never top up an overheated engine with cooler and
utilize only appropriate liquids.
- Always operate when the engine is turned off: whether
particular circumstances require maintenance
intervention on running engine, be aware of all risks
involved with such operation.
- Be equipped with adequate and safe containers for
drainage operation of engine liquids and exhaust oil.
- Keep the engine clean from oil tangles, diesel fuel and or
chemical solvents.
- Use of solvents or detergents during maintenance may
originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Do not leave rags impregnated with flammable
substances close to the engine.
- Upon engine start after maintenance, undertake proper
preventing actions to stop air suction in case of runaway
speed rate.
- Do not utilize fast screw-tightening tools.
- Never disconnect batteries when the engine is running.
- Disconnect batteries before any intervention on the
electrical system.
- Disconnect batteries from system aboard to load them
with the battery loader.
- After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
from accidental short circuit and oxidation.
- Do not disconnect and connect electrical connections
in presence of electrical feed.
- Before proceeding with pipelines disassembly
(pneumatic, hydraulic, fuel pipes) verify presence ofliquid
or air under pressure. Take all necessary precautions
bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
injury and poisoning.
APPENDIX 3F4AE NEF ENGINES

- Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
personnel’s safety and health shall be adopted.
- Be informed and inform the personnel as well of laws in
force regulating use and exhaust of liquids and engine
exhaust oil. Provide for adequate board indications and
organize specific training courses to ensure that
personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Collect exhaust oils in adequate specially provided
containers with hermetic sealing ensuring that storage is
made in specific, properly identified areas that shall be
aerated, far from heat sources and not exposed to fire
danger.
- Handle the batteries with care, storing them in aerated
environment and within anti-acid containers. Warning:
battery exhalation represent serious danger of
intoxication and environment contamination.
Respect of the Environment- Avoid incorrect tightening or out of couple. Danger:
incorrect tightening may seriously damage engine’s
components, affecting engine’s duration.
- Avoid priming from fuel tanks made out of copper alloys
and/or with ducts not being provided with filters.
- Do not modify cable wires: their length shall not be
changed.
- Do not connect any user to the engine electrical
equipment unless specifically approved by Iveco Motors.
- Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any
unauthorized modification will compromise warranty
assistance and furthermore may affect engine correct
working and duration.
For engines equipped with electronic gearbox:
- Do not execute electric arc welding without having
priory removed electronic gearbox.
- Remove electronic gearbox in case of any intervention
requiring heating over 80ºC temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.
4 APPENDIX F4AE NEF ENGINES

Section
Main electrical power on the machine 1
Troubleshooting 2
Part 3
MAIN ELECTRICAL POWER ON THE
MACHINE AND TROUBLESHOOTING
Section 1 describes the electrical equipment as regards its
characteristics and its general operation in relation to the
engines described in the preceding parts.
Section 2 describes the fault diagnosis of the engines described
in the preceding parts, dedicated to technical support providers
who need straightforward guidelines in order to verify the
causes of the main failures.
Print P4D32N001GB Base - April 2007

Base - April 2007 Print P4D32N001GB

Example
α
Tighten to torque
1∅
∅ 2
SPECIAL REMARKS

Removal
Disconnection
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
Tighten to torque
Tolerance
Weight difference
α
Regulation
Adjustment
Angle
Angular value
Visual inspection
Preload
Measurement
Value to find
Check
Machine finish bar
Pressure
Interference
Strained assembly
Oversized
Higher than….
Maximum, peak
Thickness
Clearance
Undersized
Less than….
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 °C
Cold
Winter
Air bleeding
Temperature > 0 °C
Hot
Summer
Replacement

UPDATING

SECTION 1 - MAIN ELECTRICAL POWER ON THE MACHINE 1NEF POWER GENERATION ENGINES
SECTION 1
Main electrical power on the machine
Page
GENERATOR SET COMPONENTS LAYOUT 5.
- GENEF - MECHANIC PUMP 5. . . . . . . . . . . . .
- GENEF - COMMON RAIL 6. . . . . . . . . . . . . . .
LOCATION OF COMPONENTS ON ENGINE 7
POWER NETWORK 9. . . . . . . . . . . . . . . . . . . . .
ASSEMBLY DRAWING OF INJECTION SYSTEM AND
CONTROL PANEL INTERFACE GENEF -
COMMON RAIL. 11. . . . . . . . . . . . . . . . . . . . . .
- Key 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electric wiring GENEF - COMMON RAIL 13. . .
- Connectors GENEF - COMMON RAIL 14. . . . .
GENERATOR SET WIRING DIAGRAMS 15. . . . .
- Generator set with manual column panel PGM1
for 230Vac applications
GENEF - MECHANIC PUMP 15. . . . . . . . . . . . .
- Generator set with PG804 automatic panel
- Generator set with Compact Mage manual panel
- Generator set with Compact Mage automatic panel
- Key to components on engine side 19. . . . . . . . .
- Key to control panel components 19. . . . . . . . . .
- Wiring diagram for 12Vdc applications
GENEF - COMMON RAIL 20. . . . . . . . . . . . . . .

2 SECTION 1 - MAIN ELECTRICAL POWER ON THE MACHINE NEF POWER GENERATION ENGINES
Page
- Key to components 21. . . . . . . . . . . . . . . . . . . . .
- Function symbols for the control panel 21. . . . . .
with manual control panel PGM1 GENEF -
COMMON RAIL 22. . . . . . . . . . . . . . . . . . . . . . .
- PGM1 control panel components 23. . . . . . . . . .
- Components on engine 23. . . . . . . . . . . . . . . . . .
with automatic control panel PGM1 GENEF -
COMMON RAIL 24
- Components of automatic control panel PG804 25
with manual control panel Compact Mage
- Components of manual control panel
Compact Mage 27. . . . . . . . . . . . . . . . . . . . . . . .
with Compact Mage automatic control panel
- Components of automatic control panel
Compact Mage 29. . . . . . . . . . . . . . . . . . . . . . . .
- Key to components 31. . . . . . . . . . . . . . . . . . . . .
- Function symbols for the control panel 31. . . . . .
with manual control panel PGM1 GENEF -
COMMON RAIL 32. . . . . . . . . . . . . . . . . . . . . . .
- PGM1 control panel components 33. . . . . . . . . .
with automatic control panel PG804 GENEF -
COMMON RAIL 34. . . . . . . . . . . . . . . . . . . . . . .
Page
- Components of automatic control panel PG804 35
with manual control panel Compact Mage
- Components of manual control panel
Compact Mage 37. . . . . . . . . . . . . . . . . . . . . . . .
with Compact Mage automatic control panel
- Components of automatic control panel
Compact Mage 39. . . . . . . . . . . . . . . . . . . . . . . .
LINE DIAGRAMS 40. . . . . . . . . . . . . . . . . . . . . . . .
- Wiring of engine for generator set
- Wiring from interface box to engine for 12/24Vdc
applications GENE - COMMON RAIL - One line dia-
gram 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Wiring from interface box to engine for 12/24Vdc
applications GENEF - COMMON RAIL - Multi-line
diagram 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Wiring from control panel to interface box for
12/24Vdc application GENEF -
COMMON RAIL 43. . . . . . . . . . . . . . . . . . . . . . .
- Engine wiring for generator set without interface
box with 12/24Vdc application GENEF200E 44. .
- Engine wiring for generator set without interface
box with 24Vdc application GENEF -
COMMON RAIL 45. . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL - ENGINE INTERFACE BOX
(12V/24V) 46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERNAL CONNECTORS TO ENGINE INTERFACE
BOX 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EDC SYSTEM 50. . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM ON ENGINE SIDE 51. . . . . .

Page
EDC CONTROL UNIT 52. . . . . . . . . . . . . . . . . . . .
INJECTION CONTROL 52. . . . . . . . . . . . . . . . . . .
- Electroinjector connector (A) 53. . . . . . . . . . . . .
- EDC engine control unit connector (B) 54. . . . .
- Sensor connector ( C)Connettore sensori (C) 55
- Engine speed sensor 56. . . . . . . . . . . . . . . . . . . .
- Pulse sensor on timing system 56. . . . . . . . . . . . .
- Electro-injectors 56. . . . . . . . . . . . . . . . . . . . . . . .
- Oil pressure / oil temperature sensor 57. . . . . . .
- Fuel temperature sensor 57. . . . . . . . . . . . . . . . .
- Coolant temperature sensor 57. . . . . . . . . . . . . .
- Turbocharging air temperature
and pressure sensor 58. . . . . . . . . . . . . . . . . . . . .
- Fuel pressure sensor 58. . . . . . . . . . . . . . . . . . . .
- Solenoid valve for fuel pressure regulator 58. . . .
SENSORS FOR INSTRUMENTS ON AUTOMATIC/
MANUAL PANEL 59. . . . . . . . . . . . . . . . . . . . . .
- High water temperature transmitter sensor
(TATA) 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Oil pressure transmitter (TPO) 60. . . . . . . . . . . .
- Water temperature transmitter (TTA) 61. . . . . .
- Oil pressure switch (TBPO) 62. . . . . . . . . . . . . . .
- Multistate Switch (M.S.S.) supplied by Iveco
(Applications with no interface box) 63. . . . . . . .
- Power switch 63. . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL COMPONET LAYOUT
(6 CYL. ENGINES WITH ROTARY PUMP)
GENEF 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Cooling liquid temperature sensor 65. . . . . . . . . .
- Starter 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Injection pump water temperature sensor 65. . . .
- Oil pressure sensor 66. . . . . . . . . . . . . . . . . . . . .
- Alternator 66. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1
GENERATOR SET GENEF - MECHANIC PUMP
1. Three-phase generator - 2. Control board - 3. Battery - 4. Engine - 5. Heat exchanger - 6. Support frame - 7. Fuel tank -
8. Air intake and filter.
GENERATOR SET COMPONENTS LAYOUT
GENEF - MECHANIC PUMP
119649

Figure 2
GENERATOR SET GENEF - COMMON RAIL
1. Three-phase generator - 2. Control panel - 3. Alternator - 4. Control panel/engine interface box -
5. Starter motor - 6. Fuel tank - 7. Battery.
GENEF - COMMON RAIL
107432

Figure 3
LOCATION OF COMPONENTS ON ENGINE
1. High engine water temperature and engine water temperature transmitter - 2. Low fuel level transmitter - 3. Low engine
water level transmitter - 4. Water temperature sensor for KSB - 5. KSB control - 6. Stop solenoid valve - 7. Low engine oil
pressure transmitter - 8. Engine oil pressure transmitter.
107761

Figure 4
1. Diesel heating element - 2. Water in the fuel filter transmitter - 3. Low engine oil pressure transmitter - 4. Oil pressure
transmitter - 5. EDC electronic control unit 7 - 6. High engine water temperature transmitter - 7. Engine water temperature
transmitter - 8. Low engine water level transmitter - 9. Low fuel level transmitter and no fuel transmitter.
GENEF - COMMON RAIL
107433

Figure 5
MAIN COMPONENTS OF THE POWER NETWORK
1. Three-phase generator - 2. Starter motor - 3. Battery - 4. Control panel.
POWER NETWORK
107506

Figure 6
MAIN COMPONENTS OF THE POWER NETWORK
1. Battery 12VDC - 2. Interface box - 3. Starter motor - 4. Alternator - 5. Positive cable from battery to starter motor -
6. Positive cable from starter motor to alternator - 7. Negative cable from battery to starter motor - 8. Interface box
earthing point - 9. Three-phase generator/support earthing point.
GENEF - COMMON RAIL
107436

119625
Figure 7
ASSEMBLY DRAWING OF INJECTION SYSTEM AND CONTROL PANEL INTERFACE GENEF
- COMMON RAIL
AUTOMATIC /
MANUAL PANEL
INTERFACE
BOARD

Key
REF. DESCRIPTION
1 Coolant temperature sensor
2 Pre-heating element (starter heater)
3 Electro-injectors
4 Air temperature/pressure sensor
5 Fuel pressure sensor
6 Fuel heating element
7 Pressure regulator solenoid valve
8 Timing sensor
9 Fuel temperature sensor
10 Starter motor
11 Crankshaft sensor
12 Water in the fuel filter transmitter (TPAC)
13 Oil temperature/pressure sensor
14 Preheating electromagnetic switch
15 Blink-Code indicator light (AUTOMATIC/MANUAL panel)
16 Multistate switch (engine speed selection)
17 Blink-Code push-button
18 Diagnosis connector
19 Sensors for instruments on AUTOMATIC/MANUAL panel
TBLA Low water level transmitter (AUTOMATIC/MANUAL panel)
TBPO Low oil pressure transmitter (AUTOMATIC/MANUAL panel)
TATA High water temperature transmitter (AUTOMATIC/MANUAL panel)
TPO Oil pressure transmitter (AUTOMATIC/MANUAL panel)
TTA Water temperature transmitter (AUTOMATIC/MANUAL panel)
TBLC Low fuel level transmitter (AUTOMATIC/MANUAL panel)
TCE No fuel transmitter (AUTOMATIC/MANUAL panel)
TS Water heater thermostat

Figure 8
ELECTRIC WIRING
1. Wiring from EDC control unit to injectors - 2. Wiring from EDC control unit to EDC system components -
3. Wiring from EDC control unit to interface box - 4. Wiring from interface box for power connection - 5. Wiring from
interface board to control board.
Electric wiring GENEF - COMMON RAIL
119650

Figure 9
CONNECTORS
1. EDC control unit connector (B) - 2. Connector (J1) for power connection -
3. Connector (J2) between interface box and engine wiring - 4. Connector from interface box to control board
(Connectors J3, J7 e J9 inside the interface board) - 5. Connector for diagnostic tool.
Connectors GENEF - COMMON RAIL
119651

Figure 10
GENERATOR SET WIRING DIAGRAMS
Generator set with manual column panel PGM1 for 230Vac applications
107799

Figure 11
Generator set with PG804 automatic panel
107800

Figure 12
Generator set with Compact Mage manual panel
107801

Figure 13
Generator set with Compact Mage automatic panel
107802

Key to components on engine side
BAT Starter battery 12V
M Starter motor
G Battery charger alternator
TBLA Low engine water level transmitter
TPO Engine oil pressure switch
TBPO Low engine oil level pressure switch
TTA Engine water temperature transmitter
TBLC Float for fuel level
TS Engine water heater thermostat
TATA High engine water temperature thermostat
EC Stop solenoid valve
KSB Advance regulator
Key to control panel components
CONTROL PANEL PG804 CONTROL PANEL PGM1
B
CB
F1-8
F9-10
T1-2-3
J1
J2
JL
JM
JV
K1
K2
KS
PE
R1
SE
XU
BA
QG
Buzzer
Battery charger
Disconnectable fuses 230 Vac
Fuses 12 - 24 Vdc
Amperometric transformers
Switch connector
Switch connector
Engine connector
Engine connector
Voltage selection connector
Stop relay
Start relay
Water heater cut-in relay
Emergency button
Current limiting resistor TBPO
Safety selector
User terminal block
Switch coil
Switch
CDA
F1
F2
F3
F4
T1-2-3
H1
JL
JM
K1
P1
P2
P3
P4
P5
P6
P7
P8
PE
S1
BA
QG
Starter switch
2 A fuse
2 A fuse
2 A fuse
20 A delayed fuse
Electronic siren 12 - 24 Vdc
Engine connector
Engine connector
Contactor
Ammeter
Ammeter
Ammeter
Voltmeter
Frequency meter
Hour meter
Engine oil pressure gauge
Engine water temperature thermometer
Emergency stop button
Ammeter three-way switch
Switch coil
Switch
MANUAL CMAGE CONTROL PANEL AUTOMATIC CMAGE CONTROL PANEL
H1
F1-F2
T1-T2-T3
J1
J2
JL
JM
JV
K1
K2
S1
S2
XU
D1
R1
BA
QG
Buzzer
Switch connector
Switch connector
Engine connector
Engine connector
Start relay
Emergency button
Panel ignition selector
User terminal block
Diode to signal battery charging
Resistor to signal battery charging
Switch coil
Switch
H1
F1-F2
T1-T2-T3
J1
J2
JL
JM
JV
JF
K1
K2
S1
S2
XU
D1
R1
BA
QG
Buzzer
Switch connector
Switch connector
Engine connector
Engine connector
Fuel pump connector
Start relay
Emergency button
Panel ignition selector
User terminal block
Diode to signal battery charging
Resistor to signal battery charging
Switch coil
Switch

Figure 14
Wiring diagram for 12Vdc applications
GENEF - COMMON RAIL
107325

Key to components
M Starter motor
RFC Fuel filter heating resistor
TPAC Water in the fuel filter transmitter
TCE No fuel transmitter (option)
EDC Engine electronic control unit
SI Control panel - engine interface box
Function symbols for the control panel
ENGINE WATER TEMPERATURE THERMOMETER
LOW ENGINE OIL PRESSURE VISUAL WARNING
ENGINE OIL PRESSURE GAUGE
STARTING THE ENGINE (+50)
NO BATTERY CHARGING VISUAL WARNING
LOW ENGINE WATER LEVEL VISUAL WARNING
CAPTIVE KEY POSITIVE (+15)
WATER IN THE FUEL FILTER VISUAL WARNING
HIGH ENGINE WATER TEMPERATURE VISUAL WARNING
CAN LINE
CONTROL PANEL POWER SUPPLY
ENGINE PRE-HEATING
FUEL LEVEL VISUAL WARNING
NO FUEL VISUAL WARNING (OPTION)

Figure 15
with manual control panel PGM1 GENEF - COMMON RAIL
107325

PGM1 control panel components
CDA Ignition switch
F1 Fuse - 2 A
F2 Fuse - 2 A
F3 Fuse - 2 A
F4 20 A delayed fuse
T1-T2-T3 Amperometric transformers
H1 Electronic siren 12 - 24 Vdc
JL Engine connector
JM Engine connector
K1 Contactor
P1 Ammeter
P2 Ammeter
P3 Ammeter
P4 Voltmeter
P5 Frequency meter
P6 Hour meter
P7 Engine oil pressure gauge
P8 Engine water temperature thermometer
PE Emergency stop button
S1 Ammeter three-way switch
BA Switch coil
QG Switch
Components on engine
M Starter motor
RFC Fuel filter heating element

Figure 16
with automatic control panel PGM1 GENEF - COMMON RAIL
107327

Components of automatic control panel PG804
B Buzzer
CB Battery charger
F1-8 Disconnectable fuses 230 Vac
F9-10 Fuses 12 - 24 Vdc
T1-2-3 Amperometric transformers
J1 Switch connector
J2 Switch connector
JL Engine connector
JM Engine connector
JV Voltage selection connector
K1 Stop relay
K2 Start relay
KS Water heater cut-in relay
PE Emergency button
R1 Current limiting resistor TBPO
SE Safety selector
XU User terminal block
BA Switch coil
QG Switch
M Starter motor

Figure 17
with manual control panel Compact Mage GENEF - COMMON RAIL
107328

Components of manual control panel Compact Mage
H1 Buzzer
F1-F2 Disconnectable fuses 230 Vac
J1 Switch connector
J2 Switch connector
JL Engine connector
JM Engine connector
K1 Start relay
K2 Water heater cut-in relay
S1 Emergency button
S2 Panel ignition selector
D1 Diode to signal battery charging
R1 Resistor to signal battery charging
BA Switch coil
QG Switch
M Starter motor

Figure 18
with Compact Mage automatic control panel GENEF - COMMON RAIL
107329

Components of automatic control panel Compact Mage
H1 Buzzer
J1 Switch connector
J2 Switch connector
JL Engine connector
JM Engine connector
JF Fuel pump connector
K1 Start relay
S1 Emergency button
BA Switch coil
QG Switch
M Starter motor

Figure 19
Wiring diagram for 24Vdc applications GENEF - COMMON RAIL
107331

Key to components
M Starter motor
RFC Fuel filter heating resistor
Function symbols for the control panel
ENGINE WATER TEMPERATURE THERMOMETER
LOW ENGINE OIL PRESSURE VISUAL WARNING
ENGINE OIL PRESSURE GAUGE
STARTING THE ENGINE (+50)
NO BATTERY CHARGING VISUAL WARNING
LOW ENGINE WATER LEVEL VISUAL WARNING
CAPTIVE KEY POSITIVE (+15)
WATER IN THE FUEL FILTER VISUAL WARNING
HIGH ENGINE WATER TEMPERATURE VISUAL WARNING
CAN LINE
CONTROL PANEL POWER SUPPLY
ENGINE PRE-HEATING
FUEL LEVEL VISUAL WARNING
NO FUEL VISUAL WARNING (OPTION)

Figure 20
with manual control panel PGM1 GENEF - COMMON RAIL
107332

PGM1 control panel components
CDA Ignition switch
F1 Fuse - 2 A
F2 Fuse - 2 A
F3 Fuse - 2 A
F4 20 A delayed fuse
H1 Electronic siren 12 - 24 Vdc
JL Engine connector
JM Engine connector
K1 Contactor
P1 Ammeter
P2 Ammeter
P3 Ammeter
P4 Voltmeter
P5 Frequency meter
P6 Hour meter
P7 Engine oil pressure gauge
P8 Engine water temperature thermometer
PE Emergency stop button
S1 Ammeter three-way switch
BA Switch coil
QG Switch
M Starter motor

Figure 21
with automatic control panel PG804 GENEF - COMMON RAIL
107333

Components of automatic control panel PG804
B Buzzer
CB Battery charger
F1-8 Disconnectable fuses 230 Vac
F9-10 Fuses 12 - 24 Vdc
T1-2-3 Amperometric transformers
J1 Switch connector
J2 Switch connector
JL Engine connector
JM Engine connector
K1 Stop relay
K2 Start relay
KS Water heater cut-in relay
PE Emergency button
R1 Current limiting resistor TBPO
SE Safety selector
BA Switch coil
QG Switch
M Starter motor

Figure 22
with manual control panel Compact Mage GENEF - COMMON RAIL
107334

Components of manual control panel Compact Mage
H1 Buzzer
J1 Switch connector
J2 Switch connector
JL Engine connector
JM Engine connector
K1 Start relay
S1 Emergency button
BA Switch coil
QG Switch
M Starter motor

Figure 23
with Compact Mage automatic control panel GENEF - COMMON RAIL
107335

Components of automatic control panel Compact Mage
H1 Buzzer
J1 Switch connector
J2 Switch connector
JL Engine connector
JM Engine connector
JF Fuel pump connector
K1 Start relay
S1 Emergency button
BA Switch coil
QG Switch
M Starter motor

Figure 24
LINE DIAGRAMS
Wiring of engine for generator set GENEF - MECHANIC PUMP
107803
Figure 25
107849
LIST OF COMPONENTS
B+/D+. Alternator - TBLA. Low radiator water level transmitter - -31/+30/50. Starter motor -
JM/JL. Control panel connectors - TTA. Engine water temperature transmitter - EC. Stop solenoid valve - TBPO. Low
engine oil pressure transmitter - TPO. Engine oil pressure transmitter - TS. Heater transmitter - TATA. High engine water
temperature transmitter - TBLC. Low fuel level transmitter.

Figure 26
Wiring from interface box to engine for 12/24Vdc applications GENEF - COMMON RAIL - One line
diagram
107322
LIST OF COMPONENTS
BATT. Battery - +30/-31/50. Starter motor - B+/GG. Alternator - TBLA. Low engine water level transmitter - TS. Heater
thermostat - TATA. High engine water temperature transmitter - TTA. Engine water temperature transmitter - EDC. Engine
electronic control unit - TBPO. Low engine oil pressure transmitter -
TPO. engine oil pressure transmitter - TPAC. Water in the fuel filter transmitter - RFC. Fuel filter heating element - TBLC.
Low fuel level transmitter - J1/J2. Interface box connectors.

Figure 27
Wiring from interface box to engine for 12/24Vdc applications GENEF - COMMON RAIL - Multi-
line diagram
107321

Figure 28
Wiring from control panel to interface box for 12/24Vdc application GENEF - COMMON RAIL
107323
LIST OF COMPONENTS
JM/JL. Control panel connectors - JB1/JB2. Connectors from control panel to CAN line - JC. Connector inside the control
panel for CAN line - J3/J7. Connectors for interface box - P1/P2. Bulkhead connector.

Figure 29
Engine wiring for generator set without interface box with 12/24Vdc application GENEF - COM-
MON RAIL
107324
LIST OF COMPONENTS
electronic control unit - TBPO. Low engine oil pressure transmitter -
TPO. engine oil pressure transmitter - TPAC. Water in the fuel filter transmitter - RFC. Fuel filter heating element - TBLC.
Low fuel level transmitter - TCE. No fuel transmitter (option) - K6. Contactor for heater - J2. Instrument panel/control panel
connector - J3A/J3B/J7. Services panel/control panel connectors - J5. Test connector/control panel connector - J6.
Connector for CAN line - J15. Connector for pre-heating indicator light (prearrangement).

Figure 30
Engine wiring for generator set without interface box with 24Vdc application GENEF - COMMON
RAIL
107330
LIST OF COMPONENTS
electronic control unit - TBPO. Low engine oil pressure transmitter - TPO. Engine oil pressure transmitter - TPAC. Water in
the fuel filter transmitter - RFC. Fuel filter heating element - TBLC. Low fuel level transmitter - TCE. No fuel transmitter
(option) - K6. Contactor for heater - J5. Test connector/control panel connector.

Figure 31
CONTROL PANEL - ENGINE INTERFACE BOX (12V/24V)
107437
LIST OF COMPONENTS
K1. Power relay with key inserted (+15) - K2. Starting phase signal relay - K3. Starting relay - K4. Relay to cut in fuel filter
heating element - JP1. Jumper to select frequency (jumper on 1-2= 50Hz - jumper on 2-3= 60Hz) - JP2. Jumper to select
operating mode (jumper on 1-2= diagnosis - jumper on 2-3= standard operation) - JP3. Jumper to select cold start signal
connection (1-2= connected - 2-3= disconnected) - JP4. Jumper to select heat. function for cold starting (1-2= connected -
2-3= disconnected) - JP5. Jumper for CAN line presence selection (1-2 = CAN line connected - 2-3 = CAN line not
connected) - JP6. Not used - JP8. Not used - BP1. Switch for blink-code signal request - LD1. LED signalling blink/code -
F1. 10A fuse for starting engine - F2. 3A fuse for diagnostics - F3. 20A fuse for fuel filter heating element - F4. 30A fuse for
electronic control unit - F5. 10A fuse for control panel - F6. 5A fuse for cut-in +15 ON ECU - F7. Not used - F8. Not used
- F9. Not used - J1. Connector for power connections - J2. Connector for interface with engine control unit - J3. Connector
for interface with control panel - J7. Connector for interface with control panel - J9. Connector for interface with control
panel.

Figure 32
INTERNAL CONNECTORS TO ENGINE INTERFACE BOX
107437
CONNECTOR J1 on engine interface box - control panel for power supplies
1 To terminal 50 of the starter motor
2 Supply from F3 for fuel filter heating resistance
3 Battery negative
4 Battery positive
5 To connector GG (pin a) of the alternator
6 Free -
107438
107439

CONNECTOR J2 on engine interface box - control panel for EDC electronic control unit connections
1 Key positive (+15) to supply EDC electronic control unit (pin 39)
2 Positive from keyswitch (+50) for engine starting phase in EDC control unit (pin 20)
3 Signal from low engine oil pressure switch for visual warning on panel (to connector J3 pin 3)
4 Signal from engine water temp. transmitter for thermometer on panel (to connector J3 pin 2)
5 Signal from high engine water temp. thermostat for visual warning on panel (to connector J7 pin 1)
6 Signal from no fuel transmitter (optional) (to connector J7 pin 8)
7 Signal from fuel level float for visual warning on panel (to connector J7 pin 7)
8 Positive for water in fuel filter transmitter
9 Sign. from water in fuel filter transm. for visual warning on panel (to connector J3 pin 10)
10 Negative for water in fuel filter transmitter
11 Negative for starting relay and diesel heating relay from EDC control unit (pin 2)
12 Positive for starting relay from EDC control unit (pin 37)
13 Battery positive to power EDC control unit (pin 1)
14 Battery positive to power EDC control unit (pin 12)
15 Free
16 Free
17 Positive for low engine water level transmitter
18 Signal from low engine water level transm. for visual warning on panel (to connector J3 pin 8)
19 Negative for low engine water level transmitter
20 From D+ alternator for visual warning no battery charging on panel (to connector J3 pin 7)
21 Engine water temperature signal from EDC control unit (pin 6). Available from connector J9 pin 7
22 Negative from EDC control unit (pin 64) for visual indicator ”BLINK-CODE”
23 Positive from EDC control unit (pin 28) for visual indicator ”BLINK-CODE”
24 Alarm signal for low engine oil pressure from electronic control unit (pin 63)
25 From resistor module to EDC control unit (pin 32)
26 To the diagnosis connector (line L - pin A) from EDC control unit (pin 30)
27 To the diagnosis connector (line K - pin B) from EDC control unit (pin 31)
28 To the diagnosis connector (engine timing signal - pin F) from EDC control unit (pin 48)
25829 Positive from Blink-code request button to EDC control unit (pin 27)
30 Free
31 Signal from engine oil pressure switch for pressure gauge on panel (to connector J3 pin 4)
32 Signal from engine water heater thermostat (to connector J7pin 6)
33 Negative for no fuel transmitter (opt), for fuel level float and
heater thermostat and low engine oil level signal pressure switch
34 Free
35 Free - jumpered with pin 6 of connector J9
36 Free
37 Free
39 Free
40 Positive for diesel heating relay from EDC control unit (pin 36)
41 Battery positive for EDC control unit (pin 7)
42 Battery positive for EDC control unit (pin 13)
43 Free
44 Free
46 Positive for cold start signal from EDC (pin 8) (opt)
47 Connected with EDC (pin 60)
48 Negative for pre-heating visual signal from EDC electronic control unit (pin 46)
49 Positive for pre-heating cut-in relay from EDC control unit (pin 4)
50 Negative for pre-heating cut-in relay from EDC control unit (pin 16)
51 Alarm signal for high engine water temperature from EDC control unit (pin 65)
52 Engine oil pressure signal from EDC control unit (pin 66)
53 Common resistance module for EDC control unit frequency selection (pin 87)
54 To the diagnosis connector (engine speed signal - pin E) from EDC control unit (pin 49)
55 To the diagnosis connector (CAN line L - pin D) from EDC control unit (pin 52)
56 To the diagnosis connector (CAN line H - pin C) from EDC control unit (pin 53)
NOTE Pins 3 - 9 - 14 - 15 of the EDC control unit are connected to the battery negative

CONNECTOR J3 inside the engine interface box for signals to control panel
1 Free
2 From the engine water temperature transmitter for signal to thermometer on control panel
3 From the low engine oil pressure switch for visual warning on control panel
4 From engine oil pressure switch for signal to pressure gauge on control panel
5 Free
6 Ignition control
7 From the alternator for battery charging visual indicator on control panel
8 From the low engine water level transmitter for visual warning on control panel
9 To the control panel for stop control
10 From the water in fuel filter transmitter for visual warning on control panel
11 Free
12 Free
CONNECTOR J7 inside the engine interface box for signals to control panel
1 From the engine coolant high temp. thermostat (connector J2 - pin5) for visual signal on control panel
2 CAN line L to the control panel
3 Positive to power control panel
4 Negative to power control panel
5 CAN line H to the control panel
6 From the engine water heater thermostat (connector J2 - pin32) to the control panel
7 From the fuel level transmitter (connector J2 - pin7) for visual warning on control panel
8 From the no fuel transmitter (opt) (connector J2 - pin6)
CONNECTOR J9 inside the engine interface box
1 Cold start signal (option) if jumper JP3 set on 1-2
2 Cold start signal (option) if jumper JP3 set on 1-2
3 Cold start heater relay (option) if jumper JP4 set on 1-2
4 Cold start heater relay (option) if jumper JP4 set on 1-2
5 Free
6 Free
7 Coolant temperature check from ECU
8 Low oil pressure signal from ECU
9 Coolant temperature signal from ECU
10 Oil pressure check from ECU

Figure 33
EDC SYSTEM
1. Coolant temperature sensor - 2. Electro-injector - 3. RAIL pressure sensor -
4. Air temperature/pressure sensor - 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.
107469

Figure 34
WIRING DIAGRAM ON ENGINE SIDE
107851
1. Connection for cylinders 1 and 2 - 2. Connection for cylinders 3 and 4 - 3. Connection for cylinders 5 and 6 -
4. Engine speed sensor - 5. Pulse sensor on timing system - 6. Engine oil temperature and pressure sensor - 7. Diesel
temperature sensor - 8. Engine water temperature sensor - 9. Turbocharging air temperature and pressure sensor - 10. Fuel
pressure sensor (rail) - 11. Solenoid valve for fuel pressure regulator - 12. EDC electronic control unit.
107441
Figure 35

35
89 72
53 18 36 17
54 6 1171
1
7
12
1612
6
1 5
11
Figure 36
EDC CONTROL UNIT
It is fitted straight onto the engine via a heat exchanger to cool it, using rubber-type blocks that reduce the vibration transmitted
by the engine.
INJECTION CONTROL
Depending on the information from the sensors, the control unit governs the pressure regulator and varies pre-injection and
the main injection. On Nef engines, pre-injection is active at any engine speed.
50351
Electro-injector connector ”A”
102374
102376
Sensor connector ”C”
Connector ”B”
6 8 16 9 15 22
36 29302331
4
5
102375
AC
B

1612
6
1 5
11
Figure 37
102374
Colours
B WHITE V GREEN
R RED N BLACK
L BLUE A AZURE
H GREY W HAZEL
M BROWN S PINK
G YELLOW
C ORANGE
Electro-injector connector ”A”
PIN CABLE COLOUR FUNCTION
1 - -
2 - -
3 MN Cylinder injector 2
4 MV Cylinder injector 3
5 VB Cylinder injector 4
6 HR Cylinder injector 2
7 - -
8 - -
9 MB Cylinder injector 1
10 VN Cylinder injector 6
11 VG Cylinder injector 5
12 HN Cylinder injector 3
13 HG Cylinder injector 1
14 CN Cylinder injector 4
15 CB Cylinder injector 6
16 CL Cylinder injector 5

Figure 38
Connector (B) engine control EDC electronic control unit
102376
PIN-OUT
1 Al J2 pin 13 of the interface box - Battery positive
2 To J2 pin 11 of the interface box - Negative for starting relay and diesel heating relay
3 Battery negative
4 To J2 pin 49 of the interface box - Positive for pre-heating cut-in relay
5 Free
6 To J2 pin 21 of the interface box - Engine water temperature signal
7 To J2 pin 41 of the interface box - Battery positive
8 To J2 pin 46 of the interface box - Key positive (+15)
9 Battery negative
10-11 Free
14 Battery negative
15 Battery negative
16 To J2 pin 50 of the interface box - Negative for pre-heating cut-in relay
17-19 Free
20 To J2 pin 2 of the interface box - Positive from key switch (+50) for starting phase
engine
21-26 Free
27 To J2 pin 29 of the interface box - Positive from Blink-code request button
28 To J2 pin 23 of the interface box - Positive for visual indicator ”BLINK-CODE”
29 Free
30 To J2 pin 26 of the interface box - To the diagnosis connector (line L - pin A)
31 To J2 pin 27 of the interface box - To the diagnosis connector (line K - pin B)
32 To J2 pin 25 of the interface box - Resistor module
33-35 Free
36 To J2 pin 40 of the interface box - Positive for diesel heating relay
37 To J2 pin 12 of the interface box - Positive for starting relay control
38 Free
40-45 Free
46 To J2 pin 48 of the interface box - Negative for pre-heating visual indicator
47 Free
48 To J2 pin 28 of the interface box - To the diagnosis connector (engine phase signal - pin F)
49 To J2 pin 54 of the interface box - To the diagnosis connector
50-51 Free
52 To J2 pin 55 of the interface box - To the diagnosis connector (CAN line L - pin D)
53 To J2 pin 56 of the interface box - To the diagnosis connector (CAN line H - pin C)
54-59 Free
61-62 Free
63 To J2 pin 24 of the interface box - Alarm signal for low engine oil pressure
64 To J2 pin 22 of the interface box - Negative for visual indicator ”BLINK-CODE”
65 To J2 pin 51 of the interface box - Alarm signal for high engine water temperature
66 To J2 pin 52 of the interface box - Engine oil pressure signal
67-86 Free
87 To J2 pin 53 of the interface box - Resistor module
88-89 Free
35
89 72
53 18 36 17
54 6 1171
1
7
12
FUNCTION

Figure 39
Colours
G GREEN
B BLACK N BROWN
U BLUE Y YELLOW
W WHITE R RED
P CYAN O ORANGE
6 8 16 9 15 22
36 29302331
4
5
102375
Sensor connector ”C”
PIN CABLE COLOUR FUNCTION
1-4 - Not connected
5 C Negative for pressure regulator
6 - Not connected
7 V Positive for pressure regulator
8 - Not connected
9 MN Positive for engine oil temperature/pressure sensor
10 CR Positive for air temperature/pressure sensor
11 - Not connected
12 HN Positive for rail pressure sensor
13-16 - Not connected
17 BL Negative for fuel temperature sensor
18 CV Negative for coolant temperature sensor
19 GV Negative for engine oil temperature/pressure sensor
20 BZ Negative for rail pressure sensor
21 GN Negative for air pressure/temperature sensor
22 - Not connected
23 R Camshaft sensor (timing)
24 B Engine shaft sensor (rounds)
25 R Engine shaft sensor (rounds)
26 - Not connected
27 RV Signal form rail pressure sensor
28 LN Signal from air pressure sensor
29 BH Signal from air temperature
30 B Camshaft sensor (timing)
31 - Not connected
32 - Not connected
33 GR Signal from engine oil temperature sensor
34 CN Positive from fuel temperature sensor
35 NS Signal from engine oil pressure sensor
36 BG Positive from coolant temperature sensor

Figure 40Engine speed sensor
This inductive sensor is located on the front left part of the
engine.
It generates signals obtained from lines of magnetic flux that
close through the openings of a phonic wheel keyed onto the
crankshaft.
It is connected to the control unit on pins 25C - 24C.
The sensor resistance is ∼ 900 Ohm.
- Supplier Bosch
- Tightening torque 8 ± 2 Nm
8520
8519
Pulse sensor on timing system
This inductive sensor is located on the rear left part of the
engine.
It generates signals obtained from lines of magnetic flux that
close through the holes of a gear keyed onto the camshaft.
The signal generated by this sensor is used by the electronic
control unit as an injection phase signal.
While being the same as the crankshaft sensor it is NOT
interchangeable since it has a different outer shape.
The sensor resistance is ∼ 900.
- Supplier Bosch
- Tightening torque 8 ± 2 Nm
Figure 41
8520
8519
Electro-injectors
It is a N/O solenoid valve.
They are connected to the EDC control unit on connector
A.
The coil resistance of each single injector is 0.56 - 0.57 Ohm.
The construction of the injector is similar to that of
conventional ones, except that
there are no needle return springs.
The electro-injector can be considered to comprise two
parts:
- actuator - nozzle composed of a pressure rod, needle
and nozzle;
- control solenoid valve composed of coil and pilot valve.
The solenoid valve controls the lift of the needle of the
nozzle.
INJECTION START
When the coil is energized, it causes the shutter to move
upwards.
The fuel of the control volume flows out towards the
backflow pipe, causing a drop in pressure in the control
volume.
At the same time, the pressure of the fuel in the pressure
chamber causes the needle to rise, with fuel getting injected
into the cylinder as a result.
INJECTION END
When the coil is de-energized, the shutter goes back into its
closed position to form such a balance of forces as to make
the needle go back into its closed position and end injection.
Figure 42
107442

Figure 43Oil pressure / oil temperature sensor
It is fitted on the engine oil filter in a horizontal position.
It measures the engine oil temperature and pressure.
The signal is sent to the EDC control unit.
The engine oil temperature is used only by the EDC control
unit.
Fuel temperature sensor
It measures the temperature of the fuel to give the control
unit a pointer on the thermal state of the diesel.
The control unit pilots the control relay for heating the filter
to a fuel temperature less than or equal to 36 °C.
Its resistance at 20°C = 2.50 KOhm.
Figure 44
Coolant temperature sensor
It is a variable resistance sensor able to measure the coolant
temperature to give the control unit a pointer on the thermal
state of the engine.
It is located at the top of the engine.
Figure 45
107443
107471
It is connected to the control unit on pins 19C - 33C - 9C
- 35C.
Pin 19/C - 35/C Temperature
Pin 9/C - 33/C Pressure
107444
Its resistance at 20 °C = 2.50 KOhm.
107488

Figure 46Turbocharging air temperature and pressure
sensor
This component integrates a pressure and a temperature
sensor.
Fitted on the intake manifold, it measures the maximum flow
rate of air introduced in order to accurately calculate the
quantity of fuel to inject in each cycle.
The output voltage is proportional to the pressure or
temperature measured by the sensor.
It is supplied at 5 Volts.
Fuel pressure sensor
Fitted on one end of the rail, it measures the existing fuel
pressure in order to determine the injection pressure.
The injection pressure is used to control the pressure itself
and to determine the duration of the electrical injection
command.
It is supplied at 5 Volts.
It is connected to the control unit on pins 20C - 27C - 12C.
Figure 47
Solenoid valve for fuel pressure regulator
Located at the high-pressure pump inlet, on the low-pressure
system, it modulates the quantity of fuel with which to supply
the high-pressure pump according to the commands
received from the electronic control unit.
Figure 48
107443
It is connected to the control unit on pins 21C - 29C - 10C
- 28C.
Pin 21C - 29C Temperature
Pin 10C - 28C Pressure
107444
It is a N/O solenoid valve.
Its resistance is ∼ 3.2 Ohm.
101638
107470

Figure 49
SENSORS FOR INSTRUMENTS ON AUTOMATIC/MANUAL PANEL
High water temperature transmitter sensor (TATA)
Note: measurements in mm
Technical data:
- Operating voltage: 6V ÷ 24V
- Trigger temperature 100 ± 3 °C
- Max temperature 160 °C
- Switch capacity: 3W max non-inductive
0050167t
Wiring diagram:
Contact closed with temperature
above the trip threshold.
Stamping on hexagon:
0050174t
0050168t
1. VDO reference - 2. Calibration value - 3. Maximum working temperature -
4. Date of construction - 5. Electrical specifications.

Figure 50
Oil pressure transmitter (TPO)
Note: measurements in mm
Operating voltage: from 12V to 24V
Setting: from 0 to 8 kg/cm2
Table of transducer electrical specifications
0 bar - 259 Ohm
2 bar - 172 Ohm
4 bar - 106 Ohm
6 bar - 60 Ohm
8 bar - 32 Ohm
0050169t
M10x1 tapered

Figure 51
Water temperature transmitter (TTA)
Sensor trend in relation to temperature:
0050171t
T°C Resist. R mini R Maxi
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
84756.89
60561.83
43783.02
31979.02
23595.57
17580.07
13220.97
10032.16
7678.16
5925.19
4608.79
3812.24
2851.93
2267.52
1815.08
1462.37
1185.68
968.98
793.23
654.34
542.66
452.36
378.97
319.01
269.77
229.15
195.47
167.44
144.00
124.32
107.72
93.68
81.75
71.57
62.87
55.40
48.96
43.39
38.57
62760
45563
33403
24728
18477
13932
10596
8126
6283
4895
3842
3038
2418
1938
1563
1288
1035
850
702
582
488
407
343
290
247
210
180
155
134
115
99
88
75
65
57
50
44
39
35
108734
75801
54183
39230
28714
21228
15846
11936
9074
6955
5375
4187
3288
2597
2067
1657
1338
1084
885
728
600
498
415
348
293
248
211
180
154
133
118
101
89
78
69
61
54
48
43

Figure 52
Oil pressure switch (TBPO)
Technical data:
Operating voltage: from 6V to 24V
Setting: from 0.5 to 0.8 bar
Closing pressure: 0.5 bar
Opening pressure: 0.8 bar
Switch capacity: 15 A non-inductive
Isolated pole transmitter
0050172t
Wiring diagram:
Stamping on hexagon:
0050175t
0050173t
1. Class - 2. Customer classification - 3. Settings - 4. Customer abbreviation - 5. Date of construction.
N/C contact with engine stationary or oil pressure < 0.5 bar

Figure 53
Multistate Switch (M.S.S.) supplied by Iveco (Applications with no interface box)
Depending on the destination country it is possible to select the working frequency of the current generator (50/60 Hz) with
an appropriate configuration of the Multistate Switch.
R between pin 2 and pin 4 = 1330 Ω
0050165t
R between pin 4 and pin 5 = 820 Ω
TP = Timed Contactor
Note: When the operating frequency changes 50-60 Hz it is necessary to set the AVR (automatic voltage regulator) of the
electrical machine appropriately.
Power switch
Inserted in the electric panel. It must be regulated according to the Imax current delivered. The maximum current delivered
by the electric machine depends on the selected working frequency 50-60 Hz.
0050166t
FOR CONFIGURATION 50 HZ
Connector B
of the EDC
control unitMultistate Switch
TP
Delay etc. I’’
FOR CONFIGURATION 60 HZ
Connector B
of the EDC
control unitMultistate Switch
TP
Delay etc. I’’

Figure 54
Below there are listed the electric components which are
present on NEF F4GE engines.
1. Cooling liquid temperature sensor;
2. Starter;
3. Injection pump water temperature sensor;
4. Magnets mounted on feed pump:
5. Oil pressure sensor;
7. Alternator.
ELECTRICAL COMPONET LAYOUT (6 CYL. ENGINES WITH ROTARY PUMP)
GENEF
106662

Cooling liquid temperature sensor
It is a component integrating a temperature sensor.
It is assembled to the engine head close to the thermostat
unit and its duty is to detect engine cooling liquid
temperature.
Specifications:
Range of working temperatures:
Connection side -40 ÷ +150 ºC for < 10 min.
Bulb side on engine: -40 ÷ +140 ºC
Working tensions: 6 ÷ 28 V
Settings:
80 ºC 0.304 ÷ 0.342 kΩ
20 ºC 2.262 ÷ 2.760 kΩ
-10 ºC 8.244 ÷ 10.661 kΩ
Starter
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.
Specifications:
BOSCH 4 kW - 24V
Figure 55 Figure 56
75717
Injection pump water temperature sensor
It is assembled to the cylinder head on the engine left hand
side.
Specifications:
Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 32±2 ºC Contact opening
upon increasing temperature
22±2 ºC Contact closure
upon decreasing temperature
Figure 57
75718
B
C
A
A B
C
1
75719

Oil pressure sensor
Figure 58
75722
It is assembled to the block on the engine’s left hand side.
Specifications:
Contact closure
upon lower pressure: 0.2 bar
Contact opening
upon higher pressure: 0.9 bar
Figure 59
Alternator
It is place front view on the right hand side of the engine, and
is driven by tooth belt.
Specifications:
Rated tensions: 24 V
Current delivered: 90A (at 6000 rpm)
Absorption in stand-by: ≤ 1mA
Sense of rotation: clockwices
75725

SECTION 2 - TROUBLESHOOTING 1NEF POWER GENERATION ENGINES
SECTION 2
Troubleshooting
Page
PREFACE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
METHODS OF DIAGNOSIS 4. . . . . . . . . . . . . . .
- Blink code 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- PT-01 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS WITH BLINK CODE 5. . . . . . . . . . .
- Indicator light off 5. . . . . . . . . . . . . . . . . . . . . . .
- Indicator light on steady 5. . . . . . . . . . . . . . . . .
- Indicator light blinking 5. . . . . . . . . . . . . . . . . . .
- BLINK CODE activation / reading 5. . . . . . . . . .
EDC BLINK-CODE 6. . . . . . . . . . . . . . . . . . . . . . .
- Procedure for failure memory clear by
Blink Code key 7. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING
Software release 4.1_2 9. . . . . . . . . . . . . . . . . .
TROUBLESHOOTING WITH PT-01
PORTABLE TESTER 27. . . . . . . . . . . . . . . . . . . .
PT-01 PORTABLE TESTER 29. . . . . . . . . . . . . . . . .
- Main functions 29. . . . . . . . . . . . . . . . . . . . . . . . .
- Test parameters 29. . . . . . . . . . . . . . . . . . . . . . .
FAILURE CODES
(SOFTWARE VERSION 3.3_1) 30. . . . . . . . . . .
FAILURE CODES
(SOFTWARE VERSION 4.1_2) 32. . . . . . . . . . .
TROUBLESHOOTING 35. . . . . . . . . . . . . . . . . . . .
- F4GE engines 37. . . . . . . . . . . . . . . . . . . . . . . . .
- F4AE engines 45. . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 2 - TROUBLESHOOTING NEF POWER GENERATION ENGINES

PREFACE
A successful troubleshooting is carried out with the
competence acquired by years of experience and attending
training courses.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper
consideration using them to acquire any useful information to
focus the intervention.
After the detection of the existing anomaly, it is
recommended to proceed with the operations of
troubleshooting by decoding the auto-troubleshooting data
provided by the EDC system electronic central unit.
The continuous efficiency tests of the components connected
to, and the check of working conditions of the entire system
carried out during working, can offer an important diagnosis
indication, available through the decoding of the
”failure/anomaly” codes issued by blinking of the failure led:
the ”blink-code” (whether programmed).
Please consider that the interpretation of the indications
provided by the blink-code is not sufficient to guarantee the
solution to the existing anomalies.
Using Iveco Motors 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.
Every time there is a breakdown claim and this breakdown is
actually detected, it is necessary to proceed inquiring the
electronic unit in one of the ways indicated and then proceed
with the diagnostic research making trials and tests in order to
have a picture of the working conditions and identify the root
causes of the anomaly.
In case the electronic device is not providing any indication, it
will be necessary to proceed relying on the experience,
adopting traditional diagnosis procedures.
In order to compensate the operators’ lack of experience in
this new system, we are hereby providing the USER’s
GUIDELINE FOR TROUBLESHOOTING in the following
pages.
The GUIDELINE is composed of three different parts:
- Blink Code, relating to the anomalies identified by the
gearbox, mainly of electric and electrical nature;
- Troubleshooting guide using PT-01 portable tester.
Tool identified as IVECO p/n 8093731.
- Guideline for troubleshooting without blink code, divided
per symptoms, describing all possible anomalies not
detected by the electronic gearbox, often of mechanical
and hydraulic nature.
Any kind of operation on the electronic center unit
must be executed by qualified personnel, duly
authorized by Iveco Motors.
Any unauthorized tamper will involve decay of
after-sales service in warranty.
NOTE

Figure 1
METHODS OF DIAGNOSIS
The available diagnosis systems are currently:
- BLINK CODE
- PT-01
- SYMPTOMS
1. Connector with 19-pin diagnosis socket - 2. LED signalling communication between the instrument - control unit and
correct power supply - 3. USB indicator light - 4. Serial port indicator light -
5. Power supply connector (power only to update SW with serial port).
117696
PT-01
Blink code
This is the preliminary information that the electronic control unit gives the operator (with a blink code) about any trouble with
the system.
The blink-code test button, blink-code signal request button and 19 pole connector for the PT-01 instrument are integrated in
the interface box.

DIAGNOSIS WITH BLINK CODE
EDC indicator light behaviour
After turning the key selector onto ”ON” the EDC indicator light will come on; afterwards, if no trouble is found, the EDC indicator
light must go out.
Depending on whether there is any trouble, the indicator light may behave as follows:
Indicator light off
1. No fault
2. Slight trouble
performance not affected
fault detectable with BLINK CODE and diagnostic instrumentation.
Indicator light on steady
1. Serious fault
fault detectable with BLINK CODE or diagnostic instrumentation
Indicator light blinking
2. Very serious fault
In many cases, switching off the engine
fault detectable with BLINK CODE or diagnostic instrumentation.
BLINK CODE activation / reading
The blink code is activated by pressing the BLINK CODE button inside the interface box.
The BLINK CODE identifies one problem at a time without distinguishing between present and intermittent faults. To display all
the codes in memory you need to activate the BLINK CODE button several times.
The code is composed of two digits and is displayed with slow blinks followed by fast blinks.
If there are no faults in the system, the EDC indicator light will give no information and come on just once.
Each time the key is turned ”ON”, the EDC indicator light has to come on; if this does not occur, check the wiring and indicator
light.
IMPORTANT
The operations of removing and refitting the control unit must be performed with the positive pole of the battery disconnected.

EDC BLINK-CODE
Blink-Code Description of anomaly Power reduction
ENGINE 1
2.1 Signal from cooling liquid temperature sensor -
2.2 Signal from air temperature sensor, boosting -
2.3 Signal from fuel temperature sensor -
2.4 Signal form sensor of pressure boosting -
2.5 Signal from atmospheric pressure sensor -
2.6 Signal from oil pressure sensor -
2.7 Signal from oil temperature sensor -
2.8 Signal from heated filter driving relé -
2.9 Signal from pre-post heating resistor driving relé -
ENGINE 2
3.7 Battery tension -
3.8 Alert led pre-post heating -
3.9 Pre-post heating resistor -
INJECTORS (6 cylinders)
5.1 Electro-valve injector of cylinder 1 X
5.7 Power stage 1 (cylinders 1-2-3) X
5.8 Power stage 2 (cylinders 4-5-6) X
X = Power reduction

Procedure for failure memory clear by Blink Code key
Key change over switch in OFF position.
Keep the Blink Code key pressed for 4 to 8 seconds after turning the key change over switch in ON position.
Wait at least for 10 seconds before switching off the key change over switch.
Blink-Code Description of anomaly Power reduction
ENGINE RUNNING
6.1 Signal from engine driving shaft sensor -
6.2 Signal from camshaft sensor -
6.4 Engine runaway speed rate XX
6.5 Relé of the starter -
6.6 -
FUEL PRESSURE
8.1 Control fuel pressure X
8.2 Fuel pressure signal X
8.3 Pressure regulating electro-valve X
8.4 Intervention to double stage boosting valve X
8.5 Rail Min/Max pressure failure X
EDC
9.4 Main relè -
9.6 Gearbox disconnection procedure -
9.7 Sensor feed -
X = Power reduction
XX = Engine disconnection

TROUBLESHOOTING
Software release 4.1_2

Note:TheEDCindicatorlightconditionreferstoanOCCURREDerror
BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
1.2NotusedNotusedNotusedNotusedNotused
2.1OnWatertemperaturesensor
shortedorcircuitopen
Measurableparameterreadout:
withthiserror,thewatertem-
peraturereadonthecontrolunit
willbethesameastheengineoil.
Usingamultimeter,checkthein-
tegrityofthesensor(R=approxi-
mately2.5kOhmat20°C)be-
tweenitspins1and2
Ifthesensorisintegral,checkthe
wiringbetweenthesensorcon-
nector(wiringside)pin1andthe
EDCconnectorpinC18,be-
tweenthesensorconnector(wir-
ingside)pin2andtheEDCcon-
nectorpinC36.
2.2OffAirtemperaturesensoronintake
manifoldshortedorcircuitopen
Measurableparameterreadout
withthediagnosisinstrument:
withthiserror,theturbocharging
airtemperaturewillbefixedon
30°C.
Ifthetemperatureisfixedon30
°C,checktheintegrityofthesen-
sor(R=approximately2.5kOhm
at20°C)itspins1and2.
nectorpinC29.
Thetemperaturesensorisinte-
gratedwiththepressuresensor.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
2.3OffFueltemperaturesensorshorted
orcircuitopen.
withthiserror,thefueltempera-
turewillbefixedon20°C.
Checktheintegrityofthesensor
(R=approximately2.5kOhmat
20°C).
nectorpinC34.
2.4OnAirpressuresensoronintake
manifoldshortedorcircuitopen.
pressurewillbefixedon1600
mbar.
Checkthewiringbetweenthe
sensorconnector(wiringside)
pin3andtheEDCconnectorpin
C10,betweenthesensorcon-
EDCconnectorpinC28.
Thepressuresensorisintegrated
withthetemperaturesensor.
Iftheelectricsareinorder,check
theturbochargerwastegatevalve
worksproperly.
2.5OffAmbientpressuresensorshorted
orcircuitopen.
pressurewillbefixedon970
mbar
CalltheHelpDeskandfollow
theirinstructionstoreplacethe
controlunit,ifnecessary.
Thesensorisintegratedinthe
EDCcontrolunitandcannotbe
changedonitsown.
Anypaintingoftheengine/con-
trolunitcanjeopardizethe
measurementoftheambient
pressure.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
2.6OnOilpressuresensorshortedor
circuitopen.
withthiserror,theoilpressure
willbefixedon60mbar.
EDCconnectorpinC35.
Thepressuresensorisintegrated
withthetemperaturesensor.
2.7OnOiltemp.sensorshortedorcir-
cuitopen.
withthiserror,theengineoiltem-
peraturewillbefixedon120°C.
(R=approximately2.5kOhmat
20°C).
EDCconnectorC19,between
thesensorconnector(wiring
side)pin2andtheEDCcon-
nectorpinC33.
Iftheoiltemperatureistoolow,
immediatelyafterstarting,engine
speedislimitedaccordingtothe
oiltemperature(engineprotec-
tionstrategy).
2.8OffFuelfilterheaterrelaydefective
(optional).
a)Heateralwayson.Thebat-
teriesrundown.
b)Heaterneverturnson.Poss-
iblefiltercloggingduetofuel
paraffiningwithverylowout-
sidetemperatures(<-15°C).
a)Possiblysaving2.3becausethe
fuelheatsuptoomuch

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
2.9OnPre-postheatingelementcontrol
relaydefective.
a)Thepre/post-heatingel-
ementsarenotpowered,cold
startingmaybedifficultand
smokinessonstarting.
b)Thepre/post-heatingelement
isalwayspowered:earlyde-
teriorationoftheheatingel-
ement,thebatteriesquickly
rundown.
Diagnosisactive.
relaypin85andEDCconnector
pinB4,betweentherelaypin86
andEDCconnectorpinB36.
3.7On(software
releasefor
single-stage
valve).
Off(software
releasefor
twin-stage
valve).
BatteryvoltagesignaltoolowMeasurableparameterreadout
tocheckthebatteryvoltage.
Maketheappropriatecheckson
thevoltageregulator,batteries
andrechargingsystem.
Thevoltagemightnotactuallybe
toolow,butthecontrolunit
mightrecognizeitassuch.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
3.8OffPre-heatingindicatorlamp
shortedordefective(optional).
a)Pre-heatingindicatorlightal-
wayson.
b)Pre-heatingindicatorlightal-
waysoff.
Performactivediagnosiswiththe
diagnosisinstrument.
Iftheresultisnegative,checkthe
integrityoftheindicatorlight
module.
Iftheindicatorlightmoduleis
integral,checkthewiringbe-
tweentheindicatorlightmodule
pin14andtheEDCconnector
pinB46passingthroughthebulk-
headconnectorBpin19.
Coldstartingmaybedifficultbe-
causepre-heatingworksbutno
feedbackisobtainedfromthe
indicatorlamp.
3.9OnPre/post-heatingprocedure
monitoring(optional).
Possiblesmokinessafterstarting.Checkthatthecablesarefirmly
securedtotheterminalsofthe
pre/post-heatingelement.
Checktheintegrityofthepre/
post-heatingelement(R=ap-
proximately0.5Ohm).
Checkthewiringandconnec-
tionsbetweenthecontactorof
thepre/post-heatingelementpin
87andthe(+)terminalofthe
heatingelement,passingthrough
thebulkheadconnectorEpin40.
Checkthewiringandconnec-
tionsbetweenthe(—)terminalof
theheatingelementandearth.
Thecontrolunitdoesnotdetect
theincreaseintemperaturere-
sultingfromtheoperationofthe
heatingelement(viatheairtem-
peraturesensorintheintake
manifold).

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
5.1OnElectricalpartofinjectorcylinder
no.1shortedorcircuitopen.
Theenginerunson3(5)cylin-
ders.
Checkthatthecableretaining
nutsonthesolenoidvalveofthe
injectorarecorrectlytightenedto
atorqueof1.5Nm.
Checkthecontinuityandresis-
tanceoftheinjectorsolenoid
valve(R=approximately0.5
Ohm).
Ifthesolenoidvalveisintegral,
checkthewiringonthecylinder
headbetweenconnector1pin3
and4andtheelectro-injector.
Ifthecylinderheadwiringisinte-
gral,checktheenginecablebe-
tweencylinderheadconnector1
A13,betweencylinderheadcon-
nector1pin4andtheEDCcon-
nectorpinA9.
Immediatelyafterwardstheen-
ginemightkeeponturningon2
(3)cylindersastheinjectorsare
controlledbytwopowerstages.
Inthiscaseerror5.7couldbe
savedtomemorytoo.
ders.
atorqueof1.5Nm.
Ohm).
nectorpinA6.
Inthiscaseerror5.7(6cylinders)
or5.8(4cylinders)couldbesaved
tomemorytoo.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
ders.
atorqueof1.5Nm.
Ohm).
nectorpinA4.
tomemorytoo.
ders.
atorqueof1.5Nm.
Ohm).
nectorpinA14.
tomemorytoo.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
Theenginerunson5cylinders.Checkthatthecableretaining
atorqueof1.5Nm.
Ohm).
nectorpinA11.
cylindersastheinjectorsarecon-
trolledbytwopowerstages.In
thiscaseerror5.8couldbesaved
tomemorytoo
Theenginerunson5cylindersCheckthatthecableretaining
atorqueof1.5Nm.
Ohm).
nectorpinA15.
cylindersastheinjectorsarecon-
trolledbytwopowerstages.In
thiscaseerror5.8couldbesaved
tomemorytoo.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
5.7OnPowerstagefortheelectro-injec-
torsofcylinders1-4(4cylinder
engine)or1-2-3(6cylinderen-
gine)defective.
ders.
Deletethefaultmemoryandtry
again.
Iftheerrorremains,andonlyafter
excludingtheinjectordefect(see
note5.x),calltheHelpDeskand
followtheirinstructionstore-
placethecontrolunit,ifnecess-
ary.
5.8OnPowerstagefortheelectro-injec-
torsofcylinders2-3(4cylinder
engine)or4-5-6(6cylinderen-
gine)defective.
ders.
again.
Iftheerrorremains,andonlyafter
excludingtheinjectordefect(see
note5.x),calltheHelpDeskand
followtheirinstructionstore-
placethecontrolunit,ifnecess-
ary.
6.1OnCrankshaftsensor:nosignalor
signalnotplausible.
Highreductioninpoweronthe
softwareversionforenginewith
single-stagepressurereliefvalve.
Slightreductioninpoweronthe
twin-stagepressurereliefvalve.
Checkthesensoriscleanandcor-
rectlysecured.
Checkthephonicwheelisclean
andintegral.
(R=approximately920Ohm).
nectorpinC24.
Error6.1isalwaysassociatedwith
6.3.
Theenginefailstostartbecause
afterafewturnsthecontrolunit
turnsoffthestartermotor.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
6.2OnCamshaftsensor:nosignalorsig-
nalnotplausible.
Startingdifficultinallconditions.
Falseinjectionsandsmokinessat
exhaustduringstarting.
Slightreductioninpoweronthe
single-stagepressurereliefvalve.
Checkthesensoriscleanandcor-
rectlysecured.
(R=approximately890Ohm).
nectorpinC30.
Thiserrorisalwaysassociated
with6.3
6.3OnNoplausibilitybetweenthesig-
nalsoftheflywheelsensorand
thecamshaftsensor.
Slightpowerreduction.Faultmemoryreading:checkthe
ambientconditionsassociated
withthiserror.
Iftheerrorhasbeensavedwith
enginespeedunder650rpm,de-
letethefaultmemoryandresolve
thevehicle.
Onthecontrary,checktheinteg-
rityofthedamperflywheelandof
thephonicwheelonthecrank-
shaft,thecleanlinessandcorrect
fixingofthetwosensors.
Sometimesonlyerror6.3issaved
tomemorywhereasinactualfact
thecamshaftsignalisdefective.
Inthiscase,runthecheckspre-
scribedtoresolveproblem6.2
Thiserrorcouldoccasionallyget
savediftheengineisswitchedoff
withthebuttonunderthecab.
Ifthedamperflywheelhasde-
teriorated,itwillbelocally
buckledand,ifthejoiningareasof
theenclosurehavestartedto
give,inthesurroundingareathere
willbetracesofsilicone.
Checkthattherearenostripsof
adhesivetapeonthephonic
wheelandthatitturnswithno
axialoscillationduetoimpactde-
formation.
6.4BlinkingEngineoverspeed.Enginecutsout(onlyonthesoft-
wareversionforenginewith
single-stagepressurereliefvalve).
FlightRecorder(SavedData)re-
adouttoascertaintheextentand
frequencyofthephenomenon.
Makethedriverawareofhowto
drivecorrectly.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
6.5OnRelayforstartermotorshorted
orcircuitopen.
Impossibletostarttheengine.
Ifitisalreadyrunning,itcutsout.
Checktheintegrityofthecompo-
nent.
relayandEDCconnectorpinB37.
6.6OffRevcountersignalshortedorcir-
cuitopen.
Therevcounterdoesnotwork.Checkthewiringbetweenpin3
oftheinstrumentandEDCcon-
nectorpinB49.
6.8OffSynchronizationsignalfromEDC
tothediagnosisinstrument
shortedorcircuitopen.
Checktheintegrityofthewiring
betweenEDCconnectorpinB48
anddiagnosissocketpin23pas-
singthroughthebrownbulkhead
connectorBpin11.
7.2OffCANlineCheckthewiring,connections
andclosingresistance(120ohm)
oftheCANline.
7.6Off
(optional)
Lowengineoilpressurewarning
lightsignalshortedorcircuit
open.
Thewarninglightdoesnotwork
orisalwayson.
Checktheintegrityoftheindica-
torlightbetweenpins2and4of
theoilpressureinstrument.
Ifthewarninglightisintegral,
checkthewiringbetweenpin2of
theinstrumentandEDCcon-
nectorpinB63passingthrough
thebrownbulkheadconnectorB
pin17.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
7.8Off(optional)Highenginecoolanttemperature
warninglightsignalshortedorcir-
cuitopen.
Thewarninglightdoesnotwork
orisalwayson.
Checktheintegrityoftheindica-
torlightbetweenpins1and4of
thetemperatureinstrument.
Ifthewarninglightisintegral,
checkthewiringbetweenpin1of
theinstrumentandEDCcon-
thebrownbulkheadconnectorB
pin15.
8.1BlinkingFuelpressureadjustment:the
pressureintherailisloweror
greaterthanthatcalculatedby
thecontrolunit.
Considerablepowerreduction.(withrelease2-2001andlater):
innormalconditions,atidlingwith
noloadandtheenginewarm,this
valuemustbeapproximately5%
lower.
Ifthisvalueishigher,makethefol-
lowingchecks.
8.1Blinkinga)Fuelsuctiontubeinthetank
partiallyblockedbydebrisor
bucklingduetooverheating
Checkwhethertheprimingpump
onthepre-filterworkscorrectly.
Iftheknobofthepumpremains
suckeddownbythelowerpres-
sure,removeandcheckthetank
suctiontube.
Ifthesuctiontubeisalright,
changethepre-filter.
Ifanychipshavebeensuckedup
(duetomachiningperformedby
thebodybuilderonthefueltank),
cleanthetankcarefully.
Theproblemcouldrecurdueto
otherchipsleftinthetank.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
8.1Blinkingb)Airintakeupstreamfromthe
fuelgearpump.
ChecktheO-Ringsandthatthe
fittingsofthepipesbetweenthe
tankandfuelpumparecorrectly
connected(theclipsmustbeout
andthefittingswellhookedon).
8.1Blinkingc)Fuelleakagefromthefittingsor
low-pressurepipesdown-
streamfromthefuelpump.
d)Possibledefectoftherailpres-
suresensorsignal.
ChecktheO-Ringsandthatthe
fittingsofthepipesdownstream
fromthefuelpumparecorrectly
connected(theclipsmustbeout
andthefittingswellhookedon).
Inspecttheintegrityofthelow-
pressurepipes.
e)Runthechecksof8.2
8.2BlinkingRailpressuresensorshortedor
circuitopen.
Enginecutsout(onlyonthesoft-
wareversionforenginewith
single-stagepressurereliefvalve).
Highreductioninpower(onlyon
thesoftwareversionforengine
withtwin-stagepressurerelief
valve).
nectorpinC12.
Afterexcludingallotherpossibi-
lities,replacethesensor.
8.3BlinkingPressureregulatorshortedorcir-
cuitopen.
Considerablepowerreduction.Checkthattheconnectoriscor-
rectlyconnectedtothepressure
regulator.
Usingamultimeter,checkthein-
tegrityofthepressureregulator
solenoidvalve(r=APPROXI-
MATELY3.2Ohm).
Ifthecomponentisintegral,check
thewiringbetweenthepressure
regulatorconnectorandtheEDC
connectorpinC5—C7.
RememberthatasofSeptember
2003thepressureregulator,
whichcanbereplacedonitsown,
isavailableasasparepart.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
8.4BlinkingTwin-stagepressurereliefvalve
trips.
Considerablepowerreduction.Runthechecksprescribedfor8.2
and8.3.
(onlyonthesoftwareversionfor
enginewithtwin-stagepressure
reliefvalve).
If8.1issavedatthesametime,re-
solve8.4firstsince8.1isadirect
consequence.
Intheeventof8.4(withEDC
warninglightoff)on210HPand
240HPwithsingle-stagepressure
reliefvalve,calltheHelpdesk.
8.5BlinkingRailmin-maxpressureerror.Enginecutsout.Changethepressurereliefvalve.
Checkthatthefuelsuctionand
returnpipesfromthetankhave
notbeenswappedover.
Ifthetroubleremains,runthe
checksprescribedfor8.2and8.3.
(onlyonthesoftwareversionfor
enginewithtwin-stagepressure
reliefvalve).
9.4OnMainrelayfailstoturnoffThecontrolunitisalwayspow-
eredandtheEDCindicatorlight
staysonevenwiththekeyOFF.
Thebatteriesrundown.
Trytakingoutandputtingbackin
theEDCfuseanddeletethefault
memory.
Ifthetroubleremains,callthe
HelpDesktoreplacethecontrol
unit,ifnecessary.
Themainrelayisincorporatedin
theEDCcontrolunitandcannot
bechangedonitsown.

BLINK
CODE
EDC
INDICATOR
LIGHT
POSSIBLECAUSE
REACTIONSOF
THESYSTEM/VEHICLE
RECOMMENDEDTESTS
ORACTION
NOTES
9.6OnFailureoftheinternaltestpro-
cedureinthecontrolunitevery
timetheengineisstopped.
ConsiderablepowerreductionCheckthewiringbetween+15of
thekeyandthecontrolunitcon-
thebulkheadconnectorBpin2.
again:ifinnormalconditionsof
switchingofftheenginetheerror
signalpersists,calltheHelpDesk
toreplacethecontrolunit,if
necessary.
Theenginefailstostopintheset
timewhenthe+15keyisturned
OFF.
9.7OnInternaldefectofthecontrolunit
inthesensorsupplycircuit.
Irregularengineoperationdueto
sensorsnotbeingcorrectlysup-
plied.
Powerreduction.
again.
Ifthetroubleremains,callthe
HelpDeskandfollowtheirin-
structionstoreplacethecontrol
unit,ifnecessary.
Possiblesignallingofdefectwith
varioussensorspoweredbythe
controlunit.

TROUBLESHOOTING WITH PT-01 PORTABLE TESTER
(IVECO P.N. 8093731)

PT-01 PORTABLE TESTER
Using PT-01 with portable tester it is possibile to execute
troubleshooting and test the EDC7 electronic module of NEF
engines.
PT-01 has been designed and developed to ensure stoutness
and practicality and is particularly suitable to be used in work-
shop and industrial environment.
The tool is connected to the engine gearbox by means of one
only cable providing both tester feed and communication with
the electronic module.
Main functions
Before connecting the tester to the electronic mod-
ule, check the wording on the electronic module to
select the correct software on the tool.
1 2 3 4 5 6 7 8 . A B C
u m m k a a * * . v a 0
a a software 3.3_1
a b software 4.1_2
Easy access to different functions is available through the
menu:
- ID. Reading of the electronic module;
- Reading of failure memory and relevant environment
conditions;
- Failure memory clear;
- Reading of working parameters;
- Reading of status parameters;
- Active troubleshooting (switching on heat starter, fuel
pump, EDC warning led and so on)
Test parameters
- Engine revolutions;
- Spark advance;
- Battery voltage;
- Accelerator foot pedal position;
- Over voltage pressure;
- Over voltage air temperature;
- Cooling liquid temperature;
- Fuel temperature;
- Oil temperature;
- Oil pressure;
- Fuel delivery;
- Fuel pressure;
- Rail pressure duty cycle electro-valve.
NOTE

Blink code Warning type Failure description
System
degradation
ENGINE1
2.1 1 Coolant Temp. Signal 0
2.2 0 Boost Temp. Signal 0
2.3 0 Fuel Temp. Signal 0
2.4 1 Boost Pressure Signal 0
2.5 0 Atmospheric Pressure Signal 0
2.6 1 Oil Pressure Signal 0
2.7 1 Oil Temp. Signal 0
2.8 0 Power stage Fuel filter heater 0
2.9 1 HS Power stage cold start heater relay 0
ENGINE2
3.1 0 Adapt.cylinder balancing Cyl.1 0
3.7 0 Battery voltage signal 0
3.8 0 LS Power stage cold start lamp 0
3.9 1 Cold start heater monitoring 0
INJECTORS
5.1 1 Injector solenoid valve Cyl.1 0
5.2 1 Injector solenoid valve Cyl.5 (•) 0
5.7 1 Injector Booster Voltage C1 0
FAILURE CODES (SOFTWARE VERSION 3.3_1)
System degradation:
0 = 0% derate
1 = slight derate
2 = moderate derate
3 = significant derate
4 = engine stop
Blink types:
0 = No light
1 = Continous light
2 = Blinking light
Classification of power output:
LS = slight level
HS = high level
SS = moderate signal

System
degradation
ENGINE SPEED
6.1 1 Increment speed signal 1
6.2 1 Segment speed signal 1
6.3 1 Engine speed sensing 1
6.4 2 Engine overspeed 0
6.5 1 HS power stage 8 for Starter control 0
6.6 0 SS power stage 1 for TD-signal 0
6.8 0 SS power stage 2 for sync.-signal 0
FUEL PRESSURE
8.1 2 Fuel pressure monitoring CP3 3
8.2 2 System degradation 3
8.3 2 CC HS Power stage 1 fuel press. Control 3
8.4 2 Monitoring of rail pressure relief valve 3
8.5 2 Rail pressure Min/Max error 4
8.6 - CC HS Power stage 2 EGR control 0
8.7 - Air Mass Signal 0
8.8 - Ambient Temp. Signal 0
ECU
9.4 1 Main relay defect 0
9.6 1 ECU: Self Test Shutoff Paths 3
9.7 1 Power supply for sensors 0
System degradation:
0 = 0% derate
1 = slight derate
2 = moderate derate
4 = engine stop
Blink types:
0 = No light
1 = Continous light
2 = Blinking light
LS = slight level
HS = high level

System
degradation
ENGINE1
2.1 1 Coolant Temp. Signal 0
2.2 0 Boost Temp. Signal 0
2.3 0 Fuel Temp. Signal 0
2.4 1 Boost Pressure Signal 0
2.5 0 Atmospheric Pressure Signal 0
2.6 1 Oil Pressure Signal 0
2.7 1 Oil Temp. Signal 0
2.8 0 Power stage Fuel filter heater 0
2.9 1 HS Power stage cold start heater relay 0
ENGINE2
3.2 0 Adapt.cylinder balancing Cyl.5 (•) 0
3.4 0 Adapt.cylinder balancing Cyl.6 (•) 0
3.7 0 Battery voltage signal 0
3.8 0 LS Power stage cold start lamp 0
3.9 1 Cold start heater monitoring 0
INJECTORS
FAILURE CODES (SOFTWARE VERSION 4.1_2)
System degradation:
0 = 0% derate
1 = slight derate
2 = moderate derate
4 = engine stop
Blink types:
0 = No light
1 = Continous light
2 = Blinking light
LS = slight level
HS = high level
(•): not applicable for the 4 cylinders
*) System degradation for STUP failure not applicable (not available in ASAP)
*) Masked out
**) Masked out

System
degradation
ENGINE SPEED
6.1 1 Increment speed signal 1
6.2 1 Segment speed signal 1
6.3 1 Engine speed sensing 1
6.4 2 Engine overspeed 0
6.5 1 HS power stage 8 for Starter control 0
6.6 0 SS power stage 1 for TD-signal 0
6.8 0 SS power stage 2 for sync.-signal 0
FUEL PRESSURE
8.1 2 Fuel pressure monitoring CP3 3
8.2 2 System degradation 3
8.3 2 CC HS Power stage 1 fuel press. Control 3
8.4 2 Monitoring of rail pressure relief valve 3
8.5 2 Rail pressure Min/Max error 4
8.6 - CC HS Power stage 2 EGR control 0
8.7 - Air Mass Signal 0
8.8 - Ambient Temp. Signal 0
ECU
9.4 1 Main relay defect 0
9.6 1 ECU: Self Test Shutoff Paths 3
9.6 2 ECU: Self Test Shutoff Paths *
9.7 1 Power supply for sensors 0
System degradation:
0 = 0% derate
1 = slight derate
2 = moderate derate
4 = engine stop
Blink types:
0 = No light
1 = Continous light
2 = Blinking light
LS = slight level
HS = high level
*) System degradation for STUP failure not applicable (not available in ASAP)
*) Masked out
**) Masked out

TROUBLESHOOTING

F4GE engines

ANOMALY
POSSIBLECAUSE
(*)=ifavailableintheequipment
REMEDYNOTE
TheenginedoesnotstartBatteryflatorfaulty.Checkandrechargebattery.Replacebat-
teryifnecessary.
Connectionstobatteryterminalscor-
rodedorloose.
Clean,examineandtightenthenutson
thebatteryterminals.Replacethecable
terminalsandthenutsifexcessivelycor-
roded.
Incorrecttimingofinjectionpump.Checkandcorrectlytimetheinjection
pump.
SeeyourIvecoMotorsdealer.
Depositsorwaterinthefueltank.Disconnectthehosesandcleanthem
usingajetofcompressedair.
Dismantleandcleantheinjectionpump.
Removewaterfromtankandrefuel.
Drainfeedsystem.
Nofuelintank.Refuel.
Nopowersupply.Overhaulorreplacethefuelortransfer
pump.
Airbubblesinthefuellinesorinjection
pump.
Checkthehosestoensurethatairisin
factpresentandalsocheckthefuelpump.
Eliminatetheairfromtheinjectionpump
byunscrewingthecapandworkingthe
fuelpumpbyhand.
Faultystartermotor.Repairorreplacethestartermotor.

ANOMALY
POSSIBLECAUSE
REMEDYNOTE
Theenginedoesnotstartatlowtem-
peratures
Fuelsystemcloggedwithparaffincrystals
formingduetotheuseofunsuitablefuel.
Replacethefuelwithfuelsuitableforuse
atlowtemperatures.Replacethefuelfil-
ters.
Theenginecutsout.Idlerpmtoolow.Adjustwithadjustmentscrew.SeeyourIvecoMotorsdealer.
Irregularflowofinjectionpump.Adjustflow.Drainfeedsystem.
Impuritiesorwaterinthefuellines.Disconnectthehosesandcleanthem
usingajetofcompressedair.Dismantle
andcleantheinjectionpump.Remove
waterfromfueltankandrefuel.
Cloggedfuelfilter.Dismantleandreplaceifnecessary.
Presenceofairinthefuelandinjection
system.
Checkthatthehosesarenotcrackedor
theunionsloose.Replacewornparts,re-
movetheairfromthehosesanddeaerate
theinjectionpumpandfuelfilterbyun-
screwingthecapsandworkingtheprimer
pumpbyhand.
Brokeninjectionpumpcontrols.Replacethefaultyparts.
Abnormalclearancebetweencamshaft
camsandtappets.
Adjustclearancebyreplacingshims.
Burnt,corrodedorchalkyvalves.Replacethevalves,rectifyorreplacethe
cylinderheadseatings.

ANOMALY
POSSIBLECAUSE
REMEDYNOTE
TheengineoverheatsFaultywaterpump.Checktheunitandreplaceifnecessary.
Replacethegasket.
Malfunctioningthermostat.Replacethethermostat.
Foulingincoolantopeningsinthecylinder
headandcylindergroups.
Washfollowingthestandardsspecified
forthetypeofdescalingproductused.
Waterpumpdrivebeltslack.Checkandadjustthetightnessofthebelt.Onapplicationsprovidedwithautomatic
tensioner,checkcorretworchingofsuch
device.
Coolantleveltoolow.Top-upradiatorwithcoolant.
Incorrectenginetiming.Checktimingandtunecorrectly.
Incorrectcalibrationofinjectionpump.Correctthedeliveryrateofthepumpon
abenchsothattheinjectionisatthe
specifiedrate.
Dryaircleanerblocked.Cleantheairfilterorreplaceifnecessary.
Engineoperationisirregularandlacks
power
Incorrecttimingofinjectionpump.Checktimingandcorrectlysetpump.
K.S.B.automaticcoldadvancedevicemal-
functioning.
Checkorreplaceinjectionpump.
Excessivepistonwear.Checkorreplaceinjectionpump.
Incorrectcalibrationofspeedregulator.Checkandcorrectlycalibratetheregula-
tor.
SeeyourIvecodealer.

ANOMALY
POSSIBLECAUSE
REMEDYNOTE
Engineoperationisirregularandlacks
power
Partialblockageofnozzlesorfaultyoper-
ationofinjectors.
Cleanthenozzlesoftheatomisersusing
theappropriatetoolsandcompletely
overhaultheinjectors.
Impuritiesorwaterinthefuelandinjec-
tionsystem.
Carefullycleanthesystemandrefuel.Ifnecessarydrainfeedsystem.
Incorrectplaybetweencamshaftcams
andtappets.
Checkandcorrectplay
Faultyturbocharger.Replacecompleteunit.
Aircleanerblocked.Cleanorreplaceaircleaner.
Tierodsbetweenacceleratorpedaland
regulationleverincorrectlyadjusted.
Adjustthetie-rodssothatthecommand
levercanbemovedtothefulldelivery
position.
EnginerunningwithabnormalknockingFaultyoperationofinjectors.Replaceallinjectors.
Fuellinesblocked.Dismantlethehoses,cleanthemandre-
placethosethatareseriouslydented.
Incorrectset-upofinjectionpump.Correcttheset-upofthepumpsothatin-
jectionoccursatthespecifiedangle.

ANOMALY
POSSIBLECAUSE
REMEDYNOTE
EnginerunningwithabnormalknockingKnockingofcrankshaftcausingexcessive
playononeormoremainorrodbearings
orexcessiveplayonshoulders.
Rectifythepinsofthecrankshaftandin-
stallsmallerbearings.Replacethethrust
half-rings.
Crankshaftunbalanced.Checkalignmentofcrankshaft.
Looseningofscrewssecuringflywheel.Replacetheloosenedscrewsandtighten
allthescrewstothespecifiedtorque.
Misalignmentofrods.Replacetherods.
Noisefrompistonjournalsduetoexcess-
iveplayofpistonhubsandintherod
bushing.
Loosebushingsintherodseatings.
Replacethepistonjournaland/orthepis-
tonandrodbushing.
Replacewithnewbushings.
Noisytiming.Adjusttheplaybetweencamshaftcams
andtappetsandcheckthatthereareno
brokensprings,thatthereisnoexcessive
playbetweenthevalvestemsandthe
valveguides,tappetsandseatings.
Theenginesmokesabnormally.Blackor
darkgreysmoke.
Excessivemaximumpumpoutput.Disconnectthepumpandadjustdelivery
inaccordancewiththedatagiveninthe
calibrationtable.
Thereisanexcessivedelayontheinjec-
tionpump.
Correcttheset-up.

ANOMALY
POSSIBLECAUSE
REMEDYNOTE
Theenginesmokesabnormally.Blackor
darkgreysmoke.
Theinjectionpumphasanexcessivead-
vance.
Correcttheset-up.
Theholesintheatomisers(orsomeof
them)arepartiallyorentirelyblocked.
Replacetheinjectorswithaseriesofnew
injectorsorcleanandrectifytheoriginal
onesusingsuitableequipment.
Aircleanerblockedordeteriorated.Cleanorreplacethefilterelement.
Lossofcompressionintheenginedueto:
stuckorwornflexiblerings;
worncylinderliners;
valvesdeterioratedorbadlyadjusted.
Overhaultheengineorlimittheinterven-
tionstotherelativeparts.
Unsuitableinjectors,differenttypesofin-
jectorsorincorrectlycalibrated.
Replaceorcalibratetheinjectors.
Injectionhoseswithanunsuitableinternal
diameter,endofhosespinchedduetore-
peatedblocking.
Checkconditionsoftheendorunions
andwherenecessaryreplacethehoses.
Blue,grey-blue,greysmoketendingto
white.
Excessivedelayininjectionpump.Correcttheset-upofthepump.SeeyourIvecoMotorsdealer.
Faultyinjector.Replacetheinjector.
Leakingofoilfromthepistonringscaused
bygluedorwornringsorwearingofcylin-
derlinerwalls.
Overhaultheengine.
Engineoilpassingthroughtheintake
guides-valvesfollowingwearingofguides
orvalvestems.
Reconditionthecylinderhead.
Enginetoocold(thermostatblockedor
inefficient).
Replacethethermostat.

F4AE engines

ANOMALY
POSSIBLECAUSE
RECOMMENDEDTESTSOR
INTERVENTION
REMARKS
Lowperformanceatloadrequest.
Possibleexessivesmoke.
Lowfuelpressure(error8.1).
Insufficientfuellevelinthetank.Checkfuellevel.Theexcessivesmokeisduetothefact
that,incaseofinsufficientfuelfeeding,the
enginecontrolmoduletriestocompen-
sateprolongingtheinjectorsworking
time.
Fueltankdevicepartiallyobstructedby
impuritiesordeformedbecauseofover-
heating.
Checkiftheprimingpumpofthepre-filter
isworkingcorrectly.
Ifthepumpplungerispermanentlyde-
presseddisassembleandcheckthetank
pick.-uptube.Ifthisisinorder,replacethe
pre-filter.
Obstructedairfilter.Replacetheairfilter.Solvethecauseofthefilter’sobstruction.
Excessivefuelblow-byfromrailboost
valve.
ChecktheORingsandthecorrectcon-
nectionofthepipefittingsunderthe
feedingpump(thelockersmuststayout-
sideandthefittingsmustbewelllocked).
Visuallycheckthelowpressurepipeline
integrity.
Unlesstheleakageissignificant,noper-
formancefailureswillbedetected.
ToverifyO-ringsintegrity,extractfrom
thetankthefuelrecyclingpipeline,seal
theendandactivatetheprimingpump
drivingthelowpressurecircuit.
Excessivefuelblow-byfromrailboost
valve.
Disconnectthepipeandvisuallycheckif
thereareanysignificantblow-byfromthe
boostgaugevalve;insuchcasereplace
thevalve.
Theenginesuddenlystops(withnoprevi-
ousproblems)anddoesnotstartagain.
Obstructedfuelfilter.Replacethefuelfilter.Solvethecauseofthefilter’sobstruction
(emptyandcleanthetankandthepartof
thecircuitoverthefilter,refillwithclean
fuel).

ANOMALY
POSSIBLECAUSE
RECOMMENDEDTESTSOR
INTERVENTION
REMARKS
Theenginedisconnectsordoesnotstart.(*)
EDC”burned”byshortcircuitonthewir-
ingharnessofthefrictionclutch.
Eliminatetheshortcircuitandreplacethe
EDC.
Verifythatthewireline,closetothe
pedal,isnotexposedto.
Difficultstartandlowperformanceinall
conditions.
Inefficienthighpressurepump.Afterhavingexcludedanyotherpossible
cause,replacethehighpressurepump.
Difficultstart,lowperformanceanden-
ginerunningwithonecylinderless.
Injectorwithobstructerorsolenoid
(mechanicalpart)blockedopen.
Thenon-workinginjectoriseasilyrecog-
nisabledetectingbyfeelingtheabsenceof
pulsingwithintherelevanthighpressure
pipe.
Incaseoflowentityblow-by,inficiating
themechanicalworkingoftheinjector
butnotinvolvingflowlimiteractivation,
thereisnoerrormemorisationintheen-
ginecontrolmodule.
Iftheflowlimiterisactivated.Checkerror
codememory.
Startingrequiresinexcessoftenseconds,
followedbyhugewhiteexhaustfumes,
andafuelsmell.
Injectorblockedinopenposition(with
noreturn).
pipe.
Usually,whethersuchsymptomsappear,
itisinstinctivetogiveupenginestart.
However,byinsisting,itispossibletostart
theengine.
Asamatteroffacts,byinsisting,ifwithin
therailthepressuremakestheflowli-
mitercloseup,theenginestartswithone
cylinderlessandgraduallythegradeof
fumesreducesanddisappears.
Breakingofhighpressurepipelinefrom
pumptorail.
Strangevibrationsprovokedbyslackof
pipebracket.
Replacethepipelineensuringthecorrect
tighteningoftheanti-vibrationbracket
screws.
Itisveryimportant,inadditiontocorrect
blocking,tokeepthebracketsintheorig-
inalposition.
Theengineworkswithonecylinderless,
withoutmemorisingfailureblinkcodesin
theenginecontrolmodule.
Injectorblockedinclosedposition.Identifytheinjectorthatisnotworking
anymoreandtherelatinghighpressure
filler.
pipe.

Iveco workshop manual

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