New Holland F4HE9484CJ102 F4HE9484CJ103 Tier 3 Engine Repair Manual 87643867 - PDF DOWNLOAD

ENGINE REPAIR MANUAL ENGINE

F4HE9484C*J102 F4HE9484C*J103 TIER 3

Bur • Issued 01June07 Printed in U.S.A. • Book/Form Number 87643867 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.

REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01June07

F4HE9484C*J102, F4HE9484C*J102 Tier 3

87643867 NA

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America LLC. Carol Stream, IL 60188 U.S.A.

1

TO READER This manual has been printed for a skilful engineer to supply necessary technical information to carry out service operations on this engine.

CNH ITALIA S.p.A. Technical Information Viale delle Nazioni, 55 41100 MODENA - Italy

Read carefully this manual to collect correct information relevant to repair procedures.

For any question or remark, or in case of any error relevant the contents of this manual, please contact:

COMPLETE REPAIR MANUAL This Repair Manual contains the necessary technical information to carry out service and repairs on the “Engine”, indicates the necessary tools for maintenance operations, delivers information about service standards, about the removal and installation procedures and disassembly and assembly procedures. " The complete Service Manual consists of following volume:

VOLUME Service Manual - “Engine”

TYPE

PRINT NUMBER

F4HE9484C*J102 F4HE9484C*J103

87643867

2

AVOID ACCIDENTS The majority of accidents and injuries which occur in the workshop, at the work site, at home or on the road, are caused by the failure to observe simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before the accident occurs.

A careful operator and / or technician is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands of serious injuries each year.

This precaution is: Never attempt to clean, lubricate or adjust a machine while it is in motion.

CNH ITALIA S.p.A. Technical Information Viale delle Nazioni, 55 41100 MODENA - Italy All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.

NEF-F4HE ENGINE 1. TECHNICAL SPECIFICATIONS................................................................................................................... 1 2. MAIN DATA .................................................................................................................................................. 2 2.1 CRANKCASE......................................................................................................................................... 2 2.2 CRANKSHAFT AND BEARINGS .......................................................................................................... 2 2.3 CONNECTING ROD.............................................................................................................................. 2 2.4 CYLINDERS AND PISTONS ................................................................................................................. 3 2.5 VALVE GEAR TIMING........................................................................................................................... 3 2.6 TAPPETS............................................................................................................................................... 3 2.7 ROCKERS AND VALVES...................................................................................................................... 4 2.8 CYLINDER HEAD.................................................................................................................................. 4 2.9 TIGHTENING TORQUES ...................................................................................................................... 5 3. TOOLS.......................................................................................................................................................... 9 4. OPERATION............................................................................................................................................... 10 4.1 LUBRICATION..................................................................................................................................... 10 4.2 COOLING ............................................................................................................................................ 11 4.3 SUPPLY............................................................................................................................................... 12 5. TROUBLESHOOTING................................................................................................................................ 25 6. ENGINE DISASSEMBLY............................................................................................................................ 29 7. ENGINE ASSEMBLY.................................................................................................................................. 42 8. CHECKS, MEASUREMENTS AND REPAIR OPERATIONS ..................................................................... 72 8.1 CRANKCASE AND CYLINDERS LINERS .......................................................................................... 72 8.2 CRANKSHAFT..................................................................................................................................... 74 8.3 CONNECTING ROD............................................................................................................................ 76 8.4 PISTONS ............................................................................................................................................. 78 8.5 VALVES AND CAMSHAFT.................................................................................................................. 81 8.6 VALVE SPRINGS ................................................................................................................................ 83 8.7 TAPPETS............................................................................................................................................. 83 8.8 CAMSHAFT ......................................................................................................................................... 84 8.9 CAMSHAFT BUSHINGS ..................................................................................................................... 85 8.10 CYLINDER HEAD.............................................................................................................................. 86

9. MAINTENANCE.......................................................................................................................................... 87 9.1 GENERAL NOTES - SAFETY PRECAUTIONS .................................................................................. 87 9.2 PRECAUTIONS DURING MAINTENANCE......................................................................................... 88 9.3 DAILY CHECKS................................................................................................................................... 89 9.4 REPLACEMENTS................................................................................................................................ 94 10. ELECTRICAL COMPONENTS ................................................................................................................. 96 10.1 COOLANT TEMPERATURE SENSOR ............................................................................................. 97 10.2 ELECTROINJECTORS...................................................................................................................... 97 10.3 FUEL PRESSURE SENSOR............................................................................................................. 98 10.4 TEMPERATURE SENSOR OF AIR BOOST PRESSURE ................................................................ 98 10.5 ENGINE CABLE ................................................................................................................................ 98 10.6 MAIN VALVE GEAR TIMING SENSOR ............................................................................................ 99 10.7 PRESSURE REGULATOR................................................................................................................ 99 10.8 FUEL TEMPERATURE SENSOR ................................................................................................... 100 10.9 ELECTRONIC CONTROL MODULE............................................................................................... 100 10.10 CRANKSHAFT SENSOR .............................................................................................................. 101 10.11 ENGINE OIL PRESSURE TEMPERATURE SENSOR ................................................................. 101 10.12 PRE-AFTER-HEATING RESISTOR .............................................................................................. 102

NEF-F4HE ENGINE

1.

1

TECHNICAL SPECIFICATIONS

MODEL Models .................................................................................................................... F4HE9484C*J102 - C*J103 Cycle ....................................................................................................................................... diesel, four stroke Injection............................................................................................................................. direct (Common Rail) Number of cylinders .......................................................................................................................................... 4 Number of valves per cylinder .......................................................................................................................... 2 Piston bore................................................................................................................................. 140 mm (5.5 in) Piston stroke .............................................................................................................................. 132 mm (5.2 in) Cylinder displacement........................................................................................................ 4485 cm3 (273.7 in3) Compression Ratio ................................................................................................................................... 17.5:1 Maximum power................................................................................................................. 82 kW (60741 ft·lb/s) Revolution number (maximum power) ................................................................................................. 2200 rpm Maximum torque (CEE) ......................................................................................................516 Nm (380.6 lbf·ft) Revolution number (maximum torque)................................................................................................. 1400 rpm LUBRICATION Pressure feed lubrication ........................................................ with gear pump, pressure control valve, oil filter Oil pressure (with engine hot): at idle speed .......................................................................................................................... 0.7 bar (10 psi) at top speed .............................................................................................................................. 4 bar (58 psi) COOLING Type ........................................................................................................................................ with cooling liquid H2O .......................................................................................................................................... pump belt control Thermostat (opening starts at)................................................................................. 81 ± 2 °C (177.8 ± 35.6 °F) VALVE GEAR TIMING Intake Start: before T.D.C. ............................................................................................................................... 18.5° End: after B.D.C..................................................................................................................................... 29.5° Exhaust Start: before T.D.C. .................................................................................................................................. 67° End: after B.D.C........................................................................................................................................ 35° Valve and rocker operating clearance (with cold engine) Intake ..................................................................................................... 0.20 ÷ 0.30 mm (0.0078 ÷ 0.011 in) Exhaust ................................................................................................ 0.45 ÷ 0.55 mm (0.0177 ÷ 0.0216 in) SUPPLY Type ......................................................................................................... BOSCH high pressure, Common Rail Overfeed ..................................................................................................................................... with intercooler Turbocharger .............................................................................................................................. HOLSET HX35 Injectors ...................................................................................................................................................CRIU 2 Injection sequence ................................................................................................................................... 1-3-4-2 Injection pressure........................................................................................... 250 - 1600 bar (3625 - 23197 psi)

2

NEF-F4HE ENGINE

2.

MAIN DATA

2.1

CRANKCASE

Crankcase ............................................................... monoblock in cast iron, complete with cylinders liners seats, crankshaft, camshaft and tappets Cylinder liner diameter ...................................................................... 104.000 ÷ 104.024 mm (4.094 ÷ 4.095 in) Cylinder liner oversized diameter...................................................... 104.500 ÷ 104.424 mm (4.114 ÷ 4.111 in) Half bearing housing diameter: outer no. 1-5................................................................................. 87.982 ÷ 88.008 mm (3.4638 ÷ 3.4648 in) inner no. 2-3-4.............................................................................. 87.977 ÷ 88.013 mm (3.4636 ÷ 3.4650 in) Camshaft bushing housing diameter: rear................................................................................................... 59.222 ÷ 59.248 mm (2.331 ÷ 2.332 in) Housing diameter for normal tappets on crankcase.............................. 16.000 ÷ 16.030 mm (0.629 ÷ 0.631 in)

2.2

CRANKSHAFT AND BEARINGS

Crankshaft................................................................................................... balanced with inner counterweights Normal main journals diameter ............................................................. 82.990 ÷ 83.010 mm (3.267 ÷ 3.268 in) Undersizes on main journals diameter................................................0.250 ÷ -0.500 mm (0.0098 ÷ -0.0196 in) Normal main half bearing thickness ...................................................... 2.456 ÷ 2.464 mm (0.0966 ÷ 0.0970 in) Undersizes on spare main half bearing inside diameter ....................... 0.250 ÷ 0.500 mm (0.0098 ÷ 0.0196 in) Clearance between main journals and bearings: no. 1-5 .......................................................................................... 0.041 ÷ 0.119 mm (0.00161 ÷ 0.00469 in) no. 2-3-4....................................................................................... 0.041 ÷ 0.103 mm (0.00161 ÷ 0.00406 in) Diameter for normal connecting rod pins .............................................. 68.987 ÷ 69.013 mm (2.716 ÷ 2.717 in) Undersizes on connecting rod pins ....................................................... 0.250 ÷ 0.500 mm (0.0098 ÷ 0.0196 in) Normal connecting rod half bearing thickness ...................................... 1.955 ÷ 1.968 mm (0.0769 ÷ 0.0774 in) Undersizes on spare connecting rod half bearing inside diameter ....... 0.250 ÷ 0.500 mm (0.0098 ÷ 0.0196 in) Clearance between bearings and connecting rod pins ....................... 0.054 ÷ 0.094 mm (0.00213 ÷ 0.0037 in) Main bearing width for shoulder ................................................................ 32.18 ÷ 32.28 mm (1.267 ÷ 1.271 in) Corresponding crankshaft journal width................................................ 37.475 ÷ 37.545 mm (1.475 ÷ 1.478 in)

2.3

CONNECTING ROD

Connecting rods ........................................................................................ steel drop forging with crosswise cut Bushing housing diameter on connecting rod small end....................... 40.987 ÷ 41.013 mm (1.613 ÷ 1.614 in) Connecting rod small end bushing outside diameter ............................ 41.279 ÷ 41.553 mm (1.625 ÷ 1.636 in) Interference between bushing and housing on connecting rod small end 0.266 ÷ 0.566 mm (0.010 ÷ 0.022 in) Connecting rod small end bushing inside diameter (to be obtained after force-fitting) .......................................................... 38.019 ÷ 38.033 mm (1.496 ÷ 1.497 in) Half bearing housing diameter on connecting rod................................. 72.987 ÷ 73.013 mm (2.873 ÷ 2.874 in) Crankshaft journal-connecting rod end play...................................... 0.019 ÷ 0.039 mm (0.00075 ÷ 0.00154 in)

NEF-F4HE ENGINE 2.4

3

CYLINDERS AND PISTONS

Pistons ......... in light alloy complete with three snap rings two of which used as seals and one as a wiper seal Normal piston diameter 49.5 mm (1.95 in) from the skirt base, measured at right angles to the pin axis ........................................... 103.714 ÷ 103.732 mm (4.083 ÷ 4.084 in) Clearance between pistons and cylinder liners................................... 0.223 ÷ 0.263 mm (0.00878 ÷ 0.1035 in) Spare piston oversizes.......................................................................................................... 0.4 mm (0.0157 in) Piston protrusion at T.D.C. in relation to crankcase...................................... 0.28 ÷ 0.52 mm (0.011 ÷ 0.020 in) Piston pin diameter ............................................................................... 37.994 ÷ 38.000 mm (1.495 ÷ 1.496 in) Pin housing diameter on piston......................................................... 38.010 ÷ 38.016 mm (1.4964 ÷ 1.4967 in) Clearance between pin and housings on piston ................................. 0.010 ÷ 0.022 mm (0.0004 ÷ 0.00087 in) Clearance between piston pin and connecting rod small end bushing0.019 ÷ 0.039 mm (0.00075 ÷ 0.00154 in) Piston ring groove height: 1st ring ............................................................................................. 2.705 ÷ 2.735 mm (0.1065 ÷ 0.1076 in) 2nd ring ................................................................................................ 2.44 ÷ 2.46 mm (0.0960 ÷ 0.0968 in) 3rd ring................................................................................................. 4.030 ÷ 4.050 mm (0.158 ÷ 0.159 in) Snap rings thickness: 1st ring ................................................................................................. 2.560 ÷ 2.605 mm (0.1008 ÷ 0.1025) 2nd ring ................................................................................................ 2.350 ÷ 2.380 mm (0.092 ÷ 0.093 in) 3rd ring................................................................................................... 3.97 ÷ 3.990 mm (0.156 ÷ 0.157 in) Assembly clearance between snap rings and their housing on piston (vertical): 1st ring ................................................................................................. 0.100 ÷ 0.175 mm (0.004 ÷ 0.007 in) 2nd ring .................................................................................................. 0.06 ÷ 0.11 mm (0.002 ÷ 0.0043 in) 3rd ring............................................................................................... 0.040 ÷ 0.08 mm (0.0015 ÷ 0.0031 in) Assembly clearances between ends of rings, inserted in cylinder liners: 1st ring ..................................................................................................... 0.30 ÷ 0.40 mm (0.012 ÷ 0.015 in) 2nd ring .................................................................................................... 0.60 ÷ 0.80 mm (0.023 ÷ 0.031 in) 3rd ring..................................................................................................... 0.35 ÷ 0.55 mm (0.013 ÷ 0.021 in) Snap rings oversize .............................................................................................................. 0.4 mm (0.0157 in)

2.5

VALVE GEAR TIMING

Bushings inside diameter (forced-fitted and finished in housing).......... 54.083 ÷ 54.147 mm (2.129 ÷ 2.131 in) Camshaft pin diameter.......................................................................... 53.995 ÷ 54.045 mm (2.125 ÷ 2.127 in) Clearance between pins and bushings ................................................. 0.038 ÷ 0.162 mm (0.0015 ÷ 0.0063 in) Camshaft end play ............................................................................................................................................. Play between camshaft teeth and crankshaft .................................................................................................... -

2.6

TAPPETS

Tappet housing diameter on crankcase................................................ 16.000 ÷ 16.030 mm (0.630 ÷ 0.631 in) Normal tappet outside diameter............................................................ 15.924 ÷ 15.954 mm (0.627 ÷ 0.628 in) Clearance between tappets and their housings on crankcase ......... 0.025 ÷ 0.070 mm (0.00098 ÷ 0.00276 in)

4 2.7

NEF-F4HE ENGINE ROCKERS AND VALVES

Rocker holder shaft diameter ................................................................ 21.965 ÷ 21.977 mm (0.864 ÷ 0.865 in) Rocker holder shaft housing diameter .................................................. 22.001 ÷ 22.027 mm (0.866 ÷ 0.867 in) Clearance between rocker holder and shaft ....................................... 0.024 ÷ 0.062 mm (0.00094 ÷ 0.0024 in) Clearance between rockers and valves for engine operation (cold): intake valve .............................................................................................. 0.20 ÷ 0.30 mm (0.007 ÷ 0.011 in) exhaust valve ........................................................................................... 0.45 ÷ 0.55 mm (0.017 ÷ 0.021 in) Useful cam lift: intake valve .................................................................................................................... 7.582 mm (0.298 in) exhaust valve ................................................................................................................. 6.045 mm (0.237 in)

2.8

CYLINDER HEAD

Cylinder head ....................... cast iron with inserted valve seats and seats for injectors and thermostatic valve Maximum thickness removable from cylinder head for regrinding ...................................... 0.130 mm (0.005 in) Valve stem seat diameter on cylinder head .............................................. 7.042 ÷ 7.062 mm (0.277 ÷ 0.278 in) Valve stem diameter ..................................................................................... 6.97 ÷ 6.99 mm (0.274 ÷ 0.275 in) Assembly clearance between valve stem and its housing ........................ 0.052 ÷ 0.092 mm (0.002 ÷ 0.003 in) Valve seat inclination angle on cylinder head: for intake valve ............................................................................................................................. 60° ± 0.25° for exhaust valve .......................................................................................................................... 45° ± 0.25° Inclination angle of valves: for intake valve ............................................................................................................................. 60° ± 0.25° for exhaust valve .......................................................................................................................... 45° ± 0.25° Diameter on head for valve seat insert: for intake valve ................................................................................. 34.863 ÷ 34.863 mm (1.372 ÷ 1.372 in) for exhaust valve .............................................................................. 34.837 ÷ 34.863 mm (1.371 ÷ 1.372 in) Valve seat insert outside diameter: for intake valve ................................................................................. 34.917 ÷ 34.931 mm (1.374 ÷ 1.375 in) for exhaust valve .............................................................................. 34.917 ÷ 34.931 mm (1.374 ÷ 1.375 in) Valve sinking in relation to cylinder head surface: for intake valve ......................................................................................... 0.59 ÷ 1.11 mm (0.023 ÷ 0.043 in) for exhaust valve ...................................................................................... 0.96 ÷ 1.48 mm (0.037 ÷ 0.058 in) Interference between valve seat and head: for intake valve ......................................................................................... 0.54 ÷ 0.94 mm (0.021 ÷ 0.037 in) for exhaust valve ...................................................................................... 0.54 ÷ 0.94 mm (0.021 ÷ 0.037 in) Intake and exhaust valve spring modifications: Free spring nominal length............................................................................................... 47.75 mm (1.87 in) spring length under a load of 339.8 + 19 N (34.65 + 1.93 kgf)......................................... 35.33 mm (1.39 in) spring length under a load of 741 + 39 N (75.55 + 3.97 kgf).............................................. 25.2 mm (0.99 in)

NEF-F4HE ENGINE 2.9

5

TIGHTENING TORQUES TORQUE VALUE

ITEM

Nm

kgm

M6 studs for camshaft sensors

8±2

0.8 ± 0.2

M8 studs for supply pump

12 ± 2

1.2 ± 0.2

M12 fixing screw for rear gear box M10 fixing screw for rear gear box M8 fixing screw for rear gear box

77 ± 12 47 ± 5 24 ± 4

7.7 ± 1.2 4.7 ± 0.5 2.4 ± 0.4

M6 fixing nut for camshaft sensor

10 ± 2

1 ± 0.2

8±1 24 ± 4

0.8 ± 0.1 2.4 ± 0.4

M8 front cover fixing screw

24 ± 4

2.4 ± 0.4

M8 camshaft longitudinal retainer plate fixing screw

24 ± 4

2.4 ± 0.4

M8 camshaft gear fixing screw

36 ± 4

3.6 ± 0.4

M10 underblock plate fixing screw

43 ± 5

4.3 ± 0.4

M18 high pressure pump gear fixing nut

105 ± 5

10.5 ± 0.5

M8 fuel pump fixing nuts

24 ± 4

2.4 ± 0.4

1/5.08 cm (0.39/2 in) cylinders head plug 6 mm (1/4 in) cylinders head plug 18 mm (3/4 in) cylinders head plug

24 ± 4 36 ± 5 12 ± 2

2.4 ± 0.4 3.6 ± 0.5 1.2 ± 0.2

8.5 ± 0.35

0.85 ± 0.035

M8 fixing screw for oil pump

Injectors M6 fixing screws 1ststep

1nd step 2nd step

1nd step 2nd step

75° ± 5

Injector supply connector fixing nut

50 ± 5

5 ± 0.5

M6 nut preheating grid on intake manifold

8±2

0.8 ± 0.2

M8 intake manifold fixing screw

24 ± 4

2.4 ± 0.4

M12 engine lift rear brackets fixing screw

77 ± 12

7.7 ± 1.2

M8 Common Rail fixing screws

24 ± 4

2.4 ± 0.4

M14 high pressure fuel pipes connectors

20 ± 2

2 ± 0.2

35 ± 5

3.5 ± 0.5

M12 (12 x 1.75 x 130) cylinder head fixing screw M12 (12 x 1.75 x 150) cylinder head fixing screw

1nd step

Angle

2nd step

90° ± 5°

3nd step

90° ± 5°

Rockers holder fixing screw

36 ± 5

3.6 ± 0.5

Valves clearance adjusting nuts

24 ± 4

2.4 ± 0.4

M14 fixing nuts for supply pipes from high pressure pump to Common Rail

20 ± 2

2 ± 0.2

6

NEF-F4HE ENGINE

TORQUE VALUE

ITEM

Nm

kgm

M8 high pressure hose connector fixing screw

24 ± 4

2.4 ± 0.4

M6 fixing screw for through-wall head of wiring

10 ± 2

1 ± 0.2

M8 fixing screw for electric wiring holder of electroinjectors supply

24 ± 4

2.4 ± 0.4

Fixing nuts of wiring on each electroinjector

1.5 ± 0.25

0.15 ± 0.025

M12 fixing screw for fuel filter holding bracket

77 ± 8

7.7 ± 0.8

M8 fuel filter holder fixing screw

24 ± 4

2.4 ± 0.4

Fuel filter

contact + 3/4 of turn

M22 fixing screw of oil pressure control valve on oil filter support

80 ± 8

8 ± 0.8

M8 screw of radiator seal and oil filter support

24 ± 4

2.4 ± 0.4

Oil filter

contact + 3/4 of turn

35 mm (11/8 in) connection on filter support for turbine lubrication

24 ± 4

2.4 ± 0.4

M12 fixing nut for turbine lubrication pipe fixing

10 ± 2

1 ± 0.2

M10 fixing screw for engine coolant inlet connection

43 ± 6

4.3 ± 0.6

90° elbow fixing (if required) on engine liquid inlet connection

24 ± 4

2.4 ± 0.4

Turbocharger cooling pipes on cylinder head

22 ± 2

2.2 ± 0.2

M6 fixing screw for engine coolant exhaust connection

10 ± 2

1 ± 0.2

Pins fixing on engine block for exhaust manifold

10 ± 2

1 ± 0.2

M10 fixing screw for exhaust manifold on cylinder head

53 ± 5

5.3 ± 0.5

50 ± 5

5 ± 0.5

M12 fixing screw for dumper adapter

Angle

1nd step 2nd step

90°

M10 crankshaft pulley fixing screw

68 ± 7

6.8 ± 0.7

M8 water pump fixing screw

24 ± 4

2.4 ± 0.4

M10 drive belt tensioner of additional tools fixing screw

43 ± 6

4.3 ± 0.6

M10 fixed pulley for drive belt of additional tools fixing screw

43 ± 6

4.3 ± 0.6

M10 flywheel box fixing screw M12 flywheel box fixing screw

85 ± 10 49 ± 5

8.5 ± 1 4.9 ± 0.5

M6 heat exchanger for control module fixing screw M8 heat exchanger for control module fixing screw

10 ± 2 24 ± 4

1 ± 0.2 2.4 ± 0.4

NEF-F4HE ENGINE

7

TORQUE VALUE

ITEM

Nm

kgm

M12 fuel inlet-outlet on heat exchanger connection

12 ± 2

1.2 ± 0.2

M8 valves cover fixing nut

24 ± 4

2.4 ± 0.4

M6 camshaft sensor fixing nut

8±2

0.8 ± 0.2

M6 crankshaft sensor fixing screw

8±2

0.8 ± 0.2

M14 sensor of engine coolant temperature fixing screw

20 ± 3

2 ± 0.3

M5 pressure sensor - oil temperature fixing screw

6±1

0.6 ± 0.1

Fuel pressure sensor fixing screw

35 ± 5

3.5 ± 0.5

M14 Fuel temperature sensor fixing screw

20 ± 3

2 ± 0.3

Fixing screw of air temperature/pressure sensor on intake manifold

6±1

0.6 ± 0.1

M12 engine oil level sensor fixing screw

12 ± 2

1.2 ± 0.2

M8 studs

7±1

0.7 ± 0.1

M8 nuts

24 ± 4

2.4 ± 0.4

M12 adapter on turbine for lubrication oil pipes (inlet)

35 ± 5

3.5 ± 0.5

Pipes fixing on M10 adapter for turbine lubrication

35 ± 5

3.5 ± 0.5

Pipes fixing on M10 adapter for turbine lubrication

35 ± 5

3.5 ± 0.5

Pipes fixing on M10 adapter for turbine lubrication on crankcase

43 ± 6

4.3 ± 0.6

2.4 ± 0.4

24 ± 4

10±2

1±0.2

30 ± 4

3 ± 0.4

Turbine to exhaust manifold fixing:

Oil exhaust pipes M8 fixing pipes on turbine M6 connector fixing for oil return from cylinders head to flywheel M12 engine flywheel fixing screw

1ndstep 2ndstep

60° ± 5°

M8 engine lift front bracket fixing screw

24 ± 4

2.4 ± 0.4

Engine sump fixing screw

24 ± 4

2.4 ± 0.4

15 ± 3

1.5 ± 0.3

50 ± 6 80 ± 6

5 ± 0.6 8 ± 0.6

M8 lubrication nozzles cylinder liners fixing screws 1ndstep M12 crankshaft caps fixing screw

2ndstep 3ndstep

90° ± 5°

M8 camshaft longitudinal retainer plate fixing screw

24 ± 4

2.4 ± 0.4

M8 camshaft gear fixing screw

36 ± 4

3.6 ± 0.4

60 ± 5

6 ± 0.5

M11 connecting rod caps fixing screw

1ndstep 2ndstep

Angle

60° ± 5°

8

NEF-F4HE ENGINE

ITEM

TORQUE VALUE Nm

kgm

M10 fixing screw of bracket on connector + water inlet

43 ± 6

4.3 ± 0.6

M10 alternator fixing screw

43 ± 6

4.3 ± 0.6

43 ± 6

4.3 ± 0.6

Alternator

Starter Starter fixing screw

Angle

NEF-F4HE ENGINE

3.

TOOLS P/N

FUNCTION

380000144

Tool for retaining flywheel

380000158

Torque screwdriver for calibrating injector solenoid valve connector check nut

380000220

Tool for inserting piston in cylinder liner

380000221

Pliers for disassembly and reassembly the piston rings

380000302

Tool for disassembly and reassembly the engine valves

380000362

Tool for lifting the crankshaft

380000364

Dial gauge holder base for miscellaneous measurements (use with 380001004)

380000661

Brackets fastening engine to revolving stand 380000978

380000663

Tool for removing crankshaft rear seal

380000664

Tool for installing crankshaft rear seal

380000665

Tool for removing crankshaft front seal

380000666

Tool for installing crankshaft front seal

380000667

Drift for disassembly and reassembly the camshaft bushings (use with 380000668)

380000668

Grip for drifts

380000669

Tool for removing seals

380000670

Tool for engine oil filter disassembly

380000978

Revolving stand

380000980

Double-acting lift

380000981

Pair of brackets

380000988

Tool for retaining and turning flywheel

380000993

Rocking sling for engine disassembly and reassembly

380001001

Gauge torque for angular tightening

380001004

Dial gauge

380001099

Tool for removing injectors

380001218

Hand-held tester PT-01

9

10

NEF-F4HE ENGINE

4.

OPERATION

4.1

LUBRICATION

B

Oil circulation in the engine Oil falling Exhaust

Lubrication layout Lubrication by forced circulation takes place through the following components: " oil pump, housed in the front part of the crankcase, driven by the grooved bushing keyed onto the crankshaft spigot; " water / oil heat exchanger, housed in the crankcase;

" oil pressure adjustment valve incorporated in the exchanger unit; " by-pass valve for shutting off clogged oil filter, incorporated in the exchanger unit; " cartridge oil filter.

NEF-F4HE ENGINE 4.2

11

COOLING

Thermostat water outlet Water circulation in the engine Pump water inlet The engine cooling system is by forced circulation with closed circuit and includes the following components: " expansion tank: it can change location, shape and dimension according to the engine outfit; " radiator, has the task to dissipate the heat drawn from the engine by the coolant. Also this component is a feature of the outfit both as location and as size; " viscostatic fan with the aim to increase the dissipating power of radiator: it is also part of the engine specific outfit; " an heat exchanger to cool down the lubrication oil: it is also part of the engine specific outfit;

A. Expansion tank B. Heater C. Radiator " a centrifugal water pump house in the front side of the engine crankcase; " a thermostat regulating the cooling liquid circulation; " the circuit can possibly reach also the compressor if the outfit includes this.

12 4.3

NEF-F4HE ENGINE SUPPLY

The Common Rail system allows to inject fuel under pressures between 1450-1600 bar (2102223197 psi), while injection accuracy, obtained

through the electronic control of the system, optimizes the engine operation and limits its exhausts and consumption.

Exhaust Intake (low pressure) 1. High pressure pump 2. Pressure control valve on high pressure pump, 5 bar (73 psi) 3. Pressure control valve installed on fuel return of electroinjectors 1, 3 ÷ 2 bar (15, 44 ÷ 29 psi) 4. Common Rail overpressure relief valve 5. Common Rail 6. Pressure sensor 7. Electroinjector 8. Return pipeline

High pressure pump feed (low pressure) High pressure 9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Control module heat exchanger Mechanical lift pump Prefilter installed on frame (if installed) Fuel tank Mechanical feeding pump Fuel filter Pressure regulator High pressure pump cooling pipeline.

By-pass valve By-pass valve

NEF-F4HE ENGINE The pressure regulator, installed uphill of high pressure pump, regulates the fuel flow required for low pressure system. Next the high pressure pump feeds the Common Rail correctly. This solution pressurizes only the required fuel, improves the energy performance and limits the heating of the fuel system.

The pressure control valve (2), installed on the high pressure pump, has the aim to hold pressure, at pressure regulator intake constant at 5 bar (73 psi), apart from fuel filter and uphill system efficiency. The pressure control valve (2) actuation creates an increase of fuel flow in the cooling system of high pressure valve, through inlet (16) and outlet (8) pipeline.

The pressure control valve, housed on cylinders head, installed on electroinjectors return (3), limits the fuel return flow from electroinjectors at a pressure of 1.3 ÷ 2 bar (15, 44 ÷ 29 psi).

Two by-pass valves are parallel positioned in relation to the mechanical feeding pump.

The by-pass valve (18) allows to let the fuel flow from the mechanical pump outlet to its inlet, when the pressure at fuel filter inlet exceeds the limit value permitted. The by-pass valve (17) allows to fill the supply system through the manual lift pump (10).

13

14

NEF-F4HE ENGINE

OPERATION

High pressure Low pressure Fuel exhaust 1.

2.

3.

4.

Electroinjector Common Rail Pressure limiter for fuel return Common Rail overpressure relief valve

The Common Rail system includes a special pump that holds the fuel constantly under high pressure, regardless of the phase and of the cylinder receiving the injection and accumulates it into a duct common to all electroinjectors. At electroinjectors inlet fuel is always available for injection pressure evaluated by the electronic module.

When the solenoid valve of an electroinjector is actuated by electronic module, the fuel, taken from the Common Rail, is injected inside of relevant cylinder.

The feeding system consists of a low pressure circuit and of a high pressure one.

The high pressure circuit consists of following pipelines:

5.

6.

7.

8.

Pre-filter installed on the frame High pressure pump Mechanical pump with rotors Fuel filter.

" pipeline connecting the high pressure pump outlet to the Common Rail; " pipeline feeding the electroinjectors from the Common Rail.

The low pressure circuit consists of following pipelines: " fuel intake pipeline from tank to pre-filter; " pipelines supplying the mechanical feeding pump through the heat exchanger of the control module, the manual lift pump and the pre-filter; " pipelines feeding the high pressure pump through the fuel filter.

The feeding system is complete with fuel exhaust circuit from Common Rail, with injectors and cooling circuit of high pressure pump.

NEF-F4HE ENGINE

15

HIGH PRESSURE PUMP The pump with 3 radial pumping elements, driven through the camshaft gear, does not need timing. In the rear side of high pressure pump is installed the mechanical feeding pump, driven by the shaft of high pressure pump.

NOTE: the high pressure pump assy cannot be overhauled and it can therefore not be disassembled and its fixing screws are not to be removed. The sole intervention allowed concerns the replacement of the drive gear and of the pressure regulator.

Components

1.

2.

3.

4.

5.

6.

Fuel outlet connector to Common Rail High pressure pump Pressure regulator Drive gear Fuel inlet connector from filter Fuel outlet connector to filter support

7. Fuel inlet connector from heat exchanger of control module 8. Fuel outlet connector from mechanical pump to filter 9. Mechanical feeding pump.

16

NEF-F4HE ENGINE

MECHANICAL FEEDING PUMP The gear pump, installed on the rear side of high pressure pump, has the aim to feed the same. It is driven by the high pressure pump shaft.

NOTE: the mechanical feeding pump cannot be replaced as single unit, it must not therefore be disassembled from the high pressure pump.

Normal operating condition A. B. 1.

2.

Fuel inlet from tank Fuel outlet to filter By-pass valve closed.

By-pass valve closed.

Outlet overpressure condition The by-pass valve (1) actuates when overpressure is generated at port B. The pressure overcomes the spring elastic resistance (1) and sets the outlet with the inlet (2) in contact.

Bleeding condition The by-pass valve (2) actuates when, with engine shut-off, the feeding system has to be filled through the lift pump. Under this condition, the by-pass valve (1) holds closed and the by-pass valve (2) opens, due to the inlet pressure effect and fuel flows out from port B.

NEF-F4HE ENGINE Inner pump structure

1.

2.

3.

4.

Cylinder Trilobal element Plate intake valve Ball suction valve

Each pumping element consists of: " a piston (5) actuated by a trilobal element (2) floating on the pump shaft (6). The element (2) is floating on the offset end of shaft (6), during the shaft rotation it does not turn with the same, but it is only moved into a circular movement on a wider radius, with the result of alternative activation of the three pumping elements; " plate intake valve (3); " a ball suction valve (4).

5.

6.

7.

8.

Piston Pump shaft Low pressure fuel inlet Fuel ducts for pumping elements feeding.

17

18

NEF-F4HE ENGINE

Operation principle

1.

2.

3.

4.

Fuel outlet connector to Common Rail Feeding valve to Common Rail Pumping element Pump shaft

The pumping element (3) is directed towards the cam of the pump shaft (4). During the intake phase, the pumping element is fed through the feeding duct (5). The fuel quantity to be sent to the pumping element is established by pressure regulator (7). The pressure regulator, according to the control received by the control module, allows a partial fuel

5. pumping element feeding duct 6. Pressure regulator feeding duct 7. Pressure regulator flow to the pumping element. During the compression phase pumping element, the fuel reaches such a pressure to open the suction valve to Common Rail (2) opens, feeds it though the outlet (1).

NEF-F4HE ENGINE 1.

2.

3.

4.

5.

6.

7.

8.

9.

Inlet to pumping element Ducts for pump lubrication Inlet to pumping element Main duct for pumping elements feeding Pressure regulator Inlet to pumping element Regulator exhaust duct 5 bar pressure control valve Fuel exhaust from regulator inlet.

The illustration shows the fuel paths under low pressure inside of pump, are outlined the mains duct for pumping elements feeding (4), the pumping elements feeding ducts (1-3-6), the ducts used for pump lubrication (2), the pressure regulator (5), the 5 bar (73 psi) pressure control valve (8) and the fuel exhaust (7). The pump shaft is lubricated by fuel through feeding and return ducts (2). The pressure regulator (5) establishes the fuel quantity for pumping elements feeding; the excess fuel flows through duct (9). The 5 bar (73 psi) pressure control valve, beyond being used as a manifold for fuel exhausts, has also the function to keep pressure constant at 5 bar (73 psi) at regulator inlet.

1. Fuel outlet duct 2. Fuel outlet duct 3. Fuel outlet from the pump with connector for high pressure pipeline for Common Rail.

The illustration shows the high pressure fuel flow through the ducts outlets of the pumping elements.

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NEF-F4HE ENGINE

Operation The cylinder is filled through the plate suction valve only if the feeding pressure is able to open the feeding valves installed on the pumping elements (2 bar (29 psi) approx.). The fuel quantity feeding the high pressure pump, is regulated by the pressure regulator, located on the low pressure system; the pressure regulator is controlled through the control module by means of a signal. When fuel is sent to the pumping element, the relevant piston shifts downwards (intake stroke). When the piston stroke reverts, the intake valve closes and the fuel left in the pumping chamber, being trapped, is compressed beyond the feeding pressure value contained in the Common Rail. The pressure generated in this way, causes the opening of the exhaust valve and the compressed fuel reaches the high pressure circuit. The pumping element compresses the fuel until the T.D.C. is achieved. After that the pressure decreases until the exhaust valve closes. The piston of the pumping element returns to the B.D.C. and the fuel left decompresses. When the pressure in the chamber of pumping element becomes lower than the feeding pressure, the intake valve opens again and the cycle is repeated. The suction valves must always be free during their movement, showing any contamination or oxidation. The suction pressure to the Common Rail is regulated between 250 and 1600 bar (3625 and 23197 psi) from the electronic module, through the solenoid of the pressure regulator. The pump is lubricated and cooled by the same fuel. The disassembly-assembly time of the pump on the engine is remarkably reduced in relation to the traditional injection pumps, because it does not need any timing.

In case of disassembly-assembly of pipeline between fuel filter and high pressure pump, observe the maximum cleanliness of hands and components.

NEF-F4HE ENGINE COMMON RAIL (PRESSURE ACCUMULATOR) 1.

2.

3.

4.

Common Rail Fuel inlet from high pressure pump Overpressure relief valve Pressure sensor

The Common Rail volume is of contained sizes to allow a quick pressurization at start-up, at idle run or in case of high flow rates.

Its volume is though sufficient to reduce fuel residuals caused by the opening and closing of injectors and by the operation of pump under high pressure.

This operation is further eased through a calibrated hole located downhill of the high pressure pump. A fuel pressure sensor (4) is screwed on the Common Rail.

This sensor sends a feedback signal to the electronic module, according to which the pressure value inside of the Common Rail is verified and, if necessary, corrected.

OVERPRESSURE RELIEF VALVE This valve is fitted on one Common Rail end and has the aim to protect the system components in case of misfunctioning of the Common Rail pressure sensor or pressure regulator of the high pressure pump, causing an excessive increase of pressure in the high pressure system. When the pressure inside the Common Rail reaches 1800 bar (26096 psi), the valve actuates initially to let fuel flow and to decrease pressure to safety values and then it regulates mechanically the pressure inside of the Common Rail at about 800 bar (11598 psi). This valve allows the engine operation for long periods of time at limited output and avoids overheating of fuel, protecting the tank return pipeline.

ELECTROINJECTOR The engines NEF TIER 3 use BOSCH-CRIN 2 electroinjectors with different atomizers, according to the output of the engine.

Atomizers

kW Outputs

Bar pressures

DLLA

major than I52

250 ÷ 1600 bar (3625 ÷ 23197 psi)

DSLA

minor than I52

250 ÷ 1450 bar (3625 ÷ 21022 psi)

The injector construction is similar to traditional ones, except for the absence of return springs in the poppet. The injector consists of two parts: " actuator-atomizer including a pressure rod (1), a poppet (2) and a nozzle (3); " control solenoid including a coil (4) and a pilot valve (5).

The solenoid valve controls the lifting of the atomizer poppet.

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NEF-F4HE ENGINE

Injector to resting position 1. Pressure rod 2. Poppet 3. Nozzle 4. Coil 5. Pilot valve 6. Ball plug 7. Check area 8. Pressure chamber 9. Check volume 10. Check duct 11. Feeding duct 12. Check fuel outlet 13. Electric connection 14. Spring 15. High pressure fuel inlet

Injection start When the coil (4) is energized, it shifts the ball plug (6) upwards. The fuel of check volume (9) flows to the flow-back duct (12) causing a pressure drop in the check volume (9).

At the same time the fuel pressure inside of pressure chamber (8) causes the lifting of the poppet (2), with consequent injection of fuel inside cylinder.

Injection end When the coil (4) is de-energized, the ball plug (6) returns to closure position, to recreate a balance of forces that resets the poppet (2) to closure position and ends the injection.

NOTE: the electroinjector cannot be overhauled and therefore it should not be disassembled.

NEF-F4HE ENGINE PRESSURE LIMITER FOR FUEL RETURN Housed in the rear section of the cylinders head, it regulates the pressure of return fuel from injectors at a pressure between 1.3 ÷ 2 bar (19 ÷ 29 psi). By ensuring this service pressure to return fuel, the formation of fuel steam inside of the electroinjectors is avoided, optimizing the atomization of fuel and its combustion.

A. To the tank B. From electroinjectors

BOOST PRESSURE The turbocharger (A) consists of following main components, a turbine, a boost pressure regulating valve, a central body and a compressor. During the engine operation the exhaust gases flow through the turbine body actuating the turbine impeller. The turbocharger impeller, being connected with a shaft to the turbine impeller, turns with this one compressing the air sucked through an air filter (B). The air is cooled through the radiator (C) and sent through the intake manifold to the pistons. The turbocharger is equipped with a pressure control valve, installed on the exhaust manifold before the turbine and connected with a pipeline to the intake manifold. Its aim is to reduce the exhaust gas output by sending a part of it to the exhaust tube (D) when the boost pressure downhill of the turbocharger reaches the prescribed bar value.

The cooling and lubrication of the turbocharger and bearings is performed by the engine oil.

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NEF-F4HE ENGINE

EXHAUST GAS RECIRCULATION With TIER3 version, the exhaust cam profile has been modified to allow a partial opening of the relevant valve, during the intake phase (EGR exhaust gas recirculation) with the following re-introduction of a part of exhaust gases into the engine cylinders.

The exhaust gases can be partially re-introduced into the cylinders to reduce the maximum combustion temperature values, causing the formation of nitrogen oxides (NOx). The exhaust gas recirculation system (EGR), reduces the combustion temperature, with the oxygen concentration decrease inside of the combustion chamber, and represents therefore an effective check system for the emission of NOx. The inner EGR system is not equipped with electronically controlled elements: the system is always activated.

Its configuration does not need any additional element such as check valves, pipelines or heat exchangers. The exhaust cam beyond being equipped with a main lobe, is also provided of a further lobe corresponding to the configuration without EGR. The additional curve, during the intake phase of the concerned cylinder, allows a short opening of the exhaust valve, generating a recirculation due to the exhaust gas collection caused by the depression created during the suction phase inside of cylinder.

NEF-F4HE ENGINE

5.

25

TROUBLESHOOTING PROBLEM

Engine does not start.

CAUSE Partially run down batteries.

REMEDY Check, recharge the batteries and replace them if necessary.

Connections to batteries terminals Clean, examine, tighten the nuts corroded or loose. and, if necessary, replace the terminals and the nuts extremely corroded.

Incorrect timing of injection pump on Correctly time the injection pump on engine. the engine.

Collection of impurity or water in the Disconnect the lines, injection pump fuel lines. and clean them accurately and, if necessary, clean and dry the fuel tank.

The engine stops.

Fuel tank without fuel.

Fill.

No supply from injection pump.

Check and, if necessary, change the supply pump.

Air in the fuel circuit.

Check the lines, connectors, fuel pump, filters and injection pump for the presence of air; then bleed the circuit.

Starter motor damaged.

Repair or change the starter motor.

Idle rpm too low.

Adjust the idle speed.

Irregular flow of injection pump.

Check the flow rates on a test bench.

Collection of impurity or water in the Disconnect the lines, injection pump fuel lines. and clean them accurately and, if necessary, clean and dry the fuel tank.

Fuel filters clogged.

Change the filter cartridges.

Abnormal clearance between valves Adjust the clearance between valves and rockers. and rockers.

Burnt or cracked valves.

Change the valves.

Air in the fuel circuit.

Check the lines, connectors, fuel pump, filters and injection pump for the presence of air; then bleed the circuit.

Injection pump controls damaged.

Replace damaged items.

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NEF-F4HE ENGINE

PROBLEM

CAUSE

The engine overheats.

REMEDY

Cooling circuit centrifugal pump not Overhaul the pump and change it if working properly. necessary.

Faulty thermostat.

Change the thermostat.

Partial radiator failure.

Wash to remove any scaling, find and repair any leaks from the pipes.

Scaling where the coolant fluid flows Wash thoroughly. to the cylinder head and crankcase.

Centrifugal pump and fan drive belt Check and adjust the belt tension. too slack.

The engine abnormally.

is

Coolant fluid (low quantity).

Restore the level in the expansion tank using the specified fluid.

Incorrect engine timing.

Check and time the engine correctly.

Air cleaner clogged.

Clean the unit and, if necessary, change the filtering element.

knocking Partially clogged injectors.

or

damaged Clean, overhaul and set the injectors correctly.

Collection of impurity or water in the Clean the lines and change heavily fuel lines. damaged ones; if necessary, clean the injection pump.

Incorrect timing of injection pump on Correctly time the injection pump on engine. the engine.

Crankshaft knocking caused by too Grind the crankshaft pins, assemble much clearance of one or more main oversized shoulder bearings and or connecting rod bearings or high rings. shoulder clearance.

Crankshaft unbalanced.

Check shaft balancing and necessary.

alignment and change it if

Slack flywheel fixing screws.

Change the slackened screws and tighten all screws to the specified torque + angle.

Connection rods out of parallel.

Straighten the connecting rods, check parallelism and, if necessary, change the actual connecting rods.

Piston knocking due to abnormal Bore the cylinder liners wear. assemble oversized pistons.

Noisy piston pins due to too much clearance in the piston stubs and in the connecting rod bushing.

Bushings free in the housing on the connecting rod.

and

Replace the piston pin with an oversized one, reface the stubs on the piston and the connecting rod bushings. Replace the bushings with new ones. Replace bushings with new ones.

NEF-F4HE ENGINE

PROBLEM The engine abnormally.

is

CAUSE knocking Ticking due to noisy timing gear.

27

REMEDY Check for broken springs, too much clearance between stems and guides, tappets and seats; adjust the clearance between valves and rockers.

Abnormal engine smoke: Maximum injection pump flow rate Adjust the injection pump on the bench following the calibration table. black or dark grey smoke. too high.

The injection pump is delayed too Correctly time the injection pump on much or the automatic advance the engine or check the automatic advance variator. variator is damaged.

The injection pump is too much Correctly time the injection pump on the engine. advanced.

Partially and/or totally clogged or Clean, overhaul and adjust the injectors correctly; change them if incorrectly set injectors. necessary.

Air cleaner clogged.

Clean the unit and, if necessary, change the filtering element.

Loss of compression in the engine Change the damaged parts or, if necessary, overhaul the engine. caused by: - piston rings stuck; - cylinder liners worn; - valves worn out or not adjusted.

Injection lines damaged.

Check the condition of the lines and change them if necessary.

Blue, grey-blue or whitish grey The injection pump is delayed too Correctly time the injection pump on smoke. much or the automatic advance the engine or check the automatic advance variator. variator is damaged.

Blocked or faulty injectors.

Clean, overhaul and adjust the injectors correctly; change them if necessary.

Oil passing from the piston rings Change the damaged parts or, if caused by stuck rings or liner wear. necessary, overhaul the engine.

Oil passing through the intake valve Overhaul the cylinders head. guide caused by worn guides or valve stems.

The engine fails to reach operating Change the thermostat. temperature (damaged thermostat).

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NEF-F4HE ENGINE

PROBLEM Start-up difficult and performance under conditions.

CAUSE low Inefficient high pressure pump. all

REMEDY After examination of all other possible causes, replace the high pressure pump.

Difficult start-up, low Injector with plug or solenoid coil The injector not operating is easy to performance and engine turn (mechanical part) locked open. locate by feeling with the fingers the with one cylinder less. absence of pulsation in the relevant high pressure line.

Start-up requires a tens of Injector blocked open (irreversibly). seconds, enormous development of white smoke at exhaust and fuel smell.

The injector not operating is easy to locate by feeling with the fingers the absence of pulsation in the relevant high pressure line.

High pressure pipeline break Anomalous vibrations due to loose Replace the pipeline, verify the from pump to Common Rail. pipe fastening. correct tightening of anti-vibration brackets screws.

The engine operates with one Injector clogged. cylinder less, without storing the errors in the control module.

Locate the injector clogged and replace it with relevant high pressure filler.

NEF-F4HE ENGINE

6.

ENGINE DISASSEMBLY

WARNING Handle all parts with great care. Never put your hands and fingers between one part or another.

Wear proper protective clothing such as safety goggles, gloves and footwear.

Drain oil from the engine by removing the plug of the sump and the oil filling plug.

Disconnect the fan assy from the blower pulley.

To apply at engine crankcase the brackets 380000981 for fastening the engine to overhauling trestle, you have to perform following at the left side of engine: with tool 380000670 disassemble the fuel filter (5) from the support (2); disconnect the electric connection (3) from the support (2) and the heater connection (always located on the filter support); disconnect the fuel pipelines at low pressure (1 - 4 6) from the support (2); disconnect the pipeline (7) from the support (2); disconnect the supporting bracket (2) from the crankcase.

Disconnect the high pressure fuel line (1) from the Common Rail diffuser and from the high pressure pump (2) and remove it from the engine crankcase, by loosening the fastening clamps.

Disconnect the pipeline (3) supplying the mechanical pump coupled to the high pressure pump through a heat exchanger of the electronic module.

To disconnect the fuel line at low pressure from the relevant connector the hold the little spring (1) pressed and slide out the quick plug-in connector.

To connect the low pressure fuel line with the connector, plug-in, into this latter the quick plug-in connector (2) and press until the retainer (3) clicks.

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NEF-F4HE ENGINE

From the right side remove the fixing screws and disconnect the line (2) for oil return from turbocharger tube (1) and from engine crankcase.

Remove the starter motor (2) from flywheel cover (1).

Apply the brackets 380000661 to the crankcase and fasten with them the engine to the rotary trestle 380000978.

Remove or disconnect the injectors wiring (1), the cooling water sensor (2), the fuel pressure sensor cable (3), the engine oil temperature sensor (4), the crankshaft sensor (5), the electroinjector (6), the air temperature sensor (7), the valve gear timing sensor (8), the fuel heater cable and fuel temperature sensor (9), the pressure control cable (10) and the control module (11).

NEF-F4HE ENGINE Disconnect the fuel lines (5) from Common Rail (2) and from the manifolds (6) of the electroinjectors.

NOTE: during the disconnection of the connectors (1) for lines fixing (5) to the Common Rail (2) prevent with suitable wrench, the possible rotation of the flow limiters (4).

Remove the screws (3) and disconnect the Common Rail (2).

Disconnect the pipeline (2) for fuel return from the pressure limiter (1), by handling on connections.

Unscrew the nut and loose the retaining clamp of the oil steam pipeline (5).

Disconnect the hose (6).

Unscrew the screws (3) and disassemble the blowby filter (4).

By handling on the nuts, disconnect the tappets cover.

Remove the nuts (8) and disconnect the electric cables from electroinjectors (7).

Remove the screws (1) and disconnect the support (2) of electroinjectors complete with gasket.

Remove the screws (5) and disconnect the temperature/air pressure sensor (6).

Remove the nuts (3) and take out the fuel manifolds (4).

NOTE: the fuel manifolds (4) once disassembled, are not to be reused, but they must be replaced with new ones.

Loosen the fixing nuts (1) for tappet adjustment and unscrew the adjustments.

Remove the screws (2), remove the rockers assy (3) consisting of support (6), rockers (4), shafts (5) and remove the spindles (7) from the valves.

Disassemble the rods (8).

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NEF-F4HE ENGINE

Remove the fixing screws of electroinjectors and with tool 380001099 (1) take out the electroinjectors (2) from the cylinders head.

Handle on belt tensioner (1) and slide out the belt (2) from the alternator pulleys, of water pumps and crank pulleys. Remove the belt tensioner (1). Unscrew the screws fixing the alternator (3) to the support and disassemble it.

Disconnect the oil line (3) from the heat exchanger/ oil filter support and from the connector (4) of the turbine.

Remove the fixing nuts and disconnect the turbocharger (1) from the exhaust manifold (2).

Remove the screws and disconnect the exhaust manifold (2) from the cylinders head.

From the opposite side, unscrew the intake manifold fixing screws (1) and disassemble it with the air heater (2) for engine cold start.

NEF-F4HE ENGINE Hook the brackets 380000661 (1) with metallic wires and with an hoist detach the cylinders head (2) from the crankcase.

Remove the screws (2) and disconnect the alternator support (3).

Drain the engine oil by removing the plug from the oil sump.

IMPORTANT: collect the oil and dispose of it according to current regulations.

With tool 99360076 disassemble the oil filter (1).

Remove the screws (4) and disassemble the oil pressure/temperature sensor (3).

Remove the screws (1) and disassemble the support (2) of heat exchanger/oil filter, intermediate plate (6) and relevant gaskets.

Disassemble the oil level sensor (5).

Remove the screws (1) and disconnect the electronic module (2) complete with heat exchanger.

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NEF-F4HE ENGINE

Loosen screws (3) and disassemble the cover (1).

Collect the gasket (4), the PTO (2) and the second gasket (4).

Remove the nuts (3) and disconnect the high pressure pump (4) complete with feeding pump (5).

Remove the nut (1) and disassemble the timing sensor (2).

Apply to flywheel box (1) tool 380000144 (2) to lock the flywheel rotation (3).

Loosen screws (4).

Loosen screws (3) and disassemble the damper flywheel (2) and the pulley (1).

NOTE: the locking tool for the flywheel can easy the disassembly of damper flywheel (2) assembled on the pulley (1).

NEF-F4HE ENGINE Remove the screws (1) and disconnect the water pump (2).

Remove the screw (3) and disassemble the roller (4).

Remove the screw (5) and disconnect the engine rpm sensor (6).

NOTE: the water pump (2) cannot be overhauled. In case of faulty operation, it must be replaced.

Removal of crankshaft front seal ring.

Apply tool 380000980 (4) on crankshaft front spigot (2).

Through the guide holes of tool 380000980 (4), drill the inner seal ring (1), with a drill tip (ø 3.5 mm (0.137 in)), for a depth of 5 mm (0.196 in).

Fasten the tool 380000980 (4) to the ring (1) with screws (3) provided.

Proceed with the ring (1) extraction by screwing the screw (5).

Apply a tie-rod (3) of tool 380000669 to the outer seal ring (1) and by means of lever (4), take out the same from the front cover (2).

Remove the front cover (2).

Remove the screws (1) and (3) and disconnect the front cover (2).

NOTE: mark the mounting position of screws (1) because they have different sizes.

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NEF-F4HE ENGINE

Remove the screws (2) and the oil gear pump (1).

NOTE: the oil pump (1) cannot be overhauled.

In case of faulty operation, it must be replaced.

Remove two opposed screws (1) where the puller pins will be inserted.

Unscrew the remaining fastening screws of crankshaft (4) flywheel (3).

Remove the tool 380000144 (2) blocking the flywheel.

Screw two screws of middle length into the holes (4) to sling the flywheel (1) at an hoist.

By means of two pins (2) screwed into the crankshaft holes (3) guide the extraction of flywheel (1) by means of an hoist.

Removal of crankshaft rear seal ring Remove the seal ring by applying on crankshaft rear spigot (1) the tool 380000665 (3). Through the guide holes of tool 380000665 (3), drill the inner seal ring (5), with a drill tip (ø 3.5 mm (0.137 in)), for a depth of 5 mm.

Fasten the tool 380000665 (3) to the ring (5) by screwing screws (2) provided. Proceed with the ring (5) extraction by screwing the screw (4).

Remove the screws (2) and disconnect the flywheel box (1).

NOTE: mark the mounting position of the screws (2) because they differ in size.

NEF-F4HE ENGINE Remove the screws (2) and disassemble the flywheel box (1).

NOTE: mark the screws (2) position.

Overturn the engine, remove the screws (2), disassemble the plate (3) and detach the oil sump (1).

Remove the screws (1) and (4) and disassemble the oil suction rose (5).

Remove the screws (2) and disassemble the plate stiffening plate (3).

Remove the screws (1) and disassemble the gear (3) from the camshaft (2).

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NEF-F4HE ENGINE

The valves are disassembled by means of tool 380000302 (1) exerting pressure on the plate (3) so that by compressing the springs (4), it is possible to remove the cotters (2).

After that remove: the plate (3), the springs (4).

Repeat the operation on all the valves (5).

Overturn the cylinders heads and take out all the valves (5).

Disassemble the seal rings (1) and (2) from the relevant valve guides.

NOTE: the seal rings (1) of intake valves are yellow: the seal rings (2) of exhaust valves are green:

The intake (1) and exhaust valves (2) have the mushroom with the same diameter.

The central hollow part of the exhaust valve (2) differs from the one of the intake valve.

NOTE: before valves disassembly from cylinders head, number them to ease their reassembly, in the same position marked during disassembly, if they will not be replaced.

A = intake side - S = exhaust side

Major valves specifications.

NEF-F4HE ENGINE Remove the screws (2) and the timing gear box (1).

NOTE: mark the mounting position of the screws (2) because they differ in size.

Remove the fixing screws (1) of connecting rod caps (2) and disassemble them.

Slide out the pistons complete with connecting rods from the top part of the crankcase.

NOTE: keep the half bearings in their housings, because if they are reused, they will have to be reinstalled in their original position.

Remove the snap rings (1) from the piston (3) with pliers 380000221 (2).

The rings (2) retaining the piston pin (1) are removed using a scribe (3).

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NEF-F4HE ENGINE

Remove the screws (1) and disassemble the main bearing caps (2).

The second last main bearing cap (1) and its support have the half bearing (2) with shoulder.

Remove the pistons with the corresponding connecting rods.

NOTE: mark the assembly position of the lower and upper half bearings, because if they are reused, they will have to be reinstalled in their original position.

By means of tool 380000362 (1) and lift, remove the crankshaft (2) from the crankcase.

Remove the main half bearings (1).

Remove the screws (2) and disassemble the oil spray jets (3).

NEF-F4HE ENGINE Remove the screws (1) and disassemble the plate (3) retaining the camshaft (2).

NOTE: mark the assembly position of the plate (3).

Carefully remove the camshaft (1) from the crankcase.

Remove the tappets (1) from the crankcase.

For disassembly and replacement of front and rear bushings (1) of crankcase use drift 380000667 (2) and grip 380000668 (3).

41

42

7.

NEF-F4HE ENGINE

ENGINE ASSEMBLY

When total or partial engine disassembly is carried out, all the seals must be changed.

Lubricate rotating parts and seals with engine oil, before putting them in place.

At oil filter assembly, lubricate the seal with engine oil.

WARNING Handle all parts with great care. Never put your hands between one part or another and use the most appropriate tools for aligning bores.

Wear proper protective clothing such as safety goggles, gloves and footwear.

BUSHING ASSEMBLY For assembly and replacement of front and rear bushings (1) of the camshaft use drift 380000667 (2) and grip 380000668 (3).

NOTE: at assembly the bushings (1) should be directed so that the lubrication holes coincide with those on the crankcase housings.

TAPPER ASSEMBLY Lubricate the tappets (1) and assemble them into the relevant housings of the crankcase.

NEF-F4HE ENGINE CAMSHAFT ASSEMBLY Lubricate the camshaft support bushings and assemble the camshaft (1) taking care not to damage the bushings or support housings while doing so.

Place the plate (1) retaining the camshaft (2) with the slot facing the top part of the crankcase and the stamping facing the operator, tighten the screws (3) to the prescribed torque.

Check that the end play of the camshaft (1) is within the specified range of tolerance.

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OIL SPRAY JET ASSEMBLY Assemble the spray jets (2) and tighten the fixing screws (1) to the prescribed torque.

CRANKSHAFT ASSEMBLY If the main journals and connecting rod pins show signs of seizure, scores or excessive ovalisation, regrind them. Before grinding the pins (1), use a micrometric gauge (2) to measure the shaft pins and establish, according to the spare undersizes the diameter to which the pins are to be reduced.

Check that the toothing of the gear (1), keyed onto the crankshaft (2) is not damaged or worn, if so, remove it using a suitable puller tool (3).

To assemble the new gear, heat it in the oven for 10 minutes at a temperature of 180 °C (356 °F) and shrink it onto the shaft interposing the key.

NEF-F4HE ENGINE

NOTE: if the crankshaft main journals are undersized, the main bearings should be replaced with those of the same undersized class.

The spare main bearings (1) are undersized on the inside diameter between 0.250 ÷ 0.500 mm (0.0098 ÷ 0.019 in).

NOTE: do not do any adaptation work on the bearings.

Carefully clean the main half bearings (1) with hole for lubrication and assemble them in their housing.

The second-last main half bearing (1) is fitted with the half thrust rings.

Assemble the crankshaft (1).

Check the clearance between the crankshaft main journals and the respective bearings.

Clean the parts carefully to eliminate all traces of oil.

Place on the crankshaft journals (4) on parallel with the longitudinal axis a length of calibrated wire (3).

Assemble the caps (1), complete with half bearings (2), on the corresponding supports.

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Insert the screws (1) lubricated beforehand and tighten them in three steps.

1st and 2nd step with torque spanner to specified torque.

3rd step with tool 380001001 (1) positioned as shown tighten further the screws (2) with an angle of 90° ± 55°.

Remove the caps from the supports.

The clearance between the main bearings and the respective journals is measured comparing the width of the calibrated wire (1) in the point mostly squeezed, with the graduated scale on the packet (2) containing the calibrated wire.

The numbers on the scale indicate the coupling clearance in millimetres.

Check that the clearance is as specified, then lubricate the main bearings and definitely assemble the supports tightening the fixing screws as described previously.

The crankshaft assembly and play is checked using a dial gauge (2) with magnetic base on the crankshaft (3) as illustrated, the normal assembly clearance must be within the tolerance specified.

If the clearance is higher, replace the main half bearings of the second last rear support (1) and check the clearance again between the crankshaft journals and the main half bearings.

NEF-F4HE ENGINE CONNECTING ROD-PISTON ASSEMBLY The following references are etched on the piston crown: 1. Spare part number and design change number.

2. Arrow showing the direction of assembly of the piston in the cylinder liner, it must be faced towards the crankcase front (auxiliary components side).

3. Date of manufacture.

4. Stamp indicating the 1st insert inspection.

With the pin (3) connect the piston (2) to the connecting rod (4) so that the reference arrow (1) for piston (2) assembly in the cylinder liner and the numbers (5) etched on the connecting rod (4) are visible.

Insert the snap ring (2) for pin (1) fastening.

To assemble the snap rings (1) on the piston (3) use pliers 380000221 (2).

NOTE: the snap rings are supplied as spares in the following sizes: standard, marked with yellow paint; oversized by 0.5 mm (0.19 in) and marked with yellow/green paint.

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Assemble the half bearings (1) on the connecting rod (2) and on the cap (3).

NOTE: if the crankpins are undersized, the crank bearings should be replaced with those of the same undersized class.

Never try to adapt the half bearings.

ASSEMBLY OF CONNECTING ROD-PISTON ASSY IN THE CYLINDER LINERS Thoroughly lubricate the pistons, including the snap rings and the inside of cylinder liners.

With the help of tool 380000220 (2), assemble the connecting rod piston assy (1) in the cylinder liners.

The piston ring openings are to be offset by 120°; The connecting rod piston assemblies must all be of the same weight.

The arrow (1) stamped on the piston crown must be facing the engine auxiliary components and the notch on the piston skirt corresponding with the position of the oil spray jets.

NEF-F4HE ENGINE To measure the clearance, proceed as follows: " clean the parts carefully to eliminate all traces of oil; " place on the crankshaft journals (1) a length of calibrated wire (2); " assemble the connecting rods caps (3) with the corresponding half bearings (4).

CONNECTING ROD CAP ASSEMBLY Use a torque spanner (2) to tighten the screws (1) lubricated beforehand with engine oil to the torque specified.

Apply tool 380001001 (1) on the socket spanner and further tighten the screws (2).

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Remove the cap and find the clearance, comparing the width of the calibrated wire (1) with the graduation of the scale on the packet (2) that contained the wire.

Check that the clearance is as specified on page 5, then lubricate the connecting rod half bearings and definitively assemble them tightening the connecting rod cap fixing screws.

NOTE: before final assembly of the connecting rod cap fixing screws, check that their diameter, measured at the centre of the thread length, is not 0.1 mm (0.004 in) lower than the diameter measured at approximately 10 mm (0.4 in) from the end of the screw.

Check by hand that the connecting rods (1) slide axially on the crankshaft journals and that their end play measured with thickness gauge (2) is the prescribed one.

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TIMING GEAR BOX ASSEMBLY Carefully clean the timing gear box (1) and the crankcase.

Cleaning the surface to be sealed is absolutely necessary to obtain effective tightness. Apply LOCTITE 5205 on the box to form a seam with a diameter of a few mm (in). It must be even (no lumps), with no bubbles, thin or discontinuous areas.

Any imperfections should be corrected in the shortest time possible.

Avoid using excess material for sealing the joint. Too much sealant would tend to come out on both sides of the joint and obstruct the passages of the lubricant.

Diagram of LOCTITE application spots After application of the sealant, the joints require immediate assembly (10 - 20 minutes).

Reconnect the box to the crankcase.

Tighten the fixing screws (2) in the position noted at disassembly and to prescribed torques.

Screws tightening diagram CYLINDERS HEAD ASSEMBLY Lubricate the valve stems (1) and insert them in their guide valves according to the position marked during disassembly.

Assemble the seal rings (2) and (3) on the guide valves.

NOTE: the seal rings (2) of intake valves are yellow: the seal rings (3) of exhaust valves are green.

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On the cylinders head position: the spring (4) and the upper plate (3); use tool 380000302 (1) to compress the spring (4) and restrain the parts to the valve (5) through the cotters (2).

Check that the cylinder head surface (1) and the one on the crankcase are clean.

Do not dirty the cylinder head gasket.

NOTE: before reusing the cylinder head fixing screws, make sure they have no signs of wear or distortion, if so, change them.

Use dial gauge 380001004 (1) equipped with base 380000364 (2) to check that the protrusion of the pistons taken to the T.D.C. in relation to the crankcase top surface, is within the tolerance specified.

NEF-F4HE ENGINE As two types of head gasket exist, to choose the thickness (1.25 mm (0.049 in) Type A and 1.15 mm (0.045 in) Type B) carry out the following measurements: " for each piston, measure as illustrated, at a distance of 45 mm (1.77 in) from the centre of the piston its protrusions S1 and S2 in relation to the crankcase top surface and then calculate the mean: S1 + S2 Scil1 =

2

Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the mean value: S=

Scil1 + Scil2 + Scil3 + Scil4 + Scil5 + Scil6 6

If S is > 0.40 mm (0.015 in) use gasket type A. If S is < 0.40 mm (0.015 in) use gasket type B. After installing the gasket, assemble the cylinder head (2) on the crankcase tightening the screws (1) without locking to the torque.

Assemble the cylinder head (1), tighten the screws (2) and lock them in three steps, following the sequence and procedure shown in the next figure.

WARNING Angle tightening is carried out using tool 380001001 (3).

WARNING Before every assembly, always check that the threads of the holes and the screws reveal no signs of wear or traces of dirt.

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Tightening sequence of cylinder head fixing screws: " 1st preliminary tightening step with torque spanner: - Screw 12x1.75x130 ( ) 35 ± 5 Nm (25.8 ± 3.68 lbf·ft) - Screw 12x1.75x150 ( ) 55 ± 5 Nm (40.5 ± 3.68 lbf·ft) " 2rd step locking with an angle of 90º ± 5º " 3rd step locking with an angle of 90º ± 5º A. Front side

INJECTORS ASSEMBLY Assemble a new seal ring (2) lubricated with vaseline and a new seal washer (3) on the electroinjector (1).

Install the electroinjectors (1) in the housings on the cylinder head, directed so that the fuel admission hole (2) is facing the housing (3) of the fuel manifolds.

A

NEF-F4HE ENGINE Using tool 380001099 (1) set the electroinjector (2) in its housing.

Tighten the electroinjector fixing screws without locking them.

Install a new seal ring (3), lubricated with vaseline, on the fuel manifold (2) and insert it in the housing on the cylinder head so that the positioning balls (5) coincide with the corresponding housing (4).

NOTE: the fuel manifolds (2) once disassembled, are not to be reused, but they must be replaced with new ones.

Tighten the fixing nuts without locking them.

WARNING During this operation move the electroinjector (1) so that the fuel manifold (3) inserts correctly in the fuel admission hole.

Use a torque spanner to gradually and alternately tighten the electroinjector fixing screws (1) to a torque of 8.5 ÷ 0.8 Nm (6.3 ÷ 0.6 lbf·ft).

Tighten the nuts (2) fixing the fuel manifolds (3) to a torque of 50 Nm (36.8 lbf·ft).

Assemble the rocker unit after checking the parts.

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ROCKER UNIT ASSEMBLY Rocker unit components: 1. Screws 2. Rockers 3. Support 4. Spindles

Check the spindle (2) and the rocker (1) coupling surfaces for excessive wear or damage.

Before assembly check the rocker control rods (1): they should not be distorted; the round housings in contact with the rocker adjustment screw and with the tappet (arrows) should not reveal traces of seizure or wear; if so, change them. The rods that control the intake and exhaust valves are identical and therefore interchangeable.

Assemble the rods (2).

Position the bridges (1) on the valves with notches ( ) directed to the exhaust manifold.

NEF-F4HE ENGINE Check that the tappet adjustment screws (1) are slackened to prevent them from sticking on the rods (2) during assembly of the rocker unit.

Then assemble the rocker units formed of the support (5), rockers (3) spindles (4) and fasten them to the cylinder head tightening the screws to a torque of 36 Nm (26.55 lbf·ft).

Check the clearance between the rockers and valves using an Allen wrench (1), a polygonal wrench (3) and a thickness gauge (2).

The clearance is: " intake valves 0.25 ± 0.05 mm (0.0098 ± 0.0019 in) " exhaust valves 0.50 ± 0.05 mm (0.019 ± 0.0019 in).

WARNING With TIER 3 engines, owing to the presence of the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure with adjustment of the clearance of all the valves with just 2 positionings of the crankshaft.

Every cylinder must be checked taking it to the T.D.C. (top dead centre) at the end of the compression stroke and adjusting the clearance of both valves only on the cylinder in question.

Apply on the connection surface of the intake manifold (1) complete with heater (2) a sufficient coating of LOCTITE 5999 and tighten the screws to the prescribed torque.

Assemble the sensor (3) with a new seal.

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Assemble the Common Rail (2) and tighten the fixing screws (1) to the specified torque, connect the ground cable (M) to the intake manifold tightening the fixing nut to the prescribed torque.

Disconnect the fuel lines (1) from the Common Rail (3) and from the manifolds (2) of the electroinjectors.

NOTE: the pipe assembly (6) should be tightened to a torque of 20 Nm (14.75 lbf·ft), using the special spanner (5) and torque spanner (4). The connectors (3) should be tightened keeping the flow limiting valves still using the special hexagon spanner (1).

Connect the fuel line (6) to the Common Rail (2) following the procedures described below.

To connect the low pressure fuel line with the connector, plug-in, into this latter the quick plug-in connector (2) and press until the retainer (1) clicks.

NOTE: make sure that the fuel line is connected properly.

NEF-F4HE ENGINE Check the conditions of the electrical cables (5), change them if damaged cutting the clamps that fasten them to the support (2) and removing the screws (4) fastening them to the connectors (3).

Install a new seal (1) on the support (2).

Fit the wiring support (2), tighten the screws (1) and lock them to the specified torque.

WARNING Before every assembly, always check that the threads of the holes and the screws reveal no signs of wear or traces of dirt.

Connect the electrical cables (1) to the electroinjectors (3) and use torque spanner 380000158 (4) to tighten the fixing nuts (2) to the prescribed torque.

Install a new seal (2) on the tappet cover (1).

Assemble the tappet cover tightening the nuts and lock them to the prescribed torque.

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TIMING GEARS ASSEMBLY Use a marker pen to mark the tooth of the driving gear (1) fitted on the crankshaft (2) on the side of which the timing notch ( ) is stamped.

Direct the crankshaft (3) and camshaft (4) so that when the driven gear (1) is assembled on the latter, the marks stamped on the gears coincide (2).

Tighten the screws (1) fastening the gear (2) to the camshaft (3) and lock them to the prescribed torque.

NEF-F4HE ENGINE SUCTION ROSE ASSEMBLY Assemble the plate (1) and the suction rose (2).

Screw in screws (3), (4) and (5) and tighten them to prescribed torque.

OIL SUMP ASSEMBLY Install the new seal (1) on the oil sump (2).

Assemble the oil sump (1).

Insert the screws (2) and tighten them to prescribed torque.

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FLYWHEEL ASSEMBLY Carefully clean the connection surfaces of the flywheel box (1) and of the timing gear box.

Cleaning the surface to be sealed is absolutely necessary to obtain effective tightness.

Apply LOCTITE 5205 on the box (1) to form a seam with a diameter of a few mm.

It must be even (no lumps), with no bubbles, thin or discontinuous areas.

Any imperfections should be corrected in the shortest time possible.

Avoid using excess material for sealing the joint.

LOCTITE application diagram Too much sealant would tend to come out on both sides of the joint and obstruct the passages of the lubricant.

After application of the sealant, the joints require immediate assembly (10 - 20 minutes).

Reconnect the box to the crankcase, tighten the fixing screws (2) in the position noted at disassembly and lock them to the prescribed torque.

Screws tightening diagram CRANKSHAFT REAR SEAL ASSEMBLY On the rear spigot (3) of the crankshaft apply part (4) of tool 380000666, fasten it with the screws (5) and key the new seal ring (6) on it.

Position part (1) on part (4) and tighten the nut (2) until completely assembled the seal ring (6) in the flywheel box.

NEF-F4HE ENGINE FLYWHEEL ASSEMBLY Check that the clutch plate resting surface shows no signs of scores, if so, face it.

Check the conditions of the ring gear teeth (1), if breakage or excessive wear is noted, change it. Install the new one after heating it at a temperature of 150 °C (302 °F) for 15 - 20 minutes.

Tighten two pins (2) of suitable length in the holes of the shaft (3) and assemble the engine flywheel (1) using a suitable sling.

Key the flywheel (1) onto the crankshaft tightening the screws (2) by hand.

Suitably block the flywheel before tightening the screws to their torque with tool 380000144 (3).

Tighten the screws (1) fixing the flywheel (2) in two steps: " 1st step, tightening with a torque spanner to a torque of 30 ± 5 Nm (22.12 ± 3.68 lbf·ft); " 2nd step, locking with an angle of 60° ± 5°.

NOTE: angle tightening is carried out using tool 380001001.

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OIL PUMP ASSEMBLY Assemble the oil pump (1).

Insert the tightening screws (2) and tight them the prescribed torque.

FRONT COVER ASSEMBLY Fit the seal ring (2) on the front cover (1), carefully clean the connection surface to the crankcase and coat it with LOCTITE 5205.

Carefully clean the front cover connection surface on the crankcase (2) and install the front cover.

Insert the screws (1) and (3) tighten them to prescribed torque.

NEF-F4HE ENGINE CRANKSHAFT FRONT SEAL ASSEMBLY On the front spigot (3) of the crankshaft apply part (4) of tool 380000666, fasten it with the screws (5) and key the new seal ring (6) on it. Position part (1) on part (4) and tighten the nut (7) until completely fitting the seal ring (6) in the front cover (2).

WATER PUMP ASSEMBLY Fit a new seal ring (2) on the water pump (1).

Assemble the water pump (1).

Tighten the screws (2) and lock them to the prescribed torque.

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CRANKSHAFT FRONT PULLEY ASSEMBLY Key the pulley (1) and damper flywheel (2) on the crankshaft.

Tighten the fixing screws (3) and lock them to torque of 68 ± 7 Nm (50.15 ± 5.16 lbf·ft).

Fit a new seal ring on the rpm sensor (3).

Fit the rpm sensor (3) in the front cover (1) and tighten the fixing screw (2) to the prescribed torque.

NEF-F4HE ENGINE OIL FILTER ASSEMBLY Install on the crankcase: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter support (4).

Tighten the screws (5) and lock them to the prescribed torque.

WARNING Before every assembly, always check that the threads of the holes and the screws reveal no signs of wear or traces of dirt.

Lubricate the seal ring (2) and hub with engine oil and place it on the oil filter (3).

Tighten the oil filter (3) manually on the support connector (1) up to detent, tighten further the oil filter (3) by 3/4 of turn.

Apply a new seal ring to the temperature/oil pressure sensor (4) and assemble it on the support (1).

Tighten the screws (5) and lock them to the prescribed torque.

Place on the crankcase seat a new seal ring (6).

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ALTERNATOR ASSEMBLY Position the alternator support (1) so that the pins (3) are directed towards the engine crankcase.

Tighten the screws (2) and lock them to the prescribed torque.

WARNING Before every assembly, always check that the threads of the holes and the screws reveal no signs of wear or traces of dirt.

Reinstall the alternator (1).

Tighten the screws (2) and lock them to the prescribed torque.

Reconnect the automatic belt tensioner (2).

Screw the screw (3) and tighten it to the prescribed torque.

Turn the automatic belt tensioner (2) so as to key the belt (1) on the pulleys and guide rollers.

NEF-F4HE ENGINE HIGH PRESSURE PUMP ASSEMBLY Reconnect the high pressure pump (3) complete with feeding pump and tighten nuts (3) to prescribed torque. Assemble the support (4) with a new seal ring, the timing sensor (2) with a new seal ring and tighten relevant fixing nut (1) to prescribed torque.

ELECTRONIC CONTROL MODULE ASSEMBLY Assemble the electronic control module (2) complete with heat exchanger and tighten the screws (1) to prescribed torque.

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EXHAUST MANIFOLD ASSEMBLY Fit the exhaust manifold (2) with a new gasket and tighten the fixing screws to prescribed torque.

Sling the turbocharger (1) and place it above the manifold after placing a new gasket.

Connect the oil line (3) to the heat exchanger/oil filter support. Fasten the pipeline (3) to the turbocharger connector (1).

If installed, insert the blow-by filter (4) by tightening the screws (3). Connect the pipe (6) and fasten the oil vapour recovery pipe (5) using the clamp; tighten the nut fastening it to the top end. Connect the pipeline (2) to pressure limiter (1).

NEF-F4HE ENGINE ENGINE COMPLETION Suitably support the engine using the lift, release it from the rotary stand, remove the brackets 380000981 and rest it on a suitable support for the completion operations.

Assemble the starter motor (2) on the inner part of the flywheel cover (1).

Assemble the bracket and the support (2) of fuel filter (5).

Then connect in sequence the pipes (1), (4), and (6) of the high pressure pump support.

Connect the pipeline (7) from the high pressure pump to the heat exchanger of electronic control module.

Connect the pipeline (1) from the high pressure pump to the Common Rail diffuser.

Connect the electrical connection (3).

All the fuel pipes are fastened with the clamps illustrated.

To connect the low pressure fuel line with the connector, plug-in, into this latter the quick plug-in connector (1) and press until the retainer (2) clicks.

NOTE: if pipes are reused the ends must be plugged. Make sure that the fuel line is connected properly.

Fit the engine electric cable connecting all the sensors, the control unit and the Common Rail diffuser.

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8.

CHECKS, MEASUREMENTS AND REPAIR OPERATIONS

8.1

CRANKCASE AND CYLINDERS LINERS

After engine disassembly, clean the parts of the crankcase unit thoroughly.

Use the special lifting rings to handle the unit.

Carefully check that the crankcase is not cracked.

Check the conditions of the seal plugs on the crankcase. Change them if they are rusted or not tight.

Examine the cylinder liner surfaces; they should not show signs of scores, ovalisation, taper or excessive wear.

Checking the inside diameter of cylinder liners to find the amount of ovalisation, taper and wear is carried out using the bore gauge (1) fitted with dial gauge, reset beforehand on a ring gauge (2) of the diameter of the cylinder liner.

NOTE: if a ring gauge is not available, use a micrometer for resetting.

The measurements are to be carried out on every single cylinder liner at three different heights of the cylinder and on two perpendicular planes: one parallel with the longitudinal axis of the engine (A) and the other perpendicular (B); generally the highest amount of wear is noted on the latter plane in correspondence with the first measurement.

If ovalisation, taper or in any case wear is noted beyond the tolerances given, bore and grind the cylinder liners.

Regrinding the cylinder liners must be carried out in relation to the diameter of the pistons supplied as spare (oversized by 0.4 mm (0.015 in) compared with the nominal value) and to the assembly clearance.

NEF-F4HE ENGINE

NOTE: in the event of regrinding, all the liners must have the same oversize (0.4 mm (0.015 in)).

Check the housings of the main bearings proceeding as follows: " assemble the main bearing caps on the supports without bearings; " tighten the fixing screws to the prescribed torque; " with a suitable dial gauge for internal parts, check that the diameter of the housings is the prescribed value.

If a higher value is noted, change the crankcase. Examine the resting surface of the head on the cylinder unit for distortion. This check can be carried out after removing the dowels (2) with a calibrated rule (1) and thickness gauge (4). After having ascertained the distortion areas, reface the resting surface using a grinder.

The flatness error may not be over 0.075 mm (0.003 in).

NOTE: crankcase refacing may be carried out only after making sure that, at the end of the work, the protrusion of the piston from the cylinder liner is not over the value specified.

Check the conditions of the machining plugs (3) of the crankcase unit; if rusted, or in the slightest doubt as to their tightness change them. Upon completing refacing restore the chamfer of the cylinder liners.

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NEF-F4HE ENGINE CRANKSHAFT

Before carrying out any operation, clean the various parts thoroughly.

Carefully examine the crankshaft, which should be changed in the case of even slight cracks.

If the main journals and connecting rod pins show signs of seizure, scores or excessive ovalisation, regrind them. Before grinding the pins (1), use a micrometric gauge (2) to measure the shaft pins and establish, to which the pins are to be reduced.

NOTE: it is advisable to note the values measured on a table.

The undersizes are 0.2500 - 0.500 mm (0.0098 0.0196 in).

NOTE: the main journals and connecting rod pins must always be ground to the same undersize.

The undersize carried out on main journals and connecting rod pins should be marked by a special stamping on the side of the arm of crank no.1.

The letter M for undersized connecting rod pins.

The letter B for undersized main journals.

The letter MB for undersized connecting rod pins and main journals.

Table on which to note the values measured of crankshaft main journals and connecting rod pins.

* Nominal value

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Main crankshaft tolerances

* measured on a radius of over 45.5 mm (1.79 in) ** between adjacent main journals TOLERANCES

TOLERANCE CHARACTERISTIC

GRAPHIC SYMBOL

Roundness SHAPE Cilindricity Parallelism DIRECTION

Perpendicularity Straightness

POSITION

Concentricity or coaxiality Circular oscillation

OSCILLATION Total oscillation CLASS OF IMPORTANCE ATTRIBUTED TO PRODUCT CHARACTERISTICS CRITICAL IMPORTANT SECONDARY

GRAPHIC SYMBOL C

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8.3

CONNECTING ROD

Aside are indicated the main data of connecting rod (1), bushing (2), piston pin (3) and half-bearings (4) NOTE: the connecting rod-cap coupling surfaces are knurled for improved coupling. Therefore, do not remove the knurling.

Each connecting rod is marked: " on the body and on the cap with a number indicating their pairing and the cylinder in which it is fitted.

In the case of replacement, it is therefore necessary to number the new connecting rod with the same number as the one replaced. " On the connecting rod body by a letter indicating the weight class of the factory fitted connecting rod: - V, 1820 ÷ 1860 (marked in yellow); - W, 1861 ÷ 1900 (marked in green); - X, 1901 ÷ 1940 (marked in blue); Spare connecting rods are supplied with class W marked in green *.

Material removal is not allowed.

CONNECTING ROD BODY (1) 1234

W

Connecting rod no.

Weight

0001

V

L

W

9999

X

CONNECTING ROD CAP (2) 1234

A

123

Connecting rod no.

Year

Day

0001

A 1998

001

L

B 1999

L

9999

C 2000

366

D 2001

NEF-F4HE ENGINE INSPECTION Bushings Check that the bushing in the connecting rod small end is not loose and shows no signs of scores or seizure.

Otherwise, change it.

The bushing is removed and fitted using a suitable drift.

During assembly, ensure that the holes for the passage of oil on the bushing and on the connecting rod small end coincide. Use a reamer to reface the bushing and obtain the specified diameter.

Checking the torsion Check the torsion of the connecting rod (2) comparing two points (A) and (B) of the pin (4) on the horizontal plane of the connecting rod axis.

Position the support (1) of the dial gauge (5) so that it preloads by ~ 0.5 mm (0.0196 in) on the pin (4) in point (A) and reset the dial gauge (5). Move the spindle (3) with the connecting rod (2) and compare any deviation on the opposite side (B) of the pin (4): the difference between (A and B) should be no more than 0.08 mm (0.003 in).

Checking the flexure Check the flexure of the connecting rod (3) comparing two points (C) and (D) of the pin (4) on the vertical plane of the connecting rod axis. Position the vertical support (2) of the dial gauge (1) so that it rests on the pin (4) in point (C) as illustrated. Swing the connecting rod back and forth seeking the highest position of the pin and in this condition reset the dial gauge (1). Move the spindle with the connecting rod (3) and repeat the check in the highest point on the opposite side (D) of the pin (4). The difference between point (C) and point (D) should be no more than 0.08 mm (0.003 in).

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78 8.4

NEF-F4HE ENGINE PISTONS

Pistons nominal dimensions

PISTON DIAMETER MEASUREMENT Use a micrometer (2) to measure the piston diameter (1), to determine the assembly clearance.

The clearance between piston and cylinder liner can be measured with gauge and shims (1).

NEF-F4HE ENGINE PISTON PINS Piston pin diameter measurement (2) with micrometer (1).

Install the pins on the pistons checking that the coupling clearance between the pin and the housing is within the values given.

CONDITIONS FOR CORRECT PIN PISTON COUPLING Lubricate the pin (1) and its housing on the piston stubs with engine oil; the pin should insert in the piston pressing lightly with the fingers and it should not fall out by gravity.

SNAP RINGS Use a micrometer (1) to check that the thickness of the 1°2°3° seal rings (2) is within the tolerances given.

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NEF-F4HE ENGINE

Use a thickness gauge (3) to check that the clearance between the snap rings (2) and their houses on the piston (1) are within the prescribed values.

LAYOUT FOR MEASURING THE CLEARANCE OF THE TRAPEZOIDAL RING Due to the particular shape of the first trapezoidal ring, the clearance between the groove and the ring should be measured as follows; make the piston (1) protrude from the crankcase so that the ring (3) in question is half out of the cylinder liner (2).

In this position, use a thickness gauge to check the clearance (X) between the ring and the groove: this clearance should be as specified.

Use a thickness gauge (1) to check that the clearance between the ends of the rings (2) inserted in the cylinder liner (3) is as specified.

NEF-F4HE ENGINE 8.5

VALVES AND CAMSHAFT

Dimensions (mm (in)) of the intake valves (A) and exhaust valves (B).

VALVE DESCALING, CHECKING AND GRINDING Remove any carbon deposits on the valves (2) using the special metal brush (1).

Check that the valves reveal no signs of seizure, cracking or burns.

If necessary, grind the chamfers on the valve mushrooms, removing as little material as possible.

Use a micrometer (1) to measure the valve stems (2) and check that they are within the range of tolerance.

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Valve seat dimensions (mm (in))

Valve seat housing dimensions (mm (in))

1. Intake 2. Exhaust If the valve seats cannot be restored by refacing only, they can be replaced with spares. Using the special tool and taking care not to notch the cylinder head, remove the highest possible amount of valve seat material, until it is possible to remove them from the cylinder head with a punch. Heat the cylinder head to 80 ÷ 100 °C (176 ÷ 212 °F) and use a suitable drift to fit the new valve seats on it, after cooling them.

Then reface the valve seats according to the values given.

NEF-F4HE ENGINE After refacing operations, use the base 380000364 (2) and dial gauge 380001004 (1), to check that the sinking of the valves in relation to the cylinder head top surface is within the specified value.

8.6

VALVE SPRINGS

The figure shows the main data for checking intake and exhaust valve springs.

Before assembly, check the flexibility of valve springs using tool 380000976. Compare the loading and elastic distortion data with those given in the table below.

Height

Under a load of

mm (in)

N (kgf)

H (free)

47.75 (1.88)

H1

35.33 (1.39) P1

339.8 ± 19 N (34.65 ± 1.94 kfg)

H2

25.20 (0.99) P2

741 ± 39 N (75.5 ± 3.97 kfg)

8.7

No load

TAPPETS

Main data of tappets and their housings on the crankcase.

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84 8.8

NEF-F4HE ENGINE CAMSHAFT

Main camshaft data

The surfaces of the shaft support pins and those of the cams must be very smooth; in the event of traces of seizure and scoring, the shaft and its bushings should be changed.

CHECKING CAM LIFT AND PIN ALIGNMENT Place the shaft on dead centres and use a centesimal dial gauge on the centre support to check that the alignment error is no more than 0.04 mm (0.00157 in), otherwise change the shaft.

Check the lift of the cams: it should be of 6.045 mm (0.238 in) for the exhaust ones and of 7.582 for the intake ones. With different values the camshaft must be replaced.

Check the diameter of the camshaft support pins (2) with the micrometer (1) on two perpendicular axes.

NEF-F4HE ENGINE 8.9

CAMSHAFT BUSHINGS

Bushings data and relevant seats

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8.10 CYLINDER HEAD CHECKING THE CYLINDER HEAD RESTING SURFACE Check the head resting surface (1) on the cylinder unit using a ruler (2) and a thickness gauge (3).

The distortion measured on the whole length of the cylinder head should be no more than 0.20 mm (0.0078 in).

For higher values reface the cylinder head according to the values given in the following figure.

CYLINDERS HEAD THICKNESS The nominal thickness A of the cylinder head is 105 ± 0.25 mm (4.133±0.009 in), the maximum permissible removal of metal should not exceed the thickness B of 0.13 mm (0.005 in).

NOTE: after refacing, check the sinking of the valves and if necessary reface the valve seats to obtain the specified sinking.

CHECKING THE CYLINDER HEAD TIGHTNESS Check the hydraulic tightness using suitable equipment.

Through a pump, admit water heated to ~ 90 °C (194 °F) at a pressure of 2 ÷ 3 bars (29 ÷ 44psi).

If leaks are noted from the cup plugs (1), change them using a suitable drift for disassembly - assembly.

NOTE: before fitting the plugs, coat their sealing surface with water-reactive sealant.

If leaks are noted from the cylinder head, change it.

NEF-F4HE ENGINE

9.

MAINTENANCE

9.1

GENERAL NOTES - SAFETY PRECAUTIONS

Do not carry out any maintenance operations until you have read and understood the instructions and warnings given in this manual.

Keep the workshop at the highest degree of cleanliness and with proper ventilation.

For the works performed in closed rooms suck the emissions with a suction system and ventilate the room properly.

Verify the presence of a first aid kit, well visible and always equipped with proper medicines.

Keep at hand proper fir-extinguishing means, duly indicated and always free accessible. Check their efficiency periodically and inform the personnel on the priority of the intervention methods.

Do not smoke or use open flames in the vicinity of very hot engine parts, batteries or flammable material.

Wear proper and safety equipment: " use a safety helm, safety shoes, safety gloves and goggles, well fitting clothes to the body (without free skirts or sleeves); " carry out all operations with cold engine; " do not use different tools from the prescribed ones.

Dispose according to environment rules and current legislation, oils, fuels, detergents, solvents and components containing oil or fuel, like filters, rags, worn pieces.

Use the containers suited for disposal.

Also “ecological” hydraulic oil and biodegradable must be disposed of separately as any other oil.

Do not pour fuel, oils and oily waste into the earth or water, polluting in this way the environment.

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88 9.2

NEF-F4HE ENGINE PRECAUTIONS DURING MAINTENANCE

Never remove the filling plug of the cooling system when the engine is hot. The service pressure could splash out liquid under high temperature with the hazard of serious scalds. Wait until the temperature lowers below 50 °C (122 °F).

Never add coolant into an overheated engine and use exclusively proper liquids.

Always work with engine shut down: if particular conditions require maintenance with the engine running, consider all risks that such operation involves.

Keep at hand proper and safe containers for the engine liquids and waste oil discharge.

Keep the engine free from stains of oil, diesel fuel and/or chemical solvents.

The use of solvents or detergents during maintenance can develop toxic vapours. Keep the working rooms always ventilated. When necessary, use protective masks.

Never leave rags soaked with flammable liquid close to the engine.

At engine start-up after a repair, provide suitable measures to stop the air intake in case of overrun.

Do not use automatic screwdrivers.

Never disconnect the batteries while the engine is running.

Disconnect the batteries before any kind of service on the electrical system.

Disconnect the negative (–) ground cable first and the positive cable (+) next.

When the operation is complete, disconnect the positive cable (+) first and the negative cable (-) last.

At the end of each service work, make sure that the terminals polarity is correct and that the terminals are properly tight and protected against short-circuits and oxidation.

Never disconnect and connect the electrical links when under voltage.

Before starting the disassembly of pipelines (hydraulic, fuel), check he possible presence of liquid.

Adopt the necessary precautions relieving the residual pressures.

Always wear the proper masks or safety goggles.

The lack of compliance with these rules can cause serious accidents and poisoning.

NEF-F4HE ENGINE Avoid wrong tightening or wrong torques. Hazard to damage the engine components even seriously, shortening its life.

Never perform modification of electrical wiring or of the fuel system if not expressly requested by the Manufacturer.

For engines equipped with electronic control modules: Never perform arc welding without having removed the electronic control modules beforehand.

Remove the electronic control modules in case of maintenance service requiring to reach temperatures above 80 °C (176 °F).

Never paint the electronic components or connections.

Never vary or change the data contained inside of the electronic control module of the engine. Each mishandling or alteration of electronic components makes the engine service warranty to become null and void, beyond impairing its operation and life.

9.3

DAILY CHECKS

It is a good rule to carry out simple checks before start-up, these could be a safe ensurance to avoid faults even serious ones during engine operation.

Levels check and verification of possible leaks from the fuel, cooling and lubrication circuits.

Indication to service technicians in case of faults; top-ups if necessary.

After the engine start and with engine running, carry out following verifications and checks: " check of possible leaks from the fuel, cooling and lubrication circuits; " verification of noise and knocking during operation; " verification by means of machine gauges, the pressure, temperature prescribed values, etc.; " visual check of smokes (exhaust gas colour). " visual check of cooling liquid level in the expansion tank.

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ENGINE OIL LEVEL CHECK This check has to be carried out with engine shut down and cold.

This check is performed with the relevant dipstick (1) located on the right of the electronic control module.

Take out the dipstick from its housing and check that the level is between the minimum and maximum notches, engraved on the same.

If the reading is not corresponding to a possible reference, clean the dipstick with a lintfree rag and place it back into its housing. Pull it out again and check the level.

If the level is close to the minimum reference, top up with oil. Always make sure to add oil with the same features of the one contained in the sump. Mixtures are not allowed that cannot ensure the correct lubrication of the inner part of the engine.

To carry out the oil top up, fill through the upper plug or through the lateral one. During oil filling plugs should be removed as well as the dipstick so as to easy the oil flow.

The engine oil is highly polluting and poisoning.

In case of skin contact, wash with plenty of water and detergent.

Protect the skin and eyes adequately; follow the safety rules.

Dispose of waste in a proper way and anyway according to current legislation.

FUEL SYSTEM CHECK This check has to be carried out both with engine shut and running.

The check has to be carried out through the fuel lines coming from the tank to the prefilter (if installed), to the high pressure pump and Common Rail diffuser and from this to the head.

Pay particular attention to the high pressure pipes connections.

Because of the high pressure inside of the pipes going from the pump to the Common Rail diffuser and from this one to the electroinjectors also possible leaks must be carefully checked.

Protect eyes and the skin from high pressure jets: these can penetrate the skin deeply creating heavy burns and poisoning.

NEF-F4HE ENGINE COOLING SYSTEM CHECK This check has to be carried out both with engine shut and running.

Check the pipes from the engine to radiator, from expansion tank and vice versa; detect possible leaks, the pipes status expecially in proximity of the union clamps.

Check the radiator cleaning status, the integrity of the ventilation fins, the possible leaks from the clamps, from the sleeves and from the heater body.

Due to high temperature inside of the system, never operate immediately after the engine shut down, but wait until the time necessary for temperature lowering.

Protect eyes and the skin from high pressure jets of coolant.

The cooling liquid density must anyway be checked each year during the winter season and replaced anyway each two years.

NOTE: in case of new filling, bleed the system through the vents of the engine.

The leak of bleeding on the system could cause serious damages to the engine for the presence of air bags in the engine head.

LUBRICATION SYSTEM CHECK This check has to be carried out both with engine shut and running.

Check for the presence of oil leaks from the head, from the engine oil sump or from the heat exchanger.

The engine oil is highly polluting and poisoning.

In case of skin contact, wash with plenty of water and detergent.

Protect the skin and eyes adequately; follow the safety rules.

Dispose of waste in a proper way and anyway according to current legislation.

WATER IN THE FUEL FILTER The components of the Common Rail system get damaged very rapidly by the presence of water or dirt in the fuel.

Handle quickly on prefilter to drain the water contained in the supply circuit.

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CHECK / REPLACEMENT OF BLOW-BY FILTER This filter is arranged for the collection, filtering and condensation of lubricating oil vapours.

Inside of the filter body (1) are installed two filter cartridges (2).

CHECK AFTER THE ENGINE ASSEMBLY ON THE MACHINE Start the engine and let it run at a sped slightly higher than the idle and wait until the cooling liquid temperature reaches the value for the thermostat opening, then check: " for the presence of leaks in the connection sleeves of the engine cooling circuits and heating circuit of the cabin, by tightening the locking clamps; " thoroughly check the low pressure fuel pipes connection with the relevant connectors; " the presence of oil leaks between cover and cylinders head, between oil sump and crankcase, between heat exchanger oil and relevant seats between the various pipes of the lubrication circuit; " the presence of fuel leaks from the fuel pipeline; " ensure the correct operation of the warning lights on the instrument dashboard and of the devices still connected during the engine shut down; " check and bleed very carefully the cooling circuit of the engine with repeated bleedings.

NEF-F4HE ENGINE CHECK OF THE BELT TENSION The belt tensioning is performed through an automatic tensioner and does not require any intervention if not the one for belt wear status.

VALVE CLEARANCE ADJUSTMENT Check the clearance between the rockers and valves using an Allen wrench (1), a polygonal wrench (3) and a thickness gauge (2).

The clearance is: " intake valves 0.25 ± 0.05 mm (0.0098 ± 0.00197 in) " exhaust valves 0.50 ± 0.05 mm (0.0196 ± 0.00197 in).

NOTE: with TIER 3 engines, owing to the presence of the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure with adjustment of the clearance of all the valves with just 2 positionings of the crankshaft.

Each cylinder must be checked by moving it to T.D.C. (Top Dead Centre) at compression end and by adjusting the clearance of both valves only on the cylinder concerned.

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94 9.4

NEF-F4HE ENGINE REPLACEMENTS

REPLACEMENT OF ENGINE OIL AND FILTER

WARNING Because of the high operation temperature of the engine, we advise to wear safety protections. The engine oil reaches very high temperatures: always wear protective gloves.

Position a suitable container to collect the oil under the sump, under the drain plug.

Unscrew the plug (1) and then take out the dipstick for level check and the filling plug to ease the lubrication oil flow.

WARNING The engine oil is highly polluting and poisoning.

In case of skin contact, wash with plenty of water and detergent.

Protect the skin and eyes adequately; follow the safety rules.

Dispose of waste in a proper way and anyway according to current legislation.

When the drainage is complete, tighten the plug and refill with clean oil.

WARNING Use only suggested oils or with the features requested for the correct engine operation.

In case of top ups, do not mix oil with different features.

The lack of compliance with these rules can cause serious accidents and poisoning.

Check the level through the dipstick up to obtain a level close to maximum level reference engraved on the same dipstick.

Replace the lubricating oil together with the filter.

The filter (2) consists of a support (3) and of a cartridge (1).

For the replacement of this latter use tool 380000670.

WARNING The oil filter contains inside a quantity of engine oil of about 1 kg (2 lb).

Position a container with a suitable capacity to collect the liquid.

Avoid to get in contact with the engine oil: In case of skin contact, wash with flushing water.

The engine oil is highly polluting: dispose of it according to current legislation.

NEF-F4HE ENGINE Replace the filter cartridge (4) with a new one and tighten by hand until the seal comes in touch with the support.

Tighten further with the help of tool 380000670 for 3/ 4 of turn.

Run the engine for several minutes and recheck the level through the dipstick. If necessary top up to compensate the quantity of oil used for the filling of the filter cartridge.

CHANGE FUEL FILTER IMPORTANT: do not smoke during this operation, do not use open flames.

Avoid to inhale the vapours coming from the filter.

Discharge the fuel contained inside of the filter by handling on the water bleeding screw. Collect the fuel in a clean container.

Unscrew the cartridge with the suitable special tool 380000670.

Collect possible fuel still present inside of the filter cartridge.

Clean the gasket seat on the support and lubricate slightly the gasket of the new filter cartridge.

Tighten by hand the new filter cartridge until the gasket leans completely on its seat.

Tighten further with the help of tool 380000670 to the torque 10-15 Nm (7.37-11.06 lbf·ft).

ALTERNATOR BELT REPLACEMENT Handle on belt tensioner (1) and slide out the belt (2) from the alternator pulleys, of water pumps and crank pulleys.

Replace each worn belt with new one.

Place the belt on the pulleys (3) and guide rollers (4).

Position the automatic belt tensioner so as to key the belt into operation position (tighten the belt to prescribed torque).

No further adjustments are required.

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10. ELECTRICAL COMPONENTS

1.

2.

3.

4.

5.

6.

Coolant temperature sensor Electroinjector Pressure sensor Intake air/temperature sensor Valve gear timing sensor Pressure regulator solenoid valve

7.

8.

9.

10.

11.

Fuel temperature sensor Electronic control module Crankshaft sensor Engine oil pressure/temperature sensor Pre-after-heating resistor

NEF-F4HE ENGINE

97

10.1 COOLANT TEMPERATURE SENSOR This sensor has a variable resistor able to detect the coolant temperature to deliver the control module a parameter of the engine thermal status.

This signal is used from the control module to pilot a possible temperature gauge on the dashboard.

Is connected to the control module on pins 15C 26C. Its resistor is about 20 °C (68 °F) and about 2.50 :.

10.2 ELECTROINJECTORS This solenoid valve is of the type normally open.

They are connected to the EDC control module on connector A. The coil resistor of each single injector is of 0.56 ÷ 0.57 :.

Item

CONNECTOR 1

CONNECTOR 2

CONNECTOR 3

Description

Control module PIN

1

2nd cylinder injector

11 A

2

2nd cylinder injector

6A

3

1st cylinder injector

13 A

4

1st cylinder injector

4A

1

4th cylinder injector

14 A

2

4th cylinder injector

3A

3

3rd cylinder injector

12 A

4

3rd cylinder injector

5A

1

6th cylinder injector

15 A

2

6th cylinder injector

2A

3

5th cylinder injector

1A

4

5th cylinder injector

16 A

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NEF-F4HE ENGINE

10.3 FUEL PRESSURE SENSOR Assembled on the Common Rail end, it measures the fuel pressure available and transfer this information to the control module (feedback).

The value of the injection pressure is used to check the same and to determine the electric injection control timing.

Is connected to the control module on pins 12C 14C - 13C. Is powered at 5 Volt.

Item

Description

Control module PIN

1

Mass

12C

2

Signal

14C

3

Feed

13C

10.4 TEMPERATURE SENSOR OF AIR BOOST PRESSURE This component completes a temperature sensor and a pressure sensor.

Assembled on the intake manifold, it measures the maximum delivery of air introduces used to calculate accurately the fuel quantity to be injected at each cycle.

Is connected to the control module on pins 25C - 36C - 33C - 34C. Is powered at 5 Volt.

The tension at the output is proportional to the pressure or temperature detected by the sensor.

Pin 24C - 28C Temperature Pin 33C - 34C Pressure

10.5 ENGINE CABLE It is the electric cable connecting all the electrical components of the engine.

NEF-F4HE ENGINE

99

10.6 MAIN VALVE GEAR TIMING SENSOR This is an inductive sensor, placed on the front port side of the engine. It generates signals received from the magnetic flow lines closing through the holes of the gear keyed on the camshaft. The signal generated by this sensor is used by the electronic control module as signal for injection timing.

Even if being similar to the flywheel sensor, it is NOT interchangeable because of its outer different shape.

Is connected to the control module on pins 9C - 10C. The sensor resistor value is ~ 900 :.

Item

Description

Control module PIN

1

Signal

10C

2

Signal

9C

3

Shield

10.7 PRESSURE REGULATOR Fuel inlet from high pressure pump The fuel quantity feeding the high pressure pump, is regulated by the pressure regulator, located on the low pressure system; the pressure regulator is controlled through the control module by means of a signal.

The suction pressure to the Common Rail is regulated between 250 and 1450 bar (3625 and 21022 psi) from the electronic module, through the solenoid of the pressure regulator.

It is a valve normally open.

Is connected to the control module on pins 9A - 10A. Its resistor is about 3.2 :.

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NEF-F4HE ENGINE

10.8 FUEL TEMPERATURE SENSOR This sensor is similar to the previous one.

It detects the temperature of the fuel to deliver to the control module a parameter of the thermal status of fuel.

Is connected to the control module on pins 35C 18C. Its resistor is about 20 °C (68 °F) and about 2.50 :.

A. Fuel temperature sensor B. Filter heating resistor

Item

Description

Control module PIN Water

Fuel

1

Mass

15C

35C

2

Temperature signal

26C

18C

10.9 ELECTRONIC CONTROL MODULE The NEF F4HE engines are completely monitored by the electronic control module. This one is installed directly on the engine and it is cooled through an heat exchanger, by means of elastic struts reducing the engine vibrations.

Use the following test to check for proper operation of the swing brake.

A. Injectors connector B. Frame connector C. Sensors connector

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101

10.10CRANKSHAFT SENSOR This is an inductive sensor, placed on the front port side of the engine.

It generates signals received from the magnetic flow lines closing through the holes of the gear keyed on the camshaft.

Is connected to the control module on pins 19C 23C. The sensor resistor value is ~ 900 :.

Item

Description

Control module PIN

1

Signal

19C

2

Signal

23C

3

Shield

10.11 ENGINE OIL PRESSURE TEMPERATURE SENSOR This sensor is similar to the previous one.

It is assembled on the engine oil filter support vertically.

It measures the temperature and pressure of the engine oil.

Is connected to the control module on pins 24C 28C - 32C - 27C. Is powered at 5 Volt. This signal is detected and sent to the control module driving on its turn the gauge on the dashboard (gauge + low pressure lamp).

The oil temperature is not visualized by any gauge, it is used only by the control module.

Pin 24C - 28C Temperature Pin 32C - 27C Pressure

Item

Description

Control module PIN Oil

Air

1

Mass

24C

25C

2

NTC (temperature) signal

28C

36C

3

+5 V Supply

32C

34C

4

Signal (pressure)

27C

34C

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NEF-F4HE ENGINE

10.12PRE-AFTER-HEATING RESISTOR This resistor is placed on the intake manifold.

Is used to heat the air during the pre-after heating operations. Is supplied by a remote switch.

Its resistor is about 0.5 :.

The remote control switch is connected to the control module through connector B. This control is sent with water and/or fuel temperature lower than 5 °C (41 °F).

Its resistor is about 15 :.