F4AFE411A

NEF SERIES
EURO VI
On Road - Road Sweeper application
(Pivot)
F4AFE411A*C005
F4AFE411C*C026
N45 ENT 6 W
Technical and Repair manual

This document provides data, specifications, instructions and
methods to perform repair interventions on the assembly and
its components.
Anyhow, this document is addressed to qualified and special-

ised personnel.
Before performing any intervention, check that the document

relating to the vehicle model on which the intervention is being
performed is available and also make sure that all accident pre-
vention devices, including but not limited to, goggles, helmet,
gloves, shoes, as well as work equipment, lifting and transport
equipment, etc., are available and efficient, and also make sure
that the vehicle is in safety conditions for intervention.
Making interventions strictly observing the indications given

here, as well as using specific equipment indicated, assures a
correct repair intervention, execution timing observance and
operators safety.
Each repair intervention must be finalised to the recovery of

functionality, efficiency and safety conditions that are provided
by FPT.
Each intervention on the vehicle that is finalised to a modifica-

tion, alteration or anything else which has not been authorised
by FPT relieves FPT of any liability, and, in particular, where the
assembly is covered by a warranty, each intervention will
immediately invalidate the warranty.
FPT declines any liability for repair work.
FPT is available to provide any information necessary for the

implementation of the interventions and to provide instruc-
tions for any cases and situations not covered in this publica-
tion.
The data contained in this issue may not be up-to-date due to

possible modifications made by the Manufacturer for technical
or commercial reasons, or to adaptations required by laws in
force in different countries.
In the event of discordance between the information in this

publication and the actual assembly, please contact the FPT
network before performing any interventions.
The complete or partial reproduction of the text or illustra-
tions herein is forbidden.
Publication edited by:

FPT Industrial S.p.A.
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print P1D32N021 E - 1st Edition 03.2015
NEF SERIES EURO VI INTRODUCTION 1
Introduction
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
SYMBOLS - WARNINGS . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
REGARDING THE ELECTRICAL SYSTEM . . . . 7
- Grounding and screening . . . . . . . . . . . . . . . . . 8
OPTIONAL ELECTRICAL AND MECHANICAL

PARTS INSTALLATIONS . . . . . . . . . . . . . . . . . 9
CONVERSIONS BETWEEN THE MAIN UNITS

OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND THE MOST COMMONLY USED
DERIVED SIZES . . . . . . . . . . . . . . . . . . . . . . . . . 9
PAGE HEADER AND FOOTER INTERPRETATION 10
UPDATE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Print P1D32N021 E Base - March 2015

2 INTRODUCTION NEF SERIES EURO VI
Base - March 2015 Print P1D32N021 E

GENERAL INFORMATION
Manuals for repairs are split into Parts and Sections, each one of which is marked by a number; the contents of these sections
are indicated in the general table of contents.
Sections with mechanical contents include technical data, tightening torque collections, tool lists, assembly connections - discon-
nections, overhauls at the bench and scheduled maintenance.
On sections or parts of the electric/electronic system section there are the descriptions of the electric network and the electronic
systems of the assembly, wiring diagrams, electric characteristics of components.
Section 1. describes the engines illustrating its features and working in general.
Section 2. describes the fuel supply type and engine operation.
Section 3. is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on
the basis of their specific use.
Section 4. describes scheduled maintenance and specific overhauling.
Section 5. deals with removal and refitting of the main engine components.
Section 6 describes general mechanical servicing of the engine on the revolving stand.
Section 7 gives engine technical characteristics such as data, installation clearances and tightening torques.
Section 8 is about the tools necessary for performing these operations.
The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians,
must comply with to prevent any serious injury.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set
of symbols has been defined to classify warnings, while another set has been specified for service operations.
SYMBOLS - Warnings
Danger for persons

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

The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify
the warranty.
General danger
! Includes the dangers of both above described signals.
Environmental protection
Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.
NOTE Indicates an additional explanation for a piece of information.

Service operations
Example:
1 1= Housing for connecting rod

small end bush.
Tighten to torque + angle value

2 2= Housing for connecting rod
bearings

Removal
Intake
Disconnect
Refitting
Exhaust
Connect
Disassembly
Operation
Dismantling
Assembly
Assemble Compression ratio
Tolerance
Tighten to the specified torque
Weight difference
Tighten to the specified torque + angle value Rolling torque

Press or caulk Rotation
Registration Angle
Adjustment Angle value
Warning
! Preload
Note
Visual check
Revolutions per time unit
Fitting position check
Measuring
Value to be found Temperature
Check
Tools Pressure
bar
Surface for machining

Oversized
Finished workpiece
Oversized by no more than .....
Undersized
Interference
Undersized by no more than.....
Forced assembly
Clearance
Selection
Shim
of oversizing class
Lubricate Temperature < 0o C
Moisten Cold
Grease Winter
Temperature > 0o C
Coolant
Hot
Sealant
Summer
Bleeding air

GENERAL WARNINGS
The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors
! should be contacted whenever a dangerous situation that has not been described occurs.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and mainte-
nance handbooks. Check the working condition and suitability of tools not subject to periodic review.
The manual handling of loads must be assessed in advance since it also depends not only on weight but also on its
size and on the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such
tools is strictly permitted by authorised personnel only. Stay at a safe distance from the load and never below it.
In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken
out from accidentally striking workshop personnel.
Shop activities performed by two technicians must always been executed with caution; avoid operations that may
be dangerous for any collaborators due to lack of field of vision or incorrect position.
Keep any personnel not assigned to the operations clear of working area.
Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it. Scrupulously
observe all safety warnings on the assembly.
Do not leave the assembly in motion unattended during repair work.
When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands
and that the manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp.
When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also
observe all the specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12
point cards of harmful materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes,
free flames or sparks, in order to prevent sudden fires/explosions. Adequately store inflammable, corrosive and pollu-
ting fluids and liquids according to what provided by regulations in force. Strictly avoid using containers for food to
store harmful liquids. Avoid drilling or burning pressurised containers and discard cloths impregnated with inflammable
substances into suitable containers.
Worn out, damaged or consumable parts must be replaced with original spare parts.
During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and
stains of liquids and oils. Electric sockets and electrical equipment necessary to perform repair operations must meet
safety rules.

Wear all required P.P.E and garments when called for by the operation at issue. Contact with moving parts may cause
serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc.
Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside.
Do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated
areas. Wear an appropriate respirator in the presence of paint dust.
Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid
direct contact with liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact
occurs.
Before overhauling, clean the assemblies and make sure they are integral and complete. Tidy up detached or disassem-
bled parts with their securing elements (screws, nuts, etc.) into special containers.
Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking
nuts with nylon inserts must always be replaced.
Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.
Before pressure washing mechanical parts, protect electrical connectors and any control units.
The tightening of screws and nuts should always be carried out according to directions. FPTs sales and assistance net-
work is available to provide any clarifications necessary to carry out any repair work not covered by this document.
Before welding:
- Disconnect all electronic control units and unplug the power cable from the batterys positive terminal (connec-
ting it to the chassis ground) and connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
- Wait approximately 15 minutes before proceeding with welding.
- Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable
materials flow when welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), remove the electronic control units.
The disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting
! the chassis earth cable first of all from the negative terminal of the battery.
Before connecting the batteries to the system, make sure that the system is suitably insulated.
Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from
the battery terminals.
Do not cause sparks to verify the presence of voltage in a circuit.
Do not use a test lamp to verify circuit continuity, but proper control equipment only.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen brai-
ding, grounding, etc.) conform with the FPT system and that they are carefully restored after repair or maintenance
work.
Measurements on the ECUs, jack connections and electrical connections of components must be done only on regular
test lines, with special jacks and jack bushings. Never use improvised equipment like metal wires, screwdrivers, pins
or similar. This may not only cause short circuits, but also damage the jack connectors, resulting in poor contact.
Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or
special truck.
Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries)
may lead to their destruction.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening
torque.
Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
Do not directly supply current to components served by electronic control units with nominal vehicle voltage.
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.
NOTE The connectors are shown from cable side. Connector views contained in the manual are representative of cable side.

Grounding and screening

The negative leads connected to a system grounding point must be as short as possible and connected to one another in star
configuration; make sure that they are tightened in an orderly and adequate manner (Figure 1 ref. M).
The following precautions must be observed regarding the electronic components:
- The electronic control units must be connected to the circuits ground when they have metallic casing.
- Control unit negative cables must be connected to a system ground point, such as the dashboard compartment ground (do
not use serial or chain connections), and to the negative terminal of the battery/ies.
- Even if not connected to the circuit ground/battery negative terminal, analog ground (sensors) should have optimal isolation.
Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
- The metal braid of shielded circuits must be in electric contact only at the end towards the control unit where the signal enters
(Figure 2).
- In the case of junction connectors, the unshielded section d, near the connectors must be as short as possible (Figure 2).
- The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Figure 1
1. STAR CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT GROUND M
Figure 2
88039
2. SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR

d. DISTANCE ! 0

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

Accessory installation, additions and changes on the assembly must be carried out in compliance with the FPT assembly directives.
It is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional)
sockets in order to simplify and normalise the electrical intervention by fitters.
It is strictly forbidden to carry out any modifications or connections to the electronic control unit wiring. In particular,
the data line between the control units (CAN line) is to be considered untouchable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND THE MOST COMMONLY USED DERIVED SIZES
Power
1 kW = 1.36 CV
1 kW = 1.34 hp
1 CV = 0.735 kW
1 CV = 0.986 hp
1 hp = 0.746 kW
1 hp = 1.014 CV
NOTE the unit CV is converted into hp for simplicity according to a ratio of 1:1 1 hp = 1 CV
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rpm = 0.1047 rad/s
1 rad/s = 9.55 rpm
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
NOTE Where accuracy is not particularly required:

- the unit Nm is converted into kgm for simplicity according to a ratio of 10:1
1 kgm = 10 Nm;
- the unit bar is converted into kg/cm2 for simplicity according to a ratio of 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 273.15 K
0 F = 255.37 K
0 C = 32F (the conversion factor between Celsius and Fahrenheit is 1:1.8)

PAGE HEADER AND FOOTER INTERPRETATION
Type Section Page

of engine title number
Language Basic edition with reference When present, a

Number of
of Publication to the month-year month-year update
printed copies
closing the drafting phase (Revi) to the basic edition

UPDATE DATA
Section Section name Modification description Page Date of revision


NEF SERIES EURO VI
Section
General specifications 1
Operating diagrams 2
Electrical equipment 3
Scheduled Maintenance 4
Removal-refitting of the main engine components 5
General mechanical overhaul 6
Technical specifications 7
Tools 8
Safety prescriptions Appendix


NEF SERIES EURO VI SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General information
Page
IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . 3
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 3
TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . . 4
COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . . 5
ISO VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TORQUE AND POWER TYPICAL CURVES . . 7
- F4AFE411A*C005 . . . . . . . . . . . . . . . . . . . . . . 7
- F4AFE411C*C026 . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 11

2 SECTION 1 - GENERAL SPECIFICATIONS NEF SERIES EURO VI

IDENTIFICATION PLATE
Figure 1
221352
1. Technical code - 2. Month and year construction date - 3. Engine serial number
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code
F4AFE411A*C005
N45 ENT 6 W
F4AFE411C*C026

TECHNICAL CODE
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize
its application and power output level. It is stamped on a side of crank-case, close to oil filter.
F4 A F E 4 1 1 A * C 005
F4 A F E 4 1 1 C * C 026
Progressive numbers showing engine variants
Emissions level:
A = TIER 4a
B = TIER 4full/STAGE IV
C = EURO 6
D = Not emissioned
E = STAGE 2
Performances:
1,2,3... A,B,C...= Engine power or torque level
Application:
0 = Other application 5 = Genset
1 = Trucks 6 = Marine
2 = Buses 7 = Industrial / Agricultural turbo eVGT
3 = Industrial / Agricultural 8 = Cars and derivatives
4 = Industrial / Agricultural 9 = Military
Engine main characteristics:

0 = Turbocharged CNG
1 = Turbocharged diesel i.d. aftercooled
2 = Naturally Aspirated diesel i.d
3 = Naturally Aspirated diesel i.i
4 = Naturally Aspirated petrol
5 = Naturally Aspirated CNG
6 = Turbocharged diesel i.d.
7 = Turbocharged diesel i.i.
8 = Turbocharged petrol
9 = Turbocharged diesel i.i. aftercooled
No. of cylinders
Cylinder configuration:
A = 4 stroke vertical E = 4 stroke vertical with post-treat
B = 4 stroke horizontal F = 4 stroke horizontal with post-treat
C = 4 stroke vertical with EGR G = 4 stroke horizontal with EGR + post treat
D = 4 stroke horizontal with EGR L = 4 stroke vertical with EGR + post treat
F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6
Code Type of base: Application

A Not structural ON-ROAD
D Structural OFF-ROAD
H Not structural OFF-ROAD
F4 = New Engine Family

COMMERCIAL CODE
The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical pur-
pose of recognizing the engines components, which is served by the ENGINE S/N.
N 45 E N T 6 W
ENGINE CONTROL UNIT: W = EDC17CV41
EMISSION LEVEL: 6 = Euro VI
AIR INTAKE: T = INTERCOOLED TURBOCHARGED
ENGINE BLOCK: N = NOT STRUCTURAL
FUEL SUPPLY: E = ELECTRONIC INJECTION
DISPLACEMENT: 45 = 4.500 cc NOMINAL
ENGINE FAMILY IDENTIFIER: N = NEF

ISO VIEW
Figure 2
227538
F4AFE411 engine
The engine F4AFE411 is a 4-cylinder in-line turbocharged with intercooler with 4 valves per cylinder; it belongs to the NEF series
and operates according to a four-stroke diesel cycle.
The engine supply system is electronically-controlled and its based on the direct injection of the fuel in the combustion chamber
by means of high pressure pump and common rail.
The intake and exhaust valves are timed with the camshaft tappets, the push rods and the rocker arm assembly.

TORQUE AND POWER TYPICAL CURVES

F4AFE411A*C005
Figure 3
TORQUE (Nm)
POWER (kW)
600,0 140,0
550,0 120,0
100,0
500,0
80,0
Nm
kW
450,0
60,0
400,0
40,0
350,0 20,0
300,0 0,0
600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
rpm 227495
POWER max. 118 kW (158 HP) at 2.500 rpm

TORQUE max. 580 Nm (59.14 kgm) at 1.250 rpm
F4AFE411C*C026
Figure 4
TORQUE (Nm)
POWER (kW)
800,0 160,0
750,0
140,0
700,0
120,0
650,0
100,0
600,0
Nm
kW
550,0 80,0
500,0
60,0
450,0
40,0
400,0
20,0
350,0
300,0 0,0
600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
rpm 227496
POWER max. 152 kW (204 HP) at 2500 rpm

TORQUE max. 750 Nm (76.47 kgm) at 1.400 rpm
ENGINE VIEWS
(F4AFE411A*C005 - F4AFE411C*C026)
Figure 5
227539
INTAKE SIDE VIEW
1. Rail - 2. High pressure fuel pipe - 3. Fuel pump - 4. Fuel filter - 5. Oil sump - 6. Engine control unit EDC17CV41 -
7. Engine cable - 8. Intake manifold
Figure 6
EXHAUST SIDE VIEW 227540
1. Blow-by breather - 2. Oil level dipstick - 3. Thermostat cover - 4. Exhaust manifold - 5. Turbocharger oil delivery pipe -
6. Alternator - 7. Coolant inlet pipe - 8. Engine oil filter - 9. Starter motor - 10. Turbocharger oil return pipe -
11. Turbocharger - 12. Motorized throttle valve (engine brake) - 13. Throttle valve control actuator - 14. Tappet cover

Figure 7
227542
FRONT VIEW
1. Engine cable - 2. Fixed belt tensioner - 3. Water pump - 4. Damper pulley - 5. Auxiliary drive belt - 6. Fixed belt tensioner -
7. Automatic belt tensioner - 8. Alternator - 9. Thermostat cover
Figure 8
227541
REAR VIEW
1. Tappet cover - 2. Throttle valve control actuator - 3. Motorized throttle valve (engine brake) - 4. Engine flywheel -
5. Fuel low pressure pipes - 6. Lifting eyelet

Figure 9
227543
TOP VIEW
1. Intake manifold - 2. Rail - 3. Oil filler cap - 4. Blow-by breather - 5. Thermostat cover
6. Alternator - 7. Turbocharger - 8. Throttle valve control actuator - 9. Exhaust manifold - 10. Tappet cover

GENERAL CHARACTERISTICS
Type F4AFE411A*C005 F4AFE411C*C026
Cycle Four stroke - Diesel engine
Fuel system Common Rail Injection System
Injection Direct
Number of cylinders 4 in line

Bore mm 104
Stroke mm 132
+ + +.. = Total displacement cm3 4485
TIMING GEAR
start before T.D.C. A 8 30

end after B.D.C. B 8 30
start before B.D.C. D 51 00

end after T.D.C. C 12 30
For timing check

mm
X X
mm
INJECTION
supply High pressure common rail
Type: Bosch EDC 17CV41
Nozzle type and brand BOSCH CRIN2.0
Injection sequence 1-3-4-2
Injection pressure bar 1600
Compression ratio 17 : 1

Type F4AFE411A*C005 F4AFE411C*C026
Max. power kW 118 152

(hp) (158) (204)
rpm 2500 2500
Maximum torque Nm 580 750

(kgm) (59.14) (76.47)
rpm 1.250 1.400
Low idle speed with no load rpm 750
Peak engine speed with no load rpm 2.800
TURBOCHARGING With aftercooler

Turbocharger type HONEYWELL GT 25S
By means of centrifugal pump, thermostat,

LUBRICATION
radiator, heat exchanger, aftercooler
bar
Oil pressure at 80C
- at idle speed bar 2.0
- at max speed bar 4.0
By means of centrifugal pump, thermostat,
COOLING (1)
radiator, heat exchanger, aftercooler
Total capacity litres 8
Water pump drive Belt driven
Thermostat
- start of opening C 79 2
- maximum opening C 96
REFILLING (2)
- Lubrication circuit total capacity (3) litres 13,5
kg 12.2
- engine sump at minimum level litres 9
kg 8.1
- engine sump at maximum level litres 12
kg 10.8
(1) The quantities indicated only relate to the engine in its standard configuration. Use a 50% mixture of water and PARAFLU HT
even during the summer months. As an alternative to PARAFLU HT, use another product that complies with FPI9.COOL002
or CNH MAT 3624 or SAE J1034 specifications.
(2) Only use lubricants which meet the international standards API CJ-4 / ACEA E9-E6. Recommended oil is SAE 10W-40 or
5W-30 meeting FPI9.LUBR001 or CNH MAT 3521. The oil used is considered to be acceptable until a quantity equalling 0.15%
of fuel consumption is reached.
(3) The quantities indicated relate to the first refill only and are relative to the engine, oil sump and filter filling.
Data, features and performances are valid only if the technician fully complies with all the installation requirements provided
! by FPT.
Furthermore, the equipment assembled by vehicle manufacturer shall always be in compliance with torque, power and
number of revs based on which the engine has been designed.
Warning - Refuelling from drums or tanks may result in pollution of the diesel fuel, with the risk of damage to the injection
! system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.

NEF SERIES EURO VI SECTION 2 - OPERATING DIAGRAMS 1
SECTION 2
Operating diagrams
Page
COMMON RAIL INJECTION SYSTEM . . . . . . . 3
- General specifications . . . . . . . . . . . . . . . . . . . 3
- Electric system . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Main sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- System functions . . . . . . . . . . . . . . . . . . . . . . . 4
- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 5
- Fuel system diagram . . . . . . . . . . . . . . . . . . . . 6
- Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Mechanical supply pump . . . . . . . . . . . . . . . . . 9
- High pressure pump CP3.3 . . . . . . . . . . . . . . . 10
- Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Pressure relief valve . . . . . . . . . . . . . . . . . . . . . 15
- Electro-injector . . . . . . . . . . . . . . . . . . . . . . . . 15
- Quick coupler for fuel return . . . . . . . . . . . . . 16
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 18
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 20
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 21
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INTAKE AND EXHAUST SYSTEM . . . . . . . . . . 25
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2 SECTION 2 - OPERATING DIAGRAMS NEF SERIES EURO VI
Page
- Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Throttle valve . . . . . . . . . . . . . . . . . . . . . . . . . 27
EXHAUST GAS AFTER-TREATMENT SYSTEM

(ATS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- ATS system heating/cooling system . . . . . . . . 31
MAIN COMPONENTS OF ATS SYSTEM . . . . . . 32
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- AdBlue fluid level gauge control . . . . . . . . . . . 32
- DeNOx 2.2 supply module

(SM - Supply Module) . . . . . . . . . . . . . . . . . . . 33
- Filter removal . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . 35
- DeNOx 2.5 dosing module

(DM - Dosing Module) . . . . . . . . . . . . . . . . . . 36
- Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . 37
- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Nitrogen oxide detecting sensor . . . . . . . . . . 39
- Exhaust gas temperature sensor . . . . . . . . . . . 40
- Temperature and humidity sensor . . . . . . . . . 41
- Catalytic converter . . . . . . . . . . . . . . . . . . . . . 42
- Differential pressure sensor . . . . . . . . . . . . . . 43
SCHEDULED MAINTENANCE FOR ATS SYSTEM

(DRAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REPLACING THE DPF

(DIESEL PARTICULATE FILTER)
CATALYTIC CONVERTER . . . . . . . . . . . . . . . 45
- Removing the DPF catalytic converter . . . . . . 45
- Refitting the DPF catalytic converter . . . . . . . 47

COMMON RAIL INJECTION SYSTEM

General specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
Electric system
Figure 1
221783
1. Electro-injector connections - 2. Motorized throttle valve actuator connector (Exhaust flap) -

3. Boost pressure and air temperature sensor - 4. Rail pressure sensor - 5. Timing segment speed sensor (camshaft) -
6. Fuel temperature sensor - 7. Fuel high pressure pump metering unit - 8. In line connector - 9. Rpm increment speed
sensor (crankshaft) - 10. Engine Control Unit EDC17CV41 - 11. Engine oil pressure and temperature sensor -
12. Coolant temperature sensor
Main sensors This information is then used to calculate the injection time.
Through the sensors, present on the engine, the ECU con- The sensor is fitted on the intake manifold.
trols the engine operation.
The output voltage is proportional to the pressure (or tem-
perature) measured by the sensor.
Boost pressure and air temperature sensor
The boost pressure and air temperature sensor is an integrated
component which has the task of detecting the pressure and Engine oil temperature and pressure sensor
temperature of the air inside the intake manifold. It is fitted on the crankcase and measures the engine oil pres-
sure and temperature.
Both pieces of information are needed by the injection control
unit to define the amount of air taken in by the engine.

Rail pressure sensor Injection control

Assembled on a rail end, it measures the fuel pressure in the On the basis of the information from the sensors and the
rail in order to determine the injection pressure. mapped values, the control unit controls the pressure regula-
tor and changes the pre-injection and main injection mode.
The signal provided by the sensor is used by the engine mana-
gement control unit to adjust the injection pressure and
duration. Closed loop injection pressure management
Depending on engine load, measured by processing signals
Coolant temperature sensor coming from various sensors, the control unit controls the
This is a variable resistance sensor that is able to measure regulator in order to always have the optimum pressure.
coolant temperature and transmit a signal to the control unit
reflecting the thermal conditions of the engine. Pilot and main injection advance control
The control unit, depending on signals coming from various
Fuel temperature sensor sensors, computes the optimum injection point according to
This sensor is identical to the previous one. an internal mapping.
It detects the temperature of the fuel to give the control unit
information about the fuel oil temperature conditions. Idle speed control
The control unit processes signals coming from various sen-
Rpm increment speed sensor sors and adjusts the amount of injected fuel.
It is an inductive sensor placed on the front part of the engine. It controls the pressure regulator and changes the injection
Signals generated through the magnetic flow that is closed on time of electro-injectors.
the tone wheel, change their frequencies depending on Within certain thresholds, it also takes into account the bat-
crankshaft rotation speed. The engine management control tery voltage.
unit uses the rpm sensor signal to determine the rotation
speed and angular position of the crankshaft. Maximum speed limiting
At 2700 rpm, the control unit limits fuel flow-rate by reducing
Timing segment speed sensor the electro-injectors opening time.
This inductive sensor is located in the left rear part of the
Over 3000 rpm it deactivates the electro-injectors.
engine. It generates signals obtained from magnetic flux lines
which close through the holes situated in gears force fitted Cut Off
to the camshaft. The signal generated by this sensor is used
by the engine management control unit as the injection phase Fuel cut off upon deceleration is controlled by the control
signal. unit performing the following logics:
- it cuts off electro-injectors supply;
Although it is similar to the rpm sensor, it is NOT interchan- - it re-activates the electro-injectors shortly before idle
geable as it has a different shape. speed is reached;
- it controls the fuel pressure regulator.
System functions
Smokiness on acceleration control
Self-diagnostics With important load requests, the control unit, depending on
The control unit self-diagnostics system checks the signals signals received by air inlet meter and engine speed sensor,
from the sensors and compares them with the allowed limit controls the pressure regulator and changes the electro--
values. injectors actuation time, in order to avoid exhaust smokes.
FPT Code recognition Checking fuel temperature

The engine management control unit communicates with When the fuel temperature exceeds 75C (measured by the
the Immobilizer control unit to obtain the startup consent. sensor placed on fuel filter) the control unit intervenes and
reduces the injection pressure.
Engine pre-heating resistance management
If the temperature exceeds 90C, the power is reduced to
The pre-post heating is activated when even only one of the
60%.
water, air or fuel temperature sensors signals a temperature
that is less than 5C.
AC compressor engagement control
Synchronization search The control unit is able to control the engagement and disen-
By means of signals from the sensor on the camshaft and that gagement of the electromagnetic clutch of the compressor
on the crankshaft pulley, at start-up the cylinder into which on the basis of the coolant temperature.
fuel is to be injected is recognised. If the coolant temperature reaches 105C, it disengages.
After Run
The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the follo-
wing startup.

Hydraulic system
Figure 2
227537
A. Low pressure - B. Return - C. High pressure

1. Rail pressure relief valve - 2. Quick coupler for fuel return - 3.Common Rail - 3. Fuel filter - 4. High pressure pump
5. Mechanical feed pump - 6. Fuel filter - 7. ECU - 8. Electro-injectors
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylin-
der that has to receive the injection and accumulates fuel in a common duct for all electro-injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the ECU.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is made up of the following pipes:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying electro-injectors from rail.
The low-pressure circuit is made up of the following pipes:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel return circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

Fuel system diagram

This Common Rail injection system, with CP3.3 pump is Due to the very high pressure that builds within this
shown in diagram form in the 4 cylinder version. ! hydraulic system, the following precautions must be
observed for safety reasons:
The pressure regulator, placed upstream of the high-pressure
pump, adjusts the fuel flow that is necessary on the low-pres- - avoid connecting high-pressure pipe fittings with
sure system. Afterwards, the high-pressure pump takes care approximate tightening;
of supplying the rail properly. This solution, only pressurising - avoid disconnecting the high-pressure pipes
the necessary fuel, improves the energy efficiency and limits when the engine is running (DO NOT make any
heating the fuel in the system. attempt at bleeding: this is absolutely useless and
Function of the limiting valve (8), assembled on the highpres- dangerous!).
sure pump, is keeping the pressure, at the pressure regulator
inlet, constant at 5 bar, independently from the efficiency of
the fuel filter and of the system set upstream.
To ensure correct operation of the system, it is
The intervention of the pressure relief valve (8) brings about essential that the low-pressure circuit is intact.
an increase in the fuel flow in the high-pressure pump cooling !
circuit, through the inlet and drain pipe (19) from the pipe Therefore, avoid any attempt at modification or alte-
(10). ration and intervene immediately if a leak is identified.
The quick coupler housed on the cylinder head, fitted on the
electro-injector return (11), limits the fuel return flow from
the electro-injectors at a pressure of 1.3 2bar. After high-pressure pipeline installation, during the
Two by-pass valves are placed in parallel with the mechanical ! following 20 hours of work, frequently check engine
supply pump. oil level. (IT MUST NOT INCREASE).
The by-pass valve (17) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure
exceeds the allowed threshold value.
The by-pass valve (18) allows filling the supply system
through the manual priming pump (3).

Print P1D32N021 E
Figure 3
NEF SERIES EURO VI
A. Outlet connection to high pressure pump - B. Inlet connection from mechanical supply pump - C. Low pressure - D. Fuel discharge - E. High pressure
1. Fuel tank - 2. Prefilter - 3. Manual pump - 4. Engine control unit - 5. Fuel filter - 6. Flow rate modulator - 7. High pressure pump -
8. Limiting valve on high pressure pump, 5 bar - 9. Mechanical supply pump - 10. High pressure pump reflux pipe -
SECTION 2 - OPERATING DIAGRAMS
11. Quick coupler for fuel return from the injectors - 12. Return pipe - 13. Common rail excess pressure valve 14. Common rail - 15. Pressure sensor -
16. Injector - 17. By-pass valve - 18. By-pass valve - 19. High-pressure pump cooling piping
227484
7
Base - March 2015

Fuel prefilter Fuel filter

Figure 4 Figure 5
227475
1. Heater connector - 2. Fuel filter - 3. Electric fuel heater -

4. Fuel temperature sensor - 5. Fuel filter support
A. Inlet connection from mechanical supply pump
B. Outlet connection to high-pressure pump
It is located on the crankcase in the circuit between the feed

pump and the high pressure pump.
Cartridge filtering degree: 4 microns
Pressure delta: 0.1 bar.
70494 Fuel temperature sensor and heater resistors are located on
the support.
The fuel temperature, signalled by the relative sensor to the
The fuel filter is of the high water separation type, it is fitted engine management control unit, allows a very accurate cal-
on the right side of the vehicle chassis with the sensor (4) for culation of the fuel flow-rate to be injected into the cylinders.
detecting water in fuel on the cartridge (3) base.
Priming pump (5) and system air bleeding screw (2) located
on the filter support.
The presence of condensate into filter is signalled by sensor
(4) when a warning light on the instrument panel is lit.
If the warning light comes on, it is necessary to act

! immediately to remove the cause; the components
of the common rail system will be quickly damaged
if the fuel contains water or other impurities.

Mechanical supply pump Air bleeding conditions

Gear pump, fitted on the rear side of the high pressure pump
Figure 8
and used to supply it. It is driven by the high pressure pump
shaft.
Normal operating conditions
Figure 6
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this situa-
72592 tion the by-pass valve (1) stays closed and the by-pass valve
(2) opens as a result of the incoming pressure. The fuel flows
A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass out of outlet B.
valves in close position.
The mechanical supply pump cannot be replaced

Overpressure condition at outlet ! individually, therefore it cannot be removed from the
high pressure pump.
Figure 7
72593
The by-pass valve (1) intervenes in the presence of overpres-

sure at the outlet B. The pressure of the fuel overcomes the
force exerted by the spring of the valve (1), thereby placing
the pump outlet in communication with the inlet by way of
passage (2).

High pressure pump CP3.3

Pump with three radial pistons controlled by the timing gear,
without needing any setting. The mechanical supply pump
controlled by the high pressure pump shaft is fitted on the
rear side of the high pressure pump.
The high pressure pump - feed pump assembly cannot be overhauled and therefore should not be removed and the
! fastening screws should not be tampered with.
The only operation that can be carried out is the replacement of the drive gear.
Figure 9
72595
1. Fuel outlet fitting to rail - 2. High pressure pump - 3. Pressure regulator - 4. Drive gear - 5. Fuel inlet fitting from filter -
6. Fuel outlet fitting to tank - 7. Fuel inlet fitting from ECU heat exchanger - 8. Fuel outlet fitting from supply pump to filter -
9. Mechanical supply pump.

High pressure pump internal structure
Figure 10
Sect. B - B
Sect. C - C
70498
1. Cylinder - 2. Triple-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft
7. Low-pressure fuel inlet - 8. Plungers supplying fuel ducts
Every plunger unit is composed of: - cap intake valve (3);

- a piston (5) actuated by a three-lobe element (2) floating - ball delivery valve (4).
on the pump shaft (6). The element (2), as it floats on
a misaligned part of the shaft (6), when the shaft rotates,
does not rotate with it but is only translated in a circular
movement along a wider radius, with the result of alter-
natively activating the three pumping elements;

Operating principle
Figure 11
Sect. B - B
Sect. D - D
72597
1. Connection between fuel outlet and rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply pipe -
6. Pressure regulator supply pipe - 7. Pressure regulator.
Plunger (3) is oriented to pump shaft (4) cam. During intake, the flow of fuel to the pumping element. During plunger com-
the plunger is supplied through supply duct (5). The fuel pression stage, fuel reaches the pressure required to open
amount to be sent to the plunger is set by the pressure regu- the delivery valve to common rail (2) and to feed it through
lator (7). The pressure regulator meters fuel flow to plunger outlet (1).
according to

Figure 12 Figure 13
72601
72598
Sect. C - C Sect. A - A
1. Plunger inlet - 2. Pump lubrication pipes - 3. Plunger 1. Fuel outlet pipe - 2. Fuel outlet pipe - 3. Fuel outlet
inlet - 4. Main plunger supply pipe - 5. Pressure regulator - from pump with connector for high-pressure pipe for the
6. Plunger inlet - 7. Regulator drainpipe - 8. Pressure common rail.
limiting valve 5 bar - 9. Fuel drainage from regulator inlet.
The figure shows the low-pressure fuel paths inside the The figure shows the flow of the fuel at high pressure through
pump; it shows the main supply pipe of the pumping elements the outlet ducts of the pumping elements.
(4), the pumping element supply pipes (1 - 3 - 6), the pipes
used to lubricate the pump (2), the pressure regulator (5), the
5-bar pressure relief valve (8) and the fuel discharge (7).
Pump shaft is lubricated by fuel through delivery and return
ducts (2).
The pressure regulator (5) establishes the quantity of fuel to
be supplied to the plungers; The excess fuel flows off through
the pipe (9).
5 bar pressure relief valve acts as fuel return collector and
keeps 5 bar constant pressure at regulator inlet.

Operation Pressure regulator description

The cylinder is filled through the cap intake valve only if the The pressure regulator is fitted on the low pressure circuit
supply pressure is suitable to open the delivery valves set on of pump CP.3. The pressure regulator modulates the amount
the pumping elements (about 2 bars). of fuel sent to the high-pressure circuit according to the
commands received directly from the engine control unit.
The amount of fuel supplying the high-pressure pump is
The pressure regulator is mainly composed of the following
metered by the pressure regulator, placed on the low-pres-
components:
sure system; the pressure regulator is controlled by the
engine management control unit through a PWM signal. - connector,
When fuel is sent to a pumping element, the related piston - casing,
is moving downwards (suction stroke). When the piston
- solenoid,
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come - pre-load spring
out, is compressed above the supply pressure value existing
- shutter cylinder.
in the rail.
When there is no signal, the pressure regulator is normally
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure cir- open, therefore with the pump providing maximum delivery.
cuit. The engine control unit, via the PWM (Pulse Width
The pumping element compresses the fuel till the top dead Modulation) signal, modulates the change in fuel flow rate in
the high-pressure circuit by partially closing or opening the
center (delivery stroke) is reached. Afterwards, the pressure
decreases till the exhaust valve is closed. sections of passage of the fuel in the low-pressure circuit.
The pumping element piston goes back towards the bottom

dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less
Figure 14
than the supply pressure, the intake valve is again opened and
the cycle is repeated.
The delivery valves must always be free in their movements,
free from impurities and oxidation.
The rail delivery pressure is modulated between 250 and
1600 bars by the electronic control unit, through the pres-
sure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection - reconnection time on the
engine is highly reduced in comparison with traditional injec-
tion pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean. 185436
1. Solenoid - 2. Magnetic core - 3. Shutter cylinder -

4. Fuel inlet - 5. Fuel outlet.
When the engine control unit operates the pressure
regulator (via PWM signal), the solenoid (1) is energized,
which in turn generates the movement of the magnetic core
(2). The shift of the core causes the shutter cylinder (3) to
move axially, choking the flow of fuel.

Figure 15 Pressure relief valve

The function of the valve fitted at one end or rail is to protect
system components against any fault which might result in
overpressure in high pressure system.
This valve enables to have the engine operated for long time
with limited performance and inhibits fuel excessive overhea-
ting, so preserving the pipings returning from the tank.
Electro-injector
The electro-injector essentially consists of two parts:
- actuator - spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve checks the lift of the nozzle needle.
185437
1. Solenoid - 2. Magnetic core - 3. Preload spring -

4. Shutter cylinder.
When the solenoid (1) is not energized, the magnetic core

is pushed into the rest position by the pre-load spring (3). In Injector in resting position
this position the shutter cylinder (4) allows the greatest Figure 17
section of passage for the fuel flow.
Rail
Figure 16
15
108500
1. Rail - 2. Pressure sensor - 3. Fuel intake from HP pump

4. Relief valve.
The rail volume is of reduced sizes to allow a quick pressurisa-

tion at startup, at idle and in case of high flow-rates.
It anyway has enough volume as to minimise pulsations cau-
sed by injectors openings and closings and by the high-pres-
sure pump operation. This function is further enabled by a
calibrated hole being set downstream of the high-pressure
pump. 70505
A fuel pressure sensor (2) is screwed to the rail. The signal 1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil -
sent by this sensor to the electronic control unit is a feed-- 5. Pilot valve - 6. Ball shutter - 7. Control area - 8. Pressure
back information, depending on which the rail pressure value chamber - 9. Control volume - 10. Control pipe - 11. Supply
is checked and, if necessary, corrected. pipe - 12. Control fuel outlet - 13. Power connection -
14. Spring - 15. High pressure fuel inlet.

Beginning of injection Quick coupler for fuel return

It is housed on the rear part of the cylinder head and adjusts
Figure 18 the pressure of fuel returning from the injectors to a pressure
of between 1.3 2 bars.
Figure 19
15
186859
A To tank - B From electro-injectors
70506
When coil (4) is energised, it makes shutter (6) move

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

therefore it must not be disassembled.

LUBRICATION
The forced circulation lubrication is carried out by the lobe The lubricant oil is conveyed from the oil sump to the crank-
oil pump (5), housed in the front part of the crankcase and shaft, to the camshaft and to the valve control.
driven by the straight-toothed gear keyed to the crankshaft Lubrication also includes the heat exchanger, the turbochar-
tang. ger and the compressor if there is a compressed air system.
All these components often vary depending on use and are
therefore dealt with in the specific part of the manual.
Figure 20
227478
LUBRICATION SYSTEM LAYOUT

A. Oil under pressure - B. Oil in freefall -
C. To the heat exchanger and to the turbocharger - D. Recovery of oil from the turbocharger
1. Oil introduction - 2. Crankshaft - 3. Oil sump - 4. Suction strainer - 5. Oil pump

Oil pump Figure 21

Housed in the front of the crankcase, the oil pump is a rotary
pump commanded by a spur gear fitted to the stub of the
crankshaft.
NOTE Since the oil pump cannot be overhauled, it shall

be replaced when damaged.
The oil pump is driven directly by the crankshaft.
PUMP PRESSURE NOMINAL

SPEED FLOW
(rpm) (bar) (L/min) 70576
750 2 12.2
4.200 4 75.9
Heat exchanger
Figure 22
200097
1. Heat exchanger body with filter bracket - 2. Oil pressure control valve - 3. By-pass valve to cut off clogged oil filter -
4. Internal gasket - 5. Oil - water heat exchanger - 6. Gasket between exchanger unit and engine block

Oil pressure regulator valve

Figure 23
1. Threaded plug - 2. Spring - 3. Valve

4. Oil filter body - 5. By-pass valve
Pressure regulation at 100C oil temperature

- 1.2 bar min pressure;
- 3.8 bar max. pressure
107418
By-pass valve to cut out clogged oil filter.
Figure 24 Figure 25
Flow
70482
Max section :
107419 20 cm3/1 at pressure of 0.83 bar and oil temperature of
26.7C.
MAIN DATA TO CHECK THE Opening pressure:
OIL PRESSURE CONTROL VALVE SPRING 3.0 to 3.8 bar

OIL VAPOUR RECYCLING

Figure 26
201723
1. Tappet cover - 2. Oil vapour breather - 3. Oil vapour separator control valve - 4. Oil vapour filter housing
The oil vapour recirculation circuit is used to decant and burn the breather gases from the crankcase.
These gases consist of a mix of air, fuel vapours and lubricant oil vapours.
The gases from the crankcase rise back up to the cylinder head and are then conveyed into a separator fitted inside the tappet
cover. The separator is equipped with a diaphragm valve which allows:
- the condensation and recovery of the vapours;
- the lower part of the crankcase to be kept at the right vacuum value.
The condensed vapours fall back into the sump while the remaining vapours are conveyed to the filter via the designated pipes
before being released into the atmosphere.
In order for the engine to operate correctly, the lower part of the crankcase must be at a slightly lower pressure. For this reason,
the diaphragm valve of the separator adjusts the vacuum to approximately 65 mbar.

COOLING SYSTEM
The engine cooling system, of the closed-loop forced-circulation type, consists of the following components:
- Expansion tank: the position, shape and dimensions can change depending on the engine outfitting.
- Radiator, for dissipating the heat taken from the engine by the coolant. This component can also change depending on the
outfitting both in terms of position and dimensions.
- Heat exchanger to cool the lubricant oil: this is also part of the specific outfitting for the engine.
- Centrifugal water pump set in the front part of the engine block.
- Thermostat regulating the circulation of the cooling liquid.
- The circuit extends to the compressor.
Figure 27
227479
A. Water coming out from thermostat - B. Water recirculating in engine - C. Water coming into pump
1. Thermostat - 2. Water pump - 3. Radiator - 4. Expansion tank - 5. Water/oil heat exchanger.

Water Pump
Figure 28
70486
Sec. A-A
The water pump is located in a hollow obtained in the cylinder block and is driven by and a poly-V belt.
An automatic tensioner keeps the belt tension.
Pump performances
Coolant fluid temperature: 100 5 C
Anti-freeze concentration: 50%
Pump speed [rpm] Flow [L/min] Pressure [bar]

5.000 210 2.00 to 2.45
2.500 110 0.50 to 0.65

Thermostat
The thermostat, located in the cylinder head, is of the by-pass type and doesnt need regulations.
If there are doubts as to its proper functioning, replace it.
The basic parts of a thermostat are: heat motor, which includes a valve attached to a piston that is embedded in a special wax,
flange, spring and frame.
The thermostat has a jiggle pin that allows trapped air in the cooling system to pass through the thermostat and be released
from the system.
The thermostat has two important jobs:
- Accelerate engine warm-up by blocking the circulation of coolant between the engine and radiator until the engine has
reached its predetermined temperature.
- Regulate the engines operating temperature by opening and closing in response to specific changes in coolant temperature
to keep the engines temperature within the desired operating range.
Figure 29
209191
1. Flange - 2. Stem (piston) - 3. Frame - 4. Min. stroke at full opening temperature - 5. Jiggle pin - 6. Flange seal -
7. Main spring - 8. Wax slug - 9. By-pass valve
Thermostat performances
Min. allowed working temperature: -40 C
Max. allowed working temperature: 135 C
Max. allowed peak temperature (5 minutes): 150 C
Max. working differential pressure: 3 bar
Opening start: 79 2 C
Full opening temperature: 96 C
Min. stroke at full opening temperature: 7.5 mm

Operation description
- When the engine is cold, the thermostat is normally closed; restricting flow to the radiator allowing the engine to warm-up;
- As the engine warms, the increase in heat causes the wax to melt and expand, pushing against a piston inside a rubber boot;
- This forces the piston outward, opening the thermostat so coolant can start to circulate between the engine and radiator;
- As heat increases, the thermostat continues to open until engine cooling requirements are satisfied;
- If the temperature of the circulating coolant begins to drop, the wax element contracts; allowing spring tension to close
the thermostat, which decreases coolant flow through the radiator.
Figure 30
209198
A. Thermostat closed (coolant to water pump through by-pass port)

B. Thermostat open (coolant to radiator)

INTAKE AND EXHAUST SYSTEM

Figure 31
227494
1. Intake manifold - 2. Exhaust manifold - 3. Turbocharger - 4. Motorized throttle valve (Exhaust flap)
A. Cooled compressed air from intercooler (compressed cold air) - B. Turbocharger compressed air outlet to
intercooler (compressed hot air) - C. Turbocharger filtered air inlet from air filter (filtered air) - D. Turbocharger
exhaust gas outlet from motorized throttle valve (Exhaust flap) (exhaust gas)
Description
The engine intake system recalls external air through the air After combustion, the exhaust manifold collects the fuel
filter. gases coming from the cylinders and conveys them directly
to the turbocharger to activate it.
The filtered air runs through the entry hose to the turbochar-
ger. The adoption of turbocharging makes it possible to increase
the power developed by the engine by emitting, at each cycle,
Exiting from the turbocharger, the filtered and compressed a quantity of combustive air greater than what the engine
air passes through the intercooler. would have been able to intake naturally through the alterna-
The compression causes an increase in air temperature and ting motion of the pistons.
hence its expansion. A greater quantity of air emitted into the combustion cham-
In order to introduce a greater quantity of mixture into the ber makes it possible to completely burn a higher quantity of
combustion, the air is inter-cooled thus increasing its density fuel, so as to respect the optimal stoichiometric ratio.
at the same pressure. The exhaust gases cause rotation of the turbine splined to
the centrifugal compressor by means of a connecting shaft.
The cycle ends with the introduction of inter-cooled air into
the intake manifold and then to the pistons to be used inside Rotation of the turbine involves the rotation of the compres-
the combustion chamber. sor which compresses the air coming from the filter.

Turbocharger
The turbocharger is composed of the following main parts: a turbine, boost-pressure regulation valve (Waste-Gate), a central
body and a compressor.
During engine operation, the exhaust gases pass through the turbine body spinning the turbine rotor.
The compressor rotor is connected by a shaft to the turbine rotor, which it spins and in doing so compresses the air taken in
through the air filter.
The air is then cooled by the intercooler and sent to the cylinders via the intake manifold.
The turbocharger is fitted with a Waste-Gate valve which is driven by a pneumatic actuator allowing the passage of the exhaust
gas to the turbine to be reduced depending on the pressure reached at the compressor outlet.
The engine oil is used to cool and lubricate the turbocharger and the bearings.
Figure 32
227480
A. Intake air - B. Compressed air - C. Exhaust gas

1. Gasket on exhaust manifold - 2. Studs - 3. Fastening nuts - 4. Exhaust gas turbine -
5. Waste-gate valve - 6. Air compressor

Waste-Gate valve
The function of the Waste-Gate valve is to choke the exhaust gas outlet, by conveying part of the gas directly into the exhaust
pipe, when the boosting pressure downstream the turbocharger reaches the calibration value.
Figure 33
227497
Closed throttle valve Throttle valve open
DEMONSTRATIVE CROSS-SECTION OF A TURBOCHARGER WITH WASTE-GATE VALVE
Throttle valve
The throttle valve is positioned at the turbocharger exhaust gas outlet, its controlled by an electric actuator via signals from
the engine management control unit.
The main new feature is an electric actuator which allows the exhaust gas outlet to be choked to increase the outlet temperature.
This possibility is exploited in order to quickly bring catalytic converter up to standard thermal conditions (reduction of emissions
when is cold).
The throttle valve is cooled by the engine coolant.
Figure 34
221358
1. Electric connection - 2. Electric actuator - 3. Studs - 4. Gasket -

5. Fastening nuts - 6. Motorized throttle valve (Exhaust flap)

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic
2-WAYS DIVERTER VALVE VERSION
Figure 35
204274
A. AdBlue pump module supply line - B. AdBlue return line to tank - C. AdBlue system heating line - D. AdBlue delivery
line to dosing module.

Figure 36
227498
A. AdBlue pump module supply line - B. AdBlue return line to tank - C. AdBlue system heating line - D. AdBlue delivery
line to dosing module.

The ATS system consists essentially of:

- a DOC oxidizing catalytic converter DOC (6);
- a DPF particulate filter catalytic converter (5);
- a differential pressure sensor (11) which detects the difference in pressure of the particulate filter inlet and outlet;
- a tank (8) for reagent solution (water - urea: AdBlue) with level gauge (7);
- an 2-ways/3-ways H2O diverter valve (9);
- pump module (10);
- an injection and dosing module 2.2/2.5 (12);
- a SCR catalytic converter (2);
- three exhaust gas temperature sensors (1): one at the DOC catalytic converter inlet (6), one after the DPF catalytic conver-
ter (5) and the other on the exhaust gas outlet pipe from the catalytic converter (2);
- one humidity detection sensor fitted on the engine air inlet pipe downstream of the air filter;
- two nitrogen oxide (NOx) detection sensors (3) fitted upstream and downstream of the catalytic converter;
- one ammonia (NH3) detection sensor (4) at the exhaust gas outlet.
To restrict the emissions in the exhaust to within the limits prescribed by legal regulations, an exhaust gas post-treatment system
(ATS) has been adopted combining two devices:
- a catalytic converter/particulate filter for the treatment of the HC (unburnt hydrocarbons), the CO (Carbon monoxide)
and the particulate;
- The DeNOx 2.2 device for the treatment of NOx (nitrogen oxide).
The ATS system is controlled electronically by the EDC17CV41 control unit which on the basis of the engine rpm, torque
delivered, the exhaust temperature, the quantity of nitrogen oxides and the intake air humidity, adjusts the flow rate of the
AdBlue solution to be introduced into the system.
The pump module picks up the reagent solution from the tank and sends it under pressure to the mixing and injection module
to be injected into the exhaust pipe.

Figure 37
180401
1. NOx upstream of catalytic converter - 2. Differential pressure sensor - 3. Dosing module 2.2/2.5 - 4. NOx downstream
of catalytic converter - 5. NH3 sensor - 6. SCR catalytic converter outlet temperature sensor - 7. SCR catalytic converter -
8. SCR catalytic converter inlet temperature sensor - 9. DPF catalytic converter - 10. DOC catalytic converter - 11. DPF
catalytic converter inlet temperature sensor.
In the first stage the exhaust gases leaving the turbine encounter the catalytic converter DOC (10) in which the hydrocarbons
(HC) and carbon monoxide (CO) are transformed, through oxidation reactions, into carbon dioxide (CO2) and water (H2O).
Subsequently the exhaust gases pass through the DPF particulate filter (9) which holds back the carbonaceous particles forming
the particulate.
In order for the system to remain efficient, it needs to be regenerated and for this purpose there is a differential pressure sensor
(2) which, by detecting the difference in input and outlet pressure is able to provide the control unit with an index for the clog-
ging of the filter.
The particulate filter regeneration is performed through the Exhaust Flap device to choke the outlet section of the exhaust
gas from the turbine creating a dummy load to the engine. This way the exhaust gases reach the filter at a high temperature
and the particles of the particulate burn keeping the filter clean.
In the second phase the dosing module (3), through an injector placed in the exhaust pipe upstream of the SCR catalytic conver-
ter (7), introduces a solution of water and urea (AdBlue) into the exhaust gas.
The first stage of the process takes place in the first part of the SCR catalytic converter: due to the effect of the exhaust gas
temperature, the reagent solution evaporates instantly and is hydrolysed to ammonia (2NH3) and carbon dioxide (CO2); at
the same time, the solution evaporates lowering the exhaust gas temperature to levels close to the optimum temperature requi-
red for the process.
Exhaust gases containing ammonia at the temperature required for the reaction enter the SCR catalytic converter (7), where
the second stage of the process takes place: by reacting with the oxygen in the exhaust gas the ammonia is converted into
free nitrogen (N2) and water vapour (H2O).
The Clean Up Catalyst (CUC) is in the end section of the catalytic converter and serves to oxidise the excess urea produced
by the engine in the transient operating phases.
The amount of AdBlue injected is controlled through a NH3 sensor (5) fitted on the outlet pipe of the silencer, which detects
the presence of ammonia in the exhaust gas and sends a signal to the engine management control unit thereby providing a
feedback signal.
The engine control unit, on the basis of the engine rpm, torque, exhaust gas temperature, intake air humidity, amount of nitrogen
oxide and the amount of urea present in the exhaust gas, detected by the respective sensors, regulates the flow of AdBlue
to be injected into the system.

ATS system heating/cooling system

The system has two functions:
- continuous cooling of the dosing module;
- heating the AdBlue tank, the supply module and the AdBlue pipes.
Figure 38
HEATING AND COOLING
CONDITION
A. ATS System cooling/heating

circuit
B. AdBlue
C. Coolant circuit
1. 3-ways diverter valve version
2. AdBlue tank
3. Supply module filter
4. Supply Module
5. Dosing Module 2.2/2.5
6. Catalyst
227481
Figure 39
HEATING AND COOLING
CONDITION
A. ATS System cooling/heating
circuit
B. AdBlue
C. Coolant circuit
1. 2-ways diverter valve version
2. AdBlue tank
3. Supply module filter
4. Supply Module
5. Dosing Module 2.2/2.5
6. Catalyst
204280
The system is equipped with a heating circuit to adjust the temperature of AdBlue and avoid incurring the risk of freezing (AdBlue
freezes at -11C.).
The diverter valve allows the passage of a part of the engine coolant in the coil inside the AdBlue tank and subsequently inside
the supply module.
The system heats pipes and tank when engine is started; AdBlue metering is engaged only when the system is free of ice.
The dosing module, given its unfavourable assembly position from a cooling point of view and given the high temperatures rea-
ched by the exhaust gases downstream of the catalytic converter, is connected to the engine cooling circuit and continuously
cooled.

MAIN COMPONENTS OF ATS SYSTEM

Tank
Figure 40
204272
The tank with the level indicator command (1) contains the reducing substance comprising a solution of 35% urea and water,
known as AdBlue. There is a gauze filter on the filler (2).
AdBlue fluid level gauge control

Figure 41
116181
1. AdBlue liquid delivery pipe - 2. AdBlue liquid return pipe - 3. Engine cooling hot liquid inlet pipe -
4. AdBlue temperature sensor (NTC) - 5. Engine cooling hot liquid outlet pipe - 6. Float (level sensor) -
7. AdBlue liquid heating coil - 8. AdBlue breather.
The indicator control for the AdBlue liquid level is a device consisting of:
- a float (level sensor);
- an NTC temperature sensor;
- a coil for heating the liquid in low temperatures.
It informs the ECU of changes in the current due to the resistance, caused by the position of the float in relation to the level
of the AdBlue liquid.

DeNOx 2.2 supply module (SM - Supply Module)

Figure 42
185025
1. Main filter - 2. Electric connector - 3. Pressure compensation diaphragm - 4. Feed pipe from tank -
5. Pump module heating liquid inlet pipe - 6. AdBlue return pipe to tank - 7. Pump module heating liquid outlet pipe -
8. Delivery line to dosing module
The AdBlue supply module consists mainly of a diaphragm pump which takes up the AdBlue from the tank and sends it to the
dosing module.
It is equipped with a circuit connected to the engine cooling system which, in low temperatures, stops the AdBlue from freezing.
Inside there is a pressure sensor.
The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and are
dependent on the operating conditions of the engine and from the signals sent by the sensors.
Figure 43
185029
1. Engine coolant connector - 2. AdBlue inlet from tank - 3. AdBlue return to tank -
4. AdBlue outlet to dosing module - 5. Pressure sensor - 6. Filter - 7. Diaphragm pump - 8. Valve 4/2.
To prevent any damage to the pump and the dosing module, the supply module contains a filter which cleans the AdBlue of
any impurities.
Refer to the procedure described below to replace the filter.

Filter removal Figure 47
Figure 44
185430
185435 - On the basis of the colour of the filter, insert the correct
part of the tool (1) into the filter
NOTE During installation of the supply module, bear in
mind the minimum clearance for replacing the filter.
The minimum measurement is approximately 155 Figure 48
mm.
Figure 45
185431
- Insert the specific tool (1) until a click is heard indicating

that the filter (2) has been completely engaged.
185428
- Unscrew and remove the filter cover (1).

Figure 49
Figure 46
185432
185429
- Remove the compensation element (1). - Remove the filter (1).

Filter assembly Figure 53

Figure 50
185428
185433 - Thoroughly clean the filter cover (1).

- Thoroughly clean the contact surface (1) with water. - Screw on the filter cover and tighten to a torque of 20
5 Nm.
Figure 51
Figure 54
185434
- Moisten the gaskets and insert the new filter (1).
185435
Figure 52
NOTE During installation of the supply module, bear in

mind the minimum clearance for replacing the filter.
The minimum measurement is approximately 155
mm.
185429
- Insert the new compensation element (1).
NOTE Make sure that the filter cover and the contact sur-
face of the supply module show no signs of being
cracked or damaged. If they do, replace the dama-
ged components.

DeNOx 2.5 dosing module (DM - Dosing Module)
Figure 55 Figure 56
2. 2 version 2.5 version
227499 193974
1. Power connection - 2. AdBlue inlet - 3. Coolant inlet/outlet.
The dosing module is controlled by the engine control unit. Its function is to dose the AdBlue to be injected into the exhaust
pipe upstream of the SCR catalytic converter.
It is fitted on the catalytic converter and while in operation it is subject to high temperatures. For this reason it is connected
to the engine cooling circuit by means of the pipes (3).
Maximum AdBlue injection pressure: 9 bar.
DM 2.5 is based on DM 2.2 with improved cooling design.
For DM 2.5 the limit for max. ambient temperature was increased to 140C with adjusted useful lifetime (DM 2.2 max. ambient
temperature 120C). This requires the usage of components with increased temperature robustness.
Benefits:
- Dosing Module can be mounted closer to exhaust gas flow
- High lifetime due to low thermal stress
- Robustness against high exhaust gas temperatures

Diverter valve
Figure 57 Figure 58
3-WAYS DIVERTER VALVE VERSION 2-WAYS DIVERTER VALVE VERSION
227483 227482
1. Engine coolant pipe - 2. Dosing module coolant pipe - 1. Engine coolant pipe - 2. AdBlue tank heating fluid pipe -
3. AdBlue tank heating fluid pipe - 4. Electrical connector 3. Electrical connector
The diverter is a 2-position 2-way/3-way solenoid valve heats the AdBlue tank and pipes with the engine coolant.
Depending on the temperatures detected by the NTC sensor, the switch valve closes or opens the passage of the engine coolant
into the AdBlue tank heating coil. The cooling circuit of the dosing module instead always stays open.
The first position, in fact, allows the cooling of the Dosing Module (DM) whereas the second position allows the heating of the
AdBlue tank, the Supply Module (SM) and the relevant pipes, besides cooling the DM.

NH3 sensor
Figure 59
185027
The NH3 sensor is connected to the engine management control unit and by detecting the amount of ammonia (NH3) present
in the exhaust gas leaving the catalytic converter it allows an exact adjustment of the amount of AdBlue to be injected.
Figure 60
185028
A. Vehicle side connector - B. Sensor side connector.

101. Power supply - 102. CAN LINE H - 103. CAN LINE L - 104. Ground.
NH3 SENSOR CHARACTERISTICS NOMINAL
Operating voltage 10 to 32 V
Average current 1.2 A
Peak current 4.0 A
Operating limit values -40 to 105 C
Tightening torque: 50 10 Nm

Nitrogen oxide detecting sensor
Figure 61
102302
1. Positive - 2. Ground connection - 3. CAN LINE L - 4. CAN LINE H - 5. Spare

The NOx sensor detects the amount of nitrogen oxide present in the exhaust gas entering and leaving the catalytic converter.
On the basis of this information the engine control unit adjusts the amount of AdBlue to be injected and also measures the effi-
ciency of the catalytic converters.
NOx SENSOR CHARACTERISTICS NOMINAL

Ambient temperature: - 40 to +105 C
(+105 to +115 C allowed for 10 min)
Cable temperature: 230 C allowed for 100 h
Tightening torque: 50 10 Nm

Exhaust gas temperature sensor
Figure 62
102303
Figure 63
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable power voltage at output - 3. Connector - 4. Grey signal cable - 5. White ground cable -
6. Sensor
It has the function of sending information to the control unit regarding the temperature of the exhaust gas entering and exiting
the catalyst that is necessary for calculating the amount of urea to inject in the system.
EXHAUST GAS TEMPERATURE SENSOR CHARACTERISTICS NOMINAL
Power supply 5.00 V 0.1%
Voltage at a temperature -40 to 1.000 C 0.727 to 2.297 V
Pull-up resistance 1,000 0.1%
Cable resistance 1
Tightening torque: 45 4.5 Nm

Temperature and humidity sensor

Figure 64
125531
1. Power supply - 2. Percentage of humidity - 3. Ground - 4. Temperature

This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to
the ECU These data are used by the ECU to determine the level of nitrogen oxide emissions.
Figure 65
102312
ELECTRIC BLOCK DIAGRAM

1. Power supply unit - 2. Percentage of humidity - 3. Ground - 4. Temperature - A. Sample frequency generator -
B. Reference oscillator - C. NTC temperature sensor - D. Low pass amplifier filter
HUMIDITY SENSOR SPECIFICATIONS NOMINAL
Supply voltage 5.00 0.25 VDC
Current absorption 10 mA
Operating range 0% RH to 100% RH
Output impedance 70 ohms
Insulating resistance 1 Mohm @ 500 V
TEMPERATURE SENSOR SPECIFICATIONS NOMINAL

Operating range -40 to 125 C
Resistance at 25 C NTC 2,186 kohms 1%
Maximum power at 25 C 100 mW
Tightening torque: 14.5 2.5 Nm

Catalytic converter
Figure 66
204271
The catalytic converter consists of 2 main parts:

- the first stage is made up of a DOC catalytic converter followed by a DPF catalytic converter in which the exhaust gas
is cleaned of the HC (unburnt hydrocarbons), CO (carbon monoxide) and the particulate;
- the second stage is made up of a SCR catalytic converter, upstream of which is the AdBlue dosing module; the reactions
to reduce the NOx (nitrogen oxide) takes place in this catalytic converter.

Differential pressure sensor

The differential pressure sensor (1), connected downstream and upstream of the DPF particulate filter, measures the corre-
sponding difference in pressure.
Figure 67
192083
This difference in pressure is converted into a voltage signal sent to the engine management control unit and consists of a clog-
ging index of the DPF particulate filter.

SCHEDULED MAINTENANCE FOR ATS SYSTEM

Below are indicated the checks, tests and adjustments which are to be carried out on the components of the ATS system at
the established time interval.
The frequency of the operations are indicative since the engine use and its characteristics are essential in evaluating replacements
and checks.
Not only it is permitted, but it is also recommended that the staff in charge of maintenance also perform those checking and
maintenance operations which may not be included in the list below but which are recommended by good-practices and particu-
lar conditions of use of the engine.
Furthermore, in case of clear malfunctioning of the system, prompt measures must be taken to verify the causes of the defect.
Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with acci-
dent-prevention laws for the safety of the staff in charge of maintenance.
Periodic maintenance
Component Maintenance and interval
Tank Neck Filter (300 or 100 m) No regular service planned (Cleaning, if required)
Tank Breather Filter (5/10* m) No regular service planned (Cleaning, if required)
SM Pre-Filter (100 or 70* m) Cleaning with water @ every oil change interval
SM Inlet-Filter (100 m) No regular service planned (Replacement, if required)
SM Main-Filter Change every 3.600 hours or 2 years (whichever occurs first)
SM Backflow-Filter (100 m) No regular service planned (Replacement, if required)
Dosing Valve Filter (36 m) Not serviceable
* for application working in dusty environment only.
Extraordinary maintenance
Component Maintenance and interval
Service regeneration 150 hours (**)
AdBlue change in the urea tank 6 months
DPF filter replacement Once clogging signals require the substitution
** to be performed every six months even if the specified operating hours interval has not been reached.
Figure 68
227505
ATS SYSTEM FILTER LOCATION

1. Dosing valve filter (36 m) - 2. Dosing module - 3. Supply module main-filter - 4. Supply module backflow-filter
(100 m) - 5. Supply module pre-filter (100 or 70* m) - 6. Tank breather filter (5/10* m) - 7. AdBlue tank -
8. Tank neck filter (300 or 100* m) - 9. Supply module inlet-filter (100 m) - 10. Supply module
* for application working in dusty environment only

REPLACING THE DPF Figure 71

(DIESEL PARTICULATE FILTER)
CATALYTIC CONVERTER
(Demonstrative figures)
Removing the DPF catalytic converter
Figure 69
203464
- Remove the cover (1).

204283
- Unscrew the screws (1) and remove the guards that are The weight of the cover (1) is ~ 8.3 kg.
on the catalytic converter. !
Figure 70 Figure 72
204284 204285
- Undo the screws (1) fixing the cover (2). - Remove and scrap the cage nuts (2).
Pay maximum attention to sharp edges (1); when

! removing DPF catalytic converter always wear pro-
tective gloves.

Figure 73 Figure 75
204286 204287
- Loosen the screws (2) and move the flat band clamp (1)
NOTE Mark axial position of flat band clamp (1) on cone approx. 60 mm in the direction indicated by the arrow
with marker pen (minimum 120 of circumfer- ().
ence).
NOTE Once the flat band clamp (1) has been removed it
must not be reused but replaced.
Figure 74
NOTE During the removal of the screws, pay close atten-

tion in order to prevent the screws removed drop
inside the ATS system.
Figure 76
204288
- Loosen the V-Clamp (2) by turning the screws (1) and

(3) at the same time and remove it.
NOTE Once the V-Clamp (2) has been removed it must

204289
not be reused but replaced.
- Remove the DPF catalytic converter (1) from its seat
using a suitable lifting device.
NOTE During the removal of the screws, pay close atten-

tion in order to prevent the screws removed drop The weight of the cover (1) is ~ 24 kg.
!
inside the ATS system.

Figure 77 Refitting the DPF catalytic converter

Figure 79
204295
1. Cover - 2. Flat band clamp - 3. DPF catalytic converter -

204290
4.Rings - 5. Gasket - 6. V-Clamp.
Pay maximum attention to sharp edges; always
! wear protective gloves.
NOTE All screws have to be tightened first by 3 revolu-
tions by hand to avoid damage to threads and
- Remove the 2 pressure rings (1) from the catalytic con- screws of ATS.
verter and DPF.
NOTE The pressure rings may be reused when refitting

after they have been cleaned.
One pressure ring stays on the DOC, second ring
has to be switched to the new (cleaned) DPF. Figure 80
Figure 78
204291
- Fit a new metal gasket (1) by clips (6x). The one previ-
204291 ously removed may not be reused.
- Remove the metal gasket (1). - Clean and install the pressure rings that were previously
removed in their seats on the DOC and the second ring
NOTE Clean the sealing surfaces and make a visual inspec- has to be switched to the new (cleaned) DPF.
tion of the DOC. - Install 8 new cage M8 nuts.

Figure 81 Figure 84
203474
204292
- Insert a new flat band clamp (1) on the DPF catalytic con-
verter (2). Position of flat band clamp (1) according to marking
! with pen on cone.
Rotational positioning of DPF with label (2) show-
ing to outside.
Figure 82 Figure 83
204293
204289
- Push the new flat band clamp (1) in the direction indic-
- Position the new DPF catalytic converter (1) in its seat.
ated by the arrow () until it reaches its correct posi-
tion.
The weight of the cover (1) is ~ 24 kg. NOTE Sliding of new flat band clamp into the direction of
! the rolled cone until clamp hits the marking done
with a pen.

Figure 85 Figure 86
204294
- Positioning the screw joints of V-clamp by using dimple

in front system baffle (see detail A);
204296 - Positioning of screw joint of flat band clamp by using
dimple in rear system baffle (see detail B).
- Install a new V-Clamp (5) and tighten screws by hand
first; tighten in sequence the fixing screws (1) and (2) to
the required torque.
Figure 87
Ref No. Description Tightening
torques
(1, 2) 2 1st phase 11 Nm
2nd phase 18 1 Nm
- Tighten in sequence the screws (3) and (4) by hand first

and then to the required torque.

torques
(3, 4) 2 1st phase 25 Nm
2nd phase 35 Nm
3rd phase 42.5 2.5 Nm
204285
NOTE Open V-clamp completely on one side and slide it
around DPF. Close screws (6) by hand first.
- Check cage nuts (2).
Ref No. Description

(2) 8 M8
NOTE If nuts are lost, control of DPF chamber for loose

parts and when required removal of those parts
and replacement at accurate position.
Pay maximum attention to sharp edges (1); when

! installing DPF catalytic converter always wear pro-
tective gloves.

Figure 88 Figure 90
204283
- Refit the guards on the silences and tighten the fixing

203481 screws (1) to the required torque.
- Refit the cover (1).
The weight of the cover (1) is ~ 8.3 kg. torques
! (1) 12 14 1.4 Nm
Figure 89
204284
- Tighten the screws (1) fixing cover (2) to the required

torque.

torques
(1) 8 M8x25 15 1 Nm

NEF SERIES EURO VI SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRONIC CONTROL UNIT (EDC17CV41) 5
- EDC System functions . . . . . . . . . . . . . . . . . . 5
ENGINE SIDE ELECTRICAL WIRING . . . . . . . . 8
- Topographic view . . . . . . . . . . . . . . . . . . . . . . 8
- Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- ECU connection to the injection cable

on engine side (housing A) . . . . . . . . . . . . . . . 10
VEHICLE SIDE ELECTRICAL WIRING . . . . . . . . 12
- ECU connection to the injection cable

on vehicle side (housing B) . . . . . . . . . . . . . . . 12
MAIN ELECTRICAL/ELECTRONIC EQUIPMENT 14
- Camshaft timing segment speed sensor . . . . . 14
- Crankshaft rpm increment speed sensor . . . . . 15
- Boost pressure and air temperature sensor . . 16
- Engine oil pressure and temperature sensor . . 17
- Rail pressure sensor . . . . . . . . . . . . . . . . . . . . 18
- Coolant temperature sensor . . . . . . . . . . . . . . 19
- Pressure regulator - high pressure pump . . . . . 21
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . 22
- Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Electric starter motor . . . . . . . . . . . . . . . . . . . 26
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2 SECTION 3 - ELECTRICAL EQUIPMENT NEF SERIES EURO VI

LOCATION OF THE MAIN ELECTRICAL COMPONENTS
Figure 1
227536
1. Fuel high pressure pump metering unit - 2. Fuel temperature sensor - 3. Engine Control Unit EDC17CV41 -
4. Timing segment speed sensor (camshaft) - 5. Engine coolant temperature sensor - 6. Electro-injectors (CRIN2) -
7. Rail pressure sensor (RDS) - 8. Boost pressure and air temperature sensor - 9. Rpm increment speed sensor (crankshaft)

Figure 2
227535
1. Engine oil pressure and temperature sensor - 2. Starter electric motor -

3. Motorized throttle valve actuator connector (Exhaust flap) - 4. Alternator

ELECTRONIC CONTROL UNIT (EDC17CV41)
Figure 3
201724
A. Engine side connector - B. Vehicle side connector
The control unit is a flash EPROM and so it can be repro- EDC System functions
grammed from outside without manipulating the hardware.
The EDC 17CV41 electronic center manages the following
The ECU processes the signals from the sensors by applying main functions:.
software algorithms and controls the actuators (especially
the electro-injectors and pressure regulator). - Fuel injection
It records, in the non-volatile memory area, the information - Motorized throttle valve
on the engine parameters originally set or acquired during Self-diagnosis
engine operation.
- Recovery
The control unit is mounted on the left-hand side of the
engine and two connectors are fitted, of which: - It also enables:
- a connector for the engine cable (injector and sensor - Interfacing with other electronic systems (if any) availa-
connector); ble on the vehicle.
- a connector for the chassis cable. - Diagnosis

Fuel dosing Injection lead electronic control

Fuel dosing is calculated based on: Injection lead, or the start of fuel delivery expressed in deg
rees , can differ from one injection to the next, even from one
- accelerator position
cylinder to another and is calculated similarly to delivery acc
- engine rpm ording to engine load, namely, accelerator position, engine
rpm and air admitted.
- quantity of air admitted
Lead is corrected as required:
The result can be corrected based on:
- during acceleration;
- fuel temperature (DIESEL DENSITY)
- according to water temperature;
- water temperature
and to obtain:
or to prevent:
- reduced emissions, noise abatement and no overload;
- noise
- better vehicle acceleration.
- fumes
High injection lead is set at start, based on water tempera-
- overloads ture.
- overheating. Delivery start feedback is given by injection electro valve
Pressure can be adjusted in case of: impedance variation.
- motorized throttle valve actuation Engine speed limiter
- serious defects involving load reduction or engine stop The control unit controls the engine speed at all revranges
an d in particular:
- ANTI-POLLUTION devices cutting in: NOx sensor,
NH3 sensor. - at idle;
Once the control unit has determined the mass of the intro- - at top speed.
duced air and measured its pressure and temperature, it cal-
culates the corresponding fuel load needed to inject into the Engine start
cylinder (mg. per delivery). Cylinder 1 step and recognition signal synchronization (fly-
wheel and drive shaft sensors) takes place at first engine
It also takes diesel temperature into account (density). turns.
The fuel load calculated in this way is converted into crank Accelerator pedal signal is ignored at start.
degrees i.e. injectionadvance and duration
Start delivery is set exclusively based on water temperature,
Delivery correction based on water temperature via a specific map.
When cold, the engine encounters greater operating resis The center enables the accelerator pedal, when it detects fly-
tan ce, mechanical friction is high, oil is till very viscous and wheel acceleration and rpm such as to consider the engine
operating plays are not optimized yet. as started and no longer drawn by the starter motor.
Fuel injected also tends to condense on cold metal surfaces. Cold starting
Fuel dosing with a cold engine is therefore greater than when Pre-post heating is activated when just one of the three sen-
hot. sors (water, air or fuel) registers a temperature lower than
5 C.
Delivery correction to prevent noise, fumes or overloads
Upon activation of the key contact, the pre-heating warning
Behaviors that could lead to the defects under review are light turns on the electronic dash-board and remains on for
well known, so the designer has added specific instructions a variable amount of time depending on the temperature
to the center to prevent them. (while the heating element at the intake manifold heats the
air), then it flashes.
De-rating
It is now possible to start up the engine.
In the event of engine overheating, decreasing delivery pro-
por t ionally to the temperature reached by the coolant chan- When the engine is running, the warning lamp goes out but
ges injection. the heater element continues working for a certain (variable)
period of time for post-heating.
The control unit uses the oil temperature reading in the ev
ent of a coolant temperature sensor failure. If, with the warning lamp blinking, the engine is not started
within 2025 seconds (absence time) the operation is can-
celled in order not to discharge the batteries.
The pre-heating curve is also variable in relation to the bat-
tery voltage.

Warm starting Cut-off

When the ignition key is inserted and the reference tempera- It refers to the supply cut-off function during deceleration.
ture exceeds 10 C, a warning light turns on for approxima- Cylinder Balancing
tely 2 seconds as a short test, then goes out.
Individual cylinder balancing contributes to increasing com-
It is now possible to start up the engine. fort and operability.
Run Up This function enables individual personalized fuel delivery
control and delivery start for each cylinder, even differently
When the ignition key is inserted, the center transfers data
between each cylinder, to compensate for injector hydraulic
stored at previous engine stop to the main memory (Cf. After
tolerances.
run), and diagnoses the system.
The flow (rating feature) differences between the various
After Run injectors cannot be evaluated directly by the control unit.
At each engine stop with the ignition key, the center still
This information is provided by the entry of the codes for
remains fed by the main relay for a few seconds, to enable
every single injector, by means of the diagnosis instrument.
the microprocessor to transfer some data from the main
volatile memory to an non-volatile, cancelable and rewritable Synchronization Search
(Eeprom) memory to make tem available for the next start If the camshaft sensor signal fails, the control unit can still
(Cf. Run Up). recognize the cylinders into which fuel is to be injected.
These data essentially consists of: If this takes place when the engine is already running, the fuel
flow is already acquired as a result of which the ECU conti-
- miscellaneous settings, such as engine idling and the like;
nues with the sequence already synchronized.
- settings of some components;
If this occurs when the engine is off, the control unit energizes
- breakdown memory. a single solenoid valve.
The process lasts for some seconds, typically from 2 to 60 At the latest by the 2nd engine shaft revolution, an injection
according to the amount of data to be stored, after which the will occur in that cylinder, for which the central unit only has
ECU sends a command to the main relay and makes it discon- to synchronize itself on the combustion sequence and start
nect from the battery. the engine.
NOTE This procedure must never be interrupted, by cut-

ting the engine off from the battery cutout or
disconnecting the latter before 60 seconds at least
after engine cut-out.
In this case, system operation is guaranteed until the fifth

improper engine cutout, after which an error is stored in the
breakdown memory and the engine operates at lower per-
formance at next start while the EDC warning light stays on.
Repeated procedure interruptions could in fact lead to cen-
ter damage.

ENGINE SIDE ELECTRICAL WIRING

Topographic view
Figure 4
227493
1. Electro-injector connector (cylinder 1-2) - 2. Electro-injector connector (cylinder 3-4) - 3. Boost pressure and air
temperature sensor - 4. Timing segment speed sensor (camshaft) - 5. Motorized throttle valve actuator connector (Exhaust
flap) - 6. Fuel temperature sensor - 7. Fuel high pressure pump metering unit (ZME) - 8. In line connector: signal for
dashboard - 9. Engine connector EDC 96 pin - 10. Rpm increment speed sensor (crankshaft) - 11. Engine oil pressure and
temperature sensor - 12. Rail pressure sensor (RDS4) - 13. Engine coolant temperature sensor

Diagram
Print P1D32N021 E
Figure 5
NEF SERIES EURO VI
221356
1. Engine connector EDC 96 pin - 2. Fuel temperature sensor - 3. Engine coolant temperature sensor - 4. Engine oil pressure and temperature sensor - 5. Boost
pressure and air temperature sensor - 6. Motorized throttle valve actuator connector (Exhaust flap) - 7. In line connector: signal for dashboard - 8. Timing segment
speed sensor (camshaft) - 9. Rpm increment speed sensor (crankshaft) - 10. Fuel high pressure pump metering unit (ZME) - 11. Rail pressure sensor (RDS4) -
SECTION 3 - ELECTRICAL EQUIPMENT
12. Electro-injector (cylinder 4) - 13. Electro-injector (cylinder 3) - 14. Electro-injector (cylinder 2) - 15. Electro-injector (cylinder 1) - E1. Electro-injector
connector (cylinder 1-2) - E2. Electro-injector connector (cylinder 3-4)
9
Base - March 2015

ECU connection to the injection cable on engine side (housing A)

Pin
ECU Function
01 Electro-injector cylinder 3
03 -
04 -
05 -
06 Engine oil pressure and temperature sensor ground
07 Boost pressure and air temperature sensor power supply
08
09
10
11 Rail pressure sensor power supply
12 Fuel temperature sensor ground
13 Engine oil pressure and temperature sensor NTC
14 -
15 -
16 -
17 Motorised throttle valve actuator connector - Exhaust flap: CAN H
18 Motorised throttle valve actuator connector - Exhaust flap: CAN L
19 -
20 -
21 -
22 -
23 -
24 -
27 -
28 -
29 -
30 -
31 Engine oil pressure and temperature sensor power supply
32 -
33 -
34 -
35 Engine oil pressure and temperature sensor pressure signal
36 Rail pressure sensor signal
37 Boost pressure and air temperature sensor NTC
38 -
39 Coolant temperature sensor ground
40 -
41 -
42 -
43 -
44 -
45 -
46 -
47 -
48 -
51 -
52 -
53 -
54 -
55 -

Pin
ECU Function
56 -
57 -
58 Fuel pressure regulator on HP pump
59 Coolant/fuel temperature sensor NTC
60 Rail pressure sensor ground
61 -
62 -
63 -
64 -
65 Rpm sensor ground
66 Rpm sensor signal
67 Timing sensor ground
68 Timing sensor signal
69 Timing and rpm sensor shield
70 -
71 -
72 -
75 -
76 -
77 -
78 -
79 -
80 -
81 -
82 -
83 Fuel pressure regulator on HP pump
84 -
85 -
86 Boost pressure and air temperature sensor pressure signal
87 -
88 -
89 -
90 Boost pressure and air temperature sensor ground
91 -
92 -
93 -
94 -
95 -
96 -

VEHICLE SIDE ELECTRICAL WIRING

ECU connection to the injection cable on vehicle side (housing B)
Ref. Function
1 V1
2 -
3 W1
4 -
5 W1
6 -
7 SCR pressure sensor
8 SCR tank level & temperature sensor
9 SCR downstream exhaust gas temperature sensor (T7)
10 W4
11 Engine compartment stop switch
12 -
13 Water in fuel switch
14 -
15 Humidity sensor with ambient temperature sensor
16 Exhaust gas temperature upstream sensor
17 -
18 -
19 -
20 ATS Intelligent sensor auxiliary relay
21 -
22 -
23 DEF dosing module
24 -
25 V1
26 V1
27 Fuel filter/pre-filter heating relay
28 W1
29 -
30 -
31 SCR tank level &temperature sensor
32 SCR upstream exhaust gas temperature sensor (T6)
33 -
34 Engine speed for speedometer
35 -
36 -
37 -
38 Engine compartment starter switch
39 W5
40 Humidity sensor with ambient temperature sensor
41 -
42 -
43 W3
44 ODB Led
45 ATS Intelligen sensor auxiliary relay
46 Diagnostic connector CAN High
47 Diagnostic connector CAN Low
48 -
49 V1
50 V3
51 -
52 W1
53 -
54 -
55 DPF delta pressure sensor
56 -
57 -
58 -
59 -
60 -

Ref. Function
61 Fuel filter/pre-filter heating relay
62 -
63 -
64 -
65 -
66 -
67 -
68 SCR pressure sensor
69 K15
70 K-line (flash programming UDS)
71 Controller Area Network 1 (High)
72 SCR tank heating valve
73 V1
74 V2
75 W1
76 -
77 -
78 -
79 -
80 -
81 -
82 -
83 Grid heater relay
84 SCR pump motor
85 SCR reverting valve
86 -
87 -
88 -
89 SCR pump motor
90 VS
91 -
92 -
93 -
94 -
95 Controller Area Network 1 (Low)
96 DEF dosing module

MAIN ELECTRICAL/ELECTRONIC EQUIPMENT

Camshaft timing segment speed sensor
The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the cam-
shaft. The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.
The timing sensor is connected to the control unit on pins 67A - 68A - 69A. The sensor impedance is 900 .
Figure 6
209186
Figure 7 Figure 8
183652 50288
Connector Wiring diagram
CAMSHAFT TIMING SEGMENT SPEED SENSOR PIN OUT

Ref. Description ECU Pin
1 Ground 67A
2 NTC 68A
3 Shield 69A

Crankshaft rpm increment speed sensor

The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a phonic wheel fitted
on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 65A - 66A - 69A. The sensor impedance is 900 .
Figure 9
50319
Figure 10 Figure 11
183652 50288
Connector Wiring diagram
CRANKSHAFT RPM INCREMENT SPEED SENSOR PIN OUT

1 Ground 65A
2 NTC 66A
3 Shield 69A

Boost pressure and air temperature sensor

This component incorporates a temperature sensor and a pressure sensor.
Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate
calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 90A - 37A - 07A - 86A.
The power supply is 5 Volt
Voltage at the sensor output is proportional to the detected pressure or temperature.
Pin 37A Temperature signal
Pin 86A Pressure signal
Figure 12 Figure 13
213601 227491
SIGNAL EVALUATION WITH LOAD

RESISTOR TO UH = 5.5 TO 16V
TECHNICAL DATA
Pressure range 50 to 400 kPa
Temperature range -40 to 130 C
Supply voltage 4.75 to 5.25 V
BOOST PRESSURE AND AIR TEMPERATURE SENSOR PIN OUT

1 Ground 90A
2 NTC signal (temperature) 37A
3 +5 V power input 07A
4 Signal (pressure) 86A

Engine oil pressure and temperature sensor

The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position.
This sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 06A - 13A - 31A - 35A.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative
device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.
Pin 13A Temperature signal
Pin 35A Pressure signal
Figure 14 Figure 15
PRESSURE SENSOR
4
213602 190518
Wiring diagram
ENGINE OIL PRESSURE AND TEMPERATURE SENSOR PIN OUT

1 Ground 06A
3 +5 V power input 31A
4 Signal (pressure) 35A

Rail pressure sensor

Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feed-
back).
The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection
command.
This sensor is connected to the control unit on pins 60A - 36A - 11A.
The power supply is 5 Volt.
Figure 16
201030
RAIL PRESSURE SENSOR PIN OUT

Ref. Description ECU pin
1 Ground 60A
2 Signal 36A
3 Power supply 11A

Coolant temperature sensor

It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies
the need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.
This sensor is connected to the control unit on pins 39A - 59A.
The impedance of the coolant temperature sensor at 20 C is approximately 2.50 .
Figure 17 Figure 18
213603 107798
COOLANT TEMPERATURE SENSOR PIN OUT

1 Ground 39A

Fuel temperature sensor

This sensor is identical to the coolant temperature sensor.
It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery.
The fuel temperature sensor is connected to the control unit on pins 12A - 59A.
The sensor impedance at 20 C is approximately 2.50 .
Figure 19 Figure 20
107798
213603
Connector
FUEL TEMPERATURE SENSOR PIN OUT

1 Ground 12A

Pressure regulator - high pressure pump Figure 21

Pump with 3 radial pistons controlled by the timing gears,
requiring no timing adjustment, with rotor type feed pump
fitted to the back.
A. Connection between fuel discharge outlet and filter hou-
sing
B. Connection for fuel inlet from control unit heat exchan-
ger
C. Connection for fuel inlet from fuel filter
D. Connection between fuel outlet from feed pump and fil-
ter
E. Connection between fuel outlet and rail
1. High-pressure pump
2. Feed pump
3. Pressure regulator (NO solenoid valve regulated by the
control unit by means of PWM signal).
Situated at the inlet of the high pressure pump on the low
pressure system, this device adjusts the quantity of fuel rea-
ching the high pressure pump on the basis of the commands
received from the electronic control unit.
It mainly consists of the following parts:
- tapered shutter;
- valve control pin;
- pre-load spring;
- coils. A
In the absence of a control signal, the pressure regulator is
normally open, and thus the high pressure pump is in maxi- 1 B
mum delivery mode. C
The ECU regulates a PWM control signal which reduces, to 3
a greater or lesser extent, the section carrying fuel to the high
pressure pump. 2
D
This component cannot be replaced individually and thus
should not be dismantled.
E
The amount of fuel feeding the high pressure pump is mete-
red by a proportional valve on the low pressure system -
managed by the engine management control unit.
The delivery pressure to the rail is regulate between 250 and
000912t
1400 bar by the ECU acting on the pressure regulator sole-
noid valve.
It is a N.O. solenoid valve.
Its resistance is approximately 3.2 .
PRESSURE REGULATOR PIN OUT

Ref Description ECU Pin
1 Supply 58A
2 Signal 83A

Electro-injectors Figure 22
The electro-injector essentially consists of two parts:
- an actuator - spray nozzle consisting of a pressure rod
1, a needle 2 and a nozzle 3;
- driving solenoid valve made up of coil 4 and pilot valve
5.
The solenoid valve checks the lift of the nozzle needle.
50336
Beginning of injection
When the coil (4) is energised, it makes the shutter (6) move
upwards.
The control volume fuel 9 flows back towards the backflow
duct 12 resulting in a drop in pressure in the control volume Figure 23
9.
At the same time, the fuel pressure in the pressure chamber
8 moves the needle 2 upwards resulting in the fuel being
injected into the cylinder.
End of injection
When power to the coil 4 is cut off, the shutter 6 closes again
so as to re-create a balance of forces which moves the needle
2 back into its closed position and stops the injection process.
This is an N.O. solenoid valve.

They are individually connected to the engine management
control unit on connector A.
The resistance of the coil of each individual injector is 0.56
to 0.57 .
000933t
INJECTOR IN RESTING POSITION

1. Pressure rod - 2. Needle - 3. Nozzle - 4. Coil -
5. Pilot valve - 6. Ball shutter - 7. Control area - 8. Pressure
chamber - 9. Control volume - 10. Control pipe -
11. Supply pipe - 12. Control fuel outlet -
13. Power connection - 14. Spring.

Connection connectors
Figure 24
171595
Wiring diagram
Figure 25
171596
ELECTRO-INJECTORS PIN OUT

Ref. Description Control unit pin
1 Cylinder 2 injector 02
CONNECTOR 1 3 Cylinder 1 injector 73
CONNECTOR 2 3 Cylinder 3 injector 25

Motorized throttle valve actuator connector (Exhaust flap)

Figure 26
221555
MOTORIZED THROTTLE VALVE ACTUATOR CONNECTOR PIN OUT

Ref. Description
1 V Bat -
2 Ground -
3 Can low 18A
4 Can high 17A

Fuel pre-filter Resistance control remote control switch

The water separation type fuel filter is mounted on the right The remote control switch is connected to the EDC control
hand side of the vehicle frame and has, on the cartridge base unit.
3, a sensor 4 detecting the presence of water in the fuel.
It is activated when the temperature of the water or the diesel
The filter support houses a manual priming pup 5 and a screw oil exceeds 5 C.
2 to bleed the air from the system.
The remote control switch coil resistance is about 15 .
The presence of condensate in the filter and the filter clogged
condition are revealed by sensor 4 by turning on a single warn-
ing light in the dash.
Figure 28
C
If the warning light lights up, take action immediately
! to remove the cause, as common rail system com-
ponents deteriorate quickly if there is water or
impurities in the fuel.
Figure 27
1 50325
C. Remote control switch
2 5
000910t
Tightening torque
Bleed screw 2 6 to 8 Nm
Filtering cartridge 3 18 0.1 Nm
Sensor 4 0.8 0.1 Nm

Electric starter motor

Figure 29
227488
Figure 30 Figure 31
227489 227490
WIRING DIAGRAM
EW: Pull-in winding
HW: Hold-on winding
The starter motor runs the engine, gaining its inertia and friction, and bringing it to a certain number of revolutions such as to initiate
the formation of the mixture required for combustion and then the autonomous movement of the engine.
The movement is transmitted by a DC electric motor, powered by the battery, via an engagement pinion which rotates the sprocket
formed on the engine flywheel.
Due to a free wheel engagement, the pinion turns off when the main engine rotates faster than the starter motor.
A relay energized by the current of the starter motor engages the pinion by means of a fork.
The starter motor included is a translation type and starts by means of the pinion, with relay housed directly above the starter motor.
Ignition is usually controlled via the ignition switch on the control panel and provides a positive voltage to the relay located on the
starter motor.
Specifications:
Type: BOSCH HX87-M
Nominal voltage: 24 V
Nominal rated power: 4 kW
Number of poles: 4
Direction of rotation: clockwise (seen from flywheel side)
Battery capacity: min. 44 Ah - Max. 110 Ah
Discharge current (DIN 43539): min. 210 A - Max. 450 A

Alternator
Figure 32
227492
Figure 33
215010
Figure 34
215008
It is frontally located on the right-hand side of the engine and is controlled by the auxiliary assembly belt.
Specifications:
Type: BOSCH NCB2
Nominal voltage: 28 V
Nominal rated current: 90 A @ 6.000 rpm
Stand-by current consumption: 1mA

Maximum continuous rotation velocity: 12,000 min-1
Operating temperature range: -40 C to +110 C
Direction of rotation: clockwise


NEF SERIES EURO VI SECTION 4 - SCHEDULED MAINTENANCE 1
SECTION 4
Scheduled Maintenance
Page
MAINTENANCE PLANNING . . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Planning of checks and periodical interventions 3
- Checks not included in maintenance planning 4
CHECKS AND PERIODICAL INTERVENTIONS 5
- Controls (when in use) . . . . . . . . . . . . . . . . . . 5
- Periodic maintenance . . . . . . . . . . . . . . . . . . . 8
- Extraordinary maintenance . . . . . . . . . . . . . . . 11

2 SECTION 4 - SCHEDULED MAINTENANCE NEF SERIES EURO VI

MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure,
immediately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
Planning of checks and periodical interventions
Checks (when in use)
Action Frequency
Visual inspection of engine 50 hours
Check engine lubricant oil level Daily
Check engine coolant level Daily
Drain water from fuel pre-filter 150 hours (1)
Check/top up electrolyte level in batteries Defined by vehicle
Check auxiliary drive belt condition 600 hours
Check condition of the exhaust duct(s) 6 months
Check coolant density 1 year
Engine EDC system check-up by diagnostic tool Only in case of anomaly
Periodic maintenance
Action Frequency
Change engine lubricant oil 600 hours (2)(3)
Change oil filter 600 hours (2)(3)(4)
Change fuel filter 600 hours (1)(4)(5)
Change fuel pre-filter (not supplied by FPT) 600 hours (1)(5)
Change blow-by filter 1200 hours (2)
Change air filter and clean housing (not supplied by FPT) (**) 1200 hours
Clean the air filter (not supplied by FPT) 600 hours
Change engine coolant 2 years
Extraordinary maintenance
Action Frequency
Turbocharger visual inspection 1200 hours
Adjustment valves/rocker arms clearance 2400 hours
Change auxiliary drive belt 2400 hours
(**)Early air filter clogging is usually due to environmental conditions. For this reason, the filter should be changed if clogging is
signalled by the related sensor, regardless of the prescriptions that shall be observed if no specific indications have been
provided.
1) Maximum period relative to the use of high quality fuel, (specification ASTM D975 or EN 590); this is reduced based on fuel
contamination and the alarm signals due to filter clogging and/or the presence ofwater in the pre-filter. The filter clogging signal
indicates that the filter must be replaced. If the signal of water present in the pre-filter does not turn off after drainage, the filter
must be replaced.
2) Perform every year even if the specified operating hour interval is not reached.
3) Frequency applicable for lubricants which meet the international standards
ACEA E9 API CJ-4 / SAE 10W-40 / ACEA E6 SAE 5W-30, as indicated in the REFILLING table.
4) Only use filters with the following specifications:
- degree of filtering < 12 m
- filtering efficiency 99.5% ( > 200).
5) Perform every two years even if the specified operating hour interval is not reached.

NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
NOTE The extraordinary maintenance operations described in the relative table are under exclusive responsibility of qualified
personnel in possession of suitable technical information and equipped with suitable work tools and protective devices.
Checks, inspections and changes are indicative and must integrate specifications for vehicles equipped with the
! NEF EURO VI engine.
The data are only valid if the fitter observes all the installation regulations provided by FPT.
Checks not included in maintenance planning

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.

CHECKS AND PERIODICAL Check engine lubricant oil level

INTERVENTIONS Figure 1
Checks (when in use)
Visual inspection of engine
Before starting, it is recommended to carry out a series of
simple checks that can significantly help avoid problems, also
of a series nature, while the engine is operating.
These checks are usually performed by the vehicle operators
and drivers.
- Check the levels and check for any leaks from the fuel,
cooling and lubrication circuits.
- Inform maintenance personnel if any problems are found;
top up if necessary.
227485
After starting the engine and with the engine operating,
perform the following checks and controls: The check must be performed when the engine is stopped and
possibly cold.
- Check for any leaks from the fuel, cooling and lubrication
circuits. The check is carried out with the flexible dipstick (2).
- Make sure there is no unusual noise or beating during Remove the dipstick (2) from its housing and check that the
operation. level is between the minimum and maximum ends etched on
it.
- Use the vehicle instruments to check the foreseen
pressure, temperature values, etc. If the reading is unclear, clean the dipstick (2) with a cloth with
no looses threads and put it back in its seat. Take it off again
- Visually check the smoke (colour of the exhaust gas). and check the level.
- Visually check the level of the coolant in the expansion If the level is insufficient, it is necessary to top up with lubricant
tank. oil which meets the international specifications API CJ-4 /
ACEA E9-E6, as indicated in the REFILLING table: remove the
lubricant oil cap (1) and pour engine lubricant oil through the
hole.
Always make sure to add oil with the same characteristics as
the one contained in the sump. Mixtures which do not ensure
the proper lubrication of the internal parts of the engine are
not permitted.
The engine oil is highly pollutant and toxic.

! In case of contact with skin, wash thoroughly with
water and detergent.
Suitably protect skin and eyes; proceed in
accordance with accident prevention standards.
Suitably dispose of the residuals and in accordance
with regulations.

Check engine coolant level Drain water from fuel pre-filter

(Component not supplied by FPT)
Proceed only with engine not running and at low temperature
to avoid any risk of burns. The high risk of refuelling with fuel that is polluted by foreign
bodies and water makes it advisable to carry out this control
- With the engine at low temperature, make sure that the
every time you refuel.
fluid level in the expansion tank is above the minimum
level. Figure 2
- Visually check that the fluid level is not more than 2/3 of
the height of the tank in order to enable any increase in
volume of the fluid caused by the temperature increase.
- Top up the tank if necessary, using clean water. Do not use
distilled water; see the REFILLING section.
NOTE If the refill operations occur frequently a diagnosis

of the cooling circuit is necessary.
In the event that only the heat exchanger without the

expansion tank is available on the vehicle, refill it if necessary,
paying attention that the fluid does not saturate the internal
volume of the exchanger in order to enable any increase in 227502
volume of the fluid caused by the temperature increase. - Proceed with the engine stopped.
- Place a container under the filter or pre-filter (2) to collect
When the engine is warm, a pressure liable to cause the fluid.
! hot liquid to be expelled with extreme violence is
created within the cooling circuits. This results in a - Unscrew the tap plug (1) in the bottom part of the filter;
danger of burning. in some lay-outs the plug includes a sensor to detect the
presence of water in the diesel.
- Drain off liquid until only diesel can be seen.
- Close the plug again, tightening it completely by hand.
- Dispose of the drained fluids according to current
requirements.
Check/top up electrolyte level in batteries

Place the batteries on a level surface, then proceed as follows.
- Visually check that the fluid level is between the Min and
Max limits; in the absence of references, check that the
fluid covers the Lead plates inside the elements.
- Top up with distilled water only those elements in which
the level is below the minimum.
- Contact specialised technical staff if the battery needs
recharging.
- Have the efficiency of the battery recharging system
tested if a voltage of less than 22 V is detected with the
engine running.
- On this occasion, make sure that the terminals and clamps
are clean, properly locked and protected by vaseline.
If all the elements of the battery need refilling with a

! considerable quantity of distilled water, contact
specialised technical personnel in order to perform
a diagnostic check on the efficiency state of the
recharge system and battery.

Check the condition of the exhaust duct(s)

The batteries contain sulphuric acid, which is
Visually check that the exhaust system is not blocked or
! extremely caustic and corrosive; always wear
damaged.
protective gloves and goggles when topping them up.
Whenever possible it is recommended that this - Make sure that there is no risk of dangerous fumes within
control be carried out by specialised personnel. the machine. Contact the Manufacturer if necessary.
Do not smoke or use live flames near the batteries
Check coolant density
during the control, and make sure that the room you
are working in is adequately ventilated. Remove the cap from the expansion tank and draw off a
sample of coolant using commercial densimeter for anti-freeze
liquid density check..
Figure 3
When the engine is hot, pressure builds up in the

! cooling circuits which may eject hot liquid violently,
resulting in a risk of burns.
Open the filler cap of the coolant tank only when the
engine is cold.
Depending on the temperature of the fluid, check the

percentage of antifreeze in the fluid on the reading scale of the
instrument.
The percentage should be higher than 40% and must not
225112 exceed 50%.
Some types of battery have a single cover for all the inspection If necessary, restore the percentage of antifreeze, bearing in
plugs. mind that the fluid needs to be replaced every 2 years.
To access the elements, use a lever as shown in the figure.
Coolant density must be checked every year before
Check auxiliary drive belt condition ! winter season and be replaced in any case every two
years.
Figure 4
Engine EDC system check-up with diagnostic tool

The diagnostic inspection can be carried out by using the
diagnostic tool supplied by the FPT Technical Service Network
to the appropriate connector.
The inspection could underline that the system is operating
even if some problems are present. In this case make provision
to carry out an exhaustive check-up.
227501
Only proceed with the engine stopped and at a low

temperature, so as to avoid the risk of burning.
- Check that the belt (1) is not torn or worn, and that there
are no lubricants or fuel on it. If this is not the case, replace
them.
- The belt tension is adjusted automatically by the calibrated
spring in the automatic belt tensioner (2). Refer to the
figure above for the correct fitting of the belt.

Periodic maintenance Ref. No. Description Tightening torques

Change engine lubricant oil (3) 1 M18x1.5 60 9 Nm
Figure 5 Change oil filter

Figure 7
227485
221779
Figure 6
- Place a container for collecting the spent oil under the filter
support (1).
- Unscrew and remove the filter (3) from its relative
support (1) by 99360076 tool.
- Replace the filter element and the sealing gasket (2)
contained inside the filter (3).
- Carefully clean the surfaces of the support (1) in contact
with the sealing gasket (2).
- Moisten the sealing gasket (2) of the new filter (3) with a
thin layer of oil.
- Manually tighten the new filter (3) on the support (1) until
it comes into contact with the sealing gasket (2).
227486
- Additionally tighten it using a 99360076 tool to prescribed
- Place a suitable container for collecting the spent oil under torque.
the oil sump (4) next to the lubricant oil drain plug (3).
- Operate the engine for a few minutes and then check the
- Unscrew the lubricant oil drain plug (3); afterwards extract level using the dipstick. If necessary, top up to compensate
the oil level dipstick (2) and remove the lubricant oil cap for the quantity of oil used to fill up the filtering cartridge.
(1) to assist the flow of the engine lubricant oil.
- Wait until the oil sump (4) has completely emptied, then Ref. No. Description Tightening torques
retighten the lubricant oil drain plug (3). (3) 1 M27x2 20 2 Nm
- Proceed with the refilling operation through the hole
situated on the tappet cover, using lubricant oil that meets Given the high operating temperature of the engine,
the international standards ACEA E9 API CJ-4 / SAE suitable protective gloves should be worn.
10W-40 / ACEA E6 SAE 5W-30, as indicated in the
REFILLING table. The engine oil is highly pollutant and noxious.
In case of contact with skin, wash thoroughly with
- Using the oil level dipstick (2), check that the engine water and detergent.
lubricant oil level is between the Min and Max levels.
Suitably protect skin and eyes; proceed in
- Whether it should be difficult to make the evaluation, accordance with accident prevention standards.
proceed cleaning the oil level dipstick (2) using a clean
cloth with no rag grinding and put it back in its slot. Draw
it off again and check the level.
- Retighten the lubricant oil cap (1).
- Together with the replacement of the engine lubricant oil
it is necessary to replace the oil filter (see paragraph
CHANGE OIL FILTER).

Change fuel filter

Do not smoke or use open flames during this
During this operation dont smoke and dont use free operation.
flames. Do not inhale the vapours that exit the filter.
Avoid to breathe the vapors coming from filter. Pay attention to the electric fuel pre-heater (if
installed) and the relative electrical connection.
Figure 8
Do not fill the new fuel filter before placing it on the
support in order to prevent harmful impurities from
entering the fuel circuit and the injection system.
Eliminate the consumables and any materials in

contact with them (for example, filters) in
accordance with current regulations.
The FPT Technical Service Network workshops are
equipped for this purpose.
Change the fuel pre-filter (Component not supplied by FPT)

Figure 9
227487
- Pay attention to the electrical fuel pre-heater (3) and

relevant electrical connection.
- Place a container for collecting the diesel under the filter
support.
- Remove the filter (3) by unscrewing it from its relative
support by means of 99360076 tool.
- Replace the filter element and the O-ring seal (2)
contained inside the filter (3).
- Carefully clean the surfaces of the support in contact with
the O-ring seal (2).
- Smear the O-ring seal (2) of the new filter (3) with oil. 227503
- Manually tighten the new filter (3) onto the support until Only proceed with the engine stopped.
it comes into contact with the gasket (2). Additionally - Should the filter be fitted with a sensor to detect the
tighten it using 99360076 tool to prescribed torque. presence of water (3), remove the whole sensor from its
seat.
Ref. No. Description Tightening torques
- Remove the pre-filter by unscrewing it.
(3) 1 M20x1.5 20 2 Nm
- Check that the new filter has performance levels that
- After the fuel filter (3) has been replaced it is possible that satisfy the needs of the engine (e.g. by comparing them
air bubbles get trapped inside the fuel supply circuit. with the old one)
- Bleed residual air from the fuel filter (3) by loosing the vent - Damp the new filter seal with diesel or engine oil.
plug (1) connecting it to a suitable container by a
transparent flexible hose. - Hand screw the new filter into place until the seal gasket
touches the support, then lock by a further 3/4 of a turn.
- With the hand pump of the fuel pre-filter pump until fuel
completely free of air bubbles flows from the vent plug (1). - Place the water presence sensor in its seat, taking care to
couple the threads correctly.
- Tighten the vent plug (1) to prescribed torque.
- Loosen the bleeder screw (1) on the pre-filter support
- Start the engine and allow it to run at minimum for a few and activate the hand pump (2) until the supply circuit is
minutes to expel any remaining air. full. Ensure that any fuel coming out is not dispersed into
the environment.
- Lock the bleeder screw tightly.
- Start the engine and run it at idle for a few minutes to
eliminate any residual air.

Clean the air filter (Component not supplied by FPT)

NOTE If it is necessary to speed up the residual air
bleeding phase, use the hand pump also while Figure 11
starting.
Change blow-by filter

Figure 10
227504
Only proceed with the engine stopped.

- Remove the filter cover (3) after first unscrewing the
locking handle.
- Remove the external cartridge (2), after unfastening the
second locking handle; during this operation, take care to
ensure that no dust get into the sleeve.
- Check that there is no dirt. If there is, clean the filter
element as indicated below.
221781
- Blow dry compressed air through the filter element, from
- Unscrew the flanged nuts (1) from dual shank screws (6) the inside outward (maximum pressure 200 kPa). Do not
and remove the tappet cover (4), recovering relevant use detergents; do not use diesel.
gasket (7) and spring dowels (10).
- Never use tools to beat the filter element, and check its
- Unscrew the ring nut (3) and remove the blow-by condition before replacing it.
breather pipe, rotating it to release it from the bayonet
coupling. - Replace the filter if any breakages or tears are found.
- Unscrew the self-locking screws (8) and remove blow-by - Check that the gasket at its base is in good condition.
control valve (9) and filter element (5) from the inner side Some filter systems are fitted with a second filter element
of the tappet cover (4). (1) which does not require cleaning; this must be replaced
at least once every 3 changes in the main element.
- Replace the blow-by filter element (5).
- Reassemble by repeating the above operations in reverse
- Fit the control valve (9) equipped with a new O-ring order.
together with the new filter (5) inside the tappet cover (4)
and tighten the self-locking screws (8) to a torque of 6 - Set up the mechanical blockage indicator for operation by
Nm. pressing the button located on the top part of the
indicator. This operation is not necessary if there is an
- Partially screw in the ring nut (3) on the filter element, electrical sensor.
insert the pipe rotating it to until the filter element engages
with the bayonet
connection and tighten the ring nut (3). NOTE Take care to ensure that the parts are
reassembled correctly.
- Refit the tappet cover (4) after having interposed a new Imperfect assembly might result in unfiltered air
gasket (7) and tighten the flanged nuts (1) after having being sucked into the engine, causing serious
interposed the spring dowels (10) on the dual shank damage.
screws (6).
Change air filter and clean housing

Refer to the instructions provided for air filter cleaning.

Change engine coolant Extraordinary maintenance

- Only proceed when the engine is not turning, and is at low
Turbocharger visual inspection
temperature, so as not to run the risk of burns.
Only proceed when the engine is not turning over.
- Place a container for collecting coolant under the heat
exchanger (radiator). Visually check that the turbine and compressor impellers and
the relative inlet and outlet ducts are not obstructed or
- Remove the pressurization cap from the expansion tank.
damaged, otherwise replace them.
- Loosen the retaining elements and remove the sleeves
connecting the engine cooling circuit to the heat Adjustment of valves/rocker arms clearance
exchanger.
Figure 12
- Drain the coolant from the heat exchanger (radiator) and
wait until it is completely empty.
- Once emptied, refit the cooling circuit making sure the
sleeves are perfectly sealed.
- Refill the engine and the heat exchanger until the cooling
circuit has been completely refilled using a mixture of 50%
water and PARAFLU HT, as contained in the REFILLING
table. Do not fill the expansion tank to the brim.
- With the coolant cap open, start the engine and let it idle
for approx. one minute. This helps to completely bleed
the air contained in the cooling circuit.
- Stop the engine and top up with more coolant, if
necessary.
182221
- When the engine is cold, make sure that the coolant in the
expansion tank is a few centimetres below the filling hole. The adjustment of the clearance between the rocker arms and
the intake and exhaust valve control rods must be strictly
- In the event of an externally located level indicator as carried out using an Allen wrench (1), box-end wrench (3) and
regards the heat exchangers, proceed with the top up a feeler gauge (2).
operation by making sure that the coolant does not overfill
the internal volume of the exchanger in order to allow the Clearance shall be as follows:
expansion of coolant volume during increases in - intake valves 0.25 0.05 mm
temperature.
- exhaust valves 0.51 0.05 mm.
The failure to observe the aforesaid procedure does
not guarantee the presence of the correct quantity NOTE In order to perform the rocker arm - valve
of coolant in the engine. clearance adjustment more quickly, proceed as
follows:
When the engine is hot, pressure builds up in the - Rotate the crankshaft, balance the valves of
cooling circuits which may eject hot liquid violently, cylinder no. 1 and adjust the valves marked by
! the asterisk as shown in the tables below:
resulting in a risk of burns. Open the filler cap of the
coolant tank only if necessary and only when the
cylinder no. 1 2 3 4
engine is cold.
intake - - * *
exhaust - * - *
- Rotate the crankshaft, balance the valves of
cylinder no. 4 and adjust the valves marked by
the asterisk as shown in the tables below:
cylinder no. 1 2 3 6
intake * * - -
exhaust * - * -

Change auxiliary drive belt

Figure 13
225129
- Pull the automatic belt tensioner (3) by using appropriate

tool on the screw (2) and remove the auxiliary drive belt
(1) from alternator, water pump, crankshaft pulley with
damper and fixed guide rollers.
- Replace the worn belt (1) with new one.
- Fit the auxiliary drive belt (1) on the pulleys and fixed guide
rollers.
- Use the appropriate tool on the automatic belt tensioner
(3) in order to fit the new belt (1) in the operating position.
- Additional adjustments are not required. The belt (1)
tension is adjusted automatically by the calibrated spring
in the automatic belt tensioner (3).
- Operate the engine for a few hours and check that the
auxiliary drive belt (1) is properly fitted.
Warning: with switched off motor (but still hot) the

belt can operate without advance notice.
Wait for the motor temperature lowering to avoid
very serious accidents.

NEF SERIES EURO VI SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS 1
SECTION 5
Removal-refitting of the main engine
components
Page
AUXILIARY DRIVE BELT AND AUTOMATIC BELT

TENSIONER REMOVAL/REFITTING . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL/REFITTING . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER PUMP REMOVAL/REFITTING . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT REMOVAL/REFITTING . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STARTER MOTOR REMOVAL/REFITTING . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE CABLE REMOVAL/REFITTING . . . . . . 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LOW PRESSURE FUEL PIPE

REMOVAL/REFITTING . . . . . . . . . . . . . . . . . 8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PIPE FROM HIGH PRESSURE PUMP

TO COMMON RAIL REMOVAL/REFITTING 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE MANAGEMENT CONTROL UNIT

REMOVAL/REFITTING . . . . . . . . . . . . . . . . . 11
2 SECTION 5 - REMOVAL-REFITTING OF THE MAIN ENGINE COMPONENTS NEF SERIES EURO VI
Page Page
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ELECTRO-INJECTOR REMOVAL/REFITTING . . 18
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL FILTER REMOVAL/REFITTING . . . . . . . . . 11 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE BRAKE REMOVAL/REFITTING . . . . . . . 21

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FUEL FILTER SUPPORT REMOVAL/REFITTING . 12
TURBOCHARGER REMOVAL/REFITTING . . . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HIGH PRESSURE PUMP REMOVAL/REFITTING 12
EXHAUST MANIFOLD REMOVAL/REFITTING . 23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COMMON RAIL REMOVAL/REFITTING . . . . . . 13
INTAKEMANIFOLD REMOVAL/REFITTING . . . 23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
OIL VAPOUR RECIRCULATION SYSTEM
(BLOW-BY) REMOVAL/REFITTING . . . . . . . . 14 CYLINDER HEAD REMOVAL/REFITTING . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TAPPETS COVER REMOVAL/REFITTING . . . . . 15 ENGINE OIL FILTER REMOVAL/REFITTING . . . 28
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ELECTRO-INJECTORWIRING SUPPORT ENGINE OIL HEAT EXCHANGER

REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 15 REMOVAL/REFITTING . . . . . . . . . . . . . . . . . . 29
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ROCKER ARM ASSEMBLY REMOVAL/REFITTING 16 OIL SUMP REMOVAL/REFITTING . . . . . . . . . . . 30
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

AUXILIARY DRIVE BELT AND AUTOMATIC ALTERNATOR REMOVAL/REFITTING

BELT TENSIONER REMOVAL/REFITTING
Removal
Removal Disconnect the electrical connections of the alternator.
Figure 1 Remove the auxiliary drive belt and automatic belt tensioner
as described in the relevant section.
Figure 2
225129
Using the designated wrench on the automatic belt tensioner

(3), reduce the tension of the belt (1) and remove it. 227449
Undo the screw(2) and remove the automatic belt tensioner Unscrew and remove the bolt (1).
(3).
Unscrew the screw (2) and remove the alternator (3).
Ref. No. Description
(2) 1 M10x1.5
(1) 1 M10x1.5
Refitting (2) 1 M10x1.5
Fit the automatic belt tensioner (3) and tighten the screw (2)
to the torque indicated in the table. Refitting
Fit the alternator (3), tighten the screw (2) and the bolt (1)
Tightening to the torque indicated in the table.
Ref. No. Description torques
(2) 1 M10x1.5 43 6 Nm Tightening
Using a specific wrench on the automatic belt tensioner (3), (1) 1 M10x1.5 43 6 Nm
fit the belt (1), making sure that the ribs on the belt fit properly
into the grooves on the pulley. (2) 1 M10x1.5 43 6 Nm
Fit the auxiliary drive belt and automatic belt tensioner as
described in the relevant section.
Connect the electrical connections of the alternator.

WATER PUMP REMOVAL/REFITTING Figure 5

Removal
Position a suitable container to collect any coolant which may
leak out.
Remove the auxiliary drive belt as described in the relevant
section.
Figure 3
201670
Fit the water pump (2) together with the new seal ring,
tighten the fastening screws (1) and tighten them to the
torque indicated in the table.
Tightening
(1) 2 M8x1.25x35 24 4 Nm
201670
Fit the auxiliary drive belt as described in the relevant section.
Unscrew the screws (1) and remove the water pump (2)
together with the seal ring.

(1) 2 M8x1.25x35
Refitting
Figure 4
70221
Apply a new seal ring (2) to the water pump (1).

THERMOSTAT REMOVAL/REFITTING STARTER MOTOR REMOVAL/REFITTING

Removal Removal
Disconnect the electrical connections of the starter motor.
Figure 6
Figure 7
227450
Unscrew the screws (1) and remove the thermostat body (2) 227451
together with the seal ring.
Unscrew the nuts (1) and remove the starter motor (2).
Remove the thermostat together with the gasket.
Ref. No. Description (1) 3 M10x1.5
(3) 2 M6x1.0x20
(3) 1 M6x1.0x50 Refitting
Fit the starter motor (2) and tighten the nuts (1) to the torque
Refitting indicated in the table.
Fit the thermostat together with the gasket.
Tightening
Fit the thermostat body (2), together with a newseal ring and Ref. No. Description torques
tighten the screws (1) to the torque indicated in the table.
(1) 3 M10x1.5 43 6 Nm
Tightening Connect the electrical connections of the starter motor.
(3) 2 M6x1.0x20 13.5 1.5 Nm
(3) 1 M6x1.0x50 13.5 1.5 Nm

ENGINE CABLE REMOVAL/REFITTING

Removal
Remove the engine cable by unplugging it from the relative brackets. Open the intermediate retaining clips securing the engine
cable to the crankcase and remove it completely.
Disconnect the following electrical connections:
Figure 8
225115
1. Electro-injector connections - 2. Motorized throttle valve actuator connector (Exhaust flap) - 3. Boost pressure and air
temperature sensor - 4. Rail pressure sensor - 5. Timing segment speed sensor (camshaft) - 6. Fuel high pressure pump
metering unit - 7. Fuel temperature sensor - 8. In line connector - 9. Rpm increment speed sensor (crankshaft) -10. Engine
Control Unit EDC17CV41 - 11. Coolant temperature sensor

Figure 9
225116
1. Coolant temperature sensor - 2. Engine oil pressure and temperature sensor -

3. Motorized throttle valve actuator connector (Exhaust flap)
Refitting
Fit the engine cable and close the retaining clips securing the
engine cable to the crank case.
Connect the engine cable to all the sensors and transmitters
of the engine electrical equipment.

LOW PRESSURE FUEL PIPE Refitting

REMOVAL/REFITTING
Figure 12
Removal
Position a suitable container to collect any fuel which
may leak out.
Figure 10
227453
Fit the fuel pipe from tank to ECU (2), engage the
intermediate retaining clips and connect the quick-fit coupling
(3).
227452 Fit the fuel return pipe (1), engage the intermediate retaining
Disconnect the quick-fit couplings and remove the fuel clips and connect the quick-fit couplings to the rail and to the
delivery pipe from the feed pump to the fuel filter (1). cylinder head.
Disconnect the quick-fit coupling of the fuel return pipe from Figure 13
the high pressure pump outlet to tank (2) and disengage it
from the intermediate retaining clips.
Disconnect the quick-fit couplings and remove the fuel return
pipe from the fuel filter to the high pressure pump inlet (3).
Disconnect the quick-fit couplings, disengage the
intermediate retaining clip and remove the fuel pipe from the
heat exchanger on the engine control unit to the feed pump
(4).
Figure 11
227452
Fit the fuel pipe from the heat exchanger on the engine
control unit to the feed pump (4), engage the intermediate
retaining clip and connect the quick-fit couplings.
Fit the return pipe from fuel filter to the high pressure pump
inlet (3) and connect the quick-fit couplings.
Fit the fuel return pipe from the high pressure pump outlet
to tank (2), engage the intermediate retaining clips and
227453
connect the quick-fit coupling.
Disconnect the quick-fit couplings (rail side and cylinder head Fit the fuel delivery pipe from the feed pump to the fuel filter
side), disengage the intermediate retaining clips and remove (1) and connect the quick-fit couplings.
the complete fuel return pipe (1).
Disconnect the quick-fit coupling (3), disengage the
intermediate retaining clips and remove the fuel pipe from
tank to ECU (2).

Figure 14 FUEL PIPE FROM HIGH PRESSURE PUMP

TO COMMON RAIL REMOVAL/REFITTING
Removal
Because of the high pressure in the pipelines running

from the high pressure pump to the rail and from
this last one to the electro-injectors, it is absolutely
required NOT to:
- disconnect the pipelines when the engine is
working;
- re-use the disassembled pipelines.
116237
Position a suitable container to collect any fuel which may
leak out.
To disconnect the low pressure fuel pipe from the relevant
connection fitting, hold the clip (1), disengage the catchs (3) Figure 15
and remove the quick fit coupling (2).
To connect the low pressure fuel pipe to the relevant
connection fitting, insert the quick-fit coupling (2) into the
connection fitting and push in until the catch (3) engages.
227454
Unscrew the fitting (1) and disconnect the fuel high pressure
delivery pipe (2) from the rail.
Unscrew the screw (3) securing the upper intermediate
retaining bracket to the crankcase.

(1) 1 M14x1.5
(3) 1 M8x1.25x20

Figure 16 Figure 18
227455 227454
Unscrew the screw (1) securing the lower intermediate Connect the fuel high pressure delivery pipe (2) to the rail,
retaining bracket to the crankcase. tighten the fitting (1) and the screw (3) securing the upper
intermediate retaining bracket to the crankcase, to the torque
Unscrew the fitting (3), disconnect the fuel high pressure
indicated in the table.
delivery pipe (2) from the high pressure pump and remove
it. Tightening
(3) 1 M14x1.5 M14x1.5
(1) 1 M8x1.25x16 (1) 1 1st phase 10 1 Nm
2nd phase 55
(3) 1 M8x1.25x20 24 4
NOTE When unlocking the fuel delivery pipe fitting (3)
to the high pressure pump, it is necessary to
prevent the fitting from rotating on the pump NOTE The fuel pipe from the high pressure pump to the
itself by using the proper wrench. common rail must always be replaced with a new
one when removed.
Refitting The pipe fittings must be tightened to the torque
indicated in the table using the wrench 99317915
Figure 17 and the torque wrench 99389829.
227455
Connect a new fuel high pressure delivery pipe (2) to the high
pressure pump, tighten the fitting (3) and the screw (1)
securing the lower intermediate retaining bracket to the
crankcase, to the torque indicated in the table.
Tightening
M14x1.5
(3) 1 1st phase 10 1 Nm
2nd phase 55
(1) 1 M8x1.25x16 24 4
ENGINE MANAGEMENT CONTROL UNIT FUEL FILTER REMOVAL/REFITTING

REMOVAL/REFITTING
Removal
Removal
Figure 20
Figure 19
227456
221567
Pay attention to the fuel temperature sensor and relevant
Disconnect the engine cable (2) fromthe ECU (3), as electrical connection.
described in relevant procedure. Place a container for collecting the diesel under the filter
Position a suitable container to catch any fuel. support.
Disconnect the quick-fit coupling (1), disengage the Remove the filter (2) by unscrewing it from its relative
intermediate retaining clips and remove fuel pipe from tank support by means of 99360076 tool.
to ECU.
Disconnect the quick-fit couplings (4), disengage the Ref. No. Description
intermediate retaining clip and remove the fuel pipe from the (2) 1 M20x1.5
heat exchanger on the engine control unit to the feed pump.
Refitting
Unscrew the fastening screws (5) and remove the ECU (3), Carefully clean the surfaces of the support in contact with the
including the heat exchanger. O-ring seal (1). Smear the O-ring seal (1) of the filter (2) with
oil.
Manually tighten the filter (2) onto the support until it comes
(5) 3 M8x1.25x45
into contact with the seal (1).
Refitting Additionally tighten it using 99360076 tool to the torque
Fit the ECU (3) including the heat exchanger on the crankcase indicated in the table.
and tighten the fastening screws (5) to the torque indicated
in the table. Tightening
control unit to the feed pump, engage the intermediate (2) 1 M20x1.5 20 2 Nm
retaining clip and connect the quick-fit coupling (4).
Fit the fuel pipe from tank to ECU, engage the intermediate
retaining clips and connect the quick-fit coupling (1).
Connect the engine cable (2) to the ECU (3), as described
in relevant section.
Tightening
(5) 3 M8x1.25x45 24 4 Nm
NOTE It is recommended that the elastic support

elements are replaced.

FUEL FILTER SUPPORT HIGH PRESSURE PUMP

REMOVAL/REFITTING REMOVAL/REFITTING
Removal Removal
Position a suitable container to collect any fuel which may Position a suitable container to collect any fuel which may
leak out. leak out.
Remove the fuel filter as described in the relevant section. Disconnect the low pressure fuel pipes from the mechanical
feed pump and from the high pressure pump as described in
Disconnect the low pressure fuel pipes as described in the
the relevant section.
relevant section.
Disconnect the fuel filter support as described in the relevant
Figure 21 section.
Remove the fuel pipe from the high pressure pump to the
common rail as described in the relevant section.
Figure 22
227457
Disconnect the electrical connection from the fuel

temperature sensor (3).
Unscrew the fastening screws (2) and remove the fuel filter
227458
support (1) from the crankcase.
Disconnect the electrical connection from the fuel high
Ref. No. Description pressure pump metering unit (3).
(2) 2 M12x1.75x30 Unscrew the fastening nuts (2) and remove the high pressure
pump (1) together with the feed pump, the adapter and the
Refitting pump gear.
Fit the fuel filter support (1) and tighten the screws (2) to the
torque indicated in the table. Ref. No. Description
(2) 3 M8x1.25
Tightening
Ref. No. Description torques Refitting
(2) 2 M12x1.75x30 80 8 Nm Fit the high pressure pump (1) together with the feed pump
and tighten the fastening nuts (2) to the torque indicated in
Connect the electrical connection to the fuel temperature the table.
sensor (3).
Connect the low pressure fuel pipes as described in the Tightening
relevant section. Ref. No. Description torques
Fit the fuel filter as described in the relevant section. (2) 3 M8x1.25 24 4 Nm
Connect the electrical connection to the fuel high pressure
pump metering unit (3).
Fit the fuel pipe fromthe high pressure pumpto the common
rail as described in the relevant section.
Fit the fuel filter support as described in the relevant section.
Connect the low pressure fuel pipes to the mechanical feed
pump and to the high pressure pump as described in the
relevant section.

COMMON RAIL REMOVAL/REFITTING Refitting

Removal Fit the common rail (2) on the intake manifold and tighten the
fastening screws (1) to the torque indicated in the table.
leak out.
Tightening
Disconnect the engine cable from the electro-injector wiring Ref. No. Description torques
connectors on the electro-injector wiring support.
(1) 3 M8x1.25x125 36 5 Nm
Disconnect the rail pressure sensor electrical connection on
the rail and the boost pressure/air temperature sensor Fit the new fuel pipes from the common rail to the electro-
electrical connection on the intake manifold. injector manifolds and tighten the relevant fittings (3, 4) to the
In order to facilitate the operations, disengage the engine
cable and move aside. Tightening
Disconnect the low pressure fuel return pipe from the torques
common rail as described in the relevant section. M14x1.5
Remove the fuel pipe from the high pressure pump to the (3) 4 1st phase 10 Nm
common rail as described in the relevant section. 2nd phase 55
M14x1.5
Figure 23 (4) 4 1st phase 10 Nm
2nd phase 55
NOTE Since the pipes are subject to high pressure, they

must always be replaced at each disassembly.
The pipe fittings must be tightened to the torque
indicated in the table using the wrench 99317915
and the torque wrench 99389829.
Fit the fuel pipe fromthe high pressure pumpto the common
Connect the low pressure fuel return pipe to the common
227459
Fit the engine cable in its seat.
Unscrew the fittings (3, 4) of the fuel pipes from the common
rail to the electro-injector manifolds. Connect the rail pressure sensor electrical connection on the
rail and the boost pressure/air temperature sensor electrical
Ref. No. Description connection on the intake manifold.
(3) 4 M14x1.5 Connect the engine cable to the electro-injector wiring
(4) 4 M14x1.5 connectors on the electro-injector wiring support.
Unscrew the intake manifold fastening screws (1) and remove

the common rail (2) together with the pressure sensor.

(1) 3 M8x1.25x125

OIL VAPOUR RECIRCULATION SYSTEM Refitting

(BLOW-BY) REMOVAL/REFITTING
Figure 26
Removal
Remove the tappet cover as described in the relevant section.
Figure 24
201691
Fit the control valve (2) equipped with a new O-ring together
with the filter element (3) and tighten the new screws (1) to
201690 the torque indicated in the table.
Unscrew the ring nut (1) and remove the blow-by breather
(2), rotating it to release it from the bayonet coupling. Tightening
Figure 25 (1) 3 M5 5 Nm
Figure 27
201691
Unscrew the self-locking screws (1) securing the control 201690

valve (2) to the tappet cover and remove it together with the
Partially screw in the ring nut (1) on the filter element, insert
filter element (3).
the pipe (2) rotating it to until the filter element engages with
the bayonet connection.
Complete the tightening of the ring nut (1).
(1) 3 M5
NOTE When assembly has been completed, the

breather pipe must be positioned transverse to
the engine, on the exhaust side as shown in the
figure.
Position and secure the tappet cover in its seat as described

in the relevant section.

TAPPETS COVER REMOVAL/REFITTING ELECTRO-INJECTORWIRING SUPPORT

REMOVAL/REFITTING
Removal
Removal
Figure 28 Remove the tappet cover as described in the relevant section.
Figure 29
227460
Unscrew the nuts (1) and remove the tappet cover (2)
together with the gasket and the oil vapour recirculation 227461
assembly. Disconnect the engine cable from the electro-injector wiring
connectors (1).
Unscrew the nuts (4) and disconnect the cables from the
(1) 4 M8x1.25
electro-injectors.

NOTE To remove the oil vapour recirculation assembly
act as described in the relevant section. (4) 8 M4
Unscrew the screws (2) and remove the electro-injector
Refitting wiring support (3) together with the gasket.
Fit a new gasket on the tappet cover.
Fit the tappet cover (2), fit the fastening nuts (1) and tighten (2) 2 M8x1.25x50
to the torque indicated in the table.
(2) 3 M8x1.25x70
Tightening Refitting
(1) 4 M8x1.25 24 4 Nm Figure 30
70352
Check electrical cable (5) conditions, replace if damaged by

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

Figure 31 ROCKER ARM ASSEMBLY

REMOVAL/REFITTING
Removal
Remove the electro-injector wiring support as described in
Figure 32
227461
Fit the wiring support (3), screw the screws (2) and tighten
them to the torque indicated in the table.
Tightening
(2) 2 M8x1.25x50 24 4 Nm
(2) 3 M8x1.25x70 24 4 Nm
70132
Loosen the tappet adjustment fastening nuts (1) and unscrew

NOTE Before each assembly, always check that the the adjusters.
thread on the holes and the screws shows no sign
of wear or dirt. Ref. No. Description
(1) 8 M8x1.25
Connect the cables to the electro-injectors and use the
torque wrench 99389834 to tighten the fastening nuts (4) to Unscrew the screws (2) and remove the rocker assembly (3)
the torque indicated in the table. consisting of: support (6), rocker arms (4), shafts (5).
Tightening Ref. No. Description

Ref. No. Description torques (2) 8 M8x1.25
(4) 8 M4 1.5 0.25 Nm Remove the bridges (7) from the valves and remove the rods
Connect the engine cable to the electro-injector wiring (8).
connectors (1).
Fit the tappet cover as described in the relevant section.

Refitting Figure 36
Figure 33
227474
The control rods of the rocker arms must show no sign of any
deformation; the spherical seats for contact with the rocker
arm adjusting screw and with the tappets (arrows) must show 74765
no trace of seizure or wear; if they do, replace them. Fit the pushrods (2).
Intake and exhaust valve pushrods are identical and are Position bridges (1) on valves with marks () facing the
therefore interchangeable. exhaust manifold.
Figure 34 Figure 37
70343
1. Screws - 2. Support - 3. Shafts - 4. Rocker arms

201697
Figure 35 Check that the tappet adjuster fastening nuts (1) are
unscrewed to prevent them sticking on the rods when fitting
the rocker arm assembly.
Then refit the rocker arm assembly consisting of the support
(5), rocker arms (3) and shafts (4) and secure them to the
cylinder head by tightening the fastening screws (2) to the
Tightening
(2) 8 M8x1.25 36 5 Nm
70344
Check that shaft/rocker arm surfaces are not excessively

worn or damaged.

Figure 38 ELECTRO-INJECTOR
REMOVAL/REFITTING
Removal
Remove the electro-injector wiring support as described in
Remove the rocker arm assembly as described in the relevant
section.
leak out.
Figure 39
70520
Adjust the clearance between rocker arms and valves

through Allen wrench (1), box wrench (3) and feeler gauge
(2).
The operating clearance is:
- 0.25 0.05 mm for the intake valve
- 0.51 0.05 mm for the exhaust valve
Tighten the tappet adjuster nuts (1) to the torque indicated
in the table.
Tightening
Ref. No. Description torques 227462
(1) 8 M8x1.25 24 4 Nm Unscrew the fittings (1, 2) and remove the high pressure fuel
pipes from the common rail to the electro-injectors manifolds.
NOTE To carry out clearance adjustment of the valve -
rocker arm assembly more quickly, proceed as (1) 4 M14x1.5
follows: (2) 4 M14x1.5
- Apply tool 99360221 (with pinion
99360222) on the flywheel. Figure 40
cylinder no. 1 and adjust the valves marked
with an asterisk as shown in the tables below:
cylinder n. 1 2 3 4
intake - - * *
exhaust - * - *
cylinder no. 4 and adjust the valves marked
with an asterisk as shown in the tables below:
cylinder n. 1 2 3 4
intake * * - -
227463
exhaust * - * -
Unscrew the nuts (1) and remove the electro-injector
manifolds (2).
Fit the electro-injector wiring support as described in the
relevant section. Ref. No. Description
(1) 4 M22x1.5
Fit the tappet cover as described in the relevant section.
Unscrew the electro-injector fastening screws (3).
(3) 8 M6x1x35

Figure 41 Figure 44
70133 70133
Using tool 99342101 (1) take the electro-injectors (2) out of Use tool 99342101 (1) to fit the electro-injector (2) into its
the cylinder head. seat.
Refitting Screw in the electro-injector fastening screws without

tightening them.
Figure 42
Figure 45
70338
Fit a new seal ring (2) lubricated with vaseline and a new
sealing washer (3) on electro-injector (1).
Figure 43
91572
Fit a new seal ring (3) lubricated with vaseline on the

electro-injector manifold (2).
Fit the electro-injector manifold (2) in the cylinder head seat
so that the positioning balls (5) coincide with the relevant
housing (4).
NOTE Disassembled electro-injector manifolds (2) must

not be used again, but must be replaced with new
ones.
70339
Fit the electro-injectors (1) on the cylinder head seats,

directed so that the fuel inlet hole (2) is facing the side of the
electro-injector manifold seat (3).

Figure 46 Figure 47
70342
227462
Screw in the fuel manifold (3) fastening nuts (2) but do not
tighten them. Fit the new high pressure fuel pipes from the common rail to
the electro-injector manifolds and tighten the fittings (1, 2) to
the torque indicated in the table.
NOTE During the operation position the
electro-injector so that the manifold inserts Tightening
correctly into the fuel inlet hole of the torques
electro-injector. M14x1.5
(1) 4 1st phase 10 1 Nm
Gradually and alternately tighten the electro-injector 2nd phase 55
fastening screws (1) to the torque and in the sequence M14x1.5
(2) 4 1st phase 10 1 Nm
Tightening 2nd phase 55
Ref. No. Description torques Since the pipes are subject to high pressure, they must always
M6x1x35 be replaced at each disassembly.
1st phase 3.5 0.35 Nm The pipe fittings must be tightened to the torque indicated
(1) 8 2nd phase 25 in the table using the wrench 99317915 and the torque
3rd phase 25 wrench 99389829.
4th phase 25 Fit the rocker arm assembly, the electro-injector wiring
support and the tappet cover as described in the relevant
Tighten the electro-injector manifold (3) fastening nuts (2) to
section.
the torque indicated in the table.
Tightening
(2) 4 M22x1.5 55 5 Nm

ENGINE BRAKE REMOVAL/REFITTING Refitting

Removal Fit the engine brake (5) on the turbocharger after having
positioned a new gasket.
Figure 48 Fit the nuts (4) and tighten them to the torque indicated in
the table.
Tightening
(4) 4 M8x1.25 25 5 Nm
Fit the coolant delivery pipe to the engine brake and tighten
the union (1) to the torque indicated in the table.
Tightening
(1) 1 M12x1.5 25 5 Nm
Fit the coolant return pipe from the engine brake and tighten
227464
the union (3) to the torque indicated in the table.
Disconnect the electrical connection (2) from the throttle Tightening
control actuator on the engine brake.
Unscrew the union (3) and disconnect the engine coolant (3) 1 M12x1.5 25 5 Nm
return pipe from the engine brake. Connect the electrical connection (2) to the throttle control
Ref. No. Description actuator on the engine brake.
(3) 1 M12x1.5
Unscrew the union (3) and disconnect the engine coolant
return pipe from the engine brake.
(1) 1 M12x1.5
Unscrew the nuts (4) and remove the engine brake (5) from
the turbocharger.
(4) 4 M8x1.25

TURBOCHARGER REMOVAL/REFITTING Refitting

Removal Fit the turbocharger (4) on the exhaust manifold (5) after
having positioned a new gasket.
Remove the engine brake as described in the relevant section.
Fit the fastening nuts (3) and tighten them to the torque
Figure 49 indicated in the table.
Tightening
(3) 4 M8x1.25 25 2.5 Nm
Fit the engine oil delivery pipe (2) to the turbocharger and
tighten the fittings to the torque indicated in the table.
Tightening
(2) 2 M16 25 5 Nm
Fit the engine oil return pipe (1) to the crankcase together
with the new gasket and tighten the screws to the torque
Tightening
(1) 2 M6x1 10 2 Nm
Fit the engine brake as described in the relevant section.
221557
Unscrew the fastening screws and remove the oil return pipe NOTE Make sure all turbocharger pipes are whole, clean
(1) to crankcase. and free from foreign bodies.
Furthermore, check that the sealing gaskets
Ref. No. Description operate correctly and that the connection
(1) 2 M6x1 sleeves are fastened.
Unscrew the fittings and remove the engine oil delivery pipe
(2) to the turbocharger.

(2) 2 M16
Unscrew the nuts (3) and remove the turbocharger (4) from
the exhaust manifold (5).

(3) 4 M8x1.25

EXHAUST MANIFOLD INTAKEMANIFOLD REMOVAL/REFITTING

REMOVAL/REFITTING
Removal
Removal Remove the common rail as described in the relevant section.
Remove the engine brake as described in the relevant section.
Disconnect the electrical connections of the boost pressure
Remove the turbocharger as described in the relevant and air temperature sensor.
section.
Remove the starter motor as described in the relevant Figure 51
section.
Figure 50
227468
Unscrew the fastening screws (1) and remove the intake

manifold (2) together with the boost pressure and air
227467
temperature sensor.
Unscrew the screws (1 and 2), the fitting (3) and remove the
oil level dipstick (4) from the crankcase.
Ref. No. Description (1) 6 M8x1.25x25
(1) 1 M10x1.5x65 (1) 1 M8x1.25x70
(2) 1 M8x1.25
(3) 1 M18x1.5 Refitting
Apply a sufficient layer of LOCTITE 5999 on the mating
Unscrew the fastening screws (5) and remove the exhaust surface of the intake manifold (2).
manifold (6) from the cylinder head.
Fit the intake manifold (2) together with the boost pressure
Ref. No. Description and air temperature sensor and tighten the screws (1) to the
(5) 8 M10x1.5x65 torque indicated in the table.
Refitting Tightening
Fit the exhaust manifold (6) with new gaskets. Ref. No. Description torques
Fit the fastening screws (5) and tighten them to the torque (1) 6 M8x1.25x25 24 4 Nm
indicated in the table. (1) 1 M8x1.25x70 24 4 Nm
Tightening Fit the common rail as described in the relevant section.
Connect the electrical connections of the boost pressure and
(5) 8 M10x1.5x65 55 3 Nm
air temperature sensor.
Fit the oil level dipstick pipe (4), tighten the fitting (3) and the
screws (1 and 2) securing the retaining brackets onto the
cranckase and onto the exhaust manifold, to the torque
Tightening
(1) 1 M10x1.5x65 55 3 Nm
(2) 1 M8x1.25 24 4 Nm
(3) 1 M18x1.5 30 Nm
Fit the starter motor as described in the relevant section.
Fit the turbocharger as described in the relevant section.
Fit the engine brake as described in the relevant section.
CYLINDER HEAD REMOVAL/REFITTING

Removal
Figure 52
227469
Remove the engine cable (3) as described in the relevant

section.
Remove the tappet cover (1) as described in the relevant
section.
Remove the common rail (4) as described in the relevant
section.
Remove the electro-injector wiring support (6) as described
Remove the rocker arm assembly (2) as described in the
relevant section.
Remove the electro-injectors (7) as described in the relevant
section.
Remove the intake manifold (5) as described in the relevant
section.
Remove the thermostat (8) as described in the relevant
section.

Figure 53
227470
Remove the engine brake (3) as described in the relevant Figure 54

section.
Remove the turbocharger (2) as described in the relevant
section.
Remove the starter motor (1) as described in the relevant
section.
Remove the exhaust manifold (4) as described in the relevant
section.
70137
Unscrew the fastening screws, hook the brackets (1) to a

suitable hoist and remove the cylinder heads (2) fromthe
crankcase.

(2) 8 M12x1.75x130
(2) 10 M12x1.75x150
Remove the cylinder head gasket from the centring bushes.

Refitting Figure 57
Figure 55
74766
70335 Fit the cylinder head (1) fastening screws (2) and tighten them
Clean the cylinder head and crankcase contact surfaces. to the torque indicated in the table.
There are two types of cylinder head gaskets: Tightening
- Type A is 1.25 mm thick
- Type B is 1.15 mm thick M12x1.75x130
1st phase 35 5 Nm
Check the average protrusion S of the pistons as indicated in (2) 8
Section 6 in the paragraph Determining gasket thickness. 2nd phase 90
3rd phase 90
If S is > 0.40 mm, use a type A gasket.
M12x1.75x150
If S is 0.40 mm, use a type B gasket. 1st phase 55 5 Nm
(2) 10
Fit the crankcase with a new gasket (1) for the cylinder head 2nd phase 90
with the marking TOP facing towards the head itself. 3rd phase 90
The arrow shows the point where the gasket thickness is
given. NOTE The external screws are the shorter ones.
Figure 56
NOTE Use tool 99395216 (3) for angle tightening.
The cylinder head screws must be tightened in three

successive phases following the sequence and manner
indicated in the following figure.
Figure 58

74766
Position the cylinder head (2) on the new gasket using the
brackets (1). A
70337
NOTE Before each assembly, always check that the - 1st phase of pre-tightening, with torque wrench:
thread on the holes and the screws shows no sign Screw M12x1.75x130 (external screws) 35 5 Nm
of wear or dirt. Screw M12x1.75x150 (internal screws) 55 5 Nm
- 2nd phase of tightening with angle of 90
- 3rd phase of tightening with angle of 90
A = Front side

Figure 59
227470
Fit the exhaust manifold (4) as described in the relevant

section.
Fit the starter motor (1) as described in the relevant section.
Fit the turbocharger (2) as described in the relevant section.
Fit the engine brake (3) as described in the relevant section.

Figure 60
227469
Remove the thermostat (8) as described in the relevant ENGINE OIL FILTER REMOVAL/REFITTING
section. Removal
Remove the intake manifold (5) as described in the relevant Position a suitable container to collect any engine oil which
section. may leak out.
Remove the electro-injectors (7) as described in the relevant
section. Figure 61
Remove the rocker arm assembly (2) as described in the
relevant section.
Remove the electro-injector wiring support (6) as described
Remove the common rail (4) as described in the relevant
section.
Remove the tappet cover (1) as described in the relevant
section.
Remove the engine cable (3) as described in the relevant
section.
201696
Using tool 99360076 remove the oil filter (1) from the
support (2).

(1) 1 M27x2

Refitting Unscrew the screws (3) and remove the oil

Lubricate a new seal ring with engine oil and place it on the pressure/temperature sensor (4).
oil filter.
Manually screw in the oil filter (1) on the support connection
(2) and then screw in further by another 3/4 turn. Check that (3) 2 M6x1x20
tightening is to the torque indicated in the table. Unscrew the screws (5) and remove the oil filter/heat
exchanger support (6), the intermediate plate and the
Tightening corresponding gaskets.
(1) 1 M27x2 20 2 Nm Ref. No. Description
Operate the engine for a few minutes and then check the (5) 15 M8x1.25x35
level using the dipstick: the level must come close to the MAX
notch which can be seen on the dipstick. Refitting
Fit the new gaskets, the intermediate plate and oil filter/heat
If this is not the case, top-up as necessary. exchanger support (6) onto the crankcase.
Tighten the screws (5) to the torque specified in the table.
ENGINE OIL HEAT EXCHANGER
REMOVAL/REFITTING
Tightening
Removal Ref. No. Description torques
Remove the auxiliary drive belt as described in the relevant (5) 15 M8x1.25x35 26 4 Nm
section.
Remove the alternator as described in the relevant section. NOTE Before each assembly, always check that the
Position a suitable container to collect any engine oil which thread on the holes and the screws shows no sign
may leak out. of wear or dirt.
Remove the engine oil filter as described in the relevant

section. Fit the oil pressure/temperature sensor (4) together with a
new seal ring onto the support (6) and tighten the screws (3)
Figure 62
Tightening
(3) 2 M6x1x20 10 2 Nm
Fit the oil delivery pipe to the turbocharger (2) and tighten
the fittings (1) to the torque indicated in the table.
Tightening
(1) 2 M16 25 5 Nm
Fit the engine oil filter as described in the relevant section.
Fit the alternator as described in the relevant section.
Fit the auxiliary drive belt as described in the relevant section.
Check the oil level with the oil level dipstick: the level must
come close to the MAX notch which can be seen on the
dipstick.
If this is not the case, top-up as necessary.
201696
Unscrew the fitting (1) and remove the engine oil delivery
pipe (2) to the turbocharger.

(1) 2 M16

OIL SUMP REMOVAL/REFITTING Refitting

Removal Fit a new gasket on the oil sump (1) and place them on the
cranckcase; suddenly place the oil pan frame (2) on the
Place an appropriate container for the oil collection under the
cranckcase and tighteen the screws (3) to the torque
sump in correspondence with the drain plug.
Open the oil filler inlet on the cylinder head and take out the
oil level dipstick to allow the oil to flow more freely. Tightening
Unscrew the drain plug and let the oil in the sump drain out torques
completely. (3) 10 M8x1.25x40 24 4 Nm
(3) 4 M8x1.25x45 24 4 Nm
Figure 63
Fit the drain plug together with the new gasket and tighten
to the torque indicted in the table.
Tightening
(-) 1 M18x1.5 60 9 Nm
Proceed to refill with the specified oil.
Operate the engine for a few minutes and then check the
level using the dipstick: the level must come close to the MAX
notch which can be seen on the dipstick.
If this is not the case, top-up as necessary the engine lubricant
oil with the specified quantity and quality of lubricant oil.
227471 Only use recommended oils or oils with the

Undo the screws (3) and remove the oil sump (1) with the properties required for proper engine operation.
gasket and its oil pan frame (2). Failure to observe these standards will invalidate the
service warranties.
(3) 10 M8x1.25x40
(3) 4 M8x1.25x45

NEF SERIES EURO VI SECTION 6 - GENERAL MECHANICAL OVERHAUL 1
SECTION 6
General mechanical overhaul
Page
ENGINE DISASSEMBLING ON BENCH . . . . . . 5
- Removal of components hindering bracket assembly 5
- Fitting the engine on the rotating stand . . . . . 9
ENGINE DISASSEMBLING
(COMPONENTS ON TOP SIDE - PART 1) . 10
- Rail removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Tappet cover removal . . . . . . . . . . . . . . . . . . . 10
- Intake manifold removal . . . . . . . . . . . . . . . . . 10
- Electro-injector wiring support removal . . . . . 11
- Rocker assembly removal . . . . . . . . . . . . . . . . 11
- Electro-injector removal . . . . . . . . . . . . . . . . . 11
(SIDE VIEW OF COMPONENTS - PART 1) 12
- Engine brake removal . . . . . . . . . . . . . . . . . . . 12
- Turbocharger removal . . . . . . . . . . . . . . . . . . . 12
- Exhaust manifold removal . . . . . . . . . . . . . . . . 12
(COMPONENTS ON FRONT SIDE - PART 1) 13
- Auxiliary drive belt and automatic

belt tensioner removal . . . . . . . . . . . . . . . . . . 13
- Alternator removal . . . . . . . . . . . . . . . . . . . . . 13
(COMPONENTS ON TOP SIDE - PART 2) . 13
- Cylinder head removal . . . . . . . . . . . . . . . . . . 13
- Intake and exhaust valve removal . . . . . . . . . . 13
(SIDE VIEW OF COMPONENTS - PART 2) 14
- Alternator support removal . . . . . . . . . . . . . . 14
- Engine oil filter housing removal . . . . . . . . . . . 14
- Engine control unit removal . . . . . . . . . . . . . . 15

2 SECTION 6 - GENERAL MECHANICAL OVERHAUL NEF SERIES EURO VI
Page Page
(COMPONENTS ON FRONT SIDE -PART 2) 15 - Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Damper pulley and crankshaft pulley removal 15 - Intake and exhaust valves . . . . . . . . . . . . . . . . 34
- Water pump - rpm sensor removal . . . . . . . . 16 - Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Crankshaft front seal ring removal . . . . . . . . . 16 - Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Crankshaft external gasket ring removal . . . . . 16 - Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Front cover removal . . . . . . . . . . . . . . . . . . . . 16 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 37
- Engine oil pump removal . . . . . . . . . . . . . . . . 17 (CRANKCASE COMPONENTS) . . . . . . . . . . . . . 37
ENGINE DISASSEMBLING - Tappets and camshaft refitting . . . . . . . . . . . . 37

(COMPONENTS ON REAR SIDE) . . . . . . . . . 17
- Piston cooling spray nozzles refitting . . . . . . . 38
- Engine flywheel removal . . . . . . . . . . . . . . . . . 17
- Main half-bearings and crankshaft refitting . . . 38
- Crankshaft rear seal ring removal . . . . . . . . . . 18
- Connecting rod and piston assembly . . . . . . . 39
- Flywheel housing removal . . . . . . . . . . . . . . . . 18
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 41
- Camshaft gear removal . . . . . . . . . . . . . . . . . . 18
(COMPONENTS ON TOP SIDE - PART 1) . . . . 41
- Timing gear case removal . . . . . . . . . . . . . . . . 18
- Intake and exhaust valves refitting . . . . . . . . . 41
(COMPONENTS ON BOTTOM SIDE) . . . . . 19 - Cylinder head refitting . . . . . . . . . . . . . . . . . . 42
- Engine oil sump removal . . . . . . . . . . . . . . . . . 19 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 43
- Engine oil intake suction strainer removal . . . . 19 (COMPONENTS ON REAR SIDE) . . . . . . . . . . . 43
(CRANKCASE COMPONENTS) . . . . . . . . . . 19 - Timing gear case refitting . . . . . . . . . . . . . . . . 43
- Pistons and connecting rod assembly removal 19 - Camshaft timing . . . . . . . . . . . . . . . . . . . . . . . 44
- Main bearing caps removal . . . . . . . . . . . . . . . 19 - Engine flywheel housing refitting . . . . . . . . . . . 45
- Crankshaft removal . . . . . . . . . . . . . . . . . . . . . 20 - Crankshaft rear seal ring refitting . . . . . . . . . . 45
- Piston cooling spray nozzles removal . . . . . . . 20 - Engine flywheel refitting . . . . . . . . . . . . . . . . . 46
- Camshaft and tappets removal . . . . . . . . . . . . 20 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 47
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 (COMPONENTS ON FRONT SIDE - PART 1) . 47
- Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . 21 - Engine oil pump refitting . . . . . . . . . . . . . . . . . 47
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 23 - Front cover refitting . . . . . . . . . . . . . . . . . . . . 47
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 - Water pump refitting . . . . . . . . . . . . . . . . . . . 47
- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 - Crankshaft pulley and damper pulley refitting . 48
- Connecting rod and piston assembly . . . . . . . 28 - Crankshaft front seal ring refitting . . . . . . . . . . 48
Page Page
- Refitting engine speed sensor . . . . . . . . . . . . . 48

- Engine brake refitting . . . . . . . . . . . . . . . . . . . 57
ENGINE ASSEMBLY
(SIDE VIEW OF COMPONENTS - PART 1) . 49 ENGINE ASSEMBLY
(COMPONENTS ON FRONT SIDE - PART 2) 58
- Engi ne oil filter support refitting . . . . . . . . . . . 49
- Auxiliary drive belt and automatic belt tensioner
- Alternator support refitting . . . . . . . . . . . . . . . 50 refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
- Alternator refitting . . . . . . . . . . . . . . . . . . . . . 50 ENGINE ASSEMBLY

(COMPONENTS ON BOTTOM SIDE) . . . . . 58
- Engine control unit refitting . . . . . . . . . . . . . . 50
- Engine oil intake suction strainer refitting . . . . 58
ENGINE ASSEMBLY
(COMPONENTS ON TOP SIDE - PART 2) . 51 - Engine oil sump refitting . . . . . . . . . . . . . . . . . 59
- Electro-injectors refitting . . . . . . . . . . . . . . . . . 51 REMOVING THE ENGINE FROM

THE ROTATING STAND . . . . . . . . . . . . . . . . 59
- Rocker assembly refitting . . . . . . . . . . . . . . . . 52
- Exhaust side - oil level dipstick and engine brake
- Electro-injector wiring support refitting . . . . . 54 water return pipe refitting . . . . . . . . . . . . . . . . 59
- Intake manifold refitting . . . . . . . . . . . . . . . . . 54 - Exhaust side - electric starter motor refitting . 60
- Tappet cover refitting . . . . . . . . . . . . . . . . . . . 54 - Intake side - fuel delivery pipe from high pressure
pump to rail and high pressure pump refitting 60
- Rail refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
- Intake side - fuel filter support refitting . . . . . . 61
ENGINE ASSEMBLY
(SIDE VIEW OF COMPONENTS -PART 2) . . 56 - Engine cable refitting . . . . . . . . . . . . . . . . . . . . 62
- Exhaust manifold refitting . . . . . . . . . . . . . . . . 56 CHECKS AND INSPECTIONS . . . . . . . . . . . . . . 64
- Checking and adjusting the Waste-Gate . . . . . 56 - Test on the pressure relief valve on the rail . . 64
- Turbocharger refitting . . . . . . . . . . . . . . . . . . . 57 - Checking the mechanical feed pump . . . . . . . 65


ENGINE DISASSEMBLING ON BENCH Removal of components hindering bracket

In order to apply the brackets 99341009 to the engine block assembly
to fix it on to the stand 99322205 for the overhaul, it is Engine cable removal
necessary to perform the following operations.
Remove the engine cable by unplugging it from the relative
brackets.
Open the intermediate retaining clips securing the engine
cable to the crankcase and remove it completely.
Disconnect the following electrical connections:
Figure 1
225115
metering unit - 7. Fuel temperature sensor - 8. In line connector - 9. Rpm increment speed sensor (crankshaft) -
10. Engine Control Unit EDC17CV41 - 11. Coolant temperature sensor

Figure 2
225116
1. Coolant temperature sensor - 2. Engine oil pressure and temperature sensor


Intake side - fuel filter support removal Intake side - fuel delivery pipe from high pressure
pump to rail and high pressure pump removal
Figure 3
Because of the high pressure in the pipelines running
from the high pressure pump to the rail and from
this last one to the electro-injectors, it is absolutely
required NOT to:
- disconnect the pipelines when the engine is
working;
- re-use the disassembled pipelines.

leak out.
Figure 5
225117
Using tool 99360076, remove the fuel filter (3) from the
support (4).
(3) 1 M20x1.5
Disconnect the quick-fit couplings and remove the fuel
delivery pipe from the feed pump to the fuel filter (1).
Disconnect the quick-fit couplings and remove the fuel return
pipe from the fuel filter to the high pressure pump inlet (2).
Unscrew the screws and remove the support (4) from the
crankcase.
225118
(4) 2 M12x1.75x30 Unscrew the fitting (1) and disconnect the fuel high pressure
delivery pipe (2) from the rail.
Figure 4 Unscrew the screw (3) securing the upper intermediate
(1) 1 M14x1.5
(3) 1 M8x1.25x20
116237
To disconnect the low pressure fuel pipe from the relevant

connection fitting, hold the clip (1), disengage the catchs (3)
and remove the quick fit coupling (2).

Figure 6 Ref. No. Description

(1) 2 M6x1
Unscrew the nuts (3) and remove the starter motor (4) from
the flywheel cover.
(3) 3 M10x1.5
Exhaust side - oil level dipstick and engine brake water

return pipe removal
Figure 8
225119
Unscrew the screw (1) securing the lower intermediate

Unscrew the fitting (6), disconnect the fuel high pressure
delivery pipe (2) from the high pressure pump and remove
it.
Disconnect the quick-fit coupling of the fuel return pipe from
the high pressure pump outlet to tank (3) and disengage it
from the intermediate retaining clips.
Disconnect the quick-fit couplings, disengage the
intermediate retaining clip and remove the fuel pipe from the
heat exchanger on the engine control unit to the feed pump 225121
(7). Unscrew the screws (1 and 3), the fitting (6) and remove the
Unscrew the fastening nuts (4) and remove the high pressure oil level dipstick (2) from the crankcase.
pump (5) together with the feed pump, the adapter and the Unscrew the union (8) (engine brake side), the union (4)
pump gear. (alternator support side), the screws (5) securing the
Ref. No. Description intermediate retaining brackets and remove the engine brake
water return pipe (7).
(1) 1 M8x1.25x16
(6) 3 M14x1.5 Ref. No. Description
(4) 3 M8x1.25 (1) 1 M10x1.5x65
(3) 1 M8x1.25
Exhaust side - starter motor removal (4) 1 M12x1.5
2 M8x16
Figure 7 (5) 1 M10x20
(8) 1 M12x1.5
(6) 1 M18x1.5
225120
Unscrew the screws (1) and remove the oil outlet pipe (2)
from the turbocharger and the crankcase.

Fitting the engine on the rotating stand

Figure 9
227448
Fit brackets 99361037 onto the crankcase and the engine

onto rotating stand 99322205. Warning: avoid contact of engine oil with the skin:
in case of skin contamination, rinse in running water.
Place a suitable container, remove the oil sump drain plug
from the oil sump and drain the engine oil.
Engine oil is highly pollutant: provide for disposal in
(-) 1 M18x1.5 compliance with the law and regulations in force.

1
Tappet cover removal

(COMPONENTS ON TOP SIDE - PART 1) Figure 11
Rail removal
Figure 10
225123
Unscrew the nuts (1) and remove the tappet cover (2)
together with the oil vapour separator and gasket.
225122
Disconnect the fuel return pipe (4) from the rail (5) and from Ref. No. Description
cylinder head (3). (1) 4 M8x1.25
Unscrew the fittings and remove the fuel pipes (1) from the Unscrew the screws (3) and remove the thermostat body (4)
rail (5) and from the electro-injector manifolds (2). together with the O-ring.
Ref. No. Description Ref. No. Description
(1) 8 M14x1.5 (3) 2 M6x1.0x20
Unscrew the screws (6) and remove the rail (5). (3) 1 M6x1.0x50
Ref. No. Description Intake manifold removal
(6) 3 M8x1.25x125
Figure 12
Disengange the fuel return pipe (4) from the intermediate
retaining clips and remove it.
225124
Unscrew the screws (1) and remove the intake manifold (2)
complete with the boost pressure and air temperature
sensor.
(1) 6 M8x1.25x25
(1) 1 M8x1.25x70

Electro-injector removal
Electro-injector wiring support removal
Figure 15
Figure 13
225125
227472
Remove the nuts (2) and disconnect the cables (1) from the Unscrewthe nuts (1) and remove the fuelmanifolds (2)
electro-injectors. together with the O-rings.

(2) 8 M4 (1) 4 M22x1.5
Unscrew the screws (4) and remove the electro-injector

wiring support (3) complete with gasket. NOTE Disassembled fuel manifolds (2) must not be used
again, but however replaced with other new
Ref. No. Description ones.
(4) 2 M8x1.25x50
(4) 3 M8x1.25x70 Unscrew the electro-injector fastening screws (3).
Rocker assembly removal Ref. No. Description

(3) 8 M6x1x35
Figure 14
Figure 16
70132
Loosen the tappet adjustment fastening nuts (1) and unscrew

the adjusters.
Unscrew the screws (2), remove the rocker assembly (3)
made up of a support (6), rocker arms (4), shafts (5) and
recover the bridge (7). 70133
Ref. No. Description Using tool 99342101 (1) remove the electro-injectors (2)
(1) 8 M8x1.25 from the cylinder head.
(2) 8 M8x1.25
Remove the rods (8).

ENGINE DISASSEMBLING Turbocharger removal

(SIDE VIEW OF COMPONENTS - PART 1)
Figure 19
Engine brake removal
Figure 17
225127
Unscrew the fittings and remove the oil delivery pipe to the
225126 turbocharger (1).
Unscrew the union (4) and disconnect the engine brake Ref. No. Description
water delivery pipe (3) from engine brake. (1) 2 M16
Unscrew the nuts (1) and remove the engine brake (2) from
Unscrew the nuts (3) and remove the turbocharger (2) from
the turbocharger.
the exhaust manifold.
(4) 1 M12x1.5
(3) 4 M8x1.25
(1) 4 M8x1.25
Exhaust manifold removal
Figure 18
Figure 20
225128
227465
Unscrew the fitting (1) and remove the engine brake water
delivery pipe (2) from crankcase. Unscrew the screws (1) and remove the exhaust manifold (2)
from the cylinder head.
(1) 8 M10x1.5x65

ENGINE DISASSEMBLING ENGINE DISASSEMBLING

(COMPONENTS ON FRONT SIDE - PART 1) (COMPONENTS ON TOP SIDE - PART 2)
Auxiliary drive belt and automatic belt Cylinder head removal
tensioner removal
Figure 23
Figure 21
70137
Unscrew the screws (1) hook the brackets to a suitable hoist

225129 and remove the cylinder heads (2) from the crankcase.
Using the designated wrench on the automatic belt tensioner
(3), reduce the tension of the belt (1) and remove it.
(2) 8 M12x1.75x130
Undo the screw(2) and remove the automatic belt tensioner
(2) 10 M12x1.75x150
(3).
Remove the cylinder head gasket from the centring bushes.
(2) 1 M10x1.5 Intake and exhaust valve removal
Alternator removal Figure 24
Figure 22
70319
The intake (1) and exhaust (2) valves have the same diameter
mushroom.
225130
The central notch distinguishes the exhaust valve (2) from the
Unscrew and remove the bolt (1). intake valve.
Unscrew the screw (2) and remove the alternator (3).
NOTE Mark the valves before removing them from the
Ref. No. Description cylinder heads so that they can be refitted in the
(1) 1 M10x1.5 same position as when they were removed.
(2) 1 M10x1.5
A = intake side
S = exhaust side

Figure 25 ENGINE DISASSEMBLING

Alternator support removal
Figure 27
70321
Using tool 99360268 (1), apply pressure to the plate (3),

compress the springs (4) and remove the cotters (2). Remove
the plate (3) and springs (4).
Repeat this operation for all the valves. 225131
Overturn the cylinder head and remove the valves (5). Unscrew the screws (1 and 2) and remove the alternator
support (3).
Figure 26 Ref. No. Description
(2) 1 M10x1.5x80
(2) 2 M10x1.5x130
Using tool 99360076, remove the engine oil filter (4).
(4) 1 M27x2
Engine oil filter housing removal

Figure 28
70322
Remove the sealing rings (1 and 2) from the relevant valve

guides.
NOTE The sealing rings (1) for the intake valve are
yellow.
The sealing rings (2) for the exhaust valve are
green.
201706
Unscrew the screws (2) and remove the engine oil

temperature/pressure sensor (3).
(2) 2 M6x1x20
Unscrew the screws (4) and remove the engine oil filter
housing (1), the heat exchanger plate (5) and the gaskets.
(4) 15 M8x1.25x35

Engine control unit removal ENGINE DISASSEMBLING

(COMPONENTS ON FRONT SIDE -PART 2)
Figure 29 Fit flywheel locking tool 99360351.
Damper pulley and crankshaft pulley removal

Figure 31
225132
Disconnect the quick-fit coupling (1), disengage the

intermediate retaining clips and remove fuel pipe from tank
to ECU (2).
227473
Unscrew the screws (4) and remove the engine control unit
Unscrew the screws (1), remove the damper pulley (3) and
(3) together with the heat exchanger.
the pulley (2).
(4) 3 M8x1.25x45
(1) 6 M10x1.25x40
Figure 30 Unscrew the screws (4) and remove crankshaft pulley (6)
together with the spacer-shaft flange (5).
(4) 6 M12x1.25x78.5
Remove the crankshaft pulley (6) from the crankshaft.
225133
Unscrew the screw (1) and remove the timing sensor (2)
complete of support.
(1) 1 M6x1

Crankshaft external gasket ring removal

Water pump - rpm sensor removal
Figure 34
Figure 32
78257
70148
Fit the tie rod (3) of tool 99363204 onto the external gasket
Unscrew the screws (1) and remove the water pump (2). (2) and remove it from the front cover (1) by means of the
lever (4).
(1) 2 M8x1.25x35 Front cover removal
Unscrew the screw (3) and remove the guide pulley (4). Figure 35
(3) 1 M10x1.5
Unscrew the screw (5) and remove the rpm sensor (6).
(5) 1 M6x1x20
Crankshaft front seal ring removal

Figure 33
225138
Unscrew the screws (1), the screws (2) and remove the front
cover (3).
(1) 5 M8x1.25x45
(1) 8 M8x1.25x30
(2) 2 M8x1.25x45
NOTE The screws securing the front cover are of

different lengths. It is recommended that the
operator makes a note of the assembly position.
78256
Fit tool 99340055 (4) on the front shank (2) of the crankshaft
and perforate the internal seal ring (1) using a drill bit ( 3.5
mm) to a depth of 5 mm.
Secure the tool (4) to the front seal ring (1) with the 6 screws
(5) provided and then extract the ring by screwing in the
screw (3).

Engine oil pump removal ENGINE DISASSEMBLING

(COMPONENTS ON REAR SIDE)
Figure 36
Engine flywheel removal
Figure 37
70150
Unscrew the screws (1) and remove the engine oil pump (2).
225134
(1) 4 M8x1.25x30
Apply tool 99360351 on the flywheel housing in order to
block the engine flywheel (3) rotation.
NOTE The engine oil pump (2) cannot be overhauled.
Screw out two opposite screws (2) fixing the engine flywheel
(3) to the crankshaft (4).
Introduce two withdrawal pins in the ports (see the following
picture).
Loosen remaining screws (1) fixing the engine flywheel (3) to
the crankshaft (4) and remove flywheel blocking tool
99360351.
(1, 2) 8 M12x1.25
Figure 38
227500
Screw up two medium length screws in the ports (2) to sling

the engine flywheel (3).
Throughout the two guide pins (4) previously screwed up
into the crankshaft ports (1) control the engine flywheel (3)
withdrawal by means of a hoist with tool 99360595.

Camshaft gear removal

Crankshaft rear seal ring removal
Figure 41
Figure 39
225135
78258
Fit tool 99340056 (3) on the rear shank (5) of the crankshaft Unscrew the screws (1) and remove the gear (3) from the
and perforate the internal seal ring (1) using a drill bit (3.5 camshaft (2).
mm) to a depth of 5 mm. Ref. No. Description
Secure the tool (3) to the rear seal ring (1) with the 6 screws (1) 6 M8x1.25x25
(4) provided and then extract the ring by screwing in the
screw (2). Timing gear case removal
Remove the external seal ring in the same way as described Figure 42
for the removal of the front seal ring of the crankshaft.
Flywheel housing removal

Figure 40
225136
Unscrew the screws (1) and remove the timing gear case (2).
(1) 1 M12x1.75
(1) 4 M8x1.25
(1) 5 M10x1.5
221788
Unscrew the fastening screws (1, 2, 3, 4 and 5) and remove NOTE The screws (2) securing the timing gear case are
the flywheel housing. of different lengths. It is recommended that the
operator makes a note of the assembly position.
(1) 10 M10x1.5
(2) 2 M12x1.75
(3) 2 M10x1.5
(4) 6 M12x1.75
NOTE Note down the installation positions of the

screws since they are of different sizes.

ENGINE DISASSEMBLING ENGINE DISASSEMBLING

(COMPONENTS ON BOTTOM SIDE) (CRANKCASE COMPONENTS)
Engine oil sump removal Pistons and connecting rod assembly removal
Rotate the engine through 180 on the overhaul stand.
Figure 45
Figure 43
70158
Unscrew the screws (1) and remove the connecting rod caps
(2).
225137
Undo the screws (3) and remove the oil sump (1) with the
gasket and its oil pan frame (2). (1) 8 M10x1.25x52
Ref. No. Description Remove the pistons together with the connecting rods.
(3) 10 M8x1.25x40
(3) 4 M8x1.25x45 NOTE Keep the half-bearings in their housings since in
case of use they shall be fitted in the same
Engine oil intake suction strainer removal position found at removal.
Figure 44 Main bearing caps removal

Figure 46
225139
70159
Unscrew the screws and remove the engine oil intake suction
strainer (1) with the relative gasket. Unscrew the screws (1) and remove the connecting rod caps
(2).
(1) 1 M10x1.5 (1) 10 M12x1.75
Unscrew the screws (2) and remove the lower crankcase
stiffening plate (3).
(2) 4 M10x1.5x25

Figure 47 Piston cooling spray nozzles removal

Figure 50
70160
70180
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2). Unscrew the screws (1) and remove the piston cooling spray
nozzles (2).
NOTE Mark the upper and lower half-bearings so that Ref. No. Description
they can be refitted in the same position noted (1) 4 M8x1.25x20
during removal.
Camshaft and tappets removal
Crankshaft removal Figure 51
Figure 48
70163
Unscrew the screws (1) and remove the camshaft (3)

70161
retaining plate (2).
Using tool 99360500 (1) and a suitable hoist, remove the
crankshaft (2) from the crankcase. Ref. No. Description
(1) 2 M8x1.25x16
Figure 49
NOTE Take note of plate (2) assembling position.
201709
Remove the main half-bearings (1).

Figure 52 CHECKS
Cylinder block
Checking cylinder liners
Figure 54
70164 s
Remove the camshaft (1) from the crankcase.
Figure 53
70166
After disassembling the engine, thoroughly clean the cylinder

assembly.
Use the suitable rings to handle the cylinder assembly.
Carefully inspect the crankcase for cracks.
Check the condition of the machining plugs. If they are worn,
replace them.
Check the condition of the surfaces of the cylinder liners
which should show no signs being scored, seized, ovalised,
70165
tapered or excessively worn.
Remove the tappets (1) from the crankcase.
To check the ovalisation, taper and wear of the cylinder liners,
check the internal diameter using the bore gauge (1) together
with the dial gauge which has been previously reset on the
ring gauge (2).
NOTE Use a micrometer to rest the bore gauge if a ring

gauge is not available.

Figure 55 Figure 56
S S
70167
Measurements shall be performed on each cylinder, at three

different heights in the bore and on two planes perpendicular
with each other: one parallel to the longitudinal axis of the
engine (A) and the other perpendicular to it (B); the greatest
wear is usually found to be on this surface and during the first
measurement.
Should ovalisation, taper or wear be found, bore and grind the
cylinder liners.
The regrinding of the cylinder liners should be carried out in
relation to the diameter of the pistons supplied as spare parts,
which are oversized by 0.4 mm of the nominal value and to
the prescribed assembly clearance.
201710
NOTE In case of regrinding, all cylinders should have the

same oversize (0.4 mm).
Check the main bearing seats as follows:

- fit the main bearings caps on the supports without
bearings;
- tighten the fastening screws to the torque specified in the
table;
Tightening
M12x1.75
(-) 10 1st phase 80 6 Nm
2nd phase 90
- using a suitable internal dial gauge, check that the seat
diameter falls within the specified value.
If the diameter of the seats is not within the prescribed value
but exceeds this value, replace the crankcase.

Checking cylinder block head contact surface

Figure 57
70170
Check that the contact surface of the head, on the cylinder

assembly is not deformed, then remove the dowels (4) and
carry out the check using a calibrated rule (2) and a feeler
gauge (3).
If there are any areas of deformation, correct the contact sur-
face with a grinding machine.
Planarity error shall not exceed 0.075 mm.
NOTE Flatten the crankcase after having checked that the

piston protrudes from the cylinder liner by no
more than the prescribed value.
Check the state of the cylinder assembly machining plugs (1);

if worn, replace them.
TIMING SYSTEM
Camshaft
Figure 58
70169
MAIN CAMSHAFT DATA

The data given refer to the normal diameter of the pins
The surfaces of the supporting pins of the shaft and those of the cams must be filed; It is recommended that the shaft and relative
bushes are replaced if there are any signs of in seizing or scoring.

Checking lift and pin alignment Checking the timing gear shaft seat and bushes
Set the shaft on tailstocks and, using a centesimal dial gauge
on the middle support, check that the alignment error is no Figure 60
greater than 0.04 mm: change the shaft if it is any greater.
Check that the cam lift is 6.045 mm for the exhaust and 7.582
for the intake; change the shaft if it is any greater.
Figure 59
70172
The bushing for the camshaft (2) must be forced into its seat.
The internal surfaces must show no signs of seizure or wear.
Measure the diameter of the bushing (2) and of the interme-
diate seats of the camshaft (1) with a bore gauge (3).
70171
Measurements should be performed on two perpendicular
Check the diameter of the camshaft (2) support pins using axes.
the micrometer (1) on two perpendicular axes.
Figure 61
Sec. A-A
107399
MAIN DATA OF BUSHING FOR CAMSHAFT AND ASSOCIATED SEAT

* Measurement to obtain after driving in the bushing.
Replacing camshaft bushing Checking camshaft end clearance

Figure 62 Figure 64
70176
70174
To disassemble and reassemble the camshaft bushing, use Lubricate the tappets (1) and fit them into the relevant hou-
drift 99360362 (2) and handgrip 99370006 (3). sings on the crankcase.
Figure 65
NOTE During assembly, the bushing (1) must be positio-

ned so that the lubrication holes are in line with the
holes in the seat of the crankcase.
Checking the washers for the tappets

Figure 63
70164
Lubricate the camshaft support bushing and mount the cam-

shaft (1).
Make sure that the bushing or support seats are not dama-
ged.
112890
MAIN DATA CONCERNING THE TAPPET WASHERS

AND THE RELEVANT HOUSINGS ON CRANKCASE

Figure 66 Crankshaft
Checking main journals and crankpins
Figure 68
70238
70182
Position the camshaft (3) retaining plate (1) with the slot
facing the top side of the crankcase and the marking facing
the operator, tighten the screws (2) to the torque indicated If signs of seizure, scoring or excessive ovalisation on main
in the table. journals and crankpins are identified, they must be refaced by
means of grinding.
Ref. No. Description Tightening tor-
ques Before grinding the journals (2) measure them with a micro-
meter (1) to decide the final end diameter to which they are
(2) 2 M8x1.25x16 24 4 Nm to be ground.
NOTE Note down the values in a table.

Figure 67 See figure below.
Undersize classes are of: 0.250 - 0.500 mm.
The main journals and crankpins must always be

! ground to the same undersize class.
The undersizing of the journals and crankpins must
always be marked on the side of crank arm n. 1.
For undersized crankpins, letter M.
Letter B for undersized main journals.
70179
For undersized crankpins and main journals, letter
MB.
Check that the camshaft end play (1) falls within 0.23 0.13
mm.

Figure 69
201711
TABLE IN WHICH THE MEASURED VALUES FOR THE MAIN JOURNALS AND CRANKPINS ARE TO BE NOTED
DOWN
* Nominal value
Figure 70
+
0.003 B--C
+
0.007
0.007
C C +
0.03 B--C
0.01 B--C
0.03 B--C
0.03 B--C
0.06 B--C
0.007 + 0.007 + 0.007 +
C
0.007 + 0.007 + 0.007 +
B--C 0.03 0.150 B--C 0.150 B--C 0.150 B--C
+ +
** **
F C B A
0.05 B--C + 0.03 B--C

+ 0.022 B--C
201714
MAIN CRANKSHAFT TOLERANCES

TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL

Circularity O
SHAPE
Cylindricity /O/
Alignment //
ORIENTATION Perpendicularity
Straightness -
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY
Figure 71
MAIN JOURNAL ON TIMING INTERMEDIATE MAIN FIRST MAIN JOURNAL
SYSTEM DRIVE SIDE JOURNALS ON FRONT SIDE
70237
Checking/replace oil pump drive gear Connecting rod and piston assembly
Figure 72 Figure 73
70184 70191
COMPONENT PARTS OF THE CONNECTING ROD

Check that oil pump drive gear toothing (1) is not damaged PISTON ASSEMBLY
or worn, otherwise remove it using an appropriate puller (3).
1. Retaining rings - 2. Pin - 3. Piston - 4. Circlips - 5. Screws
When fitting the new oil pump drive gear, heat it for 10 minu- - 6. Half-bearings - 7. Connecting rod - 8. Bushing
tes at a temperature of 180C and key it onto the crankshaft
with the key (2) in between.
NOTE Pistons are supplied as spare parts with standard
size or 0.4 mm oversize.

Disassembly of connecting rod and piston

Figure 74 Figure 75
32613 32614
Remove rings (1) from piston (2) using pliers 99360183 (3). The retaining circlips (1) and piston pin seeger rings (2) are
removed using a scriber (3).
Main data of piston assembly
Figure 76
1.5
*
*
220
201712
PISTON, PIN AND CIRCLIP DATA

* The measurement is made on the diameter of 101 mm
Checking piston diameter

Figure 77 Using a micrometer (2), measure the piston diameter (1) to
determine the assembly clearance.
NOTE The diameter is to be measured at 49.5 mm from

the piston skirt end.
32615

Checking the piston pins Figure 81

Figure 78
18857
Measuring the piston pin diameter (1) with a micrometer (2). 32620
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relative seats on the piston (2), using a
Figure 79 feeler gauge (1).
Figure 82
32619
41104
Use engine oil to lubricate the pin (1) and the corresponding
seat on the piston hubs. Pin must be inserted in the piston DIAGRAM FOR MEASURING THE CLEARANCE X
with a light finger pressure and it should not come out by gra- BETWEEN THE FIRST PISTON SLOT AND THE
vity. TRAPEZOIDAL RING
Since the first piston ring section is trapezoidal, the clearance
between the slot and the ring is to be measured as follows;
make the piston (1) protrude from the crankcase so that the
ring (2) protrudes half-way from the cylinder liner (3).
Checking the circlips In this position and using a feeler gauge, check that the clea-
Figure 80 rance (X) between the ring and the slot falls within the pre-
scribed values.
Figure 83
16552
70194
Check the thickness of the piston rings (2) with a micrometer Use a feeler gauge (1) to measure the clearance between the
(1). ends of the circlips (2) fitted into the cylinder liner (3).
Checking the connecting rod and bushes Connecting rod cap (B)
Figure 84 Rod No. Production year Production day
N = 2013
O = 2014
0001 9999 P = 2015 001 366
Q = 2016
R = 2017
2D Data Matrix (C)

1 = Suppliers code
V = Weight class
365 = Day of production
** * 13 = Year of production
Characters code (D)

1 = Suppliers code
V = Weight class
365 = Day of production
13 = Year of production
* Identification colour of connecting rod weight
NOTE Every connecting rod is marked as follows:

201713 - On the body and cap with a number showing
MAIN DATA OF CONNECTING ROD, PISTON PIN their coupling and the corresponding cylinder
BUSHING AND HALF-BEARINGS into which it is to be fitted.
In case of replacement it is therefore necessary to
* Inner diameter to be obtained after driving in the small mark the new connecting rod with the same num-
end and regrinding with borer. bers as the one being replaced.
** Dimension cannot be measured in free state - On the body with a letter showing the weight
class of the connecting rod fitted during pro-
duction:
NOTE The connecting rods have a determined fracture - V, 1734 1774 (marked with yellow);
- W, 1775 1814 (marked with green);
point and are supplied already fractured together - X, 1815 1854 (marked with blue);
with the screws fastening the caps; the connecting
rod caps are not interchangeable because the pro- Spare connecting rods are of the W class and mar-
file of the fracture varies from component to com- ked with green*.
ponent. Removal of material is not allowed.
Figure 85 Check that the bushing in the small end has not come loose
and shows no sign of seizure or scoring. Otherwise replace
it.
Remove and fit the bushing using a suitable drift.
When refitting make sure that the holes for the oil on the
bushing coincide with those on the connecting rod small end.
Ream the bushing to obtain the specified diameter using a
bore gauge.
225140
Connecting rod (A)

Rod No. Weight
V (Yellow) = 1734 1774 g
0001 9999 W (Green) = 1775 1814 g
X (Blue) = 1815 1854 g

Checking connecting rod alignment Checking connecting rod deflection

Figure 86 Figure 88
61695
61696 Check the deflection of the connecting rod (5) comparing

two points (C and D) of pin (3) on the vertical plane of the
Check the alignment of the connecting rod axes (1) using the connecting axis.
tool (5) as follows:
Position the vertical mount (1) of the dial gauge (2) so that
- fit the connecting rod (1) on the tool (5) spindle and this rests on the pin (3) at point (C).
secure it with the screw (4);
Swing the connecting rod backwards and forwards seeking
- set the spindle (3) on the V-prisms, resting the connec- the highest position of the pin and zero the dial gauge (2).
ting rod () on the stop bar (2).
Shift the spindle with the connecting rod (5) and repeat the
check on the highest point on the opposite side (D) of the
Checking connecting rod torsion pin (3). The difference between points (C) and (D) must not
Figure 87 exceed 0.08 mm.
Connecting rod and piston assembly
Figure 89
70198
61694
The piston crown is marked as follows:
Check the torsion of the connecting rod (5) by comparing
two points (A and B) of the pin (3) on the horizontal plane 1. Spare part number and design modification number.
of the connecting axis.
2. Arrow showing piston cylinder liner assembling direction
Position the dial gauge (2) support (1) to obtain a preload of into cylinder liners. This arrow is to face the front side of
0.5 mm on the pin (3) in point A and then set the dial gauge the crankcase.
(2) to zero. Shift the spindle (4) with the connecting rod (5)
3. Marking showing 1st slot insert testing.
and compare any deviation on the opposite side (B) of the
pin (3): the difference between (A) and (B) must not exceed 4. Manufacturing date
0.08 mm.
Figure 90
NOTE Circlips are supplied as spares in following sizes:
- standard;
- increased by 0.4 mm.
Figure 93
102596
Connect the piston (2) to the connecting rod (4) with pin (3)
so that the reference arrow (1) for fitting the piston (2) into
the cylinder lining and the numbers (5) stamped on the con-
necting rod (4) are as shown in the figure.
Figure 91
70200
Mount the half bearings (1) on both the connecting rod and
the cap.
NOTE If the same big-end bearings are to be reused, refit

them in the same order and position as when they
were removed.
Do not make any adjustment on the half-bearings.
Cylinder head
Cylinder head hydraulic seal check
Figure 94
72705
Fit pin (1) seeger rings (2).
Figure 92
70323
Check the hydraulic tightness using a suitable tool.

Pump in water heated to approximately 90C at a pressure
of 2 3 bar.
Replace the washer plugs (1) if leaks are found using a suitable
drift for their removal/refitting.
32613
Use pliers 99360183 (3) to fit the circlips (1) on the piston
NOTE Before refitting, smear the plug surfaces with water--
(2).
repellent sealant.
The rings need to be mounted with the word TOP facing
upwards and with the ring openings staggered 120 apart. Replace if there are any leaks from the cylinder head.

Cylinder head contact surface check Intake and exhaust valves

Figure 95 Figure 97
70324
EXHAUST INTAKE 107280
The contact surface of the cylinder head (1) with the crank-
case is checked using a rule (2) and a feeler gauge (3). INTAKE AND EXHAUST VALVE
MAIN DATA
Any deformation found on the entire length of the cylinder
head must be no greater than 0.20 mm. Descaling, checking and grinding valves
If values greater than this are detected, regrind the cylinder Figure 98
head observing the values and warnings indicated in the figure
below.
Figure 96
204301
Remove all carbon deposits from the valves using a wire
brush.
Check that the valves show no signs of seizing, cracks or
burns.
70325
If necessary, regrind the valve seats using a grinding machine
and removing as little material as possible.
Rated thickness A of the cylinder head is 105 0.25 mm;
max. metal removal must not exceed thickness B by 0.13 mm. Figure 99
NOTE After regrinding, check that the valve recessing is

within the prescribed values. Otherwise, regrind
the valve seats.
18882
Using the micrometer (2), measure the valve stem (1) and
check that it falls between the values 6.970 6.990 mm.

Valve guides Valve seats

Regrinding and replacing the valve seats
Figure 100
Figure 101
70330
Check the valve seats (2). If they are scored or burnt, regrind
using the tool (1) observing the inclination values provided
in the following figure.
Using a bore gauge, measure the internal diameter of the
valve guides and make sure that they fall within the values
indicated in the figure.
Figure 102
VALVE SEAT MAIN DATA

The valve seats are cast into the cylinder head and processed.

Figure 103
EXHAUST INTAKE
107282
If it is not possible to restore the valves simply by regrinding, inserts supplied as spare parts can be fitted.
In this case, using the suitable tool, regrind the valve seats to the values shown in the figure and fit the valve seats.
Heat the cylinder head to 80 -100 C and, using a drift, fit in the new valve seats (2), chilled beforehand.
Then, using a suitable tool, regrind the valve seats to the values shown in the following figure.
Figure 104
INTAKE EXHAUST
221791
VALVE SEAT MAIN DATA

Figure 105
After regrinding, check that the valve recessing (3) falls within
the prescribed values using the stand 99370415 (2) and the
dial gauge 99395603 (1).
70333

Valve springs Figure 108

Figure 106
70164
50676
KEY DATA FOR CHECKING INTAKE AND EXHAUST Mount the camshaft (1) and lubricate the support bushing.
VALVE SPRINGS
Make sure that the bushing and the relative seat are not
Before assembling, check the valve spring flexibility. Compare damaged in the process.
the elastic deformation and load data with those of the new
springs shown in the following table.
Height Under a load of Figure 109

mm N
H 47.75 Spare
H1 35.33 P1 339.8 19
H2 25.2 P2 741 39
70238
ENGINE ASSEMBLY
(CRANKCASE COMPONENTS) Position the camshaft (3) retaining plate (1) with the slot
Tappets and camshaft refitting facing the top side of the crankcase and the marking facing
the operator, tighten the screws (2) to the torque indicated
Figure 107 in the table.

(2) 2 M8x1.25x16 24 4 Nm
70176
Lubricate the tappets (1) and fit them into the relevant hou-
sings on the crankcase.

Piston cooling spray nozzles refitting Figure 112
Figure 110
70161
Using tool 99360500 (1) and a suitable lift, fit the crankshaft
(2) into the crankcase.
70180
Fit the nozzles (2) and tighten the screws (1) to the torque
Figure 113
(1) 4 M8x1.25x20 15 3 Nm
Main half-bearings and crankshaft refitting
Figure 111
70186
Check the clearance between the crankshaft main journals

and their respective bearings, working as follows:
- clean accurately the parts and remove any trace of oil;
- position a piece of calibrated wire (3) on the output shaft
pins (4) so that it is parallel to the longitudinal axis;
- fit caps (1), including the half bearings (2) on the relevant
supports.
70185
Figure 114
NOTE If refitting the same main bearings, refit them in the
same order and position as when they were remo-
ved.
The main bearings (1) are supplied as spare parts undersized

on the inner diameter by 0.250 - 0.500 mm.
NOTE Do not modify the bearings in any way.
Thoroughly clean the main half bearings (1) with the lubrica-
ting hole and fit them into their seats.
The second last main half bearing (1) is fitted with shoulder
half rings. 70188

Screw in the pre-lubricated screws (2) and tighten them in Connecting rod and piston assembly
two successive stages as indicated in the table.
Figure 117
Use tool 99395216 (1) for the angle tightening.
Tightening
1st phase 80 6 Nm
(2) 10 M12x1.75 2nd phase 90
Figure 115
70201
Carefully lubricate the pistons, the circlips and the inside of

the cylinder liners.
Using clamp 99360605 (2), fit the connecting rod-piston
assemblies (1) in the cylinder liners making sure that:
- The number of each connecting rod corresponds to the
cap coupling number.
70189
- remove the caps from the supports. Figure 118

The clearance between the main bearings and the related
pins can be found by comparing the width of the calibrated
wire (2) at the greatest squeezing point, with the graduation
of the scale shown on the casing (1) which holds the calibra-
ted wire.
The numbers shown on the scale indicate the clearance in
millimetres of the coupling.
If the clearance is not as prescribed, change the bearing shells
and repeat the check; on obtaining the prescribed clearance,
lubricate the main bearings and fit the supports permanently
by tightening the fastening screws as described above.
Checking crankshaft end float 70202
Figure 116
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY
- split ring openings shall be displaced each other by 120;
- the connecting rod -piston assemblies are all of the same
weight;
- the arrow stamped on the piston crown faces the front
side of the crankcase, or the slot obtained on the piston
skirt, and is in line with position of the oil nozzle.
70190
The end float is checked by placing a magnetic mounted dial

gauge (2) on the crankshaft (3), as shown in the figure; the
normal assembly clearance is 0.095 - 0.265 mm.
If higher value is found, replace the main half-bearings of the
second last rear support (1) and repeat the clearance check
between the crankshaft pins and main half bearings.

Crank pin fitting clearance check Figure 121

Figure 119

70205
70203 - apply tool 99395216 (1) to the socket wrench and

Carry out the following operations to measure the crankpin tighten the screws (2) by a further 60.
fitting clearance:
- carefully clean the parts and remove any trace of oil;
- set a piece of calibrated wire (2) on the crankshaft pins
(1);
- fit the connecting rod caps (3) with the relevant half bea-
rings (4).
Figure 120 Figure 122
70204 70206
- Lubricate the screws (1) with engine oil and then tighten - remove the cap and find the existing clearance by com-
them to the torque indicated in the table using the tor- paring the width of the calibrated wire (1) with the scale
que wrench (2). shown on the envelope (2) which contained the wire.
Tightening
M10x1.25 1st phase 50 5 Nm
(1) 8 x52 2nd phase 60

Checking the crankshaft - connecting rod end float ENGINE ASSEMBLY

(COMPONENTS ON TOP SIDE - PART 1)
Figure 123 Intake and exhaust valves refitting
Figure 125
70207
If the clearance is not as prescribed, change the half bearings

and repeat the check;
70334
On obtaining the prescribed clearance, lubricate the connec-
ting rod half bearings and fit them permanently by tightening Lubricate the valve stems (1) and fit them into the relative
the screws securing the connecting rod caps as described. valve guides according to the position marked during remo-
val.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Before the final fitting of the connecting rod cap
fastening screws, check that their diameter when
measured at the centre of the thread length is not NOTE The sealing rings (2) for the intake valves are yellow;
less than 0.1 mm of the diameter measured at sealing rings (3) for exhaust valves are green.
approximately 10 mm from the end of the screw.
Manually check that the connecting rods (1) slide axially on

the crankshaft pins and that their end float, measured with a
feeler gauge (2), is 0.10 - 0.30 mm.
Piston protrusion check
70208 770321
After fitting the connecting rod - piston assemblies, use the Fit the spring (4) and upper plate (3) on the cylinder head.
dial gauge 99395603 (1) fitted with base 99370415 (2) to Using tool 99360268 (1), compress the spring (4) and secure
check the protrusion of the pistons (3) at T.D.C. in relation the parts to the valve (5) with the cotters (2).
to the top crankcase surface verifying that it falls within the
value of 0.28 - 0.52 mm.

Checking clearance between valve stem and valve guide and Figure 129
centring valves
Figure 127
88775
When choosing the cylinder head gaskets to be fitted, two

types of gasket with different thicknesses are available: Type
70327 A 1.25 mm and Type B 1.15 mm), proceed to take the follo-
wing measurements:
Carry out the checks using a magnetic mounted dial gauge
(1), positioned as shown. the assembly clearance is 0.052 - - for each piston, measuring at a distance of 45 mm from
0.092 mm. the centre, measure protrusion S1 and S2 in relation to
the crankcase and then calculate the average:
Turn the valve (2) and check that the run out error is no grea-
S cil1 = S1 + S2
ter than 0.03 mm.
2
Repeat the operation for pistons 2, 3 and 4 and calculate the
average:
S cil1 + S cil2 + S cil3 + S cil4

S=
4
If S is > 0.40 mm, use a type A gasket
Cylinder head refitting If S is < 0.40 mm, use a type B gasket.
Determining the gasket thickness
Figure 128
Cylinder head assembly
Figure 130
70335
Check that the cylinder head and crankcase contact surfaces

are clean.
Make sure that the cylinder head gaskets are not damaged or
dirtied in the process.
70137
Fit the cylinder head gasket (1) with the marking TOP
Put a new gasket on the crankcase and fit the cylinder head
facing towards the head itself.
(2) using the brackets (1).
The arrow shows the point where the gasket thickness is
given.

Figure 131 ENGINE ASSEMBLY

(COMPONENTS ON REAR SIDE)
Timing gear case refitting
Figure 133
70336
Fit the cylinder head (1), fit the screws (2) and tighten them
in three stages as indicated in the table following the order
and manner shown in the following figure.
107272
Tightening DIAGRAM OF AREA FOR APPLYING LOCTITE 5205

Ref. No. Description torques SEALANT ON THE GEAR CASE
1st phase 35 5 Nm
Carefully clean the timing gear case box (1) and the crank-
(2) 8 M12x1.75x130 2nd phase 90
case.
3rd phase 90
1st phase 55 5 Nm
(2) 10 M12x1.75x150 2nd phase 90
Perfect seal is only obtained by cleaning accurately
3rdphase 90 ! the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
NOTE Use tool 99395216 (3) for the angle tightening. bead of few mm diameter.
Before assembly, check that the thread on the Application must be uniform (no lumps), without
holes and the screws shows no sign of wear or dirt. any air bubbles, thin areas or gaps.
Any flaws must be corrected in as short a time as
possible.
Avoid using too much material to seal the sealant
joint. Excessive sealant could come out from joint
Figure 132 sides and cause lubricant passage clogging.
After applying the sealant, the joint shall be assem-
bled immediately (max 10 minutes).
A
70337
Diagram of the tightening sequence of the cylinder head

fastening screws.
The external screws marked by a light hexagon are 130 mm
long.
The inner screws marked by a dark hexagon are 150 mm
long.
A = Exhaust side

70210 70212
Position the crankshaft (4) and the camshaft (2) so that the
DIAGRAM FOR TIGHTENING THE REAR TIMING marks stamped on the gears (1 and 3) coincide.
GEAR CASE FASTENING SCREWS
Fit the timing gear case (1) on the crankcase, fit the screws
in the positions noted during removal and tighten them to
the torque indicated in the table and following the order Figure 137
shown in the figure.

(1) 1 M12x1.75 77 12 Nm
(1) 4 M8x1.25 24 4 Nm
(1) 5 M10x1.5 47 5 Nm
NOTE Before assembly, check that the thread on the

holes and on the screws shows no sign of wear or
dirt.
Camshaft timing 225144
Figure 135 Tighten the screws (1) securing the gear (2) to the camshaft
(3) to the torque indicated in the table.

(1) 6 M8x1.25x25 36 2 Nm
70211
Highlight the drive gear (1) tooth fitted on the crankshaft (2)
and on which the mark for timing is stamped on the side.
NOTE Screw in the two pins to facilitate crankshaft rota-

tion.

Engine flywheel housing refitting Figure 139
Figure 138
221784
221561 DIAGRAM FOR TIGHTENING THE FLYWHEEL

HOUSING FASTENING SCREWS
DIAGRAM OF AREA FOR APPLYING LOCTITE 5205
SEALANT Fit the flywheel housing on the crankcase, fit the screws
(1, 2, 3 and 4) in the position noted during removal and
tighten them to the torque indicated in the table and follo-
wing the order shown in the figure.
Perfect seal is only obtained by cleaning accurately
! the surface to seal. Ref. No. Description Tightening torques
Smear the case with LOCTITE 5205 to obtain a (1) 10 M10x1.5 49 5 Nm
bead of few mm diameter. (2) 2 M12x1.75 85 10 Nm
Application must be uniform (no lumps), without (3) 2 M10x1.5 49 5 Nm
any air bubbles, thin areas or gaps. (4) 6 M12x1.75 85 10 Nm
Any flaws must be corrected in as short a time as
possible. NOTE Before assembly, check that the thread on the
Avoid using too much material to seal the sealant holes and the screws shows no sign of wear or dirt.
joint. Excessive sealant could come out from joint
sides and cause lubricant passage clogging.
Crankshaft rear seal ring refitting
After applying the sealant, the joint shall be assem-
bled immediately (max 10 minutes). Figure 140
70216
Apply tool 99346253 part (5) to the rear crankshaft tang (6),
secure it using the screws (4) and fit the new seal ring (3).
Position part (1) on part (5), fit the nut (2) until the seal ring
(3) has fitted completely into flywheel housing (7).

Engine flywheel refitting Figure 143

Figure 141
225145
225141
Check the condition of the ring gear teeth (1). Apply tool 99360351 on the flywheel housing in order to
block the engine flywheel (3) rotation.
If breakage or excessive wear is found, remove the ring gear
from the flywheel (2) using a suitable drift and fit the new one, Remove the two withdrawal pins in the ports (see the pre-
previously heated to 150C for 15 - 20 minutes vious picture).
Chamfering on the internal diameter of the ring gear must be Tighten the screws (1 and 2) fixing the engine flywheel (3)
facing the flywheel. to the crankshaft (4) in two phases.
Tightening
1st phase 30 4 Nm
(1,2) 8 M12x1.25 2nd phase 60
Figure 142
NOTE Use tool 99395216 for the angle tightening.
Before assembly, check that the thread on the
holes and the screws shows no sign of wear or dirt.
227500
Screw up two medium length screws in the ports (2) to sling

the engine flywheel (3).
Screw up two guide pins (4) having suitable length into the
crankshaft holes (1) and assemble the engine flywheel (3) by
means of a hoist with tool 99360595.

ENGINE ASSEMBLY Figure 146

(COMPONENTS ON FRONT SIDE - PART 1)
Engine oil pump refitting
Figure 144
70222
Fit the water pump (1) and tighten the screws (2) to the tor-
que indicated in the table.
70220 (2) 2 M8x1.25x35 24 4 Nm
Fit the oil pump (1) and tighten the screws (2) to the torque
(2) 4 M8x1.25x30 24 4 Nm
Water pump refitting Front cover refitting

70221
70223
Fit a new seal ring (2) to the water pump (1). Fit the new seal ring (2) on the front cover (1), carefully clean
the coupling surfaces and smear them with LOCTITE 5999.

Figure 148 Crankshaft pulley and damper pulley refitting

Figure 150
70224
Carefully clean the crankcase contact surface and fit the front 227473
cover (2).
Fit the crankshaft pulley (6) and the spacer-shaft flange (5) on
Tighten the screws (1) to the torque specified in the table. the crankshaft. Tighten the fastening screws (4) to the torque
Tightening Tightening
Ref. No. Description torques Ref. No. Description torques
(1) 5 M8x1.25x45 24 4 Nm M12x1.25 1st phase 50 5 Nm
(4) 6 x78.5 2nd phase 90
(1) 8 M8x1.25x30 24 4 Nm
NOTE Use tool 99395216 for the angle tightening of the

Fit the fixed belt tensioner and tighten the screw to the tor- fastening screws (4).
que indicated in the table.
Ref. No. Description Tightening torques Fit the damper pulley (3), the pulley (2) and then tighten the
(-) 1 M10x1.5 43 6 Nm screws (1) to the torque indicated in the table.

(1) 6 M10x1.25x40 68 7 Nm
Crankshaft front seal ring refitting
Refitting engine speed sensor
Figure 149
Figure 151
70225 225142
Apply tool 99346252 part (5) to the front crankshaft tang (6), Fit the engine speed sensor (1) with a new seal ring, on the
secure it using the screws (4) and fit the new seal ring (3). front cover (3) and tighten the screw (2) to the torque indica-
ted in the table.
Position part (1) on part (5); screw down the nut (2) to fit
the seal (3) fully inside the front cover (7).
(2) 1 M6x1x20 10 2 Nm


Engi ne oil filter support refitting
Figure 152
70232
Lubricate the seal ring (2) with engine oil and set it on the oil
filter (3).
Manually screw in the oil filter (3) on the support connection
70231 (1) and then screw in further by another 3/4 turn.
Fit a new gasket (1) onto the crankcase. Check that tightening is to the torque indicated in the table.
Fit the heat exchanger plate (2) and the engine oil filter mount
(4) together with a new gasket (3). Tightening
Tighten the screws (5) to the torque specified in the table. torques
(3) 1 M27x2 2 0 2 Nm
Tightening Fit a new seal ring on the engine oil temperature / pressure
Ref. No. Description torques sensor (4).
(5) 15 M8x1.25x35 26 4 Nm
Fit the engine oil temperature/ pressure sensor (4) on the
support (1) and tighten the screws (5) to the torque indicated
in the table.
Tightening
(5) 2 M6x1x20 10 2 Nm
Fit a new seal ring (6) in the crankcase seat.

Alternator support refitting Engine control unit refitting

225143 225133
Position the alternator support (3) and tighten the screws (1 Fit the timing sensor (2) together with the new seal ring and
and 2) to the torque specified in the table. tighten the screw (1) to the torque indicated in the table.
Tightening Tightening
torques torques
(2) 2 M10x1.5x130 43 6 Nm (1) 1 M6x1 10 2 Nm
(1) 1 M10x1.5x80 43 6 Nm
Figure 157
Alternator refitting
Figure 155
225146
Fit the engine management control unit (3) together with the
heat exchanger and tighten the screws (4) to the torque
225130
Fit the alternator (3), tighten the screw (2) and the bolt (1)
to the torque indicated in the table. Tightening
Tightening
Ref. No. Description (4) 3 M8x1.25x45 24 4 Nm
torques
(1) 1 M10x1.5 43 6 Nm Fit the fuel pipe from tank to ECU (2), engage the
(2) 1 M10x1.5 43 6 Nm intermediate retaining clips and connect the quick-fit coupling
(1).


(COMPONENTS ON TOP SIDE - PART 2)
Electro-injectors refitting
Figure 158
70338
Fit a new seal ring (2) lubricated with vaseline and a new
91572
sealing washer (3) on the electro-injector (1).
Fit a new seal ring (3) lubricated with vaseline on the fuel
manifold (2).
Figure 159
Fit the fuel manifold (2) so that the positioning balls (5)
coincide with the relevant housing (4).
NOTE Do not re-use the fuel manifolds (2), but replace

them with new ones.
Screw in but do not tighten the nuts (2) securing the

manifolds (3) shown in the figure.
It is recommended that the electro-injectors are

positioned in such a way that the manifold terminal
inserts correctly into the designated holes on the
electro-injector.
70339
Fit the electro-injectors (1) so that the fuel inlet hole (2) faces
the fuel manifold terminal (3).
Figure 160
70133
Using tool 99342101 (1) fit the electro-injector (2) into its
seat.
Screw injector fastening screws without tightening them.

108492
70344
Using a torque wrench, gradually and alternately tighten the
SHAFT-ROCKER MAIN DATA
electro-injector fastening screws (1) to the torque indicated
in the table. Check that shaft-rocker arm coupling surfaces are not
excessively worn or damaged.
Tightening
Ref. No. Description torques Figure 165
M6x1x35
1st phase 3.5 0.35 Nm
(1) 8 2nd phase 25
3rd phase 25
4th phase 25
Tighten the fuel manifold (3) fastening nuts (2) to the torque
Tightening 227474
(2) 4 M22x1.5 55 5 Nm
Figure 166
Rocker assembly refitting
Figure 163
70345
Fit the pushrods (2).
70343
Position bridges (1) on valves with marks () facing the
exhaust manifold.
ROCKER ASSEMBLY COMPONENTS:
1. Screw - 2. Support - 3. Shafts - 4. Rocker arms

Figure 167 Tappet clearance adjustment
Figure 168
70520
70346
Adjust the clearance between rocker arms and valves
Check that the tappet adjuster fastening nuts (1) are through Allen wrench (1), box wrench (3) and feeler gauge
unscrewed to prevent them sticking on the rods when fitting (2).
the rocker arm assembly.
The operating clearance is:
Then refit the rocker arm assembly consisting of the support
(5), rocker arms (3) and shafts (4) and secure them to the - 0.25 0.05 mm for the intake valve
cylinder head by tightening the fastening screws (2) to the - 0.51 0.05 mm for the exhaust valve
Tighten the tappet adjuster nuts (1) to the torque indicated
Tightening in the table.
Tightening
(2) 8 M8x1.25 36 5 Nm Ref. No. Description torques
(1) 8 M8x1.25 24 4 Nm
To carry out rocker arm - valve clearance

adjustment more quickly, proceed as follows:
Apply tool 99360221 (with pinion 99360222) on
the flywheel.
Turn the crankshaft, balance the cylinder 1 valves
and adjust the valves marked by the asterisk as
shown in the table:
cylinder n. 1 2 3 4
intake - - * *
exhaust - * - *
Turn the crankshaft, balance the cylinder 4 valves
and adjust the valves marked by the asterisk as
shown in the table:
cylinder n. 1 2 3 4
intake * * - -
exhaust * - * -

Electro-injector wiring support refitting Intake manifold refitting

70352 225124
Check the condition of the cables (5) and replace them if they Apply a bead of LOCTITE 5999 sealant on the contact
are damaged. surface of the intake manifold (2), fit it onto the cylinder head
Cut the clips (5) securing the cables to the support (2) and and tighten the screws (1) to the torque indicated in the table.
unscrew the screws (4) securing the connectors (3).
Tightening
Fit a new gasket (1) on the support (3). Ref. No. Description torques
(1) 6 M8x1.25x25 24 4
Figure 170
(1) 1 M8x1.25x70 24 4
Tappet cover refitting

Figure 172
225147
Fit the electro-injector wiring support (3) and tighten the

screws (4) to the torque indicated in the table.
Tightening 225123
Fit the tappet cover (2) together with the oil vapour
(4) 2 M8x1.25x50 24 4 Nm separator and the new gasket and tighten the nuts (1) to the
(4) 3 M8x1.25x70 24 4 Nm torque indicated in the table.
Connect the cables (1) to the electro-injectors and use the
Tightening
torque wrench 99389834 to tighten the nuts (2) to the Ref. No. Description torques
(1) 4 M8x1.25 24 4
Tightening Fit the thermostat body (4) together with the new O-ring and
Ref. No. Description torques tighten the screws (3) to the torque indicated in the table.
(2) 8 M4 1.5 0.5 Nm
Tightening
(3) 2 M6x1.0x20 13.5 1.5 Nm
(3) 1 M6x1.0x50 13.5 1.5 Nm

Rail refitting Figure 174
Figure 173
116237
To connect the low pressure fuel pipe to the relative

225148
connection fitting and push in until the catchs (3) engages.
Fit the rail (5) and tighten the screws (6) to the torque
NOTE Check proper fuel pipe connection.
Tightening
(6) 3 M8x1.25x125 36 5 Nm
Fit the fuel pipes (1) and tighten the fittings (5) rail side and
(2) the electro-injector manifolds side to the torque indicated
in the table.
Tightening
M14x1.5
(1) 8 1st phase 10 1 Nm
2nd phase 55
Engage the intermediate retaining clips and connect the fuel
return pipe (4) to the rail (5) and to the cylinder head (3).
As the pipes are subject to high pressure, they must

always be replaced with each disassembly.
The pipe fittings must be tightened to the specified
torque using the wrench 99317915 and the torque
wrench 99389829.
Connect the fuel return pipe (4) to the rail (5) following the
procedures shown in the following figure.

ENGINE ASSEMBLY Checking and adjusting the Waste-Gate

(SIDE VIEW OF COMPONENTS -PART 2) The turbocharger is fitted with a pressure regulation valve,
mounted on the exhaust manifold before the turbine and
Exhaust manifold refitting controlled by a pneumatic actuator, connected via a pipe to
the intake manifold.
Figure 175
Its job is to limit the quantity of exhaust gas acting on the
turbine by sending part of it directly into the exhaust pipe
when the boost pressure downstream of the compressor
reaches the maximum value set.
Figure 176
227466
Fit the exhaust manifold (2) together with the new gaskets
and tighten the screws (1) to the torque indicated in the table.
Tightening
221447
(1) 8 M10x1.5x65 55 3 Nm
Cover the air, exhaust gas and lubrication oil inlets and
outlets.
Carry out an accurate external cleaning of the turbocharger,
using the anticorrosive and antioxidant solution and perform
the check on the actuator (4).
Clamp the turbocharger in a vice.
Disconnect the pipe of the actuator (4) and apply to the
actuator union, the pipe of pump 99367121 (1).
Apply the magnetic-base dial gauge (2) on the exhaust gas
inlet flange in the turbine.
Position the tracer point of the gauge (2) on the tie rod (3)
end and set to zero the gauge (2).
Through the pump (1) let in compressed air, in the actuator
(4), at the prescribed pressure and make sure that such value
is kept constant for the whole check time.
In the above-mentioned conditions, the tie rod must have
carried out the prescribe stroke.
Stroke (mm) Pressure (bar)

1 1.85 0.03
4 2.18 0.006
NOTE During the operation, beat slightly the actuator

(4) in order to eliminate possible sticking of the
actuator internal spring.
NOTE Is not allowed any replacement, or adjustment of

the actuator because the calibration of this
component is performed and guaranteed by the
manufacturer for each turbocharger.

Engine brake refitting

NOTE Before refitting the turbocharger on engine, fill
the central body with Figure 178
Turbocharger refitting
Figure 177
225128
Connect the engine brake water delivery pipe (2) on the

crankcase and tighten the fitting (1) to the torque indicated
in the table.
227443
Tightening
Fit the turbocharger (2) together with the new gasket onto Ref. No. Description torques
the exhaust manifold and tighten the nuts (3) to the torque
indicated in the table. (1) 1 M14x1.5 45 4.5
Tightening Figure 179

(3) 4 M8x1.25 25 2.5 Nm
Connect the engine oil delivery pipe (1) to the heat
exchanger support and to the turbocharger (2) and tighten
the fittings to the torque indicated in the table.
Tightening
(1) 2 M16 25 5 Nm
227444
Fit the engine brake (2) and tighten the nuts (1) securing it
to the turbocharger to the torque indicated in the table.
Tightening
(1) 4 M8x1.25 25 5
Connect engine brake water delivery pipe (3) to the engine
brake and tighten the union (4) to the torque indicated in the
table.
Tightening
(4) 1 M12x1.5 25 2.5

ENGINE ASSEMBLY ENGINE ASSEMBLY

(COMPONENTS ON FRONT SIDE - PART 2) (COMPONENTS ON BOTTOM SIDE)
Auxiliary drive belt and automatic belt Engine oil intake suction strainer refitting
tensioner refitting
Figure 181
Figure 180
227445
227447
Fit the sub-crankcase stiffening plate (3) and tighten the
Fit the automatic belt tensioner (3) and tighten the screw (2) screws (2) to the torque indicated in the table.
Tightening
Tightening Ref. No. Description
torques (2) 4 M10x1.5x25 43 5 Nm
(2) 1 M10x1.5 43 6 Nm
Fit the engine oil intake suction strainer (1) and tighten the
Using a specific wrench on the automatic belt tensioner (3), screws to the torque indicated in the table.
fit the belt (1), making sure that the ribs on the belt fit properly
into the grooves on the pulley. Tightening
(1) 2 M8x1.25 24 4 Nm
(1) 1 M10x1.5 43 5 Nm

Engine oil sump refitting REMOVING THE ENGINE FROM THE

ROTATING STAND
Figure 182 Apply the arm 99360595 to engine lifting hooks, hook the
arm to a suitable hoist and remove the engine from the
rotating stand. Remove the brackets 99361037.
Exhaust side - oil level dipstick and engine brake

water return pipe refitting
Figure 183
227446
Fit a new gasket on the oil sump (1) and place them on the
cranckcase; suddenly place the oil pan frame (2) on the
cranckcase and tighteen the screws (3) to the torque
Tightening
Ref. No. Description 225121
torques
Fit the engine brake water return pipe (7), tighten the union
(3) 10 M8x1.25x40 24 4 Nm (8) on the engine brake, the union (4) on the alternator
(3) 4 M8x1.25x45 24 4 Nm support and the screws (5) securing the intermediate
retaining brackets, to the torque indicated in the table.
Place the oil sump drain plug (4) with a new gasket and tighten
it to the torque indicated in the table.
Tightening
Tightening
Ref. No. Description (8) 1 M12x1.5 25 2.5 Nm
torques
(4) 1 M18x1.5 60 9 Nm (4) 1 M12x1.5 35 3.5 Nm
2 M8x16 25 2.5 Nm
Rotate the engine through 180 on the overhaul stand. (5)
1 M10x20 36 3.6 Nm
Fit the oil level dipstick pipe (2), tighten the fitting (6) and the
screws (1 and 3) securing the retaining brackets onto the
cranckase and onto the exhaust manifold, to the torque
Tightening
(1) 1 M10x1.5x65 55 3 Nm
(3) 1 M8x1.25 24 4 Nm
(6) 1 M18x1.5 30 Nm

Exhaust side - electric starter motor refitting Intake side - fuel delivery pipe from high
pressure pump to rail and high pressure pump
Figure 184 refitting
Figure 185
225120
Fit the starter motor (4) to the flywheel cover and tighten the 225119
nuts (3) to the torque indicated in the table.
Fit the high pressure pump (5) together with the feed pump,
the adapter and the pump gear, on the timing gear case and
Tightening tighten the fastening nuts (4) to the torque indicated in the
Ref. No. Description torques table
(3) 3 M10x1.5 43 6 Nm
Fit the oil outlet pipe (2) together with the new gasket, Tightening
connect it to the turbocharger and to the crankcase and then torques
tighten the screws (1) to the torque indicated in the table. (4) 3 M8x1.25 24 4 Nm
Tightening control unit to the feed pump (7), engage the intermediate
Ref. No. Description torques retaining clip and connect the quick-fit couplings.
(1) 2 M6x1 10 2 Nm
Fit the fuel return pipe from the high pressure pump outlet
to tank (3), engage the intermediate retaining clips and
connect the quick-fit coupling.
Connect a new fuel high pressure delivery pipe (2) to the high
pressure pump, tighten the fitting (6) and the screw (1)
securing the lower intermediate retaining bracket to the
crankcase, to the torque indicated in the table.
Tightening
(1) 1 M8x1.25x16 24 4
M14x1.5
(6) 1 1st phase 10 1
2nd phase 55

Figure 186 Tightening

(4) 2 M12x1.75x30 80 8 Nm
Manually screw the fuel filter (3) until flush on the support (4);
tighten by another of a turn and check that the tightening
torque is the same as that indicated in the table.
Tightening
(3) 1 M20x1.5 20 2 Nm
Fit the fuel return pipe from fuel filter to the high pressure
pump inlet (2) and connect the quick-fit couplings.
Fit the fuel delivery pipe from the feed pump to the fuel filter
225118
(1) and connect the quick-fit couplings.
Connect the fuel high pressure delivery pipe (2) to the rail,
tighten the fitting (1) and the screw (3) securing the upper Figure 188
intermediate retaining bracket to the crankcase, to the torque
Tightening
(3) 1 M8x1.25x20 24 4
M14x1.5
(1) 1 1st phase 10 1
2nd phase 55
Use the torque wrench 99389829 together with

the tool 99317915 for the angle tightening of the
fuel delivery pipe fittings (2).
116237
If removed, the fuel delivery pipe (2) must be
replaced with new ones. Toconnect the lowpressure fuel pipe to the relative
connection fitting and push in until the catchs (3) engages.
Intake side - fuel filter support refitting When fitting is completed, top-up the engine lubricant oil
with the specified quantity and quality.
Figure 187
Only use recommended oils or oils with the
properties required for proper engine operation.
Failure to observe these standards will invalidate the
service warranties.
Check the oil level with the oil level dipstick: the level
must come close to the MAX notch which can be
seen on the dipstick.
225117
Fit the fuel filter support (4) on the crankcase and tighten the
screws to the torque indicated in the table.

Engine cable refitting

Fit the engine cable and close the retaining clips securing the engine cable to the crankcase.
Connect the following electrical connections:
Figure 189
225115
metering unit - 7. Fuel temperature sensor - 8. In line connector - 9. Rpm increment speed sensor (crankshaft) -10. Engine
Control Unit EDC17CV41 - 11. Coolant temperature sensor

Figure 190
225116
1. Coolant temperature sensor - 2. Engine oil pressure and temperature sensor -


CHECKS AND INSPECTIONS Test on the pressure relief valve on the rail
The following tests shall be made after engine assembly to the The function of the valve fitted at one end of rail is to protect
vehicle. system components against any fault which might result in
overpressure in high pressure system.
Preventively check that the liquid levels have been correctly
restored. Figure 191
Start the engine and leave it running just above the

idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:
- There is no water bleeding from the manifolds
connecting engine cooling circuit pipelines and
cabin internal heating, eventually providing to
further tighten the locking rings.
- Carefully check the fuel connection pipes to the
respective unions.
- There is no oil leakage from the lubrication
circuit of the various pipelines connecting
covers.
227476
- Cylinder head, oil pan and bearing, oil filter and
Disconnect the recirculation pipe (2) of the overpressure
heat exchanger as well as relating housings.
valve (1) and plug the pipe using the Voss coupling (3)
- There is no fuel leakage from fuel pipelines. provided with 99305453 tool.
- There is no blow-by from pneumatic pipes (if
No diesel fuel leaks shall be detected from valves at any
provided).
engine rpm.
- Verify correct working of the lighting leds of the
dashboard containing the tools as well as of the If the diagnostic system indicates the fault code Rail
equipment that was disconnected during overpressure relief valve management, this means that the
engine disconnection. control unit has identified the valve opening due to a
significant change in the pressure of the rail (greater than
- Check and blow by with care the engine cooling
1800 bar).
system, carrying out frequent drainage.
Since the valve opening is due to an abnormal pressure
increase, the valve is not faulty even if a significant quantity of
diesel oil is overflowing.
If diesel oil leaks are detected from the valve (1) and the fault
code is not emitted, replace valve.

Checking the mechanical feed pump

Figure 192
227477
1. High pressure pump (CP3.3) - 2. Mechanical feed pump - 3. External container - 4. Fuel filter support -
5. Filter inlet pipe pressure gauge - 6. Filter outlet pipe pressure gauge
The mechanical pump (2) feeds the high pressure pump If the value measured is below 6 bar, replace pump; if the value
CP3.3 (1). It is controlled by the shaft of the high pressure is above 9 bar, replace the diesel fuel filter.
pump and is fitted on its rear part.
The pressure gauge (6) must show a pressure above 5 bar;
Keeping the instruments of 99305453 kit fitted as in the if the pressure is lower, replace the diesel fuel filter.
previous figure with batteries charged ad 24.7 V, the engine
If the problem is not cleared, check the seals of the hich
must start within 20 seconds after the starter motor
pressure pump inlet and fuel filter support unions.
activation, drawing the diesel fuel from an external container
(3) placed not more than 1 metre lower than the engine.
NOTE A new mechanical feed pump which is
If the pump does not suck the diesel fuel within the time interchangeable with the previous version has
specified, therefore the engine does not start, replace pump. been included in Spare Parts.
The new pump has a new seal protecting against
NOTE If the test was performed with a new mechanical water entering the area where the two pumps
feed pump from Spare Parts, before doing the are joined, thus preventing the formation of rust
test, a fist start is necessary in order to restore which could cause breakage of the shaft
normal operation conditions. connecting the high and low pressure pumps.
The pump is equipped with seal, however the
After starting the engine, at 1500 rpm check the pressure on single seal is provided as a spare.
the pressure gauge (5). When the low pressure pump has to be replaced,
Pressure gauge pressure values 6 to 9 bar thoroughly clean the mating area with high
pressure pump CP3.3.
(87 to 130.5 psi)


NEF SERIES EURO VI SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
DATA - INSTALLATION CLEARANCES . . . . . 3
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . 9

2 SECTION 7 - TECHNICAL SPECIFICATIONS NEF SERIES EURO VI

DATA - INSTALLATION CLEARANCES
F4AFE411A*C005
Type
F4AFE411C*C026
CRANK GEAR AND CYLINDER ASSEMBLY DATA mm

1
Cylinder liners 1 104.000 104.024
X
1 0.4
Pistons
1
X Measuring point X 49.5
Outer diameter 1 103.739 103.757
2 Pin housing 2 40.010 40.016
Piston - cylinder liners 0.243 0.285
Piston diameter 1 0.4
X
Piston position
from crankcase X 0.28 0.52
3 Piston pin 3 39.994 40.000
Piston pin - pin seat 0.010 0.022

F4AFE411A*C005
Type
F4AFE411C*C026
X1 X1 2.705 2.735
X2 Circlip slots X2 2.420 2.440
X3 4.030 4.050
X3
S 1 S 1* 2.563 2.597
S 2 Circlips S2 2.350 2.380
S 3 S3 3.970 3.990
* measured on 101 mm
1 0.108 0.172
Circlips - slots 2 0.040 0.090
3 0.040 0.080
Piston rings 0.4
X1 Piston ring end gap in cylin-
X2 der liner:
X1 0.30 0.40
X3 X2 0.60 0.80
X3 0.30 0.55
1 Small end bushing seat

1 42.987 43.013
Big-end bearing seat
2 73.987 74.013
2
3 Inner diameter of
connecting rod small end
bush 3
40.019 40.033
S Connecting rod half-bear-
ings
1.958 1.968
supplied as spares S
Piston pin - bushing 0.019 0.039

Connecting rod half-bear-
0.250; 0.500
ings

F4AFE411A*C005
Type
F4AFE411C*C026

1 2 Main journals 1 82.993 83.013
Crankpins 2 69.987 70.013
Main half-bearings S1*

Connecting rod half-bearings 2.456 2.464
S2* 1.958 1.968
S 1 S 2
*supplied as spares
Main journals
3 No. 1 - 5 3 87.982 88.008
No. 2 - 3 - 4 3 87.977 88.013
Half-bearings - main journals

n 1 - 5 0.044 0.106
n 2 - 3 - 4 0.039 0.111
Half bearings
0.038 0.110
- crankpins
Main half-bearings
+ 0.250 ; + 0.500
Connecting rod half-bearings
Thrust
main journal X1 37.475 37.545
X 1
Main journal support

for thrust X2 32.18 32.28
X 2
X 3 Thrust
half rings X3 36.57 37.09
Crankshaft end play 0.385 0.975

F4AFE411A*C005
Type
F4AFE411C*C026
CYLINDER HEAD - TIMING SYSTEM mm

1
Valve guide housing

on cylinder head 1 7.042 7.062
2 Valves:
2 6.970 6.990
60 0.25
2 6.970 6.990
45 0.25
Valve stem and related guide 0.052 0.092
Housing on head for
valve seat:
1 34.837 34.863
1 1 34.837 34.863
Valve seat outside diameter;

valve seat angle on cylinder
2 head:
2
34.917 34.931

60
2

34.917 34.931
45
X 0.74 1.26
Recessing
X X 0.41 0.93
0.054 0.094
Between valve seat
and cylinder head 0.054 0.094
Valve seats -

F4AFE411A*C005
Type
F4AFE411C*C026

Valve spring height:
free spring H 47.75
H H1 under a load of:

H2 339.8 19 N H1 35.33
741 39 N H2 25.20
Injector protrusion X Not adjustable

X
Seat for camshaft bushing

no. 1 (flywheel side) 59.222 59.248
Camshaft seats
n 2-3-4-5 54.089 54.139
2-3-4
Camshaft journal diameter:

15 53.995 54.045
1 5
Internal bush
diameter 54.083 54.147
Bushing and support pins 0.038 0.152

Useful cam height:
H H 7.582
H 6.045

F4AFE411A*C005
Type
F4AFE411C*C026

1
Tappet washer seat
in crankcase 1 16.000 16.030
2
3 Tappet outside diameter:
2
15.924 15.954
3
2 15.960 15.975
Between tappets and seats 0.025 0.070
Tappets -
1
Rocker-arm shaft 1 21.965 21.977
Rocker arms 2 22.001 22.027
2
Between rockers and shaft 0.024 0.062

TIGHTENING TORQUES
PART TORQUE
Nm kgm
Piston cooling spray nozzles (4 unions M8x1.25x20) 15 3 1.5 0.3
Camshaft retaining plate (2 screws M8x1.25x16) 24 4 2.4 0.4
Main bearing caps (10 screws M12x1.75) 1st phase 80 6 8.0 0.6
2nd phase 90
Timing gear case
(1 screw M12x1.75) 77 12 7.7 1.2
(4 screws M8x1.25) 24 4 2.4 0.4
(5 screws M10x1.5) 47 5 4.7 0.5
Timing gear (6 screws M8x1.25x25) 36 2 3.6 0.2
Connecting rod caps (8 screws M10x1.25x52) 1st phase 50 5 5.0 0.5
2nd phase 60
High-pressure pump (3 nuts M8x1.25) 24 4 2.4 0.4
High pressure fuel delivery pipes (10 fittings M14x1.5) 1stphase 10 1.0
2nd phase 55
Brackets securing delivery pipe from high pressure pump to rail
(1 screw M8x1.25x20) 24 4 2.4 0.4
(1 screw M8x1.25x16) 24 4 2.4 0.4
Cylinder head
(8 screws M12x1.75x130) 1st phase 35 5 3.5 0.5
(10 screws M12x1.75x150) 55 5 5.5 0.5
2nd phase 90
3rd phase 90
Figure 193
70337
Tightening sequence
A = Front

PART TORQUE
Nm kgm
Rocker arm assembly (8 screws M8x1.25) 36 5 3.6 0.5
Tappet cover
(4 nuts M8x1.25) 24 4 2.4 0.4
(4 screws M8x1.25x20) 11 3 1.1 0.3
Electro-injector wiring (8 nuts M4) 1.5 0.25 0.15 0.025
Engine oil suction strainer
(2 screws M8x1.5) 24 4 2.4 0.4
(1 screw M10x1.5) 43 5 4.3 0.5
Engine oil pump (4 screws M8x1.25x30) 24 4 2.4 0.4
Crankcase stiffening plate (4 screws M10x1.5x25) 43 5 4.3 0.5
Front cover
(5 screws M8x1.25x45) 24 4 2.4 0.4
(8 screws M8x1.25x30) 24 4 2.4 0.4
Flywheel housing
(8 screws M12x1.75) 85 10 8.5 1.0
(12 screws M10x1.5) 49 5 4.9 0.5
Engine oil sump
(10 screws M8x1.25x40) 24 4 2.4 0.4
(4 screws M8x1.25x45) 24 4 2.4 0.4
Engine oil drain plug (1 M18x1.5) 60 9 6.0 0.9
Engine oil filter support (15 screws M8x1.25x35) 26 4 2.6 0.4
Engine oil filter (M27x2) 20 2 2.0 0.2
Crankshaft pulley (6 screws M12x1.25x78.5) 1st phase 50 5 5.0 0.5
2nd phase 90
Damper pulley (6 screws M10x1.25x40) 68 7 6.8 0.7
Electro-injectors bracket (8 screws M6x1x35) 1st phase 3.5 0.35 0.35 0.035
2nd phase 25
3rd phase 25
4nd phase 25
Electro-injector wiring support
(2 screws M8x1.25x50) 24 4 2.4 0.4
(3 screws M8x1.25x70) 24 4 2.4 0.4
(2 screws M6x1x16) 10 2 1.0 0.2
Fuel manifolds (4 nuts M22x1.5) 55 5 5.5 0.5
Intake manifold
(6 screws M8x1.25x25) 24 2.4 2.4 0.24
(1 screw M8x1.25x70) 24 2.4 2.4 0.24
Rail (3 screws M8x1.25x125) 36 5 3.6 0.5
Electric starter motor (3 nuts M10x1.5) 43 6 4.3 0.6
Turbocharger
(4 nuts M8x1.25) 25 2.5 2.5 0.25
(4 studs M8x1.25) 11 3 1.1 0.3
Oil outlet pipe from turbocharger (2 screws M6x1) 10 2 1.0 0.2
Oil deliver pipe to turbocharger (2 fittings M16) 25 5 2.5 0.5
Exhaust manifold (8 screws M10x1.5x65) 55 3 5.5 0.3

PART TORQUE
Nm kgm
Alternator support
(2 screws M10x1.5x130) 43 6 4.3 0.6
(1 screw M10x1.5x80) 43 6 4.3 0.6
Alternator
(1 screw M10x1.5) 43 6 4.3 0.6
(1 bolt M10x1.5) 43 6 4.3 0.6
Engine control unit (3 screws M8x1.25x45) 24 4 2.4 0.4
Engine oil pressure and temperature sensor (2 screws M6x1x20) 10 2 1.0 0.2
Boost pressure and air temperature sensor (1 screw M6x1x20) 10 2 1.0 0.2
Engine coolant / fuel temperature sensor (1 fitting M14x1.5) 24 4 2.4 0.4
Timing segment speed sensor (camshaft)
(1 stud M6x1) 4 0.4
(1 nut M6x1) 82 0.8 0.2
Rail pressure sensor (M18x1.5) 70 5 7.0 0.5
Overpressure valve DBV4 (M20x1.5) 100 5 10.0 0.5
Crankcase plug (1 plug M18x1.5) 24 4 2.4 0.4
Cylinder head plug (1 plug M22x1.5) 80 5 8.0 0.5
Engine rpm sensor (1 screw M6x1x20) 10 2 1.0 0.2
Fuel filter housing (2 screws M12x1.75x30) 80 8 8.0 0.8
Fuel filter (1 fitting M20x1.5) 20 2 2.0 0.2
Fixed belt tensioner (1 screw M10x1.5) 43 6 4.3 0.6
Automatic belt tensioner (1 screw M10x1.5) 43 6 4.3 0.6
Engine flywheel (8 screws M12x1.25) 1st phase 30 4 3.0 0.4
2nd phase 60
Thermostat body
(2 screws M6x1.0x20) 13.5 1.5 1.35 0.15
(1 screw M6x1x50) 13.5 1.5 1.35 0.15
Water pump (2 screws M8x1.25x35) 24 4 2.4 0.4
Oil vapour recirculation system control valve (3 screws M5) 5 0.5
Brackets for lifting engine
(4 screws M8x1.25x25) 36 5 3.6 0.5
(2 screws M12x1.75x25) 77 12 7.7 1.2
Fuel high pressure pump gear (1 nut M18x1.5) 105 5 10.5 0.5
Fuel suction pump crankcase cover (2 screws M8x1.25x20) 24 4 2.4 0.4
Oil level dipstick
(1 fitting M18x1.5) 30 3.0
(1 screws M8x1.25) 24 4 2.4 0.4
(1 screw M10x1.5x65) 55 3 5.5 0.3
Motorized throttle valve (Exhaust flap)
(4 studs M8x1.25x12) 11 3 1.1 0.3
(4 nuts M8x1.25) 25 2.5 2.5 0.25

PART TORQUE
Nm kgm
Motorized throttle valve cooling delivery/return pipes
(return pipe - 1 union M12x1.5 - alternator support side) 35 3.5 3.5 0.35
(return pipe - 1 union M12x1.5 - engine brake side) 25 2.5 2.5 0.25
(return pipe - 1 screw M10x20) 36 3.6 3.6 0.36
(return pipe - 2 screws M8x16) 25 2.5 2.5 0.25
(delivery pipe - 1 fitting M14x1.5 - crankcase side) 45 4.5 4.5 0.45

(delivery pipe - 1 union M12x1.5 - engine brake side) 25 2.5 2.5 0.25
Cylinder head plug
inch -14 24 4 2.4 0.4
inch -14 36 5 3.6 0.5
inch 12 2 1.2 0.2
inch 12 2 1.2 0.2
Crankcase plug
(1 plug M14x1.5x11) 24 4 2.4 0.4
(1 plug M10x1x9.5) 24 4 2.4 0.4
(1 plug M18x1.5x14.5) 24 4 2.4 0.4
Valve clearance adjustment (8 nuts M8x1.25) 24 4 2.4 0.4

NEF SERIES EURO VI SECTION 8 - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 8 - TOOLS NEF SERIES EURO VI

TOOLS
TOOL NO. DESCRIPTION
Tool to check the diesel supply circuit and the common-rail injection
99305453 system.
99317915 Set of five ring spanners with insert 9x12 (14 - 15 - 17 - 18 - 19)
Revolving stand for overhauling units (1000 daN capacity, 120 daNm
99322205 torque)
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket
99341001 Double acting puller

TOOLS
99341009 Pair of brackets
99341015 Press
99342101 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket
99360076 Tool to remove filters

TOOLS
99360183 Pliers for removing/refitting piston rings (65 110 mm)
99360221 Tool for rotating the engine flywheel (use with 99360222)
99360222 Pinion (use with 99360221)
99360268 Tool for removing/refitting engine valves
99360351 Tool for stopping the engine flywheel
Beater for removing/refitting camshaft bushes (to be used with

99360362 99370006)

TOOLS
99360500 Tool for lifting the output shaft
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99367121 Manual pump for pressure and vacuum measurements

TOOLS
99370006 Handgrip for interchangeable beaters
99370415 Gauge base for different measurements (to be used with 99395603)
99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)
Torque screwdriver for injector solenoid valve connector stop nut

99389834 setting (1-6 Nm)
99395216 Pair of gauges with and square head for angle tightening
99395603 Dial gauge (0 5 mm)


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

2 APPENDIX NEF SERIES EURO VI

NEF SERIES EURO VI APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

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

4 APPENDIX NEF SERIES EURO VI
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

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

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NEF SERIES

Technical and Repair manual

Anyhow, this document is addressed to qualified and special-

Before performing any intervention, check that the document

Making interventions strictly observing the indications given

Each repair intervention must be finalised to the recovery of

Each intervention on the vehicle that is finalised to a modifica-

FPT declines any liability for repair work.

FPT is available to provide any information necessary for the

The data contained in this issue may not be up-to-date due to

In the event of discordance between the information in this

Publication edited by:

- Grounding and screening . . . . . . . . . . . . . . . . . 8

OPTIONAL ELECTRICAL AND MECHANICAL

CONVERSIONS BETWEEN THE MAIN UNITS

PAGE HEADER AND FOOTER INTERPRETATION 10

Print P1D32N021 E Base - March 2015

Base - March 2015 Print P1D32N021 E

Danger for persons

Risk of serious damage to the assembly

NOTE Indicates an additional explanation for a piece of information.

1 1= Housing for connecting rod

Print P1D32N021 E Base - March 2015

Tighten to the specified torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Base - March 2015 Print P1D32N021 E

Print P1D32N021 E Base - March 2015

Base - March 2015 Print P1D32N021 E

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

Print P1D32N021 E Base - March 2015

Grounding and screening

The following precautions must be observed regarding the electronic components:

1. STAR CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT GROUND M

2. SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR

Base - March 2015 Print P1D32N021 E

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

NOTE Where accuracy is not particularly required:

Print P1D32N021 E Base - March 2015

PAGE HEADER AND FOOTER INTERPRETATION

Type Section Page

Language Basic edition with reference When present, a

Base - March 2015 Print P1D32N021 E

Print P1D32N021 E Base - March 2015

Base - March 2015 Print P1D32N021 E

NEF SERIES EURO VI

Removal-refitting of the main engine components 5

General mechanical overhaul 6

Safety prescriptions Appendix

Print P1D32N021 E Base - March 2015

Base - March 2015 Print P1D32N021 E

CORRESPONDENCE BETWEEN TECHNICAL CODE

TORQUE AND POWER TYPICAL CURVES . . 7

Print P1D32N021 E Base - March 2015

Base - March 2015 Print P1D32N021 E

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

Technical Code Commercial Code

Print P1D32N021 E Base - March 2015

Progressive numbers showing engine variants

Engine main characteristics:

F = ENGINE WITH HW DEVELOPED FOR TIER4/EURO6

Code Type of base: Application

F4 = New Engine Family

Type F4AFE411AC005 F4AFE411CC026

Type F4AFE411AC005 F4AFE411CC026