NEF SERIES
G_Drive application
NEF67
NEF67TE8W
Technical 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 specialised 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 prevention 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 modification, 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 instructions for any cases and situations not covered in this publication.
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 illustrations herein is forbidden.
Publication edited by:
FPT Industrial S.p.A.
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
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NEF G-Drive SERIES
INTRODUCTION
1
Introduction
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . .
3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION
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INTRODUCTION
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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 - disconnections, overhauls at the bench, troubleshooting and scheduled maintenance.
The electrical/electronic system section contains the descriptions of the electric network and the electronic systems of the assembly,
wiring diagrams, electrical characteristics of components and the component codes.
Sections 1 and 2 describe engine operation and the general features of the engines.
Section 3 describes the electrical part regarding wiring, electric and electronic devices, all of which differ depending on specific use.
Section 4 includes the scheduled maintenance.
Sections 5 and 6 refer to removal-installation operations of the main components and the general overhaul interventions of engines
fitted onto a rotating stand.
Section 7 and 8 include the technical characteristics of the engines, such as assembly clearances, tightening torques and specific
equipment.
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
Ø 1 = Housing for connecting rod small end bush.
α
Tighten to torque
Tighten to torque + angle value
 2 Ø 2 = Big-end bearing seat.
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INTRODUCTION
Removal
Disconnect
Intake
Refitting
Connect
Exhaust
Disassembly
Dismantling
Operation
Assembly
Assemble
α
ρ
Compression ratio
Tighten to the specified torque
Tolerance
Weight difference
Tighten to the specified torque + angle value
Rolling torque
Press or caulk
Rotation
Registration
Adjustment
Angle
Angle value
Visual check
Fitting position check
Revolutions per time unit
Measuring
Value to be found
Check
Temperature
Tools
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NEF G-Drive SERIES
bar
Pressure
Surface for machining
Finished workpiece
Oversized
Oversized by no more than .....
Max.
Interference
Forced assembly
Undersized
Undersized by .....
Minimum
Clearance
Shim
Selection
of oversizing
class
Lubricate
Moisten
Grease
Temperature < 0 ˚C
Cold
Winter
Coolant
Sealant
Temperature > 0 ˚C
Hot
Summer
Bleeding air
Preload
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INTRODUCTION
5
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 tools according to the indications provided in the respective operator’s manuals.
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.
Workshop 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 16 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 polluting 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.
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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 disassembled parts with their securing elements (screws, nuts, etc.) into special containers
Check the integrity of the parts that prevent the loosening of screws: broken washers, dowels, clips, etc. Self-locking
nuts with an insert made of nylon 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; FPT’s sales and assistance network 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 battery’s positive terminal (connecting
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.
If the vehicle is subjected to temperatures exceeding 80 ˚C (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.
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INTRODUCTION
7
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 the latter is well 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 bulb to check the continuity of a circuit. Only use the appropriate testing devices.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding,
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 the power supply voltage for the electronic control units (e.g. erroneous battery polarisation)
may damage the components irreversibly.
Disconnect the batteries from the system before recharging them by means of an external unit.
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 rated 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.
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INTRODUCTION
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Grounding and screening
The negative conductors connected to circuit ground point must be as short as possible and connected in ”star” form, ensuring
that their tightening is done neatly and sufficiently (Figure 1 ref. M).
The following precautions must be observed regarding the electronic components:
— electronic control units must be connected to the system ground when equipped with metal housings.
— The negative cables of the electronic control units must be connected at a circuit ground point, such as dashboard compartment
ground (avoiding ”serial” or ”chain” connections), as well as to the negative terminal of the battery or batteries.
— Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal insulation.
Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
— The metal braid of shielded circuits must be in contact only at the ECU side to which the signal is to be sent (Figure 2).
— In the case of junction connectors, the unshielded section (d) near to the latter 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
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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
INTERNATIONAL SYSTEM AND THE MOST COMMONLY USED DERIVED SIZES
Power
1 kW =
1 kW =
1 CV =
1 CV =
1 hp =
1 hp =
NOTE
THE
1.36 CV
1.34 hp
0.735 kW
0.986 hp
0.746 kW
1.014 CV
the unit HP is converted into hp for simplicity according to a 1:1 ratio
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 = 32˚F (the conversion factor between Celsius and Fahrenheit is 1:1.8)
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PAGE HEADER AND FOOTER INTERPRETATION
Type
of engine
Number of
printed
copies
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Section
title
Language
of Publication
Basic edition referring to
closing phase of drafting
month-year
Page
number
When present, a
month-year update
(Revi) to the basic edition
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NEF G-Drive SERIES
UPDATE DATA
Part
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Section
Section name
Modification description
Page
Date of revision
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1
NEF G-Drive SERIES
NEF 67 SERIES
Section
General information
1
Operating diagrams
2
Electric / electronic equipment
3
Diagnostics
4
Scheduled maintenance
5
Removal/refitting of the main engine components
6
General mechanical overhaul
7
Technical specifications
8
Tools
9
Safety regulations
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Appendix
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SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
1
c
SECTION 1
General information
Page
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APPROVAL PLATE . . . . . . . . . . . . . . . . . . . . . . .
3
CORRESPONDENCE BETWEEN TECHNICAL
CODES AND COMMERCIAL CODES . . . . .
4
TECHNICAL CODES . . . . . . . . . . . . . . . . . . . . .
5
COMMERCIAL CODES . . . . . . . . . . . . . . . . . . .
6
ISO VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .
8
MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - GENERAL INFORMATION
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SECTION 1 - GENERAL INFORMATION
3
APPROVAL PLATE
Figure 1
249424
Box ”I”: month and year of manufacture;
Variable data ”x” depending on the type-approval country;
Box ”P”: Serial number to be assigned in the manufacturing plant;
Refer to the Database for the remaining data to be included in the nameplate.
Support: material 3812, white;
Fixed + movable protection: shiny clear polyester;
Tape: TA 980, resin based black;
Material specifications: the adhesive plate must comply with regulation CNH 82877191;
Glueing procedure must be in accordance with I.S. 17-1610 cycle ”E” using manual roller (as for cycle ”C”).
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SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES
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Technical codes
Commercial Codes
F4HFA615A*D001
NEF67TE8W.S550
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SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
5
TECHNICAL CODES
F4
H
F
A
6
1
5
A
* 601
D
001
In particular, the first of the three numbers indicates the type of injection
0 = Common Rail 4 valves
2 = Common Rail 2 valves
3 = In line injection pump 4 valves
4 = In line injection pump 2 valves
5 = Rotary injection pump 4 valves
6 = Rotary injection pump 2 valves
8 = Lightweight engine for spare parts
A... E = Truck variants without derating
The remaining digits indicate the engine
variant
Type-approval
for performances
A = First calibration
B = Second calibration
C = Third calibration
... and so on
Main engine features
0 = Turbocharged
1 = Turbocharged direct diesel
injection intercooled
2 = Naturally aspirated direct diesel
injection
3 = Naturally aspirated indirect diesel
injection
4 = Naturally aspirated petrol
5 = Naturally aspirated methane
6 = Turbocharged direct diesel injection
7 = Turbocharged indirect diesel
injection
8 = Turbocharged petrol
9 = Turbocharged intercooled indirect
diesel injection
Number of cylinders.
(Note: 0 = 10 cylinders 1 = 12 and more)
Configuration of cylinders
A = 4 stroke vertical
B = 4 stroke horizontal
C = 4 stroke vertical with EGR
D = 4 stroke horizontal with EGR
E = 4 stroke vertical with post-treat
F = 4 stroke horizontal with post-treat
G = 4 stroke horizontal with EGR + post-treat
L = 4 stroke vertical with EGR + post-treat
P = 4 stroke vertical with internal EGR
Type-approval for standards
A
B
C
D
E
F
H
J
K
=
=
=
=
=
=
=
=
=
TIER 4a
TIER 4b
EURO 6 step A
NON EMISSIONS CERTIFIED
STAGE II
EURO 5
STAGE IIIa/TIER 3
EURO 6 step C
GB4 (China homologation)
Application
0 = Applications other than the following
1 = Truck
2 = Bus
3 = Industrial/Agricultural
4 = Industrial/Agricultural
5 = Genset
6 = Marine
7 = Industrial/Agricultural with EVGT turbo
8 = Railway
9 = Military
F = SW for Tier4/Eu6
Code
A
B
C
D
E
F
G
H
Crankcase
Boring per stroke
Valves
Not structural
Not structural
Structural
Structural
Structural
Structural
Not structural
Not structural
102 x 120
102 x 120
104 x 132
104 x 132
102 x 120
102 x 120
104 x 132
104 x 132
4
2
2
4
4
2
2
4
F4 = NEW ENGINE FAMILY
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SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
COMMERCIAL CODES
NEF
67
T
E
8
W
Application
Power level
1, 2, 3 etc. = Different power levels
for example. 1 per 180 kVA
2 per 200 kVA
Injection / Management
E = Electronic with ECU
M = Mechanical
R = Electronic + Mechanical Regulator
Intake
A = Natural
S = Turbocharged
T = Turbocharged with Air/Air intercooler
W = Turbocharged with Air/Water intercooler
Displacement or No. of Cylinders
litres per displacement > 10 litres
litres x 10 per displacement < 10 litres
No. of Cylinders for Vector
For NEF the first digit is also the number of cylinders
Engine family
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NEF G-Drive SERIES
7
ISO VIEW
Figure 2
249908
They are characterised by a 4 stroke diesel cycle, sucked in or
supercharged with 6 cylinders with 4 valves per cylinder.
They are powered with the high-pressure pump.
NOTE The data, specifications and performance figures are
only valid if the fitter complies with all the installation
regulations provided by FPT.
Furthermore, the bodybuilder appliances must always be in compliance with the torque, power and
engine speed for which the engine was designed.
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This section consists of four parts:
- the part covering specific mechanical overhaul based on
use, describing the operations necessary to remove and
install the engine components including the cylinder head,
timing gear housing and the front cover;
- the electric part, describing the connections of the various
components, the pre-post heating control unit (only for
some versions) and the sensors located on the engine;
- diagnostics;
- preventive or routine maintenance operations, with indications regarding the main operations.
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SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
ENGINE VIEWS
Figure 3
249909
LEFT SIDE VIEW
1. Air filter - 2. Common rail - 3. Blow-by filter - 4. Fuel pre-filter - 5. High pressure pump - 6. Fuel filter 7. EDC control unit - 8. Protective grille - 9. Preheating resistor - 10. Engine cable - 11. Oil filler plug
Figure 4
249910
RIGHT SIDE VIEW
1. Lifting eyelet - 2. Fan - 3. Alternator - 4. Oil heat exchanger - 5. Oil filter 6. Crankshaft damper - 7. Lubricating oil return from turbocharger pipe - 8. Oil sump 9. Starter motor - 10. Interconnection Control Unit - 11. Exhaust manifold - 12. turbocharger
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Figure 5
249911
FRONT VIEW
1. Intake manifold - 2. Fuel pre-filter - 3. Fan support pulley - 4. Auxiliary drive belt 5. Fuel filter - 6. Crankshaft damper - 7. Water pump - 8. Interconnection Control Unit - 9. Alternator 10. Automatic belt tensioner - 11. Temperature regulator cover
Figure 6
249912
REAR VIEW
1. Lubricating oil return pipe from turbocharger - 2. Interconnection Control Unit - 3. Oil drain plug 4. Engine flywheel - 5. Blow-by filter
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SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
Figure 7
249913
TOP VIEW
1. Turbocharger - 2. Exhaust manifold - 3. Tappet cover - 4. Blow-by filter - 5. Intake manifold 6. Radiator
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NEF G-Drive SERIES
11
MAIN FEATURES
Type
F4HFA615A*D001
Cycle
Diesel 4-stroke
Supply
Turbocharged with turbocharger and intercooler
Injection
Direct
Number and arrangement of
cylinders
j
+
6 in line
Bore
mm
104
Stroke
mm
132
cm3
6728
+
+.. = Total displacement
ρ
Compression ratio
17.5 : 1
Performance [gross](*)
Continuous power(1)
Prime Power(2)
Stand-by power(3)
kWm
kWm
kWm
rpm
179
222.3
244.5
1500
kWm
kWm
kWm
rpm
173
216
238.5
1500
kWm
kWm
kWm
rpm
193.6
239.5
263.5
1800
kWm
kWm
kWm
rpm
183.6
229.5
253.5
1800
Performance [net](*)
Continuous power(1)
Prime Power(2)
Stand-by power(3)
Performance [gross](*)
Continuous power(1)
Prime Power(2)
Stand-by power(3)
Performance [net](*)
Continuous power(1)
Prime Power(2)
Stand-by power(3)
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Low idle
speed
rpm
-
High idle
speed
rpm
-
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SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
Type
F4HFA615A*D001
SUPERCHARGE
Turbocharger with intercooler
Turbocharger type:
Supercharger type:
bar
Holsett HX35W
LUBRICATION
Oil pressure with hot engine
(100 ˚C ± 5 ˚C):
at idle speed
bar
at max speed
bar
Forced by gear pump, pressure relief valve, oil filter
3
5
(*) Power at the flywheel in accordance with directive 97/68 EC (without fan), after 50 hours’ operation, tolerance ± 3%, fuel
EN590;
Test in accordance with specification ISO 3046/1, turbocharger inlet air temperature 25 ˚C, atmospheric pressure 100 kPa,
humidity 30%.
Also in accordance with specification DIN 6271, BS 5514, SAE J1349.
All data is based on engine operation, with fuel system, water pump, lubrication oil pump, and restriction on suction and discharge
within (or below) the limits shown on the data sheet. Additional loads estimated at 20 N from the minimum speed at normal
speed.
The fan operation cycle must be below 20%.
(1) The continuous power is that which a generating set is capable of delivering continuously for an unlimited number of hours per
year, according to the stated maintenance intervals and under standard ambient conditions.
(2) The prime power is the maximum power available with varying loads for an unlimited number of hours. The average power
output during a 24h period of operation must not exceed 80% of the declared prime power according to the prescribed
maintenance intervals and at standard environmental conditions.
A 10% overload is permissible for 1 hour every 12 hours of operation.
(3) The stand-by power is the maximum power available for a period of 500 hours/year with a mean load factor of 90% of the
declared stand-by power.
No kind of overload is permissible for this use.
Base - May 2018
Print P4D32N015 E
SECTION 1 - GENERAL INFORMATION
NEF G-Drive SERIES
Type
F4HFA615A*D001
Liquid
COOLING
Water pump drive:
Thermostat:
initial opening
˚C
79 ± 2
maximum opening
˚C
96
TIMING SYSTEM
Start before T.D.C.
End after B.D.C.
A
B
Start before B.D.C.
end after T.D.C.
D
C
Belt driven
For timing check
X
X
Print P4D32N015 E
17˚
31˚
48˚
9˚
0.25 ± 0.05
{
mm
mm
0.50 ± 0.05
High pressure pump
SUPPLY
bar
13
Pump type:
BOSCH CP3.3
Nozzle type
CRIN2-16
Firing order
1-5-3-6-2-4
Injection pressure
bar
1,600
Base - May 2018
SECTION 1 - GENERAL INFORMATION
14
NEF G-Drive SERIES
Type
F4HFA615A*D001
FLUIDS
engine (4)
litres
10.5
G-Drive (5)
litres
15
litres
(kg)
17.2
(15.48)
Sump at minimum level
litres
(kg)
8
(7.2)
Sump at maximum level
litres
(kg)
12
(10.8)
Fuel tank (4)
litres
(kg)
(-)
Cooling circuit (*) (1)
Lubrication circuit (2) (3)
Periodic replacement:
(*). It is prohibited to mix fluids of different brands and origins inside the circuit.
(1). The quantities refer to the standard configuration of the engine. The coolant must comply with ASTM D-6210 standards. Concentrated coolants must be used as a mixture with 50% water.
(2). For the oil specifications, refer to the table of the oils.The oil used is considered to be acceptable until a quantity equalling 0.2%
of fuel consumption is reached.
(3). The quantities indicated refer to the first refuel only and are relative to the engine, oil sump and filter.
(4). Fuel tank not supplied by FPT. Refer to the data provided by the supplier/manufacturer of the power generating unit.
Only use fuel which meets the specifications of international standards ASTM D975 or EN 590.
(5). The quantities shown are relative to the total capacity of the G-Drive including engine capacity.
!
!
Filling from drums or tanks can cause contamination of the diesel, with the consequent risk of damaging the injection
system; if necessary, perform suitable filtration or sedimentation of the impurities before refuelling.
The data, specifications and performance figures are only valid if the fitter complies with all the installation instructions
provided by FPT.
Furthermore, the bodybuilder appliances must always be in compliance with the torque, power and engine speed for
which the engine was designed.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
1
SECTION 2
Operating diagrams
Page
Print P4D32N015 E
SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
3
- General information . . . . . . . . . . . . . . . . . . . .
3
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . .
3
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Pressure control valve . . . . . . . . . . . . . . . . . . .
3
- Fuel heater on filter . . . . . . . . . . . . . . . . . . . . .
3
- Fuel temperature sensor . . . . . . . . . . . . . . . . .
3
- Rail pressure sensor . . . . . . . . . . . . . . . . . . . .
3
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . .
4
SUPPLY DIAGRAM . . . . . . . . . . . . . . . . . . . . . .
5
SUPPLY SYSTEM COMPONENTS . . . . . . . . . .
6
- Mechanical supply pump . . . . . . . . . . . . . . . . .
6
- Normal operating conditions . . . . . . . . . . . . .
6
- Overpressure condition at outlet . . . . . . . . . .
6
- Air bleeding conditions . . . . . . . . . . . . . . . . . .
7
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
- High pressure pump CP3 . . . . . . . . . . . . . . . .
8
- High pressure pump internal structure . . . . . .
9
- Operating principle . . . . . . . . . . . . . . . . . . . . .
10
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
OVERPRESSURE VALVE . . . . . . . . . . . . . . . . . .
12
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . .
13
- Injector in resting position . . . . . . . . . . . . . . . .
13
- Beginning of injection . . . . . . . . . . . . . . . . . . .
13
- End of injection . . . . . . . . . . . . . . . . . . . . . . . .
13
Base - May 2018
2
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
Page
Page
LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . .
14
- General information . . . . . . . . . . . . . . . . . . . .
14
LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . .
15
LUBRICATION CIRCUIT COMPONENTS . . . . .
16
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . .
17
- Oil pressure regulating valve . . . . . . . . . . . . . .
18
- Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . .
19
- Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
- Cooling nozzles . . . . . . . . . . . . . . . . . . . . . . .
21
OIL VAPOUR RECYCLING SYSTEM . . . . . . . . .
22
- General information . . . . . . . . . . . . . . . . . . . .
22
OIL VAPOUR RECYCLING DIAGRAM . . . . . . .
23
OIL VAPOUR RECIRCULATION SYSTEM
COMPONENTS (BLOW-BY) . . . . . . . . . . . . .
Base - May 2018
24
- Blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . .
24
COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . .
25
- General information . . . . . . . . . . . . . . . . . . . .
25
COOLING DIAGRAM . . . . . . . . . . . . . . . . . . . . .
26
COOLING CIRCUIT COMPONENTS . . . . . . . .
27
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . .
28
INTAKE AND EXHAUST SYSTEM . . . . . . . . . . .
29
- General information . . . . . . . . . . . . . . . . . . . .
29
INTAKE AND EXHAUST DIAGRAM . . . . . . . . .
30
INTAKE AND EXHAUST SYSTEM COMPONENTS
31
- Intake manifolds . . . . . . . . . . . . . . . . . . . . . . .
31
- Exhaust manifolds . . . . . . . . . . . . . . . . . . . . . .
31
- HOLSET HX35W turbocharger . . . . . . . . . . .
32
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
3
SUPPLY SYSTEM
General information
The fuel supply system is composed of:
- Fuel tank
- Fuel delivery and return pipes
- Fuel filter
- High-pressure pump
- Electro-injector supply pipes
- Injectors
ELECTRICAL SYSTEM
Figure 1
252267
1. Pressure control valve on the Rail - 2. Fuel temperature sensor - 3. Fuel heater on the filter 4. Pressure sensor on the rail
SENSORS
Pressure control valve
Fuel temperature sensor
The pressure control valve is fixed at the Rail and serves to
adjust and maintain the pressure on the basis of the engine
load conditions.
If the pressure is too high, the valve opens to allow some of
the fuel to flow from the Rail to the tank; if the pressure is
too low in the Rail, the valve closes separating the high pressure side from the low pressure side.
It is a solenoid valve controlled electronically by the control
unit (EDC module). The variation in pressure is carried out
by adjusting the diesel flow returning to the tank
This sensor is identical to the coolant temperature sensor.
It detects the temperature of the fuel to give the control unit
information about the fuel temperature conditions.
Rail pressure sensor
Assembled on one end of the rail, measures the existing fuel
pressure and informs the control unit (feed - back).
The value of injection pressure is used to keep the pressure
level under control and to determine the time duration of
the injection electronic command.
Fuel heater on filter
This resistor ensures that the fuel stays in the liquid state
even if the temperature falls below the freezing point. In
extremely low temperatures, the fuel tends to form into
lumps which can lead to clogging of the electro-injectors and
ignition problems with the cylinders.
Print P4D32N015 E
Base - May 2018
4
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
HYDRAULIC SYSTEM
Figure 2
252268
1. High pressure pump - 2. Fuel filter - 3. Complete fuel pipes - 4. Electro-injector
Base - May 2018
Print P4D32N015 E
Print P4D32N015 E
1. High pressure pump - 2. Pressure relief valve on the high pressure
pump, 5 bar - 3. Pressure relief valve fitted on the fuel return from the
injectors, from 1.3 - 2 bar - 4. - Overpressure valve on the rail 5. Common Rail - 6. Pressure sensor - 7. Electro-injector - 8. Return
pipe - 9. Control unit heat exchanger - 10. Priming pump - 11. Pre-filter
fitted on chassis (if fitted) - 12. Fuel tank - 13. Mechanical supply pump
- 14. Fuel filter - 15. Pressure regulator - 16. High-pressure pump
cooling pipe - 17. Bypass valve - 18. By-pass valve
High pressure
High-pressure pump supply (low-pressure)
Intake (low pressure)
Exhaust
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
5
SUPPLY DIAGRAM
Figure 3
130198
Base - May 2018
6
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
This Common Rail injection system, with CP3 pump is shown
in diagram form in the 6 cylinder version.
SUPPLY SYSTEM COMPONENTS
The pressure regulator, placed upstream of the high-pressure
pump, adjusts the fuel flow that is necessary on the low-pressure system.
Mechanical supply pump
Afterwards, the high-pressure pump takes care of supplying
the rail properly.
This solution, only pressurising the necessary fuel, improves
the energy efficiency and limits heating the fuel in the system.
Gear pump, fitted on the rear side of the high pressure pump
and used to supply it. It is driven by the high pressure pump
shaft.
Normal operating conditions
Figure 4
The relief valve (2), assembled on the high-pressure pump,
serves to keep the pressure at the pressure regulator inlet,
constant at 5 bar, regardless of the efficiency of the fuel filter
and the system upstream.
The pressure relief valve (2) intervention brings about a fuel
flow increase in the high-pressure pump cooling circuit,
through inlet and drain piping (16) from piping (8).
The relief valve housed on the cylinder head, fitted on the
electro-injector return (3) limits the fuel return flow from the
electro-injectors at a pressure of 1.3 - 2 bar.
Two by-pass valves are placed in parallel with the mechanical
supply pump.
The by-pass valve (18) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure
exceeds the allowed threshold value.
The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
72592
A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass
valves in close position.
Overpressure condition at outlet
Figure 5
72593
By-pass valve (1) opens in the presence of overpressure 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).
Base - May 2018
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NEF G-Drive SERIES
7
SECTION 2 - OPERATING DIAGRAMS
Air bleeding conditions
Fuel filter
Figure 6
The filter is positioned near the high pressure pump and serves to retain the impurities and separate the water contained
in the fuel.
a heater and temperature sensor can be placed on the support for the uses that require it (use in cold climates).
72594
Figure 7
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this situation the by-pass valve (1) stays closed, the by-pass valve (2)
opens due to inlet pressure and fuel is drained out through
B.
NOTE
The mechanical supply pump cannot be replaced
individually, therefore it cannot be removed from
the high pressure pump.
202378
1.Fuel temperature sensor - 2. Fuel heater - 3. Cartridge 4. Complete filter support
Print P4D32N015 E
Base - May 2018
8
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
High pressure pump CP3
Pump with 3 radial plungers, controlled by distribution gears,
requires no timing.
The mechanical supply pump controlled by the high pressure
pump shaft is mounted 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 and pressure regulator.
Figure 8
72595
1. Connection between fuel outlet and rail - 2. High pressure pump - 3. Pressure regulator - 4. Drive gear 5. Filter fuel inlet
union - 6. Connection between fuel outlet and filter bracket - 7. Connection for fuel inlet from heat exchanger ECU 8. Connection between fuel outlet from mechanical pump and filter 9. Mechanical supply pump.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
9
High pressure pump internal structure
Figure 9
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:
- a piston (5) actuated by a three-lobe element (2) floating
on the pump shaft (6). Since the element (2) is floating
on an offset section of the shaft (6), the element does
not rotate with the shaft during shaft rotation but is only
pushed towards one of the pistons (5) (distributed with
an interval of 120˚ on the entire crown wheel) thereby
actuating it
- cap intake valve (3);
- ball delivery valve (4).
Print P4D32N015 E
Base - May 2018
10
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
Operating principle
Figure 10
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 plunger is supplied through supply duct (5). The fuel
amount to be sent to the plunger is set by the pressure regulator (7). The pressure regulator meters fuel flow to plunger
according to
Base - May 2018
the flow of fuel to the pumping element. During plunger compression stage, fuel reaches the pressure required to open
the delivery valve to common rail (2) and to feed it through
outlet (1).
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
Figure 11
Sect. C - C
11
Figure 12
72598
72601
Sect. A - A
1. Plunger inlet - 2. Pump lubrication pipes - 3. Plunger
inlet - 4. Main plunger supply pipe - 5. Pressure regulator 6. Plunger inlet - 7. Regulator drainpipe - 8. Pressure limiting valve 5 bar - 9. Fuel discharge from regulator inlet.
1. Fuel outlet pipe - 2. Fuel outlet duct 3. Fuel outlet from the pump with connector
for the high-pressure pipe for the common rail.
Figure 11 shows the routes of the fuel at low pressure inside
the pump; it shows the main supply pipe 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).
Figure 12 shows high pressure fuel flow through plunger
outlet ducts.
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.
Print P4D32N015 E
Base - May 2018
12
SECTION 2 - OPERATING DIAGRAMS
Operation
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on
the plungers (about 2 bars).
NEF G-Drive SERIES
RAIL
Figure 13
The amount of fuel that supplies the high pressure pump is
metered by the pressure regulator, positioned on the low
pressure system; the pressure regulator is controlled by the
EDC 7 control unit through a PWM signal.
When fuel is sent to a plunger, the related piston is moving
downwards (suction stroke). When the piston stroke is
reversed, the intake valve closes and the remaining fuel in the
plunger chamber, not being able to come out, is compressed
above the supply pressure value existing in the rail.
108609
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure circuit.
1. Rail. - 2. Fuel inlet from the high-pressure pump. 3. Overpressure valve - 4-. Pressure sensor.
The plunger compresses the fuel till the top dead centre (delivery stroke) is reached. Afterwards, the pressure decreases
till the exhaust valve is closed.
The rail volume is of reduced sizes to allow a quick pressurisation at startup, at idle and in case of high flow-rates.
The plunger piston goes back towards the bottom dead centre and the remaining fuel is decompressed.
When the plunger chamber pressure becomes less than the
supply pressure, the intake valve is again opened and the
cycle is repeated.
The delivery valves must always be free in their movements,
free from impurities and oxidation.
The rail delivery pressure is modulated between 250 and
1,600 bar by the electronic control unit through the solenoid
valve of the pressure regulator.
It anyway has enough volume as to minimise pulsations caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a
calibrated hole being set downstream of the high-pressure
pump.
A fuel pressure sensor (4) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a feedback information, depending on which the rail pressure value
is checked and, if necessary, corrected.
The pump is lubricated and cooled by the fuel.
The radialjet pump removal - refitting time on the engine is
highly reduced in comparison with traditional injection
pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
OVERPRESSURE VALVE
Once the valve has been mounted at one rail end, the valve
task is to protect system components in the case where a
fault in either rail pressure sensor or pump pressure regulator
CP3 causes pressure excessive increment in high pressure
system.
When pressure reaches 1800 bars in the rail, initially valve
intervenes to drain fuel and therefore reduce pressure to safe
values, then it mechanically adjusts pressure in rail at approx.
800 bars.
This valve enables to have the engine operated for long time
with limited performance and inhibits fuel excessive overheating, so preserving the pipings returning from the tank.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
13
Beginning of injection
ELECTRO-INJECTOR
The injector features a traditional construction, save for the
fact that it has no needle return springs.
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.
Figure 15
Injector in resting position
Figure 14
15
15
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.
70505
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 duct - 11. Supply pipe 12. Control fuel outlet - 13. Power connection - 14. Spring 15. High pressure fuel inlet.
End of injection
When coil (4) is de-energised, shutter (6) goes back to its closing position, in order to re-create such a force balance as to
make plunger (2) go back to its closing position and end the
injection.
NOTE
Print P4D32N015 E
The electro-injector cannot be overhauled and
therefore it must not be disassembled.
Base - May 2018
14
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
LUBRICATION CIRCUIT
General information
The lubrication circuit includes components such as the heat exchanger, the turbocharger, for the turbocharger version, and
possibly a compressor for the compressed air system.
All these components often vary depending on use and are therefore dealt with in the specific part of the manual.
Figure 16
Oil inlet
Oil under pressure
Oil dropping
252565
1. Heat exchanger body - 2. Turbocharger lubrication delivery pipe - 3. Oil filter - 4. Heat exchanger - 5. Oil pump.
The forced circulation lubrication is carried out by the rotor
oil pump, housed in the front part of the crankcase and driven
by the straight-toothed gear keyed to the crankshaft tang.
The lubricant oil is conveyed from the sump to the camshaft
and to the valve control.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
15
LUBRICATION DIAGRAM
Figure 17
C
T
Oil inlet
Oil under pressure
Oil recirculation from heat exchanger
Oil dropping return
199385
1. Exhaust manifold - 2. Turbocharger shaft - 3. Oil filling cap - 4. Rocker arms - 5. Piston lubricating nozzles 6. Camshaft mounts - 7. Crankshaft main bearings - 8. Oil sump - 9. Oil drain plug - 10. Connecting rod caps 11. Oil pump - 12. Oil filter - 13. Heat exchanger
Print P4D32N015 E
Base - May 2018
16
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
LUBRICATION CIRCUIT COMPONENTS
Oil pump
Figure 18
119405
Rotation speed
Delivery pressure
Nominal flow
Type of oil
Max. oil temperature
PUMP CHARACTERISTICS
750 rpm - 4200 rpm
2 Bar - 4 Bar
14.6 l/min - 93.5 l/min
SAE 20/30
80 C
1. Primary gear - 2. Secondary gear - 3. Pump body - 4. Drive shaft - 5. Layshaft - 6. Cover - 7. Inner rotor 8. Outer rotor - 9. Bush.
Base - May 2018
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NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
17
Heat exchanger
Figure 19
201794
1. Gaskets - 2. Internal heat exchanger element (7 elements) - 3. Exchanger body - 4. Pressure regulator valve
The heat exchanger, installed in the engine cooling system, serves to regulate the temperature of the oil by dissipating heat via
coolant.
Performance according to GT 0179
Pressure range
Frequency
Trend
No. of cycles
Explosion pressure
0... 2.5 MPa
0.5 - 3 Hz
Sinusoidal
>500000
> 10 MPa
Pipes
Oil
Internal oil temperature
Capacity
5W30
115.6 ˚C
51 dm3/min
Skirt
Refrigerant
Internal coolant temperature
External flow rate
glycol
82.2 ˚C
230 dm3/min
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Base - May 2018
18
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
MAIN DATA OF THE SPRING OIL PRESSURE CONTROL
VALVE
Oil pressure regulating valve
Free length = 66 mm
Figure 20
Load of the open valve = 136.9 ± 10.5 N
Height of the open valve = 41.25 mm
Operating stress = 695.8 MPa
Constant spring stress = 945.3 MPa
Natural frequency = 320 Hz
Spring flexibility = 5.4 N/mm
201797
Figure 21
202102
1. Threaded plug - 2. Seal - 3 Compression spring 4. Valve body
Base - May 2018
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NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
19
Engine oil filter
Figure 22
201798
Explosion pressure:
Pulsing pressure:
C. Filtration
20 bar (ISO 4548/3)
0-15 bar (1Hz) > 50,000 cycles
Operating temperature:
Tightening torque:
Maximum flow:
Flow loss at end of life:
Accumulation capacity:
(ISO 4548/5)
-40 / +140 C
20 0/+5 Nm
100 l/mn
2.5 bar
>20 gr
with flow loss of 1.72 bar
(SAE J1858)
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Base - May 2018
20
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
Oil sump
Figure 23
252269
1. Suction strainer - 2. Gasket - 3. Fastening plate - 4. Exhaust valve - 5. Oil sump
The oil sump, mounted at the bottom the crankcase, has the purpose of containing the engine lubricant oil.
The oil is sucked by the pump, through which it is possible to lubricate the engine in its components.
Base - May 2018
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NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
21
Cooling nozzles
Figure 24
201796
1. Cooling nozzle - 2. Nozzle union
The cooling nozzles are designed to inject the lubricant oil
to the pistons.
The orientation and layout inside the crankcase allow them
to convey the lubricant directly in correspondence with the
crankpins.
The dropping oil is then recovered in the sump.
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Base - May 2018
22
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
OIL VAPOUR RECYCLING SYSTEM
General information
The oil vapour recirculation system, blow-by, allows the
recovery of some of the oil which has evaporated at the cylinder head as a result of the high temperature inside the engine.
It also allows this oil to then be conveyed once again into the
sump.
Figure 25
252270
1. Pre-separator - 2. Pipe to air filter - 3. Return to engine - 4. Return to filter 5. Delivery from filter to engine - 6. Oil vapour filter body
A. Oil condensate - B. Oil vapours
The tappet cover houses the pre-separator (1), whose shape
and position determines an increase in oil vapour outlet
speed and condenses a part of the vapours at the same time.
Condensate oil returns to the oil sump whereas the residual
vapours are ducted, collected and filtered in the blow-by (6).
Base - May 2018
In the blow-by (6), part of the vapours condense and return
to the oil sump while the remaining part is recirculated
through intake via the pipe (2).
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
23
OIL VAPOUR RECYCLING DIAGRAM
Figure 26
Oil dropping return
Oil + vapour
202369
1.Cylinder head control volume - 2. Pre-separator - 3. Flywheel cover and gear case control volume 4. Timing gears casing - 5. Flywheel casing - 6. Oil vapour filter control volume - 7. Oil vapour filter
Print P4D32N015 E
Base - May 2018
24
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
OIL VAPOUR RECIRCULATION SYSTEM COMPONENTS (BLOW-BY)
Blow-by filter
Figure 27
252271
1. Vapour breather pipes from engine - 2. Condensed oil return pipe to engine - 3. Oil vapour intake delivery pipe 4. Condensate oil delivery pipe to filter - 5. Condensate oil return pipe from filter - 6. Oil vapour filter body
On the left side of the engine there is a valve (3) which serves to condense the oil vapours conveyed from the crankcase via
the pipe (1), making them fall due to gravity through the pipe (2). Any vapours that fail to condense are conveyed through the
breather (4), such as during aspiration.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
25
COOLING CIRCUIT
General information
Figure 28
252272
The engine cooling system, of the closed-loop forced-circulation type, is composed of the following components:
- expansion tank: the position, shape and dimensions can
change depending on the engine outfitting;
The heat exchange between the lubricant oil and the coolant
(water) is aimed at maintaining the temperature within the
established and controlled limits and takes place inside the
heat exchanger.
- 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;
By means of a pump, the coolant is sucked out of the
expansion tank the position of which can vary depending on
the engine outfitting; the fluid moves into the radiator
through the conveyor and then into the flow regulator.
- viscostatic fan with the function of increasing the dissipating power of the radiator: this is also part of the specific
engine version;
The pump then sends the coolant to the heat exchanger
(where it transits in the skirt).
- a heat exchanger to cool the lubricant oil: this is also part
of the specific engine version;
When it leaves the exchanger, it is conveyed inside the
engine and then into the thermostat whose job it is to
regulate the coolant circulation. The coolant circuit ends
with the return back into the radiator.
- centrifugal water pump set in the front part of the engine
block;
- a thermostat to control coolant circulation;
- the circuit can also extend to the compressor if the construction provides for its presence.
Print P4D32N015 E
This last component has the task of dissipating the heat
withdrawn from the engine by the coolant. The dissipating
power of the radiator is increased by the viscous fan which
is present depending on the engine outfitting.
Base - May 2018
26
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
COOLING DIAGRAM
Figure 29
Coolant fluid
202104
1. Thermostat - 2. ”Engine” volume control - 3. Rocker arm assembly - 4. Pistons - 5. Heat exchanger 6. Water pump - 7. Flow conveyor - 8. Radiator
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 2 - OPERATING DIAGRAMS
27
COOLING CIRCUIT COMPONENTS
Water pump
Figure 30
120047
SECTION ON WATER PUMP
1. Hub - 2. Shaft with bearing - 3. Pump body - 4. Gasket - 5. Impeller
The water pump is of the vane centrifugal type. The pump
bearing (2) forms a single piece with the rotor shaft. Water
tightness between the pump body (3) and the shaft (2) is
obtained by means of a gasket (4).
Thermostat
THERMOSTAT DIAGRAM
Operation
When the engine is cold, water comes out of the front part
of the cylinder head and enters a filler where the thermostat
is located that excludes water circulation into the radiator.
This way the water circulation occurs between the pump and
engine, thus allowing it to heat quickly.
The thermostat valve commences opening at about 80 ˚C,
allowing for circulation of water through the radiator and
simultaneously obstructing direct return to the engine.
Figure 31
Check that the thermostat works properly, replace it if there
is any doubt.
1.
Start stroke at approximately 79˚ ± 2 ˚C
2.
Stroke of 7.5 mm at 96 ˚C
119412
Print P4D32N015 E
Base - May 2018
28
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
Heat exchanger
Figure 32
201794
1. Gaskets - 2. Internal heat exchanger element (7 elements) - 3. Exchanger body - 4. Pressure regulator valve
The heat exchanger, installed in the engine cooling system, serves to regulate the temperature of the oil by dissipating heat via
coolant.
Performance according to GT 0179
Pressure range
Frequency
Trend
No. of cycles
Explosion pressure
0... 2.5 MPa
0.5 - 3 Hz
Sinusoidal
>500000
> 10 MPa
Pipes
Oil
Internal oil temperature
Capacity
5W30
115.6 ˚C
51 dm3/min
Skirt
Refrigerant
Internal coolant temperature
External flow rate
glycol
82.2 ˚C
230 dm3/min
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
29
SECTION 2 - OPERATING DIAGRAMS
INTAKE AND EXHAUST SYSTEM
General information
The intake and exhaust system consists of the following components:
- Intake and exhaust manifolds;
- Turbocharger with WG valve;
Figure 33
252273
1. Air inlet to compressor - 2. Exhaust manifold - 3. Intake manifold - 4. Exhaust gas inlet in turbine - 5. Air outlet from
compressor - 6. Exhaust gas outlet in turbine
A. Intake air - B. Non-cooled compressed air - C. Intercooled compressed air - D. Exhaust gas
This system allows you to manage the flow of combustion
air through the components listed above.
The combustion air is sucked by the compressor of the turbocharger, within which its pressure is increased, to then be
fed through the intake manifold in the cylinder liners. The
exhaust gas flows out of the cylinder liners towards the
exhaust manifold.
Print P4D32N015 E
Finally the exhaust gas flow is conveyed towards the turbine.
During the intake phase the exhaust valve is partially opened
with the subsequent reintroduction of some of the exhaust
gas into the engine cylinders.
Base - May 2018
30
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
INTAKE AND EXHAUST DIAGRAM
Figure 34
252274
1. Exhaust - 2. Exhaust manifold - 3. Intake manifold - 4. Intercooler - 5. Air filter
A. Intake air - B. Non-cooled compressed air - C. Intercooled compressed air - D. Exhaust gas
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
31
SECTION 2 - OPERATING DIAGRAMS
INTAKE AND EXHAUST SYSTEM COMPONENTS
Intake manifolds
The intake manifold receives cooled compressed air from the intercooler and conveys it to the cylinder chambers.
Figure 35
214274
Intake manifolds
Exhaust manifolds
The exhaust manifold however conveys the combusted gas from the cylinder chambers to the turbine.
Its internal structure allows the six flows from the chambers to come together in two distinct flows conveyed to the turbine
impeller.
Figure 36
214276
Exhaust manifolds
Print P4D32N015 E
Base - May 2018
32
SECTION 2 - OPERATING DIAGRAMS
NEF G-Drive SERIES
HOLSET HX35W turbocharger
Figure 37
75532
A. WG VALVE CLOSED
Figure 38
A. WG VALVE OPEN
(Demonstrative)
75533
Description
The turbocharger consists of the following main parts, a turbine, a valve for regulating the boost pressure, a central body
and a compressor.
During operation of the engine exhaust gases pass through
the body of the turbine by rotating the impeller of the turbine
itself.
Since the compressor impeller is connected to the turbine
impeller by means of a shaft, it turns with the turbine impeller
compressing the air taken in through the air filter.
Base - May 2018
This is cooled by the radiator and sent through the intake
manifold to the pistons.
The turbocharger is equipped with a pressure control valve
fitted on the exhaust manifold before the turbine and connected by a pipe to the intake manifold.
Its function is to choke the exhaust gas outlet, conveying a
portion of it straight into the exhaust pipe when the turbocharging pressure downstream from the compressor reaches the set value.
Cooling and lubrication of the turbocharger and the bearing
brass is performed by means of the engine oil.
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
1
SECTION 3
Electric / electronic equipment
Page
Print P4D32N015 E
GENERAL INFORMATION LOCATION
OF ELECTRICAL COMPONENTS
ON THE ENGINE . . . . . . . . . . . . . . . . . . . . .
3
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
- EDC17CV41 electronic control unit . . . . . . . .
4
EDC SYSTEM OPERATION . . . . . . . . . . . . . . . .
4
- Fuel dosing . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Correcting flow rate according to water
temperature . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Closed loop injection pressure management .
5
- Starting the engine . . . . . . . . . . . . . . . . . . . . .
5
- Cylinder Balancing . . . . . . . . . . . . . . . . . . . . . .
6
- Synchronisation Search . . . . . . . . . . . . . . . . . .
6
ENGINE SIDE WIRING . . . . . . . . . . . . . . . . . . .
7
- Engine side wiring diagram - slide 1 . . . . . . . . .
7
ENGINE SIDE WIRING . . . . . . . . . . . . . . . . . . .
8
- Engine side wiring diagram - slide 2 . . . . . . . . .
8
PIN OUT CONNECTOR A (96 PIN) CONTROL UNIT 17 CV41 . . . . . . . . . . . . . .
9
- Cable on engine . . . . . . . . . . . . . . . . . . . . . . .
10
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . .
11
- Fuel pressure sensor . . . . . . . . . . . . . . . . . . . .
12
- Turbocharged air pressure-temperature sensor
12
- Starter motor . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . .
14
- High pressure pump - pressure regulator . . . .
15
- Fuel temperature sensor . . . . . . . . . . . . . . . . .
16
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . .
17
Base - May 2018
2
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
Page
- Engine oil pressure sensor . . . . . . . . . . . . . . .
17
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
- Characteristic curve . . . . . . . . . . . . . . . . . . . .
18
- Pre/post heating contactor and resistor . . . . .
19
- Coolant temperature sensor . . . . . . . . . . . . .
20
INTERFACE HOUSING . . . . . . . . . . . . . . . . . . . .
21
INTERFACE HOUSING . . . . . . . . . . . . . . . . . . . .
22
CONNECTOR J1 . . . . . . . . . . . . . . . . . . . . . . . . .
23
INTERFACE HOUSING . . . . . . . . . . . . . . . . . . . .
25
Base - May 2018
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NEF G-Drive SERIES
3
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
GENERAL INFORMATION LOCATION OF ELECTRICAL COMPONENTS ON THE ENGINE
Figure 1
252275
The NEF F4HF engines are fully controlled by the electronic
control unit. This is mounted directly onto the engine via a heat
exchanger that allows it to cool, using rubber blocks that
decrease vibrations transmitted to the engine.
The ECU allows checking of correct engine operation..
Below is a list of the electric and electronic components on the
engine:
1.
2.
3.
4.
Electro/injector.
Interconnection control unit.
Rail pressure sensor.
Air pressure/temperature sensor.
Print P4D32N015 E
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Starter motor
Timing sensor.
Solenoid valve for pressure regulator.
Fuel temperature sensor.
EDC electronic control unit.
Crankshaft sensor.
Engine oil temperature/pressure sensor.
Alternator.
Pre/post heating resistor.
Coolant temperature sensor.
Base - May 2018
4
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
ECU
EDC SYSTEM OPERATION
EDC17CV41 electronic control unit
The electronic control unit EDC17 CV41 manages the following main functions:
The control unit is a ”flash EPROM” and therefore it can be
reprogrammed externally without needing to act on the
hardware.
- Fuel injection
The ECU processes the signals from the sensors by applying
software algorithms and controls the actuators (especially the
electro-injectors and pressure regulator).
- Recovery
It records, in the non-volatile memory area, the information
on the engine parameters originally set or acquired during
engine operation.
- Self-diagnostics
Also permits:
- Interfacing with other on-board electronic systems
(where present)
- Diagnostics
The control unit is fitted on the left-hand side of the engine and
is connected to two connectors:
1.
one connector for the engine cable
(sensors and electro-injector connector);
2.
one connector for the chassis cable.
To reduce the number of connections, the length of the
connection cables with the injectors and, as a result,
disturbances in the transmitted signal, the control unit is
mounted directly on the engine by means of a heat exchanger
that cools it, using elastic dowels which reduce the vibrations
transmitted by the engine.
Location of EDC 17 control unit connectors
Figure 2
Internally, there is an ambient pressure sensor that is used to
further improve injection system management.
Furthermore, it is also equipped with an extremely advanced
self-diagnostics system and, depending on the environmental
conditions, it is able to recognize and store possible faults, even
if intermittent, which have occurred on the system during
equipment operation, ensuring a more correct and reliable
repair action with the help of the FPT diagnostic instruments.
227159
1. Engine cable connector 2. Chassis side cable connector
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
5
Fuel dosing
Closed loop injection pressure management
The fuel metering is calculated in relation to:
According to engine load that is determined by the processing
of signals coming from different sensors, the ECU governs the
pressure regulator so as to always provide the best possible
pressure (TARGET PRESSURE). The control unit controls the
result (INJECTION PRESSURE) thanks to the sensor on the
common rail.
- engine speed;
- the amount of air introduced.
The outcome may be corrected in relation to:
- water temperature;
- fuel temperature (DIESEL DENSITY).
Or to avoid:
- overloading;
- overheating;
- turbine over-revving.
The delivery can be modified in the case of:
- a limiting device cutting in (ASR, speed limiter, etc.)
(signals via CAN);
- serious trouble decreasing the load or stopping the
engine.
Starting the engine
During the first few turns of the engine, the timing and cylinder
no. 1 recognition signals (flywheel sensor and camshaft sensor)
are synchronised.
The fuel feed for starting the engine is based on just the water
temperature using specific engine mapping.
NOTE
This procedure should never be interrupted, for
instance by switching off the engine with the battery
isolator or disconnecting the battery isolator before
at least 10 seconds have passed after the engine is
switched off.
Once the control unit has determined the mass of the
introduced air and measured its pressure and temperature, it
calculates the corresponding fuel load needed to inject into
the cylinder (mg. per delivery). It also takes diesel temperature
into account (density).
The fuel load calculated in this way is converted into crank
degrees i.e. injection advance and duration.
Correcting flow rate according to water
temperature
When it is cold, the engine encounters greater resistance to
its action: the mechanical friction is high, the oil is still very
viscous, the various clearances are not yet optimum.
In addition to this, injected fuel tends to condense on the still
cold metallic surfaces.
The fuel supply for a cold engine is therefore greater than for
a warm one.
De-rating
In the event of the engine overheating, injection is modified,
decreasing the delivery to a varying degree, in proportion to
the temperature reached by the coolant.
The ECU uses the oil temperature reading in the event of a
coolant temperature sensor failure.
Print P4D32N015 E
Base - May 2018
6
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
Cylinder Balancing
This function permits individual, customised control over the
delivery of fuel and the start of delivery for each cylinder, which
can even differ from one cylinder to another, to compensate
for the hydraulic tolerances of the injector.
The difference in fuel feed to each cylinder is not signalled by
the ECU but by an FPT instrument.
Synchronisation Search
If the camshaft sensor signal fails, the control unit can still
recognise the cylinders into which fuel is to be injected.
If this takes place when the engine is already running, the fuel
flow is already acquired as a result of which the ECU continues
with the sequence already synchronized.
If this occurs when the engine is off, the ECU energises a single
solenoid valve. Within a maximum of 2 revolutions of the
crankshaft, injection will take place in that cylinder, so the ECU
simply needs to synchronise with the firing sequence and to
start up the engine.
Engine side pin out
Figure 3
189005
Colour key
C Orange
A Light blue
B White
L Blue
G Yellow
Base - May 2018
H Grey
M Brown
N Black
W
Hazelnut
brown
S Pink
R Red
V Green
Z Violet
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
7
ENGINE SIDE WIRING
Engine side wiring diagram - slide 1
Figure 4
259606
A. EDC connector (engine side)
1. Timing sensor - 2. Crankshaft rpm sensor - 3. Pressure regulator on the high pressure fuel pump 4. Rail pressure sensor - 5. Electro-injectors for cylinders 5-6 - 6. Electro-injectors for cylinders 3-4 7. Electro-injectors for cylinders 1-2
Print P4D32N015 E
Base - May 2018
8
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
ENGINE SIDE WIRING
Engine side wiring diagram - slide 2
Figure 5
259607
A. EDC connector (engine side)
1. Air temperature and pressure sensor - 2. Oil high pressure and temperature sensor - 3. Coolant temperature
sensor - 4. Fuel temperature sensor
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
9
PIN OUT CONNECTOR A (96 PIN) - CONTROL UNIT 17 CV41
ECU
PIN
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20
A21
A22
A23
A24
A25
A26
A27
A28
A29
A30
A31
A32
A33
A34
A35
A36
A37
A38
A39
A40
A41
A42
A43
A44
A45
A46
A47
A48
FUNCTION
Cylinder 5 injector
Cylinder 6 injector
Cylinder 4 injector
Oil pressure and temperature sensor ground
Air pressure temperature sensor supply
Pressure on rail sensor power supply
Fuel temperature sensor signal
Oil pressure and temperature sensor temperature
signal
Cylinder 5 injector
Cylinder 6 injector
Cylinder 4 injector
Oil pressure and temperature sensor power
supply (5V)
Oil pressure and temperature sensor pressure
signal
Rail pressure sensor signal
Air pressure temperature sensor signal
Coolant temperature sensor signal
-
Print P4D32N015 E
ECU
PIN
A49
A50
A51
A52
A53
A54
A55
A56
A57
A58
A59
A60
A61
A62
A63
A64
A65
A66
A67
A68
A69
A70
A71
A72
A73
A74
A75
A76
A77
A78
A79
A80
A81
A82
A83
A84
A85
A86
A87
A88
A89
A90
A91
A92
A93
A94
A95
A96
FUNCTION
Cylinder 1 injector
Cylinder 3 injector
Cylinder 2 injector
Pressure regulator on the high pressure fuel pump
Common ground (fuel temperature sensor,
coolant temperature sensor)
Rail pressure sensor ground
Crankshaft sensor signal (-) (rpm)
Crankshaft sensor signal (+) (rpm)
Camshaft sensor signal (+) (rpm)
Camshaft sensor signal (-) (rpm)
Common ground
Cylinder 1 injector
Cylinder 3 injector
Cylinder 2 injector
Pressure regulator on the high pressure fuel pump
Air pressure temperature sensor signal
Air temperature and pressure sensor ground
-
Base - May 2018
1. Water temperature sensor - 2. Oil press/temperature sensor - 3. Crankshaft rpm sensor - 4. Electro-injectors cylinders 1 - 2 5. Electro-injectors cylinders 3 - 4 - 6. Electro-injectors for cylinders 5 - 6 - 7. Air temperature-pressure sensor - 8. Rail pressure sensor 9. Pump pressure adjustment sensor - 10. Fuel temperature sensor - 11. Timing sensor - 12. EDC control unit 113. ECU
10
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
Base - May 2018
NEF G-Drive SERIES
Cable on engine
Figure 6
259608
Print P4D32N015 E
NEF G-Drive SERIES
11
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
Electro-injectors
This is an N.O. solenoid valve.
Individually, they are connected to the EDC control unit.
The resistance of the coil of each individual injector is 0.56  0.57 .
Ref.
Description
CONNECTOR 1
1
2
3
4
Cylinder 2 injector
Cylinder 2 injector
Cylinder 1 injector
Cylinder 1 injector
Control unit pin
51A
75A
73A
49A
CONNECTOR 2
1
2
3
4
Cylinder 4 injector
Cylinder 4 injector
Cylinder 3 injector
Cylinder 3 injector
3A
27A
74A
50A
CONNECTOR 3
1
2
3
4
Cylinder 6 injector
Cylinder 6 injector
Cylinder 5 injector
Cylinder 5 injector
2A
26A
25A
1A
Figure 7
50343
Figure 8
50349
Print P4D32N015 E
Base - May 2018
12
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
Fuel pressure sensor
Assembled on one end of the rail, measures the existing fuel pressure and informs the control unit (feed - back).
The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection
electronic command.
It is connected to the control unit on pins 11A - 36A - 60A
It is powered at 5 Volt.
Figure 9
0051065t
Fuel pressure sensor connector
Ref.
1
2
3
Description
Ground
Signal
Power supply
Control unit pin
60A
36A
11A
Turbocharged air pressure-temperature sensor
This component incorporates a temperature sensor and a pressure sensor.
It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the
exact amount of fuel to be injected at each cycle.
It is connected to the control unit at pins 7A - 37A - 90A - 86A.
It is powered at 5 V
The voltage at the outlet is proportional to the pressure and temperature detected by the sensor.
Pin 7A - 37A
Pin 90A - 86A
Ref.
1
2
3
4
Base - May 2018
Temperature
Pressure
Description
Ground
NTC signal (temperature)
Power supply +5V
Signal (pressure)
Control unit pin
90A
37A
07A
86A
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
13
Wiring Diagram
Starter motor
Isometric view
165897
Technical view
165899
EW: PULL-IN WINDING
HW: HOLD-ON WINDING
Characteristics
Supplier: BOSCH
technical data
Rated voltage
Power
24 V
4 kW
Rotation: RIGHT
Tightening torques
Tightening torque
M10 nut (terminal 30)
M6 nut (terminal 50)
24 ±4 Nm
2.4 Nm to 3 Nm
215012
50. Terminal 50
30. Terminal 30
Print P4D32N015 E
Base - May 2018
14
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
Timing sensor
This inductive type sensor is located on the rear left part of the engine. It generates signals obtained from magnetic flux lines which
close through the holes
situated in gears keyed to the camshaft. The signal generated by this sensor is used by the control unit as the injection timing signal.
Although similar to the flywheel sensor, they are NOT interchangeable since it has a different outer shape.
It is connected to the control unit at pins 67A - 68A. The sensor’s resistance value is 900 .
Figure 10
50320
Timing sensor
3
2
1
50342
Connector connection
Ref.
1
2
3
Base - May 2018
Description
Signal
Signal
Shielding
50288
Wiring Diagram
Control unit pin
67A
68A
69A
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
15
High pressure pump - pressure regulator
Figure 11
000912t
A. Pressure regulator
The quantity of fuel that powers the high pressure pump is dosed by the pressure regulator on the low pressure system; The pressure regulator is controlled by the EDC 17 control unit.
The delivery pressure to the rail is regulated between 250 and 1450 bar by the electronic control unit acting on the pressure regulator solenoid valve.
- It is a N.O. solenoid valve.
- It is connected to the control unit at pins 58A - 83A.
- Its resistance is approximately 3.2 .
Print P4D32N015 E
Base - May 2018
16
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
Fuel temperature sensor
This sensor is identical to the previous one.
It detects the temperature of the fuel to give the control unit information about the fuel temperature conditions.
It is connected to the control unit at pins 12A - 59A.
Its resistance at 20 C is about 2.50 .
Figure 12
135233
1. Fuel temperature sensor - 2. Filter heating resistance.
The ECU controls the control contactor to heat the filter to the fuel temperature 5C.
107799
107798
Connector
Ref.
1
2
Base - May 2018
Description
Ground
Temperature signal
Control unit pin
12A
59A
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
17
Crankshaft sensor
This inductive sensor is located on the left front of the engine. It generates signals obtained from changes in magnetic flux created
by spaces between the teeth on the phonic wheel fitted to the crankshaft.
It is connected to the control unit at pins 65A - 66A. The sensor’s resistance value is 900 .
Figure 13
50319
Crankshaft sensor
Ref.
1
2
3
Description
Signal
Signal
Shielding
Control unit Pin
65A
66A
69A
Engine oil pressure sensor
This component is identical to the air temperature/pressure sensor.
It measures the temperature and pressure of the engine oil.
It measures the engine oil temperature and pressure.
It is connected to the control unit at pins 6A - 13A - 31A - 35A.
It runs on 5 Volts. The signal detected is transmitted to the EDC Control Unit, which itself controls the indicator on the instrument
panel (low pressure warning light and indicator).
The oil temperature is not shown by any of the instruments- it can only be used by the Control Unit.
Pin 6A - 13A
Pin 31A - 35A
Temperature
Pressure
Figure 14
50344
50324
Wiring Diagram
Ref.
1
2
3
4
Print P4D32N015 E
Description
Ground
NTC signal (temperature)
Power supply +5 V
Signal (pressure)
Control unit pin
6A
13A
31A
35A
Base - May 2018
18
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
Alternator
Characteristic curve
Figure 16
Figure 15
75725
It is located at the front on the right-hand side of the engine
and is controlled by the toothed belt.
Characteristics:
Working voltage:
28 V
Current strength:
70A (at 6000 rpm)
Absorption in stand-by:
1mA
Direction of rotation:
Clockwise
Storage temperature:
-40˚C/110˚C
Operating temperature:
-40˚C/100˚C
252564
Current at ambient temperature [+25˚C]:
IL1
Current at ambient temperature [+80˚C]:
IL2
Power curve
P1
Efficiency:
ETA
Figure 17
252563
ELECTRICAL SYSTEM
Base - May 2018
ALTERNATOR
REGULATOR
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
19
Pre/post heating contactor and resistor
This element is located on the intake manifold.
It is utilised to heat the air in the operations of pre / post heating. It is powered via contactor.
Its resistance is approximately 0.5 .
Figure 18
B
A
108909
A. - B. Connecting terminals
Figure 19
002371t
A. Control contactor
The control contactor is connected to the control unit connector B
The control takes place with water and/or fuel temperature below 5 C.
The resistance of the contactor is approximately 15 .
Do not use fluids or flammable gas to facilitate engine ignition.
If these substances were to come into contact with the heating element, they could easily ignite creating situations of
serious risk.
Print P4D32N015 E
Base - May 2018
20
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
Coolant temperature sensor
This is a variable resistance sensor that is able to measure coolant temperature and transmit a signal to the control unit reflecting
the thermal conditions of the engine.
The same signal is used by the control unit to manage the temperature gauge on the dashboard.
It is connected to the control unit at pins 39A - 59A.
Its resistance at 20 C is approximately 2.50 .
Figure 20
107471
Ref.
1
2
Base - May 2018
Description
Ground
NTC signal (temperature)
Control unit pin
39A
59A
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
21
<
INTERFACE HOUSING
Diagram
Figure 21
259610
A. Engine cable - B. Wiring from interface housing to Engine control unit C. Cable from interface housing to starter motor
1. Engine - 2. EDC17 CV41 electronic control unit (left side of engine) - 3. Starter motor - 4. Interface housing
Print P4D32N015 E
Base - May 2018
22
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
<
INTERFACE HOUSING
Figure 22
258618
1. Connector J1 - 2. Diagnostic connector
Base - May 2018
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
23
<
CONNECTOR J1
Diagram
Figure 23
258622
Pin-out
ECU pin
1
2
3
4
5
6
7
Print P4D32N015 E
Name
Starter motor J1 - 1
Heater PRFC J1 - 2
Negative J1 - 3
Starter motor (Positive) J1 - 4
Heater RFC J1 - 5
Node V1 J1 - 7
Notes
Not connected
Base - May 2018
24
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
<
Diagnostic connector
Figure 24
256112
Base - May 2018
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
25
<
INTERFACE HOUSING
Figure 25
258623
1. Connector J2
To permit the correct electric operation of the control unit, a connection unit has been installed in the engine. The connection unit
controls the electronic control system of the engine and the power unit system. Indications of its components and functions are
provided below. These are controlled by the programming switches.
Print P4D32N015 E
Base - May 2018
26
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
<
Figure 26
258624
JP1
Engine speed 1800 rpm (60 Hz)
JP1
Engine speed 1500 rpm (50 Hz)
JP2
Diagnostics position
JP2
Operating position
(predefined setting)
JP3
Cold starting lamp connected
JP3
Cold starting lamp not connected
(predefined setting)
JP4
Cold starting heater relay connected
JP4
Cold starting heater relay not connected
(predefined setting)
JP5
CAN line connected
JP5
CAN line not connected
(predefined setting)
Reserved
(do not use)
Reserved
(do not use)
JP6
JP8
Fuse
F5 =
40A
F3 =
30A
F4 =
20A
F6 =
20A
F10 =
10A
F8 =
15A
F11 =
10A
F7 =
5A
F9 =
15A
Base - May 2018
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
27
Figure 27
259609
A. Connector J1 - B. Connector J2 - C. ECU connector - D. Engine interface housing
1. Low water level sender - 2. Alternator (positive) - 3. Alternator (battery charge) - 4. Battery poles (+/-) 5. Sender for water in fuel - 6. Water heater thermostat - 7. Starter motor (Start-up) - 8. Starter motor (Positive) 9. Starter motor (Negative) - 10. Fuel filter heater - 11. Fuel pre-filter heater - 12. Low oil pressure sender alarm signal 13. Oil pressure sender - 14. Water temperature sender - 15. High water temperature sender - 16. Alarm contact terminal
for water high temperature sender - 17. Sender for low fuel level / fuel depleted
Print P4D32N015 E
Base - May 2018
28
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
NEF G-Drive SERIES
<
Topographic diagram - Connector J1
Figure 28
258625
B. ECU Connector (female)
B+. Battery positive - +30. Starter motor (Positive) -31. Starter motor (Negative) - 50 STARTER. Starter motor +BATT. Battery positive - -BATT. Battery negative - PRFC. Fuel pre-filter heater - RFC. Fuel filter heater.
Pin-out connector J1
Pin
1
2
3
4
5
Name
Starter motor
Fuel pre-filter heater (pin 1)
Battery negative
Battery positive
Fuel filter
heater
6
-
7
Pin 01
(Connector EDC ’B’)
Base - May 2018
Notes
Not
connected
Battery
positive (+30)
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
29
<
Topographic diagram - Connector J2
Figure 29
256820
B. ECU Connector (female)
TBLA. Low water level sender - B+. Alternator - GG. Alternator - TS. Water heater thermostat TATA-WK. High water temperature sender (alarm contact terminal) - TATA. Water high temperature sender TTA. Water temperature sender - +30. Starter motor (Positive) - -31. Starter motor (Negative) - +BATT. Battery positive -BATT. Battery negative - TCE TBLC. Fuel depleted / low fuel level sender - TPO-G. Oil pressure sender TBPO-WK. Low oil pressure sender (alarm signal) - TPAC. Sender for water in fuel.
Print P4D32N015 E
Base - May 2018
30
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
Pin-out connector J2
Pin
Name
1
Sender for water in fuel (pin 3)
2
3
Oil pressure sender
4
Water temperature sender
5
Water high temperature sender
6
Sender for low fuel level / fuel depleted
7
Sender for low fuel level / fuel depleted
8
9
Battery positive
10
Battery positive
11
12
13
Pin 71 (Connector EDC ’B’)
14
Pin 95 (Connector EDC ’B’)
15
Pin 20 (Connector EDC ’B’)
16
Pin 45 (Connector EDC ’B’)
17
Low water level sender (pin pos.)
18
Low water level sender (pin S)
19
20
Alternator (connector GG pin 2)
21
Alternator (connector GG pin 1)
Pin 51 (Connector EDC ’B’)
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
Base - May 2018
NEF G-Drive SERIES
Notes
Not connected
Not connected
Not connected
Not connected
H CAN line
L CAN line
Not connected
Not connected
Not connected
Ground for diagnostics LED1
(on engine interface board)
Positive for diagnostics LED1
(on engine interface board)
Pin 77 (Connector EDC ’B’)
Pin 41 (Connector EDC ’B’)
Pin 70 (Connector EDC ’B’)
Pin 27 (Connector EDC ’B’)
Oil pressure sender
Thermostat water heater (pin 1)
Thermostat water heater (pin 2)
Pin 63 (Connector EDC ’B’)
Battery positive
Pin 61 (Connector EDC ’B’)
Pin 19 (Connector EDC ’B’)
Pin 88 (Connector EDC ’B’)
Pin 06 (Connector EDC ’B’)
Pin 74 (Connector EDC ’B’)
Pin 83 (Connector EDC ’B’)
Pin 74 (Connector EDC ’B’)
Pin 43 (Connector EDC ’B’)
Pin 34 (Connector EDC ’B’)
Pin 47 (Connector EDC ’B’)
Pin 46 (Connector EDC ’B’)
Function
Not connected
Multistate switch (1500/1800 rpm)
Not connected
Interface ISO-K
Not connected
Not connected
Battery positive
Positive from key switch
Not connected
Not connected
Not connected
Not connected
Fuel Heater coil control (Negative)
Starter relay coil positive
Starter relay coil negative
Not connected
Not connected
Not connected
Cold starting LED signal (Negative)
Not connected
Battery positive
Signal (Negative) for Grid heater relay excitation
Battery positive
Not connected
Not connected
Rail pressure sensor ground
Engine speed sensor output signal
L CAN line
H CAN line
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
31
<
Interface connector for control panel (dedicated to bodybuilders)
The interface connectors pre-installed with the necessary signals at the vehicle control panel assembly, dedicated to the
manufacturer of the generator set are J9, J7 and J3.
The signals indicated in the tables below are available on these connectors.
Figure 30
259595
1. Connector J3 - 2. Connector J7 - 3. Connector J9
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Base - May 2018
32
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
Pin-out connector J3
NEF G-Drive SERIES
Pin-out connector J9
Pin
Function
2
Coolant temperature sensor (OUTPUT)
3
Low engine oil pressure sensor
(OUTPUT)
Pin
Function
1
Positive signal for activation of cold start
indicator light (preheating active)
2
Return signal for activation of cold starting
indicator light (preheating active)
4
Engine oil pressure sensor (OUTPUT)
6
Ignition key-activated positive (K50-INPUT)
3
Signal for preheating relay coil
(Grid heater)
7
Signal from alternator
(for battery charge indicator light)
4
Signal for preheating relay coil
(Grid heater)
8
Low engine coolant level
(OUPUT)
9
Key-activated positive (K15-IN)
Pin-out connector J7
Pin
Function
1
High coolant temperature signal (OUTPUT)
2
L CAN line
3
Battery positive from key switch
5
H CAN line
6
Thermostatic switch for pre-heating (OUTPUT)
7
Low fuel level signal (OUTPUT)
8
Signal for fuel leak from tank (OUTPUT)
Base - May 2018
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NEF G-Drive SERIES
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
33
Pin-out control unit EDC 17 CV41
Pin-out connector ”B” (female)
Pin
EDC
B01
B02
B03
B04
B05
B06
B07
B08
B09
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20
B21
B22
B23
B24
B25
B26
B27
B28
B29
B30
B31
B32
B33
B34
B35
B36
B37
B38
B39
B40
B41
B42
B43
B44
B45
B46
B47
B48
B49
B50
B51
B52
B53
B54
B55
Print P4D32N015 E
Name
Pin 07 (connector J1)
Starter motor (Negative)
Starter motor (Negative)
Pin 46 (connector J2)
Sender for water in fuel (pin 1)
Pin 41 (connector J2)
Pin 15 (connector J2)
Pin 07 (connector J1)
Pin 07 (connector J1)
Pin 30 (connector J2)
Starter motor (Negative)
Starter motor (Negative)
Pin 54 (connector J2)
Pin 25 (connector J2)
Pin 53 (connector J2)
Pin 16 (connector J2)
Pin 56 (connector J2)
Pin 55 (connector J2)
Pin 07 (connector J1)
Pin 22 (connector J2)
Starter motor (Negative)
-
Notes
Function
Battery positive
Not connected
Not connected
Cold starting LED signal (Negative)
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Starter relay coil positive
Not connected
Not connected
Not connected
Not connected
Not connected
Battery positive
Battery positive
Battery positive
Not connected
Not connected
Not connected
Not connected
Engine speed sensor output signal
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Multistate switch (1500/1800 rpm)
Not connected
Rail pressure sensor ground
Not connected
Not connected
H CAN line
L CAN line
Not connected
Battery positive
Not connected
LED1 ground
Not connected
Not connected
Not connected
Base - May 2018
34
SECTION 3 - ELECTRIC / ELECTRONIC EQUIPMENT
Pin
EDC
B56
B57
B58
B59
B60
B61
B62
B63
B64
B65
B66
B67
B68
B69
B70
B71
B72
B73
B74
B75
B76
B77
B78
B79
B80
B81
B82
B83
B84
B85
B86
B87
B88
B89
B90
B91
B92
B93
B94
B95
B96
Base - May 2018
NEF G-Drive SERIES
Name
Notes
Pin 40 (connector J2)
Pin 34 (connector J2)
Sender for water in fuel (pin 3)
Pin 27 (connector J2)
Pin 13 (connector J2)
Pin 07 (connector J1)
Pin 48 (connector J2)
Starter motor (Negative)
Starter motor (Negative)
Pin 23 (connector J2)
Pin 49 (connector J2)
Not connected
Not connected
Not connected
Not connected
Not connected
Pin 42 (connector J2)
Pin 14 (connector J2)
-
Not connected
Not connected
Not connected
Not connected
Function
Fuel Heater coil control (Negative)
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
Interface ISO-K
H CAN line
Not connected
Battery positive
Battery positive
Positive LED1
Not connected
Not connected
Not connected
Not connected
Not connected
Signal (Negative) for Grid heater relay
excitation
Starter relay coil negative
Not connected
Not connected
Not connected
Not connected
Not connected
Not connected
L CAN line
Not connected
Print P4D32N015 E
SECTION 4 - DIAGNOSTICS
NEF G-Drive SERIES
1
SECTION 4
Diagnostics
Page
Print P4D32N015 E
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . .
3
PT-BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Base - May 2018
2
SECTION 4 - DIAGNOSTICS
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 4 - DIAGNOSTICS
3
INTRODUCTION
Figure 1
254121
JP2
Mode selection
Diagnostic position
Operating position
(prearranged)
Bring the JP microswitch to the Diagnostics position when
diagnostics is carried out using the designated tool
Print P4D32N015 E
Base - May 2018
4
SECTION 4 - DIAGNOSTICS
NEF G-Drive SERIES
Figure 2
248928
A
B
C
D
PT-BOX
Interface housing
Cable 32 - 30-pins PT-BOX
30-19 pin adapter cable
Base - May 2018
E
F
G
H
56-pin cable
7-way cable
EDC 17CV41 control unit
Batteries
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 4 - DIAGNOSTICS
5
Good diagnostic skills are achieved from the expertise acquired from years of experience and from attending training courses.
When poor performance or operating faults arise, the user’s description of the problem should be considered, as it may provide
us with useful diagnostic information.
With the use of computerized FPT instruments, it is also possible to establish two-way communication with the control unit
which, not only provides error code analysis, but also a memory scan in order to obtain any further information required to
trace the origin of the fault.
Each time a problem arises and is confirmed, the electronic control unit should be consulted using one of the methods indicated.The diagnostic investigation can then be carried out using the available evidence and measurements, in order to obtain an
overview of the operating conditions, after which the actual cause of the fault can be determined.
If the electronic control unit fails to provide any indications, you should proceed by calling on your experience of traditional
diagnostic methods.
NOTE
Any type of intervention on the ECU must be carried out by specialized personnel and duly authorized by FPT.
Any unauthorized tampering will invalidate the assistance warranty.
Print P4D32N015 E
Base - May 2018
6
SECTION 4 - DIAGNOSTICS
NEF G-Drive SERIES
PT-BOX
Figure 3
248927
A
B
C
PT-BOX
32-pin connector from PT-BOX to Interface housing
Connector USB (and analog) from PT-BOX to Computer
1
2
3.
4
5
Data transfer indicator lights (flashing)
Activation indicator light
Operating indicator light
UBS indicator light
Serial port indicator light
6.
7
8
”Error” indicator light
CAN line indicator lights
Automatically manageable K line indicator lights
The PT-BOX can be used to do the following:
- Basic diagnostics: reading the identification code of the control unit, reading the fault memory, reading parameters, wiping
the fault memory and reading the ”Flight Recorder” memory;
- Active diagnostics: functional tests upon the main components (actuators, contactors, etc.);
- Reading the ”Flight Recorder” memory;
- Recognition of the replaced electronic components in the control unit;
- Recognition of the replaced electronic components in the control unit;
- Acquisition of parameters during functional tests.
Base - May 2018
Print P4D32N015 E
SECTION 4 - DIAGNOSTICS
NEF G-Drive SERIES
7
Figure 4
248723
1
2
3.
Interface housing
19-pin engine diagnostics socket
Adapter 99368555
30-19 pin adapter
Print P4D32N015 E
4
5
6.
7
Cable 99327017
Cable 30 pins PT-BOX
PT-BOX
PT-BOX USB connection cable
PC
Base - May 2018
8
SECTION 4 - DIAGNOSTICS
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
1
SECTION 5
Scheduled maintenance
Page
Print P4D32N015 E
- General information . . . . . . . . . . . . . . . . . . . .
3
- Checks and scheduled maintenance procedures
4
- Periodical maintenance . . . . . . . . . . . . . . . . . .
7
- Extra Plan Operations . . . . . . . . . . . . . . . . . . .
11
Base - May 2018
2
SECTION 5 - SCHEDULED MAINTENANCE
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 5 - SCHEDULED MAINTENANCE
3
General information
To ensure best operating conditions, the checks, tests and adjustments which are to be carried out on the different parts at
the established time are provided on the following pages.
The frequencies of the maintenance operations are indicative since the engine use and its characteristics are essential to evaluate
replacements and checks.
Not only it is permitted, but it is recommended that the staff in charge of maintenance should also perform those checking and
maintenance operations which are not included in the list below, but are recommended by good-practices and particular conditions of use of the engine.
Checks and scheduled maintenance procedures
Intervals (hours)
Check the engine lubricant oil level . . . . . . . . . . . . . .
daily
Check engine coolant level . . . . . . . . . . . . . . . . . . . . .
daily
Visual inspection of the engine * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50/15 days
Air filter and housing cleanness check * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 month (1)
Check tension and condition of ancillary belt * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hours/six months
Check electrolyte level of the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hours/six months
Check the condition of the exhaust duct(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six-months
Check the condition of blow-by filter * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 hours / six monthly
Periodical maintenance
Draining the water from the fuel pre-filter * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 hours/1 week
Drainage/suction of water, condensate and impurities from the fuel tank/s * . . . . . . . . . . . . . . . . 50 hours/1 week
Clean the heat exchanger (radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six-months
Visually inspect turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six-months
Change engine lubricant oil * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours / 1 year (2)
Lubricant oil filter replacement * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours / 1 year (2)
Replace the fuel pre-filter * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours / 1 year (3) (8)
Change fuel filter * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours / 1 year (3) (7)
Replace blow-by filters * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 hours / 1 year (4)
Replace air filter * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 hours / 2 years (5)
Replace ancillary belt * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 hours / 3 years (5)
Extra Plan Operations
Adjust valve/rocker arm clearance * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 hours
Engine coolant replacement * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 hours / 2 years (6)
1) Whenever the indicator is red.
2) For the oil specifications, refer to the table of the oils.
3) EN 590; ASTM D975.
4) Only valid for recommended fluids.
5) Interval to be halved for ambient conditions with high dust concentration.
6) Refrigerant according to specifications ASTM D 6210; mixed 50% in water in the case of the concentrated product.
7) Only use filters with the following specifications:
- filtration efficiency: 95% @ 4 m; 99.5% @ 6 m
- maximum flow rate: 380 l/h
- operating temperature: -30 ˚C to 100 ˚C
- collapsible pressure: 1000 kPa
8) Only use filters with the following specifications:
- filtration class: 25 m > 70%, 40 m > 90%
- nominal flow rate: 100 l/h
- operating temperature: -25 ˚C to 90 ˚C
- collapsible pressure: >3 bar
*
Intervention frequencies expressed in hours and timed intervals (whichever occurs first).
NOTE
Verifications, checks and replacements are by way of example and must be in addition to specific operations for the
equipment.
The data are only valid if the fitter observes all the installation regulations provided by FPT.
Print P4D32N015 E
Base - May 2018
4
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
Check engine coolant level
The check should be performed with the engine stopped and
while it is running.
Main characteristics of oil
Oil Specifications
(*)
International specifications
365
15W-40 API CI-4 /ACEA E7
(FPI9.LUBR001-T2 E7)
Check the pipes from the engine to the radiator, from the expansion tank and vice versa; detect any leakages, the state of
the pipes, in particular near the junction clamps.
(*) For the oil specifications, please refer to https://www.fptindustrial.com/global/en/service/fluids/oils-and-coolants
Check the cleanliness of the radiator, the integrity of the fan
fins, possible leakage from the clamps, sleeves, and the radiant
body.
The engine oil is highly pollutant and noxious.
Given the high temperatures which are reached inside the system, do not carry out operations immediately after the engine has stopped but wait until the
temperature has fallen.
Protect eyes and skin from any unexpected high pressure jets of coolant.
Checks and scheduled maintenance
procedures
Check the engine lubricant oil level
Only proceed when the engine is not turning and is at low
temperature in order not to run the risk of burns.
Figure 1
The density of the coolant must however be checked every
year before the winter and must be changed every two years.
(Illustrative)
In case of new refilling proceed with the de-aeration
of the system by means of the breathers on the engine.
Failure to de-aerate the system could cause serious
damage to the engine due to the presence of air pockets in the engine head.
- Make sure that when the engine is cold the fluid level in
the exchanger covers the internal elements of the exchanger.
- Top up if necessary, using water free of impurities. Do
not use distilled water.
202110
- Use the oil dipstick to check that the lubricant oil level
is between the ”Min” and ”Max” limits.
- If the level is too low, top-up with lubricant oil which
meets the requirements of international specifications:
remove the lubricant oil cap and pour engine lubricant
oil through the hole.
- Use the oil dipstick to check that the oil level lubricant
oil level does not exceed the ”Max” limit.
NOTE
if frequent top-ups are necessary, the cooling circuit must be diagnosed.
If the version has an external level indicator on the heat exchanger, proceed with the top up making sure that the liquid
does not completely fill the exchanger. This is to ensure that
the volume of the liquid can increase as the temperature increases.
The engine oil is highly pollutant and noxious.
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.
Base - May 2018
Print P4D32N015 E
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
Engine visual inspection
Before starting the engine, it is good practice to perform a series of simple checks which could represent a valid way of
avoiding problems, even serious, while the engine is running.
These checks are generally carried out by the operators.
Check the fuel level and check for any leaks in the fuel, coolant and lubrication circuits.
5
Check the tension and condition of the ancillary belt
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
Figure 2
Inform maintenance staff if any problems arise or if a top-up
is needed.
After having started the engine and while it is running, proceed to carry out the checks and verifications.
Check for any leaks in the fuel, coolant and lubrication circuits.
Check there are no unusual noises while the engine is running.
Use the equipment devices to check the specified temperature and pressure as well as other parameters.
Visually check the exhaust smoke (colour of the exhaust
emissions)
Visually check the coolant level in the expansion tank.
Air filter and housing cleanness check
Only do this with the engine off.
Remove the cover of the air filter after having released the
two quick lock retainers.
Remove the filter element; during this operation, make sure
that no dust enters the sleeve.
252279
- Remove the protective fairing of the pulley.
- Check that the belt is not worn, soiled with oil or fuel,
or showing signs of tears. Otherwise replace the belt if
necessary.
- At the same time, check the efficiency of the tensioner
as indicated in the figure.
- Reposition the protective fairing in its seat and tighten
the retaining elements.
Make sure there are no impurities. If there are, clean the filter
according to the indications provided below.
Blow dehumidified compressed air on the filter element working from the inside outward (maximum pressure 200 kPa).
Check the condition of the air filter before refitting it. Replace
the filter if it is broken or torn.
Check the condition of the gasket at the base.
Fit the filter element into its seat.
Replace the cover of the air filter and secure it using the two
quick lock retainers.
Do not use detergents or diesel to clean the air filter.
Never strike the filter element with tools. The imprecise assembly of the air filter may result in the intake
of unfiltered air and therefore cause serious damage
to the engine
Print P4D32N015 E
Base - May 2018
SECTION 5 - SCHEDULED MAINTENANCE
6
NEF G-Drive SERIES
Check electrolyte level of the batteries
The batteries used are of reduced maintenance type. Therefore, under normal conditions of use, no top up of the electrolyte is required.
However, the routine checking of the electrolyte level is
recommended.
Check the condition of the exhaust duct(s)
Visually check that the exhaust gas system is not clogged or
damaged.
- Make sure that there is no risk of harmful fumes in the
environment where the engine is being worked on. Contact the manufacturer if necessary.
Proceed after positioning the batteries on a horizontal surface.
- Visually check that the electrolyte level is between the
”Min” and ”Max” reference marks on the batteries; in the
absence of any reference marks, make sure the liquid
covers the lead plates contained in the elements by approx. 5 mm.
Check the condition of oil vapour filter
Figure 4
- Only use distilled water to top up the elements whose
level is below the minimum.
- If the battery has to be recharged, contact a specialised
workshop.
A specialised workshop should be contacted if all the
battery elements need topping up with a considerable quantity of distilled water and arrange for diagnostics of the efficiency of both the batteries and the
system.
252283
The batteries contain sulphuric acid which is highly
caustic and corrosive; during the top up operations
protective glasses and gloves must be worn, as well
as an apron to protect clothing.
If possible, have this check performed by qualified
personnel.
!
During the checks do not smoke or allow naked flames near the batteries. Ensure that the work area is
suitably ventilated.
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns:
- Remove the oil vapour filter (2) acting on the fastening
screws (1).
Ref.
(1)
No.
3
Screws description
Screw M6x1x25
- Check that the oil vapour filter (2) is free of deposits, otherwise replace it.
- Reposition the oil vapour filter (2) in the relative seat on
the flywheel and tighten the screws (1).
Figure 3
Ref.
(1)
No.
3
Screws description
Screw M6x1x25
Tightening torques
-
Dispose of consumable materials and the parts in
contact with them (for example filters) in accordance with the law.
The FPT Technical Service Network workshops are
equipped for this purpose.
198322
Some batteries have a single cover for the inspection plugs.
To access the elements, use a lever as shown in the figure.
Base - May 2018
Print P4D32N015 E
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
7
Drainage/suction of water, condensation and impurities
from the fuel tank/s
Periodical maintenance
Draining the water from the fuel pre-filter
Carry out the drainage/suction operations of the water, condensate and impurities from the fuel tank(s) by following the
instructions contained in the manual supplied by the tank
manufacturer.
Figure 5
Proceed as necessary based on the structure or location of
the tank: engines that operate in adverse environments and
conditions and/or that are refuelled using drums or jerry cans,
require more attention when cleaning the tank.
Clean the heat exchanger (radiator)
Check that the air intake surfaces of the radiators are free of
impurities.
Clean them using compressed air or steam.
Visually inspect turbocharger
Only proceed when the engine is not turning over. Visually
check that the turbine and compressor rotors and the relative inlet and outlet ducts are not clogged or damaged, otherwise replace them.
70494
In the case of a high risk of refuelling with fuel polluted with
foreign agents and water, the following check should be performed at each refuelling.
Proceed when the engine is not rotating.
- Position a container for collecting the liquid below the
filter.
- Unscrew the valve plug (4) located at the bottom of the
filter; in some versions, the plug includes the water in diesel sensor.
- Drain the liquid until only ”diesel” is released.
- Fully retighten the plug manually.
- Dispose of the drained liquids according to the applicable
regulations in force.
Print P4D32N015 E
Base - May 2018
8
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
Change engine lubricant oil
Only proceed when the engine is not turning and is at low
temperature in order not to run the risk of burns.
Lubricant oil filter replacement
NOTE
Figure 6
The oil filter must be replaced when the lubricant
oil is changed.
Figure 7
202110
- Introduce a suitable container near the oil drain plug to
collect the oil as it comes out of the oil sump.
- Unscrew the oil filler plug; remove the dipstick and
remove the oil filler plug to facilitate draining of the engine lubricant oil.
202120
- Wait for the sump to empty completely, then tighten the
lubricant oil drain plug again.
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
- Refill through the oil filler cap using lubricant oil according to international specifications.
Place a container for the oil recovery.
- Use tool 99360076 to unscrew the oil filter (1).
- Use the oil dipstick to check that the lubricant oil level
does not exceed the ”MAX” limit.
- If it is difficult to see the level of the oil, clean the dipstick
using a clean rag and then put it back into its seat.
Remove it again and check the level.
Ref.
(1)
- Tighten the oil filling cap.
No.
1
Screws description
Cartridge M27x2
Be careful since the oil filter contains a significant
quantity of engine oil.
- The filter must be replaced when the lubricant oil is changed.
Correctly position a suitable container to collect the
oil.
Caution! avoid contact of the engine oil with the skin:
in case of contact, wash thoroughly with water.
The engine oil is highly pollutant: it must be disposed
of according to current legislation.
- Tighten the oil filter (1) at the specific housing on the
heat exchanger (2).
- Operate the engine for a few minutes and then check
the level using the dipstick. If necessary, top up to compensate for the quantity of oil used to fill up the filtering
cartridge.
Ref.
(1)
Base - May 2018
No.
1
Screws description
Cartridge M27x2
Tightening torques
20 ± 2 Nm
Print P4D32N015 E
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
9
Replacing fuel filter
Replacing the fuel pre-filter
Do not smoke or use open flames during this operation.
Do not smoke or use open flames during this operation.
Do not inhale the vapours that exit the filter.
Do not inhale the vapours that exit the filter.
When replacing the filters, the feed system must always be de-aerated.
Only proceed when the engine is not turning and is at low
temperature in order not to run the risk of burns.
When replacing the filters, the feed system must
always be de-aerated.
Figure 9
Figure 8
253475
Drain the fuel from the filter by acting on the water bleed
valve plug.
Collect the fuel in a clean container.
- Unscrew the cartridge (2) using the specific tool
99360076.
- Collect any fuel still present in the filtering cartridge.
70494
- Clean the gasket seat on the support and lightly oil the
gasket on the new filtering cartridge.
- If the filter has a sensor for detecting water, remove the
whole sensor from its seat.
- Manually tighten the new filtering cartridge until the
gasket rests completely on its seat.
- Remove the pre-filter by unscrewing it.
- Using the specific tool 99360076, tighten it further to
a torque of 20 ± 2.5 Nm.
- Check that the performance levels of the new filter meet
the engine requirements (e.g. by comparing it with the
old one).
- Wet the new seal of the filter with oil or fuel.
After having replaced the fuel filter (#), it is possible that
air bubbles may remain trapped inside the fuel supply circuit.
- Manually screw down the new filter until the seal touches the support, then tighten to a torque of 20 ± 3 Nm.
- Unscrew the breather valve (1) to release the residual
air from the fuel filter (2); collect the fuel coming out
in a suitable container using a clear hose.
- Fit the water detection sensor in its seat, ensuring that
the wires are correctly coupled.
- Actuate the hand pump on the fuel pre-filter until no
further air bubbles come out of the breather valve (1).
- Loosen the bleed screw (2) on the fuel filter support and
activate the manual pump (5) until the feed circuit is full.
Make sure that the fuel coming out is not dispersed in
the environment.
- Tighten the breather valve to a torque of 10 ± 2 Nm.
- Start the engine and let run for a few minutes to eliminate any residual air.
- Tighten the bleed screw to torque.
- Start the engine and let run with no load for a few minutes to eliminate any residual air.
Print P4D32N015 E
Base - May 2018
SECTION 5 - SCHEDULED MAINTENANCE
10
NEF G-Drive SERIES
Change air filter
Only proceed when the engine is not turning and is at low
temperature in order not to run the risk of burns.
Change oil vapour filters
Figure 10
Figure 11
252283
- Remove the oil vapour filter (2) acting on the fastening
screws (1).
252280
Ref.
(1)
No.
3
Screws description
Screw M6x1x25
- Disconnect the clamp (1).
- Replace the oil vapour filter (2) and the relative gasket.
- Reposition the oil vapour filter (2) in the relative seat
on the flywheel and tighten the screws (1).
Ref.
(1)
No.
3
Screws description
Screw M6x1x25
Tightening torques
-
- Unscrew the screws (3) and remove the air filter (2)
from the relative support.
Ref.
(3)
No.
2
Screws description
Screw M8x1.25x100
- Position the air filter (2) in the relative position.
- Tighten the screws (3) to the support clamp.
- Connect the clamp (1).
Dispose of consumable materials and the parts in
contact with them (for example filters) in accordance with the law.
The FPT Technical Service Network workshops
are equipped for this purpose.
Base - May 2018
Ref.
No.
(3)
2
Screws description
Screw
M8x1.25x100
Tightening torques
-
Dispose of consumable materials and the parts in
contact with them (for example filters) in accordance with the law.
The FPT Technical Service Network workshops
are equipped for this purpose.
Print P4D32N015 E
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
Change the ancillary belt
11
Extra Plan Operations
Valve/rocker arm clearance adjustment
Figure 12
Figure 13
252279
- Remove the protective grille and the fan together with
spacer by acting on the relative fasteners.
- Loosen the bolt (1) anchoring the alternator to its lower
support and the screw (2) fastening the alternator to the
bracket.
Ref.
(1)
(2)
No.
1
2
Screws description
Screw M10x1.5
Screw M10x1.5
- Using the tool (3), rotate the automatic tensioner (4)
and remove the belt (5).
- Using the tool (3), rotate the automatic tensioner (4)
and position the new belt (5) inside the shouldering of
all the pulleys.
70520
Adjusting the clearance between the rocker arms and the intake and exhaust valve pushrods must be carried out using
an Allen wrench (1), a box-end wrench (3) and a feeler gauge
(2).
The clearance is:
- intake valves 0.25 ± 0.05 mm
- exhaust valves 0.50 ± 0.05 mm.
- Tighten the bolt (1) anchoring the alternator to its lower
support and the screw (2) securing the alternator to the
bracket.
Ref.
(1)
(2)
No.
1
2
Screws description
Screw M10x1.5
Screw M10x1.5
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
- Reposition the fan together with spacer in its seat and
the protective grilles and tighten the relative fasteners.
Print P4D32N015 E
Base - May 2018
12
SECTION 5 - SCHEDULED MAINTENANCE
NEF G-Drive SERIES
Change the engine coolant
Figure 14
129284
Only proceed when the engine is not running and is at low
temperature in order to prevent the risk of burns.
- Use suitable containers to ensure that the coolant is not
dispersed in the environment.
- Loosen the retaining elements (1 and 3) and remove the
sleeves (2) coupling the engine circuit to the heat exchanger and wait for them to empty completely. Once
emptied, restore the condition of the circuit, ensuring
the perfect seal of the sleeves.
- Refill the circuit.
- Refill the engine and the exchanger until the exchanger
is completely full.
- With the filler plug open, start the engine and idle it for
approximately 1 minute.
This phase helps to completely bleed the air contained
in the cooling circuit.
- Stop the engine and then top up with the amount which
is still needed.
- Make sure that when the engine is cold the fluid level in
the exchanger covers the internal elements of the exchanger.
- Top up if necessary, using water free of impurities. Do
not use distilled water.
NOTE
if frequent top-ups are necessary, the cooling circuit must be diagnosed.
- If in the version the level indicator is located externally
of the heat exchanger, proceed with the top up making
sure that the liquid does not saturate the internal volume
of the exchanger allowing the increase in temperature
to increase the volume of the liquid.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
1
SECTION 6
Removal/installation
of main engine components
Page
Print P4D32N015 E
PROCEDURE FOR REMOVAL/INSTALLATION
OF PROTECTIVE GRILLE . . . . . . . . . . . . . . .
5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
PROCEDURE FOR RADIATOR REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
PROCEDURE FOR FAN REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
PROCEDURE FOR AUXILIARY DEVICE BELT
REMOVAL/INSTALLATION . . . . . . . . . . . . .
9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
PROCEDURE FOR ENGINE CABLE REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
PROCEDURE FOR AIR FILTER REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
11
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
PROCEDURE FOR ALTERNATOR REMOVAL/
REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Base - May 2018
2
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NEF G-Drive SERIES
Page
Page
PROCEDURE FOR WATER PUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . .
12
PROCEDURE FOR OIL VAPOUR RECIRCULATION
SYSTEM REMOVAL/INSTALLATION . . . . . .
19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
PROCEDURE FOR THERMOSTAT
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
PROCEDURE FOR LOW PRESSURE FUEL PIPES
REMOVAL/INSTALLATION . . . . . . . . . . . . .
21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
PROCEDURE FOR ELECTRIC STARTER MOTOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
13
- Using tool 99305453, check the mechanical
feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
PROCEDURE FOR HIGH PRESSURE FUEL PIPES
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
22
PROCEDURE FOR TURBOCHARGER
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
ELECTRONIC CONTROL UNIT
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
23
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
PROCEDURE FOR FUEL FILTER
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
PROCEDURE FOR TAPPET COVER
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
25
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
PROCEDURE FOR OIL FILTER
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
15
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
PROCEDURE FOR HEAT EXCHANGER
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
16
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
PROCEDURE FOR OIL SUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
PROCEDURE FOR OIL PUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
18
PROCEDURE FOR ROCKER ARM ASSEMBLY
REMOVAL-REFITTING . . . . . . . . . . . . . . . . . .
25
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
3
Page
PROCEDURE FOR FUEL FILTER
REMOVAL/INSTALLATION . . . . . . . . . . . . .
27
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
HIGH PRESSURE PUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
28
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
PROCEDURE FOR INTAKE MANIFOLD
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
28
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
PROCEDURE FOR EXHAUST MANIFOLD
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
30
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
PROCEDURE FOR CYLINDER HEAD
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
31
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
Print P4D32N015 E
Base - May 2018
4
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
NEF G-Drive SERIES
5
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR REMOVAL/
INSTALLATION OF PROTECTIVE GRILLE
Removal
Refitting
Figure 3
Figure 1
129292
- Position a suitable container in line with the pipe (4) to
recover the coolant. Disconnect the pipe (4) acting on
the relative clamps (1).
- Unscrew the screw (3) and release the pipe (4) complete with the bracket (5) from the radiator unit (2).
Ref.
(1)
(3)
No.
2
1
- Fit the protective grille (5) of the fan
- Tighten the relative retainers (1, 3 and 4).
- Close the clamps (2).
Ref.
(1)
(2)
(3)
(4)
Screws description
M14x2x30
Screw M8x1.25x16
Figure 2
129287
No.
6
2
1
1
Screws description
Screw M6x1x16
Screw M14x2x30
Screw M8x1.25x16
Screw M6x1x16
Tightening torques
43 ± 6 Nm
114.5 ± 11.5 Nm
43 ± 6 Nm
43 ± 6 Nm
Figure 4
129292
129287
- Remove the protective grilles (5) of the fan acting on the
relative retainers (1), (3) and (4).
- Connect the pipe (4) to the radiator unit (2) complete
with the sleeves and bracket (5)
- Open the clamps (2).
- Act on the relative clamps (1).
- Tighten the screw (3).
Ref.
(1)
(2)
(3)
(4)
No.
6
2
1
1
Print P4D32N015 E
Screws description
Screw M6x1x16
Screw M14x2x30
Screw M8x1.25x16
Screw M6x1x16
Ref.
(1)
(3)
No.
2
1
Screws description
M14x2x30
Screw M8x1.25x16
Tightening torques
114.5 ± 11.5 Nm
43 ± 6 Nm
Base - May 2018
6
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NOTE
Check the state of wear of the rubber sleeves.
NEF G-Drive SERIES
Figure 7
- Refill the cooling system with coolant.
- Bleed the air from the ’supply system as described in the
relevant paragraph.
- Check the engine oil level
PROCEDURE RADIATOR
REMOVAL/INSTALLATION
Removal
Remove the protective grille as described in the relevant section.
Figure 5
129290
- Disconnect and remove the pipes (1 and 4), complete
with sleeves from the engine side.
- Unscrew the screws on the clamps (2 and 3).
Ref.
(2)
(3)
No.
1
1
Screws description
Screw M6x1x16
Screw M8x1.25x16
Figure 8
252278
- Unscrew the screws (2) and remove the pipe (1) from
the intake manifold.
Ref.
(2)
No.
4
Screws description
Screw M8x1.25x25
Figure 6
129291
- Disconnect and remove the pipe (1), complete with
sleeves, from the engine side unscrewing the screws on
the relative clamps (6).
- Disconnect and remove the pipe (2), unscrewing the nut
acting on the relative clamp (3).
- Disconnect and remove the pipe (4), complete with
sleeves, from the engine side unscrewing the screws on
the relative clamps (5).
129289
- Disconnect the air and water pipes from the radiator
unit.
- Unscrew the screws on the clamps (1, 2, 3 and 4) and
on the fixing bracket (5).
Ref.
No. Screws description
(4)
2
Screw M14x2x30
(5)
1
Screw M6x1x16
Base - May 2018
- Suitably block the radiator unit then release it from the
crankcase acting on the retainers from both sides.
- Remove the radiator unit from its seat.
Ref.
(3)
(5)
(6)
No.
2
2
2
Screws description
Nut M14x1.5
Screw M14x2x30
Screw M14x2x30
Print P4D32N015 E
NEF G-Drive SERIES
7
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
Refitting
Figure 11
Figure 9
129291
- Fit the pipe (4) complete with sleeves from the engine
side, acting on the relative clamps (5).
- Fit the pipe (2) complete with sleeves acting on the relative clamp (3).
129289
- Connect the air and water pipes to the radiator unit,
acting on the clamps (1, 2, 3 and 4) and on the fixing bracket (5).
- Fit the pipe (1) complete with sleeves from the engine
side, acting on the relative clamps (6).
Ref.
(3)
(5)
(6)
NOTE
No.
2
2
2
Screws description
Nut M14x1.5
Screw M14x2x30
Screw M14x2x30
Tightening torques
43 ± 6 Nm
114.5 ± 11.5 Nm
114.5 ± 11.5 Nm
Check the state of wear of the rubber sleeves.
Figure 10
Ref.
(4)
(5)
NOTE
No.
2
1
Screws description
Screw M14x2x30
Screw M6x1x16
Tightening torques
114.5 ± 11.5 Nm
43 ± 6 Nm
Check the state of wear of the rubber sleeves.
Figure 12
252278
- Mount the pipe (1).
129290
- Fit the pipes (1 and 4) complete with sleeves, acting on
the relative clamps (2 and 3).
Ref.
(2)
(3)
No.
1
1
Screws description
Screw M6x1x16
Screw M8x1.25x16
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
- Tighten the screws (2).
Ref.
(2)
No.
4
Screws description
Screw M8x1.25x25
Tightening torques
23 ± 2 Nm
Fit the protective grille as described in the relevant section.
NOTE
Check the state of wear of the rubber sleeves.
Print P4D32N015 E
Base - May 2018
8
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR FAN
REMOVAL/INSTALLATION
Removal
NEF G-Drive SERIES
Refitting
Figure 14
Remove the protective grille as described in the relevant section.
Remove the radiator as described in the relevant section.
Figure 13
129297
- Position the fan (1) together with the spacer.
- Tighten the screws (2).
129297
Ref.
(2)
No.
6
Screws description
Screw M10x1.5x30
Tightening torques
24 ± 4 Nm
- Unscrew the screws (2).
- Remove the fan (1) together with the spacer.
NOTE
Ref.
(2)
The shape and size of the fan vary depending on
engine use.
The relative illustrations provide a general outline
of the work to perform.
However the procedures described are applicable
anyway.
No.
6
Base - May 2018
Fit the radiator as described in the relevant section.
Fit the protective grille as described in the relevant section
Screws description
Screw M10x1.5x30
Print P4D32N015 E
NEF G-Drive SERIES
9
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR AUXILIARY DEVICE
BELT REMOVAL/INSTALLATION
Removal
Refitting
Remove the protective grille as described in the relevant section.
Remove the radiator as described in the relevant section.
Remove the fan as described in the relevant section.
- Using tool (3), rotate the automatic tensioner (4) and
reconnect the belt (5) inside the shouldering of all the
pulleys.
- Tighten the bolt (1) anchoring the alternator to its lower
support and the screw (2) securing the alternator to the
bracket.
Ref.
(1)
(2)
Figure 15
No.
1
2
Screws description
Screw M10x1.5
Screw M10x1.5
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
- Reposition the fan together with spacer in its seat and
the protective grilles and tighten the relative fasteners.
Figure 16
252279
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
- Remove the protective grille and the fan together with
spacer by acting on the relative fasteners.
- Unscrew the bolt (1) anchoring the alternator to its
lower support and the screw (2) securing the alternator
to the bracket.
Ref.
(1)
(2)
No.
1
2
Screws description
Screw M10x1.5
Screw M10x1.5
202112
BELT ASSEMBLY DIAGRAM
1. Fan pulley - 2. Idler pulley - 3. Crankshaft pulley 4. Water pump - 5. Alternator - 6. Automatic belt
tensioner
Fit the fan as described in the relevant section.
Fit the radiator as described in the relevant section.
- Using the tool (3), rotate the automatic tensioner (4)
and remove the belt (5).
Print P4D32N015 E
Fit the protective grille as described in the relevant section.
Base - May 2018
10
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NEF G-Drive SERIES
PROCEDURE FOR ENGINE CABLE REMOVAL/INSTALLATION
Removal
Figure 17
252290
1. Exhaust gas valve connection - 2. Interconnection Control Unit - 3. Air pressure / temperature sensor 4. Timing gear phase sensor - 5. Pressure regulator cable - 6. Fuel temperature sensor and fuel heater cable 7. EDC 7 electronic control unit - 8. Crankshaft sensor - 9. Fuel pressure sensor cable 10. Engine oil temperature and pressure sensor - 11. Engine coolant temperature sensor 12. Electro-injector - 13. Connections for electro-injectors.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
11
PROCEDURE FOR AIR FILTER REMOVAL/
INSTALLATION
Removal
Figure 18
Figure 20
70126
To disconnect lower pressure fuel pipes from their couplings,
press clip (1) as shown in figure B.
After disconnecting the pipe, bring the clip (1) back to the
locking position (figure A), to prevent it from deforming.
Disconnect the engine cable from the connectors: electroinjector wiring (13); (3) air pressure/temperature sensor; (9)
fuel pressure sensor; (7) Control unit; (4) timing gear phase
sensor; (11) engine coolant temperature sensor on thermostat; (8) engine rpm sensor.
Remove the clamps that hold it to the crankcase and remove
it completely.
252280
- Disconnect the clamp (1).
- Unscrew the screws (3) and remove the air filter (2)
from the relative support.
Ref.
(3)
No.
2
Screws description
Screw M8x1.25x100
Refitting
- Position the air filter (2) in the relative position.
Refitting
- Tighten the screws (3) to the support clamp.
Figure 19
- Connect the clamp (1).
Ref.
(3)
No.
2
Screws description
Screw
M8x1.25x100
Tightening torques
-
70126
To connect lower pressure fuel pipes from their couplings,
press clip (1) as shown in figure B.
After disconnecting the pipe, bring the clip (1) back to the
locking position (figure A).
Connect the engine cable from the connectors: electroinjector wiring (13); (3) air pressure/temperature sensor; (9)
fuel pressure sensor; (7) Control unit; (4) timing gear phase
sensor; (11) engine coolant temperature sensor on thermostat; (8) engine rpm sensor.
Fit the clamps that hold it to the crankcase.
Print P4D32N015 E
Base - May 2018
12
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NEF G-Drive SERIES
PROCEDURE FOR ALTERNATOR
REMOVAL/REFITTING
Removal
PROCEDURE FOR WATER PUMP
REMOVAL/INSTALLATION
Removal
Remove the protective grille as described in the relevant section.
Remove the protective grille as described in the relevant section.
Remove the radiator as described in the relevant section.
Remove the radiator as described in the relevant section.
Remove the fan as described in the relevant section.
Remove the fan as described in the relevant section.
Remove the belt as described in the relevant section.
Remove the belt as described in the relevant section.
Figure 21
Figure 22
252279
- Unscrew the screw (1) anchoring the alternator to its
lower support and the screw (2) securing the bracket.
Ref.
(1)
(2)
No.
1
2
202113
- Loosen and remove the screws (1).
- Take the water pump (2) out of its housing.
Ref.
(1)
Screws description
Screw M10x1.5
Screw M10x1.5
No.
2
Screws description
Screw M8x1.25x35
- Recover the gasket (3).
- Remove the alternator from the housing.
Refitting
Refitting
Position the alternator in its housing
- Insert the gasket (3) into the seat on the crankcase.
- Using tool (3), rotate the automatic tensioner (4) and
reconnect the belt (5) inside the shouldering of all the
pulleys.
- Position the water pump (2) in its housing and tighten
the screws (1).
- Tighten the bolt (1) anchoring the alternator to its lower
support and the screw (2) securing the alternator to the
bracket.
Ref.
(1)
(2)
No.
1
2
Screws description
Screw M10x1.5
Screw M10x1.5
Tightening torque
43 ± 6 Nm
43 ± 6 Nm
Ref.
(1)
No.
2
Screws description
Screw M8x1.25x35
Tightening torques
24 ± 4 Nm
Fit the belt as described in the relevant section.
Fit the fan as described in the relevant section.
Fit the radiator as described in the relevant section.
Fit the fan as described in the relevant section.
Fit the protective grille as described in the relevant section.
Fit the radiator as described in the relevant section.
Fit the protective grille as described in the relevant section.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR THERMOSTAT
REMOVAL/INSTALLATION
Removal
13
PROCEDURE FOR ELECTRIC STARTER
MOTOR REMOVAL/INSTALLATION
Removal
Remove the protective grille as described in the relevant section.
Figure 24
Remove the radiator as described in the relevant section.
Figure 23
252289
- Unscrew the nuts (1) securing the starter motor (2) to
the flywheel housing (3).
- Remove the starter motor (2) from its seat.
252281
- Unscrew the screws (1) securing the thermostat cover
(2).
- Remove the thermostat cover (2).
- Remove the thermostat (3).
Ref.
No. Screws description
(1)
3
Screw M6x1x20
Ref.
(1)
No.
3
Screws description
Nut M10x1.5
Refitting
- Insert the starter motor (2) in its seat at the flywheel
housing (3).
- Tighten the screws (1).
Refitting
- Insert the thermostat assembly (3) into the relative seat.
- Position the thermostat cover (2) and tighten the screws
(1).
Ref.
(1)
No.
3
Screws description
Screw M6x1x20
Ref.
(1)
No.
3
Screws description
Nut M10x1.5
Tightening torques
43 ± 6 Nm
Tightening torques
13.5 ± 1.5 Nm
Fit the radiator as described in the relevant section.
Fit the protective grille as described in the relevant section.
Print P4D32N015 E
Base - May 2018
14
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR TURBOCHARGER
REMOVAL/INSTALLATION
Removal
NEF G-Drive SERIES
Figure 27
Remove the radiator as described in the relevant section.
Remove the air filter as described in the relevant section.
Figure 25
214291
- Unscrew the nuts (1) securing the turbocharger (2) to
the exhaust manifold (3).
- Recover the gasket (4).
202117
- Unscrew the delivery pipe (2) fittings (1).
Ref.
(1)
No.
4
Screws description
Nut M10x1.5
Refitting
Ref.
(1)
No.
2
Screws description
Fitting 11/16”
Figure 28
Figure 26
214291
202118
- Unscrew the screws (1) supporting the oil return pipe
(2).
- Unscrew the screw (3) securing the pipe to the crankcase via the fastening collar (5).
- Position the gasket (4) on the exhaust manifold (3).
- Position the turbocharger (2) in the specific seat.
- Tighten the nuts (1) securing the turbocharger (2) to the
exhaust manifold (3).
- Extract the fitting (4).
Ref.
(1)
(3)
No.
2
1
Base - May 2018
Screws description
Screw M8x1.25x25
M8x1.25x16
Ref.
(1)
No.
4
Screws description
Nut M10x1.5
Tightening torques
43 ± 6 Nm
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
15
PROCEDURE FOR OIL FILTER
REMOVAL/INSTALLATION
Removal
Figure 29
Figure 31
202118
- Connect the oil return pipe (2) from the turbocharger.
- Tighten the fastening screws (1).
202120
- Tighten the screw (3) securing the pipe to the crankcase
via the fastening collar (5).
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
- Insert the fitting (4).
Place a container for the oil recovery.
- Use tool 99360076 to unscrew the oil filter (1).
Ref.
(1)
(3)
No.
2
1
Screws description
Screw M8x1.25x25
Screw M8x1.25x16
Tightening torques
24 ± 4 Nm
24 ± 4 Nm
Ref.
(1)
No.
1
Screws description
Cartridge M27x2
Refitting
- Tighten the oil filter (1) at the specific housing on the
heat exchanger (2).
Figure 30
Ref.
(1)
No.
1
Screws description
Cartridge M27x2
Tightening torques
20 ± 2 Nm
202117
- Connect the oil delivery pipe (2) to the turbocharger.
- Tighten the fittings (1).
Ref.
(1)
No.
2
Print P4D32N015 E
Screws description
Fitting 11/16”
Tightening torques
30 ± 3
Base - May 2018
16
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR HEAT EXCHANGER
REMOVAL/INSTALLATION
Removal
NEF G-Drive SERIES
Refitting
Figure 34
Remove the oil filter as described in the relevant section.
Remove the alternator as described in the relevant section.
Figure 32
- Position the gasket (5).
202122
- Insert the heat exchange elements (4).
- Position the insulating plates (3).
202121
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
- Unscrew the delivery pipe (2) fittings (1).
Ref.
(1)
No.
2
- Position the oil filter housing (2).
- Tighten the screws (1).
Ref.
(1)
No.
15
Screws description
Fitting 11/16”
Screws description
Screw
M18x1.25x35
Tightening torques
26 ± 4 Nm
Figure 35
Figure 33
202121
- Connect the oil delivery pipe (2) to the turbocharger.
- Tighten the fittings (1).
202122
- Unscrew the screws (1) and remove the oil filter housing
(2).
- Extract the insulating plates (3).
- Extract the heat exchange elements (4).
- Remove the seal gasket (5).
Ref.
(1)
No.
15
Base - May 2018
Screws description
Screw M8x1.25x35
Ref.
(1)
No.
2
Screws description
Fitting 11/16”
Tightening torques
30 ± 3 Nm
Fit the alternator as described in the relevant section.
Fit the oil filter as described in the relevant section.
Proceed to top-up the heat exchanger with the lubricant oil
and coolant.
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR OIL SUMP REMOVAL/
INSTALLATION
Removal
17
Refitting
Figure 38
Figure 36
- Position the gasket (3).
252282
- Drain the lubricant oil from the engine via the drain plug
(6).
- Overturn the engine.
- Unscrew the screws (1) and (2) securing the oil sump.
- Remove the oil sump (5).
214293
- Position the suction strainer (4) together with the supporting straps (2) in the relative seat.
- Tighten the screws (1 and 5).
Ref.
(1)
(5)
No.
1
2
Screws description
Screw M10x1.5x20
Screw M8x1.25x20
Tightening torques
45 ± 4.5 Nm
25 ± 2.5 Nm
- Remove the spacer (3) and the gasket (4).
Ref.
(1)
(2)
No.
14
4
Screws description
Screw M8x1.25x40
Screw M8x1.25x45
Figure 39
Figure 37
252282
- Position the gasket (4) and the spacer (3) in the specific
seats.
- Position the oil sump (5).
214293
- Unscrew the screws (1 and 5).
- Remove the suction strainer (4) together with the supporting straps (2).
- Recover the gasket (3).
Ref.
(1)
(5)
No.
1
2
Print P4D32N015 E
Screws description
Screw M10x1.5x20
Screw M8x20
- Tighten the screws (1 and 2).
- Overturn the engine
Ref.
(1)
(2)
No.
14
4
Screws description
Screw M8x1.25x40
Screw M8x1.25x45
Tightening torques
34 ± 3.4 Nm
34 ± 3.4 Nm
Refill with lubricant oil.
Base - May 2018
18
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR OIL
PUMP REMOVAL/INSTALLATION
Removal
NEF G-Drive SERIES
Figure 41
Remove the protective grille as described in the relevant section.
Remove the radiator as described in the relevant section.
Remove the fan as described in the relevant section.
Remove the ancillary belt as described in the relevant section.
Remove the oil sump as described in the relevant section.
202126
- Unscrew the supporting screws (1).
Figure 40
- Remove the oil pump (2).
Ref.
(1)
No.
4
Screws description
Screw M8x1.25x30
202397
- Unscrew the screws (4) securing the front damper.
- Remove the front damper (3) together with the phonic
wheel.
Refitting
Figure 42
- Unscrew the pulley screw (2).
- Unscrew the screws (1 and 6) securing the front cover
(7).
- Remove the gasket (5)
- Remove the front cover (7).
Ref.
(1)
(2)
(4)
(6)
No.
8
1
6
5
Screws description
Screw M8x1.25x30
Screw M10x1.5x70
Screw M12x1.25x78.5
Screw M8x1.25x45
202126
- Fit the oil pump (2).
- Tighten the screws (1).
Ref.
(1)
No.
4
Screws description
Screw M8x1.25x30
1st phase
2nd phase
Base - May 2018
Tightening torques
8 ± 1 Nm
24 ± 4 Nm
Print P4D32N015 E
NEF G-Drive SERIES
19
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE
FOR
OIL
VAPOUR
RECIRCULATION SYSTEM REMOVAL/
INSTALLATION
Removal
Figure 43
Remove the air filter as described in the relevant section
Figure 44
202397
- Fit the front cover (7) and correctly position the gasket
(5) in the specific seat.
- Tighten the screws (1 and 6).
- Tighten the pulley screw (2).
- Fit the front damper (3) together with the phonic wheel
and tighten the screws (4).
Ref.
(1)
(2)
(4)
(6)
No.
8
1
6
5
Screws description
Screw M8x1.25x30
Screw M10x1.5x70
Screw
M12x1.25x78.5
Tightening torques
24 ± 4 Nm
45 ± 5 Nm
1st step
Angle
Screw M8x1.25x45
50 ± 5 Nm
90˚
24 ± 4 Nm
Fit the oil sump as described in the relevant section.
249425
- Remove the clamps (2 and 4) and remove the pipes (1
and 3) from the blow-by filter (5).
Ref.
(2)
(4)
No.
1
1
Screws description
Screw M20x32
M16x25 screw
Figure 45
Fit the ancillary belt as described in the relevant section.
Fit the fan as described in the relevant section.
Fit the radiator as described in the relevant section.
Fit the protective grille as described in the relevant section.
Refill with lubricant oil.
252283
- Unscrew the screws (1) securing the oil vapour filter (2).
- Remove the filter (2).
Ref.
(1)
Print P4D32N015 E
No.
3
Screws description
Screw M6x1x25
Base - May 2018
20
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
Figure 46
NEF G-Drive SERIES
Figure 48
202399
252283
- Unscrew the support screw (1) at the clamp.
- Position the filter (2) in its seat.
- Remove the engine breather pipe (4).
- Fit the oil vapour filter (2) and tighten the screws (1).
- Unscrew the threaded fittings (2) and remove the pipe
(3).
Ref.
(1)
(2)
No.
1
2
Screws description
Screw Fitting M12x1.5x11
Ref.
(1)
No.
3
Screws description
Screw M6x1x25
Tightening torques
10 ± 2 Nm
Fit the air filter as described in the relevant section
Figure 49
Refitting
Figure 47
249425
202399
- Position the pipe (3) in the relative seat and tighten the
threaded fittings (2).
- Insert the engine breather pipe (4) into the relative seat.
- tighten the screw (1) supporting the clamp.
Ref.
(1)
(2)
No.
1
2
Base - May 2018
Screws description
Screw Fitting M12x1.5x11
- Position the pipes (1 and 3) on the blow-by filter (5) and
tighten the clamps (2 and 4) to the specified torque.
Ref.
(2)
(4)
No.
1
1
Screws description
Screw M20x32
M16x25 screw
Tightening torques
-
Tightening torques
-
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR LOW PRESSURE FUEL
PIPE REMOVAL/INSTALLATION
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
21
Using tool 99305453, check the mechanical
feed pump
Figure 51
Place a container for the oil recovery.
Removal
Figure 50
249426
- Remove the excess fuel return pipe (1) from the Common Rail.
- Remove the fuel return pipe (3) to the injection pump
(2) from the filter (5).
214343
1. Filter support outlet pipe pressure gauge 2. Filter support inlet pipe pressure gauge 3. Fuel filter support - 4. External container - 5. Gear pump
- 6. High pressure mechanical fuel pump CP 3.3.
- Remove the fuel supply pipe (4) from the control unit.
- Remove the fuel delivery pipe (6) from the fuel pump (2)
to the filter (5).
- Remove the fuel return pipe (7) from the filter (5) to the
injection pump (2).
- The gear pump (5) serves to supply the high pressure
pump CP.3.3 (6). It is controlled by the shaft of the high
pressure pump and is fitted on its rear part. Keeping the
kit instruments mounted as in the previous figure with
batteries charged to 24.7 V, the engine must start within
20 seconds after activating the starter motor, with fuel
intake from an external container (4) set at a maximum
distance of 1 meter below the engine.
- If the pump does not suck the diesel fuel within the time
indicated and therefore the engine does not start,
replace the pump.
NOTE
If the test was performed with a new mechanical
supply pump from Spares, before doing the test, a
first start is necessary in order to restore normal
operation conditions.
- After starting the engine, at 1500 rpm check the pressure
on the pressure gauge (2).
Technical data
Pressure values at
pressure gauge
Print P4D32N015 E
6 - 9 bar
Base - May 2018
22
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NEF G-Drive SERIES
- If the value measured is below 6 bar, replace the pump;
if the value is above 9 bar, replace the diesel fuel filter.
PROCEDURE FOR HIGH PRESSURE
FUEL PIPE REMOVAL/INSTALLATION
- The pressure gauge (1) must show a pressure above 5
bar; if the pressure is lower, replace the diesel fuel filter.
If the problem is not cleared, check the seals of the high
pressure pump inlet and fuel filter support unions.
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
Place a container for the oil recovery.
Removal
Figure 53
NOTE
A new mechanical fuel pump which is interchangeable with the previous version has been included
in Spares.
The new pump has a new seal protecting against
water entering the area where the two pumps are
joined, thus preventing the formation of rust which
could cause breakage of the shaft connecting the
high and low pressure pumps.
The pump is equipped with seal, however the single
seal is provided as a spare.
When low pressure pump has to be replaced, thoroughly clean the mating area with high pressure
pump CP.3.3.
252284
- Unscrew the fittings (2 and 3) connecting to the injection
pump (4).
- Remove tool 99305453.
- Remove the pipe (4).
Ref.
(1)
(2)
(3)
Refitting
Figure 52
No.
2
1
1
Screws description
Connector M14x1.5
Screw M8x1.25x16
Screw M8x1.25x20
Figure 54
249426
- Connect the fuel delivery pipe (7) from the filter (5) to
the injection pump (2).
- Connect the fuel delivery pipe (6) from the injection
pump (2) to the filter (5).
- Connect the fuel supply pipe (4) from the control unit.
- Connect the fuel return pipe (3) to the injection pump
(2) from the filter (5).
- Connect the excess fuel return pipe (1) from the Common Rail.
Base - May 2018
214297
- Unscrew the fittings (2) connecting the Common Rail.
- Unscrew the fittings (1) connecting to the injectors.
- Take out the pipes (3).
Ref.
(1)
(2)
No.
6
6
Screws description
Connector M14x1.5
Connector M14x1.5
Print P4D32N015 E
NEF G-Drive SERIES
23
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
Refitting
ELECTRONIC CONTROL UNIT
REMOVAL/INSTALLATION
The pipes which were removed cannot be refitted.
Removal
They must be replaced.
Remove the engine cable as described in the relevant section.
Remove the low pressure pipe as described in the relevant
section.
Figure 55
Figure 57
- Position the high pressure pipes (3).
214297
- Tighten the screws (2) to the supporting clamps.
- Tighten the fittings (1 and 2).
Ref.
(1)
(2)
No.
6
6
Screws description
Connector
M14x1.5
1st step
angle
202491
Tightening torques
- Unscrew the nut (4) and the corresponding stud (5).
- Remove the control unit (2).
10 ± 1 Nm
55˚
- Remove the support (1).
Connector
M14x1.5
1st step
angle
- Unscrew the screws (3 and 6).
Ref.
(3)
(4)
(5)
(6)
10 ± 1 Nm
55˚
Figure 56
No.
7
1
1
3
Screws description
Screw M6x1x30
Nut M6x1
Stud M6x1x25
Screw M8x1.25x45
Refitting
- Position the support (1) in the relative seat.
- Position the control unit (2).
- Tighten the stud (5) and the corresponding nut (4).
- Tighten the screws (3 and 6).
252284
Ref.
(3)
(4)
(5)
(6)
No.
7
1
1
3
Screws description
Screw M6x1x30
Nut M6x1
Stud M6x1x25
Screw M8x1.25x45
Tightening torques
10 ± 2 Nm
10 ± 2 Nm
10 ± 2 Nm
24 ± 4 Nm
- Position the pipe (4).
- Tighten the screws (2 and 3) to the supporting clamps.
Fit the low pressure pipes as described in the relevant section.
- Tighten the fittings (1).
Ref.
(1)
(2)
(5)
No.
6
2
2
Print P4D32N015 E
Screws description
Connector
M14x1.5
Screw M8x1.25x16
Screw M8x1.25x20
Tightening torques
Fit the engine cable as described in the relevant section.
28±2 Nm
25 ± 2.5 Nm
25 ± 2.5 Nm
Base - May 2018
24
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR FUEL FILTER REMOVAL/
INSTALLATION
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
Place a container for the oil recovery.
NEF G-Drive SERIES
Refitting
- Position the filter support (4) in the relative seat and
tighten the screws (7).
- Insert the clamp (5) supporting the low pressure pipe (8).
- Tighten the cartridge (6) using tool 99360076.
- Position the pre-filter (3) and tighten the screws (2) and
the relative nuts (1).
Removal
Remove the engine cable as described in the relevant section.
Remove the low pressure pipe as described in the relevant
section.
Figure 58
- Connect all the pipes to the pre-filter (3).
Ref.
(1)
(2)
(6)
(7)
No.
2
2
1
2
Screws description
Nut M8x1.25
Screw M8x1.25x55
Cartridge M20x1.5
Screw
M12x1.75x30
Tightening torques
20 0/+5 Nm
20 0/+5 Nm
80 ± 8 Nm
Fit the low pressure pipes as described in the relevant section.
Fit the engine cable as described in the relevant section.
214298
- Disconnect the fuel pre-filter (3) from all the connection
pipes.
- Unscrew the screw (2) and recover the relative nuts (1).
- Remove the fuel pre-filter (3).
- Unscrew the cartridge (6) of the filter using tool
99360076.
- Remove the clamp (5) supporting the low pressure pipe
(8).
- Unscrew the screws (7) and remove the filter support
(4).
Ref.
(1)
(2)
(6)
(7)
No.
2
2
1
2
Base - May 2018
Screws description
Nut M8x1.25
Screw M8x1.25x55
Cartridge M20x1.5
Screw M12x1.75x30
Print P4D32N015 E
NEF G-Drive SERIES
25
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR TAPPET
COVER REMOVAL/INSTALLATION
Removal
PROCEDURE FOR ROCKER ARM
ASSEMBLY REMOVAL-REFITTING
Removal
Remove the air filter as described in the relevant section
Remove the high pressure pipes as described in the relevant
section.
Remove the oil vapour filter as described in the relevant section
Remove the air filter as described in the relevant section.
Remove the oil vapour filter as described in the relevant section.
Figure 59
Remove the tappet cover as described in the relevant section.
Figure 60
252285
- Unscrew the flanged nuts (1) and remove the rubber
blocks (2).
- Remove the tappet cover (3).
- Recover the plate (4) for the oil vapour condensate.
- Recover the gasket (6).
202413
- Unscrew the double stem screws (5).
Ref.
(1)
(5)
No.
6
6
Screws description
Nut M8x1.25
Screw M8x1.25x17
- Unscrew the screws (1) and remove the suction (2) and
exhaust (3) rocker arms together with the rocker arm
shafts (4).
Ref.
(1)
No.
12
Screws description
Screw M8x1.25x25
Refitting
Refitting
- Tighten the double stem screws (5).
Figure 61
- Insert the gasket (6) into the relative seat.
- Insert the section (4) for the oil vapour condensate.
- Position the tappet cover (3) in the relative seat.
- Insert the rubber blocks and tighten the screws (1).
Ref.
(1)
(5)
No.
6
6
Screws description
Nut M8x1.25
Screw M8x1.25x17
Tightening torques
24 ± 4 Nm
24 ± 4 Nm
Fit the oil vapour filter as described in the relevant section.
Fit the air filter as described in the relevant section
202414
- Assemble the rocker arm assembly after having carried
out a verification.
ROCKER ASSEMBLY COMPONENTS:
1. Fastening screw - 2. Exhaust rocker arm - 3. Tappet
adjustment nuts - 4. Rocker arm shaft - 5. Tappet 6. Pad - 7. Intake rocker arm - 8. Retaining clip
Print P4D32N015 E
Base - May 2018
26
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
Figure 62
NEF G-Drive SERIES
Figure 65
75703
202415
MAIN DATA FOR SHAFT-ROCKER ARMS
Check the coupling surfaces between the support and the
shaft: there must be no sign of excessive wear or damage.
Replace if necessary.
- Insert the rocker arm assembly and the tappet cover
rods. Before re-using retaining screws take two measurements of the diameter as shown in the figure to identify
diameters D1 and D2:
if D1 - D2 < 0.1 mm, the screw can be reused
if D1 - D2 > 0.1 mm, the screw must be replaced
Figure 63
Figure 66
202416
MAIN DATA FOR ROCKER ARM ADJUSTMENT
SCREW
If disassembled, check the adjustment dimension. Tighten the
nut (1).
Ref.
(1)
No.
8
Screws description
Nut M24x1.5
Tightening torques
5 ± 1 Nm
202413
- Position the intake (2) and exhaust (3) rocker arms together with the rocker arm shafts.
- Tighten the screws (1).
Figure 64
Ref.
(1)
122587
Before assembly, check the rocker arm rods: there must be
no sign of any deformation; the spherical seats for contact
with the rocker arm adjusting screw and with the tappets
(arrows) must show no trace of seizure or wear; if they do,
replace them.
No.
12
Screws description
Screw M8x1.25x25
Tightening torques
36 ± 5 Nm
Fit the tappet cover as described in the relevant section.
Fit the oil vapour filter as described in the relevant section.
Fit the air filter as described in the relevant section.
Fit the high pressure engine cable as described in the relevant
section.
Intake and exhaust valve pushrods are identical and are therefore interchangeable.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR FUEL FILTER REMOVAL/
INSTALLATION
Refitting
Removal
- Tighten the screws (1).
Remove the high pressure pipes as described in the relevant
section.
- Introduce the injector (3) together with the fastening
bracket (4).
- Tighten the nuts (2) securing the wiring to the injectors.
Remove the air filter as described in the relevant section.
- Position the filler (5).
Remove the tappet cover as described in the relevant section.
- Tighten the nut (6) connecting to the head.
Remove the rocker arm assembly as described in the relevant
section.
Ref.
(1)
(6)
Figure 67
27
No.
12
6
Screws description
Screw M6x1x35
1st stage
Angle
Nut M22x1.5
Tightening torques
3.5 ± 0.35 Nm
25˚+25˚+25˚
55 ± 5 Nm
Fit the rocker arm assembly as described in the relevant section.
Fit the tappet cover as described in the relevant section.
Fit the air filter as described in the relevant section.
Connect the high pressure pipe as described in the relevant
section.
249427
- Unscrew the nut (6) connecting to the head.
- Remove the filler (5).
- Unscrew the nuts (2) securing the wiring to the injectors.
- Unscrew the screws (1).
- Remove the injector (3) together with the fastening
bracket (4).
Ref.
(1)
(6)
No.
12
6
Print P4D32N015 E
Screws description
Screw M6x1x35
Nut M22x1.5
Base - May 2018
28
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NEF G-Drive SERIES
HIGH PRESSURE PUMP
REMOVAL/INSTALLATION
PROCEDURE FOR INTAKE
MANIFOLD REMOVAL/INSTALLATION
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
Place a container for the oil recovery.
Place a container for the oil recovery.
Removal
Removal
Remove the engine cable as described in the relevant section.
Remove the engine cable as described in the relevant section.
Remove the low pressure pipe as described in the relevant
section.
Remove the high pressure pipe as described in the relevant
section.
Remove the high pressure pipe as described in the relevant
section.
Figure 69
Figure 68
70126
To disconnect lower pressure fuel pipes from their couplings,
press clip (1) as shown in figure B.
202412
After disconnecting the pipe, bring the clip (1) back to the
locking position (figure A), to prevent it from deforming.
- Loosen the nuts (3).
- Remove the fuel pump assembly (1).
Figure 70
- Unscrew the studs (2).
Ref.
(2)
(3)
No.
3
3
Screws description
Stud M8x1.25x50
Nut M8x1.25
Refitting
- Tighten the studs (2).
- Position the feed pump (1) in the relative seat.
- Tighten the nuts (3).
Ref.
(2)
(3)
No.
3
3
Screws description
Stud M8x1.25x50
Nut M8x1.25
Tightening torques
11 ± 3 Nm
24 ± 4 Nm
214300
- Unscrew the screws (4) and remove the pipe (5) connecting to the radiator.
Connect the high pressure pipe as described in the relevant
section.
- Remove the fuel return pipe (2) from the Common rail
(3).
Connect the low pressure pipe as described in the relevant
section.
- Unscrew the double thread screws (1).
Fit the engine cable as described in the relevant section.
Base - May 2018
- Remove the Common Rail (3).
Ref.
(1)
(4)
No.
4
4
Screws description
Screw M8x1.25x130
Screw M8x1.25x25
Print P4D32N015 E
NEF G-Drive SERIES
Figure 71
Figure 73
70126
214301
- Unscrew the screws (1 and 4).
- Remove the intake manifold (3) together with the air
pressure and temperature sensor (2).
Ref.
(1)
(4)
No.
7
3
29
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
To connect lower pressure fuel pipes from their couplings,
press clip (1) as shown in figure B.
After disconnecting the pipe, bring the clip (1) back to the
locking position (figure A).
Screws description
Screw M8x1.25x125
Screw M8x1.25x70
Figure 74
Refitting
Figure 72
214300
- Place the Common Rail (3) in its seat.
- Tighten the double thread screws (1).
214301
- Apply a sufficient layer of LOCTITE 5970 to the mating
surface of the intake manifold (3).
- Position the intake manifold (3) in to the relative seat,
together with the air pressure and temperature sensor
(2).
- Fit the fuel return pipe (2) from the Common rail (3).
- Position the pipe connecting to the radiator (5) and
tighten the screws (4).
Ref.
(1)
No.
3
(4)
4
- Tighten the screws (1 and 4).
Ref.
(1)
(4)
No.
7
3
Screws description
Screw M8x1.25x25
Screw M8x1.25x70
Tightening torques
24 ± 4 Nm
24 ± 4 Nm
Screws description
Screw
M8x1.25x130
Screw M8x1.25x25
Tightening torques
35 ± 6 Nm
23 ± 2 Nm
Fit the high pressure pipes as described in the relevant section.
Fit the engine cable as described in the relevant section.
Print P4D32N015 E
Base - May 2018
30
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
PROCEDURE FOR EXHAUST MANIFOLD
REMOVAL/INSTALLATION
NEF G-Drive SERIES
Figure 76
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
Place a container for the oil recovery.
Removal
Remove the air filter as described in the relevant section.
Remove the turbocharger as described in the relevant section.
Figure 75
214303
- Unscrew the screws (2) to the connection clamps.
- Separate the two elements (1 and 3) which make up the
exhaust manifold.
- Recover the coupling manifolds (4 and 5).
Ref.
(2)
No.
2
Screws description
Screw M6x55
Refitting
Figure 77
214302
- Unscrew the studs (7) supporting the turbocharger.
- Unscrew the screws (3 and 5) securing the exhaust
manifold (2).
- Remove the support plate (4).
- Recover the spacers (6). Remove the exhaust manifold
(2).
- Recover the gaskets (1).
Ref.
(3)
(5)
(7)
No.
9
3
4
Screws description
Screw M10x1.5x65
Screw M10x1.5x65
Stud M10x1.5x42
214303
- Insert the coupling manifolds (4 and 5) into the elements
(2 and 3) which make up the exhaust manifold, together
with the connection clamps.
- Join the elements (1 and 3).
- Tighten the screws (2) to the connection clamps
Ref.
(2)
Base - May 2018
No.
2
Screws description
Screw M6x55
Tightening torques
8 ± 0.5 Nm
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
31
PROCEDURE FOR CYLINDER
HEAD REMOVAL/INSTALLATION
Figure 78
Only proceed when the engine is not turning and is at low
temperature so as not to run the risk of burns.
Place a container for the oil recovery.
Removal
Remove the protective grille as described in the relevant section.
Remove the radiator as described in the relevant section.
Remove the fan as described in the relevant section.
Remove the engine cable as described in the relevant section.
Remove the belt as described in the relevant section.
214302
- Position the exhaust manifold (1) in the specific seat
together with the gaskets (1).
Remove the turbocharger as described in the relevant section.
- Insert the spacers (6).
Remove the exhaust manifold as described in the relevant
section.
- Insert the supporting bracket (4).
Remove the low pressure pipe as described in the relevant
section.
- Tighten the screws (3 and 5).
- Tighten the studs (7) supporting the turbocharger.
Remove the high pressure pipe as described in the relevant
section.
Ref.
(3)
(5)
(7)
Remove the intake manifold as described in the relevant section.
No.
9
3
4
Screws description
Screw M10x1.5x65
Screw M10x1.5x65
Stud M10x1.5x42
Tightening torques
55 ± 3 Nm
55 ± 3 Nm
25 ± 5 Nm
Remove the air filter as described in the relevant section.
Remove the oil vapour filter as described in the relevant section.
Remove the tappet cover as described in the relevant section.
Remove the injectors as described in the relevant section.
Figure 79
Remove the rocker arm assembly as described in the relevant
section.
214304
Tightening sequence:
4 - 11 - 5 - 10 - 3 - 12 - 6 - 9 - 1 - 8 - 2 - 7
TIGHTENING DIAGRAM FOR EXHAUST MANIFOLD
FASTENING SCREWS AS SEEN FROM ENGINE SIDE
Fit the turbocharger as described in the relevant section.
Fit the air filter as described in the relevant section.
Print P4D32N015 E
Base - May 2018
32
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NEF G-Drive SERIES
Refitting
Figure 80
Figure 82
202429
- Unscrew the screws (6) and remove the automatic belt
tensioner (7).
87759
- Position the gasket (1) on the block.
- Unscrew the screws (5) and remove the spacer (4) for
the fan coupling, together with the pulley (3).
- Unscrew the screws (2).
NOTE
- Remove the fan support (1).
Ref.
(2)
(5)
(6)
No.
4
4
2
Check that the block contact surface is clean.
Do not grease the gasket. It is recommended that
the gasket is kept in its packaging until it is fitted on
the head.
Screws description
Screw M8x1.25x45
Screw M10x1.5x110
Screw M8x1.25x30
The gasket is to be fitted in such a way that the writing on the gasket can be read as shown in the
figure.
Figure 81
NOTE
With piston protrusion equal to or less than 0.4, fit
a gasket which is 1.15 thick.
With piston protrusion greater than 0.4, fit a gasket
which is 1.25 thick.
NOTE
If the valves have been removed from the head,
they must be refitted before assembling the head
on the block.
214305
- Unscrew the screws (1 and 4).
- Using the lifting eyelets (2), remove the cylinder head
together with all the elements relating to the timing gear:
- Intake valves;
- Exhaust valves;
- Valve springs;
- Washers;
- Cotters.
- Recover the gasket (3).
Ref.
(1)
(4)
No.
14
12
Base - May 2018
Screws description
Screw M12x1.75x150
Screw M12x1.75x130
Print P4D32N015 E
NEF G-Drive SERIES
NOTE
33
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
Before re-using retaining screws take two measurements of the diameter as shown in the figure to
identify diameters D1 and D2:
Figure 84
if D1 - D2 < 0.1 mm the screw can be reused
if D1 - D2 > 0.1mm the screw must be replaced.
α
214306
- Lubricate the bolts and fit them on the engine head.
75703
- The bolts must be tightened following a ”spiral” pattern,
starting from the bolts in the centre and moving outwards.
- Tighten the bolts in numerous phases until they have all
been correctly tightened.
Figure 83
Figure 85
α
214305
- Position the cylinder head on the block.
- Tighten the screws (1 and 4).
202429
- Position the fan mount (1) and tighten the screws (2).
Ref.
No.
(1)
14
(4)
12
Screws description
Screw
M12x1.75x150
1st stage
Angle
Screw
M12x1.75x130
1st stage
Angle
Tightening torques
55 ± 5 Nm
90˚ + 90˚
35 ± 5 Nm
90˚ + 90˚
- Position the spacer (4) for affixing the fan, together with
the pulley (3).
- Tighten the screws (5).
- Position the automatic belt tensioner (7) and tighten the
screws (6).
Ref.
(2)
(5)
(6)
Print P4D32N015 E
No.
4
4
2
Screws description
Screw M8x1.25x45
Screw
M10x1.5x110
Screw M8x1.25x30
Tightening torques
30 ± 5 Nm
-
Base - May 2018
34
SECTION 6 - REMOVAL/REFITTING OF THE MAIN ENGINE COMPONENTS
NEF G-Drive SERIES
Fit the rocker arm assembly as described in the relevant section.
Fit the injectors as described in the relevant section.
Fit the tappet cover as described in the relevant section.
Fit the oil vapour filter as described in the relevant section.
Fit the air filter as described in the relevant section.
Fit the intake manifold as described in the relevant section.
Connect the high pressure pipe as described in the relevant
section.
Connect the low pressure pipe as described in the relevant
section.
Fit the exhaust manifold as described in the relevant section.
Fit the turbocharger as described in the relevant section.
Fit the belt as described in the relevant section.
Fit the engine cable as described in the relevant section.
Fit the fan as described in the relevant section.
Fit the radiator as described in the relevant section.
Fit the protective grille as described in the relevant section.
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 7 - GENERAL MECHANICAL OVERHAUL
1
SECTION 7
General mechanical overhaul
Page
Print P4D32N015 E
ASSEMBLY ON ROTATING STAND . . . . . . . .
5
- Removal of radiator assembly pipes from
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Removal of protective grille . . . . . . . . . . . . . .
5
- Radiator removal . . . . . . . . . . . . . . . . . . . . . . .
6
- Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
- Removal of components hindering bracket
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
- Removal of turbocharger lubrication return
pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
- Removal of oil filter . . . . . . . . . . . . . . . . . . . . .
8
- Removal of starter motor . . . . . . . . . . . . . . . .
9
- Engine cable removal . . . . . . . . . . . . . . . . . . .
10
- Removal of components hindering bracket
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
- Removal of fuel pipes . . . . . . . . . . . . . . . . . . .
11
- Fuel filter removal . . . . . . . . . . . . . . . . . . . . . .
11
- Feed pump removal . . . . . . . . . . . . . . . . . . . .
11
- Engine lubricant oil drainage . . . . . . . . . . . . . .
12
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT) . . . . . . .
13
- Alternator removal . . . . . . . . . . . . . . . . . . . . .
13
- Alternator mount removal . . . . . . . . . . . . . . .
13
- Removal of water pump . . . . . . . . . . . . . . . . .
13
- Removal of automatic belt tensioner and fan
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Removal of crankshaft pulley . . . . . . . . . . . . . .
14
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE) . . . .
15
- Air filter removal . . . . . . . . . . . . . . . . . . . . . . .
15
Base - May 2018
2
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Page
Page
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE) . . . . .
16
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT) . . . . . . . .
25
- Turbocharger removal . . . . . . . . . . . . . . . . . .
16
- Removing the engine - front cover sealing ring
25
- Removal of heat exchanger . . . . . . . . . . . . . .
16
- Removal of front cover . . . . . . . . . . . . . . . . . .
26
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE) . . . . .
- Oil pump removal . . . . . . . . . . . . . . . . . . . . . .
26
17
- Exhaust manifold removal . . . . . . . . . . . . . . . .
17
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE BOTTOM) . . . . . .
26
- Removal of interconnection control unit . . . .
18
- Removal of piston-connecting rod unit . . . . .
26
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON UPPER SIDE) . . . . . . . .
- Removal of crankshaft . . . . . . . . . . . . . . . . . . .
27
18
- Common Rail removal . . . . . . . . . . . . . . . . . .
18
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR) . . . . . . . . . .
28
- Intake manifold removal . . . . . . . . . . . . . . . . .
18
- Camshaft removal . . . . . . . . . . . . . . . . . . . . . .
28
- Thermostat cover removal . . . . . . . . . . . . . . .
19
- Removal of camshaft bushing . . . . . . . . . . . . .
28
- Removal of tappet cover . . . . . . . . . . . . . . . .
19
- Tappet removal . . . . . . . . . . . . . . . . . . . . . . .
28
- Rocker assembly removal . . . . . . . . . . . . . . . .
19
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
- Electro-injector removal . . . . . . . . . . . . . . . . .
20
- Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . .
29
- Removal of thermostat unit . . . . . . . . . . . . . .
20
- Checking cylinder block head contact surface
30
- Cylinder head unit removal . . . . . . . . . . . . . . .
21
- Timing system . . . . . . . . . . . . . . . . . . . . . . . . .
31
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON RIGHT SIDE) . . . . . . . .
- Measuring main journals and crank pins . . . . .
36
21
- Electronic Control Unit Removal . . . . . . . . . .
- Connecting rod and piston assembly . . . . . . .
44
21
- Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . .
46
- Oil level dipstick removal . . . . . . . . . . . . . . . .
22
- Valve unit removal . . . . . . . . . . . . . . . . . . . . .
46
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE BOTTOM) . . . . . .
22
- Removal of lifting eyelets . . . . . . . . . . . . . . . .
47
- Oil sump removal . . . . . . . . . . . . . . . . . . . . . .
22
- Cylinder head assembly fitting . . . . . . . . . . . . .
50
- Suction strainer removal . . . . . . . . . . . . . . . . .
23
- Installation of lifting eyelets . . . . . . . . . . . . . . .
50
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR) . . . . . . . . . .
23
- Refitting valve assembly . . . . . . . . . . . . . . . . .
50
- Removal of engine flywheel . . . . . . . . . . . . . .
23
ENGINE ASSEMBLY AT BENCH
(CRANKCASE COMPONENTS) . . . . . . . . . .
51
- Removal of flywheel housing seal ring . . . . . .
24
- Refitting tappets . . . . . . . . . . . . . . . . . . . . . . .
51
- Removal of flywheel housing . . . . . . . . . . . . .
24
- Refitting camshaft . . . . . . . . . . . . . . . . . . . . . .
51
- Removal of timing gear . . . . . . . . . . . . . . . . . .
24
- Installation of main half-bearings and oil injectors
51
- Removal of timing gear case . . . . . . . . . . . . . .
25
- Crankshaft refitting . . . . . . . . . . . . . . . . . . . . .
52
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Page
- Installation of pistons-connecting rods . . . . . .
52
- Installation of connecting rod caps . . . . . . . . .
54
- Piston protrusion check . . . . . . . . . . . . . . . . .
55
3
Page
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE) . . . . .
71
- Installation of interconnection control unit . . .
71
- Refitting exhaust manifold . . . . . . . . . . . . . . . .
71
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT) . . . . . . . .
55
- Refitting heat exchanger . . . . . . . . . . . . . . . . .
72
- Oil pump refitting . . . . . . . . . . . . . . . . . . . . . .
55
- Turbocharger refitting . . . . . . . . . . . . . . . . . . .
73
- Removal of front cover sea ring . . . . . . . . . . .
55
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR) . . . . . . . . . .
73
- Refitting front cover . . . . . . . . . . . . . . . . . . . .
56
- Air filter refitting . . . . . . . . . . . . . . . . . . . . . . .
73
- Installation of front cover seal ring . . . . . . . . .
56
ENGINE ASSEMBLY AT THE BENCH
(COMPONENTS AT THE REAR) . . . . . . . . . .
73
- Oil vapour filter refitting . . . . . . . . . . . . . . . . .
73
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR) . . . . . . . . . .
57
- Installation of timing gear housing . . . . . . . . . .
57
- Camshaft gear refitting . . . . . . . . . . . . . . . . . .
58
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT) . . . . . . . .
75
- Refitting engine flywheel housing . . . . . . . . . .
59
- Crankshaft pulley refitting . . . . . . . . . . . . . . . .
75
- Refitting flywheel cover housing sealing ring . .
60
- Installation of automatic belt tensioner and fan
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
- Refitting engine flywheel . . . . . . . . . . . . . . . . .
60
- Refitting water pump . . . . . . . . . . . . . . . . . . .
76
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE BOTTOM) . . . . .
61
- Refitting alternator support . . . . . . . . . . . . . . .
76
- Installation of suction strainer and sound-proof
plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting alternator . . . . . . . . . . . . . . . . . . . . .
76
61
- Installation of feed pump . . . . . . . . . . . . . . . .
77
- Oil sump refitting . . . . . . . . . . . . . . . . . . . . . .
62
- Fuel filter refitting . . . . . . . . . . . . . . . . . . . . . .
77
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE RIGHT SIDE) . . .
62
- Refitting engine cable . . . . . . . . . . . . . . . . . . .
79
- Oil level dipstick refitting . . . . . . . . . . . . . . . . .
63
- Refitting starter motor . . . . . . . . . . . . . . . . . .
80
- Electronic Control Unit Refitting . . . . . . . . . .
63
- Refitting oil filter . . . . . . . . . . . . . . . . . . . . . . .
80
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE TOP) . . . . . . . . . .
64
- Installation of lubricant return pipe from
turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . .
81
- Cylinder head assembly refitting . . . . . . . . . . .
64
- Installation of fan . . . . . . . . . . . . . . . . . . . . . . .
81
- Installation of thermostat unit . . . . . . . . . . . . .
65
- Refitting electro-injectors . . . . . . . . . . . . . . . .
65
- Refitting rocker assembly . . . . . . . . . . . . . . . .
66
- Installation of tappet cover . . . . . . . . . . . . . . .
69
- Refitting intake manifold . . . . . . . . . . . . . . . . .
70
- Common Rail Refitting . . . . . . . . . . . . . . . . . .
70
Print P4D32N015 E
Base - May 2018
4
SECTION 7 - GENERAL MECHANICAL OVERHAUL
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
ASSEMBLY ON ROTATING STAND
Removal of protective grille
Part of the operations covered in this section can be carried
out in relation to the set-up.
NOTE
5
Figure 2
Overhaul operations must be performed by qualified personnel with the specific tools.
The following description covers the engine overhaul operation limited to components that differ according to the specific use.
NOTE
For the needs dictated by application, some units
may be placed on the motor in different positions.
The section ”General mechanical overhaul” contains all the
overhaul operations for the block.
129287
- Remove the protective grilles (5) of the fan acting on the
relative retainers (1, 3 and 4).
- Open the clamps (2).
Removal of radiator assembly pipes from
engine
Figure 1
Ref.
(1)
(2)
(3)
(4)
No.
6
2
1
1
Screws description
Screw M6x1x16
Screw M14x2x30
Screw M8x1.25x16
Screw M6x1x16
Figure 3
129292
- Position a suitable container in line with the pipe (4) to
recover the coolant. Disconnect the pipe (4) acting on
the relative clamps (1).
- Unscrew the screw (3) and release the pipe (4) complete with the bracket (5) from the radiator unit (2).
Ref.
(1)
(3)
No.
2
1
Print P4D32N015 E
252278
- Unscrew the screws (2) and remove the pipe (1) from
the intake manifold.
Ref.
(2)
No.
4
Screws description
Screw M8x1.25x25
Screws description
Screw M14x2x30
Screw M8x1.25x16
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
6
NEF G-Drive SERIES
Radiator removal
Figure 6
Figure 4
129291
129289
- Disconnect the air and water pipes from the radiator
unit.
- Unscrew the screws on the clamps (1, 2, 3 and 4) and
on the fixing bracket (5).
Ref.
(4)
(5)
No.
2
1
Screws description
Screw M14x2x30
Screw M6x1x16
- Disconnect and remove the pipe (1), complete with
sleeves, from the engine side unscrewing the screws on
the relative clamps (6).
- Disconnect and remove the pipe (2), unscrewing the
screw acting on the relative clamp (3).
- Disconnect and remove the pipe (4), complete with
sleeves, from the engine side unscrewing the screws on
the relative clamps (5).
- Suitably block the radiator unit then release it from the
crankcase acting on the retainers from both sides.
- Remove the radiator unit from its seat.
Figure 5
Ref.
(3)
(5)
(6)
No.
2
2
2
Screws description
Nut M14x1.5
Screw M14x2x30
Screw M14x2x30
129290
- Disconnect and remove the pipes (1 and 4), complete
with sleeves from the engine side.
- Unscrew the screws on the clamps (2 and 3).
Ref.
(2)
(3)
No.
1
1
Base - May 2018
Screws description
Screw M6x1x16
Screw M8x1.25x16
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
7
Fan removal
Figure 7
Figure 8
249423
- Unscrew the screw (1) to open the clamp (2).
- Disconnect the exhaust pipe (3).
129297
- Unscrew the screws (2).
NOTE
The shape and size of the exhaust pipe vary depending on engine use.
The relative illustrations provide a general outline
of the work to perform.
However the procedures described are applicable
anyway.
Ref.
(1)
No.
1
- Remove the fan (1) together with the spacer.
NOTE
The relative illustrations provide a general outline
of the work to perform.
Screws description
Screw M6x55
However the procedures described are applicable
anyway.
Ref.
(2)
Print P4D32N015 E
The shape and size of the fan vary depending on
engine use.
No.
6
Screws description
Screw M10x1.5x30
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
8
NEF G-Drive SERIES
Removal of components hindering bracket
assembly
Removal of turbocharger lubrication return
pipes
Removal of oil filter
Figure 10
Figure 9
214337
202144
the lubricant oil drain pipe (2) from the turbocharger:
- unscrew the two screws (1) from below the turbocharger.
To affix brackets 99361037 securing the engine to the stand
99322205 to the engine crankcase and carry out the overhaul, act as follows.
From the right side, remove:
- using tool 99360076 (2), remove the oil filter (1) from
the support.
- Unscrew the screw (3) securing the pipe to the crankcase via the fastening collar (5).
Attention, the oil filter contains approximately 1 kg
of engine oil.
- Finally, extract the fitting (4) from the crankcase;
plug the ends of the pipe and the exhaust on the turbocharger.
Ref.
(1)
(3)
No.
2
1
Collect and dispose of the engine oil according to
applicable laws.
Screws description
Screw M8x1.25x25
Screw M8x1.25x16
Ref.
(1)
Base - May 2018
No.
1
Screws description
Cartridge M27x2
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Removal of starter motor
9
Figure 12
Figure 11
214307
202439
From the left side:
- Appropriately support the starter motor (3).
- Loosen the fastening nuts (1).
- Disconnect the fuel pre-filter (2) from all the connection
pipes.
- Remove the starter motor (3) and unscrew the studs (4).
- Unscrew the screws (1) and the relative nuts.
- Fit the supporting bracket 99361037 using the four
threaded holes (2).
- Remove the fuel pre-filter (2).
Ref.
(1)
(2)
(4)
No.
3
3
3
Screws description
Nut M10x1.5
Screw M12x1.75
Stud M10x1.5x20
Tightening torques
43 ± 6 Nm
-
- Remove the clamp (4) supporting the low pressure pipe
(7).
- Unscrew the screw (5), remove the quick-release couplings (3) and remove the low pressure pipe (7).
- Connect bracket 99361037 (6), inserting the screws (8)
into the threaded holes.
Ref.
(1)
(5)
(8)
Print P4D32N015 E
No.
2
1
4
Screws description
Screw M8x1.25x55
Screw M20x1.5
Screw M12x1.75
Ttightening torques
43 ± 6 Nm
Base - May 2018
10
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Engine cable removal
Figure 13
252290
1. Exhaust gas valve connection - 2. Interconnection Control Unit - 3. Air pressure / temperature sensor 4. Timing gear phase sensor - 5. Pressure regulator cable - 6. Fuel temperature sensor and fuel heater cable - 7. EDC 7
electronic control unit - 8. Crankshaft sensor - 9. Fuel pressure sensor cable - 10. Engine oil temperature and pressure
sensor - 11. Engine coolant temperature sensor - 12. Electro-injector - 13. Connections for electro-injectors.
Disconnect the engine cable from the connectors: (13) injector wiring; (3) air pressure/temperature sensor; (9) fuel pressure
sensor; (7) Control unit; (4) timing gear phase sensor; (11) engine coolant temperature sensor on thermostat; (8) engine speed
sensor.
Remove the clamps that hold it to the crankcase and remove it completely.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Removal of components hindering bracket
assembly
Removal of fuel pipes
Figure 14
Ref.
(2)
(3)
(6)
No.
2
1
1
11
Screws description
Screw M12x1.75x30
Cartridge M20x1.5
Sensor M14x1.5
Figure 16
249429
- Remove the excess fuel return pipe (1) from the Common Rail.
- Remove the fuel return pipe (3) to the injection pump
(2).
- Remove the fuel delivery pipe (5) to the injection pump
(2).
- Remove the fuel return pipe (7) from the injection pump
(2) to the filter (4).
- Unscrew the Voss fitting (6).
Ref.
(6)
No.
1
Screws description
Connector M12x1.5
Fuel filter removal
249428
- Unscrew the unions (1).
- Unscrew the screws (2 and 3).
- Remove the high pressure supply pipe (4) of the Rail.
Ref.
(1)
(2)
(3)
No.
2
1
2
Screws description
Connector M14x1.5
Screw M8x1.25x16
Screw M8x1.25x20
Feed pump removal
Figure 15
Figure 17
202446
- Loosen the nuts (3).
214309
- Unscrew the fuel temperature sensor (6).
- Unscrew the cartridge (3) using tool 99360076 (4).
- Unscrew the screws (2).
- Remove the fuel filter support (1), together with the fuel
preheating resistor (5).
Print P4D32N015 E
- Remove the fuel pump assembly (1).
- Unscrew the studs (2).
Ref.
(2)
(3)
No.
3
3
Screws description
Stud M8x1.25x50
Nut M8x1.25
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
12
NEF G-Drive SERIES
Engine lubricant oil drainage
Figure 18
Figure 19
158823
- Lock rotation of the high-pressure pump (1) drive shaft
(2).
- Remove the nut (3), washer (4) using the double effect
bridge 99341001, brackets 99341009 and clamp
99341015, remove the gear (5) from the shaft (2).
Ref.
(3)
No.
1
218543
- Drain the oil through the plug (1) located below the oil
sump.
The oil sump contains approximately 13.5 kg of
engine oil.
Screws description
Nut M18x1.5
Collect and dispose of the engine oil according to
applicable laws.
Ref.
(1)
Base - May 2018
No.
1
Screws description
Plug M18x1.5
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT)
13
Alternator mount removal
Figure 22
Alternator removal
Figure 20
202149
- Unscrew the screws (5 and 6).
202147
- Loosen the screw (3) anchoring the alternator to its
lower support and the bolt (4) securing the alternator
to the bracket.
Ref.
(3)
(4)
(4)
No.
1
1
1
Screws description
Screw M10x1.5
Screw M10x1.5
Nut
- Using the tool (5), rotate the automatic tensioner (1) in
the direction of the arrow and remove the belt (2).
Figure 21
- Remove the alternator mount (4).
- Unscrew the screw (1) and recover the supporting bracket (7).
- Recover the
pins (2).
Ref.
No.
(1)
1
(5)
2
(6)
1
gasket (3) and the cable reference dowel
Screws description
Screw M10x1.5x20
Screw M10x1.5x135
Screw M10x1.5x70
Removal of water pump
Figure 23
202148
- Unscrew the screw (3) anchoring the alternator to its
lower support and the screw (1) securing it to the bracket (2).
Ref.
(1)
(3)
No.
1
1
Screws description
Screw M10x1.5
Screw M10x1.5
202150
- Undo the screws (1) and remove them.
- Take the water pump (2) out of its housing.
- Recover the gasket (3).
Ref.
(1)
No.
2
Screws description
Screw M8x1.25x35
- Remove the alternator from the housing.
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
14
NEF G-Drive SERIES
Removal of automatic belt tensioner and fan
support
Removal of crankshaft pulley
Figure 26
Figure 24
214338
202151
- Unscrew the screw (7) and remove the automatic belt
tensioner (8)
- Unscrew the screws (1) and remove the belt tensioner
mount (9).
- Unscrew the screws (5) and remove the spacer (4) for
the fan coupling together with the drive pulley (3).
- Unscrew the screws (6) and remove the fan mount (2).
Ref.
(1)
(5)
(6)
(7)
No.
2
4
4
1
Screws description
Screw M8x1.25x30
Screw M10x1.5x110
Screw M8x1.25x45
Screw M10x1.5x70
- Unscrew the screws (6) securing the flange (7) to the
front hub (8).
- Remove the front hub (8).
- Unscrew the screws (5).
- Remove the spacer (4) for the shaft and the pulley (3).
- Unscrew the screw (2) securing the idler pulley.
- Remove the core plug (1).
Ref.
(2)
(5)
(6)
No.
1
6
6
Screws description
Screw M10x1.5x70
Screw M12x1.25x78.5
Screw M10x1.25x40
Figure 25
202456
- Unscrew the screw (1) and remove the crankshaft speed
sensor (4).
- Unscrew the screw (2) and remove the plug (3).
Ref.
(1)
(2)
No.
1
1
Base - May 2018
Screws description
Screw M6x1x20
Screw
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE)
15
Figure 29
Air filter removal
Figure 27
252288
- Unscrew the bolts (1) and remove the blow-by filter (2).
214313
Ref.
(1)
No.
2
Screws description
Bolt M6x1x25
- Unscrew the screws (4) and remove the air filter (1)
from the relative support.
- Unscrew the screws (2) together with the relative nuts
and remove the support (3).
Ref.
(2)
(4)
No.
2
2
Screws description
Screw M8x1.25x100
Screw M8x1.25x100
Figure 30
Figure 28
202471
- Unscrew the support screw (1) at the clamp.
- Remove the engine breather pipe (4).
252287
- Remove the clamps (2, 3 and 6).
- Remove the pipes (1, 4 and 5) connecting to the blow-by
filter.
Ref.
(2)
(3)
(6)
No.
1
2
1
Print P4D32N015 E
- Unscrew the threaded fittings (2) and remove the pipe
(3).
Ref.
(1)
(2)
No.
1
2
Screws description
Screw M6x1
Fitting M12x1.5x11
Screws description
Screw M25x40
M16x25 screw
Screw M20x32
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
16
NEF G-Drive SERIES
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE)
Figure 31
Turbocharger removal
Figure 32
252561
- Unscrew the screws (1 and 3) and remove the support
(2).
Ref.
(1)
(3)
No.
2
1
Screws description
Screw M12x1.75x25
Screw M10x1.5x20
214314
NOTE
Before proceeding, make sure that the turbocharger has been disconnected from all the exhaust gas
and engine air intake pipes.
- Unscrew the fittings (1) for the oil deliver pipe (2) to the
turbocharger (4).
- Unscrew the nuts (3) and remove the turbocharger (4).
- Recover the gasket on the intake manifold.
Ref.
(1)
(3)
No.
2
4
Screws description
Fitting 11/16”
Nut M10x1.5
Removal of heat exchanger
Figure 33
202458
- Unscrew the screws (1) and remove the oil pressure/
temperature sensor (2).
Ref.
(1)
Base - May 2018
No.
2
Screws description
Screw M6x1x20
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
17
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE)
Figure 34
Exhaust manifold removal
Figure 36
202459
- Unscrew the screws (2) and remove the oil filter bracket
(1).
214315
- Extract the insulating plates (3).
- Extract the heat exchange elements (5).
- Unscrew the studs (7) supporting the turbocharger.
- Remove the two sealing gaskets (4).
Ref.
(2)
No.
15
- Unscrew the screws (3 and 5) securing the exhaust
manifold (2).
Screws description
Screw M8x1.25x35
- Remove the support plate (4).
- Recover the spacers (6).
- Remove the exhaust manifold (2).
- Recover the gaskets (1).
Ref.
(3)
(5)
(7)
Figure 35
No.
9
3
4
Screws description
Screw M10x1.5x65
Screw M10x1.5x65
Stud M10x1.5x42
202460
From the oil filter housing (5):
- remove the pressure control valve (4).
- unscrew the plug (1), remove the compression spring (2)
and remove the pressure control valve (3).
Ref.
(1)
No.
1
Print P4D32N015 E
Screws description
Plug M22x1.5
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
18
NEF G-Drive SERIES
Removal of interconnection control unit
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON UPPER SIDE)
Common Rail removal
Figure 37
Figure 38
214316
214333
- Unscrew the nuts (1) from the rubber blocks (4).
- Remove the interconnection control unit (5) together
with the rubber blocks (4).
- Unscrew the screws (3) and remove the support (2).
Ref.
(1)
(3)
No.
8
2
Screws description
Nut M6x1
Screw M12x1.75x30
- Unscrew the nuts (1) connecting the high pressure pipes
to the Common Rail (2).
- Unscrew the double thread screws (3) and remove the
Common rail (2).
Ref.
(1)
(3)
NOTE
No.
6
4
Screws description
Nut M14x1.5
Screw M8x1.25x125
When unlocking the fittings securing the pipe to
the rail, a special wrench is needed to prevent the
possible rotation of the flow limiters.
Intake manifold removal
Figure 39
214317
- Unscrew the screw (2) and remove the air pressure and
temperature sensor (3).
- Unscrew the screws (4) and remove the cover (5).
- Recover the gasket (6).
- Unscrew the screws (1 and 8) and remove the intake
manifold (7).
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Ref.
(1)
(2)
(4)
(8)
No.
7
1
6
3
Screws description
Screw M8x1.25x25
Screw M6x1x20
Screw M6x1x20
Screw M8x1.25x70
Ref.
(1)
(3)
(5)
No.
6
1
6
19
Screws description
Nut M8x1.25
Plug M38x3
Screw M8x1.25x17
Rocker assembly removal
Thermostat cover removal
Figure 42
Figure 40
214319
252562
- Unscrew the screws (1) and remove the thermostat
cover (2).
Ref.
(1)
No.
3
- Unscrew the screws (2).
- Unscrew the nuts (1) on the electro-injectors
- Remove the connectors (3) on the electro-injectors.
Screws description
Screw M6x1x12
Ref.
(1)
(2)
No.
12
3
Screws description
M4 nut
Screw M6x1x16
Figure 43
Removal of tappet cover
Figure 41
214320
214318
- Unscrew the flanged nuts (1) and remove the rubber
blocks (2).
- Recover the oil filling cap (3).
- Remove the tappet cover (4).
- Recover the section (7) for the oil vapour condensate.
- Recover the gasket (6).
- Unscrew the double stem screws (5).
Print P4D32N015 E
- Unscrew the screws (1) and remove the rocker arm
assemblies (6).
- Unscrew the screws (2 and 5).
- Remove the housing (3) and the rocker arm pushrods
(4), together with the housing seats and the balls.
Ref.
(1)
(2)
(5)
No.
12
2
5
Screws description
Screw M8x1.25x25
Screw M8x1.25x50
Screw M8x1.25x70
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
20
NEF G-Drive SERIES
Figure 44
Figure 46
218536
- Remove the gasket (3).
- Remove the intake and exhaust pushrods (2).
- Extract the sheaths (1).
- Unscrew the coolant temperature sensor (4).
Ref.
(4)
No.
1
Screws description
Sensor M14x1.5
70133
- Using tool 99342101 (1), extract the electro-injectors
(2) from the cylinder head.
Electro-injector removal
Figure 45
Removal of thermostat unit
Figure 47
214323
- Unscrew the ring nuts (2) and remove the fillers (3).
- Unscrew the screws (1) and remove the brackets (4)
securing the injectors (5).
- Remove the injectors (5).
Ref.
(1)
(2)
No.
12
6
Base - May 2018
214324
- Remove the thermostat assembly (1) extracting it from
its seat.
Screws description
Screw M6x1x35
Ring nut M22x1.5
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Cylinder head unit removal
21
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON RIGHT SIDE)
Electronic Control Unit Removal
Figure 48
Figure 49
214305
- Unscrew the screws (1 and 4).
- Using tool 99360595 via the lifting eyelets (2), remove
the cylinder head together with all the elements relating
to the timing gear:
- Intake valves;
- Exhaust valves;
- Valve springs;
- Washers;
- Cotters.
- Recover the gasket (3).
Ref.
(1)
(4)
No.
14
12
Print P4D32N015 E
Screws description
Screw M12x1.75x150
Screw M12x1.75x130
202480
- Unscrew the screws (3 and 6).
- Unscrew the nut (4) and the corresponding stud (5).
- Remove the control unit (2).
- Unscrew the Voss fitting (7).
- Remove the support (1).
Ref.
(3)
(4)
(5)
(6)
(7)
No.
7
1
1
3
1
Screws description
Screw M6x1x30
Nut M6x1
Stud M6x1x25
Screw M8x1.25x45
Connector M12x1.25
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
22
NEF G-Drive SERIES
Oil level dipstick removal
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE BOTTOM)
Figure 50
Oil sump removal
Figure 52
214335
- Remove the core plugs (1, 3 and 4).
- Unscrew the plugs (2 and 6).
- Remove the oil level dipstick (5).
214326
- Unscrew the screws (7) and remove the cover (8) together with the gasket.
- Overturn the engine.
- Unscrew the screws (1 and 6) securing the oil sump (3).
- Remove the spacer (2) and the gasket (4).
Ref.
(2)
(6)
(7)
No.
2
2
2
Screws description
Plug M14x1.5
Plug M10x1
Screw M8x1.25x20
- Remove the oil sump (3).
Ref.
(1)
(2)
Figure 51
No.
14
4
Screws description
Screw M8x1.25x40
Screw M8x1.25x45
202481
- Unscrew the screws (5) and remove the cover (6) at the
control socket.
- Recover the gaskets (7).
- Unscrew the nut (4) and remove the camshaft speed
sensor (3).
- Unscrew the studs (1) and remove the support (2).
Ref.
(1)
(4)
(5)
No.
1
1
2
Base - May 2018
Screws description
Stud M6x1x30
Nut M6x1
Screw M12x25
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Suction strainer removal
23
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR)
Figure 53
Removal of engine flywheel
Figure 54
202179
- Unscrew the screws (2) securing the suction strainer (3).
- Unscrew the screws (1) securing the bracket (7).
- Unscrew the screw (8).
- Remove the suction strainer (3) support bracket (7).
- Remove the suction strainer (3).
- Remove the flange (4).
- Recover the gasket (5).
202484
- Unscrew the two opposing screws (2) where the extraction pins will be inserted (see following figure).
- Unscrew the remaining screws securing the flywheel (3)
from the crankshaft.
- Remove the flywheel locking tool 99360351 (1).
Ref.
(2)
No.
8
Screws description
Screw M12x1.25x30
Figure 55
- Remove the sound-proof plate (6).
- Overturn the engine.
Ref.
(1)
(2)
(8)
No.
4
2
1
Screws description
Screw M10x1.5
Screw M8x1.25x20
Screw M10x1.5x40
218548
- Screw in two screws of average length into the holes (4)
to sling the flywheel with a hoist.
- Using the two guide pins (2) previously screwed into the
crankshaft holes (3) guide the engine flywheel (1) out
with the help of the hoist.
Print P4D32N015 E
Base - May 2018
24
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Removal of flywheel housing seal ring
Removal of flywheel housing
Figure 57
Figure 56
202485
00903t
- Take out the flywheel housing seal ring applying tool
99340056 (3) onto the rear tang (5) of the crankshaft.
- Through the guiding holes of the tool itself, drill the internal seal ring with a bit (Ø 3.5 mm) to a depth of 5 mm.
- Secure tool 99340056 (3) to the ring (1) screwing in the
6 screws (4) supplied.
- Remove the ring (1) by screwing up the screw (2).
- Using an appropriate tie rod of tool 99363204 and a
lever, take out the external seal ring from the flywheel
housing.
- Unscrew the screws (1, 2, 3 and 4).
- Remove the flywheel housing (5).
Ref.
(1)
(2)
(3)
(4)
NOTE
No.
2
2
10
6
Screws description
Screw M12x1.75
Screw M10x1.5
Screw M10x1.5
Screw M12x1.75
Take note of the assembly position of the screws
since they are of different sizes.
Removal of timing gear
Figure 58
202486
- Unscrew the screws (1) and remove the timing gear (3).
- Remove the collar (2).
Ref.
(1)
Base - May 2018
No.
6
Screws description
Screw M8x1.25x25
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Removal of timing gear case
25
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT)
Figure 59
Removing the engine - front cover sealing ring
Figure 60
202487
- Unscrew the screws (1, 2, 4 and 5).
- Remove the timing gear case (3).
Ref.
(1)
(2)
(4)
(5)
NOTE
No.
4
3
1
2
Screws description
Screw M8x1.25
Screw M10x1.5
Screw M12x1.75
Screw M10x1.5
202180
- Take out the crankshaft seal ring from the front cover.
- Use tool 99340055 (4) on the front tang (2) of the crankshaft.
- Through the guiding holes of the tool itself, drill the internal seal ring (1) with a bit (Ø 3.5 mm) to a depth of 5
mm.
- Secure the tool to the ring screwing in the 6 screws supplied. Remove the ring (1) by screwing up the screw (3).
Take note of the assembly position of the screws
since they are of different sizes.
Figure 61
202181
- Using the specific tie rod (3) of tool 99363204 and with
the help of the lever (4), remove the external seal ring
(2) from the front cover (1).
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
26
NEF G-Drive SERIES
Removal of front cover
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE BOTTOM)
Figure 62
Removal of piston-connecting rod unit
Figure 64
252286
- Unscrew the screws (4 and 5) securing the front cover
(1).
- Remove the front cover (1) together with the gasket (3)
and recover the cable reference dowel pins (2).
Ref.
(4)
(5)
No.
8
5
202194
- Overturn the engine.
- Unscrew the screws (1).
Screws description
Screw M8x1.25x30
Screw M8x1.25x45
- Remove the caps (2) and the big end half-bearings.
- Withdraw the pistons including the connecting rods
from the top of the engine block.
Oil pump removal
Ref.
(1)
Figure 63
NOTE
No.
12
Screws description
Screw M10x1.25
Keep the half-bearings in their housings since in
case of use they shall be fitted in the same position
found at removal.
202184
- Unscrew the supporting screws (2).
- Remove the oil pump (1).
Ref.
(2)
No.
4
Base - May 2018
Screws description
Screw M8x1.25x30
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Removal of crankshaft
27
Figure 67
Figure 65
70162
202193
- Unscrew the main bearing cap screws (1).
- Remove the main half-bearings (1).
- Remove the main bearing caps (2).
- Unscrew the screws (2) and remove the oil injectors (3).
- Recover the cable reference dowel pins (3).
Ref.
(2)
- Recover the lower main half-bearings (4).
Ref.
(1)
No.
14
No.
4
Screws description
Screw M8x1.25x20
Screws description
Screw M12x1.75x80
The second last main bearing cap (5) and the relevant support are fitted with shoulder half-bearing (6).
NOTE
Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be
fitted in the same position found at removal.
Figure 66
202195
- Use tool 99360500 (2) and a hoist to remove the crankshaft (1) from the crankcase.
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
28
NEF G-Drive SERIES
DISASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR)
Tappet removal
Figure 70
Camshaft removal
Figure 68
70165
- Withdraw the tappets (1) from the crankcase.
202197
- Unscrew the screws (1).
- Carefully extract the camshaft (2) from the crankcase,
making sure it does not knock against the bushing (3).
- Recover the shoulder plate (4).
Ref.
(1)
NOTE
No.
2
Screws description
Screw M8x1.25x16
Take note of plate (4) assembling position.
Removal of camshaft bushing
Figure 69
70174
- Remove the camshaft bushing (3) using drift 99360362
(2) and handgrip 99370006 (3).
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
CHECKS
29
Figure 71
Cylinder block
Figure 72
70167
70166
Once the engine is disassembled, thoroughly clean the cylindercrankcase assembly.
Use the proper rings to handle the cylinder block.
Carefully inspect the crankcase for cracks.
Check the condition of casting hole plugs. If the caps are rusted,
or if there is any doubt about the efficiency of the seal, replace
them.
Inspect the surfaces of the cylinder liners; they should not be
scored, seized, ovalised, conical or worn to excess.
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 ovalization, taper or wear be found, bore and grind the
cylinders. The refacing of the cylinder liners should be made in
relation to the diameter of the pistons supplied as spare parts,
which are oversized by 0.4 - 0.8 mm of the nominal value and
to the prescribed assembly clearance.
The internal diameter of the cylinder liners is checked to ascertain the extent of ovalization, taper and wear, using the bore
meter (1) fitted with a dial gauge previously reset on the ring
gauge (2) of the diameter of the cylinder liner.
NOTE Should the ring gauge be not available, use a micrometer for zero-setting.
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
30
NEF G-Drive SERIES
Figure 73
α
107804
NOTE In case of regrinding, all cylinders are to have the
same oversize (0.4 - 0.8 mm).
Check main bearing housings as follows:
- fit the main bearings caps on the supports without bearings;
- tighten the fastening screws to the specified torque;
- use the proper internal gauge to check whether the housing diameter is falling within the specified value.
Replace if higher value is found.
Checking cylinder block head contact surface
After establishing the areas of deformation, correct the contact surface with a grinding machine.
Planarity error shall not exceed 0.075 mm.
Check the state of the cylinder assembly machining plugs; if
they are rusty or there is any doubt at all about their seal,
replace them.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
31
Timing system
Camshaft
Figure 74
84289
MAIN DATA ABOUT CAMSHAFT JOURNALS
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 need to be extra smooth; if they show any signs
of seizing or scoring, the shaft and the relevant bushings
should be replaced.
Bushings and seats
Figure 76
Cam lift and pin alignment
Set the shaft on tailstocks and, using a dial gauge on the
middle journal, check that the alignment error is no greater
than 0.04 mm: change the shaft if it is any greater.
Figure 75
70172
The bushing (2) for the camshaft must be forced into its seats.
Internal surfaces must not show seizing or wear.
Measure the diameter of the intermediate seats (1) and
bushing (2) for the camshaft using a bore gauge (3).
70171
Check camshaft (2) journals diameter using micrometer (1)
on two perpendicular axes.
Print P4D32N015 E
Measurements shall be performed on two perpendicular
axes.
Base - May 2018
32
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Figure 77
107268
BUSHING MAIN DATA FOR CAMSHAFT AND RELATING SEAT
* Dimension to be obtained after driving the bushing
Tappets
Figure 78
202493
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON CRANKCASE
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Fitting tappets - Camshaft
33
Figure 81
Figure 79
70176
70238
Lubricate the tappets (1) and fit them into the relevant housings on the crankcase.
Position the camshaft (3) retaining plate (1) with the slot
facing the top of the crankcase and the marking facing the
operator, then tighten the screws (2).
Ref.
(2)
Figure 80
No.
2
Screws description
Screw M8x1.25x16
Tightening torques
24 ± 4 Nm
Figure 82
70164
Lubricate the camshaft support bushing and fit the camshaft
(1) taking care not to damage the shaft support seats or
bushing during this operation.
Print P4D32N015 E
70179
Check the camshaft axial clearance (1).
It must be 0.23 ± 0.13 mm.
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
34
NEF G-Drive SERIES
Replacing bushing
Figure 83
Figure 85
70180
Fit the spray nozzles (2) and tighten the filler (1).
70174
Ref.
(1)
No.
4
Screws description
Screw M8x1.25x20
Tightening torques
15 ± 1 Nm
To replace the bushing (1), use drift 99360362 (2) and handgrip 99370006 (3) for assembly operations.
The gear bushings shown in Figure 84 can be replaced when
they are worn. After driving in the bushing, bore it to obtain
the diameter shown in Figure 84.
Transmission gear
Figure 84
202198
Base - May 2018
NOTE
The bushing must be driven into the gear in the
direction of the arrow setting it to the dimension
shown in Figure 84.
NOTE
During assembly, the bushing (1) must be oriented
so that the lubrication holes match with the ones
on the seats of the crankcase.
Rated assembling play between gear bushings and pins: 0.038
- 0.152 mm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
35
Crankshaft
Main journals and crankpins
Oil pump drive gear replacement
Figure 86
Figure 87
70182
70184
Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180 ˚C for 10 minutes
in an oven, then key it to the crankshaft.
If signs of seizure, scoring or excessive ovalisation on main
journals and crankpins are identified, it is necessary to regrind
the pins. Before grinding the journals (2) measure them with
a micrometer (1) to decide the final diameter to which the
pins are to be ground.
NOTE
It is recommended to record the readings on a
chart.
See Figure 88.
Undersize classes are of: 0.250 - 0.500 mm.
NOTE
The main journals and crankpins must always be
ground to the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins, letter M.
Letter B for undersized main journals.
For undersized crankpins and main journals, letter
MB.
Print P4D32N015 E
Base - May 2018
36
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Measuring main journals and crank pins
Figure 88
201764
TABLE IN WHICH TO NOTE DOWN THE MEASURED VALUES
OF THE MAIN JOURNALS AND CRANKPINS
* Nominal value
Figure 89
201765
MAIN CRANKSHAFT TOLERANCES
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
37
Figure 90
MAIN JOURNAL ON TIMING
SYSTEM DRIVE SIDE
INTERMEDIATE MAIN
JOURNALS
FIRST MAIN JOURNAL
ON FRONT SIDE
70237
TOLERANCES
SHAPE
ORIENTATION
POSITION
OSCILLATION
TYPICAL TOLERANCE
Circularity
Cylindricity
Alignment
Perpendicularity
Straightness
Concentricity or coaxiality
Circular oscillation
Total oscillation
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL
○
/○/
//
GRAPHIC SYMBOL
CRITICAL

IMPORTANT
¨
SECONDARY
©
Print P4D32N015 E
Base - May 2018
38
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Main bearings assembly
Figure 93
Figure 91
128169
- thoroughly clean the parts and remove any trace of oil
70185
NOTE
- fit caps (1), including the half bearings (2) on the relevant
supports.
Refit the main bearings that have not been replaced, in the same position found at removal.
NOTE
The main bearings (1) are supplied as spare parts undersized
on the inner diameter by 0.250 - 0.500 mm.
NOTE
Before re-using retaining screws take two measurements of the diameter as shown in the figure to
identify diameters D1 and D2:
if D1 - D2 < 0.1mm the screw can be reused
if D1 - D2 > 0.1mm the screw must be replaced
Do not modify the bearings in any way.
Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings.
75703
The second last main half bearing (1) is fitted with shoulder
half rings.
Main journal assembly clearance measurement
Figure 92
202195
Install the crankshaft (1).
Check the clearance between the crankshaft main journals
and their respective bearings as follows:
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
39
Checking crankshaft end float
Figure 94
Figure 95
α
70187
Screw in the pre-lubricated screws (1) in two phases:
- 1st phase with torque wrench;
70190
- 2nd phase with tool 99395216.
Ref.
(1)
No.
10
Screws description
Screw
M12x1.75x120
1st phase
2nd phase
Tightening torques
80 ± 8 Nm
90˚
This check is performed by setting a magnetic-base dial gauge
(2) on the crankshaft (3) as shown in the figure, the normal
assembly clearance is 0.068 - 0.410.
If a greater clearance is found, replace the main half bearings
of the second last rear support (1) carrying the thrust bearings and repeat the clearance check between the main half
bearings and crankshaft pins.
Piston-connecting rod assembly
Figure 96
60607
CONNECTING ROD - PISTON ASSEMBLY
1. Connecting rod body - 2. Half-bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Circlip - 6. Slotted oil
scraper ring with spiral spring - 7. Claw seal ring - 8. Trapezoidal seal ring - 9. Piston pin - 10. Piston
Print P4D32N015 E
Base - May 2018
40
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Make sure the pistons do not show any trace of seizing, scoring, cracking or excessive wear; otherwise, replace them.
Figure 99
Removal
Figure 97
49025
Piston pin removal (1).
If removal is difficult use an appropriate drift.
60608
Removing the circlips from the piston (2) using pliers
99360183 (1).
Circlips and seats
Pistons are equipped with three circlips: the first is a sealing
ring, with a trapezoidal section; the second is a sealing ring
with chamfer cut; the third is a scraper ring.
Figure 100
Pistons are grouped into classes A and B for diameter.
Figure 98
16552
Check the thickness of the circlip (2) using a micrometer (1).
Figure 101
49024
Removal of piston pin circlips (2) using the round tipped
pliers (1).
128140
Check the clearance between the seal rings (3) of the 2nd and
3rd slot and the relevant housings on the piston (2), using a
feeler gauge (1).
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
41
Piston pin
Figure 102
Figure 104
41104
18857
DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
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 engine block so that
the ring (2) protrudes half-way from the cylinder liner (3).
In this position, use a feeler gauge to check the clearance (X)
between the ring and the slot: this clearance must be as specified.
Measuring the diameter of the gudgeon pin (1) with a micrometer (2).
Conditions for correct pin-piston coupling
Figure 105
Figure 103
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; Pin must be inserted in the piston with
a light finger pressure and it should not come out by gravity.
Pistons
Figure 106
70194
Use feeler gauge (1) to measure the clearance between the
end of the circlip (2) fitted into the cylinder liner (3).
106220
Using a micrometer (2), measure the piston diameter (1) to
determine the assembly clearance; The diameter has to be
detected at the value indicated in figure.
Print P4D32N015 E
Base - May 2018
42
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Figure 107
201712
MAIN DATA REGARDING KS PISTON, PIN AND CIRCLIPS
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Connecting rods
43
Connecting rod check
Figure 109
Every connecting rod is marked as follows:
- On the body and cap with a number showing their coupling and the corresponding cylinder into which it is to
be fitted. If replaced, it is therefore necessary to number
the new connecting rod with the same number as the
one that has been removed.
- On the connecting rod body with a letter showing the
weight of the connecting rod assembled at production:
- V, 1734 - 1774 g
(marked in yellow);
W, 1775 - 1814 g
(marked in green);
X, 1815 - 1854 g
(marked in blue);
Replacement connecting rods are of the W class and are
marked in green.
Material removal is not allowed
Figure 108
61696
Checking the alignment of the axes
Check the connecting rods axes for parallelism (1) using a suitable device (5) and proceeding as follows.
Fit the connecting rod (1) on the spindle of the tool (5) and
lock it with the screw (4).
Set the spindle (3) on the ”V” prisms resting the connecting
rod (1) on the stop bar
246940
NOTE
To obtain best coupling the connecting rod cap
coupling surfaces are knurled. It is therefore recommended to not remove knurling.
Print P4D32N015 E
Base - May 2018
44
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Connecting rod and piston assembly
Figure 110
Figure 112
61694
Check the torsion of the connecting rod (5) by comparing
two points (A and B) of the pin (3) on the horizontal plane
of the axis of the connecting rod.
Position the dial gauge (2) support (1) so that there is a preload of ~ 0.5 mm on the pin (3) in point A and then set the
dial gauge (2) to zero. Move the spindle (4) with the connecting rod (5) and compare any deviation on the opposite side
B of the pin (3): the difference between A and B must be no
greater than 0.08 mm.
202496
1. Stamp IVECO Part Number - 2. Stamp arrow - 3. Stamp
date - 4. Stamp ”U” for completed US check of connector
fitted - 5. Mahle product traceability
Connecting rod-piston pairing
Box ”I”: month and year of registration;
Box ”N”: engine variant to be completed according to engine
records (last three digits of the theoretical code);
Box “P”: Serial number to be assigned in the manufacturing
plant;
Figure 111
202201
Bending check
Check the bending of the connecting rod (5) by comparing
two points C and D of the pin (3) on the vertical plane of the
axis of the connecting rod.
Position the vertical support (1) of the dial gauge (2) so that
it rests on the pin (3) at point C. Swing the connecting rod
to and fro, seeking the highest position of the pin and reset
the dial gauge (2) in this condition.
Move the spindle (4) with the connecting rod (5) and repeat
the check of the highest point on the opposite side D of the
pin (3). The difference between point C and point D must
not exceed 0.08 mm.
Base - May 2018
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SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Figure 113
45
Figure 115
126311
70199
Connect piston (2) to the connecting rod (4) with pin (3) so
that the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) stamped on the connecting rod (4) are read as shown in the figure.
Figure 114
Fitting the circlips
Use callipers 99360183 (1) to fit the circlip (2) on the piston.
Piston rings shall be fitted with the marking ”TOP” facing
upwards and their openings shall be displaced with each
other by 120º.
NOTE
Spare piston rings are supplied in the sizes below:
- standard;
- increased by 0.4 mm.
Figure 116
126312
Fit the pin fastening circlips (2).
70200
Fit the half bearings (1) on both the connecting rod and cap.
NOTE
Print P4D32N015 E
Not finding it necessary to replace the connecting
rod bearings, refit them in exactly the same
sequence and position as in removal. Do not make
any adjustment on the half-bearings.
Base - May 2018
46
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Cylinder head
Valve unit removal
Cylinder head assembly removal
Figure 118
Figure 117
214349
70323
NOTE
Before removing the valves from the cylinder head,
number them so that they can be re-installed in the
same positions they were removed from if they are
to be re-used.
Hydraulic seal
- Check the hydraulic seal using a suitable tool.
- Using a pump, introduce water heated to approximately
~ 90˚C at a pressure of 2 - 3 bar.
NOTE
Before fitting the plugs, apply a layer of water-repellent sealant onto the seal surface.
Replace the cylinder head if leaks are found.
- Valve removal is carried out using tool 99360268 (1) and
applying pressure on the plate (4) so that by compressing
the spring (5), it is possible to remove the valve cap (2)
and the cotters (3). Then remove: plate (4) and spring
(5).
- Repeat this operation for all the valves.
- Upturn the cylinder head, remove the valve (8), the
lower spring seat (7) and the oil seal (6).
- Remove all the core plugs.
Figure 119
70322
- Remove the sealing rings (1 and 2) from the relevant
valve guides.
NOTE
The seal rings (1) for the intake valves are yellow.
The sealing rings (2) for the exhaust valve are
green.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Removal of lifting eyelets
47
Intake and exhaust valves
Figure 122
Figure 120
EXHAUST VALVE
INTAKE VALVE
214340
- Unscrew the screws (5).
107280
INTAKE AND EXHAUST VALVE MAIN DATA
- Remove the lifting eyelet (6).
- Unscrew the threaded plug (4) and the core plug (3).
- Unscrew the screws (2) and remove the lifting eyelet (1).
Figure 123
Ref.
(2)
(5)
No.
2
4
Screws description
Screw M12x1.75x25
Screw M12x1.25x25
Surfaces on lower side of cylinder head
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If measurement results exceed this value, regrind the cylinder
head according to the values and instructions provided in the
figure below.
Figure 121
D
18625
0,4 C
0,025 /¯25,4
A
Valve descale, check and grind
Remove all carbon deposits from the valves using a wire
brush. Check that the valves show no signs of seizing, cracks
or burns.
B
0,4 T O T A L
0,01 /¯50
Regrind the valve seats, if required, removing as little material
as possible.
C
75756
The rated thickness A for the cylinder head is 95 ± 0.25 mm,
max. metal removal must not exceed thickness B of 0.13 mm.
NOTE
After regrinding, check the valve recessing and if
necessary regrind the valve seats to meet the prescribed valve recess.
Print P4D32N015 E
Base - May 2018
48
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Valve guides
Figure 124
Figure 126
18882
Use micrometer (2) to measure valve (1) stem: it should be
6.990 to 7.01 mm
218538
1. Exhaust - 2. Intake
Figure 125
Use a bore gauge, measure the internal diameter of the valve
guides; it must be equal to the value shown in the figure.
Valve seats
Figure 127
202203
Checking clearance between valve stem, valve guide and
valve centring
Use a magnetic-base dial gauge (1) set as shown, the assembling clearance must be 0.056 - 0.096 mm.
Making the valve (2) turn, check that the run out error is no
greater than 0.03 mm.
70330
Regrinding - replacing the valve seats
Check the valve seats (2). If any scoring or burn marks are
found, regrind with a suitable tool (1) according to the angles
indicated in Figure 128.
Base - May 2018
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SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
49
Figure 128
217971
VALVE SEAT MAIN DATA
If valve seats cannot be restored just by regrinding, it is possible to replace them with spare seats.
Valve springs
Using a specific tool and taking care not to nick the cylinder
head, remove as much material as possible from the valve
seats until they can be removed from the cylinder head with
a punch.
Figure 130
Heat the cylinder head to 80 - 100 ˚C and using a drift, fit the
new valve seats after they have cooled.
Then, using a suitable tool, regrind the valve seats according
to the values shown in Figure 128.
50676
KEY DATA FOR CHECKING INTAKE AND EXHAUST
VALVE SPRINGS
Figure 129
Before assembling, check the flexibility of the valve springs
using the specific tool. Compare the elastic deformation and
load data with those of the new springs shown in the following table.
1
2
3
Height
mm
H (free) 45.24
H1
35.33
H2
25.2
Under a load of
N
0
340 ± 19
741 ± 39
75758
After regrinding, check that valve (3) recessing value is the
specified one by using the stand 99370415 (2) and the dial
gauge 99395603 (1).
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
50
NEF G-Drive SERIES
Cylinder head assembly fitting
Figure 133
Surfaces on top of cylinder head
Installation of lifting eyelets
Figure 131
214349
- Upturn the cylinder head and insert the oil seal (6), the
spring seat (7) and the valve (8).
214340
- Position the lifting eyelets (1) and tighten the screws (2).
- Insert the core plug (3) and tighten the threaded plug (4).
- Fit the lifting eyelet (6).
- Tighten the screws (5).
Ref.
(2)
(5)
No.
2
4
Screws description
Screw
M12x1.75x25
Screw
M12x1.25x25
Tightening torques
- Repeat this operation for all the valves.
- Upturn the cylinder head and insert the spring (5) and
the plate (4).
- Valve assembly is carried out using tool 99360268 (1)
and applying pressure on the plate (4) so that by compressing the spring (5), it is possible to insert the cotters
(3) and the valve cap (2).
77 ± 12 Nm
36 ± 5 Nm
Refitting valve assembly
Figure 132
Figure 134
70322
- Fit the seal rings (1 and 2) on the relative valve guide.
Base - May 2018
70323
- Insert all the core plugs ensuring that a water-repellent
sealant has been applied to the surface of the seal.
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
ENGINE ASSEMBLY AT BENCH
(CRANKCASE COMPONENTS)
51
Figure 137
Refitting tappets
Figure 135
70179
- Check the camshaft axial clearance (1).
- It must be 0.23 ± 0.13 mm.
70165
- Fit the tappets (1) in the crankcase.
Refitting camshaft
Installation of main half-bearings and oil
injectors
Figure 136
Figure 138
70162
202197
- Carefully insert the camshaft (2) together with the shoulder plate (4).
- Position the oil injectors (3) and screw down the fillers
(2).
- Tighten the screws (1).
- Position the main half-bearings (1).
Ref.
(1)
No.
2
Print P4D32N015 E
Screws description
Screw M8x1.25x16
Tightening torques
24 ± 4 Nm
Ref.
(2)
No.
4
Screws description
Screw M8x1.25x20
Tightening torques
15 ± 1 Nm
Base - May 2018
52
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Crankshaft refitting
Installation of pistons-connecting rods
Figure 140
Figure 139
70201
202195
- Using tool 99360500 (2), lift the crankshaft (1) and position it inside the crankcase.
Lubricate the pistons well, including the piston rings and the
inside of the cylinder liners.
With the aid of clamp (2), fit the connecting rod-piston
assemblies (1) in the cylinder liners, checking that:
- The number of each connecting rod corresponds to the
cap coupling number.
Figure 141
- the openings of the piston rings are offset by 120º;
- connecting rod-piston assemblies shall have the same
weight;
202202
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO CYLINDERS
Base - May 2018
- the arrow stamped on the piston crown shall be facing
the front side of the engine block or the slot obtained on
the piston skirt shall be corresponding to the oil nozzle
position.
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Figure 142
53
Figure 143
128170
Crankpin assembly clearance measurement
Carry out the following operations to measure the clearance:
- carefully clean the parts and remove any trace of oil;
202193
- Fit the lower main half-bearings (4).
- Insert the cable reference dowel pins.
- Fit the main bearing caps (5).
- fit the connecting rod caps (1) with the relevant half bearings (2).
NOTE
Before re-using retaining screws take two measurements of the diameter as shown in the figure to
identify diameters D1 and D2:
NOTE
Before re-using retaining screws take two measurements of the diameter as shown in the figure to
identify diameters D1 and D2:
if D1 - D2 < 0.1mm the screw can be reused
if D1 - D2 < 0.1 mm the screw can be reused
if D1 - D2 > 0.1mm the screw must be replaced
if D1 - D2 > 0.1mm the screw must be replaced.
75703
75703
- Tighten the main bearing cap screws (1).
Ref.
(1)
No. Screws description
14 Screw
M12x1.75x120
1st step
Print P4D32N015 E
Tightening torques
80 ± 8 Nm
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
54
NEF G-Drive SERIES
Figure 144
Figure 146
α
α
70188
70205
- Tighten the screws (2) further using tool 99395216 (1).
- Tighten the screws (2) further using tool 99395216 (1).
Ref.
(1)
No. Screws description
14 Screw
M12x1.75x120
Tightening torques
Ref.
(1)
No.
12
2nd step 90 ˚
Screws description
Screw
M10x1.25x52
2nd step
Tightening torques
60˚
Installation of connecting rod caps
Figure 145
Figure 147
202488
- Position the connecting rod caps (2).
- Use a torque wrench to tighten the screws (1) after
having lubricated them with engine oil.
Ref.
(1)
No.
12
Screws description
Screw
M10x1.25x52
1st step
Base - May 2018
70207
Manually check that the connecting rods (1) are sliding axially
on the crankshaft pins and that their end float, measured with
feeler gauge (2), is 0.250 - 0.275 mm.
Tightening torques
50 ± 5 Nm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Piston protrusion check
55
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT)
Oil pump refitting
Figure 148
Figure 149
70208
After fitting the connecting rod - piston assemblies, use the
dial gauge 39395603 (1) fitted with base 99370415 (2) to
check the protrusion of the pistons (3) at T.D.C. in relation
to the top crankcase surface.
Calculating the thickness of piston no. 1:
- measuring at a distance of 45 mm from the centre, measure protrusion S1 and S2 of the piston in relation to the
top surface of the crankcase and then calculate the average;
202184
- Position the oil pump (1).
- Tighten the screws (2) of the support.
Ref.
(2)
No.
4
- repeat the operation to calculate the average protrusion
of pistons 2, 3, 4, 5 and 6, then calculate the average;
- Protrusion must be 0.28  0.52 mm.
Screws description
Screw M8x1.25
Tightening torques
1st step
8 ± 1 Nm
2nd step
24 ± 4 Nm
Removal of front cover sea ring
Figure 150
106549
- Remove the sealing ring (2) from the front cover (1) and
carefully clean the connection surfaces.
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
56
NEF G-Drive SERIES
Refitting front cover
Installation of front cover seal ring
Figure 151
Figure 153
75710
218549
- Carefully clean the contact surfaces of the engine block
and apply sealant LOCTITE 5205 forming an even and
continuous beading with no lumps.
- Apply tool 99346252 part (4) to the front crankshaft
shaft (6), secure it by screws (5) and fit the new sealing
ring (7).
- Position part (2) on part (4); screw down the nut (3) to
fit the seal (7) fully inside the front cover (1).
Figure 152
252286
- Fit the cable reference dowel pins (2).
- Position the front cover (1) in the relative seat and insert
the new gasket (3).
- Tighten the screws (4 and 5) securing the front cover (1).
Ref.
(4)
(5)
No.
8
5
Base - May 2018
Screws description
Screw M8x1.25x30
Screw M8x1.25x45
Tightening torques
24 ± 4 Nm
24 ± 4 Nm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR)
57
Figure 155
Installation of timing gear housing
Figure 154
70210
DIAGRAM FOR TIGHTENING THE REAR TIMING
GEAR CASE FASTENING SCREWS
- Position the housing (1) in the relative seat on the crankcase.
Figure 156
70209
DIAGRAM OF AREA FOR APPLYING LOCTITE 5205
SEALANT ON THE GEAR CASE
- Carefully clean the timing gear case (1) and the crankcase.
NOTE
Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
Application must be uniform (no lumps), without
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 joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joints need to be
assembled immediately (within 10 - 20 minutes).
202487
- Tighten the screws (1, 2, 4 and 5) in the position identified during removal.
Ref.
(1)
(2)
(4)
(5)
NOTE
Print P4D32N015 E
No.
4
3
1
2
Screws description
Screw M8x1.25
Screw M10x1.5
Screw M12x1.75
Screw M10x1.5
Tightening torques
24 ± 4 Nm
47 ± 5 Nm
77 ± 12 Nm
47 ± 5 Nm
Before each assembly operation, check that the
thread on the holes and the screws shows no sign
of wear or dirt.
Base - May 2018
58
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Camshaft gear refitting
Figure 159
Timing procedure
Figure 157
70211
- Use a felt-tip pen to highlight the drive gear tooth (1) fitted on the crankshaft (2) with a chamfer () on its side
for timing.
NOTE
106542
- Set the dial gauge (1) on the timing gear (2) and check
that the clearance between the gears (2) and (3) is between 0.076  0.280 mm.
Screw in the two pins to facilitate crankshaft rotation.
Figure 158
Figure 160
114791
- Direct the crankshaft (3) and the camshaft (4) so that
when fitting the driven gear (1) on the camshaft the
marks on the gears (1) coincide with the chamfer on the
gear tooth (2).
202486
- Position the collar (2) in its seat.
- Position the gear (3) and tighten the screws (1).
Ref.
(1)
Base - May 2018
No.
6
Screws description
Screw M8x1.25x25
Tightening torques
36 ± 2 Nm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Refitting engine flywheel housing
59
Figure 162
Figure 161
70215
70214
DIAGRAM OF AREA FOR APPLYING LOCTITE 5205
SEALANT
NOTE
Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
Application must be uniform (no lumps), without
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 joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joints need to be
assembled immediately (within 10 - 20 minutes).
TIGHTENING SEQUENCE DIAGRAM OF FLYWHEEL
HOUSING FASTENING SCREWS
- Position the flywheel housing (1) in the relative seat on
the crankcase.
Figure 163
202485
- Tighten the screws (1, 2, 3, and 4) securing the flywheel
housing (5).
Ref.
(1)
(2)
(3)
(4)
NOTE
Print P4D32N015 E
No.
2
2
10
6
Screws description
Screw M12x1.75
Screw M10x1.5
Screw M10x1.5
Screw M12x1.75
Tightening torques
85 ± 10 Nm
49 ± 5 Nm
49 ± 5 Nm
85 ± 10 Nm
Before each assembly operation, check that the
thread on the holes and the screws shows no sign
of wear or dirt.
Base - May 2018
60
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Refitting flywheel cover housing sealing ring
Figure 164
Refitting engine flywheel
Figure 166
0901t
75690
- Apply the part (5) of tool 99340056 to the rear tang (6)
of the crankshaft, secure it using the screws (4) and key
on the new sealing ring (3).
- Using the two guide pins (2) previously screwed into the
crankshaft holes (3), guide the engine flywheel (1) in with
the help of the hoist.
- Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into flywheel housing (7).
- Unscrew the medium length screws from the holes (4)
used to sling the flywheel.
Figure 165
Figure 167
70217
129299
- Check the clutch plate working surface (1) and turn it if
scored.
- Position the flywheel locking tool 99360351 (2) to the
flywheel housing (2).
- Check the condition of the ring gear teeth (2). In the
teeth break or are excessively worn, remove the ring
gear from the engine flywheel (1) using a general drift and
fit the new one, previously heated to 150˚C for 15 - 20
minutes Chamfering on the internal diameter of the ring
gear must be facing the engine flywheel.
- Tighten the screws (4) fastening the flywheel (3) to the
crankshaft.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
61
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE BOTTOM)
Figure 168
Installation of suction strainer and sound-proof
plate
Figure 169
α
75695
- Tighten the screws (2) securing the engine flywheel (1).
- Remove the tool 99360351 from the flywheel housing.
202179
Ref.
(1)
No.
8
Screws description
Screw
M12x1.25x30
1st phase
2nd phase
Tightening torques
- Overturn the engine
- Position the sound-proof plate (6).
30 ± 4 Nm
60˚
- Position the gasket (5).
- Position the flange (4).
- Position the suction strainer (3) together with the supporting straps (7) in the relative seat.
NOTE
Before each assembly operation, check that the
thread on the holes and the screws shows no sign
of wear or dirt.
- Tighten the screws (8).
- Tighten the bracket (7) fastening screws (1).
- Tighten the suction strainer (3) fastening screws (2).
Ref.
(1)
(2)
(8)
Print P4D32N015 E
No.
4
2
2
Screws description
Screw M10x1.5
Screw M8x1.25x20
Screw M10x1.5x20
Tightening torques
43 ± 5 Nm
25 ± 2.5 Nm
45 ± 4.5 Nm
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
62
NEF G-Drive SERIES
Oil sump refitting
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE RIGHT SIDE)
Figure 170
Figure 171
214326
- Position the oil sump (3) in the relative seat.
202481
- Position the new gasket (4) and the spacer (2).
- Tighten the screws (1 and 6) securing the oil sump (3).
- Position the support (2) and tighten the studs (1).
- Overturn the engine.
- Insert the camshaft speed sensor (3) and tighten the nut
(4).
Ref.
(1)
(2)
No.
14
4
Screws description
Screw M8x1.25x40
Screw M8x1.25x45
Tightening torques
34 ± 3.4 Nm
34 ± 3.4 Nm
- Insert the gaskets (7).
- Insert the control socket cover (6) and tighten the
screws (5).
Ref.
(1)
(4)
(5)
Base - May 2018
No.
1
1
2
Screws description
Stud M6x1x30
Nut M6x1
Screw M12x25
Tightening torques
10 ± 2 Nm
10 ± 2 Nm
65 ± 10 Nm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Oil level dipstick refitting
63
Electronic Control Unit Refitting
Figure 173
Figure 172
214335
- Position the cover (8) together with the gasket and
tighten the screws (7).
- Position the support (1)
- Insert the oil level dipstick (5).
- Tighten the Voss fitting (7).
- Tighten the plugs (2 and 6).
- Position the control unit (2) in its seat.
- Insert the core plugs (1, 3 and 4).
- Tighten the stud (5) and the corresponding nut (4).
202480
- Tighten the screws (3 and 6).
Ref.
(2)
(6)
(7)
No.
2
2
2
Print P4D32N015 E
Screws description
Plug M14x1.5
Plug M10x1
Screw M8x1.25x20
Tightening torques
10 ± 2 Nm
10 ± 2 Nm
65 ± 10 Nm
Ref.
(3)
(4)
(5)
(6)
(7)
No.
7
1
1
3
1
Screws description
Screw M6x1x30
Nut M6x1
Stud M6x1x25
Screw M8x1.25x45
Connector
M12x1.25
Tightening torques
10 ± 2 Nm
10 ± 2 Nm
10 ± 2 Nm
24 ± 4 Nm
12 ± 2 Nm
Base - May 2018
64
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE TOP)
NOTE
Cylinder head assembly refitting
Before re-using retaining screws take two measurements of the diameter as shown in the figure to
identify diameters D1 and D2:
if D1 - D2 < 0.1 mm the screw can be reused
Figure 174
if D1 - D2 > 0.1mm the screw must be replaced.
75703
Figure 176
87759
- Position the gasket (1) on the block.
NOTE
α
Check that the block contact surface is clean.
Do not grease the gasket. It is recommended that
the gasket is kept in its packaging until it is fitted on
the head.
The gasket is to be fitted in such a way that the writing on the gasket can be read as shown in the
figure.
Figure 175
214306
- Lubricate the screws and fit them on the cylinder head.
- The screws must be tightened following a ”lacing” pattern, starting from the middle screw and moving outwards.
Ref.
No.
(1)
14
(4)
12
Screws description
Screw
M12x1.75x150
1st phase
2nd phase
Screw
M12x1.75x130
1st phase
2nd phase
Tightening torques
55 ± 5 Nm
90˚ + 90˚
35 ± 5 Nm
90˚ + 90˚
214305
- Using tool 99360595 and the lifting eyelets (3), position
the cylinder head assembly together with all the elements relating to the timing:
- Intake valves;
- Exhaust valves;
- Valve springs;
- Washers;
- Cotters.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Installation of thermostat unit
65
Figure 180
Figure 177
214324
- Insert the thermostat assembly (1) into the relative seat.
Refitting electro-injectors
70133
Figure 178
- Use tool 99342101 (1) to fit the electro-injector (2) into
its seat.
- Screw injector fastening screws without tightening them.
Figure 181
70338
- Fit a new seal ring (2) lubricated with Vaseline and a new
sealing washer (3) on electro-injector (1).
Figure 179
91572
- Fit a new sealing ring lubricated (3) with Vaseline on the
fuel manifold (2) and fit it into the cylinder head seat so
that the positioning balls (5) coincide with the relevant
housing (4).
NOTE
70339
- Fit injectors (1) on the cylinder head seats, directed so
that the fuel inlet hole (2) is facing the fuel manifold seat
(3) side.
Disassembled fuel manifolds (2) must not be used
again, but however replaced with other new ones.
The fuel manifolds (2) in the engines have 2 positioning balls.
- Screw the fastening nuts (2, Figure 182) without locking
them.
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
66
NOTE
NEF G-Drive SERIES
During this operation, the electro-injector (1)
should be moved so that the manifold (2,
Figure 179) is correctly inserted into the fuel emission hole (2, Figure 181).
Figure 184
Figure 182
α
214258
SHAFT-ROCKER MAIN DATA
- Check that shaft/rocker arm surfaces are not excessively
worn or damaged.
214323
- Using a torque wrench and an angle tightening meter
99395216, gradually and alternately tighten the fastening
screws (1).
- Tighten the nuts (2) securing the manifolds (3).
Ref.
(1)
(2)
No.
12
Screws description
Screw M6x1x35
Tightening torques
6
1st stage
Angle
Ring nut M22x1.5
3.5 ± 0.35 Nm
25˚+25˚+25˚
55 ± 5 Nm
Figure 185
Refitting rocker assembly
Figure 183
122587
Before assembly, check the rocker arm rods: there must be
no sign of any deformation; the spherical seats for contact
with the rocker arm adjusting screw and with the tappets
(arrows) must show no trace of seizure or wear; if they do,
replace them.
Intake and exhaust valve pushrods are identical and are therefore interchangeable.
70343
ROCKER ASSEMBLY COMPONENTS:
1. Screws - 2. Support - 3. Shafts - 4. Rocker arms.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Figure 186
Figure 188
214320
218536
- Insert the rocker arm pushrods (4), together with the
seats and the balls and correctly position the housing (3).
- Tighten the coolant temperature sensor (4).
- Position the intake and exhaust pushrods (1).
- Tighten the screws (2 and 5).
- Insert the gasket (3).
- Insert the rocker arm pushrods (2) together with the
housing seats and the balls (3).
Ref.
(4)
No.
1
67
Screws description
Sensor M14x1.5
Tightening torques
24 ± 4 Nm
- Position the rocker arm assemblies (6) and tighten the
screws (1).
Ref.
(1)
(2)
(5)
No.
12
2
5
Screws description
Screw M8x1.25x25
Screw M8x1.25x50
Screw M8x1.25x70
Tightening torques
36 ± 5 Nm
24 ± 4 Nm
24 ± 4 Nm
Figure 189
Figure 187
202475
- Tighten the nuts (1) on the electro-injectors using the
torque wrench.
- Position the connectors (3) on the electro-injectors and
tighten the screws (2).
Check that the tappet adjusters are unscrewed to
prevent them sticking on the rods when fitting the
rocker arm assembly.
70345
- Position bridges (1) on valves with marks () facing the
exhaust manifold.
Ref.
(1)
(2)
Print P4D32N015 E
No.
12
2
Screws description
M4 nut
Screw M6x1x16
Tightening torques
1.5 ± 0.25 Nm
10 ± 2 Nm
Base - May 2018
68
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Figure 190
Figure 192
214259
123031
- Apply tools 99360221 (1) and 99360222 (2) to the flywheel housing to immobilise the flywheel (3).
- Bring cylinder 1 to the TDC (top dead centre) at the end
of compression and act on tool 99360222 (2) and a pin
(4) and using a wrench.
- Adjust the clearance between the rocker arms and valves using an Allen wrench (4), a box wrench (1) and a
feeler gauge (3).
- Tighten the nuts (2).
The clearance is:
- intake valves 0.25 ± 0.05 mm
- exhaust valves 0.50 ± 0.05 mm.
Figure 191
FIRING ORDER: 1 - 5 - 3 - 6 - 2 - 4
Crankshaft start
and
rotation
1 at TDC
120˚
120˚
120˚
120˚
120˚
214336
- Make sure that the non-drilled part (1) of the phonic
wheel is positioned at the top along its vertical axis.
Ref.
(2)
No.
8
Adjustment of
intake and exhaust
valve clearance,
cylinder no.
1
5
3
6
2
4
Screws description
Nut M8x1.25
Tightening torques
24 ± 4 Nm
Remove the tools 99360221 and 99360222 used to lock
rotation of the flywheel.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Installation of tappet cover
69
Figure 195
Figure 193
214318
- Tighten the double stem screws (5).
226944
- Check the condition of the electrical cables (1), replace
if damaged by cutting the clamps which secure them to
the support (4) and remove the screws (3) which secure
them to the connectors (2).
- Fit a new gasket on the support (2).
- Fit a new gasket (4) on the tappet cover (6).
- Position the section (7) for the oil vapour condensate.
- Position the tappet cover (4).
- Insert the rubber blocks (2) and tighten the flanged nuts
(1).
- Tighten the oil filler cap (3).
Figure 194
Ref.
(1)
(3)
(5)
No.
6
1
6
Screws description
Nut M8x1.25
Plug M38x3
Screw M8x1.25x17
Tightening torques
24 ± 4 Nm
24 ± 4 Nm
Figure 196
108571
- Connect the electric cables (1) to the electro-injectors
(3) and use the torque wrench (4) to tighten the screws
(2).
Ref.
(1)
No.
8
Screws description
M4 nut
Tightening torques
1.5 ± 0.125 Nm
252562
- Position the thermostat cover (2) and tighten the screws
(1) to the specified torque.
Ref.
(1)
Print P4D32N015 E
No.
3
Screws description
Screw M6x1x12
Tightening torques
13.5 ± 1.5 Nm
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
70
NEF G-Drive SERIES
Refitting intake manifold
Common Rail Refitting
Figure 197
Figure 198
214316
214317
- Apply a sufficient layer of LOCTITE 5970 to the mating
surface of the intake manifold (7).
- Tighten the screws (1 and 8).
- Insert a new gasket (6).
- Position the cover (5) and tighten the screws (4).
- Position the air pressure and temperature sensor (3),
insert a new gasket and tighten the screw (2).
Ref.
(1)
(2)
(4)
(8)
No.
7
1
6
3
Base - May 2018
Screws description
Screw M8x1.25x25
Screw M6x1x20
Screw M6x1x20
Screw M8x1.25x70
Tightening torques
24 ± 4 Nm
10 ± 2 Nm
10 ± 2 Nm
24 ± 4 Nm
- Position the Common Rail (2) and tighten the double
thread screws (3).
- Tighten the nuts (1) connecting the high pressure pipes
to the Common Rail (2).
Ref.
(1)
(3)
NOTE
No.
6
4
Screws description
Nut M14x1.5
Screw
M8x1.25x125
Tightening torques
24 ± 4 Nm
36 ± 5 Nm
The pipe fittings must be tightened using the designated wrench and the torque wrench.
The fittings (1) must be tightened while holding the
flow limiting valve with the designated hex wrench.
The high pressure pipes must always be replaced.
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS ON THE LEFT SIDE)
71
Refitting exhaust manifold
Installation of interconnection control unit
Figure 200
Figure 199
214315
214333
- Position the support (2) and tighten the screws (3).
- Insert the new gaskets (1).
- Position the interconnection control unit (5) together
with the rubber blocks (4).
- Position the exhaust manifold (2) and insert the spacers
(6).
- Tighten the nuts (1) on the rubber blocks (4).
- Position the supporting bracket (4).
- Tighten the screws (3 and 5) securing the exhaust manifold (2).
Ref.
(1)
(3)
No.
8
2
Print P4D32N015 E
Screws description
Nut M6x1
Screw
M12x1.75x30
Tightening torques
71.5 ± 7.5 Nm
9 ± 1 Nm
- Tighten the studs (7) supporting the turbocharger.
Ref.
(3)
(5)
(7)
No.
9
3
4
Screws description
Screw M10x1.5x65
Screw M10x1.5x65
Stud M10x1.5x42
Tightening torques
55 ± 3 Nm
55 ± 3 Nm
25 ± 5 Nm
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
72
NEF G-Drive SERIES
Refitting heat exchanger
Figure 201
202460
In the oil filter support (5):
- fit the oil pressure control valve (3), fit the compression
spring (2) and tighten the plug (1).
- Fit the pressure control valve (4) in the relative seat.
Ref.
(1)
No.
1
Screws description
Plug M22x1.5
Tightening torques
80 ± 8 Nm
Figure 202
202459
- Insert the two new sealing gaskets (4).
- Fit the heat exchange elements (5) in the relative seats.
- Fit the insulating plates (3).
- Position the oil filter support (1) in the relative seat and
tighten the screws (2).
Ref.
(2)
NOTE
No.
15
Screws description
Screw M8x1.25x35
Tightening torques
26 ± 4 Nm
Before each assembly operation, check that the
thread on the holes and the screws shows no sign
of wear or dirt.
Base - May 2018
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
73
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR)
Figure 203
Air filter refitting
Figure 205
202458
- Insert the oil pressure/temperature sensor (2) and
tighten the screws (1).
252561
Ref.
(1)
No.
2
Screws description
Screw M6x1x20
Tightening torques
35 ± 4 Nm
- Position the support (2) and tighten the screws (1 and
3).
Ref.
(1)
No.
2
(3)
1
Screws description
Screw
M12x1.75x25
Screw M10x1.5x20
Tightening torques
71 ± 7 Nm
45.5 ± 4.5 Nm
ENGINE ASSEMBLY AT THE BENCH
(COMPONENTS AT THE REAR)
Turbocharger refitting
Oil vapour filter refitting
Figure 204
Figure 206
214314
202471
- Insert the new gasket on the exhaust manifold.
- Position the pipe (3) and the threaded fittings (2).
- Position the turbocharger (4) and tighten the nuts (3).
- Insert the engine breather pipe (4).
- Tighten the fittings (1) of the oil delivery pipe (2) to the
turbocharger (4).
- tighten the screw (1) supporting the clamp.
Ref.
(1)
(3)
No.
2
4
Print P4D32N015 E
Screws description
Fitting 11/16”
Nut M10x1.5
Tightening torques
30 ± 3 Nm
43 ± 6 Nm
Ref.
(1)
(2)
No.
1
2
Screws description
Screw M6x1
Fitting M12x1.5x11
Tightening torques
10 ± 2 Nm
20 ± 2 Nm
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
74
NEF G-Drive SERIES
Figure 207
Figure 209
252288
214313
- Position the blow-by filter (2) in the relative seat and
tighten the bolts (1) to the specified torque.
- Position the support (3) and tighten the screws (2) together with the relative nuts.
Ref.
(1)
- Position the air filter (1) and tighten the screws (4).
No.
2
Screws description
Bolt M6x1x25
Tightening torques
-
Figure 208
252287
- Position the pipes (1, 4 and 5) connecting to the blow-by
filter.
- Tighten the clamps (2, 3 and 6) to the specified torque.
Ref.
(2)
(3)
(6)
No.
1
2
1
Base - May 2018
Screws description
Screw M25x40
M16x25 screw
Screw M20x32
Tightening torques
-
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE FRONT)
75
Figure 211
Crankshaft pulley refitting
Figure 210
α
202456
- Insert the plug (3) and tighten the screw (2).
- Insert the crankshaft speed sensor (4) and tighten the
screw (1).
214338
- Insert the core plug (1).
- Tighten the screw (2) securing the idler pulley.
Ref.
(1)
(2)
No.
1
1
Screws description
Screw M6x1x20
Screw M6x1x20
Tightening torques
24 ± 4 Nm
10 ± 2 Nm
- Insert the pulley (3) and the spacer (4) for the shaft.
Installation of automatic belt tensioner and fan
support
- Tighten the screws (5).
- Position the front hub (8).
- Position the flange (7) on the front hub (8) and tighten
the screws (6).
Ref.
(2)
(5)
(6)
No.
1
6
6
Screws description
Screw M10x1.5x70
Screw
M12x1.25x78.5
1st step
2nd step
Screw
M10x1.25x40
Figure 212
Tightening torques
45 ± 5 Nm
50 ± 5 Nm
90˚
24 ± 4 Nm
202151
- Position the fan mount (2) in the relative seat and tighten
the screws (6).
- Position the spacer (4) in the relative seat together with
the drive pulley (3) and tighten the screws (5).
- Position the belt tensioner mount (9) in the relative seat
and tighten the screws (1).
- Position the automatic belt tensioner (8) in the relative
seat and tighten the screw (7).
Ref.
(1)
(5)
(6)
(7)
Print P4D32N015 E
No.
2
4
4
1
Screws description
Screw M8x1.25x30
Screw
M10x1.5x110
Screw M8x1.25x45
Screw M10x1.5x70
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
30 ± 5 Nm
45 ± 5 Nm
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
76
NEF G-Drive SERIES
Refitting water pump
Refitting alternator
Figure 213
Figure 215
202150
- Fit the new gasket (3).
- Position the alternator in the relative seat together with
the bracket (2).
- Position the water pump (2) in the relative seat.
- Position but do not tighten the screw (3) anchoring the
alternator to its lower mount and the screw (1).
- Tighten the screws (1).
Ref.
(1)
No.
2
Screws description
Screw M8x1.25x35
202148
Tightening torques
24 ± 4 Nm
Ref.
(1)
(3)
No.
1
1
Screws description
Screw M10x1.5
Screw M10x1.5
Tightening torques
-
Refitting alternator support
Figure 214
Figure 216
202149
202147
- Insert the cable reference dowel pins (2) and the new
gaskets (3) in the relative seats.
- Using the tool (5), rotate the automatic tensioner (1) in
the direction of the arrow and fit the belt (2).
- Position the alternator mount (4) in the relative seat.
- Tighten the screw (4) securing the alternator to the
bracket and the screw (3) securing the alternator to the
lower mount.
- Tighten the screws (5 and 6).
- Position the bracket (7) and tighten the screw (1).
Ref.
(1)
(5)
(6)
No.
1
2
1
Base - May 2018
Screws description
Screw M10x1.5x20
Screw
M10x1.5x135
M10x1.5x70
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
43 ± 6 Nm
Ref.
(3)
(4)
(4)
No.
1
1
1
Screws description
Screw M10x1.5
Screw M10x1.5
Nut M10x1.5
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
43 ± 6 Nm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Figure 217
77
Figure 219
158823
249428
- Insert the gear (5) on the spindle (2).
- Position the high pressure supply pipe (4) on the Rail.
- Lock rotation of the high-pressure pump (1) drive shaft
(2).
- Tighten the screws (2 and 3).
- Tighten the fittings (1).
- Tighten the nut (3).
Ref.
(3)
No.
1
Screws description
Nut M18x1.5
Tightening torques
105 ± 5 Nm
Ref.
(1)
(2)
(3)
Installation of feed pump
Figure 218
No.
2
1
1
Screws description
Connector
M14x1.5
Screw M8x1.25x16
Screw M8x1.25x20
Tightening torques
28 ± 2 Nm
25 ± 2.5 Nm
25 ± 2.5 Nm
Fuel filter refitting
Figure 220
202446
- Tighten the studs (2).
214309
- Position the feed pump assembly (1).
- Tighten the nuts (3).
- Position the fuel filter support (1), together with the fuel
preheating resistor (5).
- Tighten the screws (2).
- Tighten the cartridge (3) using tool 99360076 (4).
Ref.
(2)
(3)
No.
3
3
Screws description
Stud M8x1.25x50
Nut M8x1.25
Tightening torques
11 ± 3 Nm
24 ± 4 Nm
- Tighten the fuel temperature sensor (5).
Ref.
(2)
(3)
(6)
Print P4D32N015 E
No.
2
1
1
Screws description
Screw
M12x1.75x30
Cartridge M20x1.5
Sensor M14x1.5
Tightening torques
80 ± 8 Nm
20 0/+5 Nm
20 Nm
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
78
NOTE
NEF G-Drive SERIES
Do not fill the filter to prevent any impurities from
entering the supply circuit.
Figure 221
249429
- Tighten the Voss fitting (6).
- Connect the fuel return pipe (7) from the injection pump
(2) to the filter (4).
- Connect the fuel delivery pipe (5) to the injection pump
(2).
- Connect the fuel return pipe (3) to the injection pump
(2).
- Connect the excess fuel return pipe (1) from the Common Rail.
The pipes which were removed cannot be refitted.
They must be replaced.
Ref.
(8)
No.
1
Base - May 2018
Screws description
Connector
M12x1.5
Tightening torques
22 ± 2 Nm
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 7 - GENERAL MECHANICAL OVERHAUL
79
Refitting engine cable
Figure 222
252290
1. Exhaust gas valve connection - 2. Interconnection Control Unit - 3. Air pressure / temperature sensor 4. Timing gear phase sensor - 5. Pressure regulator cable - 6. Fuel temperature sensor and fuel heater cable 7. EDC 7 electronic control unit - 8. Crankshaft sensor - 9. Fuel pressure sensor cable 10. Engine oil temperature and pressure sensor - 11. Engine coolant temperature sensor 12. Electro-injector - 13. Connections for electro-injectors.
Connect the engine cable from the connectors: electro-injector wiring (13); (3) air pressure/temperature sensor; (9) fuel pressure sensor; (7) Control unit; (4) timing gear phase sensor; (11) engine coolant temperature sensor on thermostat; (8) engine
rpm sensor.
Fit the clamps that hold it to the crankcase.
Print P4D32N015 E
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
80
NEF G-Drive SERIES
Refitting starter motor
Figure 223
Figure 225
70126
To connect lower pressure fuel pipes from their couplings,
press clip (1) as shown in figure B.
After disconnecting the pipe, bring the clip (1) back to the
locking position (figure A).
202439
- Unscrew the screw (1) and remove the second supporting bracket 99361037.
- Tighten the studs (4) and position the starter motor (3).
- Tighten the fastening nuts (2).
Figure 224
Ref.
(1)
(2)
(4)
No.
3
4
3
Screws description
Nut M10x1.5
Screw M12x1.75
Stud M10x1.5x20
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
Refitting oil filter
Figure 226
214307
From the right hand:
- Unscrew the screws (7) and remove the bracket
99361037.
- Position the low pressure pipe (6) and connect the
quick-release couplings (2).
- Tighten the screw (5).
- Connect the clamp (4) supporting the low pressure pipe
(6).
- Position the filter (2) in the relative seat.
214337
- Tighten the screws (1) and the relative nuts.
From the right side fit:
- Connect the fuel pre-filter (2) to all the pipes.
- using tool 99360076 (2), fit the oil filter (1) on the support.
Ref.
(1)
(5)
(8)
No.
2
1
4
Base - May 2018
Screws description
Screw M20x1.5
Screw M20x1.5
Screw M12x1.75
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
-
Ref.
(1)
No.
1
Screws description
Cartridge M27x2
Tightening torques
20 ± 2 Nm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
Installation of lubricant return pipe from
turbocharger
81
Figure 229
Figure 227
249423
- Connect the exhaust pipe (3) and tighten the screw (2)
to close the clamp (1).
202144
the lubricant oil drain pipe (2) from the turbocharger:
Ref.
(2)
No.
1
Screws description
Screw M6x55
Tightening torques
13 ± 2 Nm
- Release the ends of the pipe and the exhaust on the turbocharger; Insert the fitting (4) in the crankcase.
- Tighten the screw (3) securing the pipe to the crankcase
via the fastening collar (5).
Figure 230
- Tighten the two screws (1) below the turbocharger.
Ref.
(1)
(3)
No.
2
1
Screws description
Screw M8x1.25x25
Screw M8x1.25x16
Tightening torques
24 ± 4 Nm
24 ± 4 Nm
Installation of fan
Figure 228
129291
- Fit the pipe (4) complete with sleeves from the engine
side, acting on the relative clamps (5).
- Fit the pipe (2) complete with sleeves acting on the relative clamp (3).
- Fit the pipe (1) complete with sleeves from the engine
side, acting on the relative clamps (6).
Ref.
(3)
(5)
(6)
No.
2
2
2
Screws description
Nut M14x1.5
Screw M14x2x30
Screw M14x2x30
Tightening torques
43 ± 6 Nm
114.5 ± 11.5 Nm
114.5 ± 11.5 Nm
129297
- Position the fan (2) together with the spacer.
- Tighten the screws (2).
Ref.
(2)
No.
6
Print P4D32N015 E
Screws description
Screw M10x1.5x30
Tightening torques
24 ± 4 Nm
NOTE
Check the state of wear of the rubber sleeves.
Base - May 2018
SECTION 7 - GENERAL MECHANICAL OVERHAUL
82
NEF G-Drive SERIES
Figure 233
Figure 231
129290
- Fit the pipes (1 and 4) complete with sleeves, acting on
the relative clamps (2 and 3).
Ref.
(2)
(3)
NOTE
No.
1
1
Screws description
Screw M6x1x16
Screw M8x1.25x16
Tightening torques
43 ± 6 Nm
43 ± 6 Nm
Check the state of wear of the rubber sleeves.
252278
- Mount the pipe (1).
- Tighten the screws (2).
Ref.
(2)
No.
4
Screws description
Screw M8x1.25x25
Tightening torques
23 ± 2 Nm
Figure 234
Figure 232
129287
129289
- Connect the air and water pipes to the radiator unit,
acting on the clamps (1, 2, 3 and 4) and on the fixing bracket (5).
Ref.
(4)
(5)
NOTE
No.
2
1
Screws description
Screw M14x2x30
Screw M6x1x16
Tightening torques
114.5 ± 11.5 Nm
43 ± 6 Nm
Check the state of wear of the rubber sleeves.
Base - May 2018
- Fit the protective grille (5) of the fan
- Tighten the relative retainers (1, 3 and 4).
- Close the clamps (2).
Ref.
(1)
(2)
(3)
(4)
No.
6
2
1
1
Screws description
Screw M6x1x16
Screw M14x2x30
Screw M8x1.25x16
Screw M6x1x16
Tightening torques
43 ± 6 Nm
114.5 ± 11.5 Nm
43 ± 6 Nm
43 ± 6 Nm
Print P4D32N015 E
SECTION 7 - GENERAL MECHANICAL OVERHAUL
NEF G-Drive SERIES
83
Figure 235
129292
- Connect the pipe (4) to the radiator unit (2) complete
with the sleeves and bracket (5)
- Act on the relative clamps (1).
- Tighten the screw (3).
Ref.
(1)
(3)
NOTE
No.
2
1
Screws description
Screw M14x2x30
Screw M8x1.25x16
Tightening torques
114.5 ± 11.5 Nm
43 ± 6 Nm
Check the state of wear of the rubber sleeves.
- Refill the cooling system with coolant.
- Bleed the air from the ’supply system as described in the
relevant paragraph.
- Refill the engine oil as described in the relative paragraph.
Print P4D32N015 E
Base - May 2018
84
SECTION 7 - GENERAL MECHANICAL OVERHAUL
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 8 - TECHNICAL SPECIFICATIONS
1
SECTION 8
Technical specifications
Page
Print P4D32N015 E
DATA - INSTALLATION CLEARANCES . . . . .
3
TIGHTENING TORQUE (NEF67 TE1F/TE2F) . .
9
Base - May 2018
2
SECTION 8 - TECHNICAL SPECIFICATIONS
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 8 - TECHNICAL SPECIFICATIONS
3
DATA - INSTALLATION CLEARANCES
F4HFA615A*D001
Type
CRANK GEAR AND CYLINDER ASSEMBLY DATA
mm
j 1
1
X
> 1
j 1
X
j 2
Pistons
Measuring point
Outer diameter
Pin housing
X
1
2
Piston - cylinder liners
X
j 3
1
Piston position
from crankcase
X
Piston pin
0.4
49.5
103.739 - 103.757
40.010 - 40.016
0.243 - 0.285
Piston diameter
Piston pin - pin seat
Print P4D32N015 E
104.000 - 104.024
Cylinder liners
3
0.4
0.28 ÷ 0.52
39.994 ÷ 40.000
0.010 ÷ 0.022
Base - May 2018
4
SECTION 8 - TECHNICAL SPECIFICATIONS
NEF G-Drive SERIES
Type
F4HFA615A*D001
CRANK GEAR AND CYLINDER ASSEMBLY DATA
X1
X2
X3
S 1
S 2
S 3
mm
Piston ring slots
X1
X2
X3
2.705 - 2.735
2.420 - 2.440
4.030 - 4.050
Circlips
S1
S2
S3
2.560 - 2.605
2.350 - 2.380
3.970 - 3.990
1
2
3
0.100 - 0.175
0.040 - 0.09
0.040 - 0.080
Circlips - slots
Circlips
X1
X2
CIrclip end gap
in cylinder liner:
X1
X2
X3
X3
j 1
j 2
0.4
Connecting rod small end bush
seat
1
Big-end bearing seat
2
0.30 - 0.40
0.60 - 0.80
0.30 - 0.55
42.987 - 43.013
73.987 - 74.013
j 4
Base - May 2018
j 3
Connecting rod small end bush
diameter
S
Internal
Big end half-bearings
3
S
40.029 - 40.043
1.955 - 1.968
Piston pin - bushing
0.029 ÷ 0.049
Big end half-bearings
0.250; 0.500
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 8 - TECHNICAL SPECIFICATIONS
F4HFA615A*D001
Type
CRANK GEAR AND CYLINDER ASSEMBLY DATA
j 1
j 2
S 1
S 2
j 3
mm
Main journals
1
Crankpins
2
82.99 - 83.01
69.987 - 70.013
S1
2.464 - 2.472
S2
1.958 - 1.968
3
3
87.982 - 88.008
87.977 - 88.013
Main half-bearings
Connecting rod
half-bearings
Main journals
No. 1-7
No. 2-3-4-5-6
5
Half-bearings - main journals
No. 1-7
No. 2-3-4-5-6
Half bearings
- crankpins
0.028 - 0.090
0.023 - 0.092
0.038 ÷ 0.110
Main half-bearings
Connecting rod half-bearings
0.250; 0.500
Thrust
main journal
X1
37.475 - 37.545
Main journal support
for thrust
X2
32.180 ÷ 32.280
Thrust
half rings
X3
37.28 ÷ 37.38
X 1
X 2
Crankshaft thrust
Print P4D32N015 E
0.095 ÷ 0.265
Base - May 2018
6
SECTION 8 - TECHNICAL SPECIFICATIONS
NEF G-Drive SERIES
F4HFA615A*D001
Type
mm
CYLINDER HEAD - TIMING SYSTEM
j 1
Valve guide seats
on cylinder head
j 4
1
7.042 - 7.062
4

6.990 - 7.01
60˚± 0˚ 15’
4

6.990 - 7.01
45˚± 0˚ 15’
Valve stem and relative guide
0.032 - 0.072
Valves:
a
Housing on head
for valve seat:
j 1
j
34.837 - 34,863
1
34.837 - 34,863
Valve seat outside diameter;
valve housing inclination on cylinder head:
2
a
X
X
Recessing
X
Between valve seat
and cylinder head
Valve seats
Base - May 2018
1
2

34.917 - 34.931
60˚± 0˚ 15’
2

34.917 - 34.931
45˚± 0˚ 15’
0.940 - 1.460
0.110 - 0.630
0.054 - 0.094
0.054 - 0.094
-
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 8 - TECHNICAL SPECIFICATIONS
7
F4HFA615A*D001
Type
CYLINDER HEAD - TIMING SYSTEM
mm
Valve spring height:
H
H1
free spring
H
45.24
under a load of:
H 2 340 ± 19 N
741 ± 39 N
H1
H2
35.33
25.2
X
not adjustable
Injector protrusion
X
j
j
j
1 23 4
j
5
Seat for camshaft
timing system No. 1
(flywheel side)
59.222 ÷ 59.248
Camshaft seats
nº 2-3-4-5-6-7
54.089 ÷ 54.139
2
Camshaft
journal diameter:
17
j
1
j
j
3
Inner diameter
of bushes
Bushings and support pins
Print P4D32N015 E
53.995 ÷ 54.045

54.083÷ 54.147
0.038 ÷ 0.152
Base - May 2018
8
SECTION 8 - TECHNICAL SPECIFICATIONS
NEF G-Drive SERIES
F4HFA615A*D001
Type
CYLINDER HEAD - TIMING SYSTEM
Useful cam height:
mm
H
1
2
3
Tappet washer seat
in crankcase
H
-
H
-
1
16.000 ÷ 16.030
2
3
15.924 - 15.954
15.960 - 15.975
Tappet outside diameter:
2
Between tappets and seats
-
Tappets
-
 1
Rocker-arm shaft
1
21.965 - 21.977
Rocker arms
2
22.001 - 22.027
 2
Between rockers and shaft
Base - May 2018
0.024 - 0.062
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 8 - TECHNICAL SPECIFICATIONS
9
TIGHTENING TORQUE (NEF67 TE1F/TE2F)
DETAIL
Cooling nozzles
Screws for camshaft shoulder plate
Screws for main bearing caps
Quantity
6
2
M8x1.25x20
M8x1.25x16
M12x1.75x120
14
M12x1.75
M8x1.25
M10x1.5
M8x1.25x25
1
4
3
6
Screws for connecting rod caps
M10x1.25x52
12
Nut for injection pump gear
Nuts for securing injection pump
Plug for heat exchanger valve
Screws securing heat exchanger
M18x1.5
M8x1.25
M22x1.5
M8x1.25x35
1
3
1
15
Screw for timing gear case
Screws for timing gear case
Screws for timing gear case
Screws for timing gear
L = 130
Cylinder head fastening screws
M12x1.75
26
L = 150
Screws securing rocker arms
Nuts for tappet adjuster
Housing fastening screw
Tappet cover fastening nuts
Screws for sound-proofing plate
Nuts securing wiring on injectors
Screws securing suction strainer
Screws securing suction strainer bracket
Screws fastening the oil pump
Screws securing front cover
Screws securing flywheel housing
Screws securing flywheel housing
Screws securing oil sump
Plug on oil sump
Screws securing front hub
Screws for pulley on front hub
Plugs on cylinder head
Plugs on cylinder head
Plug on cylinder head
Injector fastening screws
Connectors on cylinder head
Print P4D32N015 E
M8x1.25x25
M8x1.25
M8x1.25x70
M8x1.25
M10x1.5
M4
M8x1.25x20
M10x1.5x20
12
12
5
6
14
12
2
2
M8x1.25
4
M8x1.25x30
M8x1.25x45
M12x1.75
M10x1.5
M8x1.25
M18x1.5
8
5
8
12
18
1
M12x1.25x78.5
6
M10x1.25x40
½”
¾”
¼”
6
3
2
1
M6x1
12
M22x1.5
6
TORQUE
Nm
Kgm
15 ± 1
1.5 ± 0.1
24 ± 4
2.4 ± 0.4
80 ± 8
8.0 ± 0.8
90 ˚
77 ± 12
7.7 ± 1.2
24 ± 4
2.4 ± 0.4
47 ± 5
4.7 ± 0.5
36 ± 2
3.6 ± 0.2
60 ± 5
6.0 ± 0.5
60˚
105 ± 5
10.5 ± 0.5
24 ± 4
2.4 ± 0.4
80 ± 8
8.0 ± 0.8
26 ± 4
2.6 ± 0.4
35 ± 5
3.5 ± 0.5
(90˚ + 90˚)
55 ± 5
5.5 ± 0.5
(90˚ + 90˚)
36 ± 5
3.6 ± 0.5
24 ± 4
2.4 ± 0.4
24 ± 4
2.4 ± 0.4
24 ± 4
2.4 ± 0.4
43 ± 5
4.3 ± 0.5
1.5 ± 0.125
0.2 ± 0.03
25 ± 2.5
2.5 ± 0.25
45 ± 4.5
4.5 ± 0.5
8±1
0.8 ± 0.1
24 ± 4
2.4 ± 0.4
24 ± 4
2.4 ± 0.4
24 ± 4
2.4 ± 0.4
85 ± 10
8.5 ± 1.0
49 ± 5
4.9 ± 0.5
34 ± 3.4
3.4 ± 0.34
60 ± 9
6.0 ± 0.9
50 ± 5
5.0 ± 0.5
90 ˚
24 ± 4
2.4 ± 0.4
24 ± 4
2.4 ± 0.4
36 ± 5
3.6 ± 0.5
12 ± 2
1.2 ± 0.2
3.5 ± 0.35
0.4 ± 0.04
25˚ + 25˚ + 25˚
55 ± 5
5.5 ± 0.5
Base - May 2018
10
SECTION 8 - TECHNICAL SPECIFICATIONS
NEF G-Drive SERIES
DETAIL
Screws securing intake manifold
M8x1.25x25
M8x1.25x70
Screws securing sling hook
M12x1.75x25
Screws securing sling hook
M8x1.25x25
Screws securing rail to intake manifold
M8x1.25x125
Screws securing alternator
M10x1.5
Screws securing thermostat cover
M6x1x12
Starter motor fastening nuts
M10x1.5
Nuts securing turbocharger
M10x1.5
Screws securing exhaust manifold
M10x1.5
Screws for alternator mount
M10x1.5
Screws for oil pressure sensor
M6x1
Plugs to crankcase
M18x1.5
Fittings to high pressure pipe
M14x1.5
Fittings 4896491 and 4897881
M16x1.5
Screws for plate 4896952
M6x1
Screws for water pump
M8x1.25x35
Screw for camshaft speed sensor
M6x1
Sensor on cylinder head (temperature)
M14x1.5
Union 4891285
¾” - 14
Screws for turbocharger oil drain pipe
M8x1.25x25
Breather plate screws
M6x1
Screw for plate securing breather to tappet cover
M6x1
Fittings for securing breather 4899219
M12x1.5
Oil level sensor
M12x1.5
Screws securing oil level dipstick bracket
M8x1.25
Screw for oil dipstick fastening clamp
M6x1
Fitting Voss 4896329 on cylinder head
M12x1,5
Oil filter
M27x2
Screw for crankshaft speed sensor
M6x1
Screws for fuel filter bracket
M12x1.75x30
Control unit fastening plugs
M8x1.25
Screw for belt tensioner
M10x1.5x70
Idle pulley screw
M10x1.5x70
Steering wheel screws
Plug 4899009
Screws securing control unit to support
Heater fastening screws
Fitting Voss 4896542 on control unit support
Screw securing sensor to intake manifold
Base - May 2018
Quantity
7
3
2
4
4
3
3
3
4
12
3
2
3
2
4
2
2
1
1
1
2
3
3
3
1
2
1
1
1
1
2
3
1
1
M12x1.25x30
8
M10x1
M6x1
M6x1x20
M12x1.25
M6x1
1
7
6
1
1
TORQUE
Nm
24 ± 4
24 ± 4
77 ± 12
36 ± 5
36 ± 5
43 ± 6
13.5 ± 1.5
43 ± 6
43 ± 6
55 ± 3
43 ± 6
10 ± 2
24 ± 4
28 ± 2
24 ± 4
24 ± 4
24 ± 4
10 ± 2
24 ± 4
36 ± 4
24 ± 4
10 ± 2
10 ± 2
20 ± 4
10 ± 2
24 ± 4
10 ± 2
22 ± 2
20 ± 2
10 ± 2
80 ± 8
24 ± 4
45 ± 5
45 ± 5
30 ± 4
60˚
24 ± 4
10 ± 2
10 ± 2
12 ± 2
10 ± 2
Kgm
2.4 ± 0.4
2.4 ± 0.4
7.7 ± 1.2
3.6 ± 0.5
3.6 ± 0.5
4.3 ± 0.6
1.4 ± 0.2
4.3 ± 0.6
4.3 ± 0.6
5.5 ± 0.3
4.3 ± 0.6
1.0 ± 0.2
2.4 ± 0.4
2.8 ± 0.2
2.4 ± 0.4
2.4 ± 0.4
2.4 ± 0.4
1.0 ± 0.2
2.4 ± 0.4
3.6 ± 0.4
2.4 ± 0.4
1.0 ± 0.2
1.0 ± 0.2
2.0 ± 0.4
1.0 ± 0.2
2.4 ± 0.4
1.0 ± 0.2
2.2 ± 0.2
2.0 ± 0.2
1.0 ± 0.2
8.0 ± 0.8
2.4 ± 0.4
4.5 ± 0.5
4.5 ± 0.5
3.0 ± 0.4
2.4 ± 0.4
1.0 ± 0.2
1.0 ± 0.2
1.2 ± 0.2
1.0 ± 0.2
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 9 - TOOLS
1
SECTION 9
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print P4D32N015 E
3
Base - May 2018
2
SECTION 9 - TOOLS
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 9 - TOOLS
3
TOOLS
TOOL No.
NAME
99305453
Tool for checking diesel fuel system and common rail injection system
99322205
Revolving stand for overhauling units
(capacity 1000 daN, torque 120 daNm)
99327017
Vehicle communication cable with 32-pin socket (0.42 mt) for
ECI (spare part for E.A.SY.)
99327018
USB cable with EMI filter (1.8 mt) for ECI (spare part for E.A.SY.)
99327019
USB cable with EMI filter (4.5 mt) for ECI (spare part for E.A.SY.)
99327037
Adapter for self-diagnostics for ECI (spare part for E.A.SY.)
Print P4D32N015 E
Base - May 2018
4
SECTION 9 - TOOLS
NEF G-Drive SERIES
TOOL No.
NAME
99327046
Cable with cigarette lighter socket for power supply of connector
99327037 (spare part for E.A.SY.)
99327210
Diagnostics tool PT-Plus (I)
99327220
Diagnostics tool PT-Plus (E)
99327230
Diagnostics tool PT-Plus (UK)
99327240
Diagnostics tool PT-Plus (F)
99327250
Diagnostics tool PT-Plus (D)
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 9 - TOOLS
TOOL No.
NAME
99327282
Diagnostics interface with the prepaid card
99327301
Prepaid card (component of 99327282)
99340055
Extraction tool for crankshaft front ring seal
99340056
Extraction tool for crankshaft rear gasket
99341001
Double-acting bridge
99341009
Pair of brackets
Print P4D32N015 E
5
Base - May 2018
6
SECTION 9 - TOOLS
NEF G-Drive SERIES
TOOL No.
NAME
99341015
Clamp
99342101
Extraction tool for injectors
99346252
Key to fit crankshaft front gasket
99346253
Key to fit crankshaft rear gasket
99360076
Tool to remove oil filter (engine)
99360221
Engine flywheel rotation tool (use with 99360222)
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
SECTION 9 - TOOLS
TOOL No.
NAME
99360222
Pinion (use with 99360221)
99360268
Tool to take down and fit back engine valves
99360351
Tool to retain flywheel
99360362
Drift tool for removing/fitting camshaft bushes
(to be used with 99370006)
99360500
Tool for lifting the crankshaft
99360595
Arm for removing and installing engine
Print P4D32N015 E
7
Base - May 2018
8
SECTION 9 - TOOLS
NEF G-Drive SERIES
TOOL No.
NAME
99361037
Brackets for fastening engine to 99322205 rotary stand
99363204
Tool to remove gaskets
99370006
Handle for interchangeable drift tools
99370415
Base of dial gauge for various measurements (use with 99395603)
99395603
Dial gauge (0 ÷ 5 mm)
Base - May 2018
Print P4D32N015 E
NEF G-Drive SERIES
APPENDIX
1
Appendix
Page
Print P4D32N015 E
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . .
3
- Standard safety precautions . . . . . . . . . . . . . .
3
- Accident prevention . . . . . . . . . . . . . . . . . . . .
3
- During maintenance . . . . . . . . . . . . . . . . . . . .
3
- Protection of the environment . . . . . . . . . . . .
4
Base - May 2018
2
APPENDIX
Base - May 2018
NEF G-Drive SERIES
Print P4D32N015 E
NEF G-Drive SERIES
APPENDIX
3
SAFETY REGULATIONS
Standard safety precautions
- Do not perform operations without the necessary instructions.
We direct your attention on some precautions that must be
necessarily followed in a regular work environment and, in
case of non-compliance, any other precaution will not be sufficient to protect the safety of the staff in charge of maintenance.
- Do not use equipment to perform works other than those for which they have been designed, you may sustain
accidents, even of serious type.
- Please obtain information and inform the staff on applicable laws on safety, making the informative material
available for consultation.
- Please keep the rooms as clean as possible and properly
ventilated.
- Equip the rooms with specific, well-visible first-aid boxes,
always stocked up with suitable medical aids.
- Be equipped with suitable fire extinguishing devices, properly signalled and never obstructed. Check their operation on a regular basis and train the staff on the intervention priorities and methods.
- Ensure there are gathering points for the evacuation of
the work areas, properly signalling the exit routes.
- Absolutely prohibit smoking in the areas where the
works subject to fire hazard are carried out.
- Draw the attention on prohibitions and indications with
suitable signs, which are immediately comprehensible always in case of emergency.
Accident prevention
- Do not wear cloths with loose edges, rings and chains,
while working near engines and moving organs.
- Use protective gloves and glasses when:
- filling up inhibitors or antifreeze;
- replacing or filling up lubricant;
- using air or liquids under pressure (allowed pressure
 2 bar).
- In case of checks or calibrations that require the engine
to be on, make sure that the room is properly ventilated
and use proper fans to remove exhaust gases: intoxication and death hazard.
During maintenance
- Never open the filling cap of the cooling circuit when the
engine is hot. The operating pressure will spill the high
temperature liquid with serious risk of burns. Wait until
the temperature drops below 50 ˚C.
- Never add coolant to an overheated engine and only use
appropriate fluids.
- Always operate with engine off: if particular circumstances require maintenance interventions to be carried out
with the engine running, make sure that all the risks associated with the operations in question are considered.
- Use adequate and safe containers for draining the engine
fluids and exhaust oil.
- Keep the engine clean from oil, diesel and/or chemical
solvents.
- The use of solvents or detergents during maintenance
may develop toxic vapours. Always ventilate the work
rooms. Use safety masks when required.
- Do not leave cloths soaked with flammable substances
near the engine.
- When starting up the engine after a repair operation, arrange for suitable measures to stop air suction in case of
over-revving.
- Do not use quick screwers.
- Wear a protective helmet if working in an area with suspended loads or overhead systems.
- Do not disconnect the batteries whilst the engine is running.
- Always wear safety shoes and cloths fitted to the body,
better if equipped with rubber bands at the edges.
- Before any interventions involving the electrical circuits,
disconnect the batteries.
- Use protective creams for hands.
- Disconnect the batteries from the on-board network
while charging.
- Change wet clothes as soon as possible.
- In the presence of voltage higher than 48-60V, check the
effectiveness of the ground electric connections. Make
sure your hands and feet are dry and perform the work
standing on insulating platforms.
Do not proceed if not qualified!
- Do not smoke or spark free flames near batteries and any
combustible material.
- Return oily rags or solvents to fire-proof containers.
Print P4D32N015 E
- After each intervention, make sure the polarity of the
battery’s terminals is respected and the latter are well
tightened and protected against accidental short circuits
and oxidation phenomena.
- Do not disconnect and connect the electric connections
when power is on.
- Before carrying out removal operations on pipes (pneumatic, hydraulic or fuel pipes) check the possible presence of fluid or air under pressure. Adopt the necessary
precautions, exhausting the residual pressures or closing
the shut-off valves. Always wear suitable masks or protective glasses. Failure to follow these rules may cause serious accidents and intoxication.
Base - May 2018
4
APPENDIX
- Avoid improper tightening operations or out of torque.
The engine’s components may be damaged also seriously, thus prejudicing their life cycle.
- Avoid draughts from fuel tanks in copper alloy and/or pipes without filters.
NEF G-Drive SERIES
Protection of the environment
- Allows prioritise protection of the environment implementing all necessary precautions to protect the safety
and health of staff.
- Do not connect any utility to the engine’s electric equipment, if not specifically approved by FPT.
- Make sure you and all staff are fully aware of current standards for the treatment and disposal of fluids and engine
oils. Set up adequate signage and specific courses to ensure a full understanding of the rules and the basic prevention measures.
- Do not modify the fuel or hydraulic systems without authorisation from FPT. Any unforeseen change will void
the warranty and may prejudice the engine’s duration
and life cycle.
- Collect the spent oil in suitable containers with water
tight seals and store them in areas that are adequately
marked and ventilated, at a safe distance from any sources of heat and fire hazards.
For engines equipped with electronic units:
- Handle batteries with care in well ventilated areas and
in antacid containers. Beware of fumes coming from the
batteries: they may pose a serious risk of poisoning and
contamination of the environment.
- Do not apply changes to the cabling, their length must
not be modified.
- Do not carry out any arch welding without previously
removing the electronic units.
- Remove the electronic control units in case of interventions in which the temperatures will exceed 80 ˚C.
- Do not paint the electronic components and connections.
- Do not modify or alter the data contained in the engine
management electronic control unit. Any manipulation
or alteration of the electronic components will invalidate
the engine’s service warranty and could also compromise its functionality and service life.
Base - May 2018
Print P4D32N015 E