NEF SERIES Tier 4i - Service Manual ebook · INTRODUCTION 3..... FITTING THE ENGINE TO THE ROTATING...

NEF SERIES Tier 4iIndustrial application

N67 ENT

N45 ENT

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SERIES NEF TIER 4iIndustrial application

N45N45 ENT

N67N67 ENT

Technical and Repair manual



F4HFE engines Part 1

SERIES NEF TIER 4i

1SERIES NEF TIER 4i

Print P2D32N019 E Base - March 2012



INTRODUCTION 1SERIES NEF TIER 4i

Print Base - March 2012

Introduction

Page

PREFACE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SYMBOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Service operations 3. . . . . . . . . . . . . . . . . . . . . .

GENERAL WARNINGS 5. . . . . . . . . . . . . . . . . . .

GENERAL WARNINGSON THE ELECTRIC SYSTEM 7. . . . . . . . . . . . .

- Bonding and screening 8. . . . . . . . . . . . . . . . . . .

OPTIONAL ELECTRICAL AND MECHANICALPARTS INSTALLATIONS 9. . . . . . . . . . . . . . . .

CONVERSIONS BETWEEN THE MAIN UNITSOF MEASUREMENT OF THE INTERNATIONALSYSTEM AND MOST USED DERIVEDQUANTITIES 9. . . . . . . . . . . . . . . . . . . . . . . . .

KEY OF LECTURE OF THE HEADINGSAND FOOTNOTES 10. . . . . . . . . . . . . . . . . . .



SECTION 2 - OPERATIONAL DIAGRAMS 1F4HFE ENGINES


SECTION 2

Operational diagrams

Page

HIGH PRESSURE ELECTRONIC INJECTION FUELSYSTEM (COMMON RAIL) 3. . . . . . . . . . . . . .

- General Specifications 3. . . . . . . . . . . . . . . . . . .

ELECTRIC SYSTEM 3. . . . . . . . . . . . . . . . . . . . . . .

- Sensors 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- System functionality 4. . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM 5. . . . . . . . . . . . . . . . . . . .

- Fuel system layout 7. . . . . . . . . . . . . . . . . . . . . .

FUEL SUPPLY SYSTEM COMPONENTS 8. . . . . .

- Fuel prefilter 8. . . . . . . . . . . . . . . . . . . . . . . . . .

- Fuel filter 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Mechanical supply pump 9. . . . . . . . . . . . . . . . .

- CP3 high-pressure pump 10. . . . . . . . . . . . . . . . .

- Rail 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Overpressure valve 14. . . . . . . . . . . . . . . . . . . . .

- Electro-injector 15. . . . . . . . . . . . . . . . . . . . . . . .

- Pressure limiter for fuel return 16. . . . . . . . . . . . .

LUBRICATION 17. . . . . . . . . . . . . . . . . . . . . . . . . .

- 4-cylinder engine version 17. . . . . . . . . . . . . . . . .


- Oil pump 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Heat exchanger 19. . . . . . . . . . . . . . . . . . . . . . . .

- Oil pressure relief valve 21. . . . . . . . . . . . . . . . . .

OIL VAPOUR RECYCLING 22. . . . . . . . . . . . . . . .

COOLING SYSTEM 23. . . . . . . . . . . . . . . . . . . . . .



- Water Pump 25. . . . . . . . . . . . . . . . . . . . . . . . . .

25. . . . . . . . . . . . . . . . . . .



SECTION 3 - ELECTRICAL EQUIPMENT 1F4HFE ENGINES


SECTION 3

Electrical equipment

Page

LOCATION OF THE MAIN ELECTRICALCOMPONENTS 3. . . . . . . . . . . . . . . . . . . . . . .

ENGINE CABLE 4. . . . . . . . . . . . . . . . . . . . . . . . .



ECU ELECTRONIC CONTROL UNIT(EDC7UC31) 6. . . . . . . . . . . . . . . . . . . . . . . . .

- Electroinjectors connector (A) 7. . . . . . . . . . . .

- Sensors connector (C) 8. . . . . . . . . . . . . . . . . .

FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS 9

- Crankshaft sensor 9. . . . . . . . . . . . . . . . . . . . . .

- Timing sensor 9. . . . . . . . . . . . . . . . . . . . . . . . .

- Supercharging air pressure - temperature sensor 10

- Engine oil temperature-pressure sensor 10. . . . .

- Fuel temperature and pressure sensor 11. . . . . .

- Electro-injectors 12. . . . . . . . . . . . . . . . . . . . . . .

- Pre-post heating resistance and contactor(if present) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Coolant temperature sensor 14. . . . . . . . . . . . . .

- Fuel temperature sensor 15. . . . . . . . . . . . . . . . .

- High pressure pump - fuel flow rate regulator 16



SECTION 4 - SCHEDULED MAINTENANCE 1F4HFE ENGINES

Base - March 2012

SECTION 4

Scheduled maintenance

Page

SCHEDULED MAINTENANCE 3. . . . . . . . . . . . .

- Recovery 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Regular maintenance and inspection planning 3.

- Checks not included in maintenanceplanning-daily checks 4. . . . . . . . . . . . . . . . . . .

MAINTENANCE PROCEDURES 4. . . . . . . . . . . .

- Checks and inspections 4. . . . . . . . . . . . . . . . . .



SECTION 5 - DIAGNOSTICS 1F4HFE ENGINES


SECTION 5

Diagnostics

Page

PREFACE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PT BOX 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PT-BOX INSTRUCTIONS 5. . . . . . . . . . . . . . . . .

- Hardware installation 5. . . . . . . . . . . . . . . . . . . .

- Software installation 7. . . . . . . . . . . . . . . . . . . . .

- Software Interface 18. . . . . . . . . . . . . . . . . . . . . .

- Acceptance 22. . . . . . . . . . . . . . . . . . . . . . . . . . .

- ECU diagnosis 26. . . . . . . . . . . . . . . . . . . . . . . . .

- Programming 35. . . . . . . . . . . . . . . . . . . . . . . . . .

- Active diagnosis 38. . . . . . . . . . . . . . . . . . . . . . . .

FAULT CODES 40. . . . . . . . . . . . . . . . . . . . . . . . . .

GUIDE TO DIAGNOSIS THROUGH SYMPTOMS 87



LATION OF MAIN COMPONENTS 1F4HFE ENGINES

Base - March 2012

SECTION 6

Removal and installation of maincomponents

Page

REMOVAL AND INSTALLATION AUXILIARY DRIVEBELT 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removal 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR REMOVAL AND INSTALLATION 3

- Removal 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLANT PUMP REMOVAL AND INSTALLATION 4

- Removal 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT REMOVAL AND INSTALLATION 5

- Removal 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION STARTERMOTOR 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removal 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE CABLE REMOVAL AND INSTALLATION 6

- Removal 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION LOW-PRESSUREFUEL LINES 7. . . . . . . . . . . . . . . . . . . . . . . . . .

- Removal 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS F4HFE ENGINES

Base - March 2012 Print P2D32N019 E

Page

REMOVAL AND INSTALLATION FUEL HOSE FROMHIGH PRESSURE PUMP TO COMMON RAIL 8

- Removal 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE CONTROL UNIT REMOVAL ANDINSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . .

- Removal 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL FILTER REMOVAL AND REFITTING 9. . . . .

- Removal 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL FILTER REMOVAL AND REFITTING 9. . . . .

- Removal 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION COMMONRAIL 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removal 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL VAPOUR RECIRCULATION (BLOW-BY)SYSTEM REMOVAL AND INSTALLATION 12. .

- Removal 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

TAPPET COVER REMOVAL AND INSTALLATION 13

- Removal 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 13. . . . . . . . . . . . . . . . . . . . . . . . . . .

INJECTOR WIRING SUPPORT REMOVAL ANDINSTALLATION 14. . . . . . . . . . . . . . . . . . . . . . .

- Removal 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 14. . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION ROCKER ARMASSEMBLY 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removal 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 15. . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

INJECTOR REMOVAL AND INSTALLATION 17. .

- Removal 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 17. . . . . . . . . . . . . . . . . . . . . . . . . . .

TURBOCHARGER REMOVAL AND INSTALLATION 19

- Removal 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST MANIFOLD REMOVAL-INSTALLATION 20. . . . . . . . . . . . . . . . . . . . . . .

- Removal 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . .

INTAKE MANIFOLD REMOVAL ANDINSTALLATION 21. . . . . . . . . . . . . . . . . . . . . . .

- Removal 21. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

COLD START AIR HEATER REMOVAL ANDINSTALLATION (only for F4HFE6132/39/3A/3C*A002-3/3L*A001-2 ENGINES) 22. . . . . . . . .

- Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD REMOVAL AND INSTALLATION 22

- Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 23. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL FILTER REMOVAL ANDINSTALLATION 24. . . . . . . . . . . . . . . . . . . . . . .

- Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 24. . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL AND INSTALLATION ENGINE OIL HEATEXCHANGER 25. . . . . . . . . . . . . . . . . . . . . . . . .

- Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 25. . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL SUMP REMOVAL AND INSTALLATION 26. .

- Removal 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation 27. . . . . . . . . . . . . . . . . . . . . . . . . . .



SECTION 7 - GENERAL MECHANICAL OVERHAULING 1F4HFE ENGINES


SECTION 7

General mechanical overhauling

Page

INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . .

FITTING THE ENGINE TO THE ROTATINGSTAND 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOVAL OF MAIN COMPONENTS 5. . . . . . .

BENCH ENGINE BLOCK DISASSEMBLY 14. . . . .

CRANKCASE 16. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Controls and measurements 16. . . . . . . . . . . . . .

- Checking head supporting surface on cylinderunit 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIMING SYSTEM 17. . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Cam lift check and pin alignment check 18. . . . .

BUSH 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Bush replacement 19. . . . . . . . . . . . . . . . . . . . . .

TAPPETS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting tappets — camshaft 20. . . . . . . . . . . . . . . .

CRANKSHAFT 21. . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring journals and crankpins (4-cylinder) 21.

- Measuring journals and crankpins (6-cylinder) 23.

CONNECTING ROD — PISTON ASSEMBLY 25. .

- Connecting rod-piston assembly removal 25. . . .

- Pistons 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Gudgeon pins 26. . . . . . . . . . . . . . . . . . . . . . . . .

- Piston rings 27. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rods 28. . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 7 - GENERAL MECHANICAL OVERHAULING

Base - March 2012 Print P2D32N019 E

Page

- Bushes 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod-piston assembly 29. . . .

- Connecting rod-piston assembling 29. . . . . . .

- Fitting split rings 29. . . . . . . . . . . . . . . . . . . . .

BENCH ENGINE BLOCK ASSEMBLY 30. . . . . . . .

- Replacing oil pump control gear 30. . . . . . . . .

- Fitting main bearings 30. . . . . . . . . . . . . . . . . .

- Crankshaft installation 30. . . . . . . . . . . . . . . . .

- Checking crankshaft end float 31. . . . . . . . . . .

- Fitting connecting rod half bearings 32. . . . . .

- Fitting connecting rod-piston assembly intocylinder barrels 32. . . . . . . . . . . . . . . . . . . . . .

- Checking piston protrusion 33. . . . . . . . . . . . .

CYLINDER HEAD DISMANTLING 34. . . . . . . . . .

- Removing the valves 34. . . . . . . . . . . . . . . . . .

- Checking cylinder head wet seal 34. . . . . . . . .

- Checking cylinder head supporting surface 35.

VALVES 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing carbon deposits, checking and grindingvalves 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking clearance between valve stem andvalve guide and valve centering 36. . . . . . . . . .

VALVE GUIDES 36. . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE SEATS 36. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Regrinding - replacing the valve seats 36. . . . .

VALVE SPRINGS 38. . . . . . . . . . . . . . . . . . . . . . . . .

ASSEMBLING CYLINDER HEAD 39. . . . . . . . . . . .

REFITTING MAIN COMPONENTS 40. . . . . . . . . .

Page

REMOVING THE ENGINE FROM THE ROTATINGSTAND 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPLETING ENGINE ASSEMBLY 54. . . . . . . . .

CHECKS AND INSPECTIONS 56. . . . . . . . . . . . . .



CIFICATIONS 1F4HFE ENGINES


SECTION 8

Technical specifications

Page

GENERAL SPECIFICATIONS 3. . . . . . . . . . . . . . .

CLEARANCE DATA 4. . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUE 10. . . . . . . . . . . . . . . . . .



SECTION 9 - TOOLS 1F4HFE ENGINES

Pri Base - March 2012

SECTION 9

Tools

Page

TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



APPENDIX 1F4HFE ENGINES


Appendix

Page

SAFETY PRESCRIPTIONS 3. . . . . . . . . . . . . . . . . .

- Standard safety prescriptions 3. . . . . . . . . . . . . .

- Prevention of injury 3. . . . . . . . . . . . . . . . . . . . .

- During maintenance 3. . . . . . . . . . . . . . . . . . . .

- Respect of the Environment 4. . . . . . . . . . . . . .



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NEF SERIES Tier 4i - Service Manual ebook · INTRODUCTION 3..... FITTING THE ENGINE TO THE ROTATING...

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