Post on 11-Aug-2018
NEF SERIES Tier 4iIndustrial application
N67 ENT
N45 ENT
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
Print P2D32N019 E Base - March 2012
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. . . . . . . . . . . . . . . . .
- 6-cylinder engine version 18. . . . . . . . . . . . . . . . .
- Oil pump 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Heat exchanger 19. . . . . . . . . . . . . . . . . . . . . . . .
- Oil pressure relief valve 21. . . . . . . . . . . . . . . . . .
OIL VAPOUR RECYCLING 22. . . . . . . . . . . . . . . .
COOLING SYSTEM 23. . . . . . . . . . . . . . . . . . . . . .
- 4-cylinder engine version 23. . . . . . . . . . . . . . . . .
- 6-cylinder engine version 24. . . . . . . . . . . . . . . . .
- Water Pump 25. . . . . . . . . . . . . . . . . . . . . . . . . .
25. . . . . . . . . . . . . . . . . . .
SECTION 3 - ELECTRICAL EQUIPMENT 1F4HFE ENGINES
Print P2D32N019 E Base - March 2012
SECTION 3
Electrical equipment
Page
LOCATION OF THE MAIN ELECTRICALCOMPONENTS 3. . . . . . . . . . . . . . . . . . . . . . .
ENGINE CABLE 4. . . . . . . . . . . . . . . . . . . . . . . . .
- 4-cylinder engine version 4. . . . . . . . . . . . . . . . .
- 6-cylinder engine version 5. . . . . . . . . . . . . . . . .
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
Print P2D32N019 E Base - March 2012
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
Print P2D32N019 E Base - March 2012
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
Print P2D32N019 E Base - March 2012
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
Print P2D32N019 E Base - March 2012
Appendix
Page
SAFETY PRESCRIPTIONS 3. . . . . . . . . . . . . . . . . .
- Standard safety prescriptions 3. . . . . . . . . . . . . .
- Prevention of injury 3. . . . . . . . . . . . . . . . . . . . .
- During maintenance 3. . . . . . . . . . . . . . . . . . . .
- Respect of the Environment 4. . . . . . . . . . . . . .
x
x
x
x
x
x
x
x
x