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CNG NEF SERIESVehicle application
N60
N60 ENT G
Technical and Repair manual
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P u b l i c a t i o n e d i t e d b y
I v e c o M o t o rs
I v e c o S p A
PowerTrain
M k t . A d v e rt i s i n g & P r o mo t i o n
V i a l e d e l l I n d u s tr i a , 1 5 / 1 7
2 0 0 1 0 P r e g na n a M i l a ne s e
M i l a no ( I t a l y)
Print P1C32N001GB - 1st E d . 0 4 . 20 0 5
T h i s p u b l i c a t i o n d e s c r i b e s t h e c h a r a c t e r i s t i c s , d a t a a n d c o r r e c tm e t h o d s f o r r e p a i r o p e r a t i o n s o n e a c h c o m p o n e n t o f t h e v e -hicle.
I f t h e i n st r uc t io n s p r ov i de d a r e f o ll o we d a n d t h e s p ec i fi e de qu ip me nt i s u se d, c or re ct r ep ai r o pe ra t io ns i n t he p ro -g r a m m ed t i m e w i l l b e e n s u re d , s a f e g u a r d in g a g a i n s t p o s s i b leaccidents.
B e fo r e s t ar t in g t o p e rf o rm w h at e v er t y pe o f r e pa i r, e n su r e t h a ta l l a c c i de n t p r e v e n t i o n e q u i p m en t i s a v a i l a bl e a n d e f f i c i e n t .
A l l p r ot e ct i on s s p ec i fi e d b y s a fe t y r e gu l at i on s , i . e. : g o gg l e s,h e lm e t, g l ov e s , b o o t , e t c . m u st b e c h ec k ed a n d w o rn .
A l l m a ch i ni n g, l i ft i ng a n d c o nv e yi n g e q ui p me n t s h ou l d b e i n -s p e c te d b e f o re u s e .
T h e d a t a c o n t a i n e d i n t h i s p u b l i c a t i o n w a s c o r r e c t a t t h e t i m eo f g o in g t o p r es s b u t d u e t o p o ss i bl e m o di f ic a t io n s m a d e b y
the Manufacturer for reasons of a technical or commercial na-ture or for adaptation to the legal requirements of the differ-
e n t c o u n t r i e s , s o m e c h a n g e s m a y h a v e o c c u r r e d .
N o p a r t o f t h i s p u b l i c a t i o n , i n c l u d i n g t h e p i c t u r e s , m a y b e r e -p r o d u c e d i n a n y f o r m o r b y a n y m e a n s .
B . U . T E C H N IC A L P U B LI S H I N G
I v e c o T e c h ni c a l P u b l ic a t i on s
L u n g o S t u r a L a z i o , 1 5 / 1 9
1 0 1 5 6 T u r i n - I t a l y
P r o d uc e d b y :
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F 4 B E n g i n e s Part 1
CNG NEF ENGINES
1C N G N E F E N G I N E S
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2 C N G N E F E N G IN E S
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Where possible, the same sequence of procedures has been followed for easy reference.D i a g r a m s a n d s y m b o l s h a v e b e e n w i d e l y u s e d t o g i v e a c l e a r e r a n d m o r e i m m e d i a t e i l l u s t r a t i o n o f t h e s u b j e c t b e i n g d e a l t w i t h , ( s e en e x t p a g e ) i n s t e a d o f g i v i n g d e s c r i p t i o n s o f s o m e o p e r a t i o n s o r p r o c e d u r e s .
Example
1 = h o u s i n g f o r c o n n e c t i n g r o d s m a l l e n d b u s h
2 = h o u s i n g f o r c o n n e c t i n g r o d b e a r i n g s
T i g h t e n t o t o r qu eT i g h t e n t o t o r q u e + a n g u l a r v a l u e
1
2
3C N G N E F E N G I N E S
SPECIAL REMARKS
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M a n u a l s f o r r e p a i r s a r e s p l i t i n t o S e c t i o n s , e a c h o n e o f w h i c h i s m a r k e d b y a n u m e r a l ; t h e c o n t e n t s o f t h e s e s e c t i o n s a r e i n d i c a t e di n t h e g e n e r a l t a b l e o f c o n t e n t s .E a c h s e c t i o n i s g e n e r a l l y d e d i c a t e d t o a m a i n U n i t ( e . g . : e n g i n e , g e a r b o x , e l e c t r i c s y s t e m , e t c . ) .S e c t io n s w i t h m e c h an i c a l c o n t e n t s i n c l u d e t e c h n ic a l d a t a , t i g h t e n i n g t o r q ue c o l l ec t i o ns , t o o l l i s t s , c o n n ec t i o ns d i s co n n e c ti o n s o f u n i t s t o / f r om t h e v e h i c l e , o v e r h a u l s a t t h e b e n c h a n d r e l a t i n g t r o u b l e sh o o t in g .O n t h e e l e c t r i c / e l e c t r o n i c s y s t e m s e c t i o n t h e r e a r e t h e d e s c r i p t i o n s o f t h e e l e c t r i c n e t w o r k a n d v e h i c l e e l e c t r o n i c s y s t e m s , e l e c t r i cs c h e me s , c o m p o n e nt s e l e c t ri c c h a r ac t e r i st i c s , c o m p o n en t s c o d e s a n d t r o u bl e s h o ot i n g r e l a t i n g t o t h e c e n t r a l u n i t s s p e c if i c o f t h ee l e c tr i c s y s t e m.T h e m a n u a l u s e s p r o p e r s y m b o l s i n i t s d e s c r i p t i o n s ; t h e p u r p o s e o f t h e s e s y m b o l s i s t o c l a s s i f y c o n t a i n e d i n f o r m a t i o n . I n p a r t i c u l a r ,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
PRELIMINARY REMARKS
General danger
I t i n c l u d e s t h e d a n g e r s o f a b o v e d e s c r i b e d s i g n a l s .
Danger of serious damage for the vehicle
P a rt i a l o r c o mp l et e n o n o b se r va n ce o f t h es e p r es c ri p ti o ns c a n c a us e s e ri o us d a ma g e s t o t h e v e h ic l e a n d s o me t im e sg u a r a n t e e l a p s e t o o .
Environment protectionI t i n di c at e s c o rr e ct b e ha v io u r i n o rd e r t h at v e hi c le u s e i s e n v ir o nm e nt a l ly f r ie n dl y a s m u ch a s p o ss i bl e .
Danger for persons
M i s s in g o r i n c o m p l e t e o b s e r v a nc e o f t h e s e p r e s cr i p t io n s c a n c a u s e s e r i o u s d a n g e r f o r p e r s o n s s a f e t y .
SYMBOLS - WARNINGS
I t i n d i ca t e s a n a d d i t io n a l e x p l a n a t io n f o r a p i e c e o f i n f o rm a t i on .
!
NOTE
4 C N G N E F E N G IN E S
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5C N G N E F E N G I N E S
Graph and symbols
RemovalDisconnection
Intake
Refitting
Connection
Exhaust
RemovalDisassembly
Operation
F i t t i n g i n p l a c eAssembly
C o m p re s s i on r a t i o
T i g h t e n t o t o r q ue Tolerance
Weight difference
Tighte n to torque + angle value R olling torque
P r es s o r c a ul k Replacement
O r i g in a l s p a r e p a r t s
RegulationAdjustment
Rotation
!WarningNote
AngleA n g u l a r v a l u e
V i s u a l i n s p ec t i o nF i t t i ng p o s i ti o n c h e c k
Preload
MeasurementV a l u e t o f i n dCheck
N u m b er o f r e v o l ut i o n s
Equipment Te mperature
S u r f ac e f o r m a c h in i n gM a c h in e f i n i sh bar
Pressure
InterferenceS t r a i ne d a s s e m bl y
OversizedH i g h e r t h a n.M a x i m u m , p e a k
Thickness
Clearance
U ndersized
L e s s t h a n.Minimum
LubricationDampGrease
SelectionClassesOversizing
SealantAdhesive
T e mp e ra t ur e < 0 CCold
Winter
A i r b l e e di n gT e mp e ra t ur e > 0 CHotSummer
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6 C N G N E F E N G IN E S
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Section
General specifications 1
Fuel 2
U se 3
G e n e r a l o v e r h a u l 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USERS GUIDELINE MANUAL
S e c t i o n 1 d e s c r i b e s t h e F 4 B e n g i n e i l l u s t r a t i n g i t s f e a t u r e s
a n d w o rk i ng i n g e ne r al .
S e c t i o n 2 d e s c r i b e s t h e t y p e o f f u e l f e e d .
S e ct i on 3 r e la t e s t o t h e s p ec i fi c d u ty a n d i s d i vi d ed i n f o ur s e pa -
r a t e p a r t s :
1 . M e ch a ni c al p a rt , r e la t ed t o t h e e n g i n e o v e r ha u l,
l i m i te d t o t h o s e c o m p o n e n ts w i t h d i f fe r e n t c h a r ac t e r i st i c s
b a se d o n t h e r e la t in g s p ec i fi c d u ty .
2 . E l e c t ri c a l p a r t , c o n c er n i n g w i r i n g h a r n e ss , e l e c t ri c a l
a n d e l e c t ro n i c e q u i pm e n t w i t h d i f fe r e n t c h a r a ct e r i s ti c s
b a se d o n t h e r e la t in g s p ec i fi c d u ty .
3 . M a i n te n a n c e p l a n n i n g a n d s p e c if i c o v e r h a u l .
4 . T r ou b le s ho o ti n g p a rt d e di c at e d t o t h e o p er a to r s w h o,b e in g e n ti t le d t o p r ov i de t e ch n ic a l a s s is t a nc e , s h al l h a v e s i mp l e
a n d d i re c t i n st r uc t io n s t o i d en t if y t h e c a us e o f t h e m a jo r i n co n -
veniences.
S e ct i on s 4 a n d 5 i l lu s tr a te t h e o v er h au l o p er a ti o ns o f t h e e n g i-
n e o v er h au l o n s t an d a n d t h e n e ce s sa r y e q ui p me n t t o e x ec u te
s u c h o p e ra t i o n s.
I n s t a ll a t i o n g e n e r a l p r e s c r i pt i o n s a r e r e p or t e d w i t h i n t h e a p -
pendix.
T h e a p p e n d i x r e p o r t s g e n e r a l s a f e t y p r e s c r i p t i o n s t o b e f o l l o -
w e d b y a l l o p er a to r s w h e th e r b e in g i n -c h ar g e o f i n st a ll a t io n o r
m a i n t en a n c e , i n o r d e r t o a v o i d s e r i o u s i n j u r y.
Part 1F4B ENGINES
1C N G N E F E N G I N E S
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2 C N G N E F E N G IN E S
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3C N G N E F E N G I N E S
UPDATING
Section Description Page Date of revision
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4 C N G N E F E N G IN E S
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SECTION 1 - GENERAL SPECIFICATIONS 1CNG NEF ENGINES
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL CODEAND COMMERCIAL CODE 3. . . . . . . . . . . . .
LUBRICATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .
OIL VAPOUR RECIRCULATING SYSTEM 6. . . . .
COOLING SYSTEM 7. . . . . . . . . . . . . . . . . . . . . .
AIR INDUCTION BOOST DIAGRAM 8. . . . . . . .
- Description 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 S E C T IO N 1 - G E N ER A L S P E C IF I C A TI O N S C N G N E F E N G IN E S
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CORRESPONDENCE BETWEEN TECHNICAL CODE ANDCOMMERCIAL CODE
SECTION 1 - GENERAL SPECIFICATIONS 3CNG NEF ENGINES
Technical Code Commercial Code
F4BE0641A*G102 N60 ENT G
F4BE0641A*G103 N60 ENT G
F4BE0641A*G105 N60 ENT G
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4 S E C T IO N 1 - G E N ER A L S P E C IF I C A TI O N S C N G N E F E N G IN E S
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Figure 1
LUBRICATION
L u br i ca t i on b y f o rc e d c i rc u la t io n i s a c hi e ve d t h ro u gh o i l r o ta r y e x pa n s io n p u mp , p l ac e d i n t h e f r o n t p a rt o f t h e b a se m en t ,d r iv e n b y t h e s t ra i g ht - to o th g e a r s p l i ne d t o t h e s h af t s b a r h o ld .
F r o m t h e p a n , t h e l u b r i c a t i o n o i l f l o w s t o t h e d r i v i n g s h a f t , t othe camshaft and to the valve drive.
L ubr ica tio n in vol ve s t he h ea t e xch an ge r ( 2, 3), t heturboblower for turbocompressed versions, and for any
c o m p re s s e d a i r s y s t em .
A l l t h es e c o mp o ne n ts m a y o f te n v a ry a c co r di n g t o t h e s p ec i fi cduty.
R o u t i ng o f o i l u n d e r p r e s s ur e
R o u t i n g o f o i l r e t u r n b y g r a v i t y to sump
I n t r o d u c t i o n o f o i l
76212
L U B R I CA T I O N S Y S T EM L A Y O UT
1 . L u b r i c a t i o n o i l p i p e t o s u p e r c h a r g e r - 2 . H e a t e x c h a n g e r b o d y - 3 . H e a t e x c h a n g e r - 4 . O i l r o t a r y e x p a n s i o n p u m p -
5 . O i l f i lt e r.
(Demonstrative)
S E C T IO N 1 - G E N E RA L S P E C I FI C A TI O N S 5C N G N E F E N G I N E S
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3240t
Figure 2
OIL VAPOUR RECIRCULATING SYSTEM
1 . V a l ve - 2 . B r ea t he r p i pe - 3 . T a pp et C ap .
O n t h e t a pp e t c a p ( 3 ) t h er e i s a v a l ve ( 1 ) w h o se d u ty i s t o c o nd e ns e o i l v a po u r i n d uc i ng t h es e t o f a ll d o wn b e ca u se o f g r a v it y ,to the Tappet cap underneath.
T h e r e m a i n i n g n o n - c o n d e n s e d v a p o u r s s h a l l b e p r o p e r l y c o n v e y e d t h r o u g h t h e b r e a t h e r p i p e ( 2 ) , b y s u c t i o n a s a n e x a m p l e ( c o n -n e c t i o n t o w a r d s t h e s e v a p o u r s s h a l l b e d e s i g n e d b y t h e E n g i n e e r ) .
1
2
3
6 S E C T IO N 1 - G E N ER A L S P E C IF I C A TI O N S C N G N E F E N G IN E S
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Figure 3
COOLING SYSTEM
T h e e n gi n e c o ol i ng s y st e m , c l os e d c i rc u it f o rc e d c i rc u la t io ntype, generally incorporates the following components:
- E x pa n s io n t a nk ; p l ac e me n t, s h ap e a n d d i me n si o ns a r es u b j e ct t o c h a n g e a c c o rd i n g t o t h e e n g i n e s e q u i p m e n t .
- R ad ia to r, w hi ch h as t he d ut y t o d is si pa te t he h ea ts u bt r ac t ed t o t h e e n gi n e b y t h e c o ol i ng l i qu i d. A l so t h isc o mp o ne n t w i ll h a v e s p ec i fi c p e cu l ia r it i es b a se d o n t h ee qu ip me nt d ev e lo pe d, b ot h f or w ha t c on ce rn s t hep l a ce m e n t a n d t h e d i m e ns i o n s .
- V is c p us he r f an , h av in g t he d ut y t o i nc re a se t he h ea td i ss i pa t in g p o we r o f t h e r a di a to r . T h is c o mp o ne n t a s w e llw il l b e s pe ci fi ca ll y e qu ip pe d b as ed o n t he e ng in e sdevelopment.
- H ea t e xc ha ng e r t o c oo l t he l ub ri ca t io n o il : e v en t hi sc o m po n e n t i s p a r t o f t h e e n g i n e s s p e c i f i c e q u i p me n t .
- C e nt r if u ga l w a t er p u mp , p l ac e d i n t h e f r o n t p a r t o f t h e
e n g i n e b l o c k.- T h er m os t at r e gu l at i ng t h e c i rc u la t io n o f t h e c o ol i ng l i qu i d.
- T he ci rcu it ma y e ve nt ua ll y be e xt en de d t o t hec o m p re s s o r, i f t h i s i s i n c l u d e d i n t h e e q u i p m e n t.
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
C O O L IN G S Y S T E M L A Y O U T
F R O M R A D I A T O R
T O R A D I A T O R
76216
S E C T IO N 1 - G E N E RA L S P E C I FI C A TI O N S 7C N G N E F E N G I N E S
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Figure 4
T h e t u rb o ch a rg e r i s c o mp os e d b y t h e f o ll o wi n g m a in p a rt s :o n e t u rb i ne , o n e t r an s fo r mi n g v a lv e t o r e gu l at e t h e b o os tf e e d i n g p r e s s u r e , o n e m a i n b o d y a n d o n e c o m p r e s s o r .
D u ri n g e n gi n e w o rk i ng p r oc e ss , t h e e x ha u st e m is s io n f l owthrough the body of the turbine, provoking the turbine disk
w h e e l s r o t a t io n .
T he c om pr es so r r ot or , b ei ng c on ne ct ed b y s ha ft t o t heturbine disk wheel, rotates as long as this last one rotates,
c o mp r es s in g t h e s u ck e d a i r t h ro u gh t h e a i r f i lt e r.
T h e a b o v e m e n t io n ed a i r i s t h en c o ol e d b y t h e r a d i at o r a n df l o w n t h r o u g h t h e p i s t on i n d u ct i o n c o l l e c t o r.
T h e t u rb o ch a rg e r i s e q ui p pe d w i th a t r an s fo r mi n g v a l ve t or e g u l at e t h e p r e s s ur e , t h a t i s l o c a t ed o n t h e e x h a u s t c o l l ec t o r b e f o r e t h e t u r b i n e a n d c o n n e c t e d b y p i p i n g t o t h e i n d u c t i o ncollector.
I t s d ut y i s t o c ho ke t he e xh au st o f t he e mi ss io ns , r el ea si ng p ar to f t h e m d i r e c t l y t o t h e e x h a u s t t u b e w h e n t h e b o o s t f e e d i n g
p r es s ur e , o v er t h e c o mp r es s or , r e ac h es t h e p r es c ri b ed b a r value.
T h e c o ol i ng p r oc e ss a n d t h e l u br i ca t io n o f t h e t u rb o ch a rg e r a n d o f t h e b e a r i n g s i s m a d e b y t h e o i l o f t h e e n g i n e .
Description
74195RADIATOR
A I R F I L T E R TU RBOCHARGER
EXHAU ST
AIR INDUCTION BOOST DIAGRAM
8 S E C T IO N 1 - G E N ER A L S P E C IF I C A TI O N S C N G N E F E N G IN E S
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S E C T I O N 2 - F U E L 1C N G N E F E N G I N E S
SECTION 2
Fuel
Page
CHEMICAL COMPOSITIONOF NAT URAL GAS (CNG) 3. . . . . . . . . . . . . .
A D V A NT A G E S O F M E T H AN E G A S U T I L I ZA T I O NIN AUT OMOTI VE 3. . . . . . . . . . . . . . . . . . . . .
- Mo tor a dv an ta ge s o f m et ha ne g as u ti liz at io n 4. .
- D is ad va nt ag es o f m et ha ne u ti li za ti on i n e ng in es 4
- T o rq u e a n d p o w er t y p i ca l c u r v es -F4 BE0641A eng ines 5. . . . . . . . . . . . . . . . . . . . .
GAS EMI SSIONS 6. . . . . . . . . . . . . . . . . . . . . . . . .
- Main pollutants 6. . . . . . . . . . . . . . . . . . . . . . . . .
- E m is s io n s o f I v e co C N G e n g in e c o mp a re d t o E T Cc yc le em is si on s - ga s o f r ef er en ce : G 20 an d G 25 7
I G NI T IO N A ND IN JE CT I ON IN TE GR A TE D S YS TE M 8
- Characteristics 8. . . . . . . . . . . . . . . . . . . . . . . . .
- Genera l items 8. . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTR IC I NJECTORS 9. . . . . . . . . . . . . . . . . . . .
AI R SUCTION CIRCU IT 10. . . . . . . . . . . . . . . . . . .
- Debimeter (Air flow s ensor) 10. . . . . . . . . . . . . .
- T hrottle valv e body 10. . . . . . . . . . . . . . . . . . . . .
PRESSURE REDU CER 11. . . . . . . . . . . . . . . . . . . . .
STEEL HOSE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
OXYGEN SENSOR 15. . . . . . . . . . . . . . . . . . . . . . .
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CHEMICAL COMPOSITION OF NATURAL GAS (CNG)
N a t u r a l g a s i s a m i x t u r e o f g a s e s , m a i n l y c o m p o s e d o f m e t h a n e g a s , t h e p e r c e n t a g e o f w h i c h , a s t h e o n e o f t h e o t h e r c o m p o n e n t s ,m a y v a r y f r om e a ch f i el d . I n g a s o f d o me s ti c p r od u ct i on a n d i m p o rt e d g a s a s w e ll , m a in c h ar a ct e ri s ti c s a r e t h ou g h i n c l ud e d i n a na l m o st l i m i te d r a n g e o f t o l e r an c e . C h e m i c a l c h a r ac t e r is t i c s o f n a t u r al g a s a r e d e t e r mi n e d t h r o u g h o u t c h r o m a t og r a p hi c a n a l y si sw h ic h e n a bl e s t o d e fi n e t h e c o mp o si t io n . N a t ur a l g a s i s a m i xt u re o f a l ip h at i c s a tu r at e d c o mp o un d s c a l l e d p a r a ff i n. I n t h e o n ed i s t r i b u t e d i n I t a l y , m e t h a n e ( C H4) i s f o u n d i n p e r c e n t a g e s i n c l u d e d i n r a n g e b e t w e e n 8 3 % a n d 9 9 % . T h e o t h e r c o m p o u n d s a r eg e ne r al l y e t ha n e, ( C2H6) , p ro pa n e ( C3H8) , b ut an e ( C4H10) , n it ro g en ( N2) , c ar bo n d io xi de ( CO2) , a nd s o on . T he ma inc h e m ic a l - ph y s ic a l c h a r a c t e ri s t i cs o f t h e d o m e s ti c n a t u r a l g a s a r e r e p o rt e d i n t h e t a b l e b e l o w .
N a tu r al g a s i s c o lo u rl e ss , o do u rl e ss a n d i s n o t t o x i c . T h e l a w p r es c ri b es t h at e l ec t ro n ic s y st e m s t o c o nt r ol i g ni t io n i n m e th a ne e n g in ea r e o f a ut o -a d ju s ti n g t y pe , w h ic h m e a ns a b le t o a u to m at i ca l l y m o d i fy i g ni t io n p a ra m e te r s i n p r es e nc e o f g a s w i th d i ff e re n t c o nt e nto f m e t h a n e.
ADVANTAGES OF METHANE GAS UTILIZATION IN AUTOMOTIVE
ECOLOGIC
- M e t h a ne i s w e l l - kn o w n a s t h e o n l y a l t e r na t i v e e c o l o g ic f u e l r e a l ly a v a i l a b l e .
- M e th a ne u t il i za t i on i s r e le n t le s sl y i n cr e a si n g a s b e in g t h e m o st r e as o na b le a n d f e a si b le a l te r na t iv e t o e l ec t ri c al a n d h y br i dvehicles.
TECHNICAL
- T h e e n g i n e l i k e s m e t h a n e.
STRATEGICAL
- W o r l dw i d e o i l a n d n a t u r a l g a s a v a i l a b i l it y i s v e r y h i g h , a n d p r o cu r e m e nt s o u r ce s a r e l e s s s u b j e c t t o g e o g r a p h i c al a n d p o l i t i ca lrisks.
ECONOMICAL
S E C T I O N 2 - F U E L 3C N G N E F E N G I N E S
GAS Domestic Russian Dutch Algerian
Indicative composition % % % %
Me thane 99.62 9 8.07 9 1.01 8 3.28
Ethan e 0.06 0 .60 3.70 7 .68
Propa ne 0.02 0.22 0.88 2.05
Butane 0.01 0 .09 0 .28 0 .78
Pentanes - 0.01 0.07 0.21
Hex an es + 0.01 0.02 0.07 0.11
Carbon dioxide 0.02 0.11 1.11 0.19
Nitrogen 0.26 0.87 2.84 5.52
Helium - 0.01 0.04 0.18
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Motor advantages of methane gas utilization
T h e g a s e o u s s t a t u s a n d t h e h i g h a n t i k n o c k p o w e r m a k e m e t h a n e a s u i t a b l e f u e l f o r t h e f e e d o f e n g i n e s w i t h f i r i n g c o n t r o l d r i v e nb y h i g h c o m pr e s s i on v o l u me t r i c r a t i o . ( u p t o 1 3 : 1 ).
T h e h i g h o c t a n e v a l u e ( 1 2 0 - 1 3 0) c o n f er s t o m e t h a ne s i g n i fi c a n t r e s i s t a nc e t o d e t o n a t i o n, f e a t u ri n g t h e s u p e r f u e l s .
D u e t o t h e f u e l i n i t i a l p u r i t y a n d t h e a b s e n c e o f a d d i t i v e s , c o m b u s t i o n o r i g i n a t e s l i m i t e d d e p o s i t f o r m a t i o n a n d v e r y s m a l l q u a n t i t y o f s u l p hu r o u s p ro d u ct s .
M o r eo v e r , t h e a b s e n ce o f c o n d en s a t i on p h e n om e n o n a l o n g t h e c o m b u s t i on c h a m b er d u c t s e n a b l e s e a s y s t a r t .Joint to with minor deposit accumulation, there is the possibility to use lubrication oil for a higher number of working hours.
T h e t e c h n ol o g y a d o p t e d b r i n g s f o r w ar d t h e f o l l o w i n gadvantages:
- i t e l i m i n a te sparticulate e m is s i o n s f r o m o r i g i n a l s o u r c e , t y p i ca l o f d i e s e l e n g i n e s a n d a b s e n t i n c o n t r o l l ed f i r e e n g i n e s ;
- i t r e d u c e sgas e m i s s i o n s ( u n b u r n t h y d r o c a r b o n s H C , c a r b o n o x i d e C O a n d n i t r o g e n o x i d e N O x ) t o v e r y l o w l e v e l s , l o w e r than the limits prescribed for 2008. This reduction takes place into the three-way catalyser which, when the mixture is
s t o i ch i o m et r i c , e l i m i n a t es p o l l ut i o n e m i s s i o n s o f t h e e n g i n e , w i t h o v e r 9 0 % e f f i ci e n c y;
- m o re o ve r , t h er e a r e n o e m is s io n s o f s u pe r io r h y dr o ca r bo n s, s u ch a s b e nz e ne a n d d e r i v at i ve s ;
- i t r e d u c e s t h e e m i ss i o n s o f carbon dioxide, t h a n k s t o t h e u t i l i z a t i o n o f m e t h a n e w h i c h , c o m p a r e d t o d i e s e l o i l a n d g a s o l i n e ,p r o du c e s m o r e w a t e r v a p o u r a n d l e s s c a r b o n d i o x i d e ;
- i t s i g n i fi c a n t ly r e d u ce snoise, a s t h e e n g i n e h a s c o n t r o l l e d f i r i n g .
Disadvantages of methane utilization in engines
S i nc e g a s , w i t h t h e s a me e n er g et i c c o nt e n t, o c cu p ie s h i gh e r v o l u m e t h a n l i qu i d f u el s t h is i n vo l ve s t h e f o ll o wi n g:
l e ss v o lu m et r ic e f fi c ie n cy o f t h e e n g in e ( i n p r op o rt i on t o t h e v o lu m e o f t h e g a s d e li v er e d a t i n du c ti o n) ;
O v er a ll v o lu m e / c o st / c o mp l ex i t y o f f u el s t or a ge s y st e m a b o a rd t h e v e hi c le .
L o w e r e n g i n e e f f i c i en c y c o m p a r e d t o D i e s el , b u t h i g h e r t h a n g a s o l i n e f e e d e n g i n e.
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Torque and power typical curves - F4BE0641A engines
Figure 1
87772
A . P o w e r - B . T o r q u e .
Performances
(ECE 88/185/195 after 50 hours of operation - Tolerance 5%)Max pow er 147 kW (200 CV)Max pow er rpm 2500 - 2700 rpmPiston av era ge speed 10.8 m/secMax torque 650 NmMax torque rpm 1250 - 2000 rpmEff. a verage pressu re. (with max torque) 14.3 Bar Pea k idle rpm 2900 rpmMinimum idling 650 rpmEfficiency with ma x power 34%Efficiency w ith max torque 36%Oil consumption with max power 0.4 g/kWh
rpm
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GAS EMISSIONS
1 9 99 / 96 / EC E u ro p ea n R e gu l a ti o n f o r h e a vy e n gi n es i n tr o du c ed a n e w t e st c y cl e c a ll e d E T C f o r m e t ha n e g a s f e ed e n g in e s a n ds ta te s t h e l im it s f or t he e mi ss io ns , l ow er E ur o 3 a nd E u ro 4 , f or t he E EV v eh ic le s e gm en t w it h m in im um i mp ac t t o t he e nv ir on me nt .
LIMIT VALUES PRESCRIBED BY 1999/96/EC REGULATION WITH ETC TEST CYCLE
Main pollutants
Carbon monoxide (CO)
I t i s a v e ry d a ng e r ou s g a s ( i n h i g h c o nc e nt r at i on i t b e co m es d e ad l y) w h ic h i s o r ig i na t ed w h en c o mb u st i on p r oc e ss i s c a rr i ed o u tw it h l ac k o f o xy ge n. I t i s a t yp ic al e mi ss i on o f t h e E ig ht -s tr ok e e mi ss io ns , w hi le i t m ay b e f ou nd i n d ie se l e ng i ne s i n v er y l owpercentages.
Unburnt hydrocarbons (HC)
T h es e a r e v i s c ou s p a rt i cl e s, a s a c o ns e qu e nc e o f a n i n co m pl e te c o mb u st i on o f f u e l s a n d l u br i ca n t s. T h e H C a r e e m it t e d b y E i gh tc yc l e e n gi n es a n d d i es e l e n gi n es i n di s ti n ct l y, b u t t h es e l a st o n es a r e m o re c r it i ca l b e ca u se t h ey c on t r ib u te o r ig i na t i ng t h e P a rt i cu l at e .
Nitrogen oxide (NOx)
When combustion is carried out at very high temperature, the nitrogen which is a neuter element normally, chemically combinesw i th t h e o x y g e n. T h e N O x a r e e m it t e d b y E i gh t c y cl e e n g in e s a n d d i es e l e n gi n es i n di s ti n ct l y.
Sulphur composites (SOx)
O r ig i na t ed b y o x id a ti o n o f s u lp h ur p a rt i cl e s c o nt a in e d i n d i es e l o i l. F o r t h is r e as o n t h ey a r e t y pi c al o f d i es e l e n gi n es .
Particulates (PT)
I n d i es e l e n g i n es , p a rt o f t h e f u el i n je c te d i n t h e c o mb u st i on c h am b er d o es n o t b u rn n o rm a ll y b u t i t i s t r an s fo r me d i n c a rb o n p a rt i cl e sw h i c h, j o i n in g t h e H C , c o m p o s e t h e P a r t ic u l a t es .
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(CO)g/kWh
(NMHC)g/kWh
(CH4)g/kWh
(NOx)g/kWh
(PT)g/kWh
Euro 3 - 2000 5.45 0.78 1.6 5.0 0.16 0.21
Euro 3 - 2005 4.0 0.55 1.1 3.5 0.03
Euro 3 - 2008 4.0 0.55 1.1 2.0 0.03
EEV 3.0 0.40 0.65 2.0 0.02
IVECO engine CNG 1.27 0.006 0.01 0.45 0.002
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Emissions of Iveco CNG engine compared to ETC cycle emissions - gas of reference: G20 and G25
Figure 2
87893
Figure 3
87894
Emission
(g/kWh)
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IGNITION AND INJECTION INTEGRATED SYSTEMCharacteristics
M e t a f u e l 3 s y s t e m b e l o n g s t o t h e c a t e g o r y o f t h e e l e c t r o n i c i g n i t i o n a n d i n j e c t i o n i n t e g r a t e d s y s t e m s o f s e q u e n t i a l a n d t i m e d t y p e .
T h e c e nt r al u n it e l ec t ro n ic a l ly c o nt r ol s a i r f l ow r a te t h ro u gh m o to r is e d t h ro t tl e ( d ri v en b y V D O E G A S 2) , c o nt r ol s t h e t u rb o bl o we r through special solenoid valve, regulates fuel injection in such a way that (air/fuel) ratio is always ranging within optimal value and
c a lc u la t es i g ni t io n l e ad . T h es e f u nc t io n s e n a bl e e n gi n e t o r u n r e gu l ar l y o n v a ri a ti o ns o f e n v ir o nm e nt a l p a ra m et e rs a n d a p pl i ed l o ad s .
I g ni t io n s y st e m i s o f s t a ti c t y pe w i th o n e c o i l p e r c y l i nd e r. P o we r m o du l es a r e c o nt a in e d i n s i de t h e c e n t ra l u n it .
E n gi n e c o nt r ol s y st e m , o f s e lf - ad a pt i ng t y pe , i s a b le t o d e te c t c h an g es ( c om p on e nt s d e te r io r at i on , e t c. ) o c cu r ri n g i n e n g in e a n dc o m p en s a t e t h e m a c c o rd i n g t o s e l f -a d a p t in g f u n c ti o n s w h i c h c o r r ec t c e n t ra l u n i t m a p p i n g s . A s e l f - ad a p t i ng f u n c ti o n a l l o w in g t od e te c t f u el q u a li t y i s a l so p r es e nt .
A s a c o n s e q u e n c e o f w h a t a b o v e , i t i s a f t e r e a c h m a i n t e n a n c e i n t e r v e n t i o n n e c e s s a r y t o d r i v e t h e v e h i c l e f o r a t l e a s t 1 5 m i n u t e si n t h e v a r i o us w o rk i ng c o nd i ti o ns i n o r de r t o h a ve c e nt r a l u n i t s t or i ng a n y c h an g e s t o s y st e m a n d t o t e rm i na t e a d a pt a ti o n.
Figure 4
87608
General items
1 . D e b i m e t e r - 2 . A i r f i l t e r - 3 . F r e s h a i r - 4 . T u r b o c h a r g e r - 5 . C a t a l y s t - 6 . E x h a u s t g a s - 7 . E x h a u s t g a s t e m p e r a t u r e s e n s o r -8 . L a m b d a s e n s o r - 9 . W A S T E - G A T E v a l v e - 1 0 . O i l t e m p e r a t u r e / p r e s s u r e s e n s o r - 1 1 . O i l s u m p -
1 2 . M e t h a n e g a s r e s e r v o i r - 1 3 . R e l a y - 1 4 . G a s c y l i n d e r p r e s s u r e s e n s o r - 1 5 . P r e s s u r e r e d u c e r -1 6 . R a i l t e m p e ra t u r e /p r e s su r e s e n s o r - 1 7 . A i r t e m p e ra t u r e /p r e s s ur e s e n s o r -
1 8 . V D O E G A S I I c o n t r o l u n i t - 1 9 . M i n i m u m b y - p a s s - 2 0 . T h r o t t l e v a l v e p o t e n t i o m e t e r - 2 1 . D a s h b o a r d -2 2 . P r e s su r e s e n s or - 2 3 . I n t e rc o ol e r - 2 4 . A c c e le r at o r - 2 5 . E n g i ne c o nt r ol u n it - 2 6 . C a m s ha f t r e v s e ns o r -
2 7 . C r a n k s h a f t r e v s e n s o r .
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ELECTRIC INJECTORS
Figure 5
87776
T h e e l e c t r i c i n j e c t o r s a r e s p e c i f i c f o r m e t h a n e e n g i n e s . T h e m e t h a n e j e t s a t 9 - b a r p r e s s u r e c o m e o u t o f t h e i n j e c t o r u p s t r e a m t h es u c t io n v a l v e s .
T h e o p e r a t i n g l o g i c i s o f p h a s e s e q u e n c e t y p e . T h e s i x i n j e c t o r s a r e c o n t r o l l e d a c c o r d i n g t o t h e s u c t i o n s e q u e n c e o f t h e e n g i n ec y li n de r , w h il e t h e f u el s u pp l y c a n b e s t ar t ed f o r e a ch c y li n de r a l re a dy a t t h e e x pa n s io n s t ag e u n ti l r e ac h in g t h e s u ct i on p h as e a l re a dy started.
T h e f u e l i s i n je c te d f r om a n i n je c to r f o r e a c h c y li n de r p o si t io n ed o n t h e m a ni f ol d i n le t b e fo r e t h e s u ct i on v a lv e s .
T h e e l e c t r i c i m p u l s e r e s u l t s f r o m t h e c o n t r o l u n i t w h i c h g e n e r a t e s a m a g n e t i c f i e l d i n t h e c o i l a t t r a c t i n g t h e c o r e b y l i f t i n g t h e p i nb y s o me t e nt h s o f m i ll i me t re o f f i t s h o us i ng .
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AIR SUCTION CIRCUIT
T h e a i r s u c t i o n c i r c u i t c o n s i s t s o f t h e f o l l o w i n g c o m p o n e n t s :
A i r f i l t e r D e b im e t e r ( a i r f l o w s e n s o r )A i r t e m p er a t u r e s e n s o r S u c t io n m a n i fo l d p r e s s ur e s e n s o r T u r b oc h a r ge r p r e s su r e s e n s or
TurbochargerT h r o tt l e v a l v e a n d p o s i t i o n s e n s o r S u c t io n m a n i fo l dE n g i n e i d l i n g s p e e d a c t u a t o r
Figure 6
87777
T h e a i r f l o w s e n s o r i s o f t h e n e w t y p e w i t h h e a t e d f i l m . T h i s s y s t e m i s f i t t e d w i t h a h e a t e d f i l m p o s i t i o n e d i n a m e a s u r i n g c h a n n e lthrough which the air coming from the engine air inlet flows in.
A h e a ti n g c oi l m a in t a in s t h e f i lm a t a c o ns t an t t e mp e ra t ur e ( 1 20
C).T h e a i r m a ss f l ow i ng t h ro u gh t h e m e a su r in g c h an n el a b so r bs h e at f r om t h e f i lm . T h er e fo r e, t o m a in t a in t h e f i lm t e mp e ra t ur ec o n s t a n t , i t i s n e c e s s a r y t o h a v e a p r e - e s t a b l i s h e d c u r r e n t f l o w i n g t h r o u g h t h e h e a t i n g c o i l .
Throttle valve body
T h e t h r o t t l e v a l v e b o d y f u n c t i o n i s t o d o s e t h e q u a n t i t y o f a i r s u p p l i e d t o t h e e n g i n e a c c o r d i n g t o t h e d r i v e r s r e q u e s t t h r o u g h t h eaccelerator.
T h e t h ro t tl e v a l ve b o dy i s f a st e n ed t o t h e s u ct i on m a ni f ol d . T h e t h ro t tl e v a lv e i s o p en e d b y m e an s o f a l e ve r in g s y st e m w i th d i ff e re n to p e n in g a n g l e s.
T h e t h r o t tl e v a l ve p o si t io n s e ns o r i s f i tt e d o n t h e t h r o t tl e v a l ve b o dy .
I t c o ns i st s o f a p o te n ti o me t er w i th a m o bi l e p a rt c o nt r ol l ed d i re c tl y b y t h e t h ro t tl e v a lv e s p in d le .
Debimeter (Air flow sensor)
1 . C o n n e c t o r - 2 . M e a s u r i n g c h a n n e l - 3 . H e a t e d f i l m s e n s o r A = A i r i n l e t .
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PRESSURE REDUCER
T h e T A R T A R I N I M E T A p r e s s u r e r e d u c e r i s i n s t a l l e d i n t h e e n g i n e c o m p a r t m e n t a n d i t s t a s k i s t o r e d u c e t h e g a s p r e s s u r e f r o mthe value on the cylinder to the injector supply value and keep it under control at any operating conditions.
T h e p r es s ur e r e d uc e r i s a l so f i tt e d w i th a n h y d ra u li c c o nn e ct i on t o t h e e n g in e w a te r c o ol i ng c i rc u it w h ic h s u p pl i es t h e r i g ht a m ou n to f h e a t t o t h e g a s . A s a r e s u l t , d u r i n g t h e e x p a n s i o n p h a s e t h e g a s t e m p e r a t u r e f a l l s d r a m a t i c a l l y .
Figure 7
004425t
T h e g a s a r r i v i n g f r o m t h e c y l i n d e r s f l o w s i n t o t h e r e d u c e r a t 2 0 0 - b a r p r e s s u r e a n d a f t e r t w o p r e s s u r e l o s t h e a d s , i t i s s e n t t h r o u g ha s t e e l h o s e t o t h e s u p p l y p i p e ( r a i l ) a t 9 - b a r p r e s s u r e .
I n t h e r e d u c e r t h e r e i s a l s o a s a f e t y v a l v e w h o s e f u n c t i o n i s t o p r e v e n t o v e r - p r e s s u r e .
T h e m a x i mu m o p e r a ti n g p r e s s u r e s a r e t h e f o l l ow i n g :
Ma ximum operating pressure 22000 kPa (220 bar)First hea d maximum pressure 1400 k Pa (14 bar)Second hea d maximum pressure 900 kPa (9 bar)Sa fet y v alve exha ust pre ssure 1800 kPa (18 bar)
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Installation note
Y o u a r e r e co m me n de d t o p o si t io n t h e r e du c er i n a r ea s w i th o ut d u st a n d h u mi d it y .
Actions on components
G i ve n t h e h i gh t e ch n ol o gy a n d p r e c is i on r e qu i re d a t a s se m bl y , i t i s n o t p e rm i tt e d t o c a rr y o u t o p er a ti o ns o n t h e r e du c er i n ne r parts.T h e o n l y d e v i c e s w h i c h c a n b e r e m o v e d a n d r e p l a c e d w i t h o u t c o m p r o m i s i n g t h e r e d u c e r o p e r a t i o n a r e : t h e i n p u t p i p e ( 1 ) ; t h ec o i l ( 2 ) ; t h e v a l v e u n i t ( 3 ) ; t h e f i l t e r ( 4 ) ; t h e l o w p r e s s u r e s w i t c h ( 5 ) n o t u s e d o n I V E C O a p p l i c a t i o n s ; t h e p r e s s u r e s e n s o r u n i t ( 6 ) .
Reducer main elements
Filter
O n t h e r e d u c e r i n l e t t h e r e i s a f i l t e r w h i c h p r o t e c t s t h e v a l v e s a n d t h e g a s k e t s a g a i n s t i m p u r i t i e s .I t i s t h e d e v i c e w h o s e f u n c t i o n i s t o h o l d t h e m e t h a n e i m p u r i t i e s b e f o r e i t g e t s i n s i d e t h e s o l e n o i d v a l v e a n d t h e r e f o r e i n s i d e t h ereducer.U n fo r tu n at e ly i t i s e x t re m el y d i ff i cu l t t o e s ta b li s h w h en i t i s n e ce s sa r y t o c h an g e t h e f i lt e r s i nc e i t i s i n si d e a n d i t s d e gr a da t i on d e pe n dso n l y o n t h e q u a l i t y o f m e t h a n e .
T o r e p l a c e t h e f i l t e r p r o c e e d a s f o l l o w s :
- U s e a w r en c h t o s l ac k en s l ig h tl y t h e i n le t p i pe u n io n s o t h at t h e p r e s su r e i n s id e t h e p i p e g e t s o u t i n t h e a t m o sp h er e .
- R e m o v e t h e r e d u c e r .
- U s e a w r en c h t o s l ac k e n t h e p l u g u n i t , r e m ov e t h e f i lt e r a n d r e p l ac e i t .
- T i gh t e n t h e p l ug u n it t o a t o rq u e o f 1 1 N m . B e fo r e f i t ti n g t h e r e du c er o n t h e v e hi c le , f i ll i t w i th c o mp r es s ed a i r t h r o ug h t h eg a s i n l e t p i p e u n i o n a n d p o u r i n a s o a p y s o l u t i o n t o m a k e s u r e t h e r e a r e n o l e a k s .
- F i t t h e r e du c er a n d c h e c k t i g h t ne s s w i t h a s o ap y s o lu t io n .
Intercepting solenoid valve
T h e f u nc t io n o f t h e i n te r ce p ti n g s o le n oi d v a lv e w i th e l ec t ri c -m a g ne t i c c o n t ro l i s t o c l os e o r o p en t h e m e th a ne f l ow .
First stage or high pressure phase
T h e f i r s t s t a g e h a s t h e f u n c t i o n o f r e d u c i n g t h e m e t h a n e p r e s s u r e t o 1 4 0 0 k P a (1 4 b a r ) .I t u s e s a p i s t o n w i t h c o n t r a s t s p r i n g a n d v a l v e . T h e d y n a m i c a n d s t a t i c g a s k e t s a r e m a d e o f m a t e r i a l s w h i c h e n s u r e i t s r e l i a b i l i t y .T h e c o n t r a s t s p r i n g h a s b e e n d e v i s e d t o c o v e r t h e r e d u c e r l i f e w i t h a w i d e m a r g i n .
Second stage or stabilizing phase
T h e s e c o nd s t a ge h a s t h e f u nc t io n o f r e du c in g a n d s t a b il i zi n g t h e p r es s ur e o f 1 4 00 k P a ( 1 4 b a r ) a r ri v in g f r om t h e f i r st s t ag e a ta d i f f e r e n t i a l p r e s s u r e o f 9 0 0 k P a (9 b a r ) .I t u s es a p i st o n w i t h c o nt r as t s p ri n g a n d c o un t er b al a nc i ng v a l ve .T h e s e co n d s t ag e v a lv e c o un t er b al a n ci n g m a k es i t p o ss i bl e t o o b ta i n s u bs t a nt i al v a ri a t io n s o f c a pa c it y w h il e m a in t ai n in g t h e d e li v e ry p r e s su r e w i t h i n s t r i ct t o l e ra n c e s a n d e n s u ri n g t h e s y s t e m s t a b i li t y .T h e s a m e d e s i g n c r i t e r i a a d o p t e d f o r t h e f i r s t s t a g e w e r e a p p l i e d a l s o t o t h e s e c o n d s t a g e .
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Safety valve
T h e d e vi c e i s f i tt e d w i th a s a fe t y o r o v er p re s su r e v a l v e .T h i s v a l v e m a k e s i t p o s s i b l e t o d i s c h a r g e t h e o v e r p r e s s u r e g e n e r a t e d b y f a u l t y c a p a c i t i e s o f t h e f i r s t s t a g e o u t s i d e .
Exchanger
I t i s a p i p e c o m p l e t e l y s e p a r a t e d f r o m t h e g a s c i r c u i t , w h o s e f u n c t i o n i s t o h e a t t h e m e t h a n e w h i c h t e n d s t o c o o l d o w n a f t e r t h ee x pa n si o n d u e t o t h e p r es s ur e r e du c ti o n o c cu r re d a t t h e f i rs t s t a ge .T h e h e a t i s s u p p l i e d b y t h e c o n n e c t i o n w i t h t h e e n g i n e c o o l i n g c i r c u i t .
T h e f o l l o w i n g t a b l e s h o w s t h e t i g h t e n i n g t o r q u e s o f t h e c o m p o n e n t s w h i c h c a n b e r e p l a c e d :
Complete reducer
T h e r e d u ce r h a s t h e f u nc t io n o f r e d u ci n g t h e g a s p r e s su r e f r o m t h e v a lu e o n t h e c y li n de r t o t h e i n je c to r s u p p l y v a l ue a n d k e e pi t u n d e r c o n t ro l a t a n y o p e r a t i n g c o n d i t io n s .I f t h e v e hi c le o p er a ti o n i s n o t c o rr e ct c h ec k i f t h e r e du c er c a li b ra t io n p a ra m et e rs h a v e c h a n g ed .
P r o ce e d a s f o l l ow s :
- U s e a w r en c h t o s l ac k en s l ig h tl y t h e r e du c er i n le t p i pe u n io n s o t h at t h e p r e s su r e i n s i de t h e p i p e g e t s o u t i n t h e a t m o sp h er e .
- S l ac k en t h e h o s e u n io n o n t h e R A I L s i de ( i nj e ct o r s u p p ly m a ni f ol d ) u n t i l i t b e co m es l o os e .
- C o mp l et e ly s l ac k en t h e h o s e f i xe d u n io n o n t h e r e d u ce r s i de a n d f i t a n a d a pt e r w i t h p r es s ur e i n le t .
- F i t t h e h o s e o n t h e a d ap t er .
- A p pl y p r e s s ur e g a ug e 9 9 36 0 16 3 w i th s c al e b o tt o m 1 6 0 0 k P a o n t h e p r e s su r e i n l e t.
- T ig ht e n t h e p i pe u ni on o n t h e R AI L t o a t or qu e o f 7 0 N m .
- T i gh t en t h e r e d uc e r i n l et p i pe u n io n t o a t o rq u e o f 3 6 N m .
- U s e a s o ap y s o l u ti o n t o m a k e s u r e t h e re a r e n o l e a ks f r om t h e r e d uc e r i n l et p i pe u n io n .
- S t ar t t h e e n g i ne a n d c h e ck t h e re a r e n o l e ak s o n t h e p a rt s w h er e i n t e r ve n ed .
M a k e s u r e t h e p r e s s u r e o n t h e p r e s s u r e g a u g e i s a r o u n d 9 0 0 k P a ( 9 b a r ) .
S h o u l d t h e p r e s s u r e b e f a r f r o m 9 0 0 k P a , i t i s n e c e s s a r y t o c h a n g e t h e r e d u c e r .
S E C T I O N 2 - F U E L 13C N G N E F E N G I N E S
Pos. Description Tightening
1 I nput pipe uni on 36 Nm
2 Coil unit 13 Nm
3 Valve unit 12 Nm
4 Filter plug unit 11 Nm
5 Pressure sensor 20 Nm
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T o c h an g e t h e r e du c er p r oc e ed a s f o ll o ws :
- U s e a w r en c h t o s l ac k en s l ig h t ly t h e r e d u ce r i n le t p i pe u n io n s o t h at t h e p r e s su r e i n s i de t h e p i p e g e t s o u t i n t h e a t m o sp h er e .
- T h e n s l a c k e n c o m pl e t e l y t h e p i p e u n i o n .
- R e mo v e t h e f a st o ns f r om t h e c o i l b y t a ki n g o f f a l l t h e e l ec t ri c al c o nn e ct i on s .
- S l ac k en o r r e mo v e t h e c l am p s f a s t en i ng t h e r e d u ce r h e a ti n g p i pe s .
- S l ac k en t h e t u r ni n g u n i on o f t h e h o se o n t h e R A IL s i de .
- S l ac k en c o mp l et e l y t h e f i x e d u n i o n o f t h e h o s e o n t h e r e d u ce r s i de .
- S l ac k en t h e s c r e ws f a st e ni n g t h e r e du c er t o t h e b o d y a n d c h an g e t h e r e du c er .
- F a st e n t h e n e w r e d uc e r t o t h e b o d y.
- T ig h te n t h e u ni on o n t h e R AI L s i d e t o a t or qu e o f 7 0 N m .
- R e s t o re t h e w a t e r c i r c ui t .
- T i gh t e n t h e r e d u ce r i n l e t p i p e u n i on t o a t o rq u e o f 3 6 N m .
- R e -c o nn e ct t h e f a s t on s t o t h e c o i l w i th t h e c o r r ec t p o la r it y .
- U s e a s o ap y s o l ut i on t o m a k e s u re t h er e a r e n o l e a k s f r o m t h e p i p e u n i o n.
- S t ar t t h e e n gi n e a n d c h e c k a g a i n t h e re a r e n o l e ak s f r o m t h e p i pe u n io n w i t h a s o ap y s o l u ti o n.
STEEL HOSE
I t i s t h e h o s e w h i c h c o n n e c t s t h e r e d u c e r t o t h e R A I L .A n y f a u l ts a r is i ng a r e d u e t o p o ss i bl e l e ak s .
I f t h e l e a k s a r e f r o m t h e p i p e u n i o n s , c h e c k t h e f o l l o w i n g :C h ec k i f t h e p i p e u n io n s a r e l o os e d. I f s o , t i g h t en t h em a c co r di n g t o t h e f o l l ow i ng t i gh t en i ng t o rq u es :
- O n t h e r e d u ce r : f i xe d p i p e u n i on ( A ) = 7 0 N m
- O n t h e R AI L: t ur ni ng p ip e u n io n ( B ) = 7 0 N mI n b o t h c a s e s u s e t h e r e s p e c t i v e l o c k w r e n c h e s .
I f t he p ip e u ni on s a re t ig h te ne d b ut a l ea k i s d et ec te d a ny wa y, i t i s l ik e ly t h at a n i nn er g a sk et i s m is si ng . I n t hi s c as e s la ck en t he l ea ki ngp i p e u n i o n a n d f i t t h e g a s k e t , t h e n t i g h t e n t h e p i p e u n i o n t o t h e p r e s c r i b e d t o r q u e .
I f t h e g a s l e a k i s d e t e c t e d a l o n g t h e p i p e i t i s n e c e s s a r y t o c h a n g e t h e h o s e .
- S l ac k en t h e h o s e t u r n in g u n i o n o n t h e R A I L s i d e .
- C o mp l et e ly s l ac k en t h e f i x e d p i p e u n i o n o n t h e r e d u ce r .
- R e mo v e t h e f a u l ty h o s e a n d r e p l a ce i t w i th a n e w o n e.
- F i rs t d r iv e i n t h e f i x e d u n i o n o n t h e r e d u ce r a n d m a k e s u re t h e a l um i ni u m g a s k e t p r e v io u sl y l u br i ca t ed h a s b e e n i n se r te d a sw e l l . T i g h t e n t o a t o r q u e o f 7 0 N m .
- D r iv e i n t h e t u r n in g u n i o n o n t h e R A I L a n d m a ke s u re t h e a l u m in i um g a s ke t h a s b e en i n se r te d a s w e ll . T i g h t en t o a t o rq u eo f 7 0 N m .
S t a r t t h e e n g i n e a n d u s e a s o a p y s o l u t i o n t o m a k e s u r e t h e r e a r e n o l e a k s .
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OXYGEN SENSOR
T h e o x y g e n s e n s o r i s m a d e u p o f a z i r c o n i u m d i o x i d e - b a s e d c e r a m i c b o d y c o a t e d w i t h a t h i s l a y e r o f p l a t i n u m e n c l o s e d a t o n ee n d , p l a c e d i n t o a p r o t e c t i v e t u b e , a n d h o u s e d i n a m e t a l b o d y t h a t e n s u r e e x t r a p r o t e c t i o n a n d a l l o w s t h e c e r a m i c b o d y t o b ef i t t e d t o t h e e x h a u s t m a n i f o l d . T h e e x t e r n a l p a r t o f c e r a m i c i s e x p o s e d t o t h e e x h a u s t g a s f l o w , w h e r e a s t h e i n t e r n a l p a r t c o m e si n t o c o n t a c t w i t h a m b i e n t a i r .
T h e o p e r a t i n g p r i n c i p l e i s b a s e d o n t h e v o l t a g e t h a t i s e s t a b l i s h e d b e t w e e n t h e t w o e l e c t r o d e s i n c o n t a c t w i t h d i f f e r e n t o x y g e nconcentrations.
T h e m e a su r em e nt s , m a de b y t h e s e ns o r, o f t h e e x ha u st g a s c om p os i ti o n a l lo w t h e M F 3 e l e c t ro n ic c o nt r ol u n it t o c o nt i nu o us l y a d ju s t t h e m i xt u re ( l ea n e r- r ic h er ) r e al - ti m e, t o k e e p t h e s a me a s n e ar t h e s t oi c hi o me t ri c r a ti o a s p o ss i bl e a n d i n a v e ry s h or t i n te r va lof r a n g in g b e t w e en 0 . 9 8 0 a n d 1 . 0 2 0.
T o e n su r e t h at t h e o p er a ti n g t e mp e ra t ur e ( 300 C ) i s r e ac h ed q u ic k ly , t h e s e ns o r i s e q ui p pe d w i th a n e l ec t ri c r e si s to r t h atr e d u c e s , w h e n c u r r e n t r u n s t h r o u g h i t , t h e t i m e n e c e s s a r y f o r t h e c e r a m i c t o b e c o m e a i o n c o n d u c t o r . M o r e o v e r , t h e s e n s o r c a nb e l o c a t e d i n l e s s h o t a r e a s o f t h e e x h a u s t d u c t .
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S E C T I O N 3 - U S E 1C N G N E F E N G I N E S
SECTION 3
Use
Page
GENER AL SPECIF ICAT IONS 3. . . . . . . . . . . . . . .
GENERAL PROPER TIES 4. . . . . . . . . . . . . . . . . . .
PART ONE - MECHANICAL COMPONENTS 5.
ENGI NE OVERHAUL 7. . . . . . . . . . . . . . . . . . . . .
- Pre face 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Eng ine disassembly on the stand 7. . . . . . . . . . .
- Cylinder head remov al 10. . . . . . . . . . . . . . . . . . .
- I nst allation of components 15. . . . . . . . . . . . . . . .
- Timing 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting the flywheel h ousing 16. . . . . . . . . . . . .
- Eng ine flywheel 17. . . . . . . . . . . . . . . . . . . . . . . . .
- Mounting the cylinder head 22. . . . . . . . . . . . . . .
- Completion of the eng ine 26. . . . . . . . . . . . . . . .
- Check s and inspections 29. . . . . . . . . . . . . . . . . .
PART TWO - ELECTRICAL EQUIPMENT 31. . . .
GENERAL I TEMS 33. . . . . . . . . . . . . . . . . . . . . . . . .
M F 3 I G N I T I O N A N D I N J E C T I O NINTEGRATED SY STE M 34. . . . . . . . . . . . . . . . .
- MF3 syst em characteristics 34. . . . . . . . . . . . . . . .
- I njection manag ement 34. . . . . . . . . . . . . . . . . . .
- Fuel cutoff in relea se step 35. . . . . . . . . . . . . . . . .
- Combustion control by La mbda Probe 35. . . . . .
- System se lf-adapt ation 35. . . . . . . . . . . . . . . . . . .
- Startup manag ement 36. . . . . . . . . . . . . . . . . . . .
- Eng ine rotation speed manag eme nt 36. . . . . . . . .
- I gnition manage ment 37. . . . . . . . . . . . . . . . . . . .
- Addition al loads manag ement 37. . . . . . . . . . . . .
- Turboblower regulation 37. . . . . . . . . . . . . . . . . .
- C o n n e ct i o n t o v e h i c l e t h r ou g h C A N l i n e(to ge arbox and dashboa rd central units) 38. . . .
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Page
- Acceleration deactiv ation (option) 38. . . . . . . . . .
V E H I C LE F U N C TI O N S A P P L I E D B Y C O N T RO LUNIT MF3 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MF3 CONTROL UNIT I NSTALLATION 40. . . . . . .
M F 3 C O N T R O L U N I T W I R I N G D I A G R A M(FI RST PART) 41. . . . . . . . . . . . . . . . . . . . . . . . . .
M F 3 C O N T R O L U N I T W I R I N G D I A G R A M(SECOND PART ) 42. . . . . . . . . . . . . . . . . . . . . . .
KEY 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PIN OUT MF 3 44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENTS 47. . . . . . . . . . . . . . . . . . . . . . . . . .
- Electric injectors 47. . . . . . . . . . . . . . . . . . . . . . . .
- Air suct ion circuit 48. . . . . . . . . . . . . . . . . . . . . . .
- Debimeter (Air flow sensor) 48. . . . . . . . . . . . . .
- Throt tle va lve body 49. . . . . . . . . . . . . . . . . . . . .
- Idling actuator 50. . . . . . . . . . . . . . . . . . . . . . . . .
- Fue l cut -off 51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Electronic injection (Cha ra cteristics) 51. . . . . . . .
- La mbda s ensor 52. . . . . . . . . . . . . . . . . . . . . . . . .
- Connections 52. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Air tempera ture -pre ss ure sen sor 53. . . . . . . . . . .
- Engine oil tempe ratu re-pressure sensor 53. . . . . .
- Cranksha ft sensor 54. . . . . . . . . . . . . . . . . . . . . .
- Timing se nsor 54. . . . . . . . . . . . . . . . . . . . . . . . . .
- Wasteg ate solenoid valve 55. . . . . . . . . . . . . . . .
- TARTARI NI META pressure reduce r 56. . . . . . .
- Steel hose 59. . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Thrott le valve set ting at idling 60. . . . . . . . . . . . .
PART THREE - TROUBLESHOOTING 61. . . . . .
PR EF ACE 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLINK-CODE - GENERAL I NF ORMAT ION 64. . . .
- Det ecta ble failures 64. . . . . . . . . . . . . . . . . . . . . .
- Anoma ly warning led 64. . . . . . . . . . . . . . . . . . . .
Page
- Self-diag nosis 65. . . . . . . . . . . . . . . . . . . . . . . . . .
- R e c o v er y ( o p e r a t io n w i t h c o m p o n e nt ssubjected to failure) 65. . . . . . . . . . . . . . . . . . . . .
- VDO EGAS2 Diagnosis Syst em 66. . . . . . . . . . . .
- Error deleting 66. . . . . . . . . . . . . . . . . . . . . . . . . .
T R O U BL E S H OO T I N G B Y M E A N SOF BLINK-CODES 67. . . . . . . . . . . . . . . . . . . . . .
- MF3 Diagnosis 67. . . . . . . . . . . . . . . . . . . . . . . . .
VDO DI AGNOSI S 72. . . . . . . . . . . . . . . . . . . . . . . .
- Blin k-code reading 72. . . . . . . . . . . . . . . . . . . . . .
- Cle aring the error memory 72. . . . . . . . . . . . . . .
- VDO EGAS2 system diag nosis 73. . . . . . . . . . . .
TROUBLESHOOT ING BY SYMPTOMS 74. . . . . . . .
PART FOUR - MAINTENANCE PLANNING 81. .
MAINTENANCE PLANNING 83. . . . . . . . . . . . . . .
- Recov ery 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- P la n ni ng o f c on tr ol s a n d p er io di ca l i nt er v en ti on 8 3
- C h e c ks n o t i n c l u d ed i n m a i n t e n a n ceplanning-daily checks 84. . . . . . . . . . . . . . . . . . . .
MAINTENANCE PROCEDU RES 84. . . . . . . . . . . . .
- Check s and controls 84. . . . . . . . . . . . . . . . . . . .
- Eng ine oil le vel che ck. 84. . . . . . . . . . . . . . . .
- Check of fuel syste m 85. . . . . . . . . . . . . . . . .
- Cooling syste m check 85. . . . . . . . . . . . . . . .
- Lubricat ing syst em che ck 85. . . . . . . . . . . . . .
- Ch eck in g/ re pl ac in g t he bl ow -by fi lt er 8 5. . . . .
- Check of drive belt tensioning 86. . . . . . . . . .
- Che ck of belts tear a nd w ear stat us 86. . . . .
- C heck and setting of t appet clearance 86. . . .
- C hang ing the e ngine oil and oil filter 87. . . . .
- Filter replaceme nt proce dure 87. . . . . . . . . .
- A lt e rn at or b el t - w at er p um p r ep la ce me nt 8 8
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Figure 1
The NEF F4BE0641A engines are characterized by a boostedOtto cycle with 6 cylinders and 2 valves per cylinder.
They are powered by indirect injection and common rail, andfully electronically managed so as to optimize the operationdepending on the use, thus minimizing both pollutingemissions and consumptions.
The section herein described is composed or four sections:
- Section of mechanical overhaul prescribed in accordanceto the engines specific duty, illustrating all necessaryoperation to remove and assembly the externalcomponents of the engine, including cylinder heads,gearbox of the timing system and of the front part cover;
- Electrical section, describing the connections to thedifferent components of the engine control module andof the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providinginstructions for the execution of the main operations.
!Data, features and performances are valid only if thesetter fully complies with all the installationprescriptions provided by Iveco Motors.
Furthermore, the users assembled by the setter shallalways be in conformance to couple, power andnumber of turns based on which the engine has beendesigned.
102603
GENERAL SPECIFICATIONS
102602
SECTION 3 - USE 3CNG NEF ENGINES
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!Data, features and performances are valid only if the setter fully complies with all the installation prescriptions providedby Iveco Motors.
Moreover, the devices fittedby the body builder shall always complywith the torque, rating and revs numberrequirementsto which the engine has been designed.
4 SECTION 3 - USE CNG NEF ENGINES
GENERAL PROPERTIES
*Type
...
Max. output kW(HP)
rpm
147(200)
2700
Max. torque Nm(kgm)
rpm
650(66)
1250
Loadless engineidling rpm 650
Loadless enginepeak rpm 2900
TURBOCHARGING with intercooler
Turbocharger type HOLSET HX 38 G
LUBRICATION Forced by gear pump, relief valve single action
oil filter
bar Oil pressure (warm engine)- idling bar - peak rpm bar 1.2
3.8
COOLING
Water pump control
By means of centrifugal pump, control thermostat, radiator,heat exchanger, intercooler
Through beltThermostat- start of opening- max opening
81 2 C96 C
FILLINGTotal capacity1st filling
literskg
--
URANIATurbo Gas15 W 40
- engine sumpliters
kg
min level8
7.2
max level10.89.7
- engine sump + filterliters
kg9
8.111.810.6
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PART ONE - MECHANICAL COMPONENTS
S E C T I O N 3 - U S E 5C N G N E F E N G I N E S
DIAGNOSI
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6 S E CT I ON 3 - U S E C N G N E F E N G IN E S
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87508
87606
87509
Figure 2
Figure 3
Figure 4
ENGINE OVERHAULPreface
P a rt o f t h e o p er a ti o ns i l lu s tr a te d w i th i n t h is s e ct i on c a n b ep a rt ia ll y e xe cu te d w h il e t he e ng in e i s a ss em bl ed o n t hev e h ic l e, d e pe n di n g o n t h e r o o m a v a il a bl e f o r a c c e s s t o t h ee n g in e a n d o n t h e e q ui p me n t a p pl i ca t i on a s w e ll .
T he f ol lo wi ng i nf or ma ti on r el at es t o t he e ng in e o v er ha ulo p e r a t i o n s o n l y f o r w h a t c o n c e r n s t h e d i f f e r e n t c o m p o n e n t sc u s t om i s i n g t h e e n g i n e, a c c o rd i n g t o i t s s p e c i f i c d u t i e s .I n s e ct i on G en e ra l o v er h au l , a l l t h e o p er a t io n s o f e n g in eb l oc k o v er h au l h a ve b e en c on t e mp l a te d . T h er e fo r e t h e a b ov em e nt i on e d s e ct i on i s t o b e c o ns i de r ed a s f o ll o wi n g t h e p a r thereby described.
!With regard to the engine disassembly operations from
the machine, please apply for Information consulting the
specific manual. All operations of Engine disassemblyo pe ra ti on s a s w el l a s o ve rh au l o pe ra ti on s m us t b ee x ec ut e d b y q ua l if ie d t ec h ni c ia ns p ro v id e d w i th t hespecific tooling and equipment required.
T o a p p l y b r a c k e t s 9 9 3 4 1 0 0 9 o n t h e w h e e l b l o c k t o f a s t e n t h ee n gi n e t o t h e o v er h au l s t an d , r e mo v e t h e e l ec t ro n ic c o nt r olu n i t o n t h e l e f t - h a n d s i d e .
R e m o v e t h e c o n v e y o r ( 1 ) .
D i sc o nn e ct t h e p i pe s ( 3 ) a n d t h e c o nn e ct i ng p i pe ( 6 ) w i th t h eWastegate valve. Slacken the screws (2) and remove theturbocharger (7).
R e mo v e t h e s t ar t er ( 4 ) f r o m t h e f l y w h ee l c a se ( 5 ).
R e m o v e t h e e n g i n e c a b l e ( 1 ) b y d i s c o n n e c t i n g t h e c o n n e c t o r s : f r o m t h e i n j e c t o r w i r i n g , t h e s p a r k p l u g s , t h e g a s p r e s s u r e s e n s o r ,f r o m t h e t h r o t t l e v a l v e b o d y , f r o m t h e V D O a c t u a t o r , f r o m t h e t e m p e r a t u r e s e n s o r , f r o m t h e c o m p r e s s o r , f r o m t h e c o o l a n t f l u i d
temperature sensor, from the engine oil temperature/pressure sensor, from the engine rev sensor.
Engine disassembly on the stand
S E C T I O N 3 - U S E 7C N G N E F E N G I N E S
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87510
87512
87511
87513
87514
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
R e m o v e t h e e x h a u s t m a n i f o l d ( 2 ) b y s l a c k e n i n g t h e f a s t e n i n gs c r e ws ( 1 ) .
S l a c k e n t h e s c r e w s ( 1 ) a n d r e m o v e t h e s i x c o i l s ( 2 ) .
U s e t o o l 9 9 3 5 8 0 2 4 ( 2 ) t o r e m o v e t h e s p a r k p l u g s ( 1 ) .
R e m o v e t h e h e a t g u a r d ( 2 ) b y s l a c k e n i n g t h e s c r e w s ( 1 ) .
R e m o v e t h e e n g i n e c a b l e f a s t e n i n g p l a t e ( 2 ) b y s l a c k e n i n g t h es c r e w s ( 1 ) w h i c h t i g h t e n i t t o t h e h e a d .
8 S E CT I ON 3 - U S E C N G N E F E N G IN E S
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87515
87534
87524
87552
87578
87579
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
R e mo v e t h e s c re w s ( 2 ) a n d d i sc o nn e ct t h e i n je c to r s ( 1 ).D is co nn ec t t he f ee di ng p ip es ( 3) a nd r em ov e t he r ai l ( 5)
together with the pressure/temperature sensor (4).
S l a c k e n t h e c l a m p s ( 1 ) o f t h e s u c t i o n p i p e s .
S l ac k en t h e f a st e ni n g s c re w s ( 1 ) o f t h e e n gi n e b l oc k b r ac k eta n d r e mo v e t h e s u ct i on p i pe ( 2 ) a f te r d i sc o nn e ct i ng t h e u n io n( 4 ) a n d t h e p i p e ( 3 ) .
S l a c k e n t h e f a s t e n i n g n u t ( 2 ) o f t h e t i e r o d ( 1 ) f o r t h e t h r o t t l ev a l v e c o n t ro l .
D i sc o nn e ct t h e p i pe ( 4 ) f r om t h e c o mp r es s or ( 5 ).D i sc o nn e ct t h e s u ct i on m a ni f ol d ( 5 ) t o ge t he r w i th t h e t h ro t tl ev a l ve b o dy ( 3 ) b y s l ac k en i ng t h e h e ad f a st e ni n g s c re w s ( 1 ) .
S la ck en t he f as te ni ng s cr ew s ( 1) o f t he b ra ck et ( 2) o n t hee n g i n e b l o ck .R em ov e t he V DO c on t ro l a ct ua to r ( 3) a n d t he r el ev a nt
bracket.
S E C T I O N 3 - U S E 9C N G N E F E N G I N E S
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87580
87582
87581
87607
87602
87590
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
S l a c k e n t h e s c r e w s ( 2 ) o f t h e b r e a t h i n g c o v e r ( 1 ) .R em ov e t h e c ov e r ( 1 ) b y s la ck en in g t h e c la mp ( 5) o f t h ee n g i n e b l o c k c o n n ec t i n g p i p e .S l a c k e n t h e s c r e w s ( 4 ) a n d r e m o v e t h e f i v e t a p p e t c o v e r s ( 3 ) .
R e m ov e t h e f a st e ni n g s c r e ws ( 1 ) o f t h e c y li n de r h e ad ( 2 ).
H oo k t he b ra ck et s ( 1) w it h m et al r op es a n d r em ov e t hec y li n de r h e ad ( 2 ) f r om t h e e n g in e b l oc k .
S l ac k en t h e s c re w s ( 2 ) a n d r e mo v e t h e b r ea t h er ( 1 ).
R e m o v e t h e c y l i n d e r h e a d g a s k e t ( 1 ) .O p e r a t e t h e s u i t a b l e w r e n c h o n t h e b a c k s t a n d ( 3 ) t o r e l e a s e
the belt tension (2) and remove the belt.R em ov e t he s cr ew ( 4) a nd d is co nn ec t t he a ut om at icb a c k s ta n d ( 3 ) .
R e m o v e t h e s c r e w s ( 2 ) a n d e x t r a c t t h e a l t e r n a t o r ( 1 ) .
Cylinder head removal
10 S E CT I ON 3 - U S E C N G N E F E N G IN E S
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70140
70141
70143
87601
Figure 22
Figure 23
Figure 24
Figure 25
R e mo v e t h e s c re w s ( 2 ) a n d d i sc o nn e ct t h e a l te r na t or s u pp o rt(3).U s e t o o l 9 9 3 6 0 0 7 6 t o r e m o v e t h e o i l f i l t e r ( 1 ) .
R e mo v e t h e s c re w s ( 4 ) a n d t h e o i l p r es s ur e /t e mp e ra t u res e n s o r ( 3 ) .R e m o v e t h e s c r e w s ( 1 ) , t h e o i l f i l t e r / h e a t e x c h a n g e r s u p p o r t( 2 ) , t h e i n t e r m e d i a t e p l a t e ( 6 ) a n d t h e g a s k e t s .R e m o v e t h e o i l l e v e l s e n s o r ( 5 ) .
U s e w r e n c h 9 9 3 5 5 0 1 9 t o r e m o v e t h e s c r e w s ( 1 ) a n d ( 3 ) a n dd i sc o nn e ct t h e h y dr a ul i c p o we r s t ee r in g p u mp ( 2 ) t o ge t he r w i th t h e o i l r e se r vo i r ( 4 ) f r o m t h e a i r c o m pr e ss o r ( 5 ) .
R e m o v e t h e s c r e w s ( 2 ) a n d t h e n u t s ( 1 - 4 ) a n d e x t r a c t t h e a i r compressor (3).
I n s o m e a p p l i c a t i o n s , t h e i n t e g r a t e d o i l r e s e r v o i r ( 4 )i s n o t p r e s e n t o n t h e p o w e r s t e e r i n g p u m p ( 2 ) .!
T h e f i gu r e i l lu s tr a te s a s i ng l e- c yl i nd e r c o mp r es s or ,while on other ve rsion a double-cylinder c o m pr e s s or i s u s e d .
!
S E C T I O N 3 - U S E 11C N G N E F E N G I N E S
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70340
70146
Figure 26
Figure 27
Figure 28
Figure 29
A p pl y t h e t o o l 9 9 36 0 35 1 ( 2 ) t o t h e f l y w he e l h o u s in g ( 1 ), t os t o p t h e f l y w he e l ( 3 ) r o t a t io n .
L o o s e n t h e s c r e w s ( 4 )
R em ov e t he s cr ew s ( 2) a nd r em ov e t he p ul le y ( 3) a nd t heb u m p e r f l y w h e e l ( 1 ) .
R em ov e t he s cr ew s ( 6) a nd r em ov e t he h ub ( 5) a nd t hep h o n ic w h e e l ( 4 ) .
R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e w a t e r p u m p ( 2 ) .
R e m o v e t h e s c r e w s ( 3 ) a n d r e m o v e t h e r o l l e r ( 4 ) .
R e m o v e t h e s c r e w s ( 5 ) a n d r e m o v e t h e r p m s e n s o r ( 6 ) .
78256
A pp ly o n t he f ro nt t an g ( 2) o f t he d ri vi ng s ha ft f ix tu re9 9 34 0 05 5 ( 4 ) a n d t h ro u gh t h e g u i d in g h o le s o f t h e f i x t u rei t s e l f , d r i l l t h e i n t e r n a l s e a l r i n g ( 1 ) w i t h a d r i l l ( 3 . 5 m m ) t oa d e p t h o f 5 m m . .F i x f i x t u r e ( 4 ) t o t h e r i n g ( 1 ) b y m e a n s o f t h e 6 s c r e w s i n t h ek i t e p r o c e e d w i t h t h e r e m o v a l o f t h e r i n g b y s c r e w i n g u p t h es c r e w ( 3 ) .
Figure 30
78257
A p p l y t h e p r o p e r r o d ( 3 ) o f f i x t u r e 9 9 3 6 3 2 0 4 t o t h e e x t e r n a ls ea l r in g ( 2) a s s ho wn i n t h e f ig u re a nd u se l ev er ( 4) , t o r em ov ei t f r o m t h e f r o n t c o v e r ( 1 ) .
70148
12 S E CT I ON 3 - U S E C N G N E F E N G IN E S
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70149
70150
Figure 31
Figure 32
Figure 33
Figure 34
Figure 35
R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e f r o n t c o v e r ( 2 ) .
R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e o i l p u m p ( 2 ) .
Write down the screw (1) assembling positionb e c a us e t h e y e x h i b i t d i f fe r e n t l e n g t h s .
I t i s n o t p o s s i b l e t o o v e r h a u l t h e o i l p u m p ( 2 ) .
NOTE
NOTE
R e m o v e t o o l 9 9 3 6 0 35 1 ( 2 ) .R e mo v e t h e e n g in e ( 3 ) f l yw h ee l f i xi n g s c re w s ( 1 ) t o t h e e n gi n es h a f t ( 4 ) .
S c r e w t w o p i n s ( 2 ) e x h i b i t i n g a p r o p e r l e n g t h i n t o t h e e n g i n es h a f t h o l e s ( 3 ) .
Withdraw the engine flywheel (1) in order to sling it with theh o is t er a n d p o si t io n i t i n to t h e c o nt a in e r.
78258
A p p l y f i x t u r e 9 9 3 4 0 0 5 6 ( 3 ) o n t h e r e a r t a n g ( 5 ) o f t h e d r i v i n gs ha ft a n d t hr ou gh t h e g ui di ng h ol es o f t he f ix tu re , d ri ll t hei n t e r n a l s e a l r i n g ( 1 ) w i t h a d r i l l ( 3 , 5 m m ) t o a d e p t h o f 5mm.F i x f i x t u r e ( 3 ) t o t h e r i n g ( 1 ) b y m e a n s o f t h e 6 s c r e w s ( 4 ) i n
the kit e proceed with the removal of the ring by tightening thes c r e w ( 2 ) .P e rf o rm t h e r e m o va l o f t h e e x t e r na l s e al r i ng a s s h ow n a n dd e s c ri b e d i n F i g u re 3 0 .
70151
70152
S E C T I O N 3 - U S E 13C N G N E F E N G I N E S
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70153
87600
87603
70156
70157
Figure 36
Figure 37
Figure 38
Figure 39
Figure 40
R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e r e a r c o v e r ( 2 ) .
O v e r t u r n t h e e n g i n e .R e mo v e t he s c re w s ( 2 ), r e mo v e t he p l at e ( 3 ) a n d r e mo v e t h eo i l s u m p ( 1 ) .
R e m o v e t h e s c r e w s ( 1 ) a n d r e m o v e t h e o i l s u c t i o n r o s e ( 3 ) .R e m o v e t h e s c r e w s ( 2 ) a n d r e m o v e t h e s t i f f e n i n g p l a t e ( 4 ) .
R em ov e t he s cr ew s ( 1) a nd r em ov e t he g ea r ( 3) f ro m t hec a m s h af t ( 2 ) .
Write down the screw (1) assembling positionb e c a us e t h e y e x h i b i t d i f fe r e n t l e n g t h s .
NOTE
T h e s u mp s h ow n i n t h e f i gu r e i s t h e c h a r a ct e ri s ti c ss u m p f o r t r u c k a p p l i c a t io n s .!
R e m o v e t h e s c r e w s ( 2 ) a n d t h e t i m i n g g e a r c a s e ( 1 ) .
Write down the screw (2) assembling positionb e c a us e t h e y e x h i b i t d i f fe r e n t l e n g t h s .
NOTE
14 S E CT I ON 3 - U S E C N G N E F E N G IN E S
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70209
70210
70211
Figure 41
Figure 42
Figure 43
I V E C O N o . 2 9 9 2 54 5 S E A L AN TA P P LI C A T I ON A R E A S
C le an a cc ur at el y t he t im in g g ea r c as e ( 1) a nd t he e ng i ne b lo ck .P e r f e c t s e a l i s o n l y o b t a i n e d b y c l e a n i n g a c c u r a t e l y t h e s u r f a c e
to seal.S m ea r t h e c a s e w i t h I V EC O N o . 2 9 92 5 45 t o o b t a in a b e ado f f e w m m d i a m e t e r .I t s h a ll b e u n if o rm ( n o c l o t s) , w i th o ut a i r b u bb l es , t h in a r ea sor discontinuities.A n y i m p e r f e ct i o n s h a l l b e c o r re c t e d a s s o o n a s p o s s ib l e .
A v o i d t o u s e e x c e s s m a t e r i a l t o s e a l t h e j o i n t .E x ce s si v e s e a l a nt c o ul d c o me o u t f r om j o in t s i de s a n d c a u s el u b r ic a n t p a s s ag e c l o g g in g .A f t e r a p p l y i n g t h e s e a l a n t , t h e j o i n t s h a l l b e a s s e m b l e d w i t h i n1 0 m i n u t e s .
D I A G R A M F O R T I G H T E N I N G T H E R E A R T I M I N G G E A R
C A S E F A S T E N I N G S C R E WS
R e f i t t h e c a s e ( 1 ) t o t h e e n g i n e b l o c k .S cr ew t he f as te ni ng s cr ew s i n t he s am e p os it io n f ou nd a tr e mo v al a n d t i gh t en t h em t o t h e f o ll o wi n g t o rq u e v a lu e s i n t h es e q u e n c e s h o w n i n t h e f i g u r e :
Screws M12 65 to 89 NmScrews M8 20 to 28 NmScrews M10 42 to 52 Nm
U s e a f e l t p e n t o m a r k t h e d r i v i n g g e a r ( 1 ) t o o t h f i t t e d o n t h eo u tp u t s h a f t ( 2 ) h a v i n g t h e m a rk () f o r t i m i n g o n t h e s i d esurface.
Installation of components
Timing
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Figure 44
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Figure 46
Figure 47
D i r e c t t h e o u t p u t s h a f t ( 4 ) a n d t h e c a m s h a f t ( 2 ) s o t h a t w h e nf i tt i ng t h e d r i v en g e a r ( 1 ) o n t h e c a m sh a ft t h e m a r k s o n t h eg e a r s ( 1 a n d 3 ) a r e c o i n c i d i n g .
T ig h te n t he s cr ew s ( 1) f a st e ni ng g ea r ( 2) t o c a m sh af t ( 3) t o t hespecified torque.
I V E C O N o . 2 9 9 25 4 5 S E A L A N TA P P LI C A T I ON A R E A S
S E Q UE N C E F O R T I G H T E NI N G T H E F L Y W HE E LH O U S IN G F A S T E NI N G S C R E WS
R ef it t he h ou si ng ( 1) t o t he e ng in e b lo ck a nd s cr ew t hef a st e ni n g s c re w s i n t h e s a me p o si t io n f o un d a t r e mo v a l a n d
tighten them to the following torque values in the sequences h o w n i n t h e f i g u r e :
Screw s M12 75 to 95 NmScrew s M10 44 to 53 Nm
Mounting the flywheel housing
C l ea n a c cu r at e ly t h e f l yw h ee l h o us i ng ( 1 ) a n d t i mi n g g e a r c a secoupling surfaces.P e r f e c t s e a l i s o n l y o b t a i n e d b y c l e a n i n g a c c u r a t e l y t h e s u r f a c e
to seal.S me ar h ou si ng ( 1) w it h I VE CO N o. 2 99 25 45 t o o bt ai n a b ea do f f e w m m d i a m e t e r .I t s h al l b e u n if o rm ( n o c l o t s) , w i th o ut a i r b u b b le s , t h in a r ea sor discontinuities.
A n y i m pe r fe c ti o n s h al l b e c o rr e ct e d a s s o on a s p o ss i bl e .A v o i d t o u s e e x c e s s m a t e r i a l t o s e a l t h e j o i n t .E x ce s si v e s e a la n t c o ul d c o me o u t f r o m j o in t s i de s a n d c a u s el u b r ic a n t p a s s ag e c l o g g in g .A f t e r a p p l y i n g t h e s e a l a n t , t h e j o i n t s h a l l b e a s s e m b l e d w i t h i n1 0 m i n u te s .
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Figure 48
Figure 49
Figure 50
Figure 51
A pp ly t oo l 9 93 46 25 3 p a r t ( 5) t o t he r ea r o ut pu t s ha ft t an g ( 6) ,s e c u r e i t b y s c r e w s ( 4 ) a n d f i t t h e n e w s e a l i n g r i n g ( 3 ) .
P o si t io n p a rt ( 1 ) o n p a rt ( 5 ), s c re w n u t ( 2 ) u n t il c o mp l et i n gs e a l i n g r i n g ( 3 ) f i t t i n g i n t o f l y w h e e l h o u s i n g ( 7 ) .
C h ec k c l ut c h p l at e s u pp o rt i ng s u rf a ce a n d t u rn i t i f s c or e d.
S c r e w t w o p i n s ( 2 ) h a v i n g s u i t a b l e l e n g t h i n t o s h a f t h o l e s ( 3 )
a n d r e mo v e t h e e n g i n e f l yw h ee l ( 1 ) u s i n g p r op e r s l i n g a n dhoister.
T ig h te n t he s cr ew s ( 4) f as te n in g t he e ng in e f ly wh ee l ( 3) t o t heo u tp u t s h af t . A p pl y t o ol 9 9 36 0 35 1 ( 2 ) t o t h e f l yw h ee l h o us i ng( 1 ) t o s t op e n gi n e f l yw h ee l ( 3 ) r o t a t io n .
Engine flywheel
T h e n o mi n a l t h ic k ne s s o f t h e e n g in e f l yw h ee l i s 4 9 .6 0 .1 3 m m o r 5 1 m m 0 .2 5 m m a a cc or di ng t o t heapplications.
NOTE
C he ck r in g g ea r t e et h ( 2) , i f b re ak a ge o r e x ce s si ve w e ar i sf o un d r e mo v e t h e r i ng g e ar f r om t h e e n gi n e f l yw h ee l ( 1 , F i gu r e1 0 4) u s in g a g e ne r ic b e at e r a n d f i t t h e n e w o n e , p r ev i ou s ly h e a t e d t o 1 5 0 C f o r 1 5 t o 2 0 m i n u t e s .C h am f er i ng o n r i ng g e ar i n si d e d i a m et e r s h al l b e f a ci n g t h ee n g i n e f l y w he e l .
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Figure 52
Figure 53
Figure 54
Figure 55
Figure 56
T i g ht e n e n gi n e f l y w he e l ( 2 ) f a st e n in g s c re w s ( 1 ) i n t w o s t ag e s:
- 1 st stag e, tighte ning to 30 t o 4 N m t orque withdynamometric wrench;
- 2 n d s t a ge , t i g h t en i ng t o 6 0 5 angle.
F i t t h e o i l p u m p ( 1 ) .T i g h t e n t h e f a s t e n i n g s c r e w s ( 2 ) t o t h e s p e c i f i e d t o r q u e .
A p p l y a n e w s e a l i n g r i n g ( 2 ) t o t h e w a t e r p u m p ( 1 ) .
R e mo v e t h e s e al i ng r i ng ( 2 ) f r o m t h e f r on t c o ve r ( 1 ), c l ea na c c u r a t e l y t h e c o u p l i n g s u r f a c e s a n d s m e a r t h e m w i t h I V E C ON o . 2 9 9 2 5 4 5 .
T ig ht en in g t o a ng le i s p er fo rm ed u si ng t oo l99395216.
NOTE
F i t t h e w a t e r p u m p ( 1 ) .T i g ht e n t h e s c re w s ( 2 ) t o t h e s p ec i fi e d t o rq u e.
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Figure 57
Figure 58
Figure 59
Figure 60
C l ea n a c cu r at e ly t h e f r o n t c o v e r ( 2 ) s u r f ac e a n d r e fi t i t .T i g h t e n t h e s c r e w s ( 1 ) t o t h e s p e c i f i e d t o r q u e .
A p pl y t o ol 9 9 34 6 25 2 p a rt ( 5 ) t o t h e f r o n t o u t p ut s h af t t a n g( 6) , s ec ur e i t b y s cr ew s ( 4) a nd f it t he n ew s ea li ng r in g ( 3) .P o si t io n p a rt ( 1 ) o n p a rt ( 5 ), s c re w n u t ( 2 ) u n t il c o mp l et i n gs e a li n g r i ng ( 3 ) f i t t in g i n to f r on t c o ve r ( 7 ).
F it t he p la t e ( 4) , t he s uc ti on r os e ( 3) , d ri ve i n t he f as te n in gs c r e w s ( 1 , 2 ) a n d t i g h t e n t h e m t o t h e p r e s c r i b e d t o r q u e .
S e t t h e g a s k e t ( 1 ) o n t h e o i l s u m p ( 2 ) .
I f n o t f a u l t y t h e g a s k e t c a n b e r e u s e d .NOTE
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Figure 61
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F i t t h e o i l s u m p ( 1 ) a n d a p p l y t h e p l a t e ( 3 ) t o i t .T i g ht e n t h e s c re w s ( 2 ) t o t h e s p ec i fi e d t o rq u e.
F i t t h e p h o n i c w h e e l ( 1 ) a n d t h e h u b ( 2 ) o n t h e o u t p u t s h a f t .
T i g ht e n t h e f a st e n in g s c re w s ( 3 ) i n t w o s t a g e s:
- 1st s ta ge , t ig ht en in g t o 5 0 5 Nm torque withdynamometric wrench;
- 2nd s t a g e , t i g h t e n i n g t o 9 0 angle.
F i t t h e d a m p e r f l y w h e e l ( 5 ) a n d t h e p u l l e y ( 6 ) .
T i g h t e n t h e f a s t e n i n g s c r e w s ( 7 ) t o 6 8 7 N m t o r q u e .
T ig ht en in g t o a ng le i s p er fo rm ed u si ng t oo l9 9 3 9 5 2 1 6 ( 4 ) .
NOTE
F i t a n e w s e a l i n g r i n g o n t h e s p e e d s e n s o r ( 3 ) .F i t t h e s p e e d s e n so r ( 3 ) o n t h e f r o nt c o ve r ( 1 ) a n d t i gh t en t h es c re w ( 2 ) t o t h e s p ec i fi e d t o rq u e.
F i t o n t h e e n g i n e b l o c k : a n e w g a s k e t ( 1 ) , t h e h e a t e x c h a n g e r ( 2 ) a n e w g a s k e t ( 3 ) a n d t h e o i l f i l t e r s u p