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