Iveco N Engine Workshop Service Manual

Download

NSERIES

EU/2002/88/CE

G-DRIVE application

N45

NEF45 AM1

NEF45 SM1- NEF45 SM2 - NEF45 TM1

NEF45 TM2

N67

NEF67 TE2 - NEF67 TM2 - NEF67 TM3

Technical and Repair manual

This publication contains data, features, instructions and methods for performing repair interventions on the assembly and its components.

This publication is addressed to qualified, specialised personnel.

Check that you have the publication related to the assembly on which you are about to work available before you start. Make sure that you have all the necessary safety apparatuses, such as, for example, protective eyewear, helmet, gloves, footwear, etc. Check that the working, lifting and transport equipment etc. is available and in working order. Make sure that the group is prepared and secured.

Proceed by carefully observing the instructions contained herein and use the indicated specific tools to ensure correct repair procedures, observance of time schedules and safety of operators.

All repair interventions are aimed at restoring the conditions of operation, efficiency and safety contemplated by FPT.

All on-group interventions, aimed at implementing changes, alterations or other not authorised by FPT will relieve FPT from responsibility. Specifically, the warranty (where applicable) will be immediately cancelled.

FPT cannot be held responsible for repair interventions.

FPT is available to provide any additional information needed for performing the inventions and indications in the cases and situations not contemplated in this publication.

The data contained in this publication may not be up-to-date if changes are made by the manufacturer at any time for technical or commercial reasons or if required to meet legal requirements of countries worldwide.

Contact a FPT dealership before proceeding in the event of

differences between the contents of this publication and the actual assembly.

Reproduction, even partial, of this text and the illustrations contained herein is prohibited.

Publication edited by FIAT Powertrain Technologies Mkt. Advertising & Promotion Viale dell’Industria, 15/17 20010 Pregnana Milanese Milano (Italy) Print P4D32N002 E -1

Ed. 11.2008

Produced by:

B.U. TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio, 15/19 10156 Turin - Italy

G-Drive EU/2002/88/CE N SERIES

N SERIES G -Drive EU/2002/88/CE

F4GE N Series Part 1

F4HE N Series Part 2

Print P4D32N002 E Base - November 2008

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

INTRODUCTION 1

Introduction

Page

PREFACE TO USER’S GUIDELINE MANUAL 3....

SYMBOLS 5...............................

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

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

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

GENERAL WARNINGS

ON THE ELECTRIC SYSTEM 7...............

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

CONVERSIONS BETWEEN THE MAIN UNITS

OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED

QUANTITIES 9...........................

KEY OF LECTURE OF THE HEADINGS

AND FOOTNOTES 10.....................

Print P4D32N002 E Base - November 2008

INTRODUCTION

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

INTRODUCTION

PREFACE TO USER’S GUIDELINE MANUAL

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicat ed in the general table of contents. The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules. The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the control units peculiar to the electric system. Section 1 describes the engine illustrating its features and working in general. Section 2 describes the type of fuel feed. Section 3 relates to the specific duty an d is divided in four separate parts:

1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating specific duty.

2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating specific duty.

3. Maintenance planning and specific overhaul.

4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct instructions to identify the cause of the major inconveniences. Sections 4 and 5 illust rate the overhaul operations o f the engine o v erhaul on stand and the necessary equipment to execute such operations. The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order to prevent serious accidents taking place. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.

SYMBOLS - Warnings

Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety .

Danger of serious damage for the assembly

NOTE

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may sometimes cause the warranty to become null and void.

General danger

It incl udes the dangers of above described signals.

Environment protection

Moreover,it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect the environment as much as possible.

It indicates an additional explanation for a piece of information.

Service operations

Example

∅

Print P4D32N002 E Base - November 2008

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

∅

Tighten to torque Tighten to torque + angular value

INTRODUCTION

G-Drive EU/2002/88/CE N SERIES

Removal Disconnection

Refitting Connection

Removal Disassembly

Fitting in place Assembly

Tighten to torque

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Regulation Adjustment

Intake

Exhaust

Operation

Compression ratio

Tolerance Weight difference

Angle Angular valu e

Warning Note

Visual inspection Fitting position check

Measurement Value to find Check

Equipment

Surface for machining Machine finish

Interference Strained assembly

Thickness Clearance

Lubrication Damp Grease

Sealant Adhesive

bar

Preload

Number of revolutions

Temperature

Pressure

Oversized Higher th an…. Maximum, peak

Undersized Less than…. Minimum

Selection Classes Oversizing

Temperature < 0 °C Cold Winter

Temperature > 0 °C Hot Summer

Air bleeding

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

GENERAL WARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described.

Use both specific and general-purpose t oolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check.

The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path.

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.

In disassembling operations, always observe provided prescriptions; prevent mechanical parts being t aken out from accidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations whic h could be dangerous for the co-operator because of lack of visibility or of his/her not c orrect position.

Keep personnel not authorised to operations clear of working area.

You shall get familiar with the operating and safety instructions for t h e assembly prior to operating on the latter. Stric t ly follow all the safety indications fou n d on th e assembly.

INTRODUCTION

Do not leave the running assembly unattended when making repairs.

When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting stands, and that the manual/automatic safety devices h ave been actuated in t he event that the assembly is to be lifted by means of a hoist.

When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document, as well as all the specific safety standards provided for.

Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out.

Inflammable fuel and all inflammable fluids and liquids must be handled with care, according t o what contained on

harmful materials 12-point cards. Refuellin g must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers.

Worn out, damaged or consumable parts must be replaced by original spares.

During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

Print P4D32N002 E Base - November 2008

INTRODUCTION

G-Drive EU/2002/88/CE N SERIES

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc.

Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns.Avoid directcontact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking nu ts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding:

- Disc onnect all electronic central units, take power cable off battery positive terminal (connect it t o chassis

bonding) and detach con nectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other

materials flow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central units.

The disposal o f all liquids and fluids must be performed with full observance of specific rules in force.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

GENERALWARNINGS ON THE ELECTRIC SYSTEM

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,

always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.

Before connecting the batteries to the system, make sure that the system is well isolated.

Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals.

Do not c ause sparks to be generated in checking if the circuit is energised.

Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.

Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.

Measurements in driveelectronic central units, plugged connections and electric connections to components can only be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers, clips and the like in order to avoid t he danger of causing a short c ircuit, as well as of damaging plugged connections, which would later cau se contact problems.

INTRODUCTION

To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special truck.

A wrong polarisation of supply voltage in drive electronic central un it s (for instance, a wrong polarisation of batteries) can cause them to be destroyed.

Disconnect the batteries from the system during their recharging with an external apparatus.

On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque.

Before disconnecting the junction connector from an electronic central unit, isolate the system.

Do not directly supply electronic central units servo components at nominal vehicle voltage.

Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

Once the interventionon the electric system has been completed, recoverconnectors and wiring harnessesaccording to original arrangement.

NOTE

Print P4D32N002 E Base - November 2008

Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable side.

INTRODUCTION

G-Drive EU/2002/88/CE N SERIES

Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their c entering tidily and properly made (Figure 1, re. M).

Further, following warnings are to be compulsorily observed for electronic components:

- Electronic central units must be connected to system bonding when they are provided with a metallic shell.

- Electronic c entral units negative cables must be connected both to a system bonding point such as the dashboard opening bonding (avoiding “serial“ or “chain“ connections), and t o battery negative terminal.

- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation. Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinchin g defects, etc.

- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to ch assis/body structure.

Figure 1

1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE ! 0

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

INTRODUCTION

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power

1 kW = 1.36 metric HP 1 kW = 1.34 HP 1 metric HP = 0.736 kW 1 metric HP = 0.986 HP 1 HP = 0.746 kW 1 HP = 1.014 metric HP

Torque

1 Nm = 0.1019 kgm 1 kgm = 9.81 Nm

Revolutions per time unit

1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602

Pressure

according t o ratio 1:1

1 bar = 1.02 kg/cm 1 kg/cm 1bar = 10

= 0.981 bar

Where accuracy is not particularly needed:

- Nm unit is for t he sake of simplicity converted into kgm ac cording to ratio 10:1

1 kgm = 10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm

1 kg/cm

=1bar.

Temperature

0° C= 32° F 1° C = (1 x 1.8 + 32) ° F

Print P4D32N002 E Base - November 2008

INTRODUCTION

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

G-Drive EU/2002/88/CE N SERIES

Type of

vehicle

Section

title

Page

number

Printout

number

Language

Publication

Basic edition referred to

month - year editorial

phase closing

When month - year

update is present (revi) to

the basic edition

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

Part 1 F4GE N SERIES

Section

General specifications

Fuel 2

G-DRIVE applications 3

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

Print P4D32N002 E Base - November 2008

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

UPDATING

Section Description Page Date of revision

Print P4D32N002 E Base - November 2008

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 1 - GENERAL SPECIFICATIONS 1

SECTION 1

General Specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE 3...............

LUBRICATION 4............................

OIL VAPOUR RECIRCULATING SYSTEM 7.......

COOLING SYSTEM 8........................

- Version with turbocharger (4 cylinders) 8......

- Version with turbocharger (6 cylinders) 9......

- Version without turbocharger 10.............

AIR INDUCTION BOOST DIAGRAM 11..........

- Boosting version engines 11.................

- Description 11...........................

- Inter-cooled engine version 12...............

- Description 12...........................

Print P4D32N002 E Base - November 2008

SECTION 1 - GENERAL SPECIFICATIONS

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

SECTION 1 - GENERAL SPECIFICATIONS 3

Technical Code Commercial C ode

F4GE0405A*F650 NEF45 AM1S F4GE04055C*F650 NEF45 SM1A F4GE04055A*F650 NEF45 SM2A F4GE0485A*F650 NEF45 TM2A F4GE0485C*F650 NEF45 TM1A F4GE0685D*F650 NEF67 TM2A F4GE0685B*F650 NEF67 TM3A

Print P4D32N002 E Base - November 2008

SECTION 1 - GENERAL SPECIFICATIONS

G-Drive EU/2002/88/CE N SERIES

LUBRICATION

Lubrication by forced circulation is achieved through oil rotary expansion pump, placed in the front part of the basement, driven by the straight-tooth gear splined to the shaft’s bar hold.

From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.

Figure 1

Lubrication involves the heat exchanger (2,3), the turboblower for turbocompressed versions, and for any compressed air system.

All these components may often vary according to the specific duty.

1. Heat exchanger body - 2. Lubrication oil pipe to supercharger - 3. Oil filter - 4. Heat exchanger -

LUBRICATION SYSTEM LAYOUT (4 cylinder engine)

5. Oil rotary expansion pump.

Routing of oil under pressure Routing of oil return by gravity to sump

Introduction of oil

116396

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

Figure 2

SECTION 1 - GENERAL SPECIFICATIONS 5

1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger -

112886

LUBRICATION SYSTEM LAYOUT (6 cylinder engines)

4. Oil rotary expansion pump - 5. Oil filter.

Print P4D32N002 E Base - November 2008

SECTION 1 - GENERAL SPECIFICATIONS

G-Drive EU/2002/88/CE N SERIES

Figure 3

Version without turbocharger

1. Heat exchanger body - 2. Heat exchanger - 3. Oil rotary expansion pump - 4. Oil filter.

129123

LUBRICATION SYSTEM LAYOUT

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

OIL VAPOUR RECIRCULATING SYSTEM

Figure 4

SECTION 1 - GENERAL SPECIFICATIONS 7

On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity, to the Tappet c ap underneath.

The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example (connection towards these vapours shall be designed by the Engineer).

3240t

1. Valve - 2. Breather pipe - 3. Tappet Cap

Print P4D32N002 E Base - November 2008

SECTION 1 - GENERAL SPECIFICATIONS

G-Drive EU/2002/88/CE N SERIES

COOLING SYSTEM

The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:

- Expansion tank; placement, shape and dimensions are

subject to change according to the engine’s equipment.

- Radiator, which has the duty to dissipate the heat

subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.

Version with turbocharger (4 cylinders)

Figure 5

- Viscous pusher fan, having the duty to increase the heat

dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development.

- Heat exchanger to cool the lubrication oil: even this

component is part of the engine’s specific equipment.

- Centrifugal water pump, placed in the front part of the

engine block.

- Thermostatregulating the circulation of the cooling liquid.

- The circuit may eventually be extended to the

compressor, if this is included in the equipment.

129304

DIAGRAM OF THE COOLING SYSTEM

Base - November 2008 Print P4D32N002 E

)

G-Drive EU/2002/88/CE N SERIES

ersionwith turbocharger(6 cylinders

Figure 6

SECTION 1 - GENERAL SPECIFICATIONS 9

106532

COOLING SYSTEM LAYOUT

Print P4D32N002 E Base - November 2008

SECTION 1 - GENERAL SPECIFICATIONS

ersionwithout turbocharger

Figure 7

G-Drive EU/2002/88/CE N SERIES

130199

COOLING SYSTEM LAYOUT

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

AIRINDUCTION BOOST DIAGRAM Boosting version engines

Figure 8

SECTION 1 - GENERAL SPECIFICATIONS 11

AIR FILTER

TURBOCHARGER

EXHAUST

88208

4 cylinders version

Description

The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor.

During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter.

The air coming out of the compressor is sent via the intake manifold directly to the pistons.

Print P4D32N002 E Base - November 2008

The turbocharger is equipped with a transforming valve to regulate the pressure , that i s located on the exhaust collector before the turbine and connected by piping to the induction collector.

It’s duty is to choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value.

The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

SECTION 1 - GENERAL SPECIFICATIONS

Inter-cooled engine version

Figure 9

G-Drive EU/2002/88/CE N SERIES

AIR FILTER

TURBOCHARGER

EXHAUST

RADIATOR

74195

4 cylinders version

TURBOCHARGER

EXHAUST

RADIATOR

Description

The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor.

During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter.

The above mentioned air is then cooled by the radiator and flown through the piston induction collector.

74195

6 cylinders version

The turbocharger is equipped with a transforming valve to regulate the pressure , that i s located on the exhaust collector before the turbine and connected by piping to the induction collector.

It’s duty is to choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value.

The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 2 - FUEL 1

SECTION 2

Fuel

Page

FUEL-INJECTION SYSTEM WITH STANADYNE

DB4 ROTARY PUMP 3...................

- General information 3.....................

- Description of working principles 3...........

FEED PUMP 4............................

- Description of operation 4.................

PRIMING PUMP 5.........................

FUEL FILTER 6............................

Print P4D32N002 E Base - November 2008

SECTION 2 - FUEL

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

FUEL-INJECTION SYSTEM WITH STANADYNE DB4 ROTARY PUMP General information

Fuel feed system is composed by:

- Fuel tank

- Fuel delivery and back-flow to tank

- Fuel pre-filter

- Priming pump, assembled to the engine and driven by the camshaft

- Fuel filter

- Fuel feed rotary pump

- Inject or feed pipeline

- Injectors

SECTION 2 - FUEL

Figure 1

(6-cylinder version)

106534

Description of working principles

Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft.

Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump.

Transfer pump is placed inside the feed pump, and is bladed

The fuel arrives therefore to the valve gauging the pressure inside feed pump.

The distribution plunger further increases this pressure and delivers fuel through ou t the delivery pipe fitting to the injectors.

The fuel drawing from the injectors is recovered and delivered to the tank again.

type; its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.

Print P4D32N002 E Base - November 2008

SECTION 2 - FUEL

FEED PUMP

The rotary type pump is driven by a gear mating the camshaft’s one.

Figure 2

G-Drive EU/2002/88/CE N SERIES

1. Propeller shaft - 2. Timing gear rotor - 3. Transfer pump vanes - 4. Pumping pistons (4) - 5. Cam inner ring - 6. Hydraulic head - 7. Pressure regu lator assembly - 8. Regulator - 9. Automatic advance - 10. Seat - 11. Metering valve - 12. Delivery

valve - 13. Electric power supply cut-off solenoid.

Description of operation

The main rotation components are the propeller shaft (1), timing gear rotor (2), transfer pump vanes (3) and the regulator (8). Referring to Figure 2, the propeller shaft engages th e timing gear rotor inside the hydraulic head.

The four pistons are actuated t owards each other simultaneously by the int ernal ring of the cam via the rollers and sliding blocks that are conveyed in the holes on the end portion of the rotor.

The number of cam lobes is equal to that of the engine cylinders.

The transfer pump on the rear of the rotor is the positive displacement type and is closed inside the end plug. The en d plug also contains the inlet filter screen and the pressure regulator of the transfer pump. The top of the regulator assembly is pressed against the timing gear rotor and forms an end seal for the transfer pump.

The timing gear rotor contains two inlet ports, a single axial hole and a discharge port serving all the outlets to the injection lines.

The hydraulic head contains the hole in which the rotor turns, the h ole of the metering valve, inlet opening and the unions for the delivery ou t let. The high pressure injection lines that are connected to the injectors are secured to the above-mentioned outlet unions.

106514

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 2 - FUEL

PRIMING PUMP

This pump h as the specific duty to prime t he fuel available in the tank and convey it to the feed pump inlet. It is assembled to the engine basement and driven by the camshaft.

Figure 3

88209

1. Priming pump - 2. Drive lever - 3. Camshaft.

Print P4D32N002 E Base - November 2008

SECTION 2 - FUEL

G-Drive EU/2002/88/CE N SERIES

FUEL FILTER

The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel.

On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing for those equipment applications requiring it (cold climate areas), there c an be a heater assembled to and a temperature sensor. On some versions, a water presence sensor is present at filtering cartridge base.

Figure 4

106515

1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

SECTION 3

G-DRIVE Application

GENERAL INFORMATION 3................

GENERAL SPECIFICATIONS 4...............

- 4-cylinder engines 4......................

- 4-cylinder engines 6......................

PART ONE -

MECHANICAL COMPONENTS 9.........

ENGINE OVERHAUL 11.....................

- Preface 11..............................

Page

- Removing engine from radiator 11............

- Engine setting operations for the assembly on

turning stand 16..........................

- Disassembly of application components 17.....

- STANADYNE ”D” Series Pump 18..........

- Installation of rear components 26............

- Flywheel installation 29.....................

- Installation of front components 30...........

- Completion of engine re-assembly 42.........

- Refitting engine to radiator 43...............

- Rotary feed pump disassembly and assembly

procedure 48............................

- Disassembly 49...........................

- Rotary feed pump setting check 50...........

- Assembly 50.............................

ASSEMBLY PROCEDURE OF THE ”ADC100”

ELECTRONIC ACTIVATOR ON STANADYNE

SERIES ”D” INJECTION PUMPS 52..........

- Assembly of the actuator 53................

PASSAGE FROM 50 HZ TO 60 HZ FOR NEF

MOTORS WITH STANADYNE PUMP 54.....

- Passage from 50 Hz to 60 Hz 54.............

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

- Passage from 60 Hz to 50 Hz 56.............

- Stabilization of the rotation regime 56.........

- Identification tag 56........................

REPLACEMENT OF THE ELECTRO-VALVE AND

THE SOLENOID VALVE THROTTLE ON

STANADYNE PUMPS 57..................

- Electro-valve replacemen t 58................

- Replacement of the solenoid valve throttle 60...

- Feed system bleed procedure 61.............

- Checks and controls 61....................

PART TWO -

ELECTRICAL EQUIPMENT 63..............

LOCATION OF ELECTRIC COMPONENTS

ON ENGINE 65.........................

PRINCIPLE WIRING DIAGRAM 66.............

Page

- Cooling liquid temperature sensor

(if present) 68............................

- Starter 68...............................

- KSB Water temperature sensor 68............

- O il pressure sensor 69.....................

- Alt ernator 69............................

- Pre-post h eating resistor (if present) 69........

PART THREE - TROUBLESHOOTING 71......

PART FOUR -

MAINTENANCE PLANINNG 79...........

MAINTENANCE PLANNING 81..............

- Recovery 81.............................

- Planning of controls and periodical intervention 81

- Checks not included in maintenance planning-daily

checks 82...............................

- KSB - Stanadyn e pump connection cable 67....

- Timer (if present) 67.......................

MAINTENANCE PROCEDURES 82............

- Checks and controls 82....................

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

GENERAL INFORMATION

Figure 1

SECTION 3 - G-DRIVE APPLICATION 3

F4GE

They are characteristed by diesel cycle 4 stroke atmospheric or supercharged 4 and 6 cylinders each with 2 valves.

Feed is provided by rotary mechanical pump or on line according to the equipment application.

NOTE

Data, technical specifications and performances granted shall be valid only if the Setter will follow and comply with all installation prescriptions provided by FPT.

Furthermore, the expanders assembled by the Setter must always comply with couple, power and number of revolutions based on which the engine has been designed.

129270

F4GE9455A*J600 engine

The section herein described is composed or four directories:

- directory of mechanical overhaul prescribed in

accordance to the engine’s specific duty, illustrating all necessary operations to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover;

- electrical directory, describing the connections of the

different components, of the pre-post heating gearbox (only for some versions) and of the sensors assembled to the engine;

- troubleshooting directory;

- directory of preventive and regular maintenance

operations, providing instructions for the execution of the main operations.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

GENERAL SPECIFICATIONS

4-cylinder engines

G-Drive EU/2002/88/CE N SERIES

Type

Compression ratio 17.5:1

Working power kW

rpm

Working torque Nm

rpm

Loadless engine idling rpm

Loadless engine peak rpm rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type HOLSET HX25

F4GE0455A*F650 F4GE0455C*F650

1500

471

1500

. -

- 104 x 132

4485

Without intercooler

direct injection

1500

382

1500

bar

LUBRICATION

Oil pressure (warm engine)

- idling bar

- peak rpm bar

COOLING

Water pump control Thermostat

- start of opening ºC

FILLING

engine sump liters engine sump + filter liters

Forced by gear pump, relief valve single action

oil filter

By centrifugal pump, regulating thermostat, heat

exchanger, intercooler

Through belt

81 ± 2

NOTE

Base - November 2008 Print P4D32N002 E

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT.

Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION 5

Type

Compression ratio 17.5:1

Working power kW

rpm

Working torque Nm

rpm

Loadless engine idling rpm

Loadless engine peak rpm rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type HOLSET HX27W

F4GE0485A*F650 F4GE0485C*F650

1500

471

1500

. -

- 104 x 132

4485

With intercooler

direct injection

1500

554

1500

bar

LUBRICATION

Oil pressure (warm engine)

- idling bar

- peak rpm bar

COOLING

Water pump control Thermostat

- start of opening ºC

FILLING

engine sump liters engine sump + filter liters

Forced by gear pump, relief valve single action

oil filter

By liquid

Through belt

81 ± 2

NOTE

Print P4D32N002 E Base - November 2008

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT.

Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

bar

Type

F4GE0405A*F650

Compression ratio

Max. output kW

(HP)

rpm

Max. torque Nm

(kgm)

rpm

Loadless engine idling rpm

Loadless engine peak rpm

Bore x stroke

Displacement cm

FUEL SUPPLY Direct injection aspirated

LUBRICATION

Oil pressure (warm engine)

- idling bar

Forced by gear pump, relief valve single action

17 : 1

1500

299

1500

102 x 120

5880

oil filter

NOTE

Data, features and performances are valid only if the technician fully complies with all the installation requirements provided by FPT.

Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for which the engine has been designed.

- peak rpm bar

COOLING

Water pump control

Thermostat

- start of opening ºC

FILLING

engine sump liters

engine sump + filter liters

By centrifugal pump, regulating thermostat, heat

exchanger, intercooler

Through belt

81 ± 2

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

ype

Typ

6-cylinder engines

SECTION 3 - G-DRIVE APPLICATION 7

bar

F4GE0685

D*F650 B*F650

Compression ratio 17.5:1

Working power kW

rpm

Working torque Nm

rpm

Loadless engine idling rpm

Loadless engine peak rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type HOLSET HX35W

LUBRICATION

Oil pressure (warm engine)

130

1500

815

1500

- -

- 104 x 132

6728

With intercooler

direct injection

Forced by gear pump, relief valve single action

oil filter

156

1500

969

1500

NOTE

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT.

Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

- idling bar

- peak rpm bar

COOLING Water pump control

Thermostat

- start of opening ºC

FILLING

engine sump* liters

engine sump* + filter liters

* First filling operation

Liquid

Through belt

81 ± 2

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION 9

PART ONE -

MECHANICAL COMPONENTS

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

ENGINE OVERHAUL

Preface

Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well.

NOTE

The following information relates to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties.

NOTE

With regard to the engine disassembly operations from the machine, please apply for Information consulting the specific manual. All operations o f Engin e disassembly operations as well as overhaul operations must be executed by qualified technicians provided with the specific tooling and equipment required.

For specific application exigencies, some units can be assembled to the engine in different positions.

Figure 3

129283

- Disconnect and pipe (2) and remove it c omplete with

hoses adjusting the bands (1) and (3).

In section ”General overhaul”, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.

Removing engine from radiator

- Remove the electric al wiring from all the components

indicated in the electrical equipment section.

For 4 cylinder engines

Figure 2

Figure 4

129284

- Have a special container ready by the pipe (2) for

collecting the coolant. Disconnect and pipe (2) and

- Remove the protective grilles (2) for the fan adjusting the

fastenings (1) and (3).

129285

remove it complete with hoses adjusting the bands (1) and (3).

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 5

129286

- Undo the nuts (1) and (3) and remove the bracket (2).

Repeat the operation for the second bracket.

For 6 cylinder engines

Figure 7

129287

- Remove the protective grilles (5) for the fan adjusting the

fastenings (1), (3) and (4).

- Open the bands (2).

Figure 6

- Have a special container ready by the pipe (4) for

collecting the coolant. Disconnect the pipe (4) adjusting the bands (1).

- Undo the bolt (3) and release the pipe (4) complete with

bracket (5) from the radiator assembly (2).

129292

Figure 8

129288

- Undo the bolts (2) and remove the pipe (1) from the

intake manifold.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 9

129289

- Disconnect the air and water pipes from the radiator

assembly adjusting the bands (1), (2), (3) and (4) and the mounting bracket (5).

Figure 11

129291

- Disconnect and pipe (1) and remove it c omplete with

hoses, on the engine side, adjusting the bands (6).

- Disconnect the pipe (2) and remove it, adjusting the

band (3).

- Disconnect and pipe (4) and remove it c omplete with

hoses, on the engine side, adjusting the bands (5).

Figure 10

For all engines

- Lo ck the radiator assembly appropriately, then release it

from the crankcase adjusting th e fastenings on both sides.

- Remove the radiator assembly from its housing paying

attention to any possible interference with the fan.

Figure 12

129290

- Disconnect the pipes (1) and (4) and remove them,

complete with hoses, on the engine side adjusting the bands (2) and (3).

- If present, remove the turbine guard grille (2), adjusting

the bolts (1) and (3).

129293

- Then remove the mounting brackets.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 13

129294

- Disc onnect the drainage pipe (1) from the sy stem,

adjusting the bolt (2) to open the band (3).

NOTE

The shape and the size of t he drainage pipe vary depending on the usage of the engine. The illustrations therefore provide guidelines for the operation to be carried out. The procedures described can, however, be applied.

Figure 15

129296

Figure 14

- Disc onnect and oil vapour recovery pipe (3) and remove

it adjusting the bands (2) and (4).

- Disc onnect and air intake pipe (6) and remove it

adjusting th e bands (1) and (5).

129295

- Remove the air filter (1) adjusting the fastenings (2) and

remove it from its hou sin g complete with support.

Figure 16

129297

- Remove the fan (1), complete with spacer, adjusting the

bolts (2).

NOTE

The shape and the size of t he drainage pipe vary

NOTE

depending on the usage of the engine. The illustrations therefore provide guidelines for the operation to be carried out. The procedures described can, however, be applied.

Base - November 2008 Print P4D32N002 E

The shape and the size of the fan vary depending on the usage of the engine. The illustrations therefore provide guidelines for the operation to be carried out. The procedures described can, however, be applied.

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

For versions with an oil drainage pump

Figure 17

For versions with an oil drainage tap

Figure 19

129303

- Extrac t th e dipstick and the filler plug to facilitate the

lubrication oil flow.

- Remove the oil in the engine oil sump using the tap (1).

- Disconnect the pipe and remove it, adjusting the bolt (2).

129301

- Extrac t th e dipstick and the filler plug to facilitate the

lubrication oil flow.

- Connect the special pipe for draining the pump (2) fitted

in the engine to the outside.

- Remove the oil in the engine oil sump usin g the drainage

pump (1).

- Remove the pump adjusting the nut (3).

Figure 18

NOTE

Some versions have a plug for draining the oil from the sump. The procedure involves opening this plug located underneaththe engine sump after having extracted the dipstick and the filler plug to facilitate the flow of lubrication oil.

129302

- Disconnect the pipe (2) and remove it, adjusting the bolt

(1).

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Engine setting operations for the assembly on turning stand

Figure 20

Figure relevant to turbocompressed versions

In order to apply the brackets 99361037 to the engine block to fix it on to the stand 99322205 for the overhaul, it is necessary to perform the following operations:

On the right hand side:

- disassemble pipes (1) from the union (2) fitting the

lubrication oil filter (assembled on the opposite side): unlock the nuts fixing the pipes (1) and remove them from the union (2); drain the oil eventually still inside the pipes and plug them properly in order to avoid impurity inlet.

For some versions, the oil filter (3) is directly assembled on to the heat exchanger:in such case it

shall be disassembled using tool 99360076. Warning: the oil filter contains inside aprx. 1 kg. of engine oil. Provide for oil recovery and disposal in compliance with the law and regulation s in force.

Figure 21

75670

75671

Only for turbocompressed versions

- disassemble lubrication oil exhaust pipe from the

turbo-blower: Underneath the turbo-blower loosen the two screws (2), loosen the screw (3) fixing the pipe throughout th e stop collar (4) fixing the block; finally loosen and remove the union (5) from the block; plug the pipe ends and the exhaust of the turbo-blower.

Figure 22

75672

- Disassemble th e starter;

Properly hold the starter (1) and loosen the two fixing screws (2); assemble the bracket bearing 99361037 using the four screw t hreaded ports (3).

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 23

75674

From the left-hand side:

- Assemble the second bracket 99361037 throughout th e

screw-threaded ports (1).

- Lift the engine using the rocker arm 99360595 and put

it on the turning stand 99322205.

- Drain the oil through the cap underneath the plug.

Warning: avoid co ntact of engine oil with the skin: in case of skin contamination, rinse in running water.

Engine oil is highly pollutant: provide for disposal in compliance with the law and regulation s in force.

Figure 25

116389

Proceed disassembling the supercharger:

- loosen the fixing nut (1) and remove the lubrication pipe

from the supercharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger.

- Loosen the screw nuts fixing (2) the supercharger on the

exhaust manifold.

- Hold up the supercharger and after lifting it remove the

gasket.

Disassembly of application components

Figure 24

Loosen the screws (2), remove the duct (3) and the heater (1) (if present).

Figure 26

129268

127121

- Place a container under the fuel filter and screw out the

condense drain faucet underneath s aid filter. Carry out complete drainage of the fuel contained therein.

- Screw out completely the faucet and, using equipment

99360076 disassemble oil filter (2).

- Disconnect fuel pipelines (4 and 3) respectively from

priming pump to filter bearing and from this last one to the feed pump.

- Remove the fuel filter bearing (1) from the bracket fixed

to the engine head.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 27

NOTE

To disconnect fuel pipelines (3 and 4, Figure 26), in low pressure from the relating pipe fittings, it is Necessary to press the locking fastener (1) as showninpictureB.

After having disconnected the pipeline, reset the locking fastener (1) in loc k position as shown in. picture A, to avoid any possible deformation of the fastener itself.

STANADYNE ”D” Series Pump

Figure 29

70126

Figure 28

- Remove tappet caps:

Loosen the four fixing screws (1) and lift the caps (2); remove the gaskets.

NOTE

On the cap th ere is a blow-by valve for the lubrication oil vapours.

All the gaskets shall always be replaced during assembly.

87406

- Remove the pipes forming the fuel supply (8) and

recovery (5) between the pump and the injectors (1):unscrew the ring nuts (7) securing the pipes to the pumping elements;free the collar (6) of the fuel recovery pipe returning to the injection pump;undo the ring nuts (7) fitted on the injectors and unscrew the bolts securing the fuel recovery pipe; unscrew the bolts retaining the

129298

brackets (2, 4, 9) securing the above-mentioned pipes. Put plugs on the ends of the pipes.

- Remove the injectors (1) and take them out of their seat:

retrieve the seals.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 30

88102

- Loosen the two fixing screws (2) and disassemble

priming pump (1).

Figure 32

125114

- Disassemble rocker arm bearings; loosen the two fixing

screws (2) and remove the complete ro cker arm bearing; withdraw tappet rods. Repeat the operation for all the remaining rocker arm bearings.

- Disassemble water t emperature transmitter (1).

Figure 31

- Disassemble su ction and exhaust manifolds: loosen the

8 screws (1) fixing the suction manifold plate to the cylinder head (two of them have already been screwed-out since fixing the pipe brackets to the injectors); from the exhaust manifold side; loosen the (2) fixing screws; remove the gaskets.

Figure 33

87409

127122

- Disassemble thermostat unit; loosen the three fixing

screws (1) and disassemble the thermostat unit (2) together with the bracket (4); remove the gasket (3) and the thermostat (5).

- Assemble the bracket in the original position fixing it with

the screws of the thermostat unit.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

For engines with a traditional belt tensioner

Figure 34

For engines with an automatic belt tensioner

Figure 36

108545

Release on the drive belt tensioner (1) and extract the belt (2) from the belt pulleys from the water pump ones and from the belt rebound pulleys;

Disassemble the belt tensioner (1).

Loosen the screws fixing the alternator to the support and disassemble it.

127123

- Loosen the screw nut (5) and the screw (2)

- Loosen the screw (2, figure 18)

- Reduce belt tension operating on the screw (4)

- Loosen the screw (2) on the belt tensioning bracket (3)

- Withdraw the POLY-V belt

- Remove the belt tensioning bracket loosening the screw

(1)

- Disassemble the pulleys and the guide rollers.

Figure 35

Figure 37

- Loosen the screws (1) and withdraw the alt ern ator

bearing (2).

88089

NOTE

- Properly hold the alternator (1) separating it from its

bearing by loosening the screw (2); remove screw nut and washer.

Base - November 2008 Print P4D32N002 E

The shape and the dimensions of the support of the alternator vary according to the use of the engine. The relevant pictures provide a general trace of the intervention that is to be carried out. The procedures described are always applicable.

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 38

75810

- Loosen th e screws (4) and disassemble the oil

pressure/temperature sensor (3) (if fitted).

- Loosen the screws (1) and disassemble the oil filter/heat

exchanger bearing (2), interlayer plate (6) and relating gaskets.

- Disassemble oil level sensor (5) (whether provided).

- Disassemble injection pump (see specific procedure)

and the power take-off underneath.

For 4 cylinder engines

Figure 40

75688

- Disassemble cylinder head;

loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.

For 6 cylinder engines

Figure 39

- Disassemble cylinder head;

loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.

76152

Engine versions with tool (99360339)

Figure 41

123031

- Apply tool 99360339 (1) on the flywheel housing cover

to block rotation of the flywheel (3) using a spanner on the nut (2) and a pin (4). (use the stud bolts and the nuts fixing the starter motor).

- Loosen the flywheel fixing screws to engine drive shaft.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Engine versions with tool (99360351)

Figure 42

129299

- Use the tool 99360351 (1) t o operate on the flywheel

cover box (2) in order to block flywheel rotation (3). (Utilise starter holding down studs and fixing screw nuts).

- Loosen the flywheel fixing screws (4) to engine drive

shaft.

Figure 44

70148

- Remove the screws (1) and disconnect the water pump

(2).

- Remove the screw (3) and the roller (4).

- Remove the screw (5) and disconnect the engine speed

sensor (6).

Figure 43

- Unloose the screws (3) and disassemble the damping

flywheel (2) and the pulley (1).

NOTE

In some versions, the phonic wheel mounted on pulley (1) may be not present and pulley (1) can be different from the pulley shown in Figure.

Figure 45

108548

00900t

- Remove the engine drive shaft fixing ring from the front

cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3).

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 46

00904t

- Using the specially provided tie rod (3) for the tool

99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1).

Figure 48

75811

- Loosen the screws (1) and remove oil pump (2).

Figure 47

- Loosen the screws (1 and 3) and remove the front cover

(2).

NOTE

Take note of the screw (1 and 3) assembly position, since the screws have different length.

116242

Figure 49

75695

- Screw out the opposite screws (2) from the ports where

the with drawal pins shall be introduced (see picture following).

- Loosen remaining flywheel fixing screws (1) to the

engine drive shaft.

- Remove the flywheel block tool (2).

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 50

75690

- Screw up two medium length screws in the ports (4) to

slingtheflywheelwithahoist. Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.

Figure 52

70153

- Loosen the screws (2) and remove the flywheel cover

box (1).

NOTE

Take note of the screw (1) assembly position, since the screws have different length.

Figure 51

- Remove the flywheel cover box fixing ring using the

tool 99340056 (3) to operate on the back tang (5) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring using Ø 3,5 mm drill for a 5mm depth.

- Fix the tool 99340056 (3) to the ring (1) tightening the

6 screws specially provided (4).

- Proceed with drawing the ring (1) tightening the screw

(2).

- Using th e specially provided tie rod (3) for the tool

99363204 and the lever (4), withdraw the external holding ring of th e flywheel cover box.

00903t

Figure 53

74775

- Turntheengineupside-down.

- Loosen the screws (2), disassemble the plate (3) and

remove the oil pan (1).

NOTE

The shape and dimensions of the pan and of the rose pipe may vary according to the engine application. The relating illustrations provide general guidelines of the operation to be performed. The procedures described are applicable anyway.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

For 4 cylinder engines

Figure 54

99222

- Loosen the screws (1) and disassemble the oil suction

rose pipe (3).

- Loosen the screws (2) and remove the stiffening plate

(4).

Figure 56

For 6 cylinder engines

Figure 55

- Remove the screws (1) and (4) and disassembled the

suction rose (5).

- Remove the screws (2) and disassemble the stiffening

plate (3)

86516

90505

- Loosen the screws (1) and disassemble the gear from the

camshaft (2).

Figure 57

70157

- Loosen the screws (2) and disassemble the timing

gearbox (1).

NOTE

Take note of the screw (2) assembly position, since the screws have different length.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Installation of rear components

Figure 58

DIAGRAM SHOWING SEALING LOCTITE 5205

APPLICATION WITHIN GEARBOX AREAS

- Accurately clean the timing gearbox (1) and the engine

block.

It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal.

Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter.

It must be uniform (n o crumbs), with no air blisters, thinneror irregularzones.

Any eventual imperfection shall be correct as soon as possible.

Avoid using material in excess to seal the joint. Too much sealing material w ou ld drop out on both sides of the joint and obstruct lubricant passages.

Couplings must be assembled within 10 minutes after completing th e sealing operation.

Figure 59

910

75712

DIAGRAM SHOWING SCREW

75711

TIGHTENING TO FIX REAR GEARBOX

- Reassemble to box (1) to the engine block.

- Tighten the fixing screws in the same position as found

out during disassembly and fix the screws to the locking couples listed here below, following the order as shown in the picture.

Screws M12 65 ÷ 89 Nm Screws M8 20 ÷ 28 Nm Screws M10 42 ÷ 52 Nm

NOTE

Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

Figure 60

70211

- With a felt-tip pen, h igh ligh t the conducting gear tooth

(1) mounted on the engine shaft (2) upon the upright surface on which a groove has been created for the ignition timing.

NOTE

Screw u p two pins to facilitate operation of engine drive shaft rotation.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 61

Figure 63

129300

- Turn the engine shaft (3) and the distribution shaft (4)

so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).

Figure 62

90508

- Tighten the screws (1) fixing the gear to the camshaft (3)

and lock them to the prescribed couple.

Figure 64

90507

75708

- Position comparator (1) on timing system gear (2) and

check that the clearance between gears (2) and (3) is within 0.076 ÷ 0.280 mm range.

DIAGRAM SHOWING SEALING LOCTITE 5205

APPLICATION.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

NOTE

It is necessary and essential to clean the surface to

Figure 66

be sealed in order to achieve excellent tight seal.

Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones.

Any eventual imperfection shall be correct as soon as possible.

Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of t he joint and obstruct lubricant passages.

Couplings must be assembled within 10 minutes after completing th e sealing operation.

0901t

- Apply to engine drive shaft rear tang (6), the detail (5)

of t he tool 99346252, fix it tightening the screws (4) and key the new holding ring on it (3).

- Place detail (1) on detail (5), tigh ten the screw nut (2)

until complete assembly of the fixing ring (3) into the flywheel cover box (7).

Figure 65

DIAGRAM SHOWING SCREW

TIGHTENING TO FIX FLYWHEEL COVER BOX.

- Reassemble the box (1) to the engine block, t ighten t he

fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below, following the order as shown in the picture.

Screws M12 75 ÷ 95 Nm

Screws M10 44 ÷ 53 Nm

75709

Figure 67

75696

- Check the contact surface (1) of the clutch plate and if

it is scratched, proceed with turning.

- Chec k ring gear teeth (2), if breakage or excessive wear

is found remove the ring gear from the engine flywheel (1) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing theengineflywheel.

Before assembly, always check th at the threads of the ports and of the screws have no evidence of tear

and wear nor dirt.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Flywheel installation

Figure 68

- Screw up two hooks or trail rings in the flywheel (1)

threaded ports (4) for handling .

- Using a hoist, handle the flywheel to place it in its housing

inside the flywheel cover box.

- Screw up to pins (2) having appropriate length, in the

shaft ports (3) and using them as guide, assemble the engine flywheel (1) properly placing it inside the flywheel cover box.

75690

Engine versions with tool (99360351)

Figure 70

129299

- Use the tool 99360351 (1) t o operate on the flywheel

cover box (2) in order to block flywheel rotation (3). (Utilise starter holding down studs and fixing screw nuts).

Engine versions with tool (99360339)

Figure 69

- Apply tool 99360339 (1) on the flywheel housing cover

to block rotation of the flywheel (3) using a spanner on the nut (2) and a pin (4). (use the stud bolts and the nuts fixing the starter motor).

123031

Figure 71

75695

Tighten the engine flywheel (1) fixing screws (2) in two phases:

- 1st phase; tightening by means of dynamometric wrench

to couple 30 ± 4 Nm;

- 2nd phase, 60º ± 5º angle dwell with tool 99395216.

NOTE

Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Installation of front components

Figure 72

70220

- Assemble oil pump (1).

- Tighten fixing screws (2) and lock them to th e prescribed

couple.

Figure 74

76112

- Assemble the water pump (1).

- Tighten the screws (2) and lock them to the prescribed

couple.

Figure 73

- Apply to the water pump (1) a new fixing ring (2).

70221

Figure 75

106549

- Remove the fixing ring (2) from the front cover (1),

accurately clean the plug surface.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 76

75710

- Accurately clean the contact surface of engine block and

apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs.

Figure 78

00902t

- Apply on engine drive shaft front tang (6) the detail (4)

of the tool 99346252, fix it with the screws (5) and key the new holding ring on it (7).

- Place the detail (2) on the detail (4), screw-up the

threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover.

4 cylinder engines

Figure 79

Figure 77

- Assemble the front cover (2) to the block and tighten

the screws (1) fixing them to the prescribed couple.

106550

87260

- Assemble the plate (1), the rose pipe (2), tighten the

fixing screws (3) and fix them to the prescribed couple.

6 cylinder engines

Figure 80

86516

- Assemble the plate (3), the suction rose (5) and tighten

the fixing screws (1, 2 and 4) to the prescribed torque.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 81

- Provide for new gasket replacement (1) of the oil pan (2).

NOTE

The pictures illustrating the pan and o f the rose pipe may not correspond to the ones of your model. However the procedures described are applicable anyway.

Figure 83

74175

- Assemble the pulley (1) and the dumping flywheel (2) to

the driving shaft.

- Tighten the fixing screws (3) and clamp them to the

couple 68 ± 7 Nm.

NOTE

In some versions, the phonic wheel mounted on pulley (1) may be not present and pulley (1) can be different from the pulley shown in Figure.

Figure 82

- Assemble oil pan (1), apply the plate o ver it (2). Tighten

the screws (2) and lock them to the prescribed couple.

NOTE

Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

74775

Figure 84

75814

- Assemble the following elements to the block: new

gasket (1), heat exchanger (2), new gasket (3), oil filter bearing (4). Tighten the screws (5) and lock them to the prescribed couple.

NOTE

Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 85

76113

- Lubricate the fixing ring (2) using engine oil and place it

on the oil filter (3).

- Manually start the oil filter (3) on the bearing union (1)

until counter-boring, further screw up the oil filter (3) by 3/4 turn.

- Place a new fixing ring on the block housing (6).

- Apply, (if needed) new fixing ring on the oil

temperature/pressure sensor (4) and assemble it to the bearing (1) tightening the fixing screws to the prescribed couple.

Figure 87

75686

- Connect the alternator (1) to the support.

- Tighten the screw without locking it (2).

Figure 88

Figure 86

- Assemble the alternator bearing (1) ensuring that the

pins (3 and 4) are against the engine block.

- Tighten the screws (2) and lock them to the prescribed

couple.

NOTE

The shape and the dimensions of the alternator support vary according to the use of the engine. Therefore the relevant pictures provide a general guideline of the intervention that is to be carried out. However the procedures described are applicable.

Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

76114

- Place the gasket (1) over the block.

The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface.

NOTE

Verify that the engin e block stand is clean .

Do not grease the gasket. It is recommended to keep the gasket inside packaging until assembly to the cylinder head.

Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture.

87759

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 89

75688

- Place the head (3) over the block and insert screws (1)

and (2).

NOTE

If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.

Figure 91

- Place the head (3) over the block and insert screws (1)

and (2).

NOTE

If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.

76152

NOTE Before using th e fixing screws again, measure them

twice as indicated in the picture, c h eckin g D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1-D2>0,1mmthescrewmustbereplaced.

D1D2

Figure 90

13 14

- Lubricate cylinder head bolts and install to head.

- Bolts must be torqued using stitching pattern starting

with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. Then a further 90 degrees for the M12 x 140.

M12 x 70 50 Nm + 90 deg’s M12 x 140 40 Nm + 180 deg’s

75703

76115

NOTE Before using th e fixing screws again, measure them

twice as indicated in the picture, c h eckin g D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1-D2>0,1mmthescrewmustbereplaced.

D1D2

75703

Figure 92

76214

- Lubricate cylinder head bolts and install to head.

- Bolts must be torqued using stitching pattern starting

with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. Then a further 90 degrees for the M12 x 140.

M12 x 70 50 Nm + 90 deg’s M12 x 140 40 Nm + 180 deg’s

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 93

75705

- Carry out the assembly of the rocker arms after previous

check of the components.

ROCKER ARM UNIT COMPONENTS:

1. Elastic ring - 2. S pacer- 3. Rocker arms-

4. Support.

Figure 94

18.975

18.963

Figure 96

122587

Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Arm adjustment screw and with the tappet(arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them. The rods driving t he suction and exhaust valves are identical and therefore interchangeable.

Figure 97

SHAFT AND ROCKER ARM BASIC DATA

Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary.

Figure 95

19.000

19.026

19.000

19.026

13.00

11.00

75704

116391

D1D2

75703

- Insert the tappet driving rods and the Rocker Arm unit.

Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1-D2>0,1mmthescrewmustbereplaced;

ROCKER ARM ADJUSTMENT SCREW

If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the i 0.4 - 0.6 Nm couple.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 98

125114

- Tighten the screws (2) to the prescribed couple and

assemble water temperature sensor (1).

Find the top dead centre with the tool (99395097) - False injector

Figure 100

88141

Remove the rocker covers of the 1stcylinder; remove the 1 injector and place the tool (1) to set the 1stcylinder top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then ch ecking that the intake and exhau st valves are both c l osed.

Figure 99

- Fit tool 99360339 (1) in o rder to be able to rotate the

flywheel using an Allen key.

123031

Figure 101

130192

- Check that the part of the flywheel that is not perforated

(1) is positioned at the top along the vertical axis.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 102

84071

Turn the flywheel until, w hen pushing the pin 99360616 (1), it blocks the gear (2) obtaining the TDC of the 1° cylin der.

Figure 103

NOTE

Cylinder n° Suction Exhaust

Figure 104

In order carry out a quicker adjustment of the working slack between rocker arms and valves, proceed as following: Rotate the engine drive shaft, balance the valves of cylinder 1 and adjus t the valves identified by star symbol, as indicated in the following table:

234

Rotate the engine drive shaft, balance the valves of cylinder 6 and adjus t the valves identified by star symbol, as indicated in the following table:

234 ** *- *

Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2).

Correct slack is:

- suction valves 0.25  0.05 mm

- exhaust valves 0.50  0.05 mm.

NOTE

Cylinder n° Suction Exhaust

Cylinder n°

Suction Exhaust

Rotate the engine drive shaft., balance the valves of cylinder 4 and adjus t the valves identified by star symbol, as indicated in the following table:

75806

75707

- Assemble injectors after having replaced the sealing

gasket (1).

NOTE

During assembly of injectors, verify that th e injector sphere is correctly positioned on the head housing.

1 *

234

*- -

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 105

123025

- Assemble exhaust manifold (1) providing new gaskets

(2).

Figure 107

Figure 106

- Assemble thermostat unit (2) including thermostat (5)

and gasket (3).

- Tighten the screws to the prescribed couple.

NOTE

The screws (1) have been h ave been utilised to fix the bracket (4).

Disassemble the bracket an d reassemble components from 1 to 5 as shown in the picture.

The gasket (3) must be new.

127122

75687

- Assemble the pulley fan bearing tightening the screws to

the prescribed couple.

- Mount pulley (3) and secure it to support through

screws (2).

- Assemble th e transmission pulley (1).

- Fit the new belt onto the pulleys and guide rollers.

NOTE

If not faulty the gasket can be reused.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

For engines with a traditional belt tensioner

Figure 108

Figure 110

114793

Refit the automatic belt tensioner (2). Tighten the screw (3) to the specified torque using a wrench,

turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers.

127123

- Tighten the screw (2), the screwnut (5) and the

screwnut fastening the alternator to the support.

- Assemble the alternator tensioning bracket (3) and

secure it through screw (1)

- Tighten the screw (2) without locking it

- Tension drive belt operating on the sc rew (4)

For engines with an automatic belt tensioner

Figure 109

Figure 111

127127

114792

Refit the alternator (1).

Tighten the screw (2) to the specified torque.

Print P4D32N002 E Base - November 2008

- Apply on the surface joining the suction manifold plate

(1) a sufficient coat of Loctite 5999 and provide. fixing the screws (2) to the prescribed couple.

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 112

75700

- Assemble the brackets (1) fixing the fuel pipelines to the

injectors: u se the same screws (2) fixing the manifold plateasshowninthepicture.

Figure 113

88102

- Assemble priming pump (1) providing new gasket and

tighten the screws (2) to the prescribed couple.

- Also assemble feed pump (see specific procedure) and

the power take-off underneath.

NOTE

Pump mounting requires specific procedure contained in this section.

STANADYNE ”D” Series Pump

Figure 114

129298

- Fit the pipes (5) and (8) forming the fuel supply and

recovery between the pump and the injectors:screw on the ring nuts (7) securing the pipes to the pumping elements;fasten the collar of the fuel recovery pipe

(3) on the injectors (1) and screw on the bolts securing the fuel recovery pipe; secure the pipes (2, 4 and 9) with the brackets fitted beforehand.

returning to the injection pump (6);tighten the ring nuts

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 115

129268

- Assemble th e fuel filter bearing (4) to the bracket fixed

to the engine head.

- Connect the fuel pipelines (2 and 3) respectively from

priming pump to filter bearing and from this last one to feed pump.

- Using 99360076 equipment assemble fuel filter (1).

Figure 117

87406

- Assemble cylinder covers (2) with the respectivegaskets;

- Fit the seal nods and tighten the screws fixing them to

the prescribed couple.

NOTE

Always replace the gaskets using new ones.

Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit.

Seal no ds shall have no visible deformation. In such case provide for replacement with new nods.

If not faulty the gasket can be reused.

NOTE

The filter shall be priory filled with fuel to facilitate feed system bleed operations.

Figure 116

NOTE

To connect fuel pipelines (3 and 4, Figure 115) in low pressure from the relating connection unions it is nec essary to press the locking fastener (1) as showninpictureB.

After having connected the pipeline, reset the fastener (1) into block position as shown in picture A.

70126

Figure 118

76143

For turbo-compressed versions

proceed assembling the turbocharger:

- Hold the turbocharger and place it on the exhaust

manifold after having int erposed the gasket.

- Screw up the fixing nuts (2) of the turbocharger to the

exhaust manifold tightening them to the prescribed couple.

- Tighten the lubrication pipe fixing ring. Operate in the

same way on the other end of the pipe. Connect it to the upper part of the heat exchanger.

- Assemble the turbocharger lubrication exhaust pipe by

tightening the screws (3); connect the end to the engine block..

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 119

- Refit the duct (3) and thje heater (1), after having fitted

new gaskets, and thighten the screws (2). (if present)

To complete engine assembly it is necessary to remove it from the turning stand.

- Using rocker arm 99360595 hold the engine and loosen

the screws fixing the brackets to the turning stand

99322205.

- Disassemble the brackets 99361037 from the engine

after having properly put it on a wooden bearing.

Completion of engine re-assembly

Figure 120

127121

116388

From the right-hand side:

- Re-assemble the lubrifying oil discharge pipe (1) from the

turbo-blower by inserting the joint (2) into the engine crankcase and tightening the two fastening (6) screws underneath the turbo blower;

- Tighten the screw (5) which holds the piping to th e (1)

monoblock by means of the cylinder bracket (4);

- Re-assemble the oil filter (3) onto the heat exchanger

with tool 99360076;

Figure 121

75717

- re-assemble the starting engine (1); opportunely support

the starting engine (1) and tighten the two fastening screws to the prescribed torque.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Refitting engine to radiator

For versions with an oil drainage pump

Figure 122

For versions with an oil drainage tap

Figure 124

129303

- Reposition the dipstick and the oil filler plug;

- Refit the pipe, tightening the bolt (2) to the

recommended torque.

129301

- Reposition the dipstick and the oil filler plug;

- Refit the pump tightening the nut (3) to the

recommended torque.

Figure 123

NOTE

Some versions have a plug for draining the oil from the sump. Proceedwith closing the plug under the sump, after having repositioned the dipstick and the oil filler plug.

129302

- Refit the pipe (2), tightening the bolt (1) to the

recommended torque.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

For all engines

Figure 125

129297

- Refit the fan (1), complete with spacer and tighten the

bolts (2) to the recommended torque.

NOTE

The shape and the size of the drainage pipe vary depending on the usage of the engine. The illustrations therefore provide guidelines for the operation to be carried out. The procedures described can, however, be applied.

Figure 126

Figure 127

129295

- Connect and air intake pipe (6), closing the bands (1) and

(5).

- Connect and oil vapour recovery pipe (3) closing the

bands (2) and (4).

NOTE

The shape and the size of the drainage pipe vary depending on the usage of the engine. The illustrations therefore provide guidelines for the operation to be carried out. The procedures described can, however, be applied.

- Fit t he air filter complete with mounting (1) and tighten

the bolts (2) to the recommended torque.

129296

Figure 128

129294

- Connec t the drainage pipe (1) tightening the bolt (2) to

close the band (3).

NOTE

The shape and the size of the drainage pipe vary depending on the usage of the engine. The illustrations therefore provide guidelines for the operation to be carried out. The procedures described can, however, be applied.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 129

129293

- Refit the radiator assembly on the crankcase, paying

attention to any interference with the fan and tighten the fixing bolts on both sides to the recommended torque.

Figure 131

129285

- Fit the protective grilles (2) for the fan tightening the

fastenings (1) and (3) to the recommended torque.

For 4 cylinder engines

Figure 130

- Fit the bracket (2) and tighten th e nuts (1) and (3) to the

recommended torque. Repeat the operation for the second bracket.

Figure 132

129286

129283

- Fit the pipe (2) complete with hoses adjusting the bands

(1) and (3).

NOTE

Print P4D32N002 E Base - November 2008

Check the rubber hoses for wear.

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 133

129284

- Fit the pipe (2) complete with hoses adjusting the bands

(1) and (3).

Check the rubber hoses for wear.NOTE

Figure 135

129290

- Fit the pipes (1) and (4) complete with hoses adjusting

the bands (2) and (3).

Check the rubber hoses for wear.NOTE

For 6 cylinder engines

Figure 134

- Fit and pipe (4) complete with hoses, on the engine side,

adjusting the bands (5).

- Fit the pipe (2) complete with hoses adjusting the band

(3).

- Fit and pipe (1) complete with hoses, on the engine side,

adjusting the bands (6).

Figure 136

129291

129289

- Conn ect the air and water pipes to the radiator assembly

adjusting the bands (1), (2), (3) and (4) and the mounting bracket (5).

Check the rubber hoses for wear.NOTE Check the rubber hoses for wear.NOTE

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Figure 137

129288

- Fit the pipe (1) and tighten the bolts (2) to the

recommended torque.

Figure 139

129292

- Connect the pipe (4), complete with hoses and bracket

(5) to the radiator assembly adjusting the bands (1) and tightening the bolt (3) to the recommended torque.

Check the rubber hoses for wear.NOTE

Figure 138

- Fit the protective grilles (5) for the fan tightening the

fastenings (1), (3) and (4) to the recommended torque.

- Close the bands (2).

For all engines

- Refit and connect the electrical wiring;

- refill the coolin g system with coolant;

- bleed the air from the supply system as described in the

relevant paragraph;

- check the engine oil level;

- carry out the tests and checks described i n the relevant

chapter.

129287

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Rotary feed pump disassembly and assembly procedure

NOTE

This procedure prescribes that:

- the fuel pipes (from the pumping elements to

the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed;

- the electrical connections have been

disconnected.

- Accelerator cable shall be disconnected.

Figure 140

Figure 142

Disassemblethestarterfromtheflywheelboxandusetool 99360330 to rotate the flywheel.

In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part.

On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine and disassemble it only afterwards.

The following procedure analyses this second hypothesis since it is the more complex.

Find the top dead centre with the tool (99395097) - False injector

Figure 141

130192

Check that the part of the flywheel that is not perforated (1) is positioned at the top along the vertical axis.

123031

Figure 143

84071

Turn the flywheel until, w hen pushing the pin 99360616 (1), it blocks the gear (2) obtaining the TDC of the 1° cylin der.

88141

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Disassembly

Figure 144

106659

- Partially unlock pump shaft retaining screw (1) and move

spacer with slot (2) in area with lager size hole for complete screw passage.

- Lock applying a torque ranging between 11,9 and 12,4

Nm retaining screw (1) till reaching spacer, thus locking pump shaft rot at ion.

Figure 146

106658

- From the pump side, loosen the fixing nuts (1) without

removing them in order to enable moving the pump backwards using 99340035 extractor.

- Assemble the 99340035 extractor throughout the two

threaded ports (4, Figure 145) and withdraw the gear from the pump shaft.

- Properly hold the feed pump and loosen completely the

fixing nuts.

- Withdraw the pump from the studs, together with the

gasket.

Figure 145

- From timing side, remove the cover (2) loosening the

screws (1) in order to have access to the union fixing nut (3) to the pump driving gear.

- Loosen the fixing nut (3) and remove the relating

washer.

75693

NOTE

Hold the pump driving gear to avoid interference or crawling during timing gear rotation.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Rotary feed pump setting check

Figure 147

106660

1. Slot on the hub of the hydraulic rotor -

2. Sync hronization pin 99365196 - 3. Plate.

The syn chronization pin 99365196 (2) has been designed for use in the event of the rotor shaft being inadvertently released. The correct synchronization of the pump with the engine is obtained when the synchronization pin 99365196 (2), fitted in the hole on the plate (3), enters the slot (1) on the exterior of the hydraulic rotor h ub.

Assembly

Figure 148

106658

When installing supplì pump on engine, cylinder no.1 must be at TDC, end of compression phase.

- Assemble the pump pre-set in its housing on the engine,

fitting the shaft into the gear port (not provided with wrench).

- Tighten the fixing nuts (1) locking the pump flange in the

slot centre.

NOTE

The gasket removed during pump disassemblyshall not be utilised again. Always u s e original spare parts.

Therefore:

- Remove the screw cap (3) at the centre of the plate.

- Insert the synchronization pin (1) 99365196 in the hole

on the plate (3). The synchronization position is obtained when the synchronization pin (2) enters the slot on the hydraulic rotor hub.

- Lock the control shaft in the correct position by means

of the screw (1, Figure 144).

- Remove the synchronization pin and fit the screw cap of

the plate (3). Tighten the cap using a torque of 2.3 ÷ 3.4 Nm.

NOTE

Support the pump gear to prevent interference or sticking when the timing system gears turn.

Figure 149

75693

- On the timing side, throu gh ou t the specially appointed

port, fit the washer and screw up the fixing nut (3) to the pump shaft. Lock the nut to the 190-203 Nm couple.

- Assemble the cover (2) including gasket and tighten the

screws (1).

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

Figure 150

106659

- - Svitare, senza rimuovere, la vite (1) di bloccaggio

rotazione dell’alberino della pompa e spostare il distanziale con asola nella zona del foro di dimensioni minori. Avvitare fino a battuta la vite bloccando il suddetto distanziale: in questo modo l’alberino della pompa di alimentazione è libero di ruotare.

- Disassemble the flywheel rotation/locking tool

99360339 or 99360330; arrange the starting motor in its seat.

- Connect all the pipes (from the pumpingelements to the

injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump).

- Connect the electrical connections.

SECTION 3 - G-DRIVE APPLICATION

NOTE

In case pump removal has been carried out while the engine was assembled, connect acceleration cable.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

ASSEMBLY PROCEDURE OF THE ”ADC100” ELECTRONIC ACTIVATOR ON STANADYNE SERIES ”D” INJECTION PUMPS

Figure 151

Before proceeding in the removal of the Injection Pump cover and then to the replacement with the electronic actuator, it is important to clean the external part of the pump, if necessary, using solvents. This prevents contamination of the internal part of the pump.

- Disconnect the wire of the stop electro-valve from the

clamp (I) positioned on the pump cover, being careful to isolate it.

- Remove the fuel return pipe from the connection (2)

116978

- Remove the three screws (3) of the pump cover. The

screws will then be replaced assembling the screws supplied with th e ADC100 actuator

- Remove the cover of the injection pump very carefully

so that the dirt won’t penetrate inside the pump.

- Remove the connection (2) of the fuel return pipe and

the sealing from the injection pump cover. Keep the connection (2) and the sealing that will have to be assembled on the electronic actuator.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

Figure 152

SECTION 3 - G-DRIVE APPLICATION

A. The injection pump open seen from above - B. Front (carter side) - C Rear (injector side)

I. The ”U” shaped hook of the electronic actuator - 2. Injection pump lever - 3. Droop adjustment screws

Assembly of the actuator

- Reassemble the connection for the fuel return pipe and

the pump cover’s original dealing, on the ADC100 electronic actuator.

- Position the electronic actuator on th e injection pump

with the highest part slightly titled upwards.

- Slide the electronic actuator towards the rear part of the

pump (injectors’ side) until the ”U” shape hook (I) of the actuator engages the lever of t he injection pump (2). Once engaged, align th e holes of the pump and the electronic actuator.

116979

NOTE

Couplings mistakes between the actuator’s hook (I) and the lever (2) of the injection pump cancause motoroverspeedconditions.

- Tighten the ADC100 actuator to the injection pump,

using the screws su pplied with the actuator.

- Reconnect the fuel return pipe to the connection placed

on the actuator.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS WITH STANADYNE PUMP

Figure 153

According to the specific needs of the motor employment it is possible that a request to vary the adjustment of the Stanadyne pump be made to obtain a different use frequency:

- 500rpm/50Hz

- 800rpm/60Hz

The necessary procedures will be described in order to execute the following adjustments:

- passage from 50 Hz to 60 Hz and vice versa.

- stabilizing of th e rotation regime.

NOTE

If only the Stanadyne identification tag (2) is present, this means that the injection pump presents a setting of 50 Hz. In case of modification of the setting from 50 Hz to 60 Hz done in the factory, an identification tag (1) is applied by FPT.

116400

On the FPT tag (I) reported are:

- the model of the injection pump (4);

- an identification code (3) of the specific application of

the setting of the injection pump, for example: A.S. 7.54 identifies the setting at 1800 rpm of 60 Hz.

Passage from 50 Hz to 60 Hz

To carry out the passage from 50 Hz to 60 Hz you must, first of all:

- identify the code of the injection pump from th e

Stanadyne tag (2).

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

Figure 154

SECTION 3 - G-DRIVE APPLICATION

116975

Type of injection pump

(Stanadyne tag)

DB 4629 - 5927 2 6 4

DB 4629 - 5932 2 9 7

DB 4629 - 5944 2.5 8.5 6

DB 4429 - 5945 3 6 3

DB 4429 - 5954 2 8.5 6.5

DB 4427 - 5955 3 9 6

- Act on the droop setting adjustment screw (2), rotating

it clockwise the number of rotations indicated in the chart figure, starting from the position in which the screw is.

NOTE

In case of doubt you can always unscrew the droop setting register screw (2) counterclockwise till you get to the final position - do not force it further in order to not damage the adjustment system. At this point, always referring to the chart figure, rotate the droop setting screw clockwise (2), the number of rotations indicated for the regime of 60 Hz from the final position.

Screw rotations at 50 H z

from the final position

(clockwise)

Screw rotations at

60 Hz from the final

position

Difference of rotations

from 50 Hz to 60 Hz

(clockwise)

If, for example, for a motor with an injection pump with code DB 4429 - 5945, o riginally set at 50 Hz, you want to pass to 60 Hz, it is sufficient to act on the droop setting adjustment screw (2) rotating it 3 times cloc kwise from the position in which it is, start the motor, loosen the adjustment screw of the maximum regime and accelerate with the accelerator lever, till yo u obtain the empty rotation regime equal to 62 Hz (l860 rpm),

- Then regulate the screw of the minimum regime (4) so

to block the accelerator lever in the newly obtained position and finally block both adjustment screws (I and

4) using the appropriate lock nuts (tightening torque 3,5 ÷ 4 Nm).

NOTE

- After starting the motor you must operate the maximum

(I) and minimum (4) register screws in order to block the accelerator lever (3) in the position to obtain the desired regime, considering the frequency fall in the passage from empty to full of the motor (about 2 Hz).

Print P4D32N002 E Base - November 2008

The adjustment screw of the minimum regime (4) does n ot allow the attainment of the minimum intended in the ”classical” meaning of the term because the injection pump regulator imposes a superior rotation regime since it is about an injection pump for the application of a generator

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Passage from 60 Hz to 50 Hz

To pass from a 60 Hz regime to the 50 Hz regime, operate analogously to what seen above, remembering to act on the droop setting adjustment screw (2, Figure 5), rotating the same of 3 counterclockwise rotations from the position in which it is for the functioning at 60 Hz

Stabilization of the rotation regime

In case of instability of the rotation regime, ac t on the droop setting adjustment screw (2, Figure 5) rotating lightly the same clockwise/counterclockwise till the stabilization of the motor rotation regime

NOTE

Attention! Some motors cannot undergo the passage from 50 Hz to 60 Hz and vic e versa, as they need a specific injection pump to work at the required regimes. Make reference to the SI 191 1 ”Service Information” to verify which motors cannot undergo the passage from 50 Hz to 60 Hz and vice versa.

Identification tag

Figure 155

116976

In case the FPT tag is not present because it is a motor with an injection pump that has a setting of 50 Hz, it is necessary to proceed in the application of a tag in the illustrated area as in Figure 4 stamping it as the figure example.

The blank tag can be ordered at the Part Replacement Service.

Figure 156

116977

If the FPT tag is already on the injection pump, you must proceed stamping the new identification suffix of the newly obtained setting and strikethrough the identification of the preceding setting, as illustrated in the figure example.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

REPLACEMENT OF THE ELECTRO-VALVE AND THE SOLENOID VALVE THROTTLE ON STANADYNE PUMPS

Figure 157

ETR

116980

A. Position of the electro-valve arm - I. Encapsulated coil - 2. Mobile nucleus of the electro-valve -

3. Electro-valve arm - 4. Isolator - 5. S olenoid valve ends

ETSO

A. Position of the electro-valve arm - I. Encapsulated coil - 2. Mobile nucleus of the electro-valve -

Two types of electro-valves can be used on St anadyne injection pumps:

- ETR (Energize To Run)

- ETSO (Energize To Stop).

Please note, in the figure, the different assembling position of the electro-valve according to the ETR - ETSO functions.

116981

3. Electro-valve arm - 4. Isolator - 5. S olenoid valve ends

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Electro-valve replacement

Figure 158

116982

To replace the electro-valve remove the cover of the injection pump loosening and removing the three fixing screws (I and 2) of t he cover and the relative w ashers.

Check the state of wear of the rubber couplings.NOTE

Figure 160

Figure 159

Remove the entire cover of the electro-valve (I), pulling it upwards perpendicularly to the injection pump.

Be careful that nothing falls into the injection pump.

116983

116985

Remove the electro-valve (3) from the cover (2),

NOTE

Since the ends of the component are electrically isolated from the cover, make sure to remember the assembling order of the nuts, of the washers and of the components, for the electrical connection of the electro-valve ends; one end is earthed through an appropriate element (I). Pay attention to the position of the isolating element (4).

Assemble of the new electro-valve on the injection pump’s cover, using the appropriate kits:

- I2V-ETR

- 24V-ETR

- I2V-ETSO

- 24V-ETSO

The kits contain the indicated type Check the state of wear of the rubber couplings.of electro-valve and all that is needed for its assembling. The nuts fixing the electro-valve (3) to the cover (2) must be tightened to a I, I ÷ 1, 7 Nm torque.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

Figure 161 Figure 162

The repositioning of the cover (2) must be done proceeding in reverse to what described for its disassembling, making sure that it corresponds perfectly to t he assembling seat without forcing it (for the ETR version the cover of the pump

116986

will correspond to the assembling seat only after the joint tool has been removed).

SECTION 3 - G-DRIVE APPLICATION

116987

In the electro-valve E TR kit there is the joint tool (I) which must be used to position the electro-valve’s arm (2) and to reassemble the cover on the injection pump.

NOTE

This tool (I) allows to keep in the excitation position the arm of the electro-valve (2), allowi ng the correct assembling of the cover and avoiding dangerous over rotations at the starting of the

motor.

Once the cover is put on the assembling seat and the relative screws are pointed on the injection pump, rotate the joint tool (I) and then pull it carefully from underneath the cover (3), making sure not to move or damage its sealing . Then tighten the screws with a 4,0 ÷ 5,1 Nm tightening torque, making sure not to damage the connection earthed element of the electro-valve end.

NOTE

Figure 163

A blue seal is included in the kit and it has to be positioned on the screw (I), after the cover reassembling operations (2): when new, the seal is not blue.

116998

In case the original electro-valve should be replaced and its characteristics modified (different voltage, ETR instead of ETSO, eco), it is n ec essary the application of an identification tag (I) in the indicated place. The t ag must be stamped (I) as shown in details in the figure.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Figure 164

116989

In some cases the tag may already be present. If the tag is already present, it is necessary to strikethrough the old identification elements and stamping the new ones, as shown in t h e example in th e figure.

The elec tro-valve and the solenoid valve throttle on the same injection pump, must have the same operating voltage, so in case of a chan ge in the motor’s operating voltage, both must be replaced.

Figure 166

116991

Insert the connection cable socket (I) in the cable group end and screw the nut (I, Figure 16) tightening it to a 5, 7 ÷ 6,8 Nm torque. Position the socket clamp (2, Figure 16) and screw the fixing nut tightening it to a 7, 9 ÷ 9, 0 Nm torque. Position the magnet in its seat and screw the self-blocking fixing nut, supplied with the replacement kit, tightening it to a5,1÷5,7Nmtorque.

Replacement of the solenoid valve throttle

Figure 165

Disconnect the linkage connector from the temperature sensor on the motor, and then remove the fixing nut of the socket clamp (2) and the nut (I) of the cable group end, so to release the electrical lead assembly of the solenoid valve throttle. Remove the fixing nut (3) from the magnet and remove the component from its seat.

116990

NOTE

The operating voltage of the device is easy to find looking at the colors of th e supply wires of the solenoid:

- BLACK: for the I2V device

- RED: for the 24V device

The elec tro-valve and the solenoid valve throttle on the same injection pump, must have the same operating voltage, so in case of a chan ge in the motor’s operating voltage, both must be replaced.

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION

Feed system bleed procedure

Figure 167

- Disconnectthefuelpipe(1)ofthefilterandrepeat

working on the drain lever (2) of the priming pump.

- Continue the operation until when fuel outflows.

- Connect the (1) to the filter.

129269

Checks and controls

NOTE

- There is no water bleeding from the manifolds

- Carefully check the fuel conn ec t ion pipes to the

- There is no oil leakage from the lubricat ion circ uit of th e

- Th ere is no fuel leakage from fuel pipelines.

- There is no blow-by from pneumatic pipes (if provided).

- Verify correct working of the lighting leds of the

- Check and blow by with care the engine cooling system,

The following tests sh all be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.

Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:

connecting engine cooling circu it pipelines and cabin internal heating, eventually providing to further tighten the locking rings.

respective unions.

various pipelines connecting cover and cylin der head, oil pan and bearing, oil filter and heat exchanger as well as relating housings.

dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection.

carrying out frequent drainage.

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

G-Drive EU/2002/88/CE N SERIES

SECTION 3 - G-DRIVE APPLICATION 63

PART TWO -

ELECTRICAL EQUIPMENT

Print P4D32N002 E Base - November 2008

SECTION 3 - G-DRIVE APPLICATION

G-Drive EU/2002/88/CE N SERIES

Base - November 2008 Print P4D32N002 E

Iveco N Engine Workshop Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

G-DRIVE application

N SERIES G -Drive EU/2002/88/CE

Introduction

PREFACE TO USER’S GUIDELINE MANUAL

SYMBOLS - Warnings

Service operations

GENERAL WARNINGS

GENERALWARNINGS ON THE ELECTRIC SYSTEM

Bonding and screening

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Part 1 F4GE N SERIES

UPDATING

SECTION 1 - GENERAL SPECIFICATIONS 1

General Specifications

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

LUBRICATION

OIL VAPOUR RECIRCULATING SYSTEM

COOLING SYSTEM

Version with turbocharger (4 cylinders)

Description

Inter-cooled engine version

Description

SECTION 2 - FUEL 1

Fuel

Description of working principles

FEED PUMP

Description of operation

PRIMING PUMP

FUEL FILTER

SECTION 3 - G-DRIVE APPLICATION

G-DRIVE Application

GENERAL INFORMATION

GENERAL SPECIFICATIONS

4-cylinder engines

6-cylinder engines

ENGINE OVERHAUL

Preface

Removing engine from radiator

Engine setting operations for the assembly on turning stand

Disassembly of application components

STANADYNE ”D” Series Pump

Installation of rear components

Flywheel installation

Installation of front components

Completion of engine re-assembly

Refitting engine to radiator

Rotary feed pump disassembly and assembly procedure

Disassembly

Rotary feed pump setting check

Assembly

ASSEMBLY PROCEDURE OF THE ”ADC100” ELECTRONIC ACTIVATOR ON STANADYNE SERIES ”D” INJECTION PUMPS

Assembly of the actuator

PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS WITH STANADYNE PUMP

Passage from 50 Hz to 60 Hz

Passage from 60 Hz to 50 Hz

Stabilization of the rotation regime

Identification tag

REPLACEMENT OF THE ELECTRO-VALVE AND THE SOLENOID VALVE THROTTLE ON STANADYNE PUMPS

Electro-valve replacement

Replacement of the solenoid valve throttle

Feed system bleed procedure

Checks and controls