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Make/Model Information:

  • Brand:   Iveco
  • Models included:
    • Iveco-Nef N60ENT-G

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English (EN)
  • Number of pages:   175
  • File size:  ∼ 9.25 MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   ENIV-0036

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CNG NEF SERIES
Vehicle application
N60 ENT G
CNG NEF SERIES
Vehicle application
N60 ENT G
Technical and Repair manual
F4B Engines Part 1
CNG NEF ENGINES
1 CNG NEF ENGINES
Section
General specifications 1
Fuel 2
General overhaul 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the F4B engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four sepa-
rate 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 incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
Installation general prescriptions are reported within the ap-
pendix.
The appendix reports general safety prescriptions to be follo-
wed by all operators whether being in-charge of installation or
maintenance, in order to avoid serious injury.
F4B ENGINES
1 CNG NEF ENGINES
SECTION 1 - GENERAL SPECIFICATIONS 1 CNG NEF ENGINES
SECTION 1
General specifications
CORRESPONDENCE BETWEEN TECHNICAL CODE
AND COMMERCIAL CODE 3 . . . .. . . . . . .. .
LUBRICATION 5 . . .. . . . . . .. . . . . . .. . . . . . .. .
OIL VAPOUR RECIRCULATING SYSTEM 6 . . .. .
COOLING SYSTEM 7 . . . . . .. . . . . . .. . . . . . .. .
AIR INDUCTION BOOST DIAGRAM 8 . . . . . .. .
- Description 8 . . .. . . . . . .. . . . . . .. . . . . . .. . . .
SECTION 2 - FUEL 1 CNG NEF ENGINES
SECTION 2
CHEMICAL COMPOSITION
OF NATURAL GAS (CNG) 3. . . . .. . . . . . .. .
ADVANTAGES OF METHANE GAS UTILIZATION
IN AUTOMOTIVE 3. . . . .. . . . . . .. . . . . . .. .
- Motor advantages of methane gas utilization 4..
- Disadvantages of methane utilization in engines 4
- Torque and power typical curves -
F4BE0641A engines 5. . .. . . . . . .. . . . . . .. . . .
GAS EMISSIONS 6. .. . . . . . .. . . . . . .. . . . . . .. .
- Main pollutants 6. . . . . . .. . . . . . .. . . . . . .. . . .
- Emissions of Iveco CNG engine compared to ETC
cycle emissions - gas of reference: G20 and G25 7
IGNITION AND INJECTION INTEGRATED SYSTEM 8
- Characteristics 8. . . . . . .. . . . . . .. . . . . . .. . . .
- General items 8.. . . . . . .. . . . . . .. . . . . . .. . . .
ELECTRIC INJECTORS 9. . . .. . . . . . .. . . . . . .. .
AIR SUCTION CIRCUIT 10. . .. . . . . . .. . . . . . .. .
- Debimeter(Airflowsensor) 10. . .. . . . . . .. . . .
- Throttle valve body 10. . .. . . . . . .. . . . . . .. . . .
PRESSURE REDUCER 11. . . . .. . . . . . .. . . . . . .. .
STEEL HOSE 14. . . . .. . . . . . .. . . . . . .. . . . . . .. .
OXYGEN SENSOR 15. . . . . . .. . . . . . .. . . . . . .. .
SECTION 3 - USE 1 CNG NEF ENGINES
SECTION 3
GENERAL SPECIFICATIONS 3. . . . . .. . . . . . .. .
GENERAL PROPERTIES 4. . .. . . . . . .. . . . . . .. .
PART ONE - MECHANICAL COMPONENTS 5.
ENGINE OVERHAUL 7. . . . .. . . . . . .. . . . . . .. .
- Preface 7. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Engine disassembly on the stand 7. . . . . . .. . . .
- Cylinder head removal 10.. . . . . . .. . . . . . .. . . .
- Installation of components 15. . . . .. . . . . . .. . . .
- Timing 15. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Mounting the flywheel housing 16. .. . . . . . .. . . .
- Engine flywheel 17. . . . . . .. . . . . . .. . . . . . .. . . .
- Mounting the cylinder head 22. . . .. . . . . . .. . . .
- Completion of the engine 26. . . . .. . . . . . .. . . .
- Checks and inspections 29. . . . . . .. . . . . . .. . . .
PART TWO - ELECTRICAL EQUIPMENT 31. .. .
GENERAL ITEMS 33. .. . . . . . .. . . . . . .. . . . . . .. .
MF3 IGNITION AND INJECTION
INTEGRATED SYSTEM 34.. . . . . . .. . . . . . .. .
- MF3 system characteristics 34. . . . .. . . . . . .. . . .
- Injection management 34.. . . . . . .. . . . . . .. . . .
- Fuel cutoff in release step 35. . . . . .. . . . . . .. . . .
- Combustion control by Lambda Probe 35. .. . . .
- System self-adaptation 35.. . . . . . .. . . . . . .. . . .
- Startup management 36. .. . . . . . .. . . . . . .. . . .
- Engine rotation speed management 36. . . . .. . . .
- Ignition management 37. .. . . . . . .. . . . . . .. . . .
- Additional loads management 37. .. . . . . . .. . . .
- Turboblower regulation 37. . . . . . .. . . . . . .. . . .
- Connection to vehicle through CAN line
(to gearbox and dashboard central units) 38
2 SECTION 3 - USE CNG NEF ENGINES
- Acceleration deactivation (option) 38. . . .. . . . . .
VEHICLE FUNCTIONS APPLIED BY CONTROL
UNIT MF3 39. . .. . . . . . .. . . . . . .. . . . . . .. . . . .
MF3 CONTROL UNIT INSTALLATION 40. .. . . . .
MF3 CONTROL UNIT WIRING DIAGRAM
(FIRST PART) 41. . . . . . .. . . . . . .. . . . . . .. . . . .
MF3 CONTROL UNIT WIRING DIAGRAM
(SECOND PART) 42. . . .. . . . . . .. . . . . . .. . . . .
KEY 43. . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .
PIN OUT MF3 44. .. . . . . . .. . . . . . .. . . . . . .. . . . .
COMPONENTS 47. . . . . . .. . . . . . .. . . . . . .. . . . .
- Electric injectors 47. . . .. . . . . . .. . . . . . .. . . . . .
- Air suction circuit 48. . .. . . . . . .. . . . . . .. . . . . .
- Debimeter (Air flow sensor) 48.. . . . . . .. . . . . .
- Throttle valve body 49.. . . . . . .. . . . . . .. . . . . .
- Idling actuator 50. . . . .. . . . . . .. . . . . . .. . . . . .
- Fuel cut-off 51.. . . . . . .. . . . . . .. . . . . . .. . . . . .
- Electronic injection (Characteristics) 51. .. . . . . .
- Lambda sensor 52. . . . .. . . . . . .. . . . . . .. . . . . .
- Connections 52. . . . . . .. . . . . . .. . . . . . .. . . . . .
- Air temperature-pressure sensor 53. . . . .. . . . . .
- Engine oil temperature-pressure sensor 53
- Crankshaft sensor 54. .. . . . . . .. . . . . . .. . . . . .
- Timing sensor 54. . . . . .. . . . . . .. . . . . . .. . . . . .
- Wastegate solenoid valve 55. . .. . . . . . .. . . . . .
- TARTARINI META pressure reducer 56.. . . . . .
- Steel hose 59.. . . . . . .. . . . . . .. . . . . . .. . . . . .
- Throttle valve setting at idling 60. . . . . . .. . . . . .
PART THREE - TROUBLESHOOTING 61. .. . . .
PREFACE 63. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .
BLINK-CODE - GENERAL INFORMATION 64
- Detectable failures 64. .. . . . . . .. . . . . . .. . . . . .
- Anomaly warning led 64. . . . . . .. . . . . . .. . . . . .
- Self-diagnosis 65. . . .. . . . . . .. . . . . . .. . . . . . ..
- Recovery (operation with components
subjected to failure) 65. . . . . .. . . . . . .. . . . . . ..
- VDO EGAS2 Diagnosis System 66. . . .. . . . . . ..
- Error deleting 66. . . .. . . . . . .. . . . . . .. . . . . . ..
TROUBLESHOOTING BY MEANS
OF BLINK-CODES 67.. . . . . . .. . . . . . .. . . . . . .
- MF3 Diagnosis 67. . .. . . . . . .. . . . . . .. . . . . . ..
VDO DIAGNOSIS 72. . .. . . . . . .. . . . . . .. . . . . . .
- Blink-code reading 72. . . . . . .. . . . . . .. . . . . . ..
- Clearing the error memory 72. . . . . . .. . . . . . ..
- VDO EGAS2 system diagnosis 73. . . .. . . . . . ..
TROUBLESHOOTING BY SYMPTOMS 74.. . . . . . .
PART FOUR - MAINTENANCE PLANNING 81..
MAINTENANCE PLANNING 83.. . . . . . .. . . . . . .
- Recovery 83. . . . . . .. . . . . . .. . . . . . .. . . . . . ..
- Planning of controls and periodical intervention 83
- Checks not included in maintenance
planning-daily checks 84. . . . .. . . . . . .. . . . . . ..
MAINTENANCE PROCEDURES 84. . . . . .. . . . . . .
- Checks and controls 84. . . . .. . . . . . .. . . . . . ..
- Engine oil level check. 84. . . . . . .. . . . . . .. .
- Check of fuel system 85.. . . . . . .. . . . . . .. .
- Cooling system check 85. . . . . . .. . . . . . .. .
- Lubricating system check 85. . . . .. . . . . . .. .
- Checking/replacing the blow-by filter 85. . .. .
- Check of drive belt tensioning 86.. . . . . . .. .
- Check of belt’s tear and wear status 86. . .. .
- Check and setting of tappet clearance 86. .. .
- Changing the engine oil and oil filter 87. . .. .
- Filter replacement procedure 87.. . . . . . .. .
- Alternator belt - water pump replacement 88
SECTION 4 - GENERAL OVERHAUL 1 CNG NEF ENGINES
SECTION 4
General overhaul
GENERAL SPECIFICATIONS 3. . . . . .. . . . . . .. .
CLEARANCE DATA 4. . . . . .. . . . . . .. . . . . . .. .
ENGINE OVERHAUL 10. . . . .. . . . . . .. . . . . . .. .
ENGINE REMOVAL AT THE BENCH 10. . . . . .. .
REPAIR INTERVENTIONS 11.. . . . . . .. . . . . . .. .
CYLINDER GROUP 11. . . . . .. . . . . . .. . . . . . .. .
- Controls and measurements 11. . .. . . . . . .. . . .
- Head face check on the cylinder group 13. .. . . .
TIMING SYSTEM 13. .. . . . . . .. . . . . . .. . . . . . .. .
- Camshaft 13. . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Cam lift check and pin alignment check 14. .. . . .
BUSHES 14. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .
- Bush replacement 15. . . . .. . . . . . .. . . . . . .. . . .
- Tappets 15. . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Fitting tappets - camshaft 15. . . . . .. . . . . . .. . . .
OUTPUT SHAFT 16. .. . . . . . .. . . . . . .. . . . . . .. .
- Measuring journals and crankpins 16. . . . . . .. . . .
- Replacing oil pump control gear 19.. . . . . . .. . . .
- Fitting main bearings 19. . .. . . . . . .. . . . . . .. . . .
- Finding journal clearance 19. . . . . .. . . . . . .. . . .
- Checking output shaft shoulder clearance 20
CONNECTING ROD - PISTON ASSEMBLY 21. ..
- Pistons 22. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .
- Measuring piston diameter 22. . . . .. . . . . . .. . . .
2 SECTION 4 - GENERAL OVERHAUL CNG NEF ENGINES
- Piston pins 22.. . . . . . .. . . . . . .. . . . . . .. . . . . .
- Conditions for proper pin-piston coupling 22
- Split rings 22. .. . . . . . .. . . . . . .. . . . . . .. . . . . .
- Connecting rods 23. . .. . . . . . .. . . . . . .. . . . . .
- Bushes 24. . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .
- Checking connecting rods 24. . .. . . . . . .. . . . . .
- Checking torsion 25. . .. . . . . . .. . . . . . .. . . . . .
- Checking bending 25. . .. . . . . . .. . . . . . .. . . . . .
- Fitting connecting rod-piston assembly 25.. . . . . .
- Connecting rod-piston coupling 25. . . . . .. . . . . .
- Fitting split rings 26. . . .. . . . . . .. . . . . . .. . . . . .
- Fitting connecting rod-piston assembly
into cylinder barrels 27.. . . . . . .. . . . . . .. . . . . .
- Finding crankpin clearance 27. . .. . . . . . .. . . . . .
- Checking piston protrusion 28. . . . . . .. . . . . . ..
CYLINDER HEAD 29. . . .. . . . . . .. . . . . . .. . . . . . .
- Removing the valves 29. . . . .. . . . . . .. . . . . . ..
- Checking the cylinder head supporting surface 29
- Checking the cylinder head water seal 30. . . . . ..
VALVES 30. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .
- Valve descaling, check and grinding 30.. . . . . . ..
- Checking the play between the valve stem,
valve guide and valve centring 31. . . . .. . . . . . ..
VALVE GUIDE 31. . . . . . .. . . . . . .. . . . . . .. . . . . . .
VALVE SEATS 31. . . . . . .. . . . . . .. . . . . . .. . . . . . .
- Valve seat reconditioning - replacement 31. . . ..
VALVE SPRINGS 33. . . . .. . . . . . .. . . . . . .. . . . . . .
TIGHTENING TORQUES 34. . . .. . . . . . .. . . . . . .
SECTION 5 - TOOLS 1 CNG NEF ENGINES
SECTION 5
TOOLS 3. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .
APPENDIX 1 CNG NEF ENGINES
Appendix
SAFETY PRESCRIPTIONS 3. .. . . . . . .. . . . . . .. .
- Standard safety prescriptions 3. . .. . . . . . .. . . .
- Prevention of injury 3. . .. . . . . . .. . . . . . .. . . .
- During maintenance 3. . .. . . . . . .. . . . . . .. . . .
- Respect of the Environment 4. . . .. . . . . . .. . . .


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