F4HFE413-6132 A 6139

SERIES NEF TIER 4i
Industrial application
N45
N45 ENT
N67
N67 ENT
Technical and Repair manual

This publication provides unit and relevant component repair
data, specifications, instructions and methodologies.
This publication has been drawn up for qualified and

specialised personnel.
Before performing any operation check that the part relevant

to the unit on which you must work is available along with all
safety devices for accident-prevention, such as, goggles,
helmet, gloves, shoes, etc. and hoisting and transporting
equipment.
Operations are to be performed by following the indications

included here, using the special equipment indicated and
assuring proper repair, compliance with schedule and
operators safety requirements.
Each repair must aim to restore operating efficiency and safety

in compliance with the FPT provisions.
FPT cannot be held liable for modifications, alterations or other

interventions non authorised by FPT on the vehicle and if the
unit is warranted the above mentioned interventions will cause
its expiration.
FPT is not liable for repairing interventions.
FPT will provide further details required to carry out the

interventions and all the instructions that are not included on
this publication.
Data included in this publication may not be up-to-date

therefore subject to Manufacturers modifications that can be
added at any time for technical or commercial purposes and
also to meet new law regulations in other Countries.
If issues on this publication differ from what is actually noticed

on the unit, please get in touch with the FPT network before
starting any intervention.
It is forbidden to copy this text or any of its parts and all

illustrations included.
Publication edited by
FPT Industrial S.p.A.
Via Puglia, 15
10156 Torino
(Italia)
Print P2D32N019 E - 2nd Ed. 03.2012
1st Updating 09.2012
SERIES NEF TIER 4i 1
SERIES NEF TIER 4i
F4HFE engines Part 1
Print P2D32N019 E Base - March 2012

2 SERIES NEF TIER 4i
Base - March 2012 Print P2D32N019 E

SERIES NEF TIER 4i INTRODUCTION 1
Introduction
Page
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . 7
- Bonding and screening . . . . . . . . . . . . . . . . . . . 8
OPTIONAL ELECTRICAL AND MECHANICAL

PARTS INSTALLATIONS . . . . . . . . . . . . . . . . 9
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

2 INTRODUCTION SERIES NEF TIER 4i

PREFACE
Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reat-
taching 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 assemblys elec-
tronic 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 engines illustrating its features and working in general.
Section 2 describes the fuel supply type and engine operation.
Section 3 is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the
basis of their specific use.
Section 4 describes scheduled maintenance and specific overhauling.
Section 5 describes troubleshooting for those who require simple and direct indications in order to locate the cause of the faults
while performing technical assistance.
Section 6 deals with removal and refitting of the main engine components.
Section 7 describes general mechanical servicing of the engine on the revolving stand.
Section 8 gives engine technical characteristics such as data, installation clearances and tightening torques.
Section 9 is about the tools necessary for performing these 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

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may some-
times cause the warranty to become null and void.
General danger
! It includes 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.
NOTE It indicates an additional explanation for a piece of information.
Service operations
Example
1 1 = Seat of small end bush

Close applying the required torque
Close applying the required torque + angular
2 = Seat of connecting rod bearings.
value
2

Removal
Disconnection Intake
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Number of revolutions
Fitting position check
Measurement
Value to find Temperature
Check
Equipment Pressure
bar
Oversized
Surface for machining
Higher than.
Machine finish
Maximum, peak
Undersized
Interference
Less than.
Strained assembly
Minimum
Selection
Thickness
Classes
Clearance
Oversizing
Lubrication Temperature < 0 C
Damp Cold
Grease Winter
Temperature > 0 C
Sealant
Hot
Adhesive
Summer
Air bleeding Preload

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 toolings according to the prescriptions contained in respective use and mainten-
ance 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 taken out from acci-
dentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dan-
gerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
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 have been actuated in the 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 to what contained on harmful
materials 16-point cards. Refuelling 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.

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 direct contact 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 nuts 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 avail-
able to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- 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 of all liquids and fluids must be performed with full observance of specific rules in force.

GENERAL WARNINGS 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 cause 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 drive electronic 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 the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
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 units (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 struc-
ture.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.

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 centering 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 central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding serial or chain connections), and to 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, clinching 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 chassis/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

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling
directives issued by FPT.
It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in
order to simplify and normalise the electrical intervention that is care of preparation personnel.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
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
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
Type of Section Page

vehicle title number
Basic edition referred to When month - year update

Printout Language month - year editorial
number Publication is present (revi) to the basic
phase closing edition

F4HFE ENGINES 1
Part 1
F4HFE ENGINES
Section
General specifications 1
Operational diagrams 2
Electrical equipment 3
Scheduled maintenance 4
Diagnostics 5
Removal - refitting of main components 6
General mechanical overhauling 7
Technical specifications 8
Tools 9
Safety prescriptions Appendix

2 F4HFE ENGINES

F4HFE ENGINES 3
UPDATING
Section Description Page Date of revision
7 General mechanical 42 Revi - September 2012

overhauling

Revi - September 2012
4 F4HFE ENGINES

F4HFE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL CODE

AND COMMERCIAL CODE . . . . . . . . . . . . . 3
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Engines F4HFE413A - F4HFE413D - F4HFE413L -

F4HFE413M . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Engines F4HFE6133 - F4HFE6134 - F4HFE613H 7
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Engines F4HFE6135 - F4HFE6136 -

F4HFE613C*A004 - F4HFE613L*A003 . . . . . 10
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Engines F4HFE6132 - F4HFE6139 - F4HFE613A -

F4HFE613C*A002/3 - F4HFE613L*A001/2 . . 13
GENERAL CHARACTERISTICS . . . . . . . . . . . . . 16
- 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 16
- 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . 18

2 SECTION 1 - GENERAL SPECIFICATIONS F4HFE ENGINES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code Commercial Code

F4HFE413L*A002
F4HFE413A*A003
N45 ENT
F4HFE413D*A003
F4HFE413M*A003
F4HFE6132*A002
F4HFE6133*A001
F4HFE6133*A002
F4HFE6134*A001
F4HFE6135*A001
F4HFE6136*A001
F4HFE6139*A001
F4HFE6139*A002
F4HFE613A*A001 N67 ENT
F4HFE613A*A002
F4HFE613C*A002
F4HFE613C*A003
F4HFE613C*A004
F4HFE613H*A005
F4HFE613L*A001
F4HFE613L*A002
F4HFE613L*A003

ENGINE VIEWS
Engines F4HFE413A - F4HFE413D - F4HFE413L - F4HFE413M
Figure 1
166691
LEFT-HAND SIDE VIEW
Figure 2
166692
RIGHT-HAND SIDE VIEW

Figure 3
166693
FRONT VIEW
Figure 4
166694
REAR VIEW

Figure 5
166695
TOP VIEW
Figure 6
166696
PERSPECTIVE VIEW

ENGINE VIEWS
Engines F4HFE6133 - F4HFE6134 - F4HFE613H
Figure 7
165359
LEFT-HAND SIDE VIEW
Figure 8
165362

Figure 9
165360
FRONT VIEW
Figure 10
165358
REAR VIEW

Figure 11
165361
TOP VIEW
Figure 12
166097
PERSPECTIVE VIEW

ENGINE VIEWS
Engines F4HFE6135 - F4HFE6136 - F4HFE613C*A004 - F4HFE613L*A003
Figure 13
165364
LEFT-HAND SIDE VIEW
Figure 14
165367

Figure 15
165365
FRONT VIEW
Figure 16
165363
REAR VIEW

Figure 17
165366
TOP VIEW
Figure 18
166098
PERSPECTIVE VIEW

ENGINE VIEWS
Engines F4HFE6132 - F4HFE6139 - F4HFE613A - F4HFE613C*A002/3 - F4HFE613L*A001/2
Figure 19
165369
LEFT-HAND SIDE VIEW
Figure 20
165372

Figure 21
165370
FRONT VIEW
Figure 22
165368
REAR VIEW
Figure 23
165371
TOP VIEW
Figure 24
162249
PERSPECTIVE VIEW
GENERAL CHARACTERISTICS
4-cylinder engines
Type F4HFE413L*A002 F4HFE413A*A003
Compression ratio 17 : 1
Maximum power kW 125 110
(hp) (170) (150)
rpm 2200 2200
Maximum torque Nm 700 676

(kgm) (71) (69)
rpm 1500 1500
Idle speed rpm

800
Maximum engine
speed rpm 2375
Bore x stroke 104 x 132
Total displacement cm3 4485

TURBOCHARGING With intercooler
Turbocharger type GARRETT

Forced by gear pump,
LUBRICATION
pressure relief valve, oil filter
Oil pressure with engine hot:
bar
- at idle speed bar 0.7

- at maximum speed bar 3.5
COOLING Liquid cooled
Coolant pump control Belt driven
Thermostat:
- start of opening C 79 2
- max. opening C 95
FILLING
- engine sump litres 11.5
15W40 ACEA E7/API CI-4 - engine sump
10W30 ACEA E7/API CI-4* + filter litres 14.4
10W40 ACEA E9/API CJ-4**
* For ambient temperature < -15 C

** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.
Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

Type F4HFE413D*A003 F4HFE413M*A003
(HP) (121) (102)
rpm 2200 2200

(kgm) (56) (48)
rpm 1500 1400
Idle speed rpm

800
Maximum engine
speed rpm 2375

Turbocharger type GARRETTT

LUBRICATION
bar
Thermostat:
- max. opening C 95
FILLING
15W40 ACEA E7/API CI-4
10W30 ACEA E7/API CI-4* - engine sump + filter litres 14.4

** Alternatively

6-cylinder engines
F4HFE6133*A001 F4HFE6134*A001
Type
F4HFE6133*A002 F4HFE613H*A005
(hp) (286) (247)
rpm 2200 2200

(kgm) (116) (114)
rpm 1500 1500
Idle speed rpm 850

Maximum engine
speed rpm 2375

Turbocharger type CCM HOLSET HX35W

LUBRICATION
bar

Thermostat:
- max. opening C 95
FILLING
15W40 ACEA E7/API CI-4 - engine sump
10W30 ACEA E7/API CI-4* + filter litres 17.2

** Alternatively

F4HFE6135*A001 F4HFE6136*A001
Type
F4HFE613L*A003 F4HFE613C*A004
(HP) (206) (176)
rpm 2200 2200

(kgm) (98) (83)
rpm 1500 1500
Idle speed rpm 850

Maximum engine
speed rpm 2375

Turbocharger type WLO HOLSET HX35

LUBRICATION
bar
Thermostat:
- max. opening C 95
FILLING

** Alternatively

F4HFE6139*A001
Type F4HFE6132*A002
F4HFE6139*A002
(HP) (166) (221)
rpm 2200 2200

(kgm) (74) (98)
rpm 1500 1500
Idle speed rpm 850
Maximum engine speed rpm 2375


Turbocharger type CEX HOLSET HX35

LUBRICATION
bar
Thermostat:
- max. opening C 95
FILLING
Total capacity

** Alternatively

F4HFE613C*A002 F4HFE613A*A001 F4HFE613L*A001

Type
F4HFE613C*A003 F4HFE613A*A002 F4HFE613L*A002
Maximum power kW 129 140 151
(HP) (176) (191) (206)
rpm 2200 2200 2200
Maximum torque Nm 810 866 960

(kgm) (83) (88) (98)
rpm 1500 1500 1500
Idle speed rpm 850
Maximum engine speed rpm 2375


Turbocharger type CEX HOLSET HX35

LUBRICATION
bar
Thermostat:
- max. opening C 95
FILLING

** Alternatively


F4HFE ENGINES SECTION 2 - OPERATIONAL DIAGRAMS 1
SECTION 2
Operational diagrams
Page
HIGH PRESSURE ELECTRONIC INJECTION FUEL

SYSTEM (COMMON RAIL) . . . . . . . . . . . . . . 3
- General Specifications . . . . . . . . . . . . . . . . . . . 3
ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
- Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- System functionality . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 5
- Fuel system layout . . . . . . . . . . . . . . . . . . . . . . 7
FUEL SUPPLY SYSTEM COMPONENTS . . . . . . 8
- Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Mechanical supply pump . . . . . . . . . . . . . . . . . 9
- CP3 high-pressure pump . . . . . . . . . . . . . . . . . 10
- Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 14
- Electro-injector . . . . . . . . . . . . . . . . . . . . . . . . 15
- Pressure limiter for fuel return . . . . . . . . . . . . . 16
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- 4-cylinder engine version . . . . . . . . . . . . . . . . . 17
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 19
- Oil pressure relief valve . . . . . . . . . . . . . . . . . . 21
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . . 22
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 23
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 SECTION 2 - OPERATIONAL DIAGRAMS F4HFE ENGINES
Page
TURBOCHARGING SYSTEM . . . . . . . . . . . . . . . 26
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- 4-cylinder engine version . . . . . . . . . . . . . . . . 26
- 6-cylinder engine version . . . . . . . . . . . . . . . . 26
- Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . 27
- Waste gate (only for F4HFE413A/3D/3L/3M -

F4HFE6133/34/3H engines) . . . . . . . . . . . . . 28
DeNOx 2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 29
- General Information . . . . . . . . . . . . . . . . . . . 29
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Ad Blue fluid level gauge control . . . . . . . . . . 31
- Pump module . . . . . . . . . . . . . . . . . . . . . . . . 31
- Dosing module . . . . . . . . . . . . . . . . . . . . . . . 31
- SCR pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Exhaust gas temperature sensor . . . . . . . . . . 32
- Humidity detecting sensor . . . . . . . . . . . . . . . 33
- Nitric oxide sensor . . . . . . . . . . . . . . . . . . . . 34
- Pin out DCU 15 D2-2 . . . . . . . . . . . . . . . . . . 35
- Scheduled Maintenance . . . . . . . . . . . . . . . . . 38
- DEF/AdBlue circuit filters (dosing system

DeNOx 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 38

HIGH PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL)

General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
ELECTRIC SYSTEM
Figure 1
107246
1. Injectors connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Crankshaft sensor - 6. EDC7UC31 control unit - 7. Fuel flow rate regulator - 8. Fuel heater and fuel
temperature sensor - 9. Camshaft sensor - 10. Air pressure/temperature sensor - 11. Injector.
Sensors The outlet tension is proportional to the pressure or tem-

Through the sensors, present on the engine, the ECU con- perature obtained by the sensor.
trols the engine operation.
Engine oil temperature and pressure sensor
Air pressure/temperature sensor Same as air pressure/temperature sensor, it is fitted on the
It is a component integrating a temperature sensor and a engine oil filter, in a horizontal position.
pressure sensor. It measures engine oil temperature and pressure.
Fitted on the intake manifold, it measures the max. inlet air
capacity to calculate precisely the fuel quantity to inject at
every cycle.

Fuel pressure sensor Injection control

Assembled on a rail end, it measures the fuel pressure in the The control unit, depending on information coming from
rail in order to determine the injection pressure. sensors, controls the flow rate regulator, and changes pre-in-
jection and main injection modes.
The injection pressure value is used to control the pressure
and to determine the electric injection control length. Closed-loop control for injection pressure
Fuel temperature sensor Depending on engine load, measured by processing signals
coming from various sensors, the control unit controls the
It is a sensor that is equal to the previous one.
regulator in order to always have the optimum pressure.
It measures fuel temperature to provide the control unit with
Pilot and main injection spark advance control
an index of the diesel fuel thermal state.
The control unit, depending on signals coming from various
Coolant temperature sensor sensors, computes the optimum injection point according to
It is a variable-resistance sensor suitable to measure the cool- an internal mapping.
ant temperature to provide the control unit with an index of Idle speed control
the engine thermal state.
The control unit processes signals coming from various sen-
Crankshaft sensor sors and adjusts the amount of injected fuel.
It controls the pressure regulator and changes the injection
It is an inductive sensor placed on the front engine part. Sig- time of injectors.
nals generated through the magnetic flow that is closed on Within certain thresholds, it also takes into account the bat-
the phonic wheel, change their frequencies depending on
tery voltage.
output shaft rotation speed.
Maximum speed limiting
Timing sensor Approaching the peak rpm, the ECU limits the fuel flow by
It is an inductive sensor placed on the engine rear left part. reducing the opening time of the electro-injectors.
It generates signals obtained from magnetic flow lines that are The peak rpm of the engines is 2375 revs/min. Above this rate
closed through holes obtained on the keyed gear on the cam- the ECU deactivates the electro-injectors.
shaft. The signal generated by this sensor is used by the ECU
as injection phase signal. Cut Off
Fuel cut off upon release is controlled by the control unit per-
Though being equal to the flywheel sensor, it is NOT inter-
forming the following logics:
changeable since it has a different outside shape.
- it cuts off injectors supply;
System functionality - it re-activates the injectors shortly before idle speed is re-
ached;
Self-diagnosis - it controls fuel flow rate regulator.
The ECU self-diagnostic system checks signals coming from
sensors by comparing them with threshold data. Smoke control upon acceleration
With strong load requests, the control unit, depending on sig-
Engine pre-heating resistance check nals received by air inlet meter and engine speed sensor, con-
The pre-post heating is activated when even only one of the trols the flow rate regulator and changes the injectors actua-
water, air or fuel temperature sensors signals a temperature tion time, in order to avoid exhaust smokes.
that is less than 5 C.
Fuel temperature control
Timing recognition When the fuel temperature exceeds 78 C (measured by the
By means of signals coming from camshaft sensor and fly- sensor placed on fuel filter) the control unit intervenes by re-
wheel sensor, the cylinder on which fuel must be injected is ducing injection pressure.
recognised upon startup. If the temperature exceeds 90 C, the power is reduced to
60%.
After Run
The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the fol-
lowing startup.

HYDRAULIC SYSTEM
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
Figure 2 (D)(*) (Demonstration)
High Pressure
Low Pressure
Fuel outlet
166061
(D) F4HFE413A/3D/3L/3M
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump -
6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.

The low-pressure circuit is composed of the following pipings:

- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
Figure 3 (**)
High Pressure
Low Pressure
Fuel outlet
166062
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump -
6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.

Fuel system layout The pressure relief valve (2) intervention brings about a fuel
The flow rate regulator (15), placed upstream of the high- flow increase in the high-pressure pump cooling circuit,
pressure pump, adjusts the fuel flow that is necessary on the through inlet and drain piping (16) from piping (8).
low-pressure system. Afterwards, the high-pressure pump The pressure relief valve housed on the cylinder head, as-
takes care of supplying the rail properly. This arrangement, by sembled on injector return (3), limits the fuel return flow
pressurising the necessary fuel only, improves the energetic from injectors at a pressure of 1.3 to 2 bars.
efficiency and limits fuel heating in the system.
Two by-pass valves are placed in parallel with the mechanical
Function of the pressure relief valve (2), assembled on the supply pump.
high-pressure pump, is keeping the pressure, at the flow rate
regulator inlet, constant at 5 bars, independently from the The by-pass valve (18) allows fuel to flow from mechanical
efficiency of the fuel filter and of the system set upstream. pump outlet to its inlet, when the fuel filter inlet pressure ex-
ceeds the allowed threshold value.
The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
Figure 4
EXHAUST
INTAKE (LOW PRESSURE)
HIGH-PRESSURE PUMP SUPPLY

(LOW PRESSURE)
HIGH PRESSURE
108608
1. High-pressure pump - 2. Pressure relief valve on high-pressure pump, 5 bars - 3. Pressure relief valve assembled on fuel
return from injectors, 1.3 to 2 bars - 4. Rail overpressure valve - 5. Common Rail - 6. Pressure sensor - 7. Injector -
8. Return piping - 9. Control unit heat exchanger - 10. Mechanical priming pump - 11. Prefilter assembled on chassis -
12. Fuel tank - 13. Mechanical supply pump - 14. Fuel filter - 15. Flow rate regulator -
16. High-pressure pump cooling piping - 17. By-pass valve - 18. By-pass valve.

FUEL SUPPLY SYSTEM COMPONENTS Figure 6 (D)(*)

Fuel prefilter
Figure 5
99231
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 7 (**)
70494
The fuel filter is of the high water separation type, is as-

sembled on the vehicle chassis, and has the sensor (4) for de-
tecting water in fuel placed on the cartridge (3) base.
Manual priming pump (5) and air bleeding screw (2) from sys-
tem are located on filter support.
The presence of condensate into filter is signalled by sensor
(4) when a warning light on the instrument panel is lit.
If the warning light is on, it is necessary to im-

mediately operate to remove its cause; the com-
mon rail system components are quickly damaged
by the presence of water or impurities in the fuel.
Fuel filter 166063

It is located on engine block in the circuit between feed pump (**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
and high pressure pump (CP3).
1. Fuel filter support - 2. Fuel temperature sensor -
On the support there are located: fuel temperature sensor 3. Electric fuel heater - 4. Fuel filter - 5. Adapter -
and heater resistances. 6. Heater connector - 7. Gasket
Fuel temperature, signalled by relating sensor to EDC7UC31 A. Fitting for fuel drain outlet to tank -
central unit, enables a very accurate calculation of the flow B. Fitting for outlet to high pressure pump -
rate of fuel to be injected into the cylinders. C. Fitting for drain from high pressure pump -
The electric heater is activated when the fuel temperature is D. Fitting for fuel drain inlet from rail -
less than 0 C and deactivated when the fuel temperature E. Fitting for inlet from feed pump
exceeds 5 C.

Mechanical supply pump Bleeding conditions

Feed mechanical pump is a gear pump, mounted on high
Figure 10
pressure pump rear side, having the task of feeding high pres-
sure pump. It is driven by high pressure pump shaft.
Normal operating conditions
Figure 8
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this situ-
72592 ation the by-pass valve (1) stays closed whereas by-pass valve
(2) opens due to inlet pressure, and fuel is drained out
A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass through B.
valves in close position
Overpressure condition at outlet

NOTE The mechanical supply pump cannot be replaced
individually, therefore it cannot be removed from
Figure 9 the high pressure pump.
72593
The by-pass valve (1) cuts in when overpressure is generated

at outlet B. The existing pressure, overcoming valve spring (1)
elastic strength, makes inlet and outlet communicating
through duct (2).

CP3 high-pressure pump

CP3 high pressure pump is a pump with 3 radial plungers which is driven through a timing system gear. High pressure pump
does not require timing. On high pressure pump rear side, feed mechanical pump is mounted, driven by high pressure pump
shaft.
NOTE The following work must be carried out on the feed pump / high-pressure pump assembly:
- replacing the drive gear;
- replacing the fuel flow rate regulator.
Figure 11
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Fuel flow rate regulator - 4. Control gear - 5. Fuel inlet fitting from
filter - 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from
supply pump to filter - 9.Mechanical supply pump

High-pressure pump - inside structure

Figure 12
Sec. B-B
Sec. C-C
70498
1. Cylinder - 2. Three-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft -
7. Low-pressure fuel inlet - 8. Plungers supplying fuel ducts.
Each plunger is made up of:

- one piston (5) driven by a three-lobe element (2) floating on pump shaft (6). Element (2) is floating on a misaligned side
of shaft (6). Therefore, during shaft rotation, the element is not turning together with the shaft, but is just translated, according
to a circular movement, to a wider radius. It results that the three pumping assemblies are driven alternatively;
- one cap intake valve (3);
- one delivery ball valve (4).

Operating principle
Figure 13
Sec. B B
Sec. D D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply duct
- 6. Pressure regulator supply duct - 7. Flow rate regulator.
Plunger (3) is oriented towards the cam that is present on pump shaft (4). During suction stroke, the plunger is fed through feed
duct (5). The quantity of fuel to be sent to the plunger is set by flow rate regulator (7). Flow rate regulator, on the basis of PWM
command received by control unit, partialises fuel inflow to the plunger. During plunger compression stroke, fuel reaches such
a pressure that valve delivering the fuel to common rail (2) is opened and common rail is fed by the plunger through outlet (1).

Figure 14 Figure 15
72601
72598
Sec. C C Sec. A A
1. Plunger inlet - 2. Pump lubrication ducts - 3. Plunger 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet
inlet - 4. Main plunger supply duct - 5. Flow rate from pump with high pressure pipe fitting for common rail.
regulator - 6. Plunger inlet - 7. Regulator exhaust duct -
8. 5 bar pressure relief valve - 9. Fuel drain from regulator
inlet.
Figure 15 shows high pressure fuel flow through plunger

outlet ducts.
Figure 14 shows low pressure fuel paths inside the path and
highlights: main plunger supply duct (4), plunger supply ducts
(1 3 6), pump lubrication ducts (2), flow rate regulator
(5), 5 bar pressure relief valve (8) and fuel drain duct (7).
Replacing the pressure regulator
Pump shaft is lubricated by fuel through delivery and return - Greatest cleanliness must be ensured;
ducts (2).
- avoid letting impurities into the pump pressure channels;
Flow rate regulator (5) establishes the fuel amount to send
to plungers; excess fuel is drained out through duct (9). - replace the O-rings and moisten them with Vaseline;
5 bar pressure relief valve acts as fuel return regulator and - tighten to the specified torque of 8 12 Nm.
keeps 5 bar constant pressure at regulator inlet.

Operation Rail
The cylinder is filled through the cap intake valve only if the Figure 16 (Demonstration)
supply pressure is suitable to open the delivery valves set on
the plungers (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the flow rate regulator, placed on the low-pres-
sure system; the flow rate regulator is controlled by the
EDC7UC31 control unit through a PWM signal.
When fuel is sent to a plunger, the related piston is moving
downwards (suction stroke). When the piston stroke is rev-
ersed, the intake valve closes and the remaining fuel in the
plunger chamber, not being able to come out, is compressed
above the supply pressure value existing in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure cir-
107422
cuit.
The plunger compresses the fuel till the top dead center (de-
livery stroke) is reached. Afterwards, the pressure decreases 1. Rail - 2. Pressure sensor - 3. Fuel inlet from high-pres-
till the exhaust valve is closed. sure pump - 4. Overpressure valve.
The plunger piston goes back towards the bottom dead The rail volume is of reduced sizes to allow a quick pressurisa-
center and the remaining fuel is decompressed. tion at startup, at idle and in case of high flow-rates. It anyway
has enough volume as to minimise use of plenum chambers
When the plunger chamber pressure becomes less than the caused by injectors openings and closings and by the high-
supply pressure, the intake valve is again opened and the pressure pump operation. This function is further enabled by
cycle is repeated. a calibrated hole being set downstream of the high-pressure
pump. A fuel pressure sensor (4) is screwed to the rail. The
The delivery valves must always be free in their movements,
free from impurities and oxidation. signal sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
The pressure of fuel delivered to rail is modulated by elec- value is checked and, if necessary, corrected.
tronic control unit through flow rate regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump removal refitting time on the engine is
highly reduced in comparison with traditional injection
pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
Overpressure valve
be removed-refitted, be sure that hands and components are
absolutely clean. Overpressure valve is mounted at one rail end. Overpressure
valve task is to protect system components should rail pres-
sure sensor or CP3 pump pressure regulator malfunctioning
cause a pressure excessive increase in high pressure system.
When pressure in rail is reaching 1800 bar, the valve at start
operates in order to make fuel flow and consequently de-
crease pressure to safety values, then mechanically regulates
pressure in rail. The valve enables to operate engine for long
times with limited performance and prevents fuel excessive
overheating, so preserving pipes for fuel return to tank.

Electro-injector Injection start

The injector is similar as construction to the traditional ones, Figure 18
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position

Figure 17
15
15
70506
1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot

valve - 6. Ball shutter - 7. Control area - 8. Pressure
chamber - 9. Control volume - 10. Control duct -
11. Supply duct - 12. Control fuel outlet - 13. Electric
connection - 14. Spring - 15. High-pressure fuel inlet.
70505
When coil (4) is energised, it makes shutter (6) move
upwards. The control volume (9) fuel flows towards flow
duct (12) making a pressure drop occur in control volume
1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot (9). Simultaneously the fuel pressure into pressure chamber
valve - 6. Ball shutter - 7. Control area - 8. Pressure (8) makes plunger (2) lift, with following fuel injection into the
chamber - 9. Control volume - 10. Control duct - cylinder.
11. Supply duct - 12. Control fuel outlet - 13. Electric Injection end
connection - 14. Spring - 15. High-pressure fuel inlet.
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
NOTE The injector cannot be overhauled and therefore

it must not be disassembled.

Pressure limiter for fuel return

It is housed on the rear of the cylinder head, and adjusts the
pressure of fuel returning from injectors at a pressure 1.3 and
2 bars. By guaranteeing this pressure to the return fuel, the
fuel vapours formation inside injectors is avoided, optimising
fuel spraying and combustion.
Figure 19
70507
A To tank B From injectors

LUBRICATION Lubrication involves the heat exchanger as well, the turbo-

4-cylinder engine version blower and the eventual compressor for any eventual com-
pressed air system.
Lubrication by forced circulation is achieved through oil ro-
tary expansion pump, placed in the front part of the base- All these components may often vary according to the spe-
ment, driven by the straight-tooth gear splined to the shafts cific duty and will therefore be examined in the specific sec-
bar hold. tion.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Figure 20 (Demonstration)
Oil recover from the

turbo-blower
To the exchanger
and to the
turbo-blower
Routing of oil under pressure 108511
Routing of oil return by gravity to sump

Introduction of oil
LUBRICATION SYSTEM LAYOUT

4-cylinder engines

6-cylinder engine version Also in this case, the components such as the oil exchanger,
Even for the 6 cylinders version lubrication is obtained by the turbo-blower and the eventual compressor are specifi-
forced circulation and achieved through an oil rotary expan- cally studied and made out to suit the equipment or the duty
sion pump similar to the 4 cylinders one. for which the engine has been developed.
Oil recover from the

turbo-blower
To the
exchanger and to
the
turbo-blower
Routing of oil under pressure

108512
Routing of oil return by gravity to sump
Introduction of oil
LUBRICATION SYSTEM LAYOUT

6-cylinder engines

Oil pump Figure 22
NOTE Since the oil pump cannot be overhauled. It shall

be replaced when damaged.
70576
Heat exchanger
Figure 23 (D)(*)
166064
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
1. Heat exchanger body with filter bracket and oil filter - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between
heat exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.

Clean accurately the heat exchanger components

Always replace the sealing gaskets.
Figure 24 (**)
166065
(**)F4HFE6132/39/3A/3C*A002-3/3L*A001-2
1. Heat exchanger body with oil filter - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat exchanger
unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.

Oil pressure relief valve

Figure 25
Loosen the plug (1), withdraw the spring (2) and the relief
valve (3) from the support (4).
Check whether the valve (3) is not scored and is sliding
smoothly into its seat. The spring (2) shall not be broken or
yielded.
Pressure regulation at 100 C oil temperature: 107418
- 1.2 bar min pressure; By-pass valve (5) to cut out clogged oil filter.
- 3.8 bar max. pressure
Figure 26 Figure 27
Flow
70482
107419 Max blow-by:
MAIN DATA TO CHECK OIL PRESSURE RELIEF 20 cm3/1 at 0.83 bar pressure and at 26.7 C oil temperature.
VALVE SPRING

OIL VAPOUR RECYCLING

Figure 28
70484
Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine.

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).

COOLING SYSTEM - Viscous pusher fan, having the duty to increase the heat
4-cylinder engine version dissipating power of the radiator. This component as
The engine cooling system, closed circuit forced circulation well will be specifically equipped based on the engines
type, generally incorporates the following components: development.
- Expansion tank; placement, shape and dimensions are - Heat exchanger to cool the lubrication oil: even this
subject to change according to the engines equipment. component is part of the engines specific equipment.
- Radiator, which has the duty to dissipate the heat - Centrifugal water pump, placed in the front part of the
subtracted to the engine by the cooling liquid. Also this engine block.
component will have specific peculiarities based on the - Thermostat regulating the circulation of the cooling
equipment developed, both for what concerns the liquid.
placement and the dimensions.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.
Expansion tank
Expansion tank
Heater
(optional)
Radiator
Radiator
Water coming out from thermostat
Water recirculating in engine
Water coming into pump

74194
COOLING SYSTEM LAYOUT

4-cylinder engines
6-cylinder engine version

The engine cooling system, closed circuit forced circulation
type, is of a similar design as the 4 cylinders engine.
It incorporates necessary components such as the radiator,
the heat exchanger, the expansion tank and some ancillary
components such as the heater or the compressor for the
compressed air.
Such components always vary according to the engines
equipment and duty.
Expansion tank
Expansion tank
Heater
(optional)
Radiator
Radiator
Water coming out from thermostat
Water recirculating in engine
Water coming into pump

166066
COOLING SYSTEM LAYOUT

6-cylinder engines
Water Pump The water pump is located in a hollow obtained in the cylin-
der block and is driven by and a poly-V belt.
Figure 31
An automatic tensioner keeps the belt tension.
Thermostat
Figure 32
79458
The bypass thermostat (1) is housed in the cylinder head and

needs no adjustment.
Whenever there are doubts as to its condition, replace it.
The thermometric switch/transmitter and coolant tempera-
ture sensor are mounted on the thermostat body.
A = travel start at 77 81 C;
70486
Sec. A-A B = travel at 95 C 7.5 mm

TURBOCHARGER
Description
The turbocharging system is composed of: air filter, turbocharger and intercooler.
The air cleaner is a dry type composed of a filtering cartridge that is periodically changeable.
The function of the turbocharger is to use the energy of the engines exhaust gas to deliver pressurized air to the cylinders.
The intercooler is composed of a radiator applied to the engine coolant radiator, with the function of lowering the turbocharger
output air temperature before it is sent to the cylinders.
Figure 33
AIR FILTRE TURBOCHARGER
EXHAUST
INTERCOOLER
AIR FILTRE TURBOCHARGER
EXHAUST
INTERCOOLER
74195

Turbocharger Figure 36 (**)

Figure 34 (D)
intake air
compressed air intake air
166697
exhaust compressed air
(D) F4HFE413A/3D/3L/3M exhaust 166068
GARRETT TURBOCHARGER (**) F4HFE6135/36/3C*A004/3L*A003

Figure 35 (*) WLO HOLSET HX35 TURBOCHARGER
Figure 37 (***)
intake air intake air

compressed air compressed air
166067
exhaust exhaust 166069
(*) F4HFE6133/34/3H (***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

CCM HOLSET HX35W TURBOCHARGER CEX HOLSET HX35 TURBOCHARGER
The turbocharger is composed of the following main parts:
- a central body in which a shaft is housed, supported by bushings, the ends of which are connected to: the turbine rotor and
the compressor rotor;
- a turbine casing and a compressor casing mounted on the end of the central body;
- a boost-pressure regulation valve (when present) fitted on the turbine casing.
During engine operation, the exhaust gases pass through the turbine body spinning the turbine rotor.
The compressor rotor is connected by a shaft to the turbine rotor, which it spins and in doing so compresses the air taken in
through the air filter.
The air is then cooled by the intercooler and sent to the cylinders via the intake manifold.
The engine oil is used to cool and lubricate the turbocharger and the bearings.
On F4HFE413A/3D/3L/3M and F4HFE6133/34/3H engines, the turbocharger is fitted with a pressure regulation valve, mounted
on the exhaust manifold before the turbine and controlled by a pneumatic actuator, connected via a pipe to the intake manifold.
Its job is to limit the quantity of exhaust gas acting on the turbine by sending part of it directly into the exhaust pipe when the
boost pressure downstream of the compressor reaches the maximum value set.
Apply the magnetic-base dial gauge (2) on the exhaust gas

NOTE Verifying an anomalous operation of the engine, inlet flange in the turbine.
due to the booster system, it is recommended, be-
fore performing controls on the turbosuperchar- Position the tracer point of the gauge (2) on the tie rod (3)
ger, to check the efficiency of the sealing gaskets end and set to zero the gauge (2).
and the fixing of the connection sleeves, making Through the pump (1) let in compressed air, in the actuator
sure of clogging absence inside intake sleeves, air (6), at the prescribed pressure and make sure that such value
cleaner or inside radiators. If the turbosupercharger is kept constant for the whole check time, otherwise replace
damage is due to a lack of lubrication, check that the actuator (6).
the oil circulation pipes are not broken or ob-
structed, in such case replace them or eliminate the In the above-mentioned conditions, the tie rod must have
trouble. carried out the prescribe stroke.
NOTE During the operation, beat slightly the actuator (6)

in order to eliminate possible sticking of the actua-
Bearing end play check tor internal spring.
Position the tracer point of the magnetic-base dial gauge on
the turbocharger shaft end and set to zero the dial gauge.
If a different value is found, loosen the nut (5) and operate
Move the turbocharger shaft axially and check that the clear- properly the knurled ring nut (4).
ance is not higher than the prescribed value.
Replace the turbocharger if a different value is found.
Waste gate (only for F4HFE413A/3D/3L/3M - Actuator replacement

F4HFE6133/34/3H engines)
Figure 39
Check and adjustment

Figure 38
3 2 1
166070
Remove the elastic clip (4) and withdraw the tie rod (3) from
the lever (5).
62873
Remove the nuts (2) and remove the actuator (1) from the
Cover the air, exhaust gas and lubrication oil inlets and supporting bracket. Fit the new actuator following the re-
outlets. moval operations in reverse order and fitting a new clip (4),
tighten the nuts (2) to 5.6 6.8 Nm torque.
Carry out an accurate external cleaning of the turbosuper-
charger, using the anticorrosive and antioxidant solution and Check and adjust the actuator (1), if required, as described
perform the check on the actuator (6). in the relevant chapter.
Clamp the turbosupercharger in a vice. Then, paint the nut (6) with safety paint.
Disconnect the pipe of the actuator (6) and apply to the Before refitting the turbocharger on engine, fill the central
actuator union, the pipe of pump 99367121 (1). body with engine oil.

DeNOx 2 SYSTEM
General Information
To limit the nitrogen oxide exhaust gas values (NOx) within the limits required by Tier 4i, with low fuel consumption, the vehicles
have been equipped with a post-treatment system for these substances contained in the exhaust gas, which is essentially an elec-
tronically controlled oxidative catalyst.
Using the Selective Catalytic Reduction (SCR) process, the system transforms the nitrogen oxide (NOx) into inert compounds:
free nitrogen (N2) and water vapour (H2O).
The SCR process is based on a series of chemical reactions that, due to the reaction of ammonia with the oxygen in the exhaust
gas, lead to the reduction of nitrogen oxides (NOx) contained in the exhaust gas.
The system essentially comprises:
- a tank (5) of reagent solution (water - urea: Ad Blue) with a level indicator;
- a pump module (1);
- a mixing and injection module (6);
- a catalytic converter;
- two temperature sensors (9 and 10) at the exhaust gas inlet and outlet to the catalytic converter;
- a humidity sensor fitted on the engine air intake pipe downstream of the air filter.
The SCR system is electronically managed by the DCU (Dosing Control Unit) incorporated in the pump module (1), which ac-
cording to the number of engine revs, the torque delivered, the exhaust temperature, the amount of nitrogen oxides and humidity
in the incoming air, adjusts the flow rate of the Ad Blue solution to be put into the system.
The pump module (1) picks up the reagent solution from the tank (5) and sends it under pressure to the mixing and injection
module (6) to be injected into the exhaust pipe upstream of the catalytic converter.
The first phase of the process takes part in the first part of the catalytic converter: due to the effect of the exhaust gas temperature,
the reagent solution evaporates instantly and, by hydrolysis, converts into ammonia (2NH3) and carbon dioxide (CO2).
Evaporation of the solution causes lowering of the exhaust gas temperature, bringing it closer to the optimum temperature
required by the process.
The exhaust fumes, additioned with ammonia and at the reaction temperature, are introduced into the catalytic converter, where
the second phase of the process takes place: by reacting with the oxygen in the exhaust gasses the ammonia is converted into
free nitrogen (N2) and water vapour (H2O).

Figure 40
148514
1. Pump module - 2. Tank level sensor - 3. Tank temperature sensor - 4. Ad Blue tank - 5. Prefilter - 6. Return flow valve -
7. Dosing module - 8. MV2 - 9. Exhaust gas temperature sensor - 10. Catalyst - 11. Exhaust gas temperature sensor -
12. NOx detection sensor - 13. Ad Blue pressure sensor - 14. Filter - 15. Diaphgram pump - 16. Reverting valve -
17. Ad Blue temperature sensor

Tank Pump module

Figure 41 Figure 43
108508 148510
The tank with the level indicator command (1) contains the 1. DCU control unit connector - 2. Pressure compensat-
reducing substance necessary for the SCR process, compris- tion - 3. Ad Blue solution infeed - 4. Prefilter - 5. Ad Blue
ing a solution of 35% urea and water, known as Ad Blue. solution outlet - 6. Ad Blue return pipe from dosing
module - 7. Ad Blue l tank return - 8. Filter
Dosing module
Figure 44
Ad Blue fluid level gauge control
Figure 42
108129
1. Ad Blue infeed - 2. Electrical connection -

3. Ad Blue outlet
Has the job of dosing the Ad Blue solution to be sent into
the exhaust pipe upstream of the catalytic converter.
SCR pipes
116181
NOTE The SCR pipe harnesses complete with the VOSS
are only available for production.
1. Ad Blue fluid intake pipe - 2. Ad Blue fluid return pipe - In case of repair operations, for the replacement of
3. Inlet pipe for hot engine coolant fluid - 4. NTC sensor - each component (cooling water pipes, AdBlue
5. Outlet pipe for hot engine coolant fluid - 6. Float - pipes, fittings, corrugated pipes, sectioning plates,
7. AdBlue liquid heating coil (only versions equipped with etc.) refer to the supplied spare accessories.
08277 optional) - 8. AdBlue breather

Exhaust gas temperature sensor

Figure 45
102303
Figure 46
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Earth cable (white) - 6. Sensor.
The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to
calculate the amount of urea to be injected into the system.

Humidity detecting sensor

Figure 47
102311
1. Temperature - 2. Earth - 3. Humidity percent value - 4. Power supply.

This sensor is located on the air filter output conveyor, and is used to inform the control unit of the amount (percentage) of
humidity found in sucked air, to determine the calculation of nitric oxide emissions.
Figure 48
102312
ELECTRIC BLOCK DIAGRAM

1. Earth - 2. Temperature - 3. Power supply unit - 4. Humidity percent value - A. Sample frequency generator -
B. Reference oscillator - C. NTC temperature sensor - D. Amplifier lowpass filter

Nitric oxide sensor
Figure 49
102302
1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare

This sensor has the function to communicate the dosing of AdBlue liquid (Urea) and the catalyst conditions to the control unit.

Pin out DCU 15 D2-2
Figure 50
UDS
DCU15
113576
Pin No Abbrev Name

1 V_V_BAT+R Battery + via main relay (output)
2 V_V_BAT+R Battery + via main relay (output)
3 V_V_BAT+ Battery plus
4 V_V_BAT+ Battery plus
5 B_D_CANH1 Controller Area Network 1 (high)
6 B_D_CANL1 Controller Area Network 1 (low)
7 B_D_CANH2 Controller Area Network 2 (high)
8 B_D_CANL1 Controller Area Network 2 (low)
9 dnc do not connect
10 O_S_CLH Compensation line heating
11 O_S_RAMV Reduction agent metering valve
12 O_V_RAMV Reduction agent metering valve supply (BAT+ )
14 G_G_BAT- Battery minus
15 G_G_BAT- Battery minus
17 G_R_CATTSPRE Catalyst temperature sensor ground (upstream)
18 I_A_RALS Reduction agent level sensor signal
19 G_R_RALS Reduction agent level sensor ground/Reduction agent tank temperature sensor ground

Pin No Abbrev Name

21 O_S_SVS Service soon available
22 O_S_HH1 Hose heating 1 (Suction line heating)
23 O_S_RATH Reduction agent tank heating
24 I_S_T15 Terminal 15 (switched BAT+)
25 G_R_CATTSPOST Post-catalyst temperature sensor ground (downstream)
26 I_A_CATTSPOST Post-catalyst temperature sensor signal (downstream)
28 I_A_CATTSPRE Catalyst temperature sensor signal (upstream)
29 I_A_TRATS Reduction agent tank temperature sensor signal
30 V_V_5VRALS Reduction agent level sensor supply
31 B_D_ISOK ISO-K interface
32 O_S_HH3 Hose heating 3 (Pressure line heating)
34 O_S_HH4 Hose heating 4 (Back flow to supply module line heating)
35 O_S_HH2 Hose heating 2 (Back flow to tank line heating)

Figure 51
148515

Scheduled Maintenance
DEF/AdBlue system test through PT-Box Every 1800 hours or every 2 years
DEF/AdBlue circuit filters (dosing system DeNOx 2)
FILTER TYPE POSITION MAINTENANCE

Tank mesh filter - DEF/AdBlue tank Clean (if necessary).
Filter on the DEF/AdBlue feeder line Between the tank and feeder
(Voss) 100 m module Clean at every oil change.
Feeder module prefilter - Feeder module No maintenance to be carried out.

Replacement before 3600 hours (or
Feeder module filter (Bosch) 10 m Feeder module 2 years) of activity.
100 m Dosing module entry No maintenance to be carried out.
Dosing module prefilter
100 m Dosing module exit No maintenance to be carried out.
NOTE The data are only valid if the fitter observes all the installation regulations provided by FPT.

F4HFE ENGINES SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
LOCATION OF THE MAIN ELECTRICAL

COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 4
ECU ELECTRONIC CONTROL UNIT

(EDC7UC31) . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Electroinjectors connector (A) . . . . . . . . . . . . 7
- Sensors connector (C) . . . . . . . . . . . . . . . . . . 8
FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS 9
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . 9
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Supercharging air pressure - temperature sensor 10
- Engine oil temperature-pressure sensor . . . . . 10
- Fuel temperature and pressure sensor . . . . . . 11
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . 12
- Pre-post heating resistance and contactor

(if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Coolant temperature sensor . . . . . . . . . . . . . . 14
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 15
- High pressure pump - fuel flow rate regulator 16

2 SECTION 3 - ELECTRICAL EQUIPMENT F4HFE ENGINES

LOCATION OF THE MAIN ELECTRICAL COMPONENTS

108641
The NEF F4HFE engines are fully driven by the electronic The electrical and electronic components of the engine are
engine control module, which is assembled directly to the listed here following:
engine by means of a heat exchanger enabling its cooling,
1. Coolant temperature sensor.
utilising rubber buffers to reduce vibration originated by the
engine. 2. Electro-injector.
Through the engine control module it is possible to verify the 3. RAIL pressure sensor.
correct working of the engine. (See SECTION 5 -
4. Air temperature/pressure sensor.
Diagnostics).
5. Starter motor.
6. Timing sensor.
7. Fuel flow rate regulator solenoid valve.
8. Fuel temperature sensor.
9. EDC electronic control unit.
10. Crankshaft sensor.
11. Engine oil pressure/temperature sensor.
12. Heating element for pre-post heating.

ENGINE CABLE
All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary
version, in other words at the approval stage.
Figure 2
166698
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 4. Engine rpm sensor -
5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor -
8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor -
11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).


All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary
version, in other words at the approval stage.
Figure 3
0051064t
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor -
5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor -
8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor -
11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).

ECU ELECTRONIC CONTROL UNIT (EDC7UC31)

Figure 4
102373
A. Injector connector - B. Frame connector (refer to the vehicle which the engine is fitted to) -
C. Sensor connector

Electroinjectors connector (A)

Figure 5 12 16
6 11
50350
Colour legend 1 5
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN
Z PURPLE
Pin 4-cylinder engines 6-cylinder engines

Pin Cable colour Description Cable colour Description
1 HN Cylinder 3 injector LR (*) - CL (**) Cylinder 5 injector
2 HR Cylinder 2 injector BC Cylinder 6 injector
3 - - BL (*) - CN (**) Cylinder 4 injector
4 MB Cylinder 1 injector MB Cylinder 1 injector
5 HV Cylinder 4 injector MV Cylinder 3 injector
6 - - HR Cylinder 2 injector
7 - - - -
8 - - - -
9 V Fuel flow rate regulator V Fuel flow rate regulator
10 C Fuel flow rate regulator C Fuel flow rate regulator
11 - - MN Cylinder 2 injector
12 BL Cylinder 4 injector HN Cylinder 3 injector
13 HG Cylinder 1 injector HG Cylinder 1 injector
14 - - HV (*) - VB (**) Cylinder 4 injector
15 MN Cylinder 2 injector VN Cylinder 6 injector
16 MV Cylinder 3 injector RG (*) - VG (**) Cylinder 5 injector
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
(**)F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Sensor connector (C)

6 8 16 9 15 22
Figure 6
Colour legend
C ORANGE
A LIGHT BLUE
4
B WHITE
L BLUE
5
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
V GREEN 1 3 23 30 36 29
50350
Z PURPLE
Cable colour
Pin Description
code
1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 Signal from sensor of engine revolution counter on timing (phase sensor) B
10 Ground of sensor of engine revolution counter on timing (phase sensor) R
11 - -
12 Fuel pressure sensor ground BN
13 Fuel pressure sensor power supply HN
14 Fuel pressure sensor signal RV
15 Water temperature sensor signal CV
16 - -
17 - -
18 Fuel temperature sensor ground CN
19 Engine revolution counter sensor ground B
20 - -
21 - -
22 - -
23 Signal from engine revolution counter sensor R
24 Oil pressure / temperature sensor ground GV
25 Air pressure / Temperature ground GN
26 Water temperature sensor ground BG
27 Oil pressure sensor signal GR
28 Oil temperature sensor signal NS
29 - -
30 - -
31 - -
32 Oil pressure / temperature sensor supply MN
33 Air pressure / Temperature sensor supply CL
34 Air pressure sensor signal LN
35 Fuel temperature sensor signal BL
36 Air temperature sensor signal BR

FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS

Crankshaft sensor
This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from
a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is 900 .
Figure 7
50319
Crankshaft sensor
Timing sensor
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a
magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by
the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance
is 900 .
Figure 8
50320
Timing sensor
Figure 9
3 2 1
50342 50288
Connector Wiring diagram

ECU pin
Ref. Description
Camshaft sensor Timing sensor
1 Ground 19C 10C
2 Signal 23C 9C
3 Shield

Supercharging air pressure - temperature sensor

This component incorporates a temperature sensor and a pressure sensor.
Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate
calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 25C - 36C - 33C - 34C.
The power supply is 5 Volt
Voltage at the sensor output is proportional to the detected pressure or temperature.
Pin 36C Temperature signal
Pin 34C Pressure signal
Engine oil temperature-pressure sensor

This component is analogous to the air temperature-pressure sensor.
The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position.
This sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 24C - 28C - 32C - 27C.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative
device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.
Pin 28C Temperature signal
Pin 27C Pressure signal
Figure 10
50324 50344
Wiring diagram
ECU Pin
Ref. Description
Oil Air
1 Ground 24C 25C
2 NTC signal (temperature) 28C 36C
3 +5 V power input 32C 33C
4 Signal (pressure) 27C 34C

Fuel temperature and pressure sensor

Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback).
The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection
command.
This sensor is connected to the control unit on pins 12C - 14C- 13C.
The power supply is 5 Volt.
Figure 11
0051065t
Fuel pressure sensor connector
Ref. Description ECU pin

1 Ground 12C
2 Signal 14C
3 Power supply 13C

Electro-injectors
The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The impedance of the coil of each injector is 0.56 - 0.57 .
1 Cylinder 2 injector 15 A
2 Cylinder 2 injector 2A
CONNECTOR 1
CONNECTOR 2

CONNECTOR 1
CONNECTOR 2
CONNECTOR 3
Figure 12
50343
Figure 13
50349

Pre-post heating resistance and contactor (if present)

The pre-post heating resistance is located on the intake manifold.
The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor.
The resistance impedance is approximately 0.5 .
Figure 14
B
108909
A. - B. Connection terminals
Figure 15
002371t
A. Control contactor
The control contactor is connected to the control unit B connector.

The contactor is tripped with water and/or fuel temperature below 5 C.
The contactor impedance is approximately 15 .
Do not use flammable gases or liquids to provoke the engine ignition.

These substances in contact with the resistance could easily become inflamed creating situations of serious danger.

Coolant temperature sensor

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication
of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
This sensor is connected to the control unit on pins 15C - 26C.
The impedance of the coolant temperature sensor at 20 C is approximately 2.50 .
Figure 16
107471

Fuel temperature sensor

This sensor is identical to the coolant temperature sensor.
This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.
The fuel temperature sensor is connected to the control unit on pins 35C -18C.
The sensor impedance at 20 C is approximately 2.50 .
Figure 17 (D)(*) Figure 18 (**)
166060 166092
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
(**)F4HFE6132/39/3A/3C*A002-3/3L*A001-2
1. Fuel temperature sensor - 2. Filter heating resistance.
The ECU drives the filter heater contactor at fuel temperature 5 C.
Figure 19
107799 107798
Connector
ECU Pin
Ref. Description
Coolant Fuel
1 Ground 26C 18C
2 Temperature signal 15C 35C

High pressure pump - fuel flow rate regulator

Pump with 3 radial pistons controlled by the timing gears, requiring no phase adjustment, with rotor type feed pump fitted to the
back.
Figure 20
166091
1. Fuel flow rate regulator.
The flow rate regulator is located at the inlet of the high-pressure pump on the low-pressure circuit; its function is to modulate
the quantity of fuel to feed to the high-pressure pump on the basis of commands received from the electronic control unit.
It basically consists of the following parts:
- trapezoidal section shutter;
- valve control pin;
- pre-charging spring;
- coils.
In the absence of the control signal, the flow rate regulator is normally open, and hence the high pressure pump is in its maximum
delivery conditions.
The control unit modulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying the fuel to the
high pressure pump.
This component cannot be replaced individually and hence it cannot be taken down.
The quantity of fuel supplied to the high pressure pump is metered by the flow rate regulator on the low pressure system; the
flow rate regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 and 1600 bar by the electronic control unit by controlling the flow rate
regulator solenoid valve.
- This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on pins 9A - 10A.
- The solenoid valve impedance is approximately 3.2 .

F4HFE ENGINES SECTION 4 - SCHEDULED MAINTENANCE 1
SECTION 4
Scheduled maintenance
Page
SCHEDULED MAINTENANCE . . . . . . . . . . . . . 3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Regular maintenance and inspection planning . 3
- Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE PROCEDURES . . . . . . . . . . . . 4
- Checks and inspections . . . . . . . . . . . . . . . . . . 4

2 SECTION 4 - SCHEDULED MAINTENANCE F4HFE ENGINES

SCHEDULED MAINTENANCE
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure, immedi-
ately intervene in order to find the causes.
We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident
prevention standards for the safety of maintenance personnel in charge.
Regular maintenance and inspection planning
Checks and periodical inspections (*) Frequency (hours)
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . ..................... Daily

Inspection presence of water in fuel filter or pre-filter ...................... Daily
Checking tappet clearance 2400
EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When anomaly occurs
Replacing the engine oil and oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Fuel pre-filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
Replacement of blow by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
Changing the alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000
(*) For maintenance operations concerning the DEF/AdBlue circuit filters (dosing system DeNOx 2) please consult the relevant
chapter under Section 2.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations 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.

Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconven-
iences, even serious, during engine running. Such checks are usually up to the operators and to the vehicles drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES
Checks and inspections
Figure 1
Engine oil level check
The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided flexible
rod.
Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing mini-
mum level, provide filling lubrication of the engines compo-
nents.
Always ensure the oil added has the same characteristics of
the oil contained in the sump.
Mixing is not allowed as this would not guarantee correct
lubrication of the internal parts of the engine.
166058
To provide filling, operate through the upper top or through

the lateral top (2, Figure 1). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier.
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water

and detergent.
Adequately protect the skin and the eyes, operate in

full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

Combustion system inspection Lubricating system inspection

The check must be executed both when the engine discon- The check must be executed both when the engine discon-
nected and when it is running. nected and when it is running.
The check operation consists in examining the fuel pipelines
running from the tank to the pre-filter (if provided in the spe- Verify the presence of any oil leakage or blow-by from the
cific equipment), to the filter, to the high pressure pump and head, from the engine pan of from the heat exchanger.
to the rail diffuser and from this last one to the head.
Special attention must be paid to the connections on the high

pressure pipelines. The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Due to the high pressure within the pipelines running
from the high-pressure pump to the rail diffuser and
Adequately protect the skin and the eyes, operate in
from this last one to the electro-injectors, special
full compliance with safety regulations.
attention must be aid also in checking presence of any
leakage or blow-by.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.
Protect the eyes and the skin from any eventual high
pressure jet: these may deeply penetrate under the
skin surface provoking serious poisoning.
Inspection of water presence within fuel filter or pre-filter
NOTE The components of the common rail system can be

damaged very quickly in presence of water or im-
Cooling system inspection purity within the fuel.
The check must be executed both when the engine discon-
nected and when it is running. Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the drain-
Check the pipelines from the engine to the radiator, from the age of the water within the feed circuit.
expansion tank and vice-versa. Find out any blow-by, verify the
status of the pipes specially close to the holding strips.
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit. Inspection of drive belt tensioning
The drive belt tensioning control is made using an automatic
tensioning device therefore no intervention is required apart
from checking the wear status of the belt itself.
Due to the high temperatures achieved by the sys-
tem, do not operate immediately after the engines
disconnection, but wait for the time deemed necess-
ary for the cooling. Check of belts tear and wear status
Protect the eyes and the skin from any eventual high Carefully verify the belts surface in order to detect any sign of
pressure jet of cooling liquid. incision, crack, excessive wear in correspondence of toothing;
check end and surface grinding.
The density of the cooling liquid must be checked any how

every year before winter season and be replaced in any case Danger: if the engine is switched off but is still hot, un-
every two year. expected motion of the belt may occur.
Wait for engine temperature cooling as a precaution
in order to avoid serious danger injury.
NOTE In case of new filling, proceed bleeding system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious

inconvenience might be caused to the engine due
to the presence of air pockets in the engines head.

Inspection/replacement of blow-by filter

The filter in subject has been developed and equipped for the NOTE In order to perform the rocker arm - valve clearance
collection, filtering and condense of the lubricating oil vapours. adjustment more quickly, proceed as follows:
4-cylinder engines
Within the filter unit (1) two cartridge filters are included (2). - Rotate the crankshaft, balance the valves of
cylinder no. 1 and adjust the valves marked by
Figure 2 the asterisk as shown in the tables below:
cylinder no. 1 2 3 4
intake - - * -
exhaust - * - *
- Rotate the crankshaft, balance the valves of
the asterisk as shown in the tables below:
1 2 cylinder no. 1 2 3 4
intake * * - -
74188 exhaust * - * -
The check of the filtering element is carried out by removing
the cover and drawing off the cartridges (2). 6-cylinder engines
cylinder no. 1 2 3 4 5 6
intake - - * - * *
exhaust - * - * - *

Inspection tappet clearance cylinder no. 1 2 3 4 5 6

intake * * - * - -
Figure 3 exhaust * - * - * -
166059
Check the clearance between the rocker arms and valves

using a feeler gauge (1).
Clearance shall be as follows:
- intake valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.

Oil motor and oil filter replacement Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in differ-
Warning: We recommend to wear proper protec- ent positions: the following procedure is a valid guide for all ap-
tions because of high motor service temperature. plications.
The motor oil reaches very high temperature: you - The filter is composed by a support and a filtering car-
must always wear protection gloves. tridge. For the cartridge replacement use the
9936076-tool.
Warning: the oil filter contains inside a quantity of oil

Due to the several applications, the pan shape and the oil of about 1 kg.
quantity can change slightly. However, the following oper-
ations are valid for all applications. Place properly a container for the liquid.
We recommend to carry out the oil drainage when the motor Warning: avoid the contact of skin with the motor oil:
is hot. in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the The motor oil is very pollutant: it must be disposed
pan connected with the drain plug. of according to the rules.
- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the lubrica-
tion oil.
- Replace the filtering cartidge with a new one and screw

manually until when the gasket is in contact with the sup-
The oil motor is very pollutant and harmful. port.
In case of contact with the skin, wash with much water - Tighten further using tool 99360076 to a torque of 20
and detergent. 2 Nm.
Protect properly skin and eyes: operate according to - Operate the motor for some minutes and check the level
safety rules. through the dipsick again. If it is necessary, carry out a top-
ping up to compensate the quantity of oil used for the fill-
Dispose of the residual properly following the rules. ing of the filtering cartridge.
- After the complete drainage, screw the plug and carry out
the clean oil filling.
Use only the recommended oil or oil having the re-

! quested features for the corrrect motor functioning.
In case of topping up, dont mix oils having different
features.
If you dont comply with theses rules, the service war-
ranty is no more valid.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dip-
sick.

Fuel filter replacement Alternator belt replacement

Due to several applications the belt run can change very much.
During this operation dont smoke and dont use free

flames.
Avoid to breathe the vapors coming from filter.
Warning: with switched off motor (but still hot) the

belt can operate without advance notice.
According to the applications the filters position and the quan-
Wait for the motor temperature lowering to avoid
tity can change.
very serious accidents.
However the following operations are valid for all applications.
- Drain the fuel inside the filter by operating the water re-
lease screw. Collect the fuel in a container without impu-
rities.
- Unscrew the cartridge by using the 99360076-tool. For applications with automatic belt stretcher, the procedure
- Collect the eventual fuel inside the filtering cartridge. is the following:
- Clean the gasket seat on the support and oil slightly the Figure 4
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 20 2 Nm torque.
108545
- Operate on the tightener (1) and withdraw the belt (2)

from the alternator and water pumps from pulleys and
from the returns pumps.
- Replace the worn belt with a new one.
- Place the belt on the pulleys and the guide rollers.
- Place the automatic tightener in order to key the belt in
the functioning position.
- Further adjustments are not required.

F4HFE ENGINES SECTION 5 - DIAGNOSTICS 1
SECTION 5
Diagnostics
Page
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PT-BOX INSTRUCTIONS . . . . . . . . . . . . . . . . . 5
- Hardware installation . . . . . . . . . . . . . . . . . . . . 5
- Software installation . . . . . . . . . . . . . . . . . . . . . 7
- Software Interface . . . . . . . . . . . . . . . . . . . . . . 18
- Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- ECU diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Active diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 38
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . 40
GUIDE TO DIAGNOSIS THROUGH SYMPTOMS 87

2 SECTION 5 - DIAGNOSTICS F4HFE ENGINES

PREFACE Every time there is a breakdown claim and this breakdown is

actually detected, it is necessary to proceed inquiring the elec-
A successful troubleshooting is carried out with the compet- tronic unit in one of the ways indicated and then proceed with
ence acquired by years of experience and attending training the diagnostic research making trials and tests in order to have
courses. a picture of the working conditions and identify the root
causes of the anomaly.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper consider- In case the electronic device is not providing any indication, it
ation using them to acquire any useful information to focus the will be necessary to proceed relying on the experience, adopt-
intervention. ing traditional diagnosis procedures.
Using FPT processing instruments, it is also possible to estab-
lish a bi-directional connection with the central unit, by which
not only to decoding the failure codes but also input an en-
quiry relying on memory files, in order to achieve any further
necessary information to identify the origin of the anomaly.
NOTE Any kind of operation on the electronic center unit

must be executed by qualified personnel, duly auth-
orized by FPT.
Any unauthorized tamper will involve decay of

after-sales service in warranty.

PT - BOX
PT - BOX is a test tool to be connected to a Laptop.
Figure 1
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator - 5. Serial port indicator -
6. Error indicator - 7. CAN line indicator - 8. Line K indicator for automatic management
PT-BOX functions:
- ECU ID reading;
- Failure memory reading;
- Flight recorder reading;
- Parameters reading;
- Failure memory cleaning;
- Active diagnosis: actuators activation/testing;
- Programming of repalced components and parameters/second level;
- Acquisition/Saving of parameters

PT-BOX INSTRUCTIONS Select your user configuration type and then follow the
relevant information.
Hardware installation
1. PT-PLUS configuration
- PC Panasonic user
This Sw may cause engine start-up. Be extremely - PT-BOX module
! careful. - PT-DIAGNOSIS sw
The user is responsible for the correct use of the PT- 2. PT-DIAGNOSIS configuration
DIAGNOSIS software so as not to any cause injury
to people or damage to items. - user with own PC
- PT-BOX module
The user is also responsible for complying with all - PT-DIAGNOSIS sw
the rules relating to security for activities on the
industrial applications (engine, pump, generating The PT-BOX module (Electronic Communication Interface)
set) carried out in the workshop.
Carefully read the user manual before using the PT-BOX is an interface module allowing the communication
diagnostic tool and follow the instructions displayed between the engine ecus and the PC.
on the screen. - Weight: 500 g;
- Dimension: 175x75x30mm;
General rules for use - Flash memory: 4Mb - RAM 1Mb;
The following instructions should always be strictly followed: - Thermal tolerance: 0-50 C;
- all instruments ensuring the security must be applied as - Power supply: 6-32V;
indicated in the application; - Connection interfaces: USB and RS232 standard
- ensure that the PT-BOX module is connected to the Bluetooth optional;
diagnostic socket of the engine on which work is to be - Interface for engine electronic systems: 9 KL ISO 9141
carried out; lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O
- in case of emergency, disconnect the PT-BOX module PWM.
from the engine or disconnect the USB cable; The led indicators on the front view allow to check the
- ensure that while using the software, there is nobody communication lines activity with the engine and with the PC
near the engine/vehicle you are working on; to which the instrument is connected.
- if it is necessary for more than one person to be working
on or near the engine/vehicle, they are all responsible for Figure 2
complying with security regulations of the workshop;
- we strongly suggest that the PT-BOX modules be visibly
and uniquely identified (for example by using coloured
adhesive tape, labels with names, etc).
By only accepting the use disposal it is possible to

! access PT-DIAGNOSIS (the green tick icon
becomes active). 156133
1. Led indicators to display the activity of the

The diagnosis system consists of: communication lines K/L. - 2. The upper led display the
ECUs communication activity. - 3. The lower led indicators
- a PC (Panasonic / your PC + Microsoft Windows 2000 display the CAN lines activity. - 4. The three upper led
or Windows XP Professional); indicators show the activity of the K/L communication lines.
- 5. The lower led indicator (fault) shows the presence of
- an instrument used as interface between engines/vehicles errors on the K/L lines. - 6. The upper led indicator shows
and PC (PT-BOX tester); that the PT-BOX is power-supplied. - 7. When blinking the
- a SW program (PT-DIAGNOSIS) to process data. lower led indicator (run) shows that the PT-BOX module is
correctly working. - 8. Led indicators to display the USB
By combinating the above indicated components 2 different ports (upper led). - 9. Led indicators to display the serial
configuration are possible. ports (lower led).

Connect the PT-BOX module PT-BOX - engine/vehicle connection

On the PT-BOX module there are the communication ports
for the connection to the PC and to the engine / vehicle. Figure 6
Communication ports for the connection to the PC

Figure 3
156138
- connect the module to the engine/vehicle by using the

specific connection cable.
156135
1. serial port - 2. USB port NOTE The module is power-supplied by the diagnostic
cable; for this reason to work correctly it must be
Figure 4 connected to the engine.
System requirements
Minimum
- Processor: 300 MHz Pentium-II CPU;
- Hard disk space: 3 GB available;
- Ram: 256 MB;
156136
- Display: 800 x 600 video adapter and monitor;
Connector for the connection of the engine communication
cable. - Internet connection only needed for rss and pt-diagnosis
software update (eaus): modem;
- External ports: USB connector;
PT-BOX - PC connection
- External reader: DVD-ROM reader;
Figure 5
- Os: Microsoft WindowsTM XP Professional Service Pack
2 - Microsoft Windows 2000 Service Pack 4 plus -
Windows 2000-KB835732-x86-ENU.EXE (login with
administrator privileges);
- Browser: Internet Explorer 5.5.
Recommended
- Processor: 1 GHz Pentium IV - Centrino CPU;
- Hard disk space: 5 GB available;
- Ram: 512 MB;
- Display: 1024 x 768 high colour video adapter and
156137 monitor;
- Internet connection only needed for rss and pt-diagnosis
software update (eaus): high-speed e.g. ADSL;
- connect the USB cable (PT-BOX side marked) to the PT- - External ports: 2 USB 2.0 connectors, Bluetooth;
BOX module (remove the holding screws from the PT-
BOX module, where present); - External reader: DVD-ROM reader;
- connect the USB cable to the PC; - Os: Microsoft WindowsTM XP Professional - Service Pack
3 (login with administrator privileges);
- turn the PC on.
- Browser: Internet Explorer 6.0.

Software installation
Registration
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
The registration procedure is carried out on-line and it is
different according to the user type:
- OEM users
- Dealer users
NOTE For both configurations (PT-PLUS and PT-

DIAGNOSIS) the SW installation is the same.
- A fill-in form is displayed.
Registration>OEM users The activation code received will be requested the

! first time you run the PT-DIAGNOSIS software.
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
Registration form (OEM user)
For this reason:
- Check that the registration card has been delivered The Registration allows you to download the EVCA SYNC
together with the kit. WEB application which allows you to obtain the activation
code:
- Select www.eltrac.it/ivecomotors/default.asp.
- From the starting page, select the language.
- Select pt users registration.
In the registration form:
1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
the identification data and the Network characteristics
areautomatically entered.
3. Enter the serial number of the PT-BOX instrument.

Figure 7
NOTE Before carrying out the registration we suggest to
install the PT-Diagnosis SW.
Installing the EVCA SYNC WEB (OEM users) application

To obtain the activation code it is necessary to install the
EVCA SYNC WEW application, after saving it on the desired
directory:
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module
4. Read the note in compliance with art. 13 of Italian
Legislative Degree 196 dated 30 June 2003 about the
processing of personal data Informative
5. Select the send key (only once!) wait
After sending a summary window is displayed waiting for the
end of the registration procedure.
1. Unzip the evcasyncweb1.2.6.zip (for example using

WinZip: www.winzip.com/downwz.htm).
2. Open the EVCASyncWeb1.2.6 and then
EVCASyncWeb15-09-10 (Rel1.2.6).
3. Run setup.exe and continue with the installation of the
guided application.
NOTE For further information about the installation of

EVCASyncWeb it is possible to read the detailed
guide EVCASyncWeb Setup.pdf in the directory
EVCASyncWeb1.2.6.
Then a link is available to download the EVCA SYNC WEB
application. It will be used to obtain the activation code:
6. Select the print key for printing a summary report 4. At the end of the installation, the icon of the
(registration data and number of registered instrument). EVCASyncWeb application is displayed on the desktop
of the PC.
7. Select the link to download and then select the save key,
to save the application on the PC.

Running the EVCA SYNC WEB (OEM user) application
3. Enter the PT-BOX serial number of and the Customer

PIN.
4. To continue, select the confirm key.
1. Double click on the icon EVCASyncWeb application.

At the start up of the application choose the Internet
connection mode:
- by means of the Proxy Server;
it is necessary to enter the connection parameters; at the
end select the okey. It is possible to pre-set the
connection parameters: read the EVCASyncWeb
manual;
- without Proxy Server;
select the okey.
5. Enter the alpha code supplied with the Registration Card

(scrap the card).
The starting page EVCASyncWeb is displayed; some

functions are available (for more information read the manual
EVCASyncWeb).
2. Select the applications key for pc.

Summary of the selected choices (OEM user)

At the end of the activation procedure, the summary of the
selected choices is available. The following data are displayed:
Contract Activation (OEM User)

7. Select a contract type.
The contract types available for the OEM users are indicated
below:
- Fee (annually):
the duration of the contract is for one year, starting from - The type of selected contract.
the activation date of the contract. During this phase it is
- The list of instruments (PT/PB) associated to the contract
only possible to associate one instrument to the contract.
with the generated activation codes
- Token (to be deducted):
- The expire date of the contract (in case of yearly fee) or
it is the payment for a single download of an application;
residual credit (coins):
it is possible to associate to the contract to 4 instruments.
1. We suggest you to print and keep the summary data:
select the key print selections recap.
2. Show and download the list of the available
applications belonging to your profile (FPT
activation): select the applications download key.
The window containing the activation codes is displayed.

9. Print/copy the activation codes and keep them together
with the instruments they are associated to.
10. Select the okey to end.

Download the applications Registration>Dealer users

Before using the PT-DIAGNOSIS diagnosis system you must
register on the FPT web site.
1. Connect to
http://www.fptpowertrain.com/index_main.htm.
The following information for each one of the available
2. Select the language.
applications for downloading is displayed: ECU, license, file
name, Release Date, Release Type and short description.
Each option can be used to sort the list: to sort the list in
ascending/descending order according to a given key, select
the title of the corresponding column.
1. Select the application to be downloaded; the selected line
is highlighted in red.
2. Select the download the selected application key and follow
the system instructions.
3. Identify the path where the packets have been
downloaded.
4. At the end of the download install the packets (double
click) one by one.
3. Select Fiat Powertrain Technologies and then Partner Area.
NOTE The packets must be downloaded/installed one by

one.
4. Connect to the web site by selecting Click here.

5. Fill in the fields for the login procedure.
7. Go to the registration web page; select pt users registration

a fill-in form is displayed (on-line registration form).
NOTE For the new customers:
request username and password to
areapartner@fptpowertrain.com.
For the customers already registered:
use username and password received by e-mail.
Registration form (Dealer user)

The Registration allows you to download the EVCA SYNC
WEB application which allows you to obtain the activation
code.
In the registration form:

1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
6. Please follow the indicated instructions the identification data and the Network characteristics are
automatically entered.
After Sales>Various>Diagnostic Instruments>Diagnostic
Tools

3. Fill in the yellow field by entering the alpha code supplied 6. Select the send key (only once!) wait
with the Registration Card (scrap the area on the card).
After sending a summary window is displayed waiting for the
4. Enter the serial number of the pt-box instrument. end of the registration procedure.
Wait for the following window:
- the activation code;
- the link to download the EAUS application (EAsy Update
Software).
7. Print the activation codes (print key) and keep them
together.
8. Select the link to download the EAUS application.
Installation of EAUS application (Dealer user)

The EAUS application is an update utility to automatically
download all SW Updates for all ECUs activated for FPT.
After having selected the link for downloading the EAUS
Figure 8 application, the system asks you to select the file or to directly
run it.
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module.
1. Select the run key:
5. Read the note in compliance with art. 13 of Italian the system automatically downloads first and then installs
Legislative Degree 196 dated 30 June 2003 about the the EAUS application; run the operation required by the
processing of personal data Informative. system and wait for the end of operation.

Connection
Figure 9
156138
1. Connect the PT-BOX module to the engine/vehicle using

the diagnosis cable.
2. Connect the PT-BOX module to the PC, using one of the
2. Select the end key to exit the installation. two USB cables provided with the module.
NOTE Before carrying out the registration we suggest to The PT-BOX module is supplied by the diagnosis
install the PT-Diagnosis SW. ! cable; therefore it must be connected to the engine/
vehicle to be able to work.
Figure 10
Run the EAUS (Dealer user) application
156140
3. Switch the PC on.
PT-BOX module USB driver set-up

(only for the PT-DIAGNOSIS configuration)
This operation is required only if the PC in use has never been
connected to an PT-BOX module:
1. It is now possible to download the update by using the

Automatic Update Function (tools>software update key).
1. Check that the PT-BOX module is correctly connected to
the PC via the USB cable.
2. The PC acknowledges the presence of a new hardware
component; press the cross button to continue.

5. Select the have disk> button to continue.

3. Automatically (Windows XP) the procedure starts to set-
up the driver; select the Install from a list or specific location
option; select the next> button to continue.
6. Enter the path:

ProgramFiles\EltracECI\Driver\PT-BOX.sys;
select the ok button.
4. Select the Dont search. I will choose the driver to install;

select the next> button to continue.
7. Select the next> button to continue.

4. The system asks you to enter the activation code received

from Field Service; select the tick button.
8. Driver set-up begins wait.

9. The procedure is completed; press the finish button.
5. Enter the activation code sent via Web.

6. Select the register button; a message confirms that
registration has taken place.
7. Select the cross button to close the Activation Code
window and go back to the PT-DIAGNOSIS screen.
10. The system informs that the new hardware has been
correctly installed; select the cross button to continue.
11. Re-start the PC.
Activation - first time of use of PT-DIAGNOSIS sw + PT-

BOX module
The first time the PT-DIAGNOSIS Diagnosis System is used,

it is necessary to follow the procedure described below:
1. Make sure you possess the activation codes (Web
access).
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB/BT module.
3. Start the Panasonic PC.
8. Select the stop button and restart PT-DIAGNOSIS.
Now all the software functions are available.

Activating - new PT-BOX module

The activation procedure is necessary every time you want to
use an PT-BOX module that has not yet been paired to the
PT-DIAGNOSIS diagnosis system in use; follow the
operations described below:
6. Enter the activation code received from Field Service.

7. Select the register button; a message confirms that
registration has taken place.
8. Select the cross button to end activation.
9. Re-start the PT-DIAGNOSIS (E.A.SY. icon).
1. Make sure you have requested and obtained the
activating code for the PT-BOX module.
2. Connect the PT-BOX module to the Panasonic PC and
to the engine/vehicle using the USB cable.
3. Start the PT-DIAGNOSIS software: double click on the
EASY icon (PT-DIAGNOSIS) placed on the desktop of
PC.
4. Select the tools>activations button.
5. Select the entry button.

Software Interface
The PT-DIAGNOSIS software interface is designed to facilitate access to tools, view functions and make diagnostic procedures clear
and adaptable to various needs.
All windows follow the same design with additional features which depend on the specific working environments.
Each window presents three main areas to which specific functions are univocally associated:
- Keys Area
- Title Area
- Operative Area
The Title area shows the selected function under test and previous choices by which you arrived.
The Keys The Operative

area contains Keys area contains available
for accessing the system and function
operative list referred to the
environments and intervention area.
the functions to
which they are
associated.

To go from one environment to another
3. Select the Class and the System under test to which the
engine/ vehicle belongs; then press the navigation key (is
active - green) to continue.
1. The Start Window shows the family.
Start Window
- It is possible to select a new family or to choose a family
from the database;
- green identifies a pull-down menu.
4. The window Choose Activity appears; it is here possible

to choose from four lists.
Window Choose Activity
It is now possible to choose:
- diagnosis;
- test;
- programming;
- specific functions.
Navigation keys
2. Select the fami ly of the engine/vehicle under diagnosis; They allow you to go from one environment to another.
then press the navigation key (is active - green) to Enabled keys are displayed in green and disabled keys are
continue. displayed in grey.
Family Choice Window navigation key forward disabled
- Yellow identifies a selected item in a pull-down menu;
- a paged list is used to display a large amount of navigation key forward enabled
information one page at a time; navigation tools are
available to navigate from page to page. navigation key back enabled
Database key
It allows you to access the Database

environment.
Browse key
To scroll long lists which cannot

be contained in a single window. ignition key
For the equipped engines, it allows you to operate engine

Detail of Keys area ignition directly via the diagnostic tool. Two positions (stop
In the Start Window the Keys area contains the Keys for and mar) and three states (enabled stop, disabled stop,
accessing the functions which are always available: enabled mar) are possible.
communication panel
It indicates that the communication with the ECU is active or
that the ECU is not present (no ecu).
The lower leds indicate the communication state of the
electronic system as shown below:
Square LEDs: two states (green/red); green indicates that
communication with the electronic system has been initialised;
if red indicates the communication has been interrupted.
Rectangular LEDs: blinking indicate that data exchange
between electronic system and diagnostic system is in
progress.
Utilities key
stop key
To quit PT-DIAGNOSIS application at any time.
engine/vehicle key
It allows you to return to the Family Choice Window.
utilities key
When selected the Key background will be yellow and allows
you to access a menu.
guide to diagnosis key

It allows you to access the environment Guide to Diagnosis
(only available for some ranges). It is available in the Electrical
Control Units environment.

Teleservices key
It allows you to access the remote connections services. Electronic control units key
Activations key
It allows you to access the Electronic Ecus environment.
It allows you to access the management function of the The key appears on a yellow background (default status,
activation codes. environment Electronic Control Units enabled) or on a grey
Select the measure unit key background (environment Electronic Control Units disabled).
If you want to work at the same time with more Ecus, select
It allows you to choose the measure unit system. the key environment electronic ecus>add ecu.
Electrical diagrams key

It refers to a CLASSES list for which an electrical diagram is
The Metric System (SI), the international standard one, is available. The key appears on a yellow background
based on the meter, kilogram and second. The British System (environment Electrical Diagrams enabled) or on a grey
(fps) is based on the foot, pound and second. background (environment Electrical Diagrams disabled).
Select language key To enter the Electrical Diagrams environment select the key
electrical diagrams area.
To change the language; restart the application to make the
setting operational.
Software update key Report key
It allows you to carry out the automatic update of the PT- It allows you to access the Report environment.
DIAGNOSIS software. The key appears on a yellow background (environment
Eci management key Report enabled) or on a grey background (environment
Report disabled). To access the Report environment select
It allows you to manage the connection (usb or Bluetooth) PT- the report key.
DIAGNOSIS - PT-BOX module.
On/Off-line key
It can be on-line or off-line.
The on-line key indicates that the PT-Diagnosis SW uses the
In the Start Window select the fami ly; by pressing the PT-BOX/PC module connection.
navigation key forward it is possible to access the next The off-line key indicates the PT-Diagnosis SW is working in
window. New icons appear in the Keys area for accessing simulated mode. To change the status select the key.
specific functions:

Acceptance
Environment DataBase key search
From the PT-DIAGNOSIS start window it is possible to select It allows you to search an engine by applying a filter (DATE,
a new engine or to select one from the database. engine mode l, CUSTOMER or NUMBER PLATE).
key delete search

It cancel the filter; it is active only after a search.
key order
It orders the list according to the selected ordering criterion.
key report
It gives access to the summary environment; enabled after
selecting an engine.
key delete
1. Select the database button: you access the DataBase
environment (it contains the list of accepted engines). It deletes the selected engine from the database; it is active
only after selecting an engine.
2. The list of accepted engines is available.

They can be search by means of the following keys:
3. Select an engine from the list (the background is yellow);
- DATE it is possible:
- ENGINE MODEL - to analyse engine data (report button);
- CUSTOMER - to start again the diagnosis procedure on the engine
(navigation button forward);
- NUMBER PLATE
- to return to the start window (navigation button
back).

How to order the engines list 3. If required, enter the word or the code to be searched
and confirm by selecting the tick icon.
To cancel the search and display all elements from the archive
select the cancel search key.
For the selection of a new engine see ECU Diagnosis.

!
1. Select the order key.

2. Select the order method.
- DATE
- ENGINE MODEL
- CUSTOMER
- NUMBER PLATE
Environment Report
How to search for an engine from the database
When the engine sheet of the engine under test has been
saved in the Report Environment, the engine has been
accepted.
You access the Report environment in the following ways:
1. Select the search key.

2. Select the search method.
- DATE
- from the Buttons area at any time by selecting the
- ENGINE MODEL corresponding button;
- CUSTOMER - from the DataBase environment by selecting the
required engine and the report button.
- NUMBER PLATE

Environment Report
DIAGNOSIS REPORT LIST

KEY:
summary of all performed
ENGINE DATA KEY: diagnosis operations
engine identification data;
the fields can be always
changed (with the
exception of the engine
model and the date) can be PROGRAMMING
always changed REPORT LIST KEY:
summary of all performed
programming operations
SAVE KEY: AUTOMATIC

it allows you to save the ACCEPTANCE KEY:
engine sheet (to accept it) (enabled only if the
communication is active)

Acceptance When you read or cancel the faults memory or carry out a
programming it is not possible to return directly to the window
The acceptance (sheet saving) is mandatory when important Family Choice; by selecting the engine button the following
operations are performed on the engine (read or cancel faults windows are displayed:
memory, programming).
1. Read or cancel the faults memory or carry out a 1. Before continuing it is necessary to save the data of the
programming and then select from the corresponding performed activity; select the tick icon; the Report
environment the report button; you enter the Report environment appears.
environment.
2. Enter data.
2. Enter data.
3. Save the sheet by selecting the save button.
3. Save the sheet by selecting the save button.

4. From the Buttons area select the button of the operation
you want to perform. It is now possible to return to the Family Choice window.

Automatic acceptance
From the Report environment it is also possible to accept the
engine automatically.
This operation is only possible if the communication

! with the system has been activated.
1. Read or cancel the faults memory or carry out a

programming and then select from the corresponding
environment the report button.
5. The automatic acceptance reads the following

information:
- Engine Model (engine type + engine serial number)
- PIC
- Engine type
- Engine Serial Number
6. At the select the save key.
2. You enter the Report environment. ECU diagnosis

3. Select the button automatic acceptance.
1. Sselect the Family, the Class and then the System of engine
under diagnosis.
2. Press the navigation button forward (enabled - green) to
continue.
4. By means of the automatic acceptance the system tries to
communicate with the engine ECU: confirm the displayed
message by pressing the tick icon; wait until the ECU is
ready.

3. The window Choose Activity appears; it is here possible 2. PT-DIAGNOSIS system presents a pop-up window
to choose from four lists: where to select the automatic or the manual activation of
Window Choose Activity the ignition key; select the required mode; the key button
is disabled.
- diagnosis
Under the automatic mode all activation of the ignition key are
- test controlled by the diagnosis instrument (key button working).
- programming Under the manual mode all activation of the ignition key are
- specific functions controlled by the operator on the engine.
4. The present Repair Guide describes the diagnosis

environment and the specific functions to which it is
associated:
- Identification Code Reading
- Faults Memory Reading
- Parameters Reading
Identification code reading

3. Confirm the new message by pressing the tick icon.
1. To access the Read Identification environment select the

item Identification Code Reading from the Diagnosis list
and then press the navigation button forward.

Multitasking option
report key
PT-DIAGNOSIS introduces a very important news: it is
Shows the Diagnosis Report List (and allows you to print each
possible to associate more ECUs to the family of engine under
report).
test.
Add an ecu
print key
It is possible to interrupt the diagnosis with an ECU and to start
Prints the summary page of Identification Parameters. the procedure with another one.
4. Wait until the ECU is ready; the general information

about the electronic system under test is read:
- identification code
- HW version
- SW version 1. Select the button ecus area>add ecu; the Choose Vehicle
- production date window will appear, where you can select the desired
ECU.
-
Managing more ecus
After identification code reading it is possible to carry out
other activities (step 5) or to return to the window Choose It is possible to operate with two or more connected ECUs
engine (step 6). at the same time.
1. Select the button ecus area>desired ecu.

The activity remains interrupted for the not selected ECUs
and can be started again at any time.
Cancel an ecu
5. To access the other activities from the environment It is possible to stop the activity on one of the connected
Identification Code Reading, select the choose activities ECUs.
buttons: choose an activity; the system automatically access
the selected activity.
The choose activities buttons are shown in yellow when
selected.
6. To exit the diagnosis of the engine under test select the 1. Slect the button ecus area>required ecu>cancel.
button ecus area>ecu under test>cancel.
2. Select the required ECU.

Ignition Key Button Modes - on line/off line Read faults memory

At the system start up the on/off button is on-line if the PT-
BOX module is activated and connected to the PC, otherwise
is disabled (off-line).
On line mode
The function Ignition Key is active; it can be managed in
automatic or manual mode; the ignition key screen appears
only after the selection of a function that requires it (e.g.
diagnosis functions).
In automatic mode all ignition key activations are managed by
the diagnosis instrument.
In manual mode all ignition key activations are managed by the
operator on the engine.
The automatic activation depends on the type of engine; make
sure the engine supports the function before selecting 1. To access the Read Faults Memory environment select the
automatic mode. item Faults Memory Reading from the list Diagnosis and
then press the navigation button forward.
1. After selecting the automatic mode a test procedure is

carried out.
2. Switch the ignition off. 2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation of
3. The engine chassis may move. the ignition key; select the required mode; the key button
The PT-DIAGNOSIS SW activates the ignition key and is disabled.
displays a screen page in which it asks to check the dashboard;
if it is turned on the diagnosis procedure can be continued;
otherwise the system asks for position of the key to ON in
manual mode.
Both in manual and in automatic mode:
1. Before ignition key activation a message is always
displayed: request (manual mode) or warning
(automatic).
2. When the ECU is cancelled a message indicates that it is
necessary to interrupt the communication and then to
confirm the operation.
3. The chosen mode remains until the engine under test is
changed.
Off line mode
The basis diagnosis is simulated and it is possible to read some
information about the electronic system under test.
3. Confirm the new message by pressing the tick icon.

cancel faults memory key

It cancels the faults selected in the list; it is possible to cancel
a fault at a time; the cancel operation will be effective when you
confirm it by pressing the tick icon displayed in the next pop-
up-window.
faults key
It allows you to access the Faults environment; it can be yellow
(the faults list is displayed) or gray (environment Faults
disabled).
4. Wait until the ECU is ready; the list and faults type
occurred during the working are displayed.
There are two types of failures:
- failures present during the reading procedure (red);
- intermittent failures not present during the reading
operation but which occurred at least once before
(black).
Detail of Buttons area of the Faults Memory area

New icons appear in the window Read Faults Memory for
accessing specific functions:
On line Mode
Faults Memory Reading Icons
environmental condi tions key

Active when the communication with the ECU has been
interrupted this is used to examine environmental conditions
when the failure occurred. It can be gray (default status) or
yellow (when selected).
repair guide key

Active when the communication with the ECU has been
interrupted it gives an analysis of the fault selected from the list;
On line Mode in particular other information (blink code, failure code and
Faults Memory Reading Icons fault mode) is available it can be gray (default status) or yellow
(when selected).
on key
The communication between the system and the ECU is report key
active: it performs again the Faults Reading; it updates the ECU
communication. It allows you to save the report of carried out operations see
Select the button to interrupt the reading. Report environment > button diagnosis report.
off key
The communication with the ECU has been interrupted. print key
Select the button to start again the electronic system reading. It allows you to print the displayed window.

Off line Mode 2. Select the button environmental conditions.

Faults Memory Reading Icons It examines the present environmental conditions at time of
the fault.
blink code search key
Appears only if the communication with the ECU interrupted
is (under OFF LINE Mode) recognize the fault where blink
code or required word appear.
To go from one function to another (faults, environmental
conditions, troubleshooting) select the corresponding button.
Operations like Read and Cancel Faults Memory are very
important: they are automatically stored and need the engine
acceptance.
How to get information about a fault

1. Interrupt the communication with the ECU (button on/
off) and select an item from the faults list: the fault is
described in the below blank area; in particular the
following information is available:
3. Select the repair guide button; the following information
is available:
- the blink code
- the failure code (DTC)
- the failure mode (FMI)
Appears a new icon, the measures key
measures key
The Measurements pop-up window opens with a list of

possible measurements and the relevant operating
suggestions.
- the fault
- the signal type
- the repetition type
The button faults appears on yellow background because it
is selected.

Parameters reading 3. The read parameters are shown and the values assumed
4. Select the groups key.
The groups key allows you to access the groups management
functions (see group Management).
Detail of parameters buttons area

New icons appears on the window Parameters Reading for
accessing specific functions:
1. To access the Parameters Reading environment select

the item Parameters Reading from the Diagnosis List and
then press the navigation button forward.
on key
The communication between the system and the ECU is
active: select the button to interrupt the reading.
off key
The communication with the ECU has been interrupted; select
the button to start again the electronic system reading.
groups key
2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation It opens the GROUPS window showing the list of created
of the ignition key; select the required mode; the key group (A) and the keys to create/modify the groups (B).
button is disabled.
Pay close attention to the displayed messages and wait until
the ECU is ready.
parameters acquisition key

It allows to record the trend in time of the measurable
parameters.
report key
It allows you to save the report of carried out operations.
print key
It allows you to print the displayed window.

Groups Management 9. From the drop down menu (above on the left), select one
of the available parameter groups, excluding the
parameter you are changing.
10. On the left-hand list the parameters of the selected group
are shown; on the right-hand list the parameter of the
group you are changing are shown.
The parameters with a gray background on the left-hand list
are parameters that have already been added and can not be
selected.
5. The Groups window opens.

The pre-defined parameter groups are first displayed then
the customized ones; the pre-defined parameters
(measurable and status) can not be modified.
11. To a parameter to the right-hand group, select it and

confirm by pressing the right arrow key ( ).
12. To remove a parameter (from the right-hand list select it
and confirm by pressing the left hand arrow key ( ).
Select the save key to save and exit the groups management
environment.
Modify a parameters group

Create a new parameters group
6. Select create.
7. Enter the name of the group you want to create.
8. Confirm by selecting the green tick icon.
1. Select a customized parameters group.

2. Select modify; the window for parameters groups
management opens.
3. Select the group you want to change and continue with
step 9 (link).

Cancel a parameters group Window Store Parameter
2. Select the sample time by using the arrows on the

Sampling active area.
3. Select the duration of registration by using the arrows key
1. Select a group of customized parameters on the active area Duration.
2. Select delete; confirm or cancel the request.
Appendix parameter acquisition key
4. Select the key start/stop to start the registration (a new

window open Notes where you can add a comment).
5. Close the Notes window, the registration starts.
6. Wait for the end of registration procedure (it is also
possible to interrupt the registration, by using the stop
key).
1. Select the parameters acquisition key; the window Store

Parameter opens.
The key is only active under on line mode.
7. Select the archive key: the Archive window open showing
the list of available registration in the archive.
Parameters reading

Archive window
- To display tables (horizontal or vertical).
- To colour display the area indicated by the diagram.
- Print.
- To go back
Programming
The consultation can be started
To access the programming area of the ECU under test
proceed as follows:
1. From the Archive windows, select a registration; it is

possible:
- to cancel it (cancel key)
- to read data (report key)
- to show data (show key, opens the Data Reading win-
dow)
- to print data (print key)
- to save data in text format (save as key)
- to go back (cross key)
Data Reading window
1. Select the Engine Family under diagnosis.

continue.
2. From the Archive window, select a registration and the

show key; the Data Reading window opens; it is possible:
- To select all parameters (fast selection key).
- Deselect all parameters (fast deselection key).
- To show the diagram with full-screen.
- Increase, reduce or to bring back to the original 3. Select the Class and the System under test to which the
display the time range (x-axle, seconds). engine belongs; select the forward navigation key
(enabled - green) to continue.

4. Select the programming option from the Programming 7. Read the displayed messages and select the green tick
list; select the forward navigation key (enabled - green). icon to continue.
5. If required, enter the required data, by following the 8. At the end the system permits access to the
indicated procedure. Programming environment; the components list is
displayed, on which tests can be carried out.
It is possible to carry out a programming only in During the programming do not disconnect the
! online mode. In case of error check the connections ! USB cable. Before carrying out the ECU
ECU/PT-BOX/PT-DIAGNOSIS. programming verify the charge left in the
computers battery.
It is recommended to plug the PC in (connect it to
the engine/vehicle or to the mains supply).
Programming environment
It is possible to use specific functions, by selecting the
corresponding key:
6. Select the ignition key management (automatic/manual): - Data Reading

if the electronic system engine under test is fitted with this
function, select the automatic key. - Change the configuration
- PT-DIAGNOSIS shows the running activities. - Programming
- The ignition key ON is automatically activated. - PTO (only for the PT-DIAGNOSIS full version SW)
- The connection to the ECU starts.

The available function types are determined according to the Data Reading
type of ECU under test. The Keys area contains the buttons
for accessing the functions specific for the Programming This is used to view the data concerning the ECU and the
environment. respective programming state; tampering attempts are shown.
The following are indicated:

print key
- station type and number;
If enabled, select to print a report. - programming date;
- ECU software release.
cancel key
If enabled, select to re-establish a configuration.
navigation keys
If enabled, select to move between different environments.
cross key
If enabled, select to cancel an operation.

The system views the following data classes:
- supplying data;
- factory data (never updated);
- service data (updated after each programming
event).
scroll keys
If enabled, select to scroll the list step by step.
fast scroll keys

If enabled, select to scroll the list step by step.

Active diagnosis
It is possible to carry out an active diagnosis only in
To start the Active Diagnosis online mode. In case of error check the following
!
connections ECU/PT-BOX/PT-DIAGNOSIS.
1. Select the Engine Family under diagnosis.

continue.
5. Select the ignition key management (automatic/manual):
if the electronic system engine under test is fitted with
this function, select the automatic key.
- PT-DIAGNOSIS displays some information about
the activity in progress.
- The ignition key ON is automatically activated.
- The ECU connection starts.
6. Read the displayed messages and select the green tick

icon to continue.
3. Select the Class and the System under test to which the
engine belongs; select the forward navigation key (enabled
- green) to continue.
7. At the end the system permits access to the Active

Diagnosis environment; the components list is displayed,
on which tests can be carried out.
4. From the Test list select the option acti ve diagnosis;

select the forward navigation key (it is active, in green
displayed).

Active Diagnosis environment

The components of the selected electronic system are indicated in a list; use the browse keys to display all the elements of the list.
1. Select the component on which the test will be carried out.
2. Select the forward navigation key to continue and carry out the test.
Help key Components:

if selected it shows selectable list
information about
the electronic system
under test;
information about Browse key
the guide to the
diagnosis are not
provided.
Forward navigation
key
Back navigation key

It allows you to move one
step back; if selected at
this level it allows you to
exit the Active Diagnosis
environment.

40
Long TypD IVECO

DTC OBD - Power Fault OBD Code Possible failure
Description MIL DiaLamp Term Bit fp Tester Healing Reason of failure
(HEX) System Red. mode (CDCDfp) correction
NOTE
Failure (FMI) Code
Base - March 2012

1D9 ECU internal fault: Analog Mil SysLamp ON non 0 3 NPL 12 Queue P060B No healing, since Buffer overrun No intervention
to Digital conversion fail- OFF Error Internal Con- the error reaction necessary
ure trol Module is a ECU recovery
A/D Proces-
sing Perform-
FAULT CODES
ance
SECTION 5 - DIAGNOSTICS
1EB Atmospheric Pressure Mil SysLamp OFF non 0 0 MAX 3 Signal P2229 The sensor raw Ambient pressure sen- Replace ECU (not
Sensor OFF too high Barometric signal sor inside ECU is necessary if never run-
Pressure Cir- APSCD_uRaw is defect. ning in high altitude and
cuit High below 4.70V. if turbocharger without
VGT) .
1 MIN 4 Signal P2228 The sensor raw Ambient pressure sen- Replace ECU (not
too low Barometric signal sor inside ECU is necessary if never run-
Pressure Cir- APSCD_uRaw is defect. ning in high altitude and
cuit Low above if turbocharger without
430.11mV. VGT) .
3 NPL 12 Signal P0069 No plausibility Ambient pressure sen- Replace ECU (not
not Manifold error is present sor inside ECU is necessary if never run-
plausible Absolute defect. ning in high altitude and
The fault codes depend on the application, therefore some may never be displayed during diagnosis.
to Ref- Pressure if turbocharger without

erence Barometric VGT) .
Pressure Pressure
(Boost) Correlation
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
Description MIL DiaLamp Term Bit Dfp Tester Healing Reason of failure
(HEX) System Red. Failure mode (FMI) Code (CDCDfp) correction
2F9 Too long time Mil SysLamp OFF non 0 3 NPL 12 Too long in P0401 No healing takes place Defect in the EGR actuators Check for errors of the EGR
Print P2D32N019 E
F4HFE ENGINES
spent in transi- OFF transition Exhaust Gas in the current driving (EGR- and throttle valve). actuators (correct installation,
tion mode from Recirculation cycle. wiring, electrical connectors,
RgnNrm Regener- Flow Insufficient jammed actuator)
ation to Detected
Normal
12D Grid heater Mil SysLamp ON non 0 0 MAX 3 Multi Signal P2609 No sticking detected Short circuit to ground of grid Check grid heater switch and
always OFF failure Intake Air heater. replace it.
switched on Heater System
Performance
12B Power stage Mil SysLamp ON non 0 0 MAX 3 Short to P0542 To give the possibility Short circuit of wiring to Check of wiring or replace
air heater 1 OFF Battery Intake Air for healing power stage external source or inside relay.
actuator Heater A Cir- is activated each relay.
cuit High 500.00ms for 5.00-
times in actual driving
cycle. Failure healed if
the power stage does
not report short circuit
to battery error. Else
no healing possible at
this driving cycle.
1 MIN 4 Short to P0541 Power stage hardware Short circuit of wiring to Check of wiring or replace
Ground Intake Air does not report short ground or inside relay. relay.
Heater A Cir- circuit to ground
cuit Low
2 SIG 2 Open P0543 Power stage hardware Broken or disconnected wir- Check of wiring or replace
Load Intake Air does not report open ing or defective relay. relay.
Heater A Cir- load
cuit Open
41
Base - March 2012

42
Long Typ IVECO

Base - March 2012

134 Boost pres- Mil SysLamp ON non 0 0 MAX 3 Signal too P0238 The sensor raw voltage Sensor defective or short cir- Check wiring or replace sen-
sure sensor OFF high Turbocharger/ value BPSCD_uRaw- cuit to external source sor.
Supercharger Val is below 4.85V
Boost Sensor
A Circuit High
1 MIN 4 Signal too P0237 The sensor raw voltage Sensor defective or short cir- Check wiring or replace sen-
low Turbocharger/ value BPSCD_uRaw- cuit to ground. sor.
Supercharger Val is above 337.24mV
Boost Sensor
A Circuit Low
3 NPL 12 Signal not P0236 No plausibility error is Difference of ambient and Check ambient and boost
plausible Turbocharger/ present boost pressure is out of range. pressure sensor for accuracy.
Supercharger
Boost Sensor
A Circuit
Range/Perform-
ance
126 Battery volt- Mil SysLamp ON non 0 0 MAX 3 Signal too P0563 The battery sensor raw Alternator voltage governor Replace alternator governor
age fault OFF high voltage defect device or alternator
System Voltage (BattCD_uRaw) is
High below 4.61V.
1 MIN 4 Signal too P0562 The battery sensor raw Battery defect, alternator Replace battery or alternator.
low System Voltage voltage defect, wiring problems (too Check ECU and wiring.
Low (BattCD_uRaw) is high resistance) or ECU
above 894.43mV defect. Occurence possible
during cold start.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
39E Info torque Mil SysLamp ON non 0 1 MIN 4 Torque NO CODE IN No Healing possible Active power redcution due No actions necessary due to
Print P2D32N019 E
F4HFE ENGINES
limitation: OFF Limitation DATASET (disabled by Data Set) to turbo charger protection. this failure alone.
turbo charger If power reduction occurred
protection due to actual defect, the fail-
active ure triggering the torque
limitation should also be in the
failure memory.
Follow troubleshooting of this
root error.
131 Coolant tem- Mil SysLamp ON non 0 0 MAX 3 Signal too P0118 If the raw value of the Sensor defective or short cir- Check wiring or replace sen-
perature sen- OFF high Engine Coolant coolant temperature cuit to external source. sor.
sor Temperature sensor
Sensor 1 Circuit (CTSCD_uRaw) is
High below 4.93V.
1 MIN 4 Signal too P0117 If the raw value of the Sensor defective or short cir- Check wiring or replace sen-
low Engine Coolant coolant temperature cuit to ground. sor.
Temperature sensor
Sensor 1 Circuit (CTSCD_uRaw) is
Low above 200.39mV.
3 NPL 12 Signal not P0116 Fid_CTSCD_Plaus is Coolant temperature and oil Check coolant temperature
plausible to Engine Coolant not inhibited any temperature values are not sensor and oil temperature
Oil Tem- Temperature longer. plausible, system cannot dis- sensor
perature Sensor 1 Circuit criminate which of both sen-
Range/Perform- sor is wrong
ance
43
Base - March 2012

44
Long Typ IVECO

Base - March 2012

232 Coolant tem- Mil SysLamp ON non 0 3 NPL 12 Minimum P0116 This defect cannot be Extreme ambient conditions. Ensure that engine was not
perature sen- OFF Tempera- Engine Coolant healed in the same driv- Or inaccurate sensor running in extreme ambient
sor absolute ture not Temperature ing cycle. (although sensor does not conditions. Check wiring and
test reached in Sensor 1 Circuit exceed its signal range) or accuracy of sensor, replace-
time Range/Perform- thermostat blocked open. ment of sensor
ance
132 Coolant tem- Mil SysLamp OFF non 0 3 NPL 12 Minimum P0116 This defect cannot be Extreme ambient conditions. Ensure that engine was not
perature sen- OFF Tempera- Engine Coolant healed in the same driv- Or inaccurate sensor running in extreme ambient
sor dynamic ture Rise Temperature ing cycle. (although sensor does not conditions. Check wiring and
test not Sensor 1 Circuit exceed its signal range) or accuracy of sensor, replace-
reached Range/Perform- thermostat blocked open. ment of sensor. Check ther-
ance mostat.
24F Info: Induce- Mil SysLamp ON non 0 0 MAX 3 Emergency Not found in No healing in the cur- Only an Info-Failure signaling Check and repair failures
ment Engine OFF start time database table rent driving cycle that engine shut down induce- which are activating induce-
shut off active expired ment is active. ment procedure
and shut-
down initi-
ate
14F Info torque Mil SysLamp ON non 0 0 MAX 3 Perform- Not found in As soon as no perform- A defect has occurred (in the Check and repair the faiures
limitation: OFF ance database table ance limitation is pres- EDC or DCU) which trig- which triggered the perform-
Inducement Limitation ent gered a performance limita- ance limitation
active active tion required by legislation.
13C Ambient Mil SysLamp OFF non 0 0 MAX 3 Signal too P0073 If the raw value of the Sensor defective or short cir- Check wiring or replace sen-
Temperature OFF high Ambient Air environmental air tem- cuit to external source. sor.
Sensor Temperature perature sensor
Sensor Circuit (EATSCD_uRaw) is
High below 4.90V.
low Ambient Air environmental air tem- cuit to ground. sor.
Temperature perature sensor
Sensor Circuit (EATSCD_uRaw) is
Low above 200.39mV.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
142 Running with Mil SysLamp ON non 1) yes 0 0 MAX 4 Backup P0335 Increment system is Signal interrupted do to wiring Check wiring, sensor installa-
Print P2D32N019 E
F4HFE ENGINES
camshaft sen- OFF (techni- Mode Crankshaft detected to be Ok problem, defective or incor- tion and proper functioning of
sor only cal) Position Sensor AND switch over rectly installed crankshaft crankshaft sensor (evaluated
A Circuit condition from speed sensor. raw signals).
BACKUP to OK mode
is released (procedure
prevents excessive
switching between the
two modes), engine
speed is below
6000.00rpm rpm,
0.95- < change in
engine speed
n(t)/n(t-1) < 1.05-,
2.00- segment edge
numbers after a cam-
shaft wheel gap are
detected, the simu-
lated crankshaft signal
generated from the
camsignal information
corresponds suffi-
ciently with the
measured crankshaft
signal.
143 Camshaft sen- Mil SysLamp ON non 1) yes 0 0 MAX 2 No Signal P0340 At least one camshaft Signal interrupted do to wiring Check wiring, sensor installa-
sor failure OFF (techni- Camshaft Posi- edge is detected since problem, defective or incor- tion and proper functioning of
cal) tion Sensor A the last interrupt (at rectly installed camshaft phase camshaft phase sensor (evalu-
Circuit least one phase buffer sensor. ate raw signals).
entry is displayed via
CaSCD_stPhaseSig).
1 MIN 4 Signal P0341 The healing counter, Signal interrupted do to wiring Check wiring, sensor installa-
wrong Camshaft Posi- which adds up the problem, defective or incor- tion and proper functioning of
tion Sensor A crankshaft increments rectly installed camshaft phase camshaft phase sensor (evalu-
Circuit Range/ when the camshaft sig- sensor. ate raw signals).
Performance nal is valid again
(EngM_ctIncErrSig-
DiagmaxCaSOk_mp),
exceeds 132.00.
45
Base - March 2012

46
Long Typ IVECO

Base - March 2012

141 Crankshaft Mil SysLamp ON non 1) yes 0 0 MAX 2 No Signal P0335 Healing occcurs imme- Signal interrupted do to wiring Check wiring, sensor installa-
sensor failure OFF (techni- diatly if increment signal problem, defective or incor- tion and proper functioning of
cal) Crankshaft status information rectly installed crankshaft crankshaft sensor (evaluate
Position Sensor CrSCD_stInc- speed sensor. raw signals).
A Circuit Sig_mp>=32, which
means that at least 3
increments have been
uniquely detected and
are dynamically plaus-
ible .
1 MIN 4 Signal P0336 1) The increment signal Signal interrupted do to wiring Check wiring, sensor installa-
wrong Crankshaft frequency is below problem, defective or incor- tion and proper functioning of
Position Sensor 6000.00rpm rectly installed crankshaft crankshaft sensor (evaluate
A Circuit speed sensor. raw signals).
Range/Perform- OR
ance
2) A counter for plaus-
ible increments is
started when the
increment system
(crankshaft signal)
reaches the position
valid state
(CrSCD_stInc-
Sig_mp=64) and the
error is healed if this
counter exceeds
72.00-
3) The increment sys-

tem reaches the posi-
tion valid state
(CrSCD_stInc-
Sig_mp=64).
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
144 Offset Mil SysLamp ON non 0 0 MAX 3 Offset P0016 Terminal 15 (ignition Signal interrupted do to wiring Check wiring, sensor installa-
Print P2D32N019 E
F4HFE ENGINES
between cam- OFF between Crankshaft key) is switched on and problem, defective or incor- tions and proper functioning
shaft and Signals Position Cam- off OR a new synchro- rectly installed camshaft or of camshaft and crankshaft
cranksh. shaft Position nisation of the angular crankshaft sensor. sensors (evaluate raw signals).
Correlation system is carried out
(via EngM_stSync=33
and 48) so that no dis-
tortion between cam-
shaft and crankshaft is
present anymore.
64C Info torque Mil SysLamp ON non 0 1 MIN 4 active P0217 Torque demand below Active power reduction due No actions necessary due to
limitation: OFF torque Engine Coolant torque limitation for to engine overheat protec- this failure alone. If power
Exhaust over- limitation Over Tempera- overheat protection tion. reduction occurred due to
heat protec- ture Condition actual defect, the failure
tion active triggering the torque limita-
tion should also be in the fail-
ure memory. Follow trouble-
shooting of this root error.
54C Info torque Mil SysLamp ON non 0 0 MAX 3 Engine P0219 Engine speed Engine overspeed has No reactions necessary only if
limitation: OFF Over- (Eng_nAvg) is below occurred. this fault/information status
Engine overspeed Engine Over- 3050.00rpm reoccurs frequently. In this
speed protec- speed Condi- case check driving conditions
tion active tion of vehicle, engine speed
acquisition and injection sys-
tem for quantity setpoint and
actual value during fault rec-
ognition, check also for ECU
errors.
47
Base - March 2012

48
Long Typ IVECO

Base - March 2012

49E Info torque Mil SysLamp ON non 0 1 MIN 4 Torque NO CODE IN The torque limitation Active power reduction due No actions necessary due to
limitation: OFF Limitation DATASET due to generic engine to engine mechanics protec- this failure alone. If power
generic engine protection is below the tion. reduction occurred due to
protection limits actual defect, the failure
active triggering the torque limita-
34D Performance Mil SysLamp ON non 0 1 MIN 4 Torque P0219 The torque limitation Active power reduction due No actions necessary due to
limit active OFF limitation Engine Over- due to engine mech- to engine mechanics protec- this failure alone. If power
due to either speed Condi- anics protection is tion by speed limitation. reduction occurred due to
stage tion below the limits actual defect, the failure
triggering the torque limita-
135 Fuel Temp. Mil SysLamp ON non 0 0 MAX 3 Signal too P0183 If the raw value of the Sensor defective or short cir- Check wiring or replace sen-
Signal OFF high Fuel Tempera- fuel temperature sen- cuit to external source. sor.
ture Sensor A sor (FTSCD_uRaw) is
Circuit High below 4.93V.
low Fuel Tempera- fuel temperature sen- cuit to ground. sor.
ture Sensor A sor (FTSCD_uRaw) is
Circuit Low above 200.39mV.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
149 Fuel filter Mil SysLamp OFF non 0 0 MAX 3 Short to NO CODE IN To give the possibility Short circuit of wiring to Check of wiring, replace fuel
Print P2D32N019 E
F4HFE ENGINES
heating out- OFF Battery DATASET for healing power stage external source or inside fuel filter heater.
put is activated each filter heater.
500.00ms for 5.00-
not report short circuit
to battery error. Else
no healing possible at
this driving cycle.
1 MIN 4 Short to NO CODE IN Power stage hardware Short circuit of wiring to Check of wiring, replace fuel
Ground DATASET does not report short ground or inside fuel filter filter heater.
circuit to ground. heater.
3 NPL 12 Excess NO CODE IN To give the possibility High battery voltage, high Check of wiring or replace fuel
tempera- DATASET for healing power stage ECU temperature and high filter heater, if necessary
ture is activated each load or defective wiring or replace ECU.
500.00ms for 5.00- defective fuel filter heater.
not report excessive
temperature error.
Else no healing possible
at this driving cycle.
11C Water in Fuel Mil SysLamp non 0 0 MAX 3 Water in P2269 Water in fuel no more Water separation tank of fuel Switch off ignition and empty
OFF BLINK Fuel Water in Fuel detected filter full or water level sensor water tank of fuel filter, check
detected Condition of fuel filter defective. level sensor.
49
Base - March 2012

50
Long Typ IVECO

Base - March 2012

1AF DM1DCU Mil SysLamp OFF non 1) yes 0 0 MAX 3 Error in P2BA7 DCU error is no longer At least one of the DCU error Check what SPN and corre-
SPN1 mess- OFF (OBD) DCU NOx Exceed- active and its corre- assigned to SPN1 group has sponding DCU error is active
age active ence - Empty sponding SPN is no occured and is reported via and perform troubleshooting
Reagent Tank longer transmitted via CAN to the EDC. according to DCU support.
CAN
2AF DM1DCU Mil SysLamp OFF non 1) yes 0 0 MAX 3 Error in P2BA7 DCU error is no longer At least one of the DCU error Check what SPN and corre-
SPN2 mess- OFF (OBD) DCU NOx Exceed- active and its corre- assigned to SPN2 group has sponding DCU error is active
CAN
3AF DM1DCU Mil SysLamp OFF non 0 0 MAX 3 Error in P2BA7 DCU error is no longer At least one of the DCU error Check what SPN and corre-
SPN3 mess- OFF DCU NOx Exceed- active and its corre- assigned to SPN3 group has sponding DCU error is active
CAN
4AF DM1DCU Mil SysLamp OFF non 1) yes 0 0 MAX 3 Error in Not found in DCU error is no longer At least one of the DCU error Check what SPN and corre-
SPN4 mess- OFF (OBD) DCU database table active and its corre- assigned to SPN4 group has sponding DCU error is active
age active sponding SPN is no occured and is reported via and perform troubleshooting
longer transmitted via CAN to the EDC. according to DCU support.
CAN
5AF DM1DCU Mil SysLamp OFF non 1) yes 0 0 MAX 3 Error in Not found in DCU error is no longer At least one of the DCU error Check what SPN and corre-
SPN5 mess- OFF (OBD) DCU database table active and its corre- assigned to SPN5 group has sponding DCU error is active
age active sponding SPN is no occured and is reported via and perform troubleshooting
longer transmitted via CAN to the EDC. according to DCU support.
CAN
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
1A3 Nox signal of Mil SysLamp ON non 1) yes 0 0 MAX 3 Open P2202 The NOx sensor unit Disconnected cable in the Check wiring of NOx sensor
Print P2D32N019 E
F4HFE ENGINES
Nox Sensor OFF (OBD) Load NOx Sensor does not report an wiring of the NOx sensor or and its proper functioning. If
Circuit Low open wire for one of its defective NOx sensor. necessary replace NOx sen-
Input components sor.
1 MIN 4 Short Cir- P2203 The NOx sensor unit Short circuit in the wiring of Check wiring of NOx sensor
cuit NOx Sensor does not report a short the NOx sensor or defective and its proper functioning. If
Circuit High circuit for one of its NOx sensor. necessary replace NOx sen-
Input components. sor.
3 NPL 12 Sensor not P2201 Sensor at temperature Strange driving cycle or Check installation (including
ready in NOx Sensor and valid NOx or inproper installation of the wiring) and functionality of
time Circuit Range/ lambda signal reported sensor, defective NOx sen- sensor. If necessary change
Performance by the sensor unit via sor. NOx sensor .
CAN message.
1A2 Nox signal of Mil SysLamp OFF non 0 3 NPL 12 Signal not P2201 The raw signal of the CAN communication dis- Check for proper CAN com-
Nox Sensor OFF plausible NOx Sensor NOx concentration turbed, defective or inaccur- munication and check accu-
Circuit Range/ (first two bytes of the ate NOx sensor. racy and proper functioning of
Performance CAN message NOx sensor.
NOxSens) received
from the NOx sensor is
above -100.00-.
1A8 Error / Protec- Mil SysLamp OFF non 0 0 MAX 3 Torque NO CODE IN SCR protection no Failure due to engine switch Read out the DCU failure
tion request OFF Limitation DATASET more requested off after a high load period, memory and perform
on urea valve Level2 for leading to high temperatur in troubleshooting according to
via SCR1 SCR exhaust system. A defect DCU support.
Protection occurred in the urea dosing
active system which can impair the
cooling of the urea dosing
valve.
1 MIN 4 Torque NO CODE IN . SCR protection no A defect occurred in the urea Read out the DCU failure
Limitation DATASET more requested dosing system which can memory and perform
Level1 for impair the cooling of the urea troubleshooting according to
SCR dosing valve. DCU support.
Protection
active
51
Base - March 2012

52
Long Typ IVECO

Base - March 2012

1B4 Timeout for Mil SysLamp ON non 0 0 MAX 2 CAN time- P0600 Body Computer mess- Defective CAN controller of Check presence and correct
BC2EDC1 OFF out Serial Com- age BC2EDC1 is Body Computer, undervol- connection of the BC to the
munication Link received tage of BC, missing BC, CAN network, Check correct func-
cable connecting the BC is dis- tioning of the BC CAN con-
connected or broken. Short troller and its voltage supply.
circuit in wiring. Check wiring.
1A5 Message Mil SysLamp ON non 1) yes 0 0 MAX 2 CAN time- U010E DM1DCU message is Defective CAN controller of Check presence and correct
DM1DCU OFF (techni- out Dosing control received DCU, undervoltage of DCU, connection of the DCU to the
timeout cal) unit (Reductant missing DCU, CAN cable network, check correct func-
2) yes Metering Con- connecting the DCU is dis- tioning of the DCU CAN con-
(OBD) trol Unit) - No connected or broken. Short troller and its voltage supply.
function circuit in wiring. Check wiring.
1A4 Message Nox Mil SysLamp ON non 1) yes 0 0 MAX 2 CAN time- P2200 NOx Sensor message Defective CAN controller of Check presence and correct
Sensor time- OFF (OBD) out NOxSens is received. NOx Sensor, undervoltage of connection of the NOx Sen-
out NOx Sensor NOx Sensor, missing NOx sor to the network, Check
Circuit Sensor, CAN cable connect- correct functioning of the
ing the NOx Sensor is discon- NOx Sensor CAN controller
nected or broken. Short cir- and its voltage supply. Check
cuit in wiring. wiring.
1A6 Message Mil SysLamp ON non 1) yes 0 0 MAX 2 CAN time- U010E DCU message SCR1 is Defective CAN controller of Check presence and correct
SCR1 timeout OFF (techni- out Dosing control received Dosing Control Unit , under- connection of the DCU to the
cal) unit (Reductant voltage of DCU, missing DCU, network, Check correct func-
2) yes Metering Con- CAN cable connecting the tioning of the DCU CAN con-
(OBD) trol Unit) - No DCU is disconnected or troller and its voltage supply.
function broken. Short circuit in wiring. Check wiring.
2A6 Message Mil SysLamp ON non 1) yes 0 0 MAX 2 CAN time- P0600 DCU message SCR2 is Defective CAN controller of Check presence and correct
SCR2 timeout OFF (techni- out Serial Com- received Dosing Control Unit , under- connection of the DCU to the
cal) munication Link voltage of DCU, missing DCU, network, Check correct func-
CAN cable connecting the tioning of the DCU CAN con-
DCU is disconnected or troller and its voltage supply.
broken. Short circuit in wiring. Check wiring.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
1C6 Timeout of Mil SysLamp ON non 0 0 MAX 3 CAN time- NO CODE IN TSC1-PE message is Defective CAN controller of Check presence and correct
Print P2D32N019 E
F4HFE ENGINES
CAN message OFF out DATASET received Power Take Off , undervol- connection of the PTO to the
TSC1-PE tage of PTO, missing PTO, network, Check correct func-
active CAN cable connecting the tioning of the PTO CAN con-
PTO is disconnected or troller and its voltage supply.
2C6 Timeout of Mil SysLamp ON non 0 0 MAX 2 CAN time- NO CODE IN No timeout error is Defective CAN controller of Check presence and correct
CAN message OFF out DATASET reported by the CAN Power Take Off , undervol- connection of the PTO to the
TSC1-PE controller over tage of PTO, missing PTO, network, Check correct func-
passive 500.00ms CAN cable connecting the tioning of the PTO CAN con-
PTO is disconnected or troller and its voltage supply.
1C8 Timeout of Mil SysLamp ON non 0 0 MAX 3 CAN time- NO CODE IN TSC1-VE message is Defective CAN controller of Check presence and correct
CAN message OFF out DATASET received Vehicle Control Module or connection of the VCM/BC to
TSC1-VE Body Computer , undervol- the network, Check correct
active tage of VCM/BC, missing functioning of the VCM/BC
VCM/BC, CAN cable con- CAN controller and its volt-
necting the VCM/BC is dis- age supply. Check wiring.
connected or broken. Short
circuit in wiring.
3C8 Timeout of Mil SysLamp ON non 0 0 MAX 2 CAN time- NO CODE IN No timeout error is Defective CAN controller of Check presence and correct
CAN message OFF out DATASET reported by the CAN Vehicle Control Module or connection of the VCM/BC to
TSC1-VE controller over Body Computer , undervol- the network, Check correct
passive 500.00ms tage of VCM/BC, missing functioning of the VCM/BC
VCM/BC, CAN cable con- CAN controller and its volt-
necting the VCM/BC is dis- age supply. Check wiring.
connected or broken. Short
circuit in wiring.
1B5 Timeout for Mil SysLamp ON non 0 0 MAX 2 CAN time- P0600 VCM message Defective CAN controller of Check presence and correct
VM2EDC OFF out Serial Com- VM2EDC is received Vehicle Control Module, connection of the VCM to the
munication Link undervoltage of VCM, missing network, Check correct func-
VCM, CAN cable connecting tioning of the VCM CAN con-
the VCM is disconnected or troller and its voltage supply.
53
Base - March 2012

54
Long Typ IVECO

Base - March 2012

1B7 Timeout in Mil SysLamp ON non 0 2 SIG 2 CAN time- P0600 All outgoing CAN Disturbed CAN, incorrect Check CAN communication,
CAN send OFF out Serial Com- messages acknowl- configuration of the CAN, check CAN configuration,
messages munication Link edged EDC is disconnected from the ensure proper connection of
network, EDC CAN con- the EDC to the network,
troller defective. replace EDC.
1D1 ECU internal Mil SysLamp non 0 0 MAX 3 CJ940 P0606 The error is healed if Electric disturbances, internal Replace ECU if failure remains
fault: SPI bus OFF BLINK Communi- ECM/PCM Pro- the error counter is defect of the ECU leading to present.
Fault cation fail- cessor equal to or below the a SPI bus communication
ure value of 0.00-. error.
Counter decrement at
intact detection by 1
step per event
1D2 ECU internal Mil SysLamp OFF non 0 1 MIN 4 EEPROM P0606 Immediately if the Wrong programming/flashing Try to flash the EDC correctly
fault OFF Read fail- ECM/PCM Pro- EEPROM operates of the EDC, internal defect of with a proper dataset, if defect
ure cessor correctly. the EDC. persists: replace EDC.
2 SIG 2 EEPROM P0606 Immediately if the Wrong programming/flashing Try to flash the EDC correctly
Write fail- ECM/PCM Pro- EEPROM operates of the EDC, internal defect of with a proper dataset, if defect
ure cessor correctly. the EDC. persists: replace EDC.
3 NPL 12 EEPROM P0606 Immediately if the Wrong programming/flashing Try to flash the EDC correctly
default ECM/PCM Pro- EEPROM operates of the EDC, internal defect of with a proper dataset, if defect
Value used cessor correctly. the EDC. persists: replace EDC.
1D3 ECU internal Mil SysLamp non 0 3 NPL 12 Soft reset, P0606 None Electronic disturbances, vari- Analyze what error triggered
fault OFF BLINK recovery ECM/PCM Pro- ous hardware defects (ECU the recovery (Read out label
occurred cessor internal) or configuration HWEMon_numRecovery
problems. and compare the value with
the according table). If error
occurs repeatedly, reprogram
EDC. If error remains, replace
EDC.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
2D3 ECU internal Mil SysLamp non 0 3 NPL 12 Low bat- P0606 None Electronic disturbances, vari- Analyze what error triggered
Print P2D32N019 E
F4HFE ENGINES
fault OFF BLINK tery volt- ous hardware defects (ECU the recovery (Read out label
age reset ECM/PCM Pro- internal) or configuration HWEMon_numRecovery
cessor problems. and compare the value with
EDC.
3D3 ECU internal Mil SysLamp non 0 3 NPL 12 Soft reset, P0606 None Electronic disturbances, vari- Analyze what error triggered
fault OFF BLINK recovery ECM/PCM Pro- ous hardware defects (ECU the recovery (Read out label
occurred cessor internal) or configuration HWEMon_numRecovery
problems. and compare the value with
EDC
1E9 ECU internal Mil SysLamp non 0 0 MAX 3 Supply P0659 None, since power Excessive voltage supply of a Check the battery for correct
fault: Supply OFF BLINK Voltage Actuator Sup- stage is switched off. CJ940 component: High bat- voltage supply, check wiring. If
voltage CJ940 CJ940 ply Voltage A tery voltage, defective wiring, defect remains replace EDC
upper limit above Circuit High internal defect of the EDC. (internal defect).
Limit
1EA ECU internal Mil SysLamp non 0 1 MIN 4 Supply P0658 None, since power Insufficient voltage supply of a Check the battery for suffi-
fault: Supply OFF BLINK Voltage Actuator Sup- stage is switched off. CJ940 component: Low bat- cient voltage supply, check
voltage CJ940 CJ940 ply Voltage A tery voltage, defective wiring, wiring. If defect remains
lower limit below Circuit Low internal defect of the EDC. replace EDC (internal defect).
Limit
15B Info: High Mil SysLamp OFF non 0 0 MAX 3 Rail pres- NO CODE IN The High Pressure The High Pressure Test is Wait until the High Pressure
pressure test OFF sure moni- DATASET Test is no longer requested via a diagnostic Test has terminated.
started by ser- toring active. tester.
vice tool deacti-
vated
55
Base - March 2012

56
Long Typ IVECO

Base - March 2012

2AE Info: humidity Mil SysLamp OFF non 0 0 MAX 3 Signal Ratio NO CODE IN If the raw value of the Sensor possibly saturated If failure 1AE IAHSCDStrDly
sensor poten- OFF above DATASET air humidity sensor with water droplets. also stored in memory: pro-
tially wet Limit (IAHSCD_uRaw) is ceed according that descrip-
below 4.90V. tion. If failure ACTIVE: run
engine at medium speed > 10
min, if failure does NOT get
INACTIVE: check wiring har-
ness and replace sensor if
necessary. If failure not active
AND ratio active time /

occurrence < 10 min/occur-
rence: no action needed. If fail-
ure not active AND ratio
active time / occurrence >
10 min/occurrence: possible
short circuit: check wiring har-
ness or replace sensor, if
necessary.
1 MIN 4 Signal Ratio NO CODE IN If the raw value of the Sensor defective or short cir- Check wiring. Replace sensor
below DATASET air humidity sensor cuit to ground. if necessary.
Limit (IAHSCD_uRaw) is
above 200.39mV.
1AE Humidity sig- Mil SysLamp OFF non 0 0 MAX 3 Signal Ratio NO CODE IN If the raw value of the Sensor defective or short cir- Check wiring. Replace sensor
nal ratio failure OFF above DATASET air humidity sensor cuit to external source. if necessary.
below 4.90V.
1 MIN 4 Signal Ratio NO CODE IN If the raw value of the Sensor defective or short cir- Check wiring. Replace sensor
below DATASET air humidity sensor cuit to ground. if necessary.
above 200.39mV.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
133 Boost Temp. Mil SysLamp OFF non 0 0 MAX 3 Signal too P0113 If the raw value of the Sensor defective or short cir- Check wiring or replace sen-
Print P2D32N019 E
F4HFE ENGINES
Signal OFF high Intake Air Tem- induction air tempera- cuit to external source. sor.
perature Sen- ture sensor
sor 1 Circuit (IATSCD_uRaw) is
High below 4.91V.
low Intake Air Tem- induction air tempera- cuit to ground. sor.
perature Sen- ture sensor
sor 1 Circuit (IATSCD_uRaw) is
Low above 200.39mV.
1E2 Error state of Mil SysLamp non 0 1 MIN 4 Injection P0513 1) No automatic heal- 1) Defective CAN or immo- 1) Ensure correct CAN func-
Immobilizer OFF BLINK disabled ing bilizer and new control unit tioning (timeout errors),
(no fuel Incorrect (here no PIN entry is possible) unlock fuel release via a tester
release) Immobilizer Key 2) Error is cleared after OR T15 was toggled more request, replace immobilizer
successful PIN entry than a calibratable value OR
2) Enter PIN code via acceler-
number of allowed incorrect
PIN entries is exceeded. ator pedal or instrument
cluster, ensure correct CAN
2) Defective CAN or immo- functioning (timeout errors),
bilizer OR wrong code AND replace immobilzer
code is kown by the EDC
AND T15 has not been tog-
geled excessively
171 Bank 1 specific Mil SysLamp ON non 0 0 MAX 3 Short cir- P2148 No Healing possible Short circuit of high-side to Check the wiring or replace
errors - Short OFF cuit Fuel Injector (disabled by Data Set) battery or ground. injector.
circuit / not Group A Sup-
classifiable ply Voltage Cir-
cuit High
1 MIN 4 Short Low P2147 No Healing possible Short circuit of low-side to Check the wiring or replace
Side to Fuel Injector (disabled by Data Set) ground in injector cable. injector.
Ground Group A Sup-
ply Voltage Cir-
cuit Low
3 NPL 12 Not classi- P2146 No Healing possible Depending on the pattern, Check the wiring and the
fiable fail- Fuel Injector (disabled by Data Set) various reasons can cause the injection signals, replace ECU.
ure Group A Sup- defect, internal ECU problem.
ply Voltage Cir-
cuit/Open
57
Base - March 2012

58
Long Typ IVECO

Base - March 2012

172 Bank 1 specific Mil SysLamp ON non 0 0 MAX 3 Depending P2146 Healing is only possible Defect in wiring or injector. Check the wiring and injector.
warnings - OFF on Fuel Injector if test injections are
Open load Applica- Group A Sup- allowed by application
tion ply Voltage Cir- (see system reaction)
cuit/Open and occurs after 0.00-
correct camshaft revol-
utions.
173 Bank 2 specific Mil SysLamp ON non 0 0 MAX 3 Short cir- P2151 No Healing possible Short circuit of high-side to Check the wiring or replace
errors - Short OFF cuit Fuel Injector (disabled by Data Set) battery or ground. injector.
circuit / not Group B Sup-
classifiable ply Voltage Cir-
cuit High
1 MIN 4 Short Low P2150 No Healing possible Short circuit of low-side to Check the wiring or replace
Side to Fuel Injector (disabled by Data Set) ground in injector cable. injector.
Ground Group B Sup-
ply Voltage Cir-
cuit Low
fiable fail- Fuel Injector (disabled by Data Set) various reasons can cause the injection signals, replace ECU.
ure Group B Sup- defect, internal ECU problem.
ply Voltage Cir-
cuit/Open
174 Bank 2 specific Mil SysLamp ON non 0 0 MAX 3 Depending P2149 Healing is only possible Defect in wiring or injector. Check the wiring and injector.
warnings - OFF on Fuel Injector if test injections are
Open load Applica- Group B Sup- allowed by application
tion ply Voltage Cir- (see system reaction)
cuit/Open and occurs after 0.00-
utions.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
17C Chip-specific Mil SysLamp ON non 0 0 MAX 3 Internal P2146 No Healing possible Clock error or irruption of the Check the power supply or
Print P2D32N019 E
F4HFE ENGINES
errors-->stop OFF reset - (disabled by Data Set) power supply voltage. replace ECU if problem reoc-
engine Clock Loss Fuel Injector curs.
- Voltage Group A Sup-
too low ply Voltage Cir-
cuit/Open
1 MIN 4 Unlocked - P2146 No Healing possible Defective ECU. Reset ECU. If no recovery,
Init fail Fuel Injector (disabled by Data Set) replace ECU.
Group A Sup-
ply Voltage Cir-
cuit/Open
2 SIG 2 Test Mode P2146 No Healing possible Internal failure of ECU or TESTMODE calibration
Fuel Injector (disabled by Data Set) TESTMODE takes too long. wrong or replace ECU if prob-
Group A Sup- lem reoccurs.
ply Voltage Cir-
cuit/Open
3 NPL 12 SPI Com- P2146 No Healing possible Defective SPI-bus participant, Replace ECU if problem reoc-
munication Fuel Injector (disabled by Data Set) timing problem due to soft- curs (Send in ECU for inves-
failure Group A Sup- ware bug. tigation).
ply Voltage Cir-
cuit/Open
59
Base - March 2012

60
Long Typ IVECO

Base - March 2012

27C Chip-specific Mil SysLamp ON non 0 0 MAX 3 Internal P2149 No Healing possible Clock error or irruption of the Check the power supply or
errors-->stop OFF reset - Fuel Injector (disabled by Data Set) power supply voltage. replace ECU if problem reoc-
engine Clock loss - Group B Sup- curs.
Voltage ply Voltage Cir-
too low cuit/Open
1 MIN 4 Unlocked - P2149 No Healing possible Defective ECU. Reset ECU. If no recovery,
Init fail Fuel Injector (disabled by Data Set) replace ECU.
Group B Sup-
ply Voltage Cir-
cuit/Open
2 SIG 2 Test Mode P2149 No Healing possible Internal failure of ECU or TESTMODE calibration
Fuel Injector (disabled by Data Set) TESTMODE takes too long. wrong or replace ECU if prob-
Group B Sup- lem reoccurs.
ply Voltage Cir-
cuit/Open
3 NPL 12 SPI Com- P2149 Infinite Defective ECU. Replace ECU if problem reoc-
munication Fuel Injector curs (Send in ECU for inves-
failure Group B Sup- tigation).
ply Voltage Cir-
cuit/Open
161 Cylinder1 - Mil SysLamp ON non 0 0 MAX 3 Short Low P0262 No Healing possible Short circuit in wiring with Check the wiring or replace
Short circuit OFF Side to Cylinder 1 (disabled by Data Set) external source. injector.
Low/High Battery Injector Circuit
High
2 SIG 2 Short High P0261 No Healing possible Defective coil of injector. Check the wiring and replace
Side to Cylinder 1 (disabled by Data Set) injector.
Ground Injector Circuit
Low
fiable fail- Cylinder 1 Con- (disabled by Data Set) various reasons can cause the injection signals, replace ECU.
ure tribution/Bal- defect, internal ECU prob-
ance lems also possible.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
167 Cylinder1 - Mil SysLamp ON non 0 2 SIG 2 Open P0261 Healing is only possible Broken wire or disconnection Check the wiring or replace
Print P2D32N019 E
F4HFE ENGINES
Open load OFF Load Cylinder 1 if test injections are of wiring or inside injector. injector.
Injector Circuit allowed by application
Low (see system reaction)
and ccurs after 0.00-
utions.
High
Low
Open load OFF Load Cylinder 2 Con- if test injections are of wiring or inside injector. injector.
tribution/Bal- allowed by application
ance (see system reaction)
utions.
61
Base - March 2012

62
Long Typ IVECO

Base - March 2012

High
Low
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
Print P2D32N019 E
F4HFE ENGINES
utions.
High
Low
fiable fail- Cylinder 4 Con- (disabled by Data Set) various reasons can cause the injection signals, replace ECU
16A Cylinder4 - Mil SysLamp ON non 0 2 SIG 2 Open P0272 Healing is only possible Broken wire or disconnection Check the wiring or replace
utions.
63
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64
Long Typ IVECO

Base - March 2012

Short circuit OFF Side to (disabled by Data Set) external source. injector.
Low/High Battery Cylinder 5
Injector Circuit
High

Low
16B Cylinder5 - Mil SysLamp ON non 0 2 SIG 2 Open P0275 Healing is only possible Broken wire or disconnection Check the wiring or replace
utions.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
Print P2D32N019 E
F4HFE ENGINES
High
Low
fiable fail- Cylinder 6 (disabled by Data Set) various reasons can cause the injection signals, replace ECU.
ure Injector Circuit defect, internal ECU prob-
Low lems also possible.
16C Cylinder6 - Mil SysLamp ON non 0 2 SIG 2 Open P0278 Healing is only possible Broken wire or disconnection Check the wiring or replace
utions.
16E Minimum Mil SysLamp non 0 0 MAX 3 Number of P0252 The number of defec- See individual injector and See individual injector and
number of OFF BLINK Injections Injection Pump tive cylinders is below injection-bank errors (InjVlv- injection-bank errors (InjVlv-
injectors to not Fuel Metering the limit over Cyl... and InjVlvBnk...) which Cyl... and InjVlvBnk...) which
run the engine reached Control A 65535.00- injections. have triggerd the shut-off or have triggerd the shut-off or
was not Range/Perform- error in the component. error in the component.
reached ance (Cam/
Rotor/Injector)
65
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66
Long Typ IVECO

Base - March 2012

125 Main relay Mil SysLamp OFF non 0 0 MAX 3 Short to P2510 Error cannot be healed Short circuit of main relay 2 Check the wiring and all com-
defect (for OFF Battery in current driving cycle. output to external source, ponents connected to main
High press ECM/PCM Error must be check defect in one of the con- relay 2, if defect remains main
pump Power Relay again in following after nected components or defec- relay inside ECU could be
P340/for Sense Circuit run. tive main relay 2. defective, replace ECU.
engine brake Range/Perform-
decompr.valv ance
e P342))
1 MIN 4 Short to P2510 Healing not possible in Short circuit of main relay 2 Check the wiring and all com-
Ground ECM/PCM current driving cycle output to ground, defect in ponents connected to main
Power Relay (once error is finalized). one of the connected compo- relay 2, if defect remains main
Sense Circuit nents or defective main relay relay inside ECU could be
Range/Perform- 2. defective, replace ECU.
ance
225 Interrupted Mil SysLamp OFF non 0 0 MAX 3 Relay P2610 The counter is reset The ECU is switched off by Inform driver about correct
afterrun OFF opened ECM/PCM and the error healed in main electrical switch instead vehicle shut off, check wiring,
too early Internal Engine case of a successful of terminal 15, defective main replace main relay.
(Afterrun Off Timer Per- afterrun. relay, wiring problem.
not com- formance
pleted)
129 Main relay 3 Mil SysLamp OFF non 0 0 MAX 3 Short to P0650 Error cannot be healed Short circuit of main relay 3 Check the wiring and all com-
(A/C compr./ OFF Battery Malfunction in current driving cycle. output to external source, ponents connected to main
fuel filter Indicator Lamp Error must be check defect in one of the con- relay 3, if defect remains main
heater) (MIL) Control again in following after nected components or defec- relay inside ECU could be
Circuit run. tive main relay 3. defective, replace ECU.
1 MIN 4 Short to P0650 Healing not possible in Short circuit of main relay 3 Check the wiring and all com-
Ground Malfunction current driving cycle output to ground, defect in ponents connected to main
Indicator Lamp (once error is finalized). one of the connected compo- relay 3, if defect remains main
(MIL) Control nents or defective main relay relay inside ECU could be
Circuit 3. defective, replace ECU.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
159 Metering unit Mil SysLamp ON non 0 2 SIG 2 Open load P0001 No Healing possible Broken or disconnected wir- Check of wiring or replace
Print P2D32N019 E
F4HFE ENGINES
PWM-pow- OFF Fuel Volume (disabled by Data Set) ing or defective relay. relay.
erstage Regulator Con-
trol Circuit/
Open
3 NPL 12 Excessive P0001 No Healing possible Defective wiring, ECU, pow- Check wiring, ECU, power
tempera- Fuel Volume (disabled by Data Set) erstage or metering unit. stage and metering unit.
ture Regulator Con-
trol Circuit/
Open
259 Short circuit Mil SysLamp ON non 0 0 MAX 3 Low Side P0004 Power stage is acti- Short circuit of wiring to Check of wiring or replace
to battery of OFF short cir- Fuel Volume vated every 500.00ms external source or inside relay.
metering unit cuit to bat- Regulator Con- ms (not more than relay.
output tery trol Circuit High 0.00- times per driving
cycle). Debounce time
is . No Healing possible
(disabled by Data Set)
359 Short circuit Mil SysLamp OFF non 0 1 MIN 4 Low side P0003 No Healing possible Short circuit of wiring to Check of wiring or replace
to ground of OFF short cur- Fuel Volume (disabled by Data Set) ground or inside relay. relay.
metering unit cuit to Regulator Con-
output ground trol Circuit Low
128 Main relay Mil SysLamp ON non 0 0 MAX 3 Short to P0687 Error cannot be healed Short circuit of main relay 1 Check the wiring and all com-
SCBatt OFF Battery in current driving cycle. output to external source, ponents connected to main
(Lambda H./ ECM/PCM Error must be check defect in one of the con- relay 1, if defect remains main
Grid H./ Power Relay again in following after nected components or defec- relay inside ECU could be
Batt.switch) Control Circuit run. tive main relay 1. defective, replace ECU.
High
228 Main relay Mil SysLamp ON non 0 1 MIN 4 Short to P0686 Healing not possible in Short circuit of main relay 1 Check the wiring and all com-
SCGND OFF Ground ECM/PCM current driving cycle output to ground, defect in ponents connected to main
(Lambda H./ Power Relay (once error is finalized). one of the connected compo- relay 1, if defect remains main
Grid H./ Control Circuit nents or defective main relay relay inside ECU could be
Batt.switch) Low 1. defective, replace ECU.
67
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68
Long Typ IVECO

Base - March 2012

1D4 ECU internal Mil SysLamp ON non 0 3 NPL 12 Watchdog P0606 Both error counters Defective monitoring module If error exists only temporary
fault OFF failure ECM/PCM Pro- are below the value of or CPU (e.g. impaired func- (i.e. injection reoccurs) error
cessor 5. tioning of the CPU clock) of can be ignored and error
the EDC. Disturbed SPI-Bus. deleted in the fault memory. In
case of a permanent error the
injection remains blocked and
the ECU has to be replaced.
19F Multi signal Mil SysLamp OFF non 0 0 MAX 3 Estimated P2000 Fid_NoxEstIv.0 is set Application dependent: Determine what defect has
defects in OFF Nox signal NOx Trap Effi- back to 1 due to healing Implausible sensor signals or set the Fid and resolve the
EGSys_NOx- not reliable ciency Below of triggering defect, defective sensors etc. problem causing this original
EstIv Threshold NOx estimation is defect.
again reliable.
1B1 Busoff in CAN Mil SysLamp OFF non 0 0 MAX 3 CAN Bus P0600 Bus not in OFF state of Wrong configuration of CAN Check timing configuration
A OFF off Serial Com- CAN controller for timing (Prescaler, synchroniz- with hardware compatibility,
munication Link CAN A. ation jump width, sampling, check termination resistors
propagation and phase seg- and network connection and
ments), bad termination resis- contacts. Short circuits to
tors, defective network con- external source, ground or
nection and contacts or CAN High to Low. Monitor
defective CAN controller CAN communication for
with erroneous messages. erroneous behaviour of a par-
ticipant.
B OFF off Serial Com- CAN controller for timing (Prescaler, synchroniz- with hardware compatibility,
munication Link CAN B. ation jump width, sampling, check termination resistors
propagation and phase seg- and network connection and
ticipant.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
Print P2D32N019 E
F4HFE ENGINES
C OFF off CAN controller for timing (Prescaler, synchroniz- with hardware compatibility,
Serial Com- CAN C. ation jump width, sampling, check termination resistors
munication Link propagation and phase seg- and network connection and
ticipant.
138 Oil Pressure Mil SysLamp ON non 0 0 MAX 3 Signal too P0523 If the raw value of the Sensor defective or short cir- Check wiring or replace sen-
Sensor OFF high Engine Oil Pres- oil pressure sensor cuit to external source. sor.
sure Sensor/ (OPSCD_uRaw) is
Switch High below 4.92V.
Voltage
low Engine Oil Pres- oil pressure sensor cuit to ground. sor.
sure Sensor/ (OPSCD_uRaw) is
Switch Low above 136.85mV.
Voltage
2 SIG 2 Hardware P0520 No hardware signal Sensor defective, wiring inter- Check wiring and sensor
failure Engine Oil Pres- defect present over rupted
sure Sensor/ 2.00s. Hardware signal
Switch Circuit intact detected.
3 NPL 12 Value too P0521 The oil pressure is Inaccurate oil pressure sensor Check oil pressure sensor for
high Engine Oil Pres- below the engine or defect (e.g. blocked piping) accuracy and check oil system.
sure Sensor/ speed dependant in the oil system.
Switch Range/ threshold
Performance OPSCD_pMax (calcu-
lated from map
OPSCD_pMax].
69
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70
Long Typ IVECO

Base - March 2012

238 Oil Pressure Mil SysLamp ON non 0 3 NPL 12 Value too P0524 The oil pressure is Inaccurate oil pressure sensor Check oil pressure sensor for
too low OFF low Engine Oil Pres- above the engine or defect (e.g. too low oil accuracy and check oil system.
sure Too Low speed dependant level, leakage...) in the oil sys-
threshold tem.
(OPSCD_pMin calcu-
lated from a map).
13A Oil Temp. Mil SysLamp ON non 0 0 MAX 3 Signal too P0198 If the raw value of the Sensor defective or short cir- Check wiring or replace sen-
Sensor OFF high Engine Oil Tem- oil temperature sensor cuit to external source. sor.
perature Sen- (OTSCD_uRaw) is
sor High below 4.93V.
low Engine Oil Tem- oil temperature sensor cuit to ground. sor.
perature Sen- (OTSCD_uRaw) is
sor Low above 224.83mV.
3 NPL 12 Signal not P0196 There are two condi- Inaccurate oil or coolant tem- Check oil and coolant tem-
plausible Engine Oil Tem- tions for healing of the perature sensors or insuffi- perature sensor for accuracy
with Cool- perature Sen- plausibility error. - the cient oil or coolant recircula- and check oil and coolant sys-
ant Tem- sor Range/Per- oil temperature tion (low coolant level etc.) tem for proper functioning.
perature formance OTSCD_tEngOil
becomes lower than or
equal to 89.96C OR
- the coolant tempera-
ture CTSCD_tClnt
becomes higher than
or equal to 54.96C.
23A Oil Tempera- Mil SysLamp ON non 0 3 NPL 12 Tempera- P0196 The oil temperature is Inaccurate oil temperature Check oil temperature sensor
ture above OFF ture too below 124.96C. sensor or defect (e.g. block- for accuracy and check oil sys-
normal high Engine Oil Tem- age, insufficient recirculation) tem.
perature Sen- in the oil system
sor Range/Per-
formance
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
1E3 Energising Mil SysLamp non 0 0 MAX 3 Injection P0216 No autonomous heal- Electronic disturbances, Check injection relevant
Print P2D32N019 E
F4HFE ENGINES
time exceeds OFF BLINK Time too Injector/Injec- ing. requested torque increase via application, if failure persists
limit of over- long tion Timing tester, wrong application of replace ECU.
run monitor. Control Circuit injection relevant parameters,
defective ECU.
1E4 Plausibility Mil SysLamp non 0 0 MAX 3 Speed Sig- P0321 No autonomous heal- Electronic disturbances, inter- If failure persists after rein-
error in engine OFF BLINK nal not Ignition/Dis- ing. nal ECU problem. itialization replace ECU.
speed check plausible tributor Engine
Speed Input
Circuit Range/
Performance
1FB error path of Mil SysLamp OFF non 0 0 MAX 3 Tempera- P0421 The ratio between Oxidation catayst not Check oxicat for presence
oxidation OFF ture Ratio Catalyst heating temperature change installed or damaged (major and damage, check exhaust
catalyst not out of - Temperature downstream of the cat crack or blockage etc.), defect gas piping for damages, ensure
present Range not plausible and upstream of the cat in exhaust gas pipes, tempera- accuracy of exhaust gas tem-
is below the threshold ture sensors not accurate or perature sensor up- and
1.00[-] or above mounted incorrectly. downstream of oxicat.
1.00[-].
1FC defect ratio Mil SysLamp OFF non 0 0 MAX 3 Tempera- P0425 The ratio between Temperature sensors of oxi- Check temperature sensors
between OFF ture Ratio Catalyst Tem- temperature change cat interchanged, oxicat for accuracy and correct
threshold confused perature Sen- downstream of the cat severely damaged, wrong lay- installation, check oxicat for
limits sor Circuit and upstream of the cat out of exhaust gas pipes, tem- damage, check exhaust gas
is below the threshold perature sensors not accu- piping for correct layout.
1.00[-]. rate.
71
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72
Long Typ IVECO

Base - March 2012

3FA Regeneration Mil SysLamp OFF non 0 0 MAX 3 Maximum P2459 If a regeneration Specific regeneration request Check filter and state variable
demand OFF Number Diesel Particu- number PFlt_numRgn of 2 locked. of saturation model, look for
number 2 exceeded late Filter (depends on degree of Filter could be clogged or sensor errors. Check differen-
Regeneration filter saturation, 0 for estimation of saturation tial pressure for correct func-
Frequency no regeneration) is degree could be wrong due to tioning and accuracy.
requested which is sensor errors which could
below or equal to 1. trigger too many long regen-
erations. Defective differential
pressure sensor (zero offset,
blockage etc.).
4FA Regeneration Mil SysLamp OFF non 0 0 MAX 3 Maximum P2459 If a regeneration Specific regeneration request Check filter and state variable
demand OFF Number Diesel Particu- number PFlt_numRgn of 3 locked. of saturation model, look for
number 3 exceeded late Filter (depends on degree of Filter could be clogged or sensor errors. Check differen-
Regeneration filter saturation, 0 for estimation of saturation tial pressure for correct func-
Frequency no regeneration) is degree could be wrong due to tioning and accuracy.
requested which is sensor errors which could
below or equal to 2. trigger too many long regen-
erations. Defective differential
pressure sensor (zero offset,
blockage etc.).
137 Rail pressure Mil SysLamp non 1) yes 0 0 MAX 3 Valve open Not found in Not possible. Fault will Defective rail pressure sensor Check rail pressure sensor for
relief valve OFF BLINK (techni- database table only be cleared after or in Metering Unit control or plausible values, check pres-
cal) ECU reset. pressure relief valve opening ence of other rail pressure
at at low pressure. control faults, check PRV
valve.
1 MIN 4 Pressure Not found in Not possible. Fault will PRV does not open once the Check functioning of the PRV.
shock database table only be cleared after pressure limit is reached:
requested ECU reset. Mechanical defect or wrong
application parameter.
2 SIG 2 Valve not Not found in Not possible. Fault will PRV does not open even after Check functioning of the PRV.
open after database table only be cleared after pressure shock: Stuck PRV or
shock ECU reset. wrong application parameter.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
19D Info torque Mil SysLamp ON non 0 1 MIN 4 Torque NO CODE IN The torque limitation Active power redcution due No actions necessary due to
Print P2D32N019 E
F4HFE ENGINES
limitation: OFF Limitation DATASET due to SCR induce- to the OBD performance this failure alone. If power
OBD/Induce- ments is below the limiter because of inhibited reduction occurred due to
ment torque limit.. urea injection. actual defect, the failure
limitation triggering the torque limita-
active tion should also be in the fail-
69E Info torque Mil SysLamp ON non 0 1 MIN 4 Torque NO CODE IN The torque limitation Active power redcution due No actions necessary due to
limitation: fuel OFF Limitation DATASET due to fuel quantity to limiting fuel quantity. this failure alone. If power
quantity limitation is below the reduction occurred due to
limitation limit.. actual defect, the failure
active triggering the torque limita-
136 Rail pressure Mil SysLamp non 0 0 MAX 3 Signal too P0193 No Healing possible Short circuit of wiring to Check wiring and proper func-
sensor CP3 OFF BLINK high Fuel Rail Pres- (disabled by Data Set) external source or defective tioning of rail pressure sensor.
sure Sensor A pressure sensor, rail pressure
Circuit High overshoot.
1 MIN 4 Signal too P0192 No Healing possible Short circuit of wiring to Check wiring and proper func-
low Fuel Rail Pres- (disabled by Data Set) ground or defective pressure tioning of rail pressure sensor.
sure Sensor A sensor.
Circuit Low
73
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74
Long Typ IVECO

Base - March 2012

236 Rail pressure Mil SysLamp ON non 1) yes 0 0 MAX 3 Value P0191 If the raw value of the Rail pressure sensor inaccur- Ensure correct wiring and
sensor offset OFF (techni- above limit Fuel Rail Pres- rail pressure sensor ate. proper functioning of rail pres-
monitoring cal) sure Sensor A (RailCD_uPeakRaw) is sure sensor, replace sensor.
Circuit Range/ below the limit
Performance 650.05mV during next
after-run.
1 MIN 4 Value P0191 If the raw value of the Rail pressure sensor inaccur- Ensure correct wiring and
below limit Fuel Rail Pres- rail pressure sensor ate. proper functioning of rail pres-
sure Sensor A (RailCD_uPeakRaw) sure sensor, replace sensor.
Circuit Range/ lies above the limit
Performance 351.91mV during after-
run.
152 Fuel Rail pres- Mil SysLamp non 1) yes 0 0 MAX 3 High posi- P0087 No Healing possible High pressure side: Leakage in Check for defects according
sure low with OFF BLINK (techni- tive devi- (disabled by Data Set) high pressure section, injec- to reason of failure list.
fuel high pres- cal) ation Fuel Rail/System tion nozzle stuck in open posi-
sure pump at Pressure - Too tion, worn high pressure
maximum Low pump, worn injector, leaking
flow pressure relieve valve
Low pressure side: Pressure
before gear pump too low,
gear pump output too low
(fuel filter clogged, leakage in
low pressure side).
158 Setpoint of Mil SysLamp ON non 1) yes 0 0 MAX 3 Metering P0089 No Healing possible High pressure system: Rail Check for defects according
fuel volume OFF (techni- unit posi- Fuel Pressure (disabled by Data Set) pressure sensor inaccurate, to reason of failure list.
flow through cal) tion abnor- Regulator 1 high pressure pump defective.
metering unit mal Performance
is lower than Low pressure system: Meter-
calculated ing unit reflux too low, fuel
limit system leakage, metering unit
jammed in closed position.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
153 Fuel high pres- Mil SysLamp non 1) yes 0 0 MAX 3 Rail pres- P0088 No Healing possible Metering unit stuck in open Check for defects according
Print P2D32N019 E
F4HFE ENGINES
sure pump is OFF BLINK (techni- sure too Fuel Rail/System (disabled by Data Set) position, zero-delivery to reason of failure list.
at minimum cal) high Pressure - Too throttle clogged, metering unit
delivery and High without power due to electri-
the Rail pres- cel error.
sure is not Low pressure side: Pressure
reducing before gear pump too high
(e.g. by pressure relieve
valve), pressure after zero-de-
livery throttle too high.
154 Rail pressure Mil SysLamp non 0 0 MAX 3 Rail pres- P0087 No Healing possible High pressure side: Leakage in Check for defects according
below mini- OFF BLINK sure low Fuel Rail/System (disabled by Data Set) the high pressure section, to reason of failure list.
mum value Pressure - Too injection nozzle stuck in open
Low position, worn high pressure
pump, worn injector, leaking
pressure relieve valve.
Low pressure side: Pressure
before gear pump too low or
gear pump output too low
(clogged fuel filter, leak on
output side).
155 Rail pressure Mil SysLamp non 0 0 MAX 3 Rail pres- P0088 No Healing possible Metering unit stuck in open Check for defects according
above maxi- OFF BLINK sure high (disabled by Data Set) position, zero-delivery to reason of failure list.
mum value Fuel Rail/System throttle clogged, metering unit
Pressure - Too without power due to electri-
High cel error. Low pressure side:
Pressure before gear pump
too high (e.g. by pressure
relieve valve), pressure after
zero-delivery throttle too
high.
75
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76
Long Typ IVECO

Base - March 2012

156 Rail pressure Mil SysLamp ON non 1) yes 0 0 MAX 3 Rail pres- P0093 No Healing possible Leakage in the high pressure Check for defects according
drop rate dur- OFF (techni- sure drop Fuel System (disabled by Data Set) section, injection nozzle stuck to reason of failure list.
ing overrun cal) high Leak Detected in open position, worn high
too high Large Leak pressure pump, worn injector,
leaking pressure relieve valve,
injector reflux too high.
157 Setpoint of Mil SysLamp ON non 1) yes 0 0 MAX 3 Metering P0089 No Healing possible High pressure system: Leak- Check for defects according
metering unit OFF (techni- unit posi- Fuel Pressure (disabled by Data Set) age in the high pressure sec- to reason of failure list.
in overrun cal) tion abnor- Regulator 1 tion, injection nozzle stuck in
mode not mal Performance open position, worn or defec-
plausible tive high pressure pump, worn
injector, leaking pressure
relieve valve. Low pressure
system: Zero delivery is not
active in metering unit
(excessve leakage in metering
unit).
21D SCR Catalyst Mil SysLamp OFF non 0 0 MAX 3 Too High P0422 Autonomous healing Excessive ageing of SCR- Replace catalyst and reset
Thermal Age- OFF Catalyst Main Catalyst not possible. Catatlyst. EEPROM value of catalyst
ing Limit Tempera- Efficiency ageing time via tester.
exceeded ture for Below Thresh-
excessive old
durati
31D DCU State Mil SysLamp ON non 1) yes 0 0 MAX 3 DCU not Not found in DCU reaches normal Defect or abnormal behav- Read out failure memory of
Monitoring OFF (OBD) ready in database table operating state and iour of urea dosing system. the DCU and perform
(not injecting) time remains in this state. troubleshooting, check
behaviour of urea dosing sys-
tem closely.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
71D NOx sensor Mil SysLamp ON non 1) yes 0 0 MAX 3 Lambda P2201 If the difference, NOx sensor is outside the Check if NOx sensor is
Print P2D32N019 E
F4HFE ENGINES
plausibility OFF (OBD) signal of NOx Sensor between estimated muffler (exhaust system). mounted correctly.
check NOx not Circuit Range/ Lambda and measured
plausible Performance (NOx sensor) Lambda,
is in range.
21E Catalyst effi- Mil SysLamp OFF non 0 0 MAX 3 Nox above P0420 The efficiency ratio is Measured catalyst efficiency Check Reagent, if correct con-
ciency lower OFF first OBD below the threshold lower than the estimated centration check urea dosing
than first Nox threshold Catalyst System (NH3 slip present), inaccurate system for correct dosing
prediction (MIL On) Efficiency NOx measurement (value amount (perform UDST and
threshold Below Thresh- too high) downstream of cata- Dosing Valve Check, check
level old lyst, incorrect NOx estima- DCU error memory for leak-
tion (value too low) upstream age failures), check accuracy
of catalyst, estimated catalyst of NOx-sensor and NOx-
efficiency too high (due to model (humidity, boost pres-
inaccuracies in the exhaust sure and temperature) for
mass flow calculation, the esti- plausible values, check NOx-
mated NH3 storage, tem- conversion efficiency of cata-
perature measurements up- lyst, check exhaust system for
and downstream of the cata- excessive urea deposits.
lyst) or catalyst degradation,
excessive urea deposits in
exhaust system, reagent with
too low UREA concentration
(<<32%).
77
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78
Long Typ IVECO

Base - March 2012

31E Catalyst effi- Mil SysLamp ON non 1) yes 0 0 MAX 3 Nox above P0420 The efficiency ratio is Measured catalyst efficiency Check Reagent, if correct con-
ciency lower OFF (OBD) second Catalyst System below the threshold lower than the estimated centration check urea dosing
than second OBD Efficiency (NH3 slip present), inaccurate system for correct dosing
Nox predic- threshold Below Thresh- NOx measurement (value amount (perform UDST and
tion threshold (Perform- old too high) downstream of cata- Dosing Valve Check, check
level ance limita lyst, incorrect NOx estima- DCU error memory for leak-
tion (value too low) upstream age failures), check accuracy
of catalyst, estimated catalyst of NOx-sensor and NOx-
efficiency too high (due to model (humidity, boost pres-
inaccuracies in the exhaust sure and temperature) for

mass flow calculation, the esti- plausible values, check NOx-
mated NH3 storage, tem- conversion efficiency of cata-
perature measurements up- lyst, check exhaust system for
and downstream of the cata- excessive urea deposits.
lyst) or catalyst degradation,
excessive urea deposits in
exhaust system, reagent with
too low UREA concentration
(<<32%).
3A2 Nox Sensor Mil SysLamp OFF non 0 0 MAX 3 Difference P2201 Average NOx ratio is in NOx sensor inaccurate or Check urea dosing system for
plausibility test OFF between range so many test defective, defect in wiring, correct dosing amount (per-
measured NOx Sensor cycles that defect inaccurate NOx estimation, form UDST and Dosing Valve
and simu- Circuit Range/ counter is decrem- urea injection valve jammed Check, check DCU error
lated Value Performance ented to 0. open or excessive urea memory for leakage failures),
no deposits in exhaust system, check NOx sensor for correct
defective SCR catalyst. functioning, check wiring of
sensor, check NOx estima-
tion (humidity, boost pressure
and temperature) for plaus-
ible values, check SCR catalyst
for correct functioning, check
exhaust system for excessive
urea deposits.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
11F Plausibility Mil SysLamp ON non 1) yes 0 0 MAX 3 Tempera- P042B Catalyst downstream Temperature sensor down- Check wiring and signal of
Print P2D32N019 E
F4HFE ENGINES
check of cata- OFF (OBD) ture after Catalyst Tem- temperature is plaus- stream of catalyst is inaccurate temperature sensor. Ensure
lyst system Catalyst perature Sen- ible or defective, defect in wiring complete cool down of
not plaus- sor Circuit (also check connectors). vehicle (>10 hours) without
ible Range/Perform- sun exposure and and
ance measure all 3 sensors signals.
If temperature differences are
above 20C replace defective
sensor.
1 MIN 4 Tempera- P0426 Catalyst upstream tem- Temperature sensor Check wiring and signal of
ture Catalyst Tem- perature is plausible upstream of catalyst is inac- temperature sensor. Ensure
before perature Sen- curate or defective, defect in complete cool down of
Catalyst sor Circuit wiring (also check con- vehicle (>10 hours) without
not plaus- Range/Perform- nectors). sun exposure and and
ible ance measure all 3 sensors signals.
above 20C replace defective
sensor.
2 SIG 2 Ambient P0426 Temperature are Ambient temperature sensor If the ambient temperature
Tempera- Catalyst Tem- plausible or both upstream and down- sensor is inaccurate it is likely
ture of perature Sen- stream catalyst temperature that the urea pump module
Humidity sor Circuit sensors are inaccurate, defect (DTC $E4) and urea tank
Sensor or Range/Perform- in wiring (also check con- temperature (DTC $E5) are
both Cat ance nectors). also reported implausible by
the DCU. Check wiring and
signal of temperature sensors.
Ensure complete cool down
of vehicle (>10 hours) with-
out sun exposure and and
measure all 3 sensors signals.
above 20C replace the sen-
sors which seem implausible.
3 NPL 12 Tempera- P0426 Plausible dynamic of Temperature sensor up- or Check both sensor signals and
ture Devi- Catalyst Tem- Upstream/down- downstream of the catalyst or their wiring, look for static
ation perature Sen- stream temperature both are inaccurate, defect in implausibility, check for oil
between sor Circuit sensor wiring (also check con- leakages, replace one or both
up- and Range/Perform- nectors), oil leakage into sensors.
down- ance exhaust system.
stream C
79
Base - March 2012

80
Long Typ IVECO

Base - March 2012

41E Catalyst pres- Mil SysLamp OFF non 0 0 MAX 3 Relation of P0420 Ratio of filtered tem- Temperature sensors inaccur- Check accuracy of catalyst
ence monitor- OFF tempera- Catalyst System perature variations up- ate, no catalyst present. temperature sensors, check
ing ture Efficiency and downstream of the presence of SCR-catalyst (not
behaviour Below Thresh- catalyst is in range empty pipe!).
between old
both Cat
41D Poor reduct- Mil SysLamp ON non 0 0 MAX 3 Bad Urea / P2BA9 The leading failure Maybe a wrong fluid (e.g. Replace the fluid in the Urea
ant agent OFF Reagent / NOx Exceed- (Fid_SCRCatRd- Water) is in the Urea tank. tank.
(DEF / DEF quality ence - Insuffi- cAgQlDetActv_mp) is
AdBlue) qual- cient Reagent healed.
ity Quality
1 MIN 4 P2BA9
NOx Exceed-
ence - Insuffi-
cient Reagent
Quality
4AA urea quality Mil SysLamp OFF non 1) yes 0 1 MIN 4 Urea Qual- NO CODE IN If the leading failure is This is not a standalone failure, Check and repair leading fail-
and urea OFF (OBD) ity or urea DATASET no more active this failure is triggered by ure.
warning level level error (healed), this failure will another failure via
1 1 also disappear. Fid_SCRCatWarnLvl1_mp.
7AD urea quality Mil SysLamp OFF non 0 1 MIN 4 Urea Qual- NO CODE IN If the leading failure is This is not a standalone failure, Check and repair leading fail-
and urea OFF ity or urea DATASET no more active this failure is triggered by ure.
6AA urea quality Mil SysLamp OFF non 0 1 MIN 4 Urea Qual- NO CODE IN If the leading failure is This is not a standalone failure, Check and repair leading fail-
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
Print P2D32N019 E
F4HFE ENGINES
2AD urea quality Mil SysLamp OFF non 1) yes 0 1 MIN 4 Urea Qual- NO CODE IN If the leading failure is This is not a standalone failure, Check and repair leading fail-
3AD urea quality Mil SysLamp OFF non 0 1 MIN 4 Urea Qual- NO CODE IN If the leading failure is This is not a standalone failure, Check and repair leading fail-
59D Info torque Mil SysLamp OFF non 0 1 MIN 4 Torque NO CODE IN No Healing possible Active power redcution due No actions necessary due to
limitation: OFF Limitation DATASET (disabled by Data Set) to excessive temperatures in this failure alone. If power
SCR injector the SCR catalyst. reduction occurred due to
overheat actual defect, the failure
protection triggering the torque limita-
active tion should also be in the fail-
81
Base - March 2012

82
Long Typ IVECO

Base - March 2012

1D5 ECU internal Mil SysLamp ON non 1) yes 0 1 MIN 4 Watchdog P0606 No healing. Watch dog switch off path If failure reoccurs after ECU
fault: Redun- OFF (techni- failure defect. initialisation: replace ECU.
dant shutoff cal) ECM/PCM Pro-
paths test cessor
failed
2 SIG 2 Supply P0606 No healing. Electronic disturbances, inter- If failure remains after ECU
Voltage ECM/PCM Pro- nal ECU problem. initialisation: replace ECU.
too high cessor
3 NPL 12 Supply P0606 No healing. Electronic disturbances, inter- If failure remains after ECU
Voltage ECM/PCM Pro- nal ECU problem. initialisation: replace ECU.
too low cessor
1E6 ECU sensor Mil SysLamp ON non 1) yes 0 0 MAX 3 Signal too P0687 The sensor voltage Excessive battery voltage, Check battery voltage, check
supply: 5V OFF (techni- high ECM/PCM supply 1 is in range defect in wiring harness, elec- wiring for correct voltage sup-
supply voltage cal) Power Relay trical failure in connected sen- ply of the sensor and the EDC.
1 Control Circuit sors or in the EDC. If no anomaly is found in wiring
High or connected sensors replace
EDC.
1 MIN 4 Signal too P0686 The sensor voltage Insufficient battery voltage, Check battery voltage, check
low ECM/PCM supply 1 is in range defect in wiring harness, elec- wiring for correct voltage sup-
Power Relay trical failure connected sen- ply of the sensor and the EDC.
Control Circuit sors or in the EDC. If no anomaly is found in wiring
Low or connected sensors replace
EDC.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
1E5 ECU sensor Mil SysLamp ON non 0 0 MAX 3 Signal too NO CODE IN The raw value of the Excessive battery voltage, Check battery voltage, check
Print P2D32N019 E
F4HFE ENGINES
supply: 12V OFF high DATASET 12V sensor supply sig- defect in wiring harness, elec- wiring for correct voltage sup-
supply voltage nal is in range trical failure of the EDC. ply of the sensor and the EDC.
If no anomaly is found in wiring
or connected sensors replace
EDC.
1 MIN 4 Signal too NO CODE IN The raw value of the Insufficient battery voltage, Check battery voltage, check
low DATASET 12V sensor supply sig- defect in wiring harness, elec- wiring for correct voltage sup-
nal is in range trical failure of the EDC. ply of the sensor and the EDC.
If no anomaly is found in wiring
or connected sensors replace
EDC.
supply: 5V OFF (techni- high ECM/PCM supply 2 is in range defect in wiring harness, elec- wiring for correct voltage sup-
supply voltage cal) Power Relay trical failure in connected sen- ply of the sensor and the EDC.
2 Control Circuit sors or in the EDC. If no anomaly is found in wiring
EDC.
EDC.
83
Base - March 2012

84
Long Typ IVECO

Base - March 2012

supply: 5V OFF (techni- high supply 3 is in range defect in wiring harness, elec- wiring for correct voltage sup-
supply voltage cal) ECM/PCM trical failure in connected sen- ply of the sensor and the EDC.
3 Power Relay sors or in the EDC.
Control Circuit If no anomaly is found in wiring
EDC.
EDC.
19E Info torque Mil SysLamp ON non 0 1 MIN 4 Torque NO CODE IN The torque limitation Active power redcution due No actions necessary due to
limitation: OFF Limitation DATASET due to smoke limitation to smoke limitation. this failure alone. If power
smoke limita- is below the limits reduction occurred due to
tion active actual defect, the failure
triggering the torque limita-
1E1 Starter crank Mil SysLamp ON non 1) yes 0 0 MAX 3 Short to P0659 Healing is possible in Short circuit of wiring to Check wiring or replace relay.
relay electrical OFF (techni- Battery Actuator Sup- the same driving cycle if external source or inside
failure (High cal) ply Voltage A the error is not present relay.
Side power Circuit High anymore over . High
stage) Side power stage hard-
ware does not report
short circuit to bat-
tery.
1 MIN 4 Short to P0658 Healing is only possible Short circuit of wiring to Check of wiring or replace
Ground Actuator Sup- in a new driving cycle or ground or inside relay. relay.
ply Voltage A in case of an inter-
Circuit Low rupted afterrun.
F4HFE ENGINES
Print P2D32N019 E
Long Typ IVECO
2E1 Starter crank Mil SysLamp ON non 1) yes 0 0 MAX 3 Short to P2671 No Healing possible Short circuit of wiring to Check wiring or replace relay.
Print P2D32N019 E
F4HFE ENGINES
relay electrical OFF (techni- Battery or Actuator Sup- (disabled by Data Set) external source or inside
failure (Low cal) excess ply Voltage B relay.
Side power tempera- Circuit High
stage) ture
1 MIN 4 Short to P2670 Healing is only possible Short circuit of wiring to Check of wiring or replace
Ground Actuator Sup- in a new driving cycle or ground or inside relay. relay.
ply Voltage B in case of an inter-
Circuit Low rupted afterrun
(Because current flow
necessary for monitor-
ing of LS PS is not avail-
able due to switched
off HS PS).
2 SIG 2 Open P2669 Healing is only possible Broken or disconnected wir- Check of wiring or replace
Load Actuator Sup- in a new driving cycle or ing or defective relay. relay.
ply Voltage B in case of an inter-
Circuit /Open rupted afterrun.
119 No key Mil SysLamp OFF non 0 2 SIG 2 No Signal P0685 Error can only be Due to a short circuit in the Check wiring for correct
Switched OFF healed in the next driv- ignition switch the EDC is installation and for short cir-
input (ter- ECM/PCM ing cycle. switched on, although T15 has cuits.
minal 15) sig- Power Relay not been activated.
nals detected Control Circuit
/Open
11A Terminal 50 Mil SysLamp ON non 0 0 MAX 3 Signal P0687 The terminal 50 status Permanent T50 high signal at Check wiring and look for
always OFF always on ECM/PCM signal is inactive over digital input due to wiring electrical defects.
pressed Power Relay 1000.00ms. problem or short circuit.
Control Circuit
High
85
Base - March 2012

86
Long Typ IVECO

Base - March 2012

1D6 ECU internal Mil SysLamp ON non 0 3 NPL 12 Time devi- P060A No healing, since error Electronic disturbances, If failure persists: Replace
fault: deviation OFF ation Internal Control reaction is an ECU wrong TPU timebase. ECU.
between TPU between Module Moni- recovery.
and system System toring Pro-
time and TPU cessor Per-
formance
211 Fault path 2 Mil SysLamp OFF non 0 2 SIG 2 CAN Sig- P0501 A valid vehicle speed Defective or incorrect func- Check speed measuring
for vehicle OFF nal failure Vehicle Speed signal is received via tioning speed measuring device for proper functioning
Speed sensing Sensor A CAN device, see CAN message and for its CAN configuration.
Range/Perform- Cruise control / Vehicle speed
ance (RxCCVS)
1D7 Dataset vari- Mil SysLamp non 0 2 SIG 2 Variant P0606 Not described in docu- See general remarks. See general remarks.
ant coding OFF BLINK Dataset ECM/PCM Pro- mentation.
not valid cessor
3 NPL 12 Variant P0606 Not described in docu- See general remarks. See general remarks.
could not ECM/PCM Pro- mentation.
be set cessor
1D8 ECU internal Mil SysLamp ON non 0 3 NPL 12 SPI Com- P0606 No healing, since the Disturbed SPI-Bus. If ECU functions correctly
fault: Supervi- OFF munication ECM/PCM Pro- error reaction is an after recovery only temporary
sion of SPI- failure cessor ECU recovery (reset). SPI error occurred and fault
handler Flag memory can be deleted and
error ignored. If permanent
SPI error is present and the
ECU does not leave boot
block --> Replace ECU.
F4HFE ENGINES
Print P2D32N019 E
RECOMMENDED TESTS OR
ANOMALY POSSIBLE CAUSE INTERVENTION REMARKS
Low performance at load request. Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact that,
Print P2D32N019 E
in case of insufficient fuel feeding, the en-
F4HFE ENGINES
Possible exessive smoke. gine control module tries to compensate

prolonging the injectors working time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of over- is working correctly.
heating.
If the pump plunger is permanently de-
pressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter. Replace the air filter. Solve the cause of the filters obstruction.
Excessive fuel blow-by from rail boost Check the O Rings and the correct con- Unless the leakage is significant, no per-
GUIDE TO DIAGNOSIS THROUGH SYMPTOMS
valve. nection of the pipe fittings under the feed- formance failures will be detected.
ing pump (the lockers must stay outside To verify O-rings integrity, extract from the
and the fittings must be well locked). tank the fuel recycling pipeline, seal the end
Visually check the low pressure pipeline in- and activate the priming pump driving the
tegrity. low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve. there are any significant blow-by from the
boost gauge valve; in such case replace the
valve.
The engine suddenly stops (with no previ- Obstructed fuel filter. Replace the fuel filter. Solve the cause of the filters obstruction
ous problems) and does not start again. (empty and clean the tank and the part of
the circuit over the filter, refill with clean
fuel).
87
Base - March 2012

88
RECOMMENDED TESTS OR
ANOMALY POSSIBLE CAUSE INTERVENTION REMARKS
The engine disconnects or does not start. EDC7UC31 burned by short circuit on Eliminate the short circuit and replace the Verify that the wire line, close to the pedal,
Base - March 2012

the wiring harness of the friction clutch. EDC7UC31. is not exposed to.
Difficult start and low performance in all Inefficient high pressure pump. After having excluded any other possible
conditions. cause, replace the high pressure pump
.
Difficult start, low performance and engine Injector with obstructer or solenoid The non-working injector is easily recog- In case of low entity blow-by, inficiating the
running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of mechanical working of the injector but not
pulsing within the relevant high pressure involving flow limiter activation, there is no
pipe. error memorisation in the engine control
module.
Starting requires in excess of ten seconds, Injector blocked in open position (with no The non-working injector is easily recog- Usually, whether such symptoms appear, it
followed by huge white exhaust fumes, and return). nisable detecting by feeling the absence of is instinctive to give up engine start.
a fuel smell. pulsing within the relevant high pressure However, by insisting, it is possible to start
pipe. the engine.
As a matter of facts, by insisting, if within the
rail the pressure makes the flow limiter
close up, the engine starts with one cylin-
der less and gradually the grade of fumes
reduces and disappears.
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct
pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the orig-
screws. inal position.
The engine works with one cylinder less, Injector blocked in closed position. Identify the injector that is not working any The non-working injector is easily recog-
without memorising failure blink codes in more and the relating high pressure filler. nisable detecting by feeling the absence of
the engine control module. pulsing within the relevant high pressure
pipe.
F4HFE ENGINES
Print P2D32N019 E
F4HFE ENGINES SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS 1
SECTION 6
Removal and installation of main
components
Page
REMOVAL AND INSTALLATION AUXILIARY DRIVE

BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL AND INSTALLATION 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COOLANT PUMP REMOVAL AND INSTALLATION 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT REMOVAL AND INSTALLATION 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL AND INSTALLATION STARTER

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ENGINE CABLE REMOVAL AND INSTALLATION 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL AND INSTALLATION LOW-PRESSURE

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS F4HFE ENGINES
Page Page
REMOVAL AND INSTALLATION FUEL HOSE FROM INJECTOR REMOVAL AND INSTALLATION . . 17
HIGH PRESSURE PUMP TO COMMON RAIL 8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TURBOCHARGER REMOVAL AND INSTALLATION 19
ENGINE CONTROL UNIT REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 EXHAUST MANIFOLD REMOVAL-
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL FILTER REMOVAL AND REFITTING . . . . . 9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTAKE MANIFOLD REMOVAL AND
FUEL FILTER REMOVAL AND REFITTING . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL AND INSTALLATION COMMON COLD START AIR HEATER REMOVAL AND
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION (only for F4HFE6132/39/3A/
3C*A002-3/3L*A001-2 ENGINES) . . . . . . . . . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OIL VAPOUR RECIRCULATION (BLOW-BY)
SYSTEM REMOVAL AND INSTALLATION . . 12 CYLINDER HEAD REMOVAL AND INSTALLATION 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TAPPET COVER REMOVAL AND INSTALLATION 13 ENGINE OIL FILTER REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INJECTOR WIRING SUPPORT REMOVAL AND
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL AND INSTALLATION ENGINE OIL HEAT
EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION ROCKER ARM
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 OIL SUMP REMOVAL AND INSTALLATION . . 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

REMOVAL AND INSTALLATION AUXILIA- ALTERNATOR REMOVAL AND INSTALLA-

RY DRIVE BELT TION
Removal Removal
Disconnect the electrical connections of the alternator.
Figure 1 Remove the auxiliary components drive belt as described in
the relative procedure.
Figure 2
108545
Operate on the belt tensioner (1) and extract the belt (2)
from the alternator pulleys, the coolant pump and the return 166099
pumps.
Undo the screws (1) and disconnect the alternator (2).
Installation
Turn the automatic belt tensioner (2) to fit the belt (1) on
pulleys and guide rollers. Installation
Place the alternator (2) in position, fasten the screws (1) and
tighten them to the specified torque.
Install the auxiliary components drive belt as described in the
relative procedure.
Connect the alternator electrical connections.

COOLANT PUMP REMOVAL AND INSTAL- Figure 5

LATION
Removal
Position a suitable container to catch any coolant.
Remove the auxiliary components drive belt as described in
Figure 3
166100
Place the coolant pump (2) in position, fasten the screws (1)
and tighten them to the specified torque.
relative procedure.
166100
Undo the screws (1) and remove the water pump (2).
Installation
Figure 4
70221
Apply a new seal ring (2) to the coolant pump (1).

THERMOSTAT REMOVAL AND INSTALLA- REMOVAL AND INSTALLATION STARTER

TION MOTOR
Removal Removal
Disconnect the starter motor electrical connections.
Figure 6 (D)
Figure 8
2
166699 74166
(D) 4-cylinder engine Unscrew the flywheel cover fastening screws (1) and remove
the starter motor (2).
Figure 7 (*)
Installation
Position the starter motor (2) on the internal part of the
flywheel cover (1).
Screw down the retaining screws and tighten them to the
specified torque.
Connect the starter motor electrical connections.
166624
(*) 6-cylinder engine

Unscrew the fastening screws (1) and remove the coolant
outlet coupling (2).
Then remove the thermostat (3) with its gasket.
Installation
Place the thermostat in position.
Place the coolant outlet coupling (1) in position with a new
gasket, screw in the retaining screws and tighten them to the
specified torque.

ENGINE CABLE REMOVAL AND INSTALLATION

Removal
Figure 9
107246
1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature
and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature
sensor - 9. Timing phase sensor - 10. Air temperature and pressure sensor - 11. Electro-injector
Disconnect the engine cable from the connectors: (1)

electro-injector wiring; (10) air pressure/temperature sensor;
(3) fuel pressure sensor; (6) EDC7 control unit; (9) camshaft
timing sensor; (7) fuel flow rate sensor; (8) fuel temperature
sensor; (2) engine coolant temperature sensor on
thermostat; (4) engine oil temperature and pressure sensor;
(5) engine speed sensor.
Open the straps holding the engine cable to the engine block
and remove it completely.
Installation
Place the engine cable in position, close the retaining straps
and connect the sensor, control unit and electro-injector
connectors (refer to Figure 9).

REMOVAL AND INSTALLATION LOW- Figure 12 (**)

PRESSURE FUEL LINES
Removal
Figure 10 (D)
166626
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
1. Hose from fuel pre-filter to heat exchanger on engine
control unit - 2. Hose from heat exchanger on engine
control unit to fuel pump - 3. Hose from fuel pump to fuel
filter support - 4. Hose from fuel filter support to high
pressure pump intake - 5. Fuel return Hose from common
rail outlet and pressure limiter on cylinder head to filter
173236
support - 6. Fuel return hose from high pressure fuel pump
outlet to filter support - 7. Fuel return hose from filter
(D) F4HFE413A/3D/3L/3M support to fuel tank
Figure 11 (*)
Figure 13
116237
Position a suitable container to catch any fuel.

166625
To disconnect the low pressure fuel hose from the relevant
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 connecting joint, you need to keep the clasp (1) pressed, and
1. Hose from fuel pre-filter to heat exchanger on engine release the quick fitting joint (2).
control unit - 2. Hose from heat exchanger on engine
control unit to fuel pump - 3. Hose from fuel pump to fuel
filter support - 4. Hose from fuel filter support to high
pressure pump intake - 5. Fuel return Hose from common
Installation
rail outlet and pressure limiter on cylinder head to filter To connect the low pressure fuel hose to the connection
support - 6. Fuel return hose from high pressure fuel fitting, insert the quick-fit coupling (2) in the connection
pump outlet to filter support - 7. Fuel return hose from fitting and push it in until the catch (3) engages.
filter support to fuel tank
NOTE Check proper fuel hose connection.

REMOVAL AND INSTALLATION FUEL Figure 16 (**)

HOSE FROM HIGH PRESSURE PUMP TO
COMMON RAIL
Removal
Figure 14 (D)
166633
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Unscrew the fuel hose (2) couplings (1) from the common
rail and high pressure pump, open the fastening straps and
remove it from the engine block.
Installation
173237 Position a new fuel supply hose (2) and tighten its couplings
(1) to the high pressure pump and common rail to the
(D) F4HFE413A/3D/3L/3M specified torque.
NOTE The high pressure fuel hose must always be

replaced with a new one whenever it is removed.
Figure 15 (*) The hose couplings must be tightened to 20 Nm
torque using spanner 99317915 and torque
wrench 99389829.
166632
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

ENGINE CONTROL UNIT REMOVAL AND FUEL FILTER REMOVAL AND INSTALLA-
INSTALLATION TION
Removal Removal
Disconnect the engine cable from the engine control unit Position a suitable container to catch any fuel.
electrical connections, as described in the relative section.
Figure 18 (D)
Disconnect the fuel hoses from the engine control unit heat
exchanger, as described in the relative section.
Figure 17
173238
Figure 19 (*)
74174
Remove the retaining screws (1) and disconnect the ECU (2)
including the heat exchanger.
Installation
Position the ECU, (2) including the heat exchanger, on the 166627
crankcase and tighten the screws (1) to the specified torque. (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 20 (**)
NOTE Replacing the elastic support elements is

recommended.
Connect the fuel hoses to the engine control unit heat

exchanger, as described in the relative procedure.
Connect the engine cable to the engine control unit electrical
connections, as described in the relative procedure.
166628
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Using tool 99360076, unscrew the fuel filter (1) from its
support (2) and remove it.
Installation
Fully screw the fuel filter onto the connection on its support
by hand, then further tighten to a torque of 202 Nm.

INJECTION PUMP REMOVAL AND INSTAL- REMOVAL AND INSTALLATION COMMON

LATION RAIL
Removal Removal
Position a suitable container to catch any fuel. Position a suitable container to catch any fuel.
Disconnect the low pressure fuel hose from the mechanical Disconnect the fuel pressure sensor connector as described
fuel pump and the high-pressure pump as described in the in the procedure regarding the engine cable.
relative procedure. Disconnect the low pressure fuel return hose from the
Remove the fuel hose from the high pressure pump to the common rail, as described in the relative procedure.
common rail as described in the relative procedure. Remove the fuel hose from the high pressure pump to the
common rail as described in the relative procedure.
Figure 21
Figure 22 (D)
166629
Remove the three retaining nuts (1) and remove the high
pressure pump (2) complete with the fuel supply pump (3).
Installation
173239
Position the high pressure pump (2) complete with the fuel
supply pump (3) and tighten the three retaining nuts (1) to (D) 4-cylinder engine
the specified torque.
Install the fuel hose from the high pressure pump to the
common rail as described in the relative procedure. Figure 23 (*)
Connect the low pressure fuel hose to the mechanical fuel
pump and the high-pressure pump as described in the relative
procedure.
166634

Disconnect the high pressure hose couplings (1) from the
common rail (2) and injector manifolds (3), then remove
them.

Figure 24 (D) Figure 26 (D)
173240 173241
(D) 4-cylinder engine
Figure 27 (*)
Figure 25 (*)
166636

166635
Place the new high pressure fuel hoses (1) in position and
(*) 6-cylinder engine tighten the couplings to the electro-injector collectors (3)
and the common rail (2) to the specified torque.
Remove the intake manifold retaining screws (1) and remove
the common rail (2).
Installation NOTE The hoses (1), as they are subject to high pressure,
must be replaced every time they are removed.
Place the common rail (2) in position and tighten the screws The hose couplings must be tightened to a torque
(1) fastening it to the intake manifold to the prescribed of 24 4 Nm, using spanner 99317915 (4) and
torque. torque wrench 99389829 (5).
Install the fuel hose from the high pressure pump to the
common rail as described in the relative procedure.
Connect the low pressure fuel return hose to the common
rail, as described in the relative procedure.
Connect the fuel pressure sensor connector as described in
the procedure regarding the engine cable.

OIL VAPOUR RECIRCULATION (BLOW- Installation

BY) SYSTEM REMOVAL AND INSTALLA- Place the blow-by filter (6) in position and tighten the
TION fastening screws.
Removal
Place the pipe (5) in position with new copper washers in
the tappet cover and timing case couplings (4). Then tighten
Figure 28 the couplings (4) to the specified torque.
Place the blow-by pipe (3) into the coupling located on the
timing case and secure it with the elastic strap (2).
Insert the upper coupling of the new blow-by pipe (5), with
a new seal ring, into the tappet cover and tighten the screw
(1).
166631
166631
Undo the screw (1). Loosen the elastic strap (2) and remove
the blow-by pipe (3).
Unscrew the couplings (4) and remove the pipe (5).
Undo the screws and remove the blow-by filter (6).

TAPPET COVER REMOVAL AND INSTAL- Figure 31

LATION
Removal
Figure 29
166630
Install the tappet cover (7) and tighten the nuts (6) to the
specified torque.
Place the pipe (5) in position with new copper washers in the
166630 tappet cover and timing case couplings (4). Then tighten the
couplings (4) to the specified torque.
Undo the screw (1). Loosen the elastic strap (2) and remove
the blow-by pipe (3). Place the blow-by pipe (3) into the coupling located on the
Remove the nuts (6) and take off the tappet cover (7) a new seal ring, into the tappet cover and tighten the screw
complete with seal. (1).
Installation
Figure 30
74757
Fit a new gasket (2) on the tappet cover (1).

INJECTOR WIRING SUPPORT REMOVAL Figure 34

AND INSTALLATION
Removal
Remove the tappet cover as described in the relative section.
Disconnect the engine cable from the injector wiring
connections, as described in the relative section.
Figure 32
99227
Fit the wiring bracket (2) and tighten the screws (1) to the
specified torque.
NOTE Always check that the threads on the screws and

their holes do not show any signs of wear or traces
of dirt before fitting.
166637
Remove the nuts (1) and disconnect the electrical cables

from the injectors (2). Figure 35
Take out the screws (3) and remove the injector wiring
bracket (4) together with the gasket.
Installation
Figure 33
99228
Connect the electrical cables (1) to the injectors (3) and use
the torque wrench 99389834 (4) to tighten the retaining
nuts (2) to the specified torque.
Connect the engine cable to the injector wiring connections,
74756 as described in the relative procedure.
Check the condition of the electrical cables (5), if they are Install the tappet cover as described in the relative section.
damaged replace them by cutting the straps (2) securing
them to the bracket and removing the screws (4) securing
the connectors to this (3).
Fit a new gasket (1) on the bracket (2).

REMOVAL AND INSTALLATION ROCKER Figure 38

ARM ASSEMBLY
Removal
Remove the injector wiring support as described in the
relative section.
Figure 36
70343
ROCKER ARM ASSEMBLY COMPONENTS:

1. Screws - 2. Bracket - 3. Shafts - 4. Rocker arms
Figure 39
70132
Loosen the tappet adjuster retaining nuts (1) and unscrew

the adjusters.
Unscrew the screws (2) and remove the rocker arm
assembly (3), composed of: bracket (6), rocker arms (4),
shafts (5).
Remove the bridges (7) from the valves and extract the rods
(8).
Installation 70344
Figure 37 SHAFT-ROCKER MAIN DATA

Check that shaft/rocker arm coupling surfaces are not
excessively worn or damaged.
Figure 40
122587
The control rods of the rocker arms must have no

deformations; the spherical seats for contact with the rocker
arm adjustment screw and with the tappets (arrows) must
show no trace of seizure or wear; if they do, replace them.
The intake and exhaust valve control rods are identical and
are therefore interchangeable.
74765
Fit the rods (2).

Position the bridges (1) on the valves with the marks ()
facing the exhaust manifold.
Figure 41
NOTE In order to perform the rocker arm - valve
clearance adjustment more quickly, proceed as
follows:
4-cylinder engines
cylinder no. 1 2 3 4
intake - - * -
exhaust - * - *
70346
Check that tappet adjusters (1) are loosened to prevent their cylinder no. 1 2 3 4
catching on the rods (2, Figure 40) when refitting the rocker intake * * - -
arm assembly.
exhaust * - * -
Then install the rocker assembly consisting of the bracket (5),
rockers (3) and shafts (4), securing them to the cylinder head
by tightening the retaining screws to 36 5 Nm. 6-cylinder engines
Figure 42
intake - - * - * *
exhaust - * - * - *

intake * * - * - -
exhaust * - * - * -
70520
Install the injector wiring support as described in the relative
Adjust the clearance between the rocker arms and valves section.
using Allen key (1), box wrench (3) and feeler gauge (2).
Install the tappet cover as described in the relative section.
The operating clearance is:
- 0.25 0.05 mm for the intake valves

INJECTOR REMOVAL AND INSTALLATION Figure 45

Removal
Remove the injector wiring support as described in the
relative section.
Remove the rocker arm assembly as described in the relative
section.
Figure 43
70133
Remove the injector fastening screws and use tool 99342101

(1) to remove the injectors (2) from the cylinder head.
Installation
Figure 46
166638
Disconnect the high pressure hose couplings (1) from the

common rail (2) and injector manifolds (3), then remove
them.
70338
Fit a new seal ring (2) lubricated with vaseline and a new
Figure 44
washer (3) on the injector (1).
Figure 47
166630
Unscrew the nuts (1) and remove the fuel manifolds (2). 70339
Place the injectors (1) in position on the cylinder head seats

so that the fuel inlet hole (2) is facing the fuel manifold seat
(3) side.

Figure 48 Figure 50
70342
Gradually and alternately tighten injector fixing screws (1) in

four stages:
70133 - 1st stage, tightening to 3.5 0.35 Nm torque with
dynamometric wrench.
Use tool 99342101 (1) to fit the injector (2) into position.
- 2nd stage, tightening to 25 1 angle;
Screw in the injector fastening screws without tightening
them. - 3rd stage, tightening to 25 1 angle;
- 4th stage, tightening to 25 1 angle.
NOTE Tightening to angle is performed using tool

Figure 49 99395216.
Tighten the fuel manifold (3) retaining nuts (2) to 50 5 Nm.
Figure 51
91572
Fit a new seal ring (3), lubricated with Vaseline, onto a new
fuel manifold (2).
Position the fuel manifold in place on the cylinder head seat
so that the positioning balls (5) coincide with the relevant 166640
housing (4).
tighten the couplings to the electro-injector collectors (3)
NOTE Fuel manifolds (2) must not be reused after and the common rail (2) to the specified torque.
removal but rather replaced with new ones.
NOTE The hoses (1), as they are subject to high pressure,

Screw on the fastening nuts (2, Figure 50) without tightening The hose couplings must be tightened to a torque
them fully. of 24 4 Nm, using spanner 99317915 (4) and
torque wrench 99389829 (5).
NOTE During this operation, manoeuvre the injector (1)
so that the manifold (2) is properly inserted into
the injector fuel inlet hole (2, Figure 47). Install the rocker arm assemblies, the injector wiring support
and the tappet cover as described in the relative sections.

TURBOCHARGER REMOVAL AND INSTALLATION

Removal
Figure 52 (D) Figure 54 (**)
166642
(**) F4HFE6135/36/3C*A004/3L*A003
Figure 55 (***)
173242
Figure 53 (*)
166643
(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
166641
(*) F4HFE6133/34/3H
Undo the retaining screws and remove the oil return pipe (1) from the engine block.
Unscrew the couplings on the heat exchanger/oil filter and on the turbocharger and remove the oil supply pipe (2) from the
turbocharger.
Undo the nuts (3) and remove the turbocharger (4) from the exhaust manifold (5).
Installation
Place the turbocharger (4) in position on the exhaust manifold (5), after fitting a new gasket.
Screw down the retaining nuts (3) and tighten them to the specified torque.
Place the oil supply pipe (2) in position on the turbocharger, after fitting a new gasket and tighten the couplings on the heat
exchanger/oil filter bracket and on the turbocharger to the specified torque.
Place the pipe (1) in position on the engine block, after fitting a new gasket and tighten the retaining screws (1) to the specified
torque.
EXHAUST MANIFOLD REMOVAL AND Figure 58 (**)

INSTALLATION
Removal
Remove the turbocharger as described in the relative section.
Figure 56 (D)
166645
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Undo the retaining screws (1) and remove the exhaust
manifold (2) from the cylinder head.
173243
(D) F4HFE413A/3D/3L/3M Installation

Place the exhaust manifold (2) with new gaskets in position.
Insert the fixing screws (1) and tighten them to the specified
torque.
Install the turbocharger as described in the relative section.
Figure 57 (*)
166644
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

INTAKE MANIFOLD REMOVAL AND Figure 61 (**)

INSTALLATION
Removal
Remove the common rail as described in the relative section.
Disconnect the cold-start heater electrical connections (if
fitted).
Figure 59 (D)
166648
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Undo the retaining screws (1) and remove the intake
manifold (2) complete with the cold-start heater (if fitted).
Installation
Apply a sufficient layer of LOCTITE 5999 to the contact
surface of the intake manifold (2) complete with the
cold-start heater (if fitted).
Place the intake manifold (2) in position and tighten the
retaining screws (1) to the specified torque.
173244
(D) F4HFE413A/3D/3L/3M Install the common rail as described in the relative section.
Connect the cold-start heater electrical connections (if
fitted).
Figure 60 (*)
166647
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

COLD START AIR HEATER REMOVAL AND CYLINDER HEAD REMOVAL AND INSTAL-
INSTALLATION (only for F4HFE6132/39/3A/ LATION
3C*A002- 3/3L*A001-2 engines) Removal
Removal Remove the engine cable as described in the relative section.
Disconnect the air heater electrical connections. Remove the thermostat as described in the relative section.
Remove the common rail as described in the relative section.
Remove the rocker arm assembly as described in the relative
Figure 62 section.
Remove the injectors as described in the relative section.
Remove the turbocharger as described in the relative section.
Remove the exhaust manifold as described in the relative
section.
Remove the intake manifold as described in the relative
section.
166646
Figure 63
Undo the retaining screws (1) and remove the air heater (2)
from the intake manifold (3).
Retrieve the gasket (4).
Installation
Fit the air heater (2) with a new gasket (4) in position on the
intake manifold (3) and tighten the retaining screws (1) to a
torque of 13 3 Nm.
Connect the air heater electrical connections.
74779
Undo the retaining screws, hook metal cables onto the

brackets (1) and remove the cylinder head (2) from the
engine block using a hoist.
Remove the head gasket.

Installation Figure 66
Figure 64
75703
NOTE Before re-using retaining screws (1) measure

diameters D1 and D2 as shown in the figure:
- if D1-D2 < 0.1 mm the screw can be reused
- if D1-D2 > 0.1 mm the screw must be
replaced
70335
Clean the cylinder head and engine block contact surfaces.

There are two types of head gasket:
- Type A 1.25 mm thick
- Type B 1.15 mm thick
Check the average projection S of the pistons as indicated on their holes do not show any signs of wear or traces
page 29 of Section 7. of dirt before fitting.
If S > 0.40 mm use gasket type A.
If S 0.40 mm use gasket type B.
Take care not to get the cylinder head gasket dirty. Figure 67
Arrange a new cylinder head gasket (1) on the engine block
with the marking TOP facing the head.
The arrow shows the point where the gasket thickness is
marked.
Figure 65

74766
Insert the cylinder head (1) retaining screws (2) and tighten
them in three stages, following the order and method shown
in the figure below.
NOTE The external screws are the shortest.
74779
Position the cylinder head (2), supported by the brackets (1),

on the seal. NOTE Use tool 99395216 (3) for angle tightening.

Figure 68 (D) ENGINE OIL FILTER REMOVAL AND

INSTALLATION
Removal
Position a suitable container to catch any engine oil.
Figure 70 (D)(*)

A
70337
Figure 69 (*)

166649
70476
(*) 6-cylinder engine (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Diagram of the tightening sequence for the cylinder head
fixing screws: Figure 71 (**)
- 1st pre-tightening stage, with torque wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75 x 150 ( ) 55 5 Nm
- 2nd re-tightening stage, with torque wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75 x 150 ( ) 55 5 Nm
- 3rd tightening stage to a 90 2 angle
- 4th tightening stage to a 90 2 angle
A = Front side
NOTE The double tightening is due to the special type of

highly pliable strip. Therefore, at the end of the
pre-tightening stage, the internal screws (tightened
first) will be loose.
166650
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Install the intake manifold as described in the relative section. Use tool 99360076 to remove the oil filter (1).
Install the exhaust manifold as described in the relative
section. Installation
Install the turbocharger as described in the relative section. Lubricate the seal ring (2) with engine oil and set it on the oil
filter (1).
Install the injectors as described in the relative section.
Screw the oil filter (1) all the way on to the support
Install the rocker arm assemblies as described in the relative connection (3) by hand and then tighten to 182 Nm.
chapter.
Run the engine for a few minutes and then check the level
Install the common rail as described in the relative section. using the dipstick: the level must be near the MAX mark on
Install the thermostat as described in the relative section. the dipstick.
Install the engine cable as described in the relative section. If it is much below this level, top up with the necessary
quantity.

REMOVAL AND INSTALLATION ENGINE Installation

OIL HEAT EXCHANGER
Figure 74 (D)(*)
Removal
Remove the auxiliary components drive belt as described in
Remove the alternator as described in the relative section.
Position a suitable container to catch any engine oil.
Remove the engine oil filter as described in the relative
section.
Figure 72 (D)(*)
107275
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 75 (**)
166651
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 73 (**)
166089
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Fit the following on the engine block: a new gasket (1), the
heat exchanger (2) a new gasket (3) and the oil filter bracket
(4).
Tighten the screws (5) to the specified torque.

166087
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Unscrew the coupling (1) and remove the turbocharger oil
delivery pipe (2).
Remove the screws (3) and the oil pressure / temperature
sensor (4).
Remove the screws (5) and disassemble the oil filter / heat
exchanger bracket (6), intermediate plate (6) and relative
gaskets.

Figure 76 (D)(*) OIL SUMP REMOVAL AND INSTALLATION

Removal
Place a suitable container under the oil sump drain plug to
catch the oil.
Open the oil filler on the cylinder head and remove the
dipstick to aid the flow of oil.
Unscrew the drain plug and let the oil in the sump drain
completely.
NOTE It is recommended to drain the oil when the engine

166652 is hot.
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 77 (**) Figure 78 (D)(*)
74775
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
166088
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Place the oil temperature/pressure sensor (2) in position on
the bracket (1) with a new seal ring then screw in the Figure 79 (**)
retaining screws (3) and tighten them to the specified torque.
Install the oil delivery pipe (1), screwing on the coupling (2).
Install the engine oil filter as described in the relative section.
Install the alternator as described in the relative section.
relative procedure.
Check the oil level with the dipstick: the level must be near
the MAX mark on the dipstick.
If it is much below this level, top up with the necessary
quantity. 166653
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Undo the screws (2) then remove the plate (3) and oil sump
(1), retaining the gasket.

Installation Figure 82 (D)(*)

Figure 80 (D)(*)
74775
74770 (D) F4HFE413A/3D/3L/3M

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 83 (**)
Figure 81 (**)
166653
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
166654 Place the oil sump (1) in position and apply the plate (3) to
it.
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Tighten the screws (2) to the specified torque.
Set the gasket (1) on the oil sump (2). Screw on the drain plug with a new washer and proceed to
fill with clean oil.
NOTE If it does not show any signs of damage the gasket
can be reused.
Use only recommended oils or those with the

required characteristics to ensure correct operation
of the engine.
Failure to observer these requirements shall void the
guarantees.
Check the oil level with the dipstick: the level must be near
the MAX mark on the dipstick.
If it is much below this level, top up with the necessary
quantity.


F4HFE ENGINES SECTION 7 - GENERAL MECHANICAL OVERHAULING 1
SECTION 7
General mechanical overhauling
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 3
FITTING THE ENGINE TO THE ROTATING

STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL OF MAIN COMPONENTS . . . . . . . 5
BENCH ENGINE BLOCK DISASSEMBLY . . . . . 14
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Controls and measurements . . . . . . . . . . . . . . 16
- Checking head supporting surface on cylinder

unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 17
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Cam lift check and pin alignment check . . . . . 18
BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 19
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Fitting tappets camshaft . . . . . . . . . . . . . . . . 20
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Measuring journals and crankpins (4-cylinder) . 21
- Measuring journals and crankpins (6-cylinder) . 23
CONNECTING ROD PISTON ASSEMBLY . . 25
- Connecting rod-piston assembly removal . . . . 25
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 28

2 SECTION 7 - GENERAL MECHANICAL OVERHAULING F4HFE ENGINES
Page Page
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVING THE ENGINE FROM THE ROTATING
- Fitting connecting rod-piston assembly . . . . 29 STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
- Connecting rod-piston assembling . . . . . . . 29 COMPLETING ENGINE ASSEMBLY . . . . . . . . . 54
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . 29 CHECKS AND INSPECTIONS . . . . . . . . . . . . . . 56

BENCH ENGINE BLOCK ASSEMBLY . . . . . . . . 30
- Replacing oil pump control gear . . . . . . . . . 30
- Fitting main bearings . . . . . . . . . . . . . . . . . . 30
- Crankshaft installation . . . . . . . . . . . . . . . . . 30
- Checking crankshaft end float . . . . . . . . . . . 31
- Fitting connecting rod half bearings . . . . . . 32
- Fitting connecting rod-piston assembly into

cylinder barrels . . . . . . . . . . . . . . . . . . . . . . 32
- Checking piston protrusion . . . . . . . . . . . . . 33
CYLINDER HEAD DISMANTLING . . . . . . . . . . 34
- Removing the valves . . . . . . . . . . . . . . . . . . 34
- Checking cylinder head wet seal . . . . . . . . . 34
- Checking cylinder head supporting surface . 35
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Removing carbon deposits, checking and grinding

valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Checking clearance between valve stem and

valve guide and valve centering . . . . . . . . . . 36
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . 36
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Regrinding - replacing the valve seats . . . . . 36
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 38
ASSEMBLING CYLINDER HEAD . . . . . . . . . . . . 39
REFITTING MAIN COMPONENTS . . . . . . . . . . 40

INTRODUCTION Figure 2 (*)

The following description covers general mechanical over-
haul starting from the engine which has been removed from
the vehicle.
NOTE Refer to the specific publication for removing the

engine from the vehicle.
Engine removal operations, as with overhauling,
must be carried out by specialised personnel with
specific equipment.
166072
This section contains:
- the operations to perform for mounting the engine on (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
the rotating stand,
Figure 3 (**)
- the sequence of removal operations for the main com-
ponents,
- overhaul of the engine block and the cylinder head,
- the sequence of refitting operations for the main compo-
nents,
- operations required for completing engine assembly
after removal from the rotating stand,
- final checks and tests.
Part of the operations covered in this section can be per-
formed directly on the engine still fitted in the vehicle, in rela-
tion to their accessibility in the engine compartment and on
the vehicle version; these are listed in Section 6 - Removal-re-
fitting of main engine components.
166073
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
FITTING THE ENGINE TO THE ROTATING

STAND To apply the brackets 99361037 to the engine block for
fastening the engine to the overhaul stand, proceed as fol-
lows, working from the left side of the engine:
Figure 1 (D)
- Position a suitable container to catch any fuel.
- Using tool 99360076, remove the fuel filter (1) from its
support.
- Unplug the fuel temperature sensor and the camshaft
timing sensor electrical connections (2).
- Disconnect the low-pressure fuel hoses (3) from the
filter support.
- Unscrew the fastening screws and remove the fuel filter
support (4) complete with the bracket, if fitted, from the
engine block.
- Unscrew the couplings, disconnect the high-pressure
fuel hose (5) from the common rail and high-pressure
pump, open the fastening straps and remove it from the
engine block.
173245
- Disconnect the low-pressure fuel hose (6) supplying the Figure 6 (*)
mechanical pump connected to the high pressure pump
via the electronic control unit heat exchanger.
- Remove the oil delivery pipe, if present, unscrewing and
removing the retaining screws. Remove the O-ring from
the pipe.
NOTE Because of the high pressure in the hoses running

from the high pressure pump to the rail and from
this to the injectors, you must absolutely avoid:
- Disconnecting the hoses when the engine is
running 166074
- Reusing hoses after they have been removed (*) F4HFE6133/34/3H
Figure 7 (**)
Figure 4
16675
116237
(**) F4HFE6135/36/3C*A004/3L*A003
To disconnect the low pressure fuel hose from the relevant
connecting joint, you need to keep the clasp (1) pressed, and
release the quick fitting joint (2). Figure 8 (***)
Figure 5 (D)
166076
(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
From the right of the engine, unscrew the retaining screws
and remove the oil outlet pipe (1) from the turbocharger (2)
173246
and the engine block.

Figure 9 Unscrew the flywheel cover retaining screws (1) and remove
the starter motor (2).
1 Fit brackets 99361037 to the engine block and use these to
secure the engine to the rotating stand 99322205.
Drain the oil from the engine by removing the plug from the
oil sump.
Remove the fan from the crankshaft pulley.
Dispose of the oil according to applicable laws.
2
74166
REMOVAL OF MAIN COMPONENTS
Figure 10
107246
1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature
and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature sen-
sor - 9. Camshaft timing sensor - 10. Air temperature and pressure sensor - 11. Electro-injector.
Disconnect the following engine cable connectors: (1) electro-injector wiring; (10) air pressure/temperature sensor; (3) fuel pres-
sure sensor; (6) EDC7 control unit; (9) camshaft timing sensor; (7) fuel flow rate regulator; (8) fuel temperature sensor; (2) engine
coolant temperature sensor on thermostat; (4) engine oil temperature and pressure sensor; (5) engine speed sensor.
Open the straps holding the engine cable to the engine block and remove it completely.

Figure 11 (D) Figure 13
173247
Figure 12 (*)
166077
Disconnect the pipe (2) from the fuel return pressure relief
valve (1), as described in Figure 4.
Unscrew the screw (3), loosen the retaining strap (4) and
remove the blow-by pipe (5).
Undo the screws and remove the blow-by filter (8).
Unscrew the nuts (10) and remove the tappet cover (9).
Figure 14
107247

Disconnect the fuel hose (3) from the rail (2) according to
the procedures described in Figure 3. Disconnect the fuel
hose (5) from the rail (2) and from the injector manifolds (4).
Remove the screws (1) and remove the rail (2).
74744
Remove the nuts (7) and disconnect the electrical cables

from the electro-injectors (8).
Undo the screws (1) and remove the injector wiring support
(2), complete with gasket.
Remove the screws (5) and detach the air temperature/pres-
sure sensor (6).
Undo the nuts (3) and remove the fuel manifolds (4).
NOTE Fuel manifolds (4) must not be reused after

removal but rather replaced with new ones.

Figure 15 Figure 17
70132 108545
Loosen the tappet adjuster retaining nuts (1) and unscrew the Operate on the belt tensioner (1) and extract the belt (2)
adjusters. from the alternator pulleys, the coolant pump and the return
pumps.
Remove screws (2), disassemble the rocker unit (3) including
support (6), rocker arms (4),and shafts (5) and remove the Unscrew the fastening screw and remove the belt tensioner
bridges (7) from the valves. (1).
Remove the rods (8). Unscrew the screws fastening the alternator to its bracket
and remove it.
Figure 16
70133
Undo the injector fastening screws and use tool 99342101 (1)
to remove the injectors (2) from the cylinder head.

Figure 18 (D) Figure 21 (***)
173248
166080
(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Figure 19 (*) Unscrew the couplings on the heat exchanger/oil filter sup-
port and on the turbine, disconnect the oil supply pipe (3)
and remove it.
Remove the retaining nuts and disconnect the turbocharger
(1) from the exhaust manifold (2).
Undo the screws and remove the exhaust manifold (2) from
the cylinder head.
166078
(*) F4HFE6133/34/3H
Figure 20 (**)
166079
(**) F4HFE6135/36/3C*A004/3L*A003

173249 74779
(D) F4HFE413A/3D/3L/3M Undo and remove the cylinder head retaining screws.
Hook metal cables onto the brackets (1) and remove the cyl-
inder head (2) from the engine block using a hoist.
Figure 23 (*)
Figure 26 (D)(*)
166081
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
166083
Figure 24 (**) (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 27 (**)
166082
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
From the opposite side, undo the intake manifold (1) retain-
ing screws and remove it, complete with the cold-start heater 166084
(if fitted). (**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

Undo the screws (1) and remove the alternator bracket (2).
Use tool 99360076 to remove the oil filter (3).

Figure 28 (D)(*) Figure 31
1 4 3
2
166085 74176
(D) F4HFE413A/3D/3L/3M Undo the screws (3) and remove the cover (1). Retrieve the
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 gasket (4), the PTO (2) and the second gasket (4).
Figure 29 (**)
Figure 32
166086
70145
166086
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Remove nut (1) and detach the timing sensor (2).
Remove the screws (1) and the oil pressure / temperature Remove the nuts (3) and disconnect the high pressure pump
sensor (2). (4) including the fuel supply pump (5).
Undo the screws (3) and remove the oil filter / heat
exchanger support (4), intermediate plate (5) and relative Figure 33
gaskets.
Figure 30
70146
74174
Apply the tool 99360351 (2) to the flywheel housing (1), to
Remove the screws (1) and disconnect the electronic con- stop the flywheel (3) from rotating.
trol unit (2) complete with heat exchanger. Unscrew the screws (4).

Figure 34 Figure 37
108548
Undo the screws (3) and remove the damper (2) and the
pulley (1). 00904t
The flywheel blocking device can help aid removal of the

damper (2) fitted to the pulley (1). Fit the appropriate tie-rod (3) of tool 99363204 onto the
external seal (2) as illustrated in the figure and, using the lever
(4), extract it from the front cover (1).
Figure 35
Figure 38
116241
116242
Undo the screws (1) and remove the coolant pump (2).
Undo the screws (3) and remove the roller (4). Remove screws (1 and 3) and take off the front cover (2).
Undo the screw (5) and remove the engine speed sensor (6).
NOTE Note down the installation positions of the screws

Figure 36 (1) since they are of different lengths.
00900t
Extract the crankshaft front cover seal. Fit the tool 99340055
(4) onto the front shank (2) of the crankshaft. Through the
guide holes in the tool, perforate the internal seal (1) with a
drill bit ( 3.5 mm) to a depth of 5 mm.
Secure the tool to the ring (1) with the 6 screws provided.
Then extract the ring by screwing in the screw (3).

Figure 39 Figure 42
Undo the screws (1) and remove the oil pump (2).
Figure 40 00903t
Extract the flywheel housing seal ring by fitting tool

99340056 (3) on the rear shank (5) of the drive shaft.
Through the guide holes of the tool, perforate the internal
seal ring with a drill bit ( 3.5 mm) to a depth of 5 mm.
Fix tool 99340056 (3) to the ring (1) by means of the 6
screws (4) provided.
Proceed to remove the ring (1) by screwing in the screw (2).
Fit the appropriate tie-rod of tool 99363204 onto the fly-
wheel housing external seal and extract it using the lever.
70151
Remove the two opposing screws (1) where the extraction

pins will be inserted (2, Figure 41).
Undo the remaining screws fastening the flywheel (3) to the Figure 43
drive shaft (4).
Remove flywheel blocking tool 99360351.
Figure 41
70153
Undo the screws (2) and remove the flywheel housing (1).
70152 NOTE Note down the installation positions of the screws

(2) since they are of different sizes.
Screw two medium-length screws into the holes (4) in order
to sling the flywheel with a hoist.
Remove the flywheel (1) using the hoist, guided by the two
guide pins (2) previously screwed into the holes in the drive
shaft (3).

Figure 44 (D)(*) Figure 46
74775
(D) F4HFE413A/3D/3L/3M 86516
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Undo the screws (1 and 4) and remove the oil suction
strainer (5).
Undo the screws (2) and remove the stiffening plate (3).
NOTE The stiffening plate (4) has a single part in the

engines.
Figure 45 (**)
Figure 47
166653
70156
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Remove the screws (1) and remove the gear (3) from the
Turn the engine over. camshaft (2).
Remove the screws (2), disassemble the frame (3) and Figure 48
remove the oil sump (1).
NOTE The size and shape of the sump and suction strainer
vary depending on the engine use.
The illustrations therefore provide a general out-
line of the procedure to be performed.
The procedures described are applicable in any
case.
70157
Undo the screws (2) and remove the timing gear case (1).
NOTE Note down the installation positions of the screws

(2) since they are of different sizes.

BENCH ENGINE BLOCK DISASSEMBLY Figure 51
Figure 49
70160
70158
The second-last-main cap (1) and its relevant support have
the half-bearing (2) equipped with shoulder.
Remove and remove the connecting rod cap (2) fixing
screws (1).
Extract the pistons together with the connecting rods from NOTE Write down the upper and lower half-bearing as-
the top of the crankcase. sembling position, in the event of use, they should
be mounted in the position detected when disas-
NOTE Maintain the half-bearings in their relevant seats be- sembling.
cause, in the event of use, they should be mounted
in the position detected when disassembling.
Figure 52 (D)
Figure 50
70161
Figure 53 (*)
70159
Remove the screws (1) and remove the main caps (2).
74774

Remove the crankshaft (2) from the block by means of tool
99360500 (1) and hoister.

zs
Figure 54 Figure 56
70164
70162 Carefully withdraw the camshaft (1) from the crankcase.

Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
Figure 57
Figure 55
70163
70165
Remove the screws (1) and remove the camshaft (3) check
plate (2)
Withdraw the tappets (1) from crankcase.
NOTE Write down the plate (2) assembling position.

CRANKCASE Figure 60
Controls and measurements
Figure 58 (D)
70167
The measurements must be performed for each individual cyl-

inder at three different heights from the barrel and on two per-
pendicular surfaces: one parallel to the longitudinal engine axis
(A) and the other one perpendicular (B); usually the max wear
70166
is detected on this latter surface and in correspondence with
( D) 4-cylinder engine the first measurement.
If you detect any ovalization, taper or wear, ream and grind the
Figure 59 (*) cylinders. The cylinder barrel regrinding must be performed in
relation to the diameter of the spare pistons oversized of 0.4
or 0.8 mm in respect of the nominal value and prescribed as-
sembling clearance.
Figure 61
75386

Carefully clean the crankcase, when performed the engine dis-
assembly.
Use the proper rings to transfer the crankcase.
Carefully check that the block does not present any cracks.
Check the plug conditions. Replace them if they are rusty or
in case of doubt about their conditions.
Examine the cylinder bore surfaces; they must not present any
seizing, scoring, ovalization, taper, and excessive wearing
traces.
The internal diameter check of the cylinder bore, to verify the
ovalization, taper and wearing entity, is performed by means
of bore meter (1) equipped with dial gange previously set to
zero on the ring gauge (2) of the cylinder barrel diameter.
107804
NOTE If you do not have at your disposal the ring gauge, NOTE In the event of grinding operation, all the cylinders
use a micrometer for the zero setting operation. must result of the same oversize (0.4 or 0.8 mm)

Check the main bearing seats, proceeding as follows: Checking head supporting surface on cylinder
- mount the main caps on the supports without bearings; unit
- tighten the fixing screws to the torque prescribed; When finding the distortion areas, replace the cylinder unit.
- by means of an adequate gauge, verify that the internal di- Planarity error shall not exceed 0.075 mm.
ameter of the seats correspond to the value prescribed.
Check cylinder unit operating plug conditions, replace them in
If you detect a higher value, replace the crankcase. case of uncertain seal or if rusted.
TIMING SYSTEM
Camshaft
Figure 62
70169
CAMSHAFT MAIN DATA (4 cylinders)

Specified data refer to pin standard diameter
Figure 63
84089
MAIN DATA ABOUT CAMSHAFT PINS (6 cylinders)

Specified data refer to pin standard diameter
Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft and
the bush.
Checking cam lift and pin alignment BUSH

Set the camshaft on the tailstock and using a 1/100 gauge set
Figure 65
on the central support, check whether the alignment error is
not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.
Figure 64
70172
Camshaft bush (2) shall be pressed into its housing.

Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
70171 Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two

perpendicular axes.
Figure 66
Sec. A-A
107399
CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)

* Value to be obtained after driving the bush.
Figure 67
162246
CAMSHAFT BUSH AND HOUSING MAIN DATA (6 cyl.)

* Value to be obtained after driving the bush.
Bush replacement TAPPETS

Figure 68 Figure 69
70174
To replace rear bushing (1), use, for dismounting and mount- 112890
ing it, beater 99360362 (2) and handgrip 99370006 (3). MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
NOTE Bushing (1), on mounting, must be oriented in such

a way that lubrication holes match the holes present
on block seat.

Fitting tappets camshaft Figure 73

Figure 70
70179
Check camshaft end float (1).

70176
It shall be 0.23 0.13 mm.
Lubricate the tappets (1) and fit them into the relevant hous- Figure 74
ings on the engine block.
Figure 71
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
70164
Lubricate the bushing and other timing system shaft support

seats and mount camshaft (1) taking care that, during the oper-
ation, the bushing or support seats are not being damaged.
Figure 72
70238
Set camshaft (3) retaining plate (1) with the slot facing the top
of the engine block and the marking facing the operator, then
tighten the screws (2) to the specified torque.

CRANKSHAFT
NOTE It is recommended to insert the found values in the
Measuring journals and crankpins (4-cylinder) proper table. See next Figure.
Figure 75
Undersize classes are:
NOTE Journals and crankpins shall always be ground to the

same undersize class.
Journals and crankpins undersize shall be marked on
the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB.
70182
Grind journals and crankpins if seizing, scoring or excessive

ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
Figure 76
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value

Figure 77
measured on > 45.5 mm radius

between adjacent journals
70183
OUTPUT SHAFT MAIN TOLERANCES
Figure 78
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY

Measuring journals and crankpins (6-cylinder)

NOTE It is recommended to insert the found values in the
proper table. See next Figure.
Figure 79
Undersize classes are: 0.250 0.500 mm
NOTE Journals and crankpins shall always be ground to the

same undersize class.
Journals and crankpins undersize shall be marked on
the side of the crank arm No.1.
For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
70182
Grind journals and crankpins if seizing, scoring or excessive

ovalisation are found. Before grinding the journals (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
Figure 80
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (6 CYL.)
*Rated value

Figure 81
* Measured on a radius greater than 45.5 mm

70577
** 0.500 between adjacent main journals
MAIN CRANKSHAFT TOLERANCES
Figure 82
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness
SHAPE
Cilindricity //
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL
IMPORTANT
SECONDARY

CONNECTING ROD PISTON ASSEMBLY Figure 84

Connecting rod-piston assembly removal
Figure 83
32613
Remove split rings (1) from piston (2) using pliers 99360183
70191
(3).
CONNECTING ROD PISTON ASSEMBLY COMPO-
NENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws - Figure 85
6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE Pistons are supplied spare with 0.4 or 0.8 mm over-

size.
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
Figure 86
1.5
2.705 2.420
2.560 2.735 2.440
* 2.605
220
2.350
2.380
3.970
3.990 38.010 37.994
38.016 38.000
114797
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter

Pistons Gudgeon pins

Measuring piston diameter
Figure 87 Figure 89
32615 18857
Using a micrometer (2), measure the diameter of the piston To measure the piston pin (1) diameter use the micrometer
(1) to determine the assembly clearance. (2).
Conditions for proper pin-piston coupling
Figure 88 Figure 90
70192
32619
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure. Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.

Piston rings Figure 93
Figure 91
16552 41104
Use a micrometer (1) to check split ring (2) thickness. DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
Figure 92 between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
Figure 94
32620
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
70194
Use feeler gauge (1) to measure the clearance between the

ends of the split rings (2) fitted into the cylinder barrel (3).

Connecting rods Figure 96

Figure 95
CONNECTING
ROD BODY CAP
CONN. WEIGHT CONN.

ROD Nr. ROD Nr.
CONNECTING ROD CAP

F
YEAR DAY
F = 2003
G = 2004
H = 2005
88607 I = 2006
70196
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON
PIN AND HALF BEARINGS
NOTE Every connecting rod is marked as follows:
- On body and cap with a number showing their
* Value for inside diameter to be obtained after driving in coupling and the corresponding cylinder.
connecting rod small end and grinding. In case of replacement it is therefore necessary
to mark the new connecting rod with the same
numbers of the replaced one.
NOTE The surface of connecting rod and rod cap are - On body with a letter showing the weight of the
knurled to ensure better coupling. connecting rod assembled at production:
Therefore, it is recommended not to smooth the
knurls. S V, 1560 to 1600 g (yellow marking);
S W, 1601 to 1640 g (green marking);
S X, 1641 to 1680 g (blue marking);
Spare connecting rods are of the W class with green
marking *.
Material removal is not allowed.
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set on
the bush with those set on the connecting rod small end. Grind
the bush to obtain the specified diameter.

Fitting connecting rod-piston assembly Figure 99

Connecting rod-piston assembling
Figure 97
FLYWHEEL SIDE
126312
Position the piston on the connecting rod according to the

FAN SIDE diagram shown in the figure, fit the pin and stop it by the split
162243 rings (2).
The piston crown is marked as follows: Fitting split rings
1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder Figure 100
barrel, this arrow shall face the front key of the engine
block (fan side);
3. Marking showing 1st slot insert testing;
4. Manufacturing date;
5. Product traceability
Figure 98
126311
Use pliers 99360183 (1) to fit the split rings on the piston (2).
Split rings shall be fitted with the marking TOP facing up-
wards and their openings shall be displaced with each other
by 120.
162244
NOTE Split rings are supplied spare with the following sizes:
Connect piston (2) to connecting rod (4) with pin (3) so that - standard;
the reference arrow (1) for fitting the piston (2) into the cylin-
der barrel and the numbers (5) marked on the connecting rod - 0.4 mm oversize;
(5) are read as shown in the figure. - 0.8 mm oversize.

BENCH ENGINE BLOCK ASSEMBLY Crankshaft installation

Replacing oil pump control gear Figure 103 (D)
Figure 101
70161
70184
Figure 104 (*)
Check that gear toothing (1) is not damaged or worn, other-
wise remove it using the proper puller (3).
On mounting the new gear, the gear has to be heated for 10
at 180 C temperature and keyed on engine shaft by putting
the key in between.
Fitting main bearings

Figure 102
74774

Refit the output shaft (2).
70185
NOTE Refit the main bearings that have not been replaced,
in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 0.500 mm

undersize on the internal diameter.
NOTE Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubricat-
ing hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder half
rings.

Figure 105 Figure 107
70188
128169
- 2nd stage, with tool 99395216 (1) set as shown in the fig-
ure, tighten the screws (2) with 90 2 angle.
- Clean accurately the parts and remove any trace of oil;
- fit caps (1), including the half bearings (2) on the relevant
supports.
Checking crankshaft end float
Figure 108
NOTE Before reusing the fastening screws (1), perform

two diameter measurements as shown in figure,
registering diameters D1 and D2:
if D1-D2 < 0.1 mm the screw may be reused
if D1-D2 > 0.1 mm the screw must be replaced
75703
70190
This check is performed by setting a magnetic-base dial gauge

Figure 106 (2) on the crankshaft (3) as shown in the figure.
If higher value is found, replace main thrust half bearings of the
second last rear support (1) and repeat the clearance check
between crankshaft journals and main half bearings.
70187
Tighten the pre-lubricated screws (1) in the following two suc-

cessive stages:
- 1st stage, with torque wrench to 80 6 Nm.

Fitting connecting rod half bearings Figure 111
Figure 109
162245
70200 DIAGRAM FOR INSTALLING CONNECTING ROD

PISTON ASSEMBLY INTO CYLINDER
Fit half bearings (1) on connecting rod and cap. (viewed from front)
- split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same
NOTE Refit the main bearings that have not been replaced, weight;
in the same position found at removal.
- the arrow marked on the piston crown shall be facing the
Do not try to adapt the half bearings.
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle posi-
tion.
Fitting connecting rod-piston assembly into

cylinder barrels
Figure 112
Figure 110
70201
128170
Lubricate accurately the pistons, including the split rings and - Clean the parts accurately and remove any trace of oil;
the cylinder barrel inside. - install the big end caps (1) with the relative half-bearings
Use band 99360605 (2) to fit the connecting rod-piston as- (2).
sembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to
the cap coupling number.

Figure 113 Checking piston protrusion

Figure 116
70204
166655
- lubricate the screws (1) with engine oil and then tighten
Once connecting rod-piston assemblies refitting is over, use
them to the specified torque using the torque wrench (2).
dial gauge 99395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block, carrying out the following operations:
Figure 114
- measure the protrusions S1 and S2 of piston no. 1 from
the top surface of the engine block at a distance of 45 mm
from the centre of the piston and then calculate the aver-
age protrusion:

S cil1 = S1 + S2
2
- For 4-cylinders versions:

repeat the operation to calculate the average protrusion
of pistons 2, 3 and 4, then calculate the average value of
the protrusions:
70205 S + S cil2 + S cil3 + S cil4
S = cil1
- apply tool 99395216 (1) to the socket wrench and tighten 4
screws (2) of 60 2.
- For 6-cylinders versions:
Figure 115 repeat the operation to calculate the average protrusion
of pistons 2, 3, 4, 5 and 6, then calculate the average value
of the protrusions:
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6

S=
6
70207
Check manually that the connecting rods (1) are sliding axially
on the output shaft pins and that their end float, measured
with feeler gauge (2) is 0.10 0.33 mm.

CYLINDER HEAD DISMANTLING Figure 119

Removing the valves
Figure 117
70322
Remove the sealing rings (1 and 2) from the relevant valve gui-
70319 des.
Intake (1) and exhaust (2) valves have heads with the same di-
ameter.
The central notch () of the exhaust valve (2) head distin- NOTE Sealing rings (1) for intake valves are yellow.
guishes it from the intake valve. Sealing rings (2) for exhaust valves are green.
NOTE Should valves be not replaced, number them

before removing in order to refit them in the same
position. Checking cylinder head wet seal
A = intake side S = exhaust side
Figure 120
Figure 118
70323
This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90 C and 2
to 3 bar pressure.
70321
Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
Valve removal shall be performed using tool 99360268 (1)
and pressing the cap (3) so that when compressing the springs
(4) the cotters (2) can be removed. Then remove the cap (3)
and the springs (4).
Repeat this operation for all the valves. NOTE Before refitting, smear the plug surfaces with water-
repellent sealant.
Overturn the cylinder head and withdraw the valves (5).
Replace the cylinder head if leaks are found.

Checking cylinder head supporting surface VALVES
Distortion found along the whole cylinder head shall not ex- Figure 122
ceed 0.20 mm.
EXHAUST INTAKE
If higher values are found grind the cylinder head according to VALVE VALVE
values and indications shown in the following figure.
Figure 121
162247
INTAKE AND EXHAUST VALVE MAIN DATA
70325
The rated thickness A for the cylinder head is 105 0.25 mm, Removing carbon deposits, checking and grin-
max. metal removal shall not exceed thickness B by 0.13 mm. ding valves
Figure 123
NOTE After grinding, check valve sinking. Regrind the valve
seats, if required, to obtain the specified value.
18625
Remove carbon deposits from valves using the proper metal

brush.
Check that the valves show no signs of seizing, scoring or
cracking.
Regrind the valve seats, if required, removing as less material
as possible.

Figure 124 VALVE GUIDES

Figure 126
18882
Check the valve stem (1) using a micrometer (2), it shall be

6.990 7.010 mm.
Checking clearance between valve stem and INTAKE EXHAUST

valve guide and valve centering 79457
Figure 125
Use a bore dial gauge to measure the inside diameter of the
valve guides, the read value shall comply with the value shown
in the figure.
VALVE SEATS
Regrinding replacing the valve seats
Figure 127
70327
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.032 0.072 mm.
Turn the valve (2) and check that the centering error is not ex-
ceeding 0.03 mm.
70330
Check the valve seats (2). If slight scoring or burnout is found,

regrind seats using tool (1) according to the angle values
shown in Figure 128.

Figure 128
EXHAUST INTAKE
107281
MAIN DATA OF ENGINE VALVE SEATS
The valve seats are cast in the cylinder head and machined.
Figure 129
EXHAUST INTAKE
107282
If the valve seats cannot be restored by only regrinding, it is To mount the valve seats in the cylinder head it is necessary
possible to mount the inserts supplied as spares. to heat the cylinder head to 80 - 100 C and, using a suitable
drift, mount the new valve seats (2) in them after they have
In this case, it is necessary to make the seats on the cylinder
been cooled.
head with the dimensions shown in the figure and to mount
the valve seats. Then use the specific tool to grind the valve seats to the values
given in Figure 130.

Figure 130
EXHAUST INTAKE 162248
MAIN VALVE SEAT DATA
Figure 131 VALVE SPRINGS

Figure 132
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

70333 VALVE SPRINGS
After regrinding, check with the base 99370415 (2) and the Prior to assembly, check valve spring flexibility using a suitable
dial gauge 99395603 (1) that the valve recessing (3) is as pres- tool. Compare the elastic deformation and load data with
cribed. those for new springs given in the following table.
Height Under a load of

mm N
H 35.33 Free
H1 35.33 P1 339.8 9
H2 25.2 P2 741 39

ASSEMBLING CYLINDER HEAD
Figure 133
70334
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and seal-
ing rings (3) for exhaust valves are green.
Figure 134
770321
Position on the cylinder head: the spring (4) and upper plate
(3): using tool 99360268 (1), compress the spring (4) and
fasten the plate (3) to the valve (5) with the cotters (2).

REFITTING MAIN COMPONENTS Figure 136
Figure 135
70210
70209
LOCTITE 5205 SEALANT APPLICATION AREAS

DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR
Clean accurately the timing gear case (1) and the engine block. CASE FASTENING SCREWS
Refit the case (1) to the engine block.
Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in the
sequence shown in the figure:
Screws M12 65 to 89 Nm
NOTE Perfect seal is only obtained by cleaning accurately Screws M8 20 to 28 Nm
the surface to seal. Screws M10 42 to 52 Nm
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
NOTE Before any assembly operation always verify that the
It shall be uniform (no clots), without air bubbles,
hole and screw threads have no evidence of wear
thin areas or discontinuities.
or dirt.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint. Figure 137
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 20 minutes).
70211
With a felt-tip pen, highlight the conducting gear tooth (1)

mounted on the engine shaft (2) upon the side surface of
which a groove has been created for the ignition timing.
NOTE Fasten screwing of the two pins to facilitate the

operation of engine driving shaft rotation.

Figure 138
NOTE Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 20 minutes).
114791
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 Figure 141
tooth (2).
Figure 139
70215
SEQUENCE FOR TIGHTENING THE FLYWHEEL

70213 HOUSING FASTENING SCREWS
Tighten the screws (1) fastening gear (2) to camshaft (3) to
Refit the housing (1) to the engine block and screw the
the specified torque.
fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
Figure 140 shown in the figure:
NOTE Before any assembly operation always verify that

the hole and screw threads have no evidence of
wear or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS

70152
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
0901t hoister.
Apply tool 99346253 part (6) to the rear output shaft tang Figure 145
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
Figure 143
Apply tool 99360339 (2) to the flywheel housing to stop

engine flywheel (3) rotation. Tighten the screws (1) fastening
the engine flywheel (3) to the output shaft.
Figure 146
70217
Check the supporting surface (1) of the clutch plate and if it

is scratched, it is necessary to carry out turning.
70219
Tighten engine flywheel (2) fastening screws (1) in two

stages:
- 1st stage, tightening to 50 5 Nm torque with
dynamometric wrench;
Check ring gear teeth (2), if breakage or excessive wear is
- 2nd stage, tightening to 60 2 angle.
found remove the ring gear from the engine flywheel (1,
Figure 142) using a suitable hammer and fit the new one, NOTE Tightening to angle is performed using tool
previously heated to 150 C for 15 to 20 minutes. 99395216.
Chamfering on ring gear inside diameter shall be facing the Before any assembly operation always verify that
engine flywheel. the hole and screw threads have no evidence of
wear or dirt.

Revi - September 2012
106549
70220
Remove the sealing ring (2) from the front cover (1), clean
Fit the oil pump (1).
accurately the coupling surfaces and smear them with
Tighten the fastening screws (2) to the specified torque. LOCTITE 5205.
Figure 151
Figure 148
106550
Clean accurately the front cover (2) surface and refit it.
70221
Apply a new sealing ring (2) to the water pump (1).
Figure 152
Figure 149
00902t
70222
Apply tool 99346252 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Fit the water pump (1). Position part (2) on part (4), screw nut (3) until completing
Tighten the screws (2) to the specified torque. sealing ring (7) fitting into front cover (1).

Figure 153 Figure 156 ((D)(*)
74775
108553
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Fit the plate (1), the oil pick up tube (2) and tighten the Figure 157 (**)
fastening screws (3) to the specified torque.
Figure 154 (D)(*)
166653
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
74770
Place the oil sump (1) in position and apply the plate (3) to
(D) F4HFE413A/3D/3L/3M it.
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Tighten the screws (2) to the specified torque.
Figure 155 (**)
of dirt before fitting
Figure 158
166654
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Set the gasket (1) on the oil sump (2). 108548
Fit the pulley (1) and the damper flywheel (2) onto the
NOTE If it does not show any signs of damage the gasket crankshaft.
can be reused.
Tighten the fastening screws (3) to 68 7 Nm torque.

Figure 159 Figure 162 (D)(*)
116245
Fit a new seal ring on the speed sensor (3).

Fit the speed sensor (3) on the front cover (1) and tighten 108578
the retaining screw (2) to the specified torque.
Figure 160 (D)(*) (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 163 (**)
108576
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 161 (**)
166090
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Lubricate the seal ring (2) with engine oil and place it on the
oil filter (3).
Screw the oil filter (3) all the way on to the bracket
connection (1) by hand and then tighten the oil filter (3) to
18 2 Nm.
Apply a new seal ring to the oil temperature/pressure sensor
(4) and fit it on the support (1).
166089
Fit a new seal ring (6) in the engine block seat.
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
Fit the following on the engine block: a new gasket (1), the
heat exchanger (2) a new gasket (3) and the oil filter bracket
(4).


114793
70234
Refit the automatic belt tensioner (2).
Position the alternator support (1) so that pins (3 and 4) are Tighten the screw (3) to the specified torque using a wrench,
set against the engine block. turn the automatic belt tensioner (2) to fit the belt (1) on
Tighten the screws (2) to the specified torque. pulleys and guide rollers.
Figure 167

wear or dirt.
Figure 165
70145
Refit the high pressure pump (6) including the feed pump (5)
and tighten the nuts (3) to the specified torque. Fit the
support (4) with a new sealing ring, the timing sensor (2) with
a new sealing ring and tighten the relevant fastening nut (1)
to the specified torque.
Figure 168
1 4 3
114792
Refit the alternator (1).

Tighten the screw (2) to the specified torque.
2
74176
Insert the power take-off (2) equipped with the gasket (4),
the cover (I) and its gasket (4).
Tighten the screws (3) to the prescribed matching couple.

74174
Assemble the electronic gearbox (2) equipped with the 74779
exchanger to the engine, fixing it with the screws (1). Direct the output shaft (4) and the camshaft (2) so that when
In case the rubber buffers are cracked or excessively fitting the driven gear (1) on the camshaft the marks on the
deformed, provide replacing them. gears (1 and 3) are coinciding.
NOTE Before reusing the fastening screws (1), perform

two diameter measurements as shown in figure,
registering diameters D1 and D2:
Figure 170 if D1-D2 < 0.1 mm the screw may be reused
if D1-D2 > 0.1 mm the screw must be replaced
D2 D1
75703
Figure 172
70335
Check cleanness of cylinder head and engine block coupling

surface.
There are two types of head gasket:
- Type A - 1.25 mm thick
- Type B - 1.15 mm thick
Check the average protrusion S of the pistons as indicated
70336
on page 33.
Assemble cylinder head (1), tighten the screws (2) in three
If S > 0.40 mm use gasket type A.
following steps, following order and mode shown in the
If S 0.40 mm use gasket type B. figure below.
Do not get the cylinder head gasket dirty.
Place the gasket (1) in position with the marking TOP (1) NOTE The angle tightening is carried out through tool
facing the head. 99395216 (3).
The arrow shows the point where the gasket thickness is
given.

wear or dirt.


A
70337
Figure 174 (*)

70339
Fit injectors (1) on the cylinder head seats, directed so that

the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
A
Figure 177
70476
Tightening order layout for cylinder head fastening screws:

- 1st step pre-tightening with dynamometric wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75 x 150 ( ) 55 5 Nm
- 2nd re-tightening stage, with torque wrench:
Screw 12x1.75x130 ( ) 35 5 Nm
Screw 12x1.75 x 150 ( ) 55 5 Nm
- 3rd step tightening with a 90 2 angle
- 4th step tightening with a 90 2 angle
A = Front side 70133
Use tool 99342101 (1) to fit the injector (2) into its seat.
NOTE The double tightening is due to the special type of Screw injector fastening screws without tightening them.
highly pliable strip. Therefore, at the end of the
pre-tightening stage, the internal screws (tightened
first) will be loose.
Figure 175
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).

Figure 178
NOTE Tightening to angle is performed using tool
99395216.
Tighten the fuel manifold (3) fastening nuts (2) to 50 5 Nm

torque.
Carry out the assembly of the equalisers unit , after previous
check of the components.
Figure 180 (D)
91572
Fit a new sealing ring (3) lubricated with petroleum jelly on

the fuel manifold (2) and fit it into the cylinder head seat so
that the positioning ball (5) is coinciding with the relevant
housing (4).
173249
NOTE Disassembled fuel manifolds (2) must not be used (D) F4HFE413A/3D/3L/3M
again. Replace with new items. Figure 181 (*)
The fuel manifolds (2) for engines have 2
positioning spheres. 1
Screw the fastening nuts (2, Figure 179) without locking

them.
NOTE During this operation, the injector (1) shall be

moved so that the manifold (2, Figure 176) is
properly inserted into the fuel inlet hole (2,
Figure 178).
Figure 179 166081

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 182 (**)
70342
Tighten gradually and alternately the injector fastening 166082

screws (1) in four stages: (**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
- 1st stage, tightening to 3.5 0.35 Nm torque with Apply to the coupling surface of the intake manifold (1) with
dynamometric wrench. the cylinder head, a sufficient coat of LOCTITE 5999.
- 2nd stage, tightening to 25 1 angle; Place the intake manifold (1), complete with the cold-start
- 3rd stage, tightening to 25 1 angle; heater (if fitted), in position and tighten the retaining screws
- 4th stage, tightening to 25 1 angle.

Figure 183 (D) Figure 186 (***)
166080
173248 (***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

(D) F4HFE413A/3D/3L/3M Place the exhaust manifold (2) in position with new gaskets
and tighten the retaining screws to the specified torque.
Figure 184 (*) Sling the turbocharger (1) and position it above the exhaust
manifold after fitting it with a new gasket, tighten the fastening
nuts to the specified torque.
Place the the oil supply pipe (3) in position on the
turbocharger and tighten the couplings on the turbocharger
and on the heat exchanger/oil filter bracket to the specified
torque.
Figure 187
166078
(*) F4HFE6133/34/3H
Figure 185 (**)
70343
ROCKER ASSEMBLY COMPONENTS:

1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
166079
(**) F4HFE6135/36/3C*A004/3L*A003

SHAFT-ROCKER MAIN DATA

Check that shaft/rocker coupling surfaces are not showing
excessive wear or damages.
70346
Figure 189 Check that tappet adjusters (1) are loose to prevent their
balking on the rods (2, Figure 190) when refitting the rocker
assembly.
Then refit the rocker assembly consisting of: bracket (5),
rockers (3), shafts (4) and secure them to the cylinder head
by tightening the fastening screws (2) to 36 5 Nm torque.
122587 Figure 192

Rocker control rods shall not be distorted; the ball seats in
touch with the rocker adjusting screw and with tappets
(arrows) shall not show seizing or wear; otherwise replace
them. Intake and exhaust valve control rods are identical and
are therefore interchangeable.
Figure 190
70520
Adjust clearance between rockers and valves using setscrew

wrench (1), box wrench (3) and feeler gauge (2).
Clearance shall be as follows:
- intake valves 0.25 0.05 mm
70345
Fit the rods (2).

Position jumpers (1) on valves with marks () facing the
exhaust manifold.

Figure 193 (D) Figure 196 (*)
173250
Figure 194 (*) 166640

tighten the couplings to the electro-injector collectors (3)
and the common rail (2) to the specified torque.
NOTE The hoses (1), as they are subject to high pressure,

The hose couplings must be tightened to a torque
of 24 4 Nm, using spanner 99317915 (5) and
torque wrench 99389829.
107286

Figure 197
Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut to the specified torque.
Figure 195 (D)
70352
Check the condition of the electrical cables (5), if they are

damaged replace them by cutting the straps (2) securing
them to the bracket and removing the screws (4) securing
the connectors to this (3).
Fit a new gasket (1) on the bracket (2).
173251

108570
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.
166077
the hole and screw threads have no evidence of Fit the tappet cover (9) and tighten the nuts (10) to the
wear or dirt. specified torque.
Place the blow-by filter (8) in position and tighten the
fastening screws.
Figure 199 Place the pipe (6) in position with new copper washers in the
tappet cover and timing case couplings (7). Then tighten the
couplings (7) to the specified torque.
Place the blow-by pipe (5) into the coupling located on the
a new seal ring, into the tappet cover and tighten the screw
(3).
Connect the fuel return pipe (2) to the pressure limiter (1)
and common rail as shown in following figure.
Figure 202
108571
Connect the electrical cables (1) to the injectors (3) and use
the torque wrench 99389834 (4) to tighten the fastening
nuts (2) to the specified torque.
Figure 200
116237
To connect the low pressure fuel hose to the connection

fitting, insert the quick-fit coupling (2) in the connection
fitting and push it in until the catch (3) engages.
NOTE Check proper fuel hose connection.
70355 Place the engine cable in position, close the retaining straps
and connect the sensor, control unit and electro-injector
Fit a new gasket (2) on the tappet cover (1).
connectors (refer to Figure 8 on page 5).

REMOVING THE ENGINE FROM THE Figure 205 (*)

ROTATING STAND
Support the engine appropriately with a hoist, disconnect it
from the rotating stand, remove brackets 99341009 and
place it on a suitable support to complete engine assembly.
COMPLETING ENGINE ASSEMBLY

Refit the fan to the crankshaft pulley.
Figure 203
1
166074
(*) F4HFE6133/34/3H
Figure 206 (**)
2
74166
Position the starter motor (2) on the internal part of the

flywheel cover (1).
Screw down the retaining screws and tighten them to the
specified torque.
Figure 204 (D)

166075
(**) F4HFE6135/36/3C*A004/3L*A003
Figure 207 (***)
173246
166076
(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2
From the right-hand side of the engine, place the oil drain pipe
(1) in position and tighten the screws fastening it to the
turbocharger and engine block to the specified torque.

Figure 208 (D) Perform the following operations from the left-hand side of
the engine:
- Place the oil delivery tube in position, if present, with a
new o-ring, and tighten the retaining screws.
- Connect the low-pressure fuel hose (6) supplying the
mechanical pump connected to the high pressure pump
via the electronic control unit exchanger.
- Connect a new high-pressure fuel hose (5) between the
high-pressure pump and the common rail, tighten the
couplings to the specified torque and fasten it to the
engine block with the respective clamps
NOTE Due the high pressures in the hoses running from

the high pressure pump to the rail and from this to
173245 the injectors, reuse of these hoses after removal
(D) F4HFE413A/3D/3L/3M must absolutely be avoided.
Figure 209 (*)

- Place the fuel filter support (4) in position together with
the bracket, if present, and tighten the retaining screws
- Connect the low-pressure fuel hoses (3) to the filter
support.
- Connect the fuel temperature sensor and camshaft
timing sensor electrical connections (2).
- Fully screw the fuel filter onto the connection on its
support by hand, then further tighten to a torque of 20
2 Nm.
166072
(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003
Figure 210 (**)
166073
(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

CHECKS AND INSPECTIONS
NOTE The following checking inspections must be carried

out after the engine assembly on the vehicle .
Start the engine and leave it running just above the

idling speed, wait until the coolant reaches the
temperature necessary to open the thermostat and
then check:
- that there are no water leaks from the connecting

sleeves of engine cooling circuit pipes and cab internal
heating pipes, tighten the clamping collars if required;
- check carefully the connection between the low
pressure fuel pipes and the relevant connectors;
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes (if
fitted);
- check also proper operation of the warning lights set on
the instrument panel and of the equipment
disconnected when engine was removed.
- Carefully check and bleed the engine cooling equipment
by repeated draining operations.

F4HFE ENGINES SECTION 8 - TECHNICAL SPECIFICATIONS 1
SECTION 8
Technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 10

2 SECTION 8 - TECHNICAL SPECIFICATIONS F4HFE ENGINES

GENERAL SPECIFICATIONS
Type 4 CYLINDERS 6 CYLINDERS
Cycle Four-stroke diesel engine

Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6

Bore mm 104
Stroke mm 132
+ + +.. = Total displacement cm3 4485 6728
TIMING
start before T.D.C. A 18.5

end after B.D.C. B 29.5
start before B.D.C. D 67

end after T.D.C. C 35
Checking timing
mm -
X
mm -
X
Checking operation
mm 0.20 to 0.30
X
mm 0.45 to 0.55
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC7 ECU
Injector CRIN2
Nozzle type DLLA
Injection sequence 1-3-4-2 1-5-3-6-2-4
bar
Injection pressure bar 250 - 1600

CLEARANCE DATA
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

1
Cylinder barrels 1 104.000 to 104.024
X
1 0.4 - 0.8
Spare pistons type:

1
Size X 12
X
Outside diameter 1 103.851 103.865
Pin housing 2 38.010 38.016
2
Piston diameter 1 0.4 - 0.8
Piston - cylinder liners 0.135 to 0.173
X
Piston protrusion X 0.28 to 0.52
3 Piston pin 3 37.994 to 38.000
Piston pin pin housing 0.010 to 0.022

X1 X1* 2.705 to 2.735

Split ring slots X2 2.420 to 2.440
X2
X3 4.030 to 4.050
X3
* measured on 101 mm
S 1 2.560 to 2.605
S 1*
S 2 2.350 to 2.380
Split rings S2
S 3 3.970 to 3.990
S3
1 0.100 to 0.175
Split rings - slots 2 0.040 to 0.090
3 0.040 to 0.080
1 0.4 - 0.8
Split rings 2 0.4 - 0.8
3 0.4 - 0.8
X1
Split ring end opening
X2 X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3 Small end bush diameter
S Inside 3 38.019 to 38.033

Big end half
bearings S 1.955 to 1.968
Piston pin bush 0.019 to 0.039
Big end half bearings 0.250 - 0.500


X
Size X -
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82.990 to 83.010
Crankpins 2 68.987 to 69.013
Main half bearings S1 2.456 to 2.464

S 1 S 2 Big end half bearings S2 1.955 to 1.968
Main bearings
3 No. 1 - 7 3 87.982 to 88.008
No. 2 - 3 - 4 - 5 - 6 3 87.977 to 88.013
Half bearings Journals

No. 1 - 7 0.044 to 0.106
No. 2 - 3 - 4 - 5 - 6 0.039 to 0.111
Half bearings - Crankpins 0.033 to 0.041
Main half bearings
0.250 - 0.500
Big end half bearings
Shoulder journal X1 37.475 to 37.545
X 1
Shoulder main bearing X2 32.180 to 32.280
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.265

CYLINDER HEAD TIMING SYSTEM mm

1
Valve guide seats on

cylinder head 1 7.042 to 7.062
4 Valves:
4 6.990 to 7.010
60o 0.25o
4 6.990 to 7.010
45o 0.25o
Valve stem and guide 0.032 to 0.072

Housing on head for
valve seat:
1 34.837 to 34.863
1 1 34.837 to 34.863
Valve seat outside diameter;

2 valve seat angle on cylinder
head:
2 34.917 to 34.931
60o
2 34.917 to 34.931
45o

X 0.59 to 1.11
X Sinking X 0.96 to 1.48
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -


Valve spring height:
free spring H 47.75

H H1
H 2 under a load equal to:
339.8 9 N H1 35.33
741 39 N H2 25.2
Injector protrusion X -
X
Camshaft bush housings

No. 1 (flywheel side) 59.222 to 59.248
Camshaft pin seats
No. 2-3-4-5-6-7 54.083 to 54.147
1 23 4 5
2
Camshaft journals:
17 53.995 to 54.045
1 3
Bush inside
diameter 54.083 to 54.147
Bushes and journals 0.038 to 0.152

Cam lift:
H H 6.045
H 7.582


1
Tappet cap housing
on block 1 16.000 to 16.030
2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.960 to 15.975
2
Between tappets and housings 0.025 to 0.070
Tappets -
1
Rocker shaft 1 21.965 to 21.977
Rockers 2 22.001 to 22.027
2
Between rockers and shaft 0.024 to 0.062

TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
M12x1.75 screw fastening rear gear case 77 12 7.7 1.2
1st stage 81 0.8 0.1
M8x1.25 screw fastening oil pump 2nd stage 24 4 2.4 0.4
M8x1.25 screw fastening front cover 24 4 2.4 0.4
M8x1.25 screw fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
M8x1.25 screw fastening camshaft gear 36 2 3.6 0.2
M10x1.50 screw fastening crankcase plate 43 5 4.3 0.4
M18x1.50 nut fastening high pressure pump gear 105 5 10.5 0.5
M8x1.25 nuts fastening fuel pump 24 4 2.4 0.4
inch plug on cylinder head 24 4 2.4 0.4
1st stage 3.5 0.35 0.35 0.035
M6x1 screw fastening injectors
2nd stage 25 1
3rd stage 25 1
4th stage 25 1
M22x1.5 fastening nut injector feed connector 50 5 5 0.5
M8x1.25 screw fastening intake manifold 24 4 2.4 0.4
M12x1.75 screw fastening rear brackets for engine lifting 77 12 7.7 1.2
M8x1.25 screws fastening Common Rail 36 5 3.6 0.5
M12x1.75x130 screw fastening cylinder head 35 5 3.5 0.5
M12x1.75x150 screw fastening cylinder head
} 12 st stage/
nd stage
55 5 5.5 0.5
3rd stage 90 2
4th stage 90 2
M8x1.25 screw fastening rocker bracket 36 5 3.6 0.5
Valve clearance adjusting nuts M8x1.25 24 4 2.4 0.4
M14x1.5 nuts fastening fuel pipes from high pressure pump to Common Rail 24 4 2.4 0.4
M8 screw fastening high pressure pipe connector 24 4 2.4 0.4
M6 screw fastening wiring bulkhead 10 2 1 0.2
M8 screw fastening electric wiring support for injector feed 24 4 2.4 0.4
Nuts M4 fastening wiring on each injector 1.5 0.25 0.15 0.025
M12x1.75 screw fastening fuel filter bracket (industrial) 80 8 8 0.8
M8 screw fastening fuel filter holder (agricultural) 32.5 2.5 3.25 0.25
Fuel filter 20 2 2 0.2
M22 screw fastening oil pressure relief valve on oil filter support 80 8 8 0.8
M27x2 coupling fastening oil filter 20 2 2 0.2
11/8 inch connection on filter support for turbine lubrication 24 4 2.4 0.4
M12 nut fastening turbine lubrication pipe 10 2 1 0.2
M10 screw fastening engine coolant inlet connection 43 6 4.3 0.6

TORQUE
COMPONENT
Nm kgm
M10x1.5 screw fastening exhaust manifold on cylinder head 53 5 5.3 0.5
M12 screw fastening damper adapter 1st stage 50 5 5 0.5
and damper on output shaft 2nd stage 90 5
M10x1,25 screw fastening pulley on output shaft 68 7 6.8 0.7
M8x1.25 screw fastening water pump 24 4 2.4 0.4
M10x1.50 screw fastening auxiliary component control belt tensioners 43 6 4.3 0.6
M10x1.50 screw fastening fixed pulleys for auxiliary component control belt 43 6 4.3 0.6
M12x1,75 screw fastening flywheel housing 85 10 8.5 1
M10x1.50 screw fastening flywheel housing 49 5 4.9 0.5
Nut M8x1.25 fastening valve cover 24 4 2.4 0.4
M6x1 screw fastening camshaft sensor 10 2 1 0.2
M6x1 screw fastening crankshaft sensor 10 2 1 0.2
M14x1.5 screw fastening coolant temperature sensor 24 4 2.4 0.4
M6x1 screw fastening oil pressure/temperature sensor 10 2 1 0.2
Screw fastening fuel pressure sensor 35 5 3.5 0.5
M14 screw fastening fuel temperature sensor 25 2 2.5 0.2
M6x1 screw fastening air temperature/pressure sensor on intake manifold 10 2 1 0.2
M12x1.5 screw fastening engine oil level sensor 10 2 1 0.2
pins M10 71 0.7 0.1
Turbine fixing to exhaust manifold 6-cyl. { nuts M10x1.5 43 6 4.3 0.6
M16 couplings fastening oil delivery pipe to turbocharger 36 5 3.6 0.5
Pipe fixing on adapter M10 for turbine lubrication 35 5 3.5 0.5
Oil pipe fixing on adapter M10 for turbine lubrication to block 43 6 4.3 0.6
M8x1.25 screws fastening oil drain pipe to turbine 24 4 2.4 0.4
Screw M12x1.25 screws fastening engine flywheel 1st stage 50 5 5 0.5
2nd stage 60 2
M8x1.25 screws fastening front bracket for engine lifting 36 5 3.6 0.5
M8x1.25 screws fastening engine oil sump 24 4 2.4 0.4
M8 screws fastening cylinder barrel lubricating nozzles 15 3 1.5 0.3
M12 screws fastening crankshaft caps 1st stage 80 6 8 0.6
2nd stage 90 2
M10x1.25 screw fastening connecting rod caps 1st stage 60 5 6 0.5
2nd stage 60 2
Alternator
M10x1.5 screw bracket fixing on water feed pipefitting 43 6 4.3 0.6
M10x1.5 screw alternator locking 43 6 4.3 0.6
Starter
M10x1.5 nut fastening starter motor 43 6 4.3 0.6

TORQUE
COMPONENT
Nm kgm
M8x1.25 screws fastening heat exchanger and oil filter support 26 4 2.6 0.4
M8x1.25 screws fastening housing 24 4 2.4 0.4
M8x1.25 screws fastening suction strainer 24 4 2.4 0.4
M10x1.5 screws fastening suction strainer bracket 43 5 4.3 0.5
M18x1.5 heat exchanger valve cap 60 9 6.0 0.9
M18x1.5 nut (left-handed) fastening compressor drive gear 165 10 16.5 1.0
M12x1.75 nuts fastening compressor 67 2 6.7 0.2
M8x1.25 screws fastening compressor support bracket 24 4 2.4 0.4
M6x1 screws fastening thermostat cover 10 2 1.0 0.2
M18x1.5 caps to engine block 24 4 2.4 0.4
M10x1.5 screws fastening rail tube bracket 40 5 4.0 0.2
M18x1.5 couplings 24 4 2.4 0.4
M6x1 screws fastening plate 24 4 2.4 0.4
M10x1.5 screws fastening power steering pump 43 6 4.3 0.6
3/4 coupling 36 4 3.6 0.4
M6x1 screws fastening breather plate 10 2 1.0 0.2
M6x1 screw fastening breather plate to tappet cover 10 2 1.0 0.2
M12x1.5 breather fastening couplings 20 4 2.0 0.4
M8x1.25 screws fastening dipstick 24 4 2.4 0.4
M6x1 screws fastening dipstick clamp 10 2 1.0 0.2
M12x1.5 coupling on cylinder head 22 2 2.2 0.2
M8 screw fastening the fuel filter retaining bracket (agricultural) 30.5 2.5 3.05 0.25
Fuel filter adapter 30 2 3.0 0.2
Oil filter adapter 80 8 8.0 0.8
M7x1 screws fastening intake elbow 13 2 1.3 0.2
M8x1.25 screws fastening intake elbow bracket 24 4 2.4 0.4
M8x1.25 screws fastening control unit 24 4 2.4 0.4
M10x1 cap 24 4 2.4 0.4
M6x1 screws fastening control unit to bracket 10 2 1.0 0.2
M12x1.5 coupling on control unit bracket 12 2 1.2 0.2
M8x1.25 nuts fastening heater 13 3 1.3 0.2

F4HFE ENGINES SECTION 9 - TOOLS 1
SECTION 9
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 9 - TOOLS F4HFE ENGINES

TOOLS
TOOL NO. DESCRIPTION
99305453 Tool used to check the low-/high-pressure system fuel supply circuit
99317915 Set of five ring spanners with insert 9x12 (14 - 15 - 17 - 18 - 19)
Revolving stand for overhauling units (700 daN/m capacity, 120

99322205 daN/m torque)
99327281 Tester PT-BOX
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket

TOOLS
99341001 Double acting puller
99341009 Pair of brackets
99341015 Press
99342101 Tool to remove injectors
99346252 Tool for fitting output shaft front gasket
99346253 Tool for fitting output shaft rear gasket

TOOLS
99360076 Tool to remove oil filter (engine)
99360183 Pliers for removing/refitting piston rings (65 110 mm)
99360268 Tool for removing/refitting engine valves
99360330 Tool for rotating engine flywheel
99360351 Equipment for flywheel holding
Beater for removing/refitting camshaft bushes (to be used with

99360362 993700069)

TOOLS
99360500 Tool for lifting the output shaft
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99367121* Manual pump for measuring pressure and vacuum

TOOLS
99370006 Handgrip for interchangeable beaters
99370415 Gauge base for different measurements (to be used with 99395603)
99389829 Dog type dynamometric wrench 9x12 (5-60 Nm)
Torque screwdriver (1-6 Nm) for injector solenoid valve connector

99389834 stop nut setting
99395216 Pair of gauges with and square head for angle tightening
99395603 Dial gauge (0 5 mm)
* only for F4HFE413A/3D/3L/3M F4HFE613H/33/34


F4HFE ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
- Standard safety prescriptions . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Respect of the Environment . . . . . . . . . . . . . . 4

2 APPENDIX F4HFE ENGINES

F4HFE ENGINES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different
must be followed absolutely in a standard working area and operation from the ones theyve been designed and
whose non fulfillment will make any other measure useless provided for: serious injury may occur.
or not sufficient to ensure safety to the personnel in-charge - In case of test or calibration operations requiring engine
of maintenance. running, ensure that the area is sufficiently aerated or
- Be informed and inform personnel as well of the laws in utilize specific vacuum equipment to eliminate exhaust
force regulating safety, providing information gas. Danger: poisoning and death.
documentation available for consultation.
- Keep working areas as clean as possible, ensuring During maintenance
adequate aeration.
- Never open filler cap of cooling circuit when the engine
- Ensure that working areas are provided with emergency is hot. Operating pressure would provoke high
boxes, that must be clearly visible and always provided temperature with serious danger and risk of burn. Wait
with adequate sanitary equipment. unit the temperature decreases under 50 C.
- Provide for adequate fire extinguishing means, properly - Never top up an overheated engine with cooler and
indicated and always having free access. Their efficiency utilize only appropriate liquids.
must be checked on regular basis and the personnel
must be trained on intervention methods and priorities. - Always operate when the engine is turned off: whether
particular circumstances require maintenance
- Organize and displace specific exit points to evacuate intervention on running engine, be aware of all risks
the areas in case of emergency, providing for adequate involved with such operation.
indications of the emergency exit lines.
- Be equipped with adequate and safe containers for
- Smoking in working areas subject to fire danger must be drainage operation of engine liquids and exhaust oil.
strictly prohibited.
- Keep the engine clean from oil tangles, diesel fuel and or
- Provide Warnings throughout adequate boards signaling chemical solvents.
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of - Use of solvents or detergents during maintenance may
emergency. originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
Prevention of injury
- Do not leave rags impregnated with flammable
- Do not wear unsuitable cloths for work, with fluttering substances close to the engine.
ends, nor jewels such as rings and chains when working - Upon engine start after maintenance, undertake proper
close to engines and equipment in motion. preventing actions to stop air suction in case of runaway
- Wear safety gloves and goggles when performing the speed rate.
following operations: - Do not utilize fast screw-tightening tools.
- filling inhibitors or anti-frost
- lubrication oil topping or replacement - Never disconnect batteries when the engine is running.
- utilization of compressed air or liquids under pressure - Disconnect batteries before any intervention on the
(pressure allowed: 2 bar) electrical system.
- Wear safety helmet when working close to hanging - Disconnect batteries from system aboard to load them
loads or equipment working at head height level. with the battery loader.
- Always wear safety shoes when and cloths adhering to - After every intervention, verify that battery clamp
the body, better if provided with elastics at the ends. polarity is correct and that the clamps are tight and safe
- Use protection cream for hands. from accidental short circuit and oxidation.
- Change wet cloths as soon as possible - Do not disconnect and connect electrical connections
in presence of electrical feed.
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections. - Before proceeding with pipelines disassembly
Ensure that hands and feet are dry and execute working (pneumatic, hydraulic, fuel pipes) verify presence of liquid
operations utilizing isolating foot-boards. Do not carry or air under pressure. Take all necessary precautions
out working operations if not trained for. bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
- Do not smoke nor light up flames close to batteries and Non fulfillment of these prescriptions may cause serious
to any fuel material. injury and poisoning.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.

4 APPENDIX F4HFE ENGINES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engines
components, affecting engines duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys personnels safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine
changed. exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that
equipment unless specifically approved. personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
specific approval has been released. Any unauthorized - Collect exhaust oils in adequate specially provided
modification will compromise warranty assistance and containers with hermetic sealing ensuring that storage is
furthermore may affect engine correct working and made in specific, properly identified areas that shall be
duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having environment and within anti-acid containers. Warning:
priory removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80 C temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.

F4HFE413-6132 A 6139

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SERIES NEF TIER 4i

Technical and Repair manual

This publication has been drawn up for qualified and

Before performing any operation check that the part relevant

Operations are to be performed by following the indications

Each repair must aim to restore operating efficiency and safety

FPT cannot be held liable for modifications, alterations or other

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the

Data included in this publication may not be up-to-date

If issues on this publication differ from what is actually noticed

It is forbidden to copy this text or any of its parts and all

SERIES NEF TIER 4i

F4HFE engines Part 1

Print P2D32N019 E Base - March 2012

Base - March 2012 Print P2D32N019 E

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

OPTIONAL ELECTRICAL AND MECHANICAL

CONVERSIONS BETWEEN THE MAIN UNITS

KEY OF LECTURE OF THE HEADINGS

Print P2D32N019 E Base - March 2012

Base - March 2012 Print P2D32N019 E

Danger for persons

Danger of serious damage for the assembly

NOTE It indicates an additional explanation for a piece of information.

1 1 = Seat of small end bush

Print P2D32N019 E Base - March 2012

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Air bleeding Preload

Base - March 2012 Print P2D32N019 E

Print P2D32N019 E Base - March 2012

Base - March 2012 Print P2D32N019 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Print P2D32N019 E Base - March 2012

Bonding and screening

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

1. NEGATIVE CABLES STAR CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT C. CONNECTOR

Base - March 2012 Print P2D32N019 E

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Print P2D32N019 E Base - March 2012

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Basic edition referred to When month - year update

Base - March 2012 Print P2D32N019 E

Removal - refitting of main components 6

General mechanical overhauling 7

Safety prescriptions Appendix

Print P2D32N019 E Base - March 2012

Base - March 2012 Print P2D32N019 E

Section Description Page Date of revision

7 General mechanical 42 Revi - September 2012

Print P2D32N019 E Base - March 2012

Base - March 2012 Print P2D32N019 E

CORRESPONDENCE BETWEEN TECHNICAL CODE

- Engines F4HFE413A - F4HFE413D - F4HFE413L -

- Engines F4HFE6133 - F4HFE6134 - F4HFE613H 7

- Engines F4HFE6135 - F4HFE6136 -

- Engines F4HFE6132 - F4HFE6139 - F4HFE613A -

Print P2D32N019 E Base - March 2012

Base - March 2012 Print P2D32N019 E

Type F4HFE413LA002 F4HFE413AA003

Type F4HFE413DA003 F4HFE413MA003

F4HFE613CA002 F4HFE613AA001 F4HFE613L*A001