Iveco/FPT NEF45 SM2-5 Engine

Tools: feeler gauge, hex key

1. Find TDC of cylinder n.1 (unperforated part of phonic wheel uppermost).
2. Adjust the clearance of cylinder n.1's valves using hex key, polygonal key and feeler gauge.
3. Rotate the crankshaft as shown in the firing-order table to adjust the remaining cylinders.

⚠ Do not force the droop setting screw beyond its final position to avoid damaging the adjustment system.

1. Identify the injection pump code from the Stanadyne tag.
2. Act on the droop setting adjustment screw rotating it clockwise the number of rotations from the chart.
3. Start the motor and loosen the maximum regime adjustment screw; accelerate to obtain 62 Hz (1860 rpm) no-load speed.
4. Regulate the minimum regime screw to block the accelerator lever in the newly obtained position.
5. Block both adjustment screws with lock nuts (3.5 ÷ 4 Nm).

⚠ Coupling mistakes between the actuator hook and the injection pump lever can cause motor over-speed conditions.

1. Remove the three screws of the pump cover and remove the cover carefully.
2. Remove the connection of the fuel return pipe and the sealing from the cover.
3. Disconnect the wire of the stop electro-valve from the clamp and isolate it.
4. Reassemble the connection and the pump cover's original sealing on the ADC100 electronic actuator.
5. Slide the actuator towards the rear of the pump until the U-shaped hook engages the pump lever.
6. Tighten the ADC100 actuator to the injection pump using the supplied screws.
7. Reconnect the fuel return pipe to the connection on the actuator.

⚠ With switched off but hot motor the belt can operate without advance notice; wait for temperature lowering.

1. Loosen the screw nut and the screw fastening the alternator to the support.
2. Reduce belt tension operating on the screw.
3. Withdraw the POLY-V belt.
4. Place the belt on the pulleys and the guide rollers.
5. Tension the drive belt and retighten the alternator fastening screws.

⚠ Only proceed with the engine stopped and at low temperature to avoid burning.

1. Provide suitable containers to avoid coolant dispersion.
2. Loosen the retaining elements and remove the sleeves connecting engine circuit to heat exchanger; wait until emptied.
3. Repair the circuit ensuring the sleeves are perfectly sealed.
4. Fill up the circuit and refill the engine and heat exchanger until complete top up.
5. With filler cap open start the engine and keep it idling for nearly one minute to bleed air; stop and top up again.

⚠ Use suitable protective equipment for hands, face and eyes; proceed only with engine stopped.

1. Remove the filter cover after unscrewing the locking handle.
2. Remove the external cartridge ensuring no dust enters the sleeve.
3. Blow dry compressed air through the filter element from inside outward (max 200 kPa).
4. Do not use detergents or diesel and never use tools to beat the element.
5. Reassemble by repeating the operations in reverse order.

1. Disconnect the fuel pipe of the filter.
2. Work on the drain lever of the priming pump.
3. Continue the operation until fuel outflows.
4. Connect the fuel pipe to the filter.

⚠ Do not smoke and do not use free flames; avoid breathing vapours from filter.

Tools: 99360076

1. Drain the fuel inside the filter by operating the water release screw (1).
2. Unscrew the cartridge using the 99360076 tool.
3. Clean the gasket seat on the support and oil slightly the gasket on the new cartridge.
4. Screw manually the new cartridge until the gasket is on its seat.
5. Tighten through the 99360076 tool at 10-5 Nm torque; carry out supply system deaeration.

⚠ The oil filter contains about 1 kg of oil; provide for recovery and disposal.

⚠ Wear protective gloves - motor oil reaches very high temperature.

Tools: 99360076

1. Place a container under the oil pan connected with the drain plug.
2. Unscrew the plug; take out the dipstick and filler plug to ease oil flow.
3. After complete drainage, screw the plug and carry out clean oil filling.
4. Replace the filtering cartridge with a new one and screw manually until gasket contacts the support.
5. Tighten by means of the 99360076 tool three fourths of a turn.

⚠ Avoid contact with hot coolant; wait until cooled.

Tools: 99360595

1. Remove the electrical wiring from all components.
2. Have a container ready to collect coolant; disconnect the coolant pipe adjusting the bands.
3. Remove the protective grilles for the fan adjusting the fastenings.
4. Remove the fan complete with spacer adjusting the bolts.
5. Lock the radiator assembly, release it from the crankcase and remove from its housing.

⚠ The gasket removed during pump disassembly shall not be utilized again; always use original spare parts.

Tools: 99395097, 99360616, 99340035, 99365196, 99360339, 99360330

1. Set cylinder n.1 at TDC (end of compression) using tool 99395097 (false injector) or camshaft lock pin 99360616.
2. From pump side loosen the fixing nuts without removing them and move the pump backwards using extractor 99340035.
3. Partially unlock pump shaft retaining screw and move the slotted spacer.
4. From timing side remove the cover and loosen the union fixing nut on the pump driving gear.
5. Withdraw the pump from the studs together with the gasket.
6. For assembly: fit the pump pre-set into its housing, tighten the fixing nuts locking the pump flange in slot centre.
7. Insert synchronization pin 99365196 in the plate hole; when it enters the rotor slot synchronization is obtained.
8. Fit washer and screw up the fixing nut to 190-203 Nm; assemble cover with gasket.