Case Engine NEF Tier 3 F4CE9484 F4CE9684 F4DE9484 F4DE9684 F4DE9687 F4GE9484 F4GE9684 Service Manual

SERVICE MANUAL

ENGINES NEF Tier 3 F4CE9484, F4CE9684, F4DE9484, F4DE9684, F4DE9687, F4GE9484, F4GE9684, F4HE9484, F4HE9684

84250518

Issued 12-2009

Contents INTRODUCTION DISTRIBUTION SYSTEMS............................................................. A ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A

POWER PRODUCTION ................................................................. B ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

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INTRODUCTION

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1

Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4CE9484, F4GE9484, F4CE9684, F4GE9684

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INTRODUCTION

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

NOTE: With regard to the engine disassembly operations, please apply for information consulting the specific manual.

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

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

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INTRODUCTION

Safety rules Standard safety prescriptions Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in charge of maintenance.

Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation.

•

Keep working areas as clean as possible, ensuring adequate aeration.

•

Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment.

•

Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on a regular basis and the personnel must be trained on interventon methods and priorities.

•

Organize and identify specific exit points to evacuate the areas in case of an emergency, providing for adequate indications of the emergency indications of the emergency exit lines.

•

Smoking in working areas subject to fire danger must be strictly prohibited.

•

Provide warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of an emergency.

Prevention of injury •

Do not wear unsuitable clothes for work, with fluttering ends, nor jewels such as and chains when working close to engines and equipment in motion.

•

Wear safety gloves and goggles when performing the following operations:

•

•

filling inhibitors or anti-frost

•

lubrication oil topping or replacement

•

utilization of compressed air or liquids under pressure (pressure allowed < 2 bar (29 psi)).

•

Wear safety helmet when working close to hanging loads or equipment working at head height level.

•

Always wear safety shoes and clothes adhering to the body, better if provided with elastics at the ends.

•

Use protection cream for hands.

•

Change wet clothes as soon as possible.

•

In presence of electrical current exceeding 48 - 60 V verify efficiency of earth and mass electrical connections.

Ensure that hands and feet are dry and execute working operations utilizing isolating foot boards. Do not carry out working operations if not trained for.

•

Do not smoke nor light up flames close to batteries and to any fuel material.

•

Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.

•

Do not execute any intervention if not provided with necessary instructions.

•

Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for. Serious injury may occur.

•

In case of test or calibration operations requiring engine running, ensure that the area is sufficiently ventilated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning or death.

During maintenance •

Never open filler cap of cooling system when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F).

•

Never top up an overheated engine with cooler and utilize only appropriate liquids.

•

Always operate when the engine is tuned off; when particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation.

•

Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.

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INTRODUCTION

•

Keep the engine clean from oil spills, diesel fuel and or chemical solvents.

•

Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas ventilated. Whenever necessary wear safety mask.

•

Do not leave rags impregnated with flammable substances close to the engine.

•

Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of a runaway speed rate.

•

Do not utilize fast screw tightening tools.

•

Never disconnect batteries when the engine is running.

•

Disconnect batteries before any intervention on the electrical system.

•

Disconnect batteries from system before applying a load to them with the battery loader.

•

After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

•

Do not disconnect and connect electrical connections in presence of electrical feed.

•

Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves.

Always wear adequate safety mask or goggles. Non fulfillment of these precautions may cause serious injury and poisoning.

•

Avoid incorrect tightening or out of sequence. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration.

•

Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters.

•

Do not modify cable wires: their lengths shall not be changed.

•

Do not connect to the engine electrical equipment unless specifically approved by Iveco.

•

Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration.

For engines equipped with electronic controller: •

Do not execute electric arc welding without having previously removed electronic controller.

•

Remove electronic controller in case of any intervention requiring heating over 80 °C (176 °F) temperature.

•

Do not paint the components and the electronic connections.

•

Do not vary or alter any data filed in the electronic controller 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.

Respect of the Environment •

Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted.

•

Be informed and inform personnel as well of the laws in force regulating use and exhaust of liquids and engine drain oil. Provide for adequate board indications and organic specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventative safety measures.

•

Collect drain oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be ventilated far from heat sources and not exposed to fire danger,

•

Handle the batteries with care, storing them in ventilated environment and within anti-acid containers. Warning: Battery exhalation represent serious danger of intoxication and environment contamination.

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INTRODUCTION

Torque F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Component

Size

Specification

¼" ½" ¾" M6 Nut M8 Screw

10 - 14 Nm (7.4 - 10.3 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 31 - 41 Nm (22.9 - 30.2 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M12 M8 M12x1.75x130 mm

65 - 89 Nm (47.9 - 65.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

Cylinder Head and Components Plug

Grid Heater Intake Manifold Engine Lifting Bracket Rear Front Cylinder Head First Phase Second Phase Third Phase Cylinder Head First Phase Second Phase Third Phase Rocker Bracket Rocker Arm Jam Nuts Exhaust Manifold Valve Cover Turbocharger 6 Cylinder 4 Cylinder

30 - 40 Nm (22.1 - 29.5 lb ft) 85 - 95 ° 85 - 95 ° M12x1.75x150 mm

M8 Nut

50 - 60 Nm (36.9 - 44.3 lb ft) 85 - 95 ° 85 - 95 ° 31 - 41 Nm (22.9 - 30.2 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 48 - 58 Nm (35.4 - 42.8 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 M8 M8 M8

Screw Nut Screw Nut

6 - 8 Nm (4.4 - 5.9 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 6 - 8 Nm (4.4 - 5.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

M12 Screw M10 Screw M8 Screw M10 M12

65 - 89 Nm (47.9 - 65.6 lb ft) 42 - 52 Nm (31.0 - 38.4 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 75 - 95 Nm (55.3 - 70.1 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft)

Front Case Front Cover

Rear Case Gear Case

Flywheel Housing

Cylinder Block and Crankshaft Components

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INTRODUCTION

Component Camshaft Retaining Plate Camshaft Gear Crankcase Plate Vibration Damper and Adapter First Phase Second Phase Drive Pulley Engine Flywheel First Phase Second Phase Main Caps First Phase Second Phase Third Phase Connecting Rod Caps First Phase Second Phase

Size

Specification

M8 Screw M8 Screw M10 Screw M12

20 - 28 Nm (14.8 - 20.7 lb ft) 32 - 40 Nm (23.6 - 29.5 lb ft) 38 - 48 Nm (28.0 - 35.4 lb ft) 45 - 55 Nm (33.2 - 40.6 lb ft) 90 ° 61 - 75 Nm (45.0 - 55.3 lb ft)

M10 M12

26 - 34 Nm (19.2 - 25.1 lb ft) 55 - 65 ° M12 44 - 56 Nm (32.5 - 41.3 lb ft) 74 - 86 Nm (54.6 - 63.4 lb ft) 85 - 95 ° 55 - 65 Nm (40.6 - 47.9 lb ft) 55 - 65 °

Lubrication System and Components Oil Pump First Phase Second Phase Oil Pressure Relief Valve Oil Cooler and Oil Filter Base Oil Filter Connection on Filter Base for Turbo Oil Supply Turbo Lubrication Pipe Turbo Lubrication Pipe Adapter Oil Pan Piston Spray Nozzles

M8 M8 M22 M8 Screw

7 - 9 Nm (5.2 - 6.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 72 - 88 Nm (53.1 - 64.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) Contact + ¾ Turn 20 - 28 Nm (14.8 - 20.7 lb ft)

1 ⅛" M12 Nut M12

8 - 12 Nm (5.9 - 8.9 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 12 - 18 Nm (8.9 - 13.3 lb ft)

M8

Electrical Components Camshaft Sensor

Wiring Bulkhead Support Bracket for Injector Wiring Injector Wiring ECU Cooling Plate Fuel Outlet Fuel Inlet Crankshaft Speed Sensor Coolant Temperature Sensor Oil Pressure / Temperature Sensor Fuel Pressure Sensor Fuel Temperature Sensor Air Pressure / Temperature Sensor Engine Oil Level Sensor Alternator Support Bracket Alternator Tension Bracket Starter

M6 M6 M6 M6 M8

Studs Nut Screw Screw Screw

6 - 10 Nm (4.4 - 7.4 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 1.25 - 1.75 Nm (0.92 - 1.29 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 17 - 23 Nm (12.5 - 17.0 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 17 - 23 Nm (12.5 - 17.0 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

M6 Screw M8 Screw M12 M12 M6 Screw M14 Screw M5 Screw M14 M12 M10 Screw M10 Screw

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INTRODUCTION

Component

Size

Specification

M8 Studs M18 Nut M8 Nut

10 - 14 Nm (7.4 - 10.3 lb ft) 100 - 110 Nm (73.8 - 81.1 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M6 Screw M6 Screw

8.15 - 8.85 Nm (6.0 - 6.5 lb ft) 70 - 80 ° 45 - 55 Nm (33.2 - 40.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 18 - 22 Nm (13.3 - 16.2 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 71 - 85 Nm (52.4 - 62.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) Contact + ¾ Turn

Fuel System and Components Feed Pump High Pressure Pump Gear Fuel Pump Injector First Phase Second Phase Injector Feed Connector Common Rail High Pressure Fuel Line High Pressure Pipe Connector Fuel Filter Bracket Fuel Filter Holder Fuel Filter

M8 Screw M14 Fitting M8 Screw M12 Screw M8 Screw

Cooling System and Components Engine Coolant Inlet Fitting on Coolant Inlet Compressor Cooling Pipe Engine Coolant Drain Collector Water Pump Belt Tensioner Idler Pulleys

M10 Screw 90 ° Elbow

37 - 49 Nm (27.3 - 36.1 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 24 Nm (14.8 - 17.7 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

M6 Screw M8 Screw M10 M10

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INTRODUCTION

Torque F4CE9484, F4GE9484, F4CE9684, F4GE9684

Component

Size

Specification

M8 M12x70

20 - 28 Nm (14.8 - 20.7 lb ft)

Cylinder Head and Components Rocker Assembly Cylinder Head Phase 1 Phase 2 Cylinder Head Phase 1 Phase 2 Cylinder Head Phase 1 Phase 2 Valve Cover Intake manifold Air intake elbow Exhaust manifold Rear lifting bracket Turbocharger

50 Nm (36.9 lb ft) 90 ° M12x140 40 Nm (29.5 lb ft) 180 ° M12x180

M8x1.25x25 M8x1.25 M8x1.25 M10x1.5x65 M12x1.75x30 M10

70 Nm (51.6 lb ft) 180 ° 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 65 - 89 Nm (47.9 - 65.6 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

M8x1.25x45 M8x1.25x30

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8x1.25x40 M8x1.25x25 M10x1.5 M12x120 M12x80 M10x80 M10x40 M12x1.25 M12x1.25

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 75 - 95 Nm (55.3 - 70.1 lb ft) 75 - 95 Nm (55.3 - 70.1 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 26 - 34 Nm (19.2 - 25.1 lb ft) 55 - 65 °

Front Case Front cover assembly

Rear Case Gear Case

Flywheel housing

Phase 1 Phase 2

Cylinder Block and Crankshaft Components Main bearing cap Phase 1 Phase 2 Phase 3 Connecting rod Phase 1 Phase 2 Phase 3 Timing Pin Crankshaft pulley Camshaft retaining plate Camshaft gear

44 - 56 Nm (32.5 - 41.3 lb ft) 74 - 86 Nm (54.6 - 63.4 lb ft) 85 - 95 ° M11x1.25 27 - 33 Nm (19.9 - 24.3 lb ft) 55 - 65 Nm (40.6 - 47.9 lb ft) 55 - 65 ° 4 - 6 Nm (3.0 - 4.4 lb ft) 105 - 115 Nm (77.4 - 84.8 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 32 - 40 Nm (23.6 - 29.5 lb ft)

M12x1.75 M8 M8

Lubrication System and Components

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INTRODUCTION

Component Piston Cooling Nozzles Oil pump Stiffening Plate Oil plug Oil Pick up tube Oil Pan Oil Bypass Valve Turbo Lubrication Lines Turbo end Filter base end Drain

Size

Specification

M8x1.25x10 M8x1.25x30 M10x1.25x25 M10x1 M14x1.5 M8x1.25x20 M8x1.25x25 M18x1.50 M22x1.5x10

12 - 18 Nm (8.9 - 13.3 lb ft) 7 - 9 Nm (5.2 - 6.6 lb ft) 38 - 48 Nm (28.0 - 35.4 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 9 - 13 Nm (6.6 - 9.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 51 - 69 Nm (37.6 - 50.9 lb ft) 72 - 88 Nm (53.1 - 64.9 lb ft)

M12x1.5 M8x1.25x16

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8x1.25x30 M10x1.25x25 M10 M12x1.75x120 M6x1.0 nut M10

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 8 - 11 Nm (5.9 - 8.1 lb ft) 54 - 44 Nm (39.8 - 32.5 lb ft)

M8 screw M6 screw M6 nut

20 - 28 Nm (14.8 - 20.7 lb ft) 9 - 11 Nm (6.6 - 8.1 lb ft) 9 - 11 Nm (6.6 - 8.1 lb ft)

Electrical Components Alternator

Alternator wiring Starter

Fuel System and Components Fuel pump

Fuel Pump Drive Gear Phase 1 Phase 2 Timing Pin Cap Fuel injectors Fuel lift pump

15 - 20 Nm (11.1 - 14.8 lb ft) 85 - 90 Nm (62.7 - 66.4 lb ft) 30 - 35 Nm (22.1 - 25.8 lb ft) 55 - 65 Nm (40.6 - 47.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

Cooling System and Components Water Pump Water outlet connection Fan support Fan pulley

M8x1.25x25 M8x1.25x35 M8x1.25x70 M10x1.5x20 M6 M10

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20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 28 - 38 Nm (20.7 - 28.0 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 27 - 49 Nm (19.9 - 36.1 lb ft)

INTRODUCTION

Special tools F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Tool No.

Description

380000301

Revolving engine stand

380000665

380000663

Image

REVOLVING STAND

1

FRONTSEALPULLER

2

Crankshaft front seal puller

Crankshaft rear seal puller

REARSEALPULLER

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3

INTRODUCTION

Tool No.

Description

380001099

Injector puller

380000666

380000664

Image

INJECTORPULLER

4

FRONTSEALINSTAL

5

CRANKREARSEALIN

6

Crankshaft front seal installer

Crankshaft rear seal installer

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INTRODUCTION

Tool No.

Description

380000670

Oil filter wrench

380000302

380000221

Image

OILFILTERWRENCH

7

VALVESPRINGCOMP

8

Valve spring compressor

Pliers for removing/refitting piston rings 65 - 110 mm (2.559 - 4.331 in)

PISTONRINGPLIER

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9

INTRODUCTION

Tool No.

Description

Image

380000667

Beater for removing/refitting camshaft bushes

CAMBUSHBEATER

380000362

380000216

10

Tool for lifting the crankshaft

CRANKHOIST

11

ENGINEHOIST

12

Engine lifting rig

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INTRODUCTION

Tool No.

Description

Image

380000661

Brackets for fastening the engine to the revolving stand

13

STANDBRACKETS

380000669

Seal remover

SEALREMOVER

380000668

Hand grip for interchangeable beaters

HANDGRIP

380000364

14

15

Gauge base for dial indicator

GAUGEBASE

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16

INTRODUCTION

Tool No.

Description

N/A

Torque wrench

Image

TORQUEWRENCH

380000158

Torque screwdriver

TORQUESCREWDRIV

380000304

18

Tool for angle tightening

ANGLETIGHTENING

380000988

17

Flywheel rotation tool

ROTATOR

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20

19

INTRODUCTION

Tool No.

Description

Image

Piston ring compressor

PISTONRINGCOMP

21

Dial indicator ( 0 - 5 mm (0.000 - 0.197 in))

DIALINDICATOR

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17

22

INTRODUCTION

Special tools F4CE9484, F4GE9484, F4CE9684, F4GE9684

Tool No.

Description

380000979

Injection pump gear puller

380000665

380000663

Image

PUMPGEARPULLER

1

FRONTSEALPULLER

2

Crankshaft front seal puller

Crankshaft rear seal puller

REARSEALPULLER

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3

INTRODUCTION

Tool No.

Description

380000671

Injector puller

380000666

380000664

Image

INJECTORPULLERG

4

FRONTSEALINSTAL

5

CRANKREARSEALIN

6

Crankshaft front seal installer

Crankshaft rear seal installer

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INTRODUCTION

Tool No.

Description

380000670

Oil filter wrench

380000302

380000221

Image

OILFILTERWRENCH

7

VALVESPRINGCOMP

8

Valve spring compressor

Pliers for removing/refitting piston rings 65 - 110 mm (2.559 - 4.331 in)

PISTONRINGPLIER

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9

INTRODUCTION

Tool No.

Description

380000732

Flywheel crank handle

Image

10

FLYWHEELCRANK

380000988

Flywheel rotation tool

ROTATOR

380000667

11

Beater for removing/refitting camshaft bushes

CAMBUSHBEATER

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21

12

INTRODUCTION

Tool No.

Description

380000362

Tool for lifting the crankshaft

380000216

380000994

Image

CRANKHOIST

13

ENGINEHOIST

14

Engine lifting rig

Piston ring compressor

PISTONRINGCOMP

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15

INTRODUCTION

Tool No.

Description

Image

380002729

Engine TDC positioning tool (non-structural engines only)

TIMINGPIN

380000661

16

Brackets for fastening the engine to the revolving stand

17

STANDBRACKETS

380000669

Seal remover

SEALREMOVER

380000668

18

Hand grip for interchangeable beaters

HANDGRIP

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23

19

INTRODUCTION

Tool No.

Description

Image

380000364

Gauge base for dial indicator

GAUGEBASE

380000229

Dial gauge holder and 0 5 mmDial gauge for rotary injection pump timing.

PUMPTIMEADAPT

380000304

20

21

Tool for angle tightening

ANGLETIGHTENING

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24

22

INTRODUCTION

Tool No.

Description

380001005

Dial gauge 0 - 10 mm

Image

DIALGAUGE

380001006

Diesel engine compression tester

COMPTESTER

380000140

24

Adapter for engine compression tester

COMPADAPTER

380000301

23

25

Revolving engine stand

REVOLVING STAND

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25

26

INTRODUCTION

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DISTRIBUTION SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents DISTRIBUTION SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A

FUNCTIONAL DATA Alternator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4CE9484, F4GE9484, F4CE9684, F4GE9684

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9684, F4GE9684

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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM

Alternator - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684

ALTERNATORCG2

1

The alternator is placed on the front right hand side of the engine and is driven by a Poly V-belt.

Specifications: •

Working voltage: •

•

Current delivered: •

•

90 A @ 6000 RPM

Absorption in stand-by: •

•

12 V

Less than or equal to 1 mA

Sense of rotation: •

Clockwise

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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM

Alternator - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the cables from the back of the alternator (1).

2.

Remove the retaining bolts (2) securing the alternator (1) to the support.

3.

Remove the alternator (1).

ALTERNATOR

Next operation: Alternator - Install (A.30.A)

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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM

Alternator - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Alternator - Remove (A.30.A) 1.

Install the alternator (1) and tighten the bolts (2) to the specified torque.

2.

Connect the positive and negative cables onto the back of the alternator.

ALTERNATOR

Next operation: Fan and drive Belt - Install (B.50.A)

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1

DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM

Alternator - Remove F4GE9484, F4GE9684

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Properly hold the alternator (1) separating it from its support by loosening the screw (2).

2.

Remove the screw, nut and washer.

3.

Remove the alternator (1).

ALTERNATORG

Next operation: Alternator - Install (A.30.A)

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1

DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM

Alternator - Remove F4CE9484, F4CE9684

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Properly hold the alternator (2) and loosen the screw (3) to remove the alternator from its support.

2.

Remove it from its bracket by loosening the screw (1).

3.

Recover the nuts and washers.

ALTERNATORC

Next operation: Alternator - Install (A.30.A)

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DISTRIBUTION SYSTEMS - ELECTRICAL POWER SYSTEM

Alternator - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Alternator - Remove (A.30.A) 1.

Connect the alternator (1) to the support.

2.

Tighten the screw (2) without locking it.

3.

Fit the alternator (2) bracket (1) to the engine block.

4.

Tighten the screws (3) fastening the alternator to the support.

Next operation: Fan and drive Belt - Install (B.50.A)

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ALTERNATORG

1

ALTERNATORCG

2

Index DISTRIBUTION SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Alternator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9684

Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9684

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POWER PRODUCTION - B ENGINE - 10.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents POWER PRODUCTION - B ENGINE - 10.A

TECHNICAL DATA ENGINE General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4HE9484, F4HE9684

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DE9484, F4DE9684, F4DE9687

Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4CE9484, F4CE9684

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4GE9484, F4GE9684

Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4CE9484, F4GE9484, F4CE9684, F4GE9684

FUNCTIONAL DATA ENGINE Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4HE9484, F4HE9684

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DE9484, F4DE9684, F4DE9687

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4CE9484, F4CE9684

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4GE9484, F4GE9684

Valve drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Connecting rod and piston Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Wiring harness Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4HE9484, F4HE9684

Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4DE9684, F4DE9687

Electronic control Control module - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Control module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 F4HE9484, F4HE9684 84250518 09/11/2009

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Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 F4HE9484, F4HE9684

Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4DE9484, F4DE9684, F4DE9687

Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4DE9484, F4DE9684, F4DE9687

Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 F4CE9484, F4CE9684

SERVICE ENGINE Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 F4HE9484, F4HE9684

Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 F4DE9484, F4DE9684, F4DE9687

Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 F4GE9484, F4GE9684

Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 F4CE9484, F4CE9684

Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 F4DE9484, F4DE9684, F4DE9687

Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F4GE9484, F4GE9684

Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 F4CE9484, F4CE9684

Valve drive Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Rocker assembly - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Rocker assembly Shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 F4DE9484, F4DE9684, F4DE9687

Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 84250518 09/11/2009

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Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Rocker assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 F4CE9484, F4CE9684

Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 F4GE9484, F4GE9684

Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 F4CE9484, F4CE9684

Rocker assembly - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Auxiliary drive Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 F4CE9484, F4CE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 F4GE9484, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 F4GE9484, F4GE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 F4CE9484, F4CE9684

Crankshaft Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 84250518 09/11/2009

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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Gear - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 F4CE9484, F4CE9684

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 F4HE9484, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 F4DE9484, F4DE9684, F4DE9687

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 F4GE9484, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 F4GE9484, F4GE9684

Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Connecting rod Bushing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Connecting rod Bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Connecting rod Bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 F4CE9484, F4HE9484, F4CE9684, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 F4HE9484, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 F4DE9484, F4DE9684, F4DE9687

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 F4GE9484, F4DE9484, F4GE9684, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 F4DE9484, F4DE9684, F4DE9687 84250518 09/11/2009

B.10.A / 5

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 F4CE9484, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 F4CE9484, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 F4GE9484, F4GE9684

Vibration damper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 F4HE9484, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 F4DE9484, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 F4DE9484, F4DE9684, F4DE9687

Balancer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 F4GE9484, F4GE9684

Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 F4GE9484, F4GE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 F4CE9484, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 F4GE9484, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 F4CE9484, F4CE9684

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 F4GE9484, F4GE9684

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 F4CE9484, F4CE9684

Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684 84250518 09/11/2009

B.10.A / 6

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 F4DE9484, F4DE9684, F4DE9687

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Front cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 F4DE9484, F4DE9684, F4DE9687

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 F4DE9484, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 F4DE9484, F4DE9684, F4DE9687

Rear cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 F4HE9484, F4HE9684

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 F4GE9484, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 F4GE9484, F4GE9684

Wiring harness Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 F4DE9484, F4DE9684, F4DE9687

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 F4HE9484, F4HE9684

Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Electronic control Control module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 F4HE9484, F4HE9684

Control module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 F4HE9484, F4HE9684

Sensing system Position sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

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Position sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Speed sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

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POWER PRODUCTION - ENGINE

ENGINE - General specification F4HE9484, F4HE9684

F4HECOMPLETE

1

The NEF F4HE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder.

They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.

NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed.

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POWER PRODUCTION - ENGINE

General Specifications Engine Type Cycle Power Injection Number of cylinders Bore Stroke Total Displacement Timing Start before T.D.C. End after B.D.C. Start before B.D.C. End after T.D.C. Valve Clearance Intake Exhaust Fuel Feed Injection Type Control Injector Nozzle Type Injection Sequence Injection pressure Aspiration Turbocharging Turbocharger Type Lubrication Oil Pressure @ Low Idle Oil Pressure @ Fast Idle Oil Pan Capacity Oil Filter Capacity Cooling Water Pump Thermostat

4 Cylinders

6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 ECU CRIU 2 DSLA and DLLA 1-3-4-2 1-5-3-6-2-4 250 - 1600 bar (3625 - 23200 psi) Intercooled Holset HX35 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt) Belt Driven 79 - 83 °C (174 - 181 °F)

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Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 4.086 in) (*) 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in)

Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings 2.705 - 2.735 mm (0.106 - 0.108 in) Combustion 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*) Intermediate 4.030 - 4.050 mm (0.159 - 0.159 in) Oil Control Piston Rings 2.560 - 2.605 mm (0.101 - 0.103 in) Combustion 2.350 - 2.380 mm (0.093 - 0.094 in) Intermediate 3.970 - 3.990 mm (0.156 - 0.157 in) Oil Control Piston Ring and Ring Landing Clearance 0.100 - 0.175 mm (0.004 - 0.007 in) Combustion 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) Intermediate 0.040 - 0.080 mm (0.002 - 0.003 in) Oil Control Piston Ring End Gap 0.30 - 0.40 mm (0.012 - 0.016 in) Combustion 0.60 - 0.80 mm (0.024 - 0.031 in) Intermediate 0.30 - 0.55 mm (0.012 - 0.022 in) Oil Control Connecting Rod Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in) Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in) Small end bushing Inside 38.019 - 38.033 mm (1.497 - 1.497 in) Diameter Big end bearing shell 1.955 - 1.968 mm (0.077 - 0.077 in) thickness Piston Pin and Bushing 0.019 - 0.039 mm (0.001 - 0.002 in) Clearance Oversize Big end bearing 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) Shells Crankshaft 82.99 - 83.01 mm (3.267 - 3.268 in) Main Journals 68.987 - 69.013 mm (2.716 - 2.717 in) Crankpins Main Bearing Shell Thickness 2.456 - 2.464 mm (0.097 - 0.098 in) Big end Bearing Shell 1.955 - 1.968 mm (0.077 - 0.078 in) Thickness Main Bearing Bore 87.982 - 88.008 mm (3.464 - 3.465 in) No. 1,5 / 1,7 87.977 - 88.013 mm (3.464 - 3.465 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance 0.041 - 0.119 mm (0.002 - 0.005 in) No. 1,5 / 1,7 0.041 - 0.103 mm (0.002 - 0.004 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin 0.033 - 0.041 mm (0.001 - 0.002 in) Clearance (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A 84250518 09/11/2009

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POWER PRODUCTION - ENGINE

Clearance Data Thrust Journal Thrust Bearing Bore Thrust Bearing Crankshaft End Play

37.475 32.180 37.28 0.095

-

37.545 mm (1.475 - 1.478 in) 32.280 mm (1.267 - 1.271 in) 37.38 mm (1.468 - 1.472 in) 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 7.042 - 7.062 mm (0.277 - 0.278 in) Valve Guide Bore Intake Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.052 - 0.092 mm (0.002 - 0.004 in) Clearance Valve Seat Bore 34.837 - 34.863 mm (1.372 - 1.373 in) Intake 34.837 - 34.863 mm (1.372 - 1.373 in) Exhaust Valve seat Outside Diameter: 34.917 - 34.931 mm (1.375 - 1.375 in) Intake 34.917 - 34.931 mm (1.375 - 1.375 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 0.59 - 1.11 mm (0.023 - 0.044 in) Intake 0.96 - 1.48 mm (0.038 - 0.058 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.054 - 0.094 mm (0.002 - 0.004 in) Intake 0.054 - 0.094 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 47.75 mm (1.880 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 35.33 mm (1.391 in) lb) Under a load equal to: 25.2 mm (0.992 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 53.995 - 54.045 mm (2.126 - 2.128 in) 1-5 / 1-7 Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in) Bushing and Journal Clearance 0.038 - 0.162 mm (0.001 - 0.006 in) Cam Lift 7.582 mm (0.299 in) Intake 6.045 mm (0.238 in) Exhaust Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in) Tappet outside diameter Top 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) Middle 15.924 - 15.954 mm (0.627 - 0.628 in) Bottom 0.025 - 0.070 mm (0.001 - 0.003 in) Tappets and Bore Clearance (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A 84250518 09/11/2009

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Clearance Data 21.965 - 21.977 mm (0.865 - 0.865 in) Rocker shaft 22.001 - 22.027 mm (0.866 - 0.867 in) Rockers 0.024 - 0.162 mm (0.001 - 0.006 in) Rockers and Shaft Clearance (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A

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POWER PRODUCTION - ENGINE

ENGINE - General specification F4DE9484, F4DE9684, F4DE9687

F4DECOMPLETE

1

The NEF F4DE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder.

They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.

NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed.

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POWER PRODUCTION - ENGINE

General Specifications Engine Type Cycle Power Injection Number of cylinders Bore Stroke Total Displacement Timing Start before T.D.C. End after B.D.C. Start before B.D.C. End after T.D.C. Valve Clearance Intake Exhaust Fuel Feed Injection Type Control Injector Nozzle Type Injection Sequence Injection pressure Aspiration Turbocharging Turbocharger Type Lubrication Oil Pressure @ Low Idle Oil Pressure @ Fast Idle Oil Pan Capacity Oil Filter Capacity Cooling Water Pump Thermostat

4 Cylinders

6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 ECU CRIU 2 DSLA and DLLA 1-3-4-2 1-5-3-6-2-4 250 - 1600 bar (3625 - 23200 psi) Intercooled Holset HX35 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt) Belt Driven 79 - 83 °C (174 - 181 °F)

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POWER PRODUCTION - ENGINE

Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 4.086 in) (*) 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in)

Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings 2.705 - 2.735 mm (0.106 - 0.108 in) Combustion 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*) Intermediate 4.030 - 4.050 mm (0.159 - 0.159 in) Oil Control Piston Rings 2.560 - 2.605 mm (0.101 - 0.103 in) Combustion 2.350 - 2.380 mm (0.093 - 0.094 in) Intermediate 3.970 - 3.990 mm (0.156 - 0.157 in) Oil Control Piston Ring and Ring Landing Clearance 0.100 - 0.175 mm (0.004 - 0.007 in) Combustion 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) Intermediate 0.040 - 0.080 mm (0.002 - 0.003 in) Oil Control Piston Ring End Gap 0.30 - 0.40 mm (0.012 - 0.016 in) Combustion 0.60 - 0.80 mm (0.024 - 0.031 in) Intermediate 0.30 - 0.55 mm (0.012 - 0.022 in) Oil Control Connecting Rod Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in) Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in) Small end bushing Inside 38.019 - 38.033 mm (1.497 - 1.497 in) Diameter Big end bearing shell 1.955 - 1.968 mm (0.077 - 0.077 in) thickness Piston Pin and Bushing 0.019 - 0.039 mm (0.001 - 0.002 in) Clearance Oversize Big end bearing 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) Shells Crankshaft 82.99 - 83.01 mm (3.267 - 3.268 in) Main Journals 68.987 - 69.013 mm (2.716 - 2.717 in) Crankpins Main Bearing Shell Thickness 2.456 - 2.464 mm (0.097 - 0.098 in) Big end Bearing Shell 1.955 - 1.968 mm (0.077 - 0.078 in) Thickness Main Bearing Bore 87.982 - 88.008 mm (3.464 - 3.465 in) No. 1,5 / 1,7 87.977 - 88.013 mm (3.464 - 3.465 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance 0.041 - 0.119 mm (0.002 - 0.005 in) No. 1,5 / 1,7 0.041 - 0.103 mm (0.002 - 0.004 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin 0.033 - 0.041 mm (0.001 - 0.002 in) Clearance (*) Valid for engines: F4DE9684A. 84250518 09/11/2009

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POWER PRODUCTION - ENGINE

Clearance Data Thrust Journal Thrust Bearing Bore Thrust Bearing Crankshaft End Play

37.475 32.180 37.28 0.095

-

37.545 mm (1.475 - 1.478 in) 32.280 mm (1.267 - 1.271 in) 37.38 mm (1.468 - 1.472 in) 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 7.042 - 7.062 mm (0.277 - 0.278 in) Valve Guide Bore Intake Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.052 - 0.092 mm (0.002 - 0.004 in) Clearance Valve Seat Bore 34.837 - 34.863 mm (1.372 - 1.373 in) Intake 34.837 - 34.863 mm (1.372 - 1.373 in) Exhaust Valve seat Outside Diameter: 34.917 - 34.931 mm (1.375 - 1.375 in) Intake 34.917 - 34.931 mm (1.375 - 1.375 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 0.59 - 1.11 mm (0.023 - 0.044 in) Intake 0.96 - 1.48 mm (0.038 - 0.058 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.054 - 0.094 mm (0.002 - 0.004 in) Intake 0.054 - 0.094 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 47.75 mm (1.880 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 35.33 mm (1.391 in) lb) Under a load equal to: 25.2 mm (0.992 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 53.995 - 54.045 mm (2.126 - 2.128 in) 1-5 / 1-7 Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in) Bushing and Journal Clearance 0.038 - 0.162 mm (0.001 - 0.006 in) Cam Lift 7.582 mm (0.299 in) Intake 6.045 mm (0.238 in) Exhaust Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in) Tappet outside diameter Top 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) Middle 15.924 - 15.954 mm (0.627 - 0.628 in) Bottom 0.025 - 0.070 mm (0.001 - 0.003 in) Tappets and Bore Clearance (*) Valid for engines: F4DE9684A. 84250518 09/11/2009

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POWER PRODUCTION - ENGINE

Clearance Data Rocker shaft Rockers Rockers and Shaft Clearance (*) Valid for engines: F4DE9684A.

21.965 - 21.977 mm (0.865 - 0.865 in) 22.001 - 22.027 mm (0.866 - 0.867 in) 0.024 - 0.162 mm (0.001 - 0.006 in)

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ENGINE - Service limits Maintenance Planning F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

To ensure optimized 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.

Regular maintenance and inspection planning Checks and periodical inspections

Frequency (hours)

Visual check of engine Inspection presence of water in fuel filter or pre-filter Inspection blow-by filter elements Inspection of belt wear status Inspection and setting of tappet clearance EDC Replacement of engine’s oil and filter Replacement of pre-filter Replacement of fuel filter Replacement of blow-by filter Replacement of belt

Daily Daily 4000 When anomaly occurs 500 1000 500 500 1500

NOTICE: The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacement and checks.

The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by Iveco Motors.

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.

Daily Maintenance Checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.

•

Fluid levels and checks of any eventual leakage from the fuel, cooling and lubricating circuits.

•

Notify the maintenance if any inconvenience is detected or 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 vehicle devices, the prescribed pressure, temperature and other parameters.

•

Visual check of fumes (color of exhaust emissions)

•

Visual check of cooling liquid level, in the expansion tank.

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POWER PRODUCTION - ENGINE

ENGINE - General specification F4CE9484, F4CE9684

SECTIONPICTUREC

1

NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment in general.

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

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

It differs from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine.

NOTE: The picture shows application designed for 6 cylinder versions, 2 valves per cylinder, having fuel feed by a mechanical pump.

NOTICE: Data, technical specifications and performances granted shall be valid only if the setter will follow and comply with all installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed.

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POWER PRODUCTION - ENGINE

Engine Type Compression ratio Bore Stroke Displacement Turbocharger type

4 cylinder

6 cylinder 17.5 : 1 104 mm (4.1 in) 132 mm (5.2 in)

4485 cm³ Intercooled Holset HX25W

6728 cm³ Intercooled Holset HX35W

Lubrication Oil Pressure (warm engine) Idling Peak RPM

0.8 bar (11.6 psi) 3.5 bar (50.8 psi)

Cooling Water Pump Thermostat opening temperature

Belt Driven 79 - 83 °C (174.2 - 181.4 °F)

Capacity -

Oil Pan Oil Filter

16 l (16.9 US qt) 1 l (1.1 US qt)

Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 4.086 in) (*) 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in)

Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings 2.705 - 2.735 mm (0.106 - 0.108 in) Combustion 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*) Intermediate 4.030 - 4.050 mm (0.159 - 0.159 in) Oil Control Piston Rings 2.560 - 2.605 mm (0.101 - 0.103 in) Combustion 2.350 - 2.380 mm (0.093 - 0.094 in) Intermediate 3.970 - 3.990 mm (0.156 - 0.157 in) Oil Control Piston Ring and Ring Landing Clearance 0.100 - 0.175 mm (0.004 - 0.007 in) Combustion 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) Intermediate 0.040 - 0.080 mm (0.002 - 0.003 in) Oil Control Piston Ring End Gap 0.30 - 0.40 mm (0.012 - 0.016 in) Combustion 0.60 - 0.80 mm (0.024 - 0.031 in) Intermediate 0.30 - 0.55 mm (0.012 - 0.022 in) Oil Control Connecting Rod Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in) Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in) Small end bushing Inside 38.019 - 38.033 mm (1.497 - 1.497 in) Diameter 84250518 09/11/2009

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Clearance Data Big end bearing shell thickness Piston Pin and Bushing Clearance Oversize Big end bearing Shells Crankshaft Main Journals Crankpins Main Bearing Shell Thickness Big end Bearing Shell Thickness Main Bearing Bore No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin Clearance Thrust Journal Thrust Bearing Bore Thrust Bearing Crankshaft End Play

1.955 - 1.968 mm (0.077 - 0.077 in) 0.019 - 0.039 mm (0.001 - 0.002 in) 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) 2.456 - 2.464 mm (0.097 - 0.098 in) 1.955 - 1.968 mm (0.077 - 0.078 in) 87.982 - 88.008 mm (3.464 - 3.465 in) 87.977 - 88.013 mm (3.464 - 3.465 in) 0.064 - 0.095 mm (0.003 - 0.004 in) 0.059 - 0.100 mm (0.002 - 0.004 in) 0.033 - 0.041 mm (0.001 - 0.002 in) 37.475 32.180 37.28 0.095

-

37.545 mm (1.475 - 1.478 in) 32.280 mm (1.267 - 1.271 in) 37.38 mm (1.468 - 1.472 in) 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 8.019 - 8.039 mm (0.3157 - 0.3165 in) Valve Guide Bore Intake Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.039 - 0.079 mm (0.002 - 0.003 in) Clearance Valve Seat Bore 46.987 - 47.013 mm (1.850 - 1.851 in) Intake 43.637 - 43.663 mm (1.718 - 1.719 in) Exhaust Valve seat Outside Diameter: 47.063 - 47.089 mm (1.853 - 1.854 in) Intake 43.713 - 43.739 mm (1.721 - 1.722 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 1 - 1.52 mm (0.039 - 0.060 in) Intake 1 - 1.52 mm (0.039 - 0.060 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.050 - 0.102 mm (0.002 - 0.004 in) Intake 0.050 - 0.102 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 63.50 mm (2.500 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 49.02 mm (1.930 in) lb) 84250518 09/11/2009

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Clearance Data Under a load equal to: 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 1-5 / 1-7 Bushing inside diameter Bushing and Journal Clearance Cam Lift Intake Exhaust Tappet Bore Tappet outside diameter Top Middle Bottom Tappets and Bore Clearance Rocker shaft Rockers Rockers and Shaft Clearance

38.20 mm (1.504 in) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) 53.995 - 54.045 mm (2.126 - 2.128 in) 54.083 - 54.147 mm (2.129 - 2.132 in) 0.038 - 0.162 mm (0.001 - 0.006 in) 11.02 mm (0.434 in) 10.74 mm (0.423 in) 16.000 - 16.030 mm (0.630 - 0.631 in) 15.924 15.960 15.924 0.020 18.963 19.000 0.025

-

15.954 mm (0.627 - 0.628 in) 15.975 mm (0.628 - 0.629 in) 15.954 mm (0.627 - 0.628 in) 0.065 mm (0.001 - 0.003 in) 18.975 mm (0.747 - 0.747 in) 19.026 mm (0.748 - 0.749 in) 0.063 mm (0.001 - 0.002 in)

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ENGINE - General specification F4GE9484, F4GE9684

SECTIONPICTUREG

1

NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment in general.

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

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

It differs from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine.

NOTE: The picture shows application designed for 6 cylinder versions, 2 valves per cylinder, having fuel feed by a mechanical pump.

NOTICE: Data, technical specifications and performances granted shall be valid only if the setter will follow and comply with all installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed.

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Engine Type Compression ratio Bore Stroke Displacement Turbocharger type

4 cylinder

6 cylinder 17.5 : 1 104 mm (4.1 in) 132 mm (5.2 in)

4485 cm³ Intercooled Holset HX25W

6728 cm³ Intercooled Holset HX35W

Lubrication Oil Pressure (warm engine) Idling Peak RPM

0.7 bar (10.2 psi) 3.5 bar (50.8 psi)

Cooling Water Pump Thermostat opening temperature

Belt Driven 79 - 83 °C (174.2 - 181.4 °F)

Capacity Oil Pan Oil Filter

13 l (13.7 US qt) 1 l (1.1 US qt)

15 l (15.9 US qt) 1 l (1.1 US qt)

Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 4.086 in) (*) 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in)

Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings 2.705 - 2.735 mm (0.106 - 0.108 in) Combustion 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*) Intermediate 4.030 - 4.050 mm (0.159 - 0.159 in) Oil Control Piston Rings 2.560 - 2.605 mm (0.101 - 0.103 in) Combustion 2.350 - 2.380 mm (0.093 - 0.094 in) Intermediate 3.970 - 3.990 mm (0.156 - 0.157 in) Oil Control Piston Ring and Ring Landing Clearance 0.100 - 0.175 mm (0.004 - 0.007 in) Combustion 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) Intermediate 0.040 - 0.080 mm (0.002 - 0.003 in) Oil Control Piston Ring End Gap 0.30 - 0.40 mm (0.012 - 0.016 in) Combustion 0.60 - 0.80 mm (0.024 - 0.031 in) Intermediate 0.30 - 0.55 mm (0.012 - 0.022 in) Oil Control Connecting Rod Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in) Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in) Small end bushing Inside 38.019 - 38.033 mm (1.497 - 1.497 in) Diameter 84250518 09/11/2009

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Clearance Data Big end bearing shell thickness Piston Pin and Bushing Clearance Oversize Big end bearing Shells Crankshaft Main Journals Crankpins Main Bearing Shell Thickness Big end Bearing Shell Thickness Main Bearing Bore No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin Clearance Thrust Journal Thrust Bearing Bore Thrust Bearing Crankshaft End Play

1.955 - 1.968 mm (0.077 - 0.077 in) 0.019 - 0.039 mm (0.001 - 0.002 in) 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) 2.456 - 2.464 mm (0.097 - 0.098 in) 1.955 - 1.968 mm (0.077 - 0.078 in) 87.982 - 88.008 mm (3.464 - 3.465 in) 87.977 - 88.013 mm (3.464 - 3.465 in) 0.064 - 0.095 mm (0.003 - 0.004 in) 0.059 - 0.100 mm (0.002 - 0.004 in) 0.064 - 0.090 mm (0.003 - 0.004 in) 37.475 32.180 37.28 0.095

-

37.545 mm (1.475 - 1.478 in) 32.280 mm (1.267 - 1.271 in) 37.38 mm (1.468 - 1.472 in) 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 8.019 - 8.039 mm (0.3157 - 0.3165 in) Valve Guide Bore Intake Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.059 - 0.086 mm (0.002 - 0.003 in) Clearance Valve Seat Bore 46.987 - 47.013 mm (1.850 - 1.851 in) Intake 43.637 - 43.663 mm (1.718 - 1.719 in) Exhaust Valve seat Outside Diameter: 47.063 - 47.089 mm (1.853 - 1.854 in) Intake 43.713 - 43.739 mm (1.721 - 1.722 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 1 - 1.52 mm (0.039 - 0.060 in) Intake 1 - 1.52 mm (0.039 - 0.060 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.050 - 0.102 mm (0.002 - 0.004 in) Intake 0.050 - 0.102 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 63.50 mm (2.500 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 49.02 mm (1.930 in) lb) 84250518 09/11/2009

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Clearance Data Under a load equal to: 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 1-5 / 1-7 Bushing inside diameter Bushing and Journal Clearance Tappet Bore Tappet outside diameter Top Middle Bottom Rocker shaft Rockers Rockers and Shaft Clearance

38.20 mm (1.504 in) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) 53.995 54.083 0.038 16.000

-

54.045 mm (2.126 - 2.128 in) 54.147 mm (2.129 - 2.132 in) 0.162 mm (0.001 - 0.006 in) 16.030 mm (0.630 - 0.631 in)

15.924 15.960 15.924 18.963 19.000 0.025

-

15.954 mm (0.627 - 0.628 in) 15.975 mm (0.628 - 0.629 in) 15.954 mm (0.627 - 0.628 in) 18.975 mm (0.747 - 0.747 in) 19.026 mm (0.748 - 0.749 in) 0.063 mm (0.001 - 0.002 in)

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ENGINE - Service limits Maintenance Planning F4CE9484, F4GE9484, F4CE9684, F4GE9684

To ensure optimized 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.

Regular maintenance and inspection planning Checks and periodical inspections

Frequency (hours)

Visual check of engine Inspection presence of water in fuel filter or pre-filter Inspection of belt wear status Inspection and setting of tappet clearance Replacement of engine’s oil and filter Replacement of pre-filter Replacement of fuel filter Replacement of belt

Daily Daily 4000 500 1000 500 1500

NOTICE: The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacement and checks.

The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided

by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for 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 inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.

•

Fluid levels and checks of any eventual leakage from the fuel, cooling and lubricating circuits.

•

Notify the maintenance if any inconvenience is detected or 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 vehicle devices, the prescribed pressure, temperature and other parameters.

•

Visual check of fumes (color of exhaust emissions)

•

Visual check of cooling liquid level, in the expansion tank.

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ENGINE - Component localisation F4HE9484, F4HE9684

Location of main electrical components

CRIL04D081G01

1

(1) Coolant Temperature Sensor - (2) Electro-Injector - (3) Rail Pressure Sensor - (4) Air Temperature/Pressure Sensor - (5) Engine Starter - (6) Timing Sensor - (7) Solenoid Valve for Pressure Regulator - (8) Fuel Temperature Sensor - (9) EDC Electronic Control Unit - (10) Crankshaft Sensor - (11) Oil Level Sensor - (12) Engine Oil Temperature/Pressure Sensor - (13) Heating Element for Pre-Post Heating The NEF F4HE engines are fully driven by the electronic engine control module, which is assembled directly to the engine by means of a heat exchanger enabling it’s cooling, utilizing rubber buffers to reduce vibration originated by the engine.

Through the engine control module it is possible to verify the correct working of the engine.

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ENGINE - Component localisation F4DE9484, F4DE9684, F4DE9687

Location of main electrical components

ELECCOMPD

1

(1) Coolant temperature sensor - (2) Electro-injector - (3) Starter - (4) Fuel pressure sensor - (5) Air pressure/temperature sensor - (6) Timing sensor - (7) fuel temperature sensor - (8) EDC7 electronic control module - (9) Crankshaft speed sensor - (10) Engine oil pressure/temperature sensor - (11) Pre-post heating resistor.

The NEF F4DE engines are fully driven by the electronic engine control module, which is mounted remotely on the unit utilizing rubber buffers to reduce vibration originated by the engine.

Through the engine control module it is possible to verify the correct working of the engine.

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ENGINE - Component localisation F4CE9484, F4CE9684

ECOMPONENTSC

1

(1) Coolant temperature sensor - (2) Starter - (3) Grid heater - (4) KSB water temperature sensor - (5) Electromagnets assembled to feed pump: (A) on hydraulic head unit (B) on KSB - (6) Oil pressure switch (7) (C) Fuel heater (D) Water detecting sensor - (8) Speed sensor - (9) Alternator

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POWER PRODUCTION - ENGINE

ENGINE - Component localisation F4GE9484, F4GE9684

ECOMPONENTSG

1

(1) Coolant temperature sensor - (2) Starter - (3) KSB water temperature sensor - (4) Electromagnets assembled on feed pump: (A) on hydraulic head unit (B) on KSB - (5) Oil pressure sensor - (6) Grid heater - (7) Alternator.

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POWER PRODUCTION - ENGINE

Valve drive - Overview F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Exhaust Gas Re-Circulation System (EGR) In the Tier III version, the profile of the exhaust cam lobe has been modified in order to allow the partial opening of the exhaust valve during the aspiration phase and introduces part of the exhaust gases into the engine cylinders. The exhaust gases can partially be redirected into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitrogen oxides (NOx). The EGR system reduces the combustion temperature by means of diminishing the concentration of oxygen in the combustion chamber. This process is an efficient control system of the emission of NOx. The internal EGR system is not equipped with any electronically controlled elements.

The system is always active and does not require any additional components such as check valves, piping, or heat exchangers. The exhaust cam has an additional lobe apart from the major lobe. The additional lobe, during the aspiration phase of a cylinder, allows a brief opening of the exhaust valve generating recirculation due the intake of the exhaust gases caused by the suction which is created in the aspiration phase inside the cylinder.

EGRSYSTEM

1

(A) Aspiration valve control - (B) Exhaust valve control

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Rocker Assembly Components

ROCKERCOMPONENT

2

(1) Screws - (2) Bracket - (3) Shafts - (4) Rockers.

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Connecting rod and piston - Overview Components

BAPH04APH144ASA

1

(1) Stop Rings - (2) Pin - (3) Piston- (4) Split Rings - (5) Screws - (6) Half Bearings - (7) Connecting Rod - (8) Bush NOTE: The pistons are supplied spare with the following sizes: - Standard - 0.4 mm (0.016 in) oversize.

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POWER PRODUCTION - ENGINE

Wiring harness - Electrical schema F4HE9484, F4HE9684

ELECSCHEMH

(1) Injectors for cylinders 1 and 2

1

(2) Injectors for cylinders 3 and 4

(6) Engine oil pressure/temperature sensor (7) Fuel temperature sensor

(3) Injectors for cylinders 5 and 6

(8) Coolant temperature sensor

(4) Engine RPM sensor (5) Timing sensor

(9) Air pressure/temperature sensor (10) Fuel pressure sensor

(11) Pressure regulator (12) Connector C to the EDC control unit (sensors) (13) Connector A to the EDC control unit (injectors)

Injectors Connector (A) ECU PIN

FUNCTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Pressure Regulator Pressure Regulator Cylinder 2 injector Cylinder 3 injector Cylinder 1 injector Cylinder 4 injector 84250518 09/11/2009

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Injectors Connector (A) ECU PIN

FUNCTION

15 16

Cylinder 6 injector Cylinder 5 injector

Sensors connector (C) ECU PIN

FUNCTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Timing sensor Timing sensor Negative for rail temperature and pressure sensor Positive for rail temperature and pressure sensor Signal from rail temperature and pressure sensor Coolant temperature sensor signal from fuel temperature sensor Engine RPM sensor Engine RPM sensor Negative for engine oil pressure and temperature sensor Negative for air temperature and pressure sensor Coolant temperature sensor Signal from engine oil pressure sensor Signal from engine oil temperature Positive for engine oil pressure and temperature sensor Positive for air temperature and pressure sensor Signal from air pressure sensor Negative for fuel temperature sensor Signal from air temperature sensor

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POWER PRODUCTION - ENGINE

Wiring harness - Electrical schema F4DE9484, F4DE9684, F4DE9687

Connector to injectors (A)

CONNECTORA

ECU Pin # Cable Color 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

MN MV VB HR MB VN VG HN HG CN CB CL

1

Function 4 cyl.version

6 cyl. version

Injector Earth Injector Injector Injector Injector Injector Injector Injector

Injector Injector Injector Injector Earth Injector Injector Injector Injector Injector Injector Injector Injector

Cylinder 4

Cylinder Cylinder Cylinder Cylinder Cylinder

1 2 3 4 1

Cylinder 2 Cylinder 3

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Cylinder Cylinder Cylinder Cylinder

2 3 4 2

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

1 6 5 3 1 4 6 5

POWER PRODUCTION - ENGINE

Feed connector (B) to components and to functions of the specific equipment

CONNECTORB

2

ECU Pin #

Cable #

Function

1 2 3 4 7 8

8150 0087 0000 8885/0159 8150 7777

9 12/13 14/15 16 19 20 27 28 31 32 36 37 39 44 45 46 49 50 52 53 55 62 63 64 72 73 78

0000 8150 0000 0094 0150 8153 0156 5535 2298 8837 8888 8051 9905 9906 5553 5584 0158 6109 6108 5158 0160 5503 0535 0159 0159 8162

Positive driven by battery Negative for switch of fuel filter heater/starter Earth Positive for pre-post heating resistor Positive driven by battery Positive for blink-code button, low oil pressure LED, pre-heating LED, Air conditioner switch (if available), EDC Earth Positive driven by battery Earth Negative for post-heating resistor Negative start/stop push buttons from eng./accelerator pressed Positive from change over switch to key in starting phase (+50) Positive from blink-code button Positive for EDC diagnostic LED K line for diagnostic connector, 30 poles (pin 2) Negative for multi-switch couple-limiter Positive for fuel heating switch Positive for starter Positive from key switch/ L line for diagnosis connector, 30 poles (pin 11) Negative from starter push button from engine Negative from engine stop push button from engine Negative for pre-heating LED in on position Diagnosis connector (pin 28) Negative from accelerator push button pressed CAN Line (if equipped), diagnosis connector (pin 22) CAN Line (if equipped), diagnosis connector (pin 22) Positive for sensor of foot accelerator pedal pos. / Earth multi-switch Negative for clutch sensor Negative for low engine oil pressure LED Negative for EDC diagnosis LED Positive from pressed accelerator push button / multi-switch signal Positive redundant from pressed accelerator push button Positive air conditioner device (if equipped) 84250518 09/11/2009

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POWER PRODUCTION - ENGINE

ECU Pin #

Cable #

Function

81 83 87

0157 5157 -

Negative sensor of foot accelerator pedal pos. / Earth Multi-switch Signal from sensor of foot accelerator pedal pos. / Signal Multi-switch Positive for couple multi-switch limiter

Color Legend Symbol Color

Symbol Color

C A B L G H M

N W S R V Z

Orange Sky Blue White Blue Yellow Gray Brown

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Black Light Brown Pink Red Green Purple

POWER PRODUCTION - ENGINE

Connector to sensors (C)

CONNECTORC

3

ECU Pin Cable Color #

Function

5 7 9 10 12 17 18 19 20 21 23 24 25 27 28 29 30 33 34 35 36

Earth for pressure regulator Pressure regulating device Feed for engine oil temperature/pressure sensor Feed for air pressure/temperature sensor Feed for rail pressure sensor Earth for fuel temperature sensor Earth for coolant temperature sensor Earth for engine oil temperature sensor Feed for rail pressure sensor Feed for air pressure/temperature sensor Timing system sensor Driving shaft sensor Driving shaft sensor Signal from rail pressure sensor signal from air pressure sensor Signal from air pressure sensor Earth for timing system sensor Signal from engine oil temperature sensor Signal from fuel temperature sensor Signal from engine oil pressure sensor Signal from coolant temperature sensor

C V MN CR HN BL CV GV BZ GN R B R RV LN BH B GR CN NS BG

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POWER PRODUCTION - ENGINE

Electronic control Control module - Detailed view F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

EDC7 ECU

CRIL04D082G01

1

(A) - Connector to injectors; (B) - Connector (Provide reference of the vehicle to which the engine is assembled); (C) - Connector to sensors.

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POWER PRODUCTION - ENGINE

Electronic control Control module - Overview F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

EDC 7 OPERATION Engine preheating element control Pre-post heating is activated when any of the following requirements are met. Water, air, or fuel temperature sensors detect a temperature less than or equal to 5 °C (41 °F).

Phase recognition Signals transmitted by the camshaft and crankshaft sensors determine which cylinder fuel is to be injected at the time of starting.

Injection control On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds.

Injection pressure closed loop control On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control unit administrates the regulator to maintain injection pressure at constantly optimal values.

Pilot and main injection advance control On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on the basis of internal mapping.

Idle speed control The control unit processes signals transmitted by the various sensors and adjust the quantity of fuel injected.

It also controls the pressure regulator and modulates injection duration of the electro-injectors.

Within specific limits, the control unit also monitors battery voltage.

Overheating protection If the water temperature reaches 110 °C (230 °F), the control unit reduces engine performance.

When the temperature returns below 100 °C (212 °F), the engine resumes normal operation, (in some applications, the over boosting temperature is the reference temperature).

Maximum engine speed limiting Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine speed surpasses these limits the control unit activates power reduction strategies by controlling the electro-injectors.

In some applications the maximum limiting response consists in stopping the engine.

Cut Off Fuel cut off in release phases is managed by the control unit with the following logical interventions: •

Deactivation of the electro-injectors.

•

Reactivation of electro-injectors immediately prior to reaching idle speed.

•

Control of fuel pressure regulator.

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Smoke control under acceleration With heavy load demands, in accordance with signals received from the air inlet meter and the engine speed sensor, the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent the emission of smoke from the exhaust.

After Run After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, including the faults log so that they will be available the next time the engine is started.

Control of working speed in normal operating conditions Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions.

If the load causes a reduction in power, the control unit increases torque by increasing the amount of fuel injected in order to restore the engine to maximum power.

Recovery strategies Recovery strategies are characterized by certain differences as application varies: •

Control of fuel leaks In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained with a low number of RPMs and high torque values in order to inject the maximum quantity of fuel.

•

Control of pressure in the rail When the pressure in the rail exceeds the safety values, the engine reduces power.

•

Synchronism problems In the case of synchronism problems, faulty RPM sensors, the system controls the engine by increasing the number of RPMs in order to improve interpretation of the signals.

•

Power restrictions as operating temperature increases When the temperature of the charge air rises above 88 °C (190 °F), power reduction is started. When a temperature of 120 °C (248 °F) is reached, performance is further reduced and is comparable to a naturally aspirated engine.

•

Reduction of power as reference temperature varies In normal operating conditions, the system knows the charge air, oil and water temperatures.

If the temperature of the engine water is not available, the system takes the temperature of the oil as a reference and when this reaches the threshold of 103 °C (217 °F), it starts to reduce the power available. Upon reaching 113 °C (235 °F), power is reduced to 50 %.

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Sensing system Crankshaft sensor - Overview F4HE9484, F4HE9684

CRANKSENSOR

1

This is an inductive sensor located at the left hand side of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone wheel fitted on the crankshaft.

The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ~900 Ω.

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Sensing system Camshaft speed sensor - Overview F4HE9484, F4HE9684

CAMSENSOR

1

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 no 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 Ω.

ECU pin Reference 1 2 3

Description Signal Signal Shield

Crankshaft Sensor

Timing Sensor

19C 23C -

10C 9C -

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Sensing system Crankshaft sensor - Overview F4DE9484, F4DE9684, F4DE9687

CRANKSENSOR

1

The crankshaft sensor is an inductive type sensor that is located on the front of the engine.

It generates some signals originated by the magnetic flow lines that close up through the openings of a tone wheel splined to the crankshaft. The same signal is utilized to control the eventual electronic engine speed indicator placed on the vehicle instrument board.

It is connected to the engine control module by pin 25C (signal) and 24C (signal). The third pin is for screening.

The resistance value of the sensor is about 900 Ω.

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Sensing system Camshaft speed sensor - Overview F4DE9484, F4DE9684, F4DE9687

CAMSENSOR

1

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 no interchangeable because of the different external shape.

The timing sensor is connected to the control unit on pins 23C - 30C. The sensor impedance is ~900 Ω.

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Sensing system Crankshaft sensor - Overview F4CE9484, F4CE9684

CRANKSENSOR

1

It is an induction type sensor and it is placed on the front part of the engine above the crankshaft. It generates signals obtained from magnetic flow lines.

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ENGINE - Place on stand F4HE9484, F4HE9684

NOTE: In order to apply the brackets 380000661 to the engine block, it is necessary to perform the following operations on the left hand side of the engine.

1.

Using the tool unscrew the fuel filter and remove it from the support.

2.

Disconnect the electrical connection from the support.

3.

Disconnect the fuel low pressure pipelines from the support.

4.

Disconnect pipeline from the support.

5.

Remove the sustaining support bracket from the block.

6.

Disconnect the high pressure fuel pipeline from the rail diffuser and from the high pressure pump and disassemble it from the engine block removing the fixing clamps.

7.

Disconnect the pipeline feeding the mechanical pump that is combined to the high pressure pump through the exchanger of the engine control module.

8.

F4HE123456

1

Disassemble the oil fill tube (if present) by removing the bolts. Remove the O-ring from the tube.

NOTICE: Because of the high pressure in the pipelines running from the high pressure pump to the rail and from the rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while engine is running or reuse the disassembled pipelines.

9.

Remove the screws holding the turbocharger (1) oil drain pipe (2) and remove pipe from the engine block.

TURBOLUBEF4HE

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10.

Remove the starter from the flywheel housing.

11.

Apply brackets 380001298 to the engine block and use them to secure the engine to the revolving stand 380000301.

12.

Remove the drain plug from the oil sump and drain out the oil.

13.

Remove the fan from the output shaft pulley.

STARTERF4HE

NOTICE: Collect and dispose of engine oil according to regulations in your area.

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ENGINE - Place on stand F4DE9484, F4DE9684, F4DE9687

NOTE: In order to apply the brackets 380000661 to the engine block, it is necessary to perform the following operations on the left hand side of the engine.

1.

Using the tool 380000670, unscrew the fuel filter (6) and remove it from the support (1).

2.

Disconnect the electrical connection (2) from the support (1).

3.

Disconnect the fuel low pressure pipelines (3), (4) and (5) from the support (1).

4.

Disconnect pipeline (9) from the support (1).

5.

Remove the sustaining support bracket (1) from the block.

6.

Disconnect the high pressure fuel pipeline (7) from the rail diffuser and from the high pressure pump (8) and disassemble it from the engine block removing the fixing clamps.

7.

Disconnect the pipeline feeding the mechanical pump that is combined to the high pressure pump through the exchanger of the engine control module.

8.

Disassemble the oil fill tube (if present) by removing the bolts. Remove the O-ring from the tube.

STANDMOUNTING

1

NOTICE: Because of the high pressure in the pipelines running from the high pressure pump to the rail and from the rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while engine is running or reuse the disassembled pipelines.

9.

Disconnect the oil drain pipe (1)for the turbocharger.

10.

Unscrew the fixing screws and disconnect the starting motor (2) from its seat.

PIPEANDSTARTER

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11.

Disconnect the lubricating pipe (2) from the upper side of the heat exchanger on the turbo blower (1).

12.

Undo the fastening screws (4) and remove the support (3).

13.

Disassemble the thermostat body including the seal.

14.

Make holes (1) and (2) on both sides of the engine base, brackets 380000661 and then fix by means of the later, the engine to the revolving stand 380000301.

15.

Empty the engine oil by removing the cap off the sump.

TURBOLUBEF4DE

3

STANDMOUNTHOLES

4

NOTE: Collect and dispose of the engine oil according to enforced regulations.

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ENGINE - Place on stand F4GE9484, F4GE9684

1.

In order to apply the brackets 380000661 to the engine block to fix it on to the stand 380000301 for the overhaul, it is necessary to perform the following operations.

2.

Disassemble the oil filter (1) from the support using tool 380000670.

NOTICE: The oil filter contains inside approximately 1 kg (2.2 lb) of engine oil. Provide for oil recovery and disposal in compliance with the laws and regulations in force.

3.

Disassemble lubrication oil exhaust pipe (1) from the turbo-blower.

4.

Underneath the turbo-blower, loosen the two screws (2), and loosen the screw (3) fixing the pipe throughout the stop collar (4) fixing the block.

5.

Finally, loosen and remove the union (5) from the block.

6.

Plug the pipe ends and the exhaust of the turboblower.

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OILFILTERREMOVE

1

TURBODRAING

2

POWER PRODUCTION - ENGINE

7.

Disassemble the starter (1) by loosening the fixing screws (2).

8.

Assemble the bracket bearing 380000661 using the four screw threaded ports (3).

9.

From the left hand side, assemble the second bracket 380000661 throughout the threaded ports (1).

10.

Lift the engine using the hoist 380000216 and it on the turning stand 380000301.

11.

Drain the oil through the plug in the pan.

STARTERG

3

STANDMOUNTHOLES

4

NOTICE: Avoid contact of engine oil with the skin. In case of skin contamination, rinse in running water.

NOTE: Engine oil is highly pollutant. Provide for disposal in compliance with the law and regulations in force.

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ENGINE - Place on stand F4CE9484, F4CE9684

1.

In order to apply the brackets 380000661 to the engine block to fix it on to the stand 380000301 for the overhaul, it is necessary to perform the following operations.

2.

Remove the oil level rod (4).

3.

Remove the oil filter (3) using the tool 380000670.

NOTICE: Provide for oil recovery and disposal in compliance with the law and regulations in force.

4.

Disassemble the starter (2) by loosening the fixing screws (1).

5.

Assemble the supporting brackets 380000661 using the threaded ports on the block.

6.

Assemble the second bracket 380000661 throughout the threaded ports (1).

7.

Lift the engine using the hoist 380000216 and put it on the turning stand 380000301.

8.

Drain the oil by removing the plug from the oil pan.

OILFILTERREMOVC

1

STARTERC

2

STANDMOUNTC

3

NOTICE: Avoid contact of engine oil with the skin. In the case of skin contamination, rinse in running water.

NOTE: Engine oil is highly pollutant. Provide for disposal in compliance with the law and regulations in force.

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ENGINE - Service instruction Maintenance Procedures CHECKS AND INSPECTIONS Engine oil level check The check can be made using the dipstick (1) placed on the right hand side of the EDC. NOTICE: The check must be executed when the engine is off and possibly cool.

Draw off the rod from it’s 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 contamination and put it back in it’s slot. Draw it off again and check the level.

In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components.

Add oil through the upper top or through the lateral top (2).

During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier.

OILFILLH

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

Combustion system inspection The check must be executed both when the engine off 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 specific equipment), to the filter, to the high pressure pump and 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.

WARNING Diesel fuel escaping under pressure can penetrate the skin causing serious injury. Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear protective gloves and eye protection.If any fluid is injected into the skin, obtain medical attention immeadiately or gangrene may result. Failure to comply could result in serious injury or death.

B071

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Cooling system inspection The check must be executed both when the engine is off and when it is running.

Check the pipelines from the engine to the radiator, from the 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.

DANGER Hot coolant can spray out if radiator cap is removed.

To remove radiator cap: Wear face protection, let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

SB023

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two years.

NOTE: In case of new filling, proceed bleeding the 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 engine’s head.

Lubricating system inspection The check must be executed both when the engine is off and when it is running.

Verify the presence of any oil leakage or blow-by from the head, from the engine pan or from the heat exchanger.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

Inspection of water presence within the fuel filter or pre-filter The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel.

Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.

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Inspection / replacement of blow-by filter The filter in subject has been developed and equipped for the collection , filtering and condense of the lubricating oil vapors.

Within the filter unit (1) two cartridge filters are included (2).

The check of the filtering element is carried out by removing the cover and drawing off the cartridges (2).

86070785_RESIZE

2

VALVEADJUST

3

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.

Inspection and setting of tappet clearance Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2).

Valve clearance •

Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)

•

Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)

NOTICE: On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only.

Each cylinder must be checked by taking it to the T.D.C. (top dead center) at the end of compression and adjusting the clearance of both valves on the cylinder in question.

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Engine oil and filter replacement Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.

We recommend to carry out the oil drainage when the engine is hot.

Place a proper container for the oil collecting under the pan connected with drain plug.

Unscrew the plug and then take out the control dipstick and the inserting plug to ease the downflow of the lubrication oil.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

After the complete drainage, screw the plug and carry out the clean oil filling.

NOTICE: Use only recommended oil or oil having the requested features for the correct engine functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with these rules, the service warranty is no more valid.

Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick.

Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

The filter is composed of a support and a filtering cartridge.

For the cartridge replacement use the tool 380000670.

ATTENTION: The oil filter contains inside a quantity of oil of about 1 kg.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

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Replace the filtering cartridge with a new one and screw manually until when the gasket is in contact with the support.

Tighten by means of the tool 380000670 of three fourth turn.

Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change.

However the following operations are valid for all applications.

Drain the fuel inside the filter operating the water release screw. Collect the fuel in a container without impurities.

Unscrew the cartridge by using the 380000670.

Collect the eventual fuel inside the filtering cartridge.

Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.

Screw manually the new filtering cartridge until the gasket is completely on its seat.

Tighten through the tool 380000670 at a 10 - 15 Nm (7 - 11 lb ft) torque.

Alternator belt replacement Due to several applications the belt run can change very much.

WARNING Rotating belts. Contact with rotating belts will cause serious injury or death. Always stop the engine and remove the key before working in this area.

M411

For applications with automatic belt tensioner, the procedure is the following: By means of square wrench of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure.

Remove the control belt (2) from the driven and intermediate pulleys.

Replace the worn belt with a new one.

Place the belt on the pulleys and guide rollers.

Place the automatic tightener in order to key the belt in the functioning position.

Check proper position in the races of the pulleys.

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ALTBELT

4

POWER PRODUCTION - ENGINE

ENGINE - Service instruction Maintenance Procedures F4DE9484, F4DE9684, F4DE9687

CHECKS AND INSPECTIONS Engine oil level check The check can be made using the dipstick (1) placed on the right hand side of the EDC. NOTICE: The check must be executed when the engine is off and possibly cool.

Draw off the rod from it’s 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 contamination and put it back in it’s slot. Draw it off again and check the level.

In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components.

OILFILLD

1

OILFILLD2

2

Add oil through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

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Combustion system inspection The check must be executed both when the engine is off 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 specific equipment), to the filter, to the high pressure pump and 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.

WARNING Diesel fuel escaping under pressure can penetrate the skin causing serious injury. Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear protective gloves and eye protection.If any fluid is injected into the skin, obtain medical attention immeadiately or gangrene may result. Failure to comply could result in serious injury or death.

B071

Cooling system inspection The check must be executed both when the engine is off and when it is running.

Check the pipelines from the engine to the radiator, from the 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.

DANGER Hot coolant can spray out if radiator cap is removed.

To remove radiator cap: Wear face protection, let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

SB023

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two years.

NOTE: In case of new filling, proceed bleeding the 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 engine’s head.

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Lubricating system inspection The check must be executed both when the engine is off and when it is running.

Verify the presence of any oil leakage or blow-by from the head, from the engine pan or from the heat exchanger.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

Inspection of water presence within the fuel filter or pre-filter The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel.

Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.

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.

Inspection and setting of tappet clearance Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2).

Valve clearance •

Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)

•

Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)

NOTICE: On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only.

Each cylinder must be checked by taking it to the T.D.C. (top dead center) at the end of compression and adjusting the clearance of both valves on the cylinder in question.

VALVEADJUST

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Engine oil and filter replacement Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.

We recommend to carry out the oil drainage when the engine is hot.

Place a proper container for the oil collecting under the pan connected with drain plug.

Unscrew the plug and then take out the control dipstick and the inserting plug to ease the downflow of the lubrication oil.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

After the complete drainage, screw the plug and carry out the clean oil filling.

NOTICE: Use only recommended oil or oil having the requested features for the correct engine functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with these rules, the service warranty is no more valid.

Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick.

Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

The filter is composed of a support and a filtering cartridge.

For the cartridge replacement use the tool 380000670.

ATTENTION: The oil filter contains inside a quantity of oil of about 1 kg.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

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Replace the filtering cartridge with a new one and screw manually until the gasket is in contact with the support.

Tighten by means of the tool 380000670 of three fourth turn.

Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change.

However the following operations are valid for all applications.

Drain the fuel inside the filter operating the water release screw. Collect the fuel in a container without impurities.

Unscrew the cartridge by using the 380000670.

Collect the eventual fuel inside the filtering cartridge.

Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.

Screw manually the new filtering cartridge until the when the gasket is completely on its seat.

Tighten through the tool 380000670 at a 10 - 15 Nm (7 - 11 lb ft) torque.

Alternator belt replacement Due to several applications the belt run can change very much.

WARNING Rotating belts. Contact with rotating belts will cause serious injury or death. Always stop the engine and remove the key before working in this area.

M411

For applications with automatic belt tensioner, the procedure is the following: By means of square wrench of proper of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure.

Remove the control belt (2) from the driven and intermediate pulleys.

Replace the worn belt with a new one.

Place the belt on the pulleys and guide rollers.

Place the automatic tightener in order to key the belt in the functioning position.

Check proper position in the races of the pulleys.

ALTBELT

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ENGINE - Service instruction Maintenance Procedures F4GE9484, F4GE9684

CHECKS AND INSPECTIONS Engine oil level check The check can be made using the dipstick (1) placed on the right hand side of the EDC. NOTICE: The check must be executed when the engine is off and possibly cool.

Draw off the rod from it’s 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 contamination and put it back in it’s slot. Draw it off again and check the level.

In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components.

OILLEVELG

1

OILFILLG

2

Add oil through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

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Fuel system inspection The check must be executed both when the engine is off 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 specific equipment), to the filter, to the high pressure pump and 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.

WARNING Diesel fuel escaping under pressure can penetrate the skin causing serious injury. Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear protective gloves and eye protection.If any fluid is injected into the skin, obtain medical attention immeadiately or gangrene may result. Failure to comply could result in serious injury or death.

B071

Cooling system inspection The check must be executed both when the engine is off and when it is running.

Check the pipelines from the engine to the radiator, from the 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.

DANGER Hot coolant can spray out if radiator cap is removed.

To remove radiator cap: Wear face protection, let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

SB023

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two years.

NOTE: In case of new filling, proceed bleeding the 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 engine’s head.

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Lubricating system inspection The check must be executed both when the engine is off and when it is running.

Verify the presence of any oil leakage or blow-by from the head, from the engine pan or from the heat exchanger.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

Inspection of water presence within the fuel filter or pre-filter The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel.

Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.

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.

Inspection and setting of tappet clearance Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2).

Valve clearance •

Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)

•

Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)

NOTICE: On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only.

Each cylinder must be checked by taking it to the T.D.C. (top dead center) at the end of compression and adjusting the clearance of both valves on the cylinder in question.

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Engine oil and filter replacement Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.

We recommend to carry out the oil drainage when the engine is hot.

Place a proper container for the oil collecting under the pan connected with drain plug.

Unscrew the plug and then take out the control dipstick and the inserting plug to ease the downflow of the lubrication oil.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

After the complete drainage, screw the plug and carry out the clean oil filling.

NOTICE: Use only recommended oil or oil having the requested features for the correct engine functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with these rules, the service warranty is no more valid.

Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick.

Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

The filter is composed of a support and a filtering cartridge.

For the cartridge replacement use the tool 380000670.

ATTENTION: The oil filter contains inside a quantity of oil of about 1 kg.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

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Replace the filtering cartridge with a new one and screw manually until when the gasket is in contact with the support.

Tighten by means of the tool 380000670 of three fourth turn.

Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change.

However the following operations are valid for all applications.

Drain the fuel inside the filter operating the water release screw. Collect the fuel in a container without impurities.

Unscrew the cartridge by using the 380000670.

Collect the eventual fuel inside the filtering cartridge.

Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.

Screw manually the new filtering cartridge until the gasket is completely on its seat.

Tighten through the tool 380000670 at a 10 - 15 Nm (7 - 11 lb ft) torque.

Alternator belt replacement Due to several applications the belt run can change very much.

WARNING Rotating belts. Contact with rotating belts will cause serious injury or death. Always stop the engine and remove the key before working in this area.

M411

For applications with automatic belt tensioner, the procedure is the following: By means of square wrench of proper of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure.

Remove the control belt (2) from the driven and intermediate pulleys.

Replace the worn belt with a new one.

Place the belt on the pulleys and guide rollers.

Place the automatic tightener in order to key the belt in the functioning position.

Check proper position in the races of the pulleys.

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ALTBELT

4

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ENGINE - Service instruction Maintenance Procedures F4CE9484, F4CE9684

CHECKS AND INSPECTIONS Engine oil level check The check can be made using the dipstick (1).

NOTICE: The check must be executed when the engine is off and possibly cool.

Draw off the rod from it’s 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 contamination and put it back in it’s slot. Draw it off again and check the level.

In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components.

OILLEVELC

1

OILFILLC

2

Add oil through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

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Fuel system inspection The check must be executed both when the engine is off 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 specific equipment), to the filter, to the high pressure pump and 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.

WARNING Diesel fuel escaping under pressure can penetrate the skin causing serious injury. Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear protective gloves and eye protection.If any fluid is injected into the skin, obtain medical attention immeadiately or gangrene may result. Failure to comply could result in serious injury or death.

B071

Cooling system inspection The check must be executed both when the engine is off and when it is running.

Check the pipelines from the engine to the radiator, from the 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.

DANGER Hot coolant can spray out if radiator cap is removed.

To remove radiator cap: Wear face protection, let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap. Check and service engine cooling system according to maintenance instructions.

SB023

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two years.

NOTE: In case of new filling, proceed bleeding the 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 engine’s head.

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Lubricating system inspection The check must be executed both when the engine is off and when it is running.

Verify the presence of any oil leakage or blow-by from the head, from the engine pan or from the heat exchanger.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

Inspection of water presence within the fuel filter or pre-filter The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel.

Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.

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.

Inspection and setting of tappet clearance Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2).

Valve clearance •

Intake - 0.20 - 0.30 mm (0.008 - 0.012 in).

•

Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in).

NOTICE: On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only.

Each cylinder must be checked by taking it to the T.D.C. (top dead center) at the end of compression and adjusting the clearance of both valves on the cylinder in question.

VALVEADJUSTC

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Engine oil and filter replacement Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.

We recommend to carry out the oil drainage when the engine is hot.

Place a proper container for the oil collecting under the pan connected with drain plug.

Unscrew the plug and then take out the control dipstick and the inserting plug to ease the downflow of the lubrication oil.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

After the complete drainage, screw the plug and carry out the clean oil filling.

NOTICE: Use only recommended oil or oil having the requested features for the correct engine functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with these rules, the service warranty is no more valid.

Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick.

Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

The filter is composed of a support and a filtering cartridge.

For the cartridge replacement use the tool 380000670.

ATTENTION: The oil filter contains inside a quantity of oil of about 1 kg.

CAUTION When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT run the engine or transmission when the engine or transmission oil temperatures exceed 49 C (120 F). Failure to comply will result in a environmental hazard and cause death or serious injury.

M1159

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Replace the filtering cartridge with a new one and screw manually until when the gasket is in contact with the support.

Tighten by means of the tool 380000670 of three fourth turn.

Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change.

However the following operations are valid for all applications.

Drain the fuel inside the filter operating the water release screw. Collect the fuel in a container without impurities.

Unscrew the cartridge by using the 380000670.

Collect the eventual fuel inside the filtering cartridge.

Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.

Screw manually the new filtering cartridge until the gasket is completely on its seat.

Tighten through the tool 380000670 at a 10 - 15 Nm (7 - 11 lb ft) torque.

Alternator belt replacement Due to several applications the belt run can change very much.

WARNING Rotating belts. Contact with rotating belts will cause serious injury or death. Always stop the engine and remove the key before working in this area.

M411

For applications with automatic belt tensioner, the procedure is the following: By means of square wrench of proper of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure.

Remove the control belt (2) from the driven and intermediate pulleys.

Replace the worn belt with a new one.

Place the belt on the pulleys and guide rollers.

Place the automatic tightener in order to key the belt in the functioning position.

Check proper position in the races of the pulleys.

ALTBELT

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Rocker assembly Housing - Remove Prior operation: Valve cover - Remove (B.10.A) 1.

Unscrew the nuts (3) from the top of the electro-injectors (4) and disconnect the electrical wires.

2.

Unscrew the bolts (1) securing the rocker housing (2).

3.

Remove the rocker housing (2) and gasket from the cylinder head.

ROCKERHOUSING

Next operation: Rocker assembly Housing - Install (B.10.A)

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Rocker assembly Housing - Install Prior operation: Valve drive Rocker assembly - Install (B.10.A) 1.

Check the condition of the electrical cables (5) and connectors (3), replace if damaged by removing the screw (4).

2.

Install a new gasket (1) on the support (2).

3.

VALVEBASEDH

1

VALVEBASEDH2

2

VALVEBASEDH3

3

Install the housing (2) and tighten the screws (1) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

4.

Connect the electrical cables (1) to the injectors (3) and use the torque wrench (4) to tighten the fastening nuts (2) to the specified torque.

Next operation: Valve cover - Install (B.10.A)

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Valve drive Rocker assembly - Disassemble F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Valve cover - Remove (B.10.A) 1.

Loosen tappet adjustment jam nuts (1) and unscrew the adjusting screws.

2.

Remove the rocker shaft mounting bolts (2).

3.

Remove the rocker assembly (3), which consists of the pedestal (6), rockers (4), and shaft (5).

4.

Remove the valve bridges (7).

5.

Remove the push rods (8).

BACD04APH020ASA

Next operation: Rocker assembly Shaft - Clearance (B.10.A)

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Rocker assembly Shaft - Clearance Prior operation: Valve drive Rocker assembly - Disassemble (B.10.A) 1.

Check that the shaft/rocker coupling surfaces are not showing excessive wear or damage.

SHAFTMEASURE

Next operation: Valve drive Rocker assembly - Install (B.10.A)

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Valve drive Rocker assembly - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Valve drive Camshaft - Install (B.10.A) 1.

Check that the tappet adjusters (1) are loose to prevent their binding on the rods when fitting the rocker assembly

2.

Install the rocker assembly consisting of:

3.

•

Bracket (2).

•

rockers (4).

•

shafts (3).

Secure them to the cylinder head by tightening the fastening screws (2) to a torque of 36 Nm (27 lb ft).

ROCKERASSEMDH

Next operation: Valve drive Rocker assembly - Adjust (B.10.A)

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Rocker assembly Rocker arm - Adjust Prior operation: Valve drive Rocker assembly - Install (B.10.A) 1.

Adjust the clearance between the rockers and valves using a set screw wrench (1), box wrench (3), and feeler gauge (2).

2.

Set the clearance to the following specifications.

•

Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012 in)

•

Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022 in)

NOTICE: On TIER 3 engines, due to the additional lobe on the camshaft for INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft two times only.

Each cylinder must be checked by taking it to TDC (top dead center) at the end of the compression stroke and adjusting the clearance of both valve on the cylinder in question.

Next operation: Valve cover - Install (B.10.A)

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BACD04APH162ASA

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Camshaft Gear - Remove Prior operation: Rear cover - Remove (B.10.A) 1.

Remove the screws (1) securing the camshaft gear (3) to the camshaft (2).

2.

Withdrawal the camshaft gear (3).

CAMGEARH

Next operation: Camshaft Gear - Install (B.10.A)

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Camshaft Gear - Remove F4DE9484, F4DE9684, F4DE9687

Prior operation: Rear cover - Remove (B.10.A) 1.

Undo the screws (1) and remove the gear (3) from the camshaft (2).

CAMGEARD

Next operation: Camshaft Gear - Install (B.10.A)

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Camshaft Gear - Install Prior operation: Camshaft Gear - Remove (B.10.A) NOTE: For ease of crankshaft rotation, install two pins in the end of the crankshaft.

1.

2.

3.

Highlight the timing mark on the crankshaft gear (1) with a felt tip pen so it’s easier to see.

BACD04APH064ASA

1

BACD04APH065ASA

2

BACD04APH066ASA

3

Turn the crankshaft (4) and the camshaft (2) so that by mounting the drive gear (1) on the camshaft (2), both timing marks (3) will align properly.

Tighten the bolts (1) that secure the gear (2) to camshaft (3) to the specified torque.

Next operation: Rear cover - Cleaning (B.10.A)

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Valve drive Camshaft - Remove Prior operation: Camshaft Gear - Remove (B.10.A) 1.

Remove the bolts (1)and disconnect camshaft (3)retaining plate (2).

NOTE: Take note of the retaining plate (2) assembly position.

2.

BACD04APH047ASA

1

BACD04APH048ASA

2

Carefully extract the camshaft (1) from the cylinder block.

Next operation: Valve drive Camshaft - Measure (B.10.A)

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Valve drive Camshaft - Measure Prior operation: Valve drive Camshaft - Remove (B.10.A)

Checking cam lift and pin alignment Set the camshaft on the tailstock using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm (0.002 in), otherwise replace the camshaft. Check cam lift; found values shall be: 6.045 mm (0.238 in) for exhaust cams and 7.582 mm (0.299 in) for intake cams, in case of different values replace the camshaft.

Check the camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.

BACD04APH117ASA

CAMSHAFT MAIN DATA (4 cyl.)

BACD04APH116FSA

2

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CAMSHAFT MAIN DATA (6 cyl.)

BAIL07APH360FSA

3

NOTE: Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft and the bush.

Next operation: Valve drive Camshaft - Install (B.10.A)

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Valve drive Camshaft - Install Prior operation: Valve drive Camshaft - Measure (B.10.A) 1.

2.

Lubricate the camshaft bush and fit the camshaft (1) taking care not to damage the bush or the housings.

CRIL04J056A01

1

CRIL04J064A01

2

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.

Next operation: Valve drive Camshaft - End play (B.10.A)

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Valve drive Camshaft - End play Prior operation: Valve drive Camshaft - Install (B.10.A) 1.

Check camshaft end play (1). It shall be 0.10 - 0.36 mm (0.004 - 0.014 in).

CRIL04J065A01

Next operation: Rear cover - Install (B.10.A)

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Camshaft Push rod - Install Prior operation: Valve drive Camshaft - Install (B.10.A) 1.

Before installation be sure to check that there is no signs of wear or distortion. Intake and exhaust rods are identical and therefore interchangeable.

2.

Install the push rods (2).

3.

Install the valve bridges (1) with the marks facing the exhaust manifold

Next operation: Valve drive Rocker assembly - Install (B.10.A)

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PUSHROD

1

BACD04APH093ASA

2

POWER PRODUCTION - ENGINE

Camshaft Tappet - Remove Prior operation: Valve drive Camshaft - Remove (B.10.A) 1.

Withdraw the tappets (1) from the engine block.

BACD04APH049ASA

Next operation: Camshaft Tappet - Measure (B.10.A)

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Camshaft Tappet - Measure Prior operation: Camshaft Tappet - Remove (B.10.A)

BAIL07APH361FSA

1

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK Next operation: Valve drive Camshaft - Install (B.10.A)

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Camshaft Tappet - Measure F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Camshaft Tappet - Remove (B.10.A)

TAPPETMEASURECG

1

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK (dimensions in mm) Next operation: Valve drive Camshaft - Install (B.10.A)

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Camshaft Tappet - Install Prior operation: Camshaft Tappet - Measure (B.10.A) Lubricate the tappets (1) and fit them into the relevant housings on the engine block.

CRIL04J063A01

Next operation: Valve drive Camshaft - Install (B.10.A)

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Camshaft Bushing - Measure Prior operation: Valve drive Camshaft - Remove (B.10.A)

Bushes 1.

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. Measurements shall be performed on two perpendicular axes.

CRIL04J060A01

BAIL07APH367FMA

2

MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING *Height to be obtained after driving the bush.

Next operation: Valve drive Camshaft - Replace (B.10.A)

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Camshaft Bushing - Replace Prior operation: Valve drive Camshaft - Measure (B.10.A)

Bush Replacement To replace bush (1), remove and refit it using the beater (2) and the hand-grip 380000145 (3).

NOTICE: When refitting the bush (1), direct it to make the lubricating holes coincide with the holes on the block housing.

ZEIL06EN0048A0B

Next operation: Valve drive Camshaft - Install (B.10.A)

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Valve drive Valve assembly - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Cylinder head - Remove (B.10.A) 1.

Intake (1) and exhaust (2) valves heads with the same diameter. The central notch of the exhaust valve (2) head distinguishes it from the intake valve.

NOTE: Should cylinder head valves not be replaced, number them before removing in order to refit them in the same position.

A = intake side - S = exhaust side

2.

Valve removal shall be performed using tool 380000302 (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).

3.

Repeat this operation for all the valves.

4.

Overturn the cylinder head and withdraw the valves (5).

5.

BACD04APH145ASA

1

BACD04APH146ASA

2

BACD04APH147ASA

3

Remove the sealing rings (1) and (2) from the valve guide.

NOTE: Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

Next operation: Valve drive Valve assembly - Install (B.10.A)

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Valve assembly Valve - Measure Prior operation: Valve drive Valve assembly - Cleaning (B.10.A)

VALVE

1

INTAKE AND EXHAUST VALVE MAIN DATA 1.

Check the valve stem (1) using a micrometer (2), it shall be 6.970 - 6.990 mm (0.274 - 0.275 in).

BAPH04APH152ASA

Next operation: Valve drive Valve assembly - Install (B.10.A)

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Valve assembly Valve - Cleaning Prior operation: Valve drive Valve assembly - Remove (B.10.A) 1.

Remove carbon deposits from valves using the proper metal brush.

2.

Check that the valves show no signs of seizing, scoring, or cracking.

3.

If necessary, rectify the valve seats, taking away the least amount of material possible.

BAPH04APH151ASA

Next operation: Valve assembly Valve - Measure (B.10.A)

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Valve assembly Spring - Check Prior operation: Valve drive Valve assembly - Remove (B.10.A) Before installing the valve springs use tool to check the springs flexibility. Compare load and elastic deformation data with those of the new springs in the following table:

50676

Height (H) (H1) (H2)

Under a load of 47.75 mm (1.880 in) 35.33 mm (1.391 in) 25.2 mm (0.992 in)

(P) (P1)

Next operation: Valve drive Valve assembly - Install (B.10.A)

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Free 320.8 - 358.8 N (72.1 - 80.7 lb) 702 - 780 mm (27.6 - 30.7 in)

1

POWER PRODUCTION - ENGINE

Valve drive Valve assembly - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Valve drive Valve assembly - Cleaning (B.10.A) 1.

Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal.

2.

Fit the sealing rings (2) and (3) on the valve guide.

NOTE: Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green.

3.

80713

1

BACD04APH146ASA

2

Position on the cylinder head: the springs (4) the upper cap (3) use tool 380000302 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2).

Next operation: Cylinder head - Install (B.10.A)

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Valve drive Rocker assembly - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve cover - Remove (B.10.A) 1.

Disassemble the rocker arm supports by loosening the two fixing screws (1) and remove the entire assembly as one unit.

2.

Withdraw the push rods.

ROCKERASSEMBCG

Next operation: Valve drive Rocker assembly - Install (B.10.A)

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Camshaft Gear - Remove F4CE9484, F4CE9684

Prior operation: Rear cover - Remove (B.10.A) 1.

Remove the screws (1) and disassemble the gears (3) and (4) from the camshaft (2).

CAMSHAFTGEARC

Next operation: Camshaft Gear - Install (B.10.A)

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Camshaft Gear - Install F4GE9484, F4GE9684

Prior operation: Camshaft Gear - Remove (B.10.A) 1.

With a felt tip pen, highlight the conducting gear (1) tooth mounted on the engine crankshaft (2) upon the upright surface on which a groove has been created for the injection timing.

NOTE: Screw in two pins to facilitate operation of the engine crankshaft rotation.

2.

CAMGEARTIMING

1

CAMGEARTIMING2

2

Turn the engine crankshaft (3) and the camshaft (4) so that by mounting the bevel gear (1) on the camshaft (4) so the stenciled mark on the gear (1) coincides with the groove on the gear (2).

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3.

Position a dial indicator (1) on the timing gear (2).

4.

Check the clearance between gears (2) and (3) is within 0.076 - 0.280 mm (0.003 - 0.011 in) range.

CAMGEARTIMING3

Next operation: Rear cover - Install (B.10.A)

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Camshaft Gear - Install F4CE9484, F4CE9684

Prior operation: Camshaft Gear - Remove (B.10.A) NOTE: For ease of crankshaft rotation, install two pins in the end of the crankshaft.

1.

2.

3.

Highlight the timing mark on the crankshaft gear (1) with a felt tip pen so it’s easier to see.

BACD04APH064ASA

1

CAMGEARTIMINGC

2

CAMGEARTIMINGC2

3

Turn the crankshaft (4) and the camshaft (2) so that by mounting the drive gear (1) on the camshaft (2), both timing marks (3) will align properly.

Place the dial gauge (1) on the timing gear (2) and check that the slack between the gears (2) and (3) is in the range of 0.076 - 0.280 mm (0.003 - 0.011 in).

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4.

Fit the screws (1) fastening the gears (2) to the camshaft (3) and tighten them to the prescribed torque.

CAMGEARTIMINGC3

Next operation: Rear cover - Install (B.10.A)

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Valve drive Rocker assembly - Check F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Rocker assembly - Remove (B.10.A)

ROCKERCOMPCG

1

(1) Elastic ring - (2) Spacer - (3) Rocker arms - (4) Support.

1.

Carry out the assembly of the rocker arms after checking the components.

2.

Check the coupling surfaces of bearings and shaft.

No evidence of excessive wear or damages shall be detected. Replace if necessary.

ROCKERCOMPCG2

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3.

Tighten the threaded nut (1) to 4 - 6 Nm (3.0 - 4.4 lb ft).

ROCKERCOMPCG3

Next operation: Valve drive Rocker assembly - Install (B.10.A)

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Camshaft Push rod - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Camshaft - Install (B.10.A) 1.

Before executing assembly, check the rocker arm driving rods. They shall not be deformed. The spherical ends in contact with the rocker arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear. In case of detection, replace the rods with new.

The rods driving the suction and exhaust valves are identical and therefore interchangeable.

PUSHROD

Next operation: Valve drive Rocker assembly - Install (B.10.A)

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Valve drive Rocker assembly - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Rocker assembly - Check (B.10.A) 1.

Install the assembly (1) on the cylinder head and tighten the screws (2) to the prescribed torque.

ROCKERASSEMCG2

Next operation: Rocker assembly Rocker arm - Adjust (B.10.A)

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Rocker assembly Rocker arm - Adjust F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Rocker assembly - Install (B.10.A) 1.

Adjust the clearance between the rockers and valves using a set screw wrench (1), box wrench (3), and feeler gauge (2).

2.

Set the valve clearance to the following specifications.

•

Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012 in)

•

Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022 in)

NOTICE: On TIER 3 engines, due to the additional lobe on the camshaft for INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft two times only.

Each cylinder must be checked by taking it to TDC (top dead center) at the end of the compression stroke and adjusting the clearance of both valve on the cylinder in question.

Next operation: Valve cover - Install (B.10.A)

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ROCKERADJUSTCG

1

POWER PRODUCTION - ENGINE

Valve drive Valve assembly - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Cylinder head - Remove (B.10.A) 1.

Intake (1) and exhaust (2) valves heads with the same diameter.

NOTE: Should cylinder head valves not be replaced, number them before removing in order to refit them in the same position.

A = intake side

2.

Valve removal shall be performed using tool 380000302 (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).

3.

Repeat this operation for all the valves.

4.

Overturn the cylinder head and withdraw the valves (5).

5.

VALVESCG

1

VALVESCG2

2

VALVESEALCG

3

Remove the sealing rings (1) and (2) from the valve guide.

Next operation: Valve drive Valve assembly - Cleaning (B.10.A)

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Valve assembly Valve - Measure F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Valve assembly - Cleaning (B.10.A)

VALVE

1

INTAKE AND EXHAUST VALVE MAIN DATA 1.

Check the valve stem (1) using a micrometer (2), it shall be 7.960 - 7.980 mm (0.313 - 0.314 in).

VALVESCG4

Next operation: Valve drive Valve assembly - Cleaning (B.10.A)

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Valve assembly Spring - Check F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Valve assembly - Remove (B.10.A) Before refitting use tool to check spring flexibility. Compare load and elastic deformation data with those of the new springs in the following table:

50676

Height H H1 H2

Under a load of 63.50 mm (2.500 in) 49.02 mm (1.930 in) 38.20 mm (1.504 in)

P P1

Free 320.8 - 358.8 N (72.1 - 80.7 lb) 702 - 780 mm (27.6 - 30.7 in)

Next operation: Valve drive Valve assembly - Install (B.10.A)

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Valve drive Valve assembly - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Valve assembly - Remove (B.10.A) 1.

Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal.

2.

Fit the sealing rings (2) and (3) on the valve guide.

3.

Position on the cylinder head, the protection cap (5), the spring (4), the upper cap (3).

4.

Use tool 380000302 (1) to compress the spring (4) and lock the parts to the valve (6) by the cotters (2).

Next operation: Cylinder head - Install (B.10.A)

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VALVESEALCG2

1

VALVESCG2

2

POWER PRODUCTION - ENGINE

Auxiliary drive - Remove F4HE9484, F4HE9684

1.

Unscrew the cover bolts (3) and remove the cover (1). Save the cover gasket (4).

2.

Remove the power take-off adapter (2). Save the gasket (4).

AUXDRIVEH

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Auxiliary drive - Install F4HE9484, F4HE9684

1.

Insert the power take-off adapter (2) with gaskets (4) and cover (1).

2.

Tighten the bolts (3) to the specified torque.

AUXDRIVEH

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Auxiliary drive - Install F4CE9484, F4CE9684

1.

Fit the power take-off gear (2) (where equipped) into the specially provided housing and fasten the screws (1).

AUXDRIVEC

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Auxiliary drive - Remove F4GE9484, F4GE9684

1.

Loosen the two screws (3) securing the cover plate (1).

2.

Remove the cover (1), power take-off (2) and the relative gaskets (4).

NOTE: The gasket cannot be used again. They must be replaced upon reassembly.

AUXDRIVEG

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Auxiliary drive - Install F4GE9484, F4GE9684

1.

Fit the power take-off (2) in its housing with a new gasket (4). Make sure the gears mesh properly.

2.

Install the cover plate (1) also with a new gasket (4).

Tighten the screws (3) to the prescribed torque.

AUXDRIVEG

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Auxiliary drive - Remove F4CE9484, F4CE9684

1.

Loosen the two screws (1) and remove the cover (2).

AUXDRIVEC2

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Crankshaft Front seal - Remove Prior operation: Vibration damper - Remove (B.10.A) 1.

2.

Remove the ring sealing the engine’s driving shaft from the front cover (6). Use the tool (4) to operate on the front bar hold of the driving shaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).

Fix the tool to the ring tightening the six screws (5) provided with the equipment. Then proceed removing the ring (2) by tightening the screw (3).

MAINSEALDH

1

EXHOLDRINGDH

2

Using the specific tie rod (3) of the tool 380000669 and the ancillary lever (4), remove the external holding ring (2) from the front cover (1).

Next operation: Crankshaft Front seal - Install (B.10.A)

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Crankshaft Front seal - Install Prior operation: Crankshaft Front seal - Remove (B.10.A) 1.

Apply tool (4) to the front crankshaft tang (6) and secure it by screws (5) and install the new sealing ring (7). Position part (2) on part (4), tighten nut (3) until completing installation of the sealing ring (7) into the front cover (1).

BACD04APH074ASA

Next operation: Vibration damper - Install (B.10.A)

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Crankshaft Rear seal - Remove Prior operation: Flywheel - Remove (B.10.A) 1.

Remove the holding ring of the flywheel cover box using the tool (3) to operate on the driving shaft’s back bar hold (5).

2.

Through the steering holes of the tool, perforate the inside holding ring with a straight way drill bit with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).

3.

Fix the tool (3) to the ring tighten the six screws (4) provided with the equipment.

4.

Then proceed removing the ring (1) by tightening the screw (2).

5.

REARMAINSEALDH

1

EXHOLDRINGDH

2

Using a specific tie rod (3) of the tool 380000669 and an ancillary lever (4), remove the external holding ring (2)from the rear cover (1).

Next operation: Flywheel - Remove (B.10.A)

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Crankshaft Rear seal - Install Prior operation: Crankshaft Rear seal - Remove (B.10.A) 1.

Apply tool (6), to the rear crankshaft tang (5), secure it by screws (4) and install the new sealing ring (3).

Position part (1) on part (5), tighten nut (2) until completing installation of the sealing ring (3) into the flywheel housing (7).

BACD04APH219ASA

Next operation: Flywheel - Install (B.10.A)

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Crankshaft Main bearing - Remove Prior operation: Oil pan - Remove (B.60.A) 1.

2.

Remove the screws (1) and the main bearing caps (2).

BACD04APH043ASA

1

BACD04APH044ASA

2

The second to last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).

NOTE: Take note of the lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.

Next operation: Crankshaft Main bearing - Install (B.10.A)

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Crankshaft Main bearing - Install Prior operation: Crankshaft Main bearing - Remove (B.10.A) 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 (0.010 - 0.020 in) undersize on the internal diameter.

Clean accurately the main half bearings (1) having the lubricating and fit them into their housings.

The second last main half bearing (1) is fitted with shoulder half rings.

BACD04APH056ASA

NOTICE: Do not try to adapt the bearings.

Next operation: Oil pan - Install (B.60.A)

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Crankshaft - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Crankshaft Main bearing - Remove (B.10.A) 1.

Use tool 380000362 (1)and hoist to remove the crankshaft (2) from the block.

BACD04APH045ASA

Next operation: Crankshaft Main bearing - Install (B.10.A)

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Crankshaft - Remove F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Crankshaft Main bearing - Remove (B.10.A) 1.

Use tool 380000362 (1)and hoist to remove the crankshaft (2) from the block.

CRANKSHAFTD

Next operation: Crankshaft Main bearing - Install (B.10.A)

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Crankshaft - Measure Prior operation: Crankshaft - Remove (B.10.A) Grind journals and crank pins if seizing, scoring or excessive ovalization 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.

NOTE: It is recommended to insert the found values in the table below.

NOTICE: Journals and crank pins shall always be ground to the same undersize class.

Journals and crank pins undersize shall be marked on the side of the crank arm No.1.

For undersized crank pins: letter M For undersized journals: letter B For undersized crank pins and journals: letters MB.

BACD04APH108ASA

MEASURING JOURNALS AND CRANK PINS (4 cyl.)

BACD04APH109FSA

2

Fill this table with crankshaft journal and crank pin measured values (4 cyl.) * Rated value

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Tolerances Shape

Direction Position Oscillation

Tolerance Characteristic

Graphic Symbol

Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation

Levels of Importance for Product Characteristics

Graphic Symbol

Critical Important Secondary

MEASURING JOURNALS AND CRANK PINS (6 cyl.)

BACD04APH186FSA

3

Fill this table with crankshaft journal and crank pin measured values * Rated value

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ZEIL06EN0183F0B

4

MAIN CRANKSHAFT TOLERANCES * Measured on a radius greater than 45.5 mm (1.791 in) ** 0.500 mm (0.020 in) between adjacent main journals

Tolerances Shape

Direction Position Oscillation

Tolerance Characteristic

Graphic Symbol

Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation

Levels of Importance for Product Characteristics Critical Important Secondary Next operation: Crankshaft Journal - Clearance (B.10.A)

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Graphic Symbol

POWER PRODUCTION - ENGINE

Crankshaft Gear - Replace Check that gear toothing (1) is not damaged or worn, otherwise remove it from the crankshaft (2) using the proper puller (3).

When installing the new gear, heat it to 180 °C (356 °F) for 10 minutes in an oven and then key it to the crankshaft.

CRIL04J068A01

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Crankshaft Journal - Clearance Prior operation: Crankshaft - Measure (B.10.A)

Finding journal clearance Refit the crankshaft (2).

Check the backlash between crankshaft main journals and the relevant bearings as follows:

BACD04APH057ASA

1

BACD04APH112ASA

2

80621

3

Clean accurately the parts and remove any trace of oil; Position a piece of calibrated wire (3) on the crankshaft pins (4) so that it is parallel to the longitudinal axis; Fit caps (1), including the half bearings (2) on the relevant supports.

NOTE: Before using the fixing screws again, measure them twice as indicated in the picture, checking (D1) and (D2) diameters: if (D1)- (D2) < 0.1 mm (0.004 in) the screw can be utilized again; if (D1)- (D2) > 0.1 mm (0.004 in) the screw must be replaced.

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Tighten the pre-lubricated screws (1) in the following three successive stages: STAGE 1: with torque wrench to 44 - 56 Nm (32.5 - 41.3 lb ft).

STAGE 2: with torque wrench to 74 - 86 Nm (54.6 - 63.4 lb ft).

BACD04APH058ASA

4

BACD04APH113ASA

5

BACD04APH114ASA

6

BACD04APH115ASA

7

STAGE 3: with tool 380001001 (1) set as shown, tighten the screws (2) with 85 - 95 ° angle.

Remove the caps from the supports.

The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire.

The numbers on the scale indicate the backlash in mm.

Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described.

Checking crankshaft shoulder clearance This check is performed by setting a magnetic base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 - 0.41 mm (0.003 - 0.016 in).

If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft pins and main half bearings.

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Crankshaft Rear seal - Install F4CE9484, F4CE9684

Prior operation: Crankshaft Rear seal - Remove (B.10.A) 1.

Apply tool 380000664 (6), to the rear crankshaft tang (5), secure it by screws (4) and install the new sealing ring (3). Position part (1) on part (5), tighten nut (2) until completing installation of the sealing ring (3) into the flywheel housing (7).

REARSEALC

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Timing gear housing - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

1.

Remove the screws (2) and disconnect the timing gear case (1) from the engine block.

NOTE: Mark locations of mounting screws (2) since they are different sizes. This will make assembly much easier.

TIMINGGEARHOUSI

Next operation: Timing gear housing - Cleaning (B.10.A)

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1

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Timing gear housing - Cleaning F4HE9484, F4HE9684

Prior operation: Timing gear housing - Remove (B.10.A) 1.

Clean the timing gear housing (1) and it’s mating surface on the engine block.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (2), a few millimeters thick, to the sealing surface of the housing.

NOTE: After applying the sealant, the housing should be assembled within 10 to 20 minutes.

GEARCASESEAL

Next operation: Timing gear housing - Install (B.10.A)

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Timing gear housing - Install F4HE9484, F4HE9684

Prior operation: Timing gear housing - Cleaning (B.10.A) NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.

1.

Install the housing (1) on the engine block.

2.

Insert the fastening bolts in the same position found upon disassembly and tighten them to the prescribed torque.

GEARCASEINSTALL

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Timing gear housing - Remove F4DE9484, F4DE9684, F4DE9687

1.

Disconnect the high pressure pump stroke sensor (3).

2.

Remove the screws (2) and remove the timing gear housing (1) from the engine block.

GEARHOUSING

Next operation: Timing gear housing - Cleaning (B.10.A)

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Timing gear housing - Cleaning F4GE9484, F4GE9684

Prior operation: Timing gear housing - Remove (B.10.A) 1.

Clean the timing gear housing (1) and it’s mating surface on the engine block.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (2), a few millimeters thick, to the sealing surface of the housing.

NOTE: After applying the sealant, the housing should be assembled within 10 to 20 minutes.

TIMINGGEARCASEG

Next operation: Timing gear housing - Install (B.10.A)

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Timing gear housing - Install F4GE9484, F4GE9684

Prior operation: Timing gear housing - Cleaning (B.10.A) NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.

1.

Install the housing (1) on the engine block.

2.

Insert the fastening bolts in the same position found upon disassembly and tighten them to the torque.

TIMINGGEARCASE2

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Connecting rod and piston - Remove Prior operation: Oil pan - Remove (B.60.A) 1.

Loosen the fixing screws (1) and remove the rod caps (2).

2.

Withdraw the piston including the connecting rod from the top of the engine block.

3.

Repeat these steps for the remaining cylinders.

NOTE: Keep the half bearings into their housing since in case of use they shall be fitted in the same position found at removal.

BACD04APH042ASA

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod and piston Piston - Measure Prior operation: Connecting rod and piston Piston - Remove (B.10.A) 1.

2.

Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.

BAPH04APH123ASA

1

BACD04APH124ASA

2

The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Connecting rod and piston Connecting rod - Measure

BACD04APH131BSA

1

MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN, AND HALF BEARINGS * Value for the inside diameter to be obtained after driving in connecting rod small end and grinding.

NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recommended not to smooth the knurls.

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CRIL04D023F

2

NOTE: Every connecting rod is marked as follows: (1) - On the body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement, it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.

(2) - On the body with a letter showing the weight of the connecting rod assembled at production: - V - 1820 - 1860 g (64.2 - 65.6 oz) (yellow marking) - W - 1861 - 1900 g (65.6 - 67.0 oz) (green marking) - X - 1901 - 1940 g (67.1 - 68.4 oz) (blue marking) Spare connecting rods are of the - W - class with a green marking. Material removal is not allowed.

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Connecting rod Bushing - Service instruction Prior operation: Piston Pin - Remove (B.10.A) 1.

Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loose.

Otherwise replace.

2.

Removal and refitting shall be performed using the proper beater.

3.

When refitting take care to make the oil holes in the bush coincide with the holes in the connecting rod small end.

4.

Grind the bush to obtain the specified diameter.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Piston Ring - Remove Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Remove the split rings (1) from the piston (3) using pliers 380000324 (2).

ZEIL06EN0060A0B

Next operation: Piston Ring - Measure (B.10.A)

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Piston Ring - Measure Prior operation: Connecting rod and piston Piston - Remove (B.10.A) 1.

2.

3.

4.

Use a micrometer (1) to check split ring (2) thickness.

BAPH04APH127ASA

1

BAPH04APH128ASA

2

BAPH04APH129ASA

3

BACD04APH130ASA

4

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).

Since the first sealing ring is trapezoidal, the clearance 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.

Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).

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Next operation: Connecting rod and piston Piston - Install (B.10.A)

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Piston Ring - Install Prior operation: Connecting rod and piston Piston - Remove (B.10.A) 1.

Use pliers 380000221 (3) to fit the split rings (1) on the piston (2).

NOTICE: Split rings shall be fitted with the marking "TOP" (4) facing upwards and their openings shall be displaced with each other by 120 °.

NOTE: Split Rings are supplied spare with the following sizes: - standard - 0.4 mm (0.016 in) oversize.

MID0330A

Next operation: Connecting rod and piston Piston - Install (B.10.A)

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Piston Pin - Remove Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Remove the piston pin (1) by extracting the stop rings (2) using a scriber (3).

BACD04APH121ASA

Next operation: Piston Pin - Measure (B.10.A)

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Piston Pin - Measure Prior operation: Piston Pin - Remove (B.10.A) 1.

2.

To measure the piston pin (1) diameter, use a micrometer (2).

BAPH04APH125ASA

1

BAPH04APH126ASA

2

Lubricate the pin (1) and its seat on the 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.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Connecting rod and piston - Assemble Prior operation: Piston Pin - Remove (B.10.A) 1.

2.

3.

The piston crown is marked as follows: 1.

Part number and design modification number.

2.

Arrow showing piston assembling direction into cylinder.

3.

Manufacturing date.

4.

Stamp indicating the ring carrier US inspection.

BACD04APH136ASA

1

BACD04APH137ASA

2

BACD04APH138ASA

3

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (4) are read as shown in the figure.

Position the piston (3) on the connecting rod according to the diagram shown in the figure and fit the pin (1) and stop at the stop rings (2).

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod Bearing - Install Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Fit the half-bearings (1) on the connecting rod and cap.

NOTE: Refit the bearings that have not been replaced in the same position found at removal. Do not relocate the half-bearings.

BAPH04APH059ASA

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod and piston - Install Prior operation: Connecting rod and piston Connecting rod - Install (B.10.A) 1.

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside.

2.

Use band 380000325 (1) to fit the connecting rod - piston assembly (2) into the cylinder barrels and checking the following:

MID0332A

1

BACD04APH061ASA

2

The number of each connecting rod shall correspond to the cap coupling number.

Split ring openings shall be displaced with each other by 120 °.

Connecting rod - piston assemblies shall have the same weight.

The arrow (1) marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.

Next operation: Connecting rod and piston Connecting rod - Install (B.10.A)

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Connecting rod Bearing - Clearance Prior operation: Connecting rod and piston - Install (B.10.A) 1.

Clean the parts accurately and remove any trace of oil.

2.

Set a piece of calibrated wire (2) on the crank pins (1).

3.

Fit the connecting rod caps (3) with the relevant half bearings (4).

NOTE: Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the center of the thread length is not < 0.1 mm (0.004 in) than the diameter measured at approximately 10 mm (0.394 in) from the screw end.

4.

5.

BAPH04APH139ASA

1

BACD04APH140ASA

2

0B00200405BACD0

3

BACD04APH141ASA

4

Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench (2).

Apply tool 380001001 (1) to the socket wrench and tighten screws (2) to 60 °.

6.

Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).

7.

If a different clearance value is found, replace the half bearings and repeat the check.

8.

Once the specified clearance has been obtained, lubricate the half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.

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9.

Check manually that the connecting rods (1) are sliding axially on the crank pins and that their end float, measured with a feeler gauge (2) is 0.10 - 0.33 mm (0.004 - 0.013 in).

BACD04APH142ASA

Next operation: Connecting rod and piston Piston - Check (B.10.A)

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Connecting rod and piston Piston - Check Prior operation: Connecting rod and piston Connecting rod - Clearance (B.10.A) 1.

Once connecting rod - piston assemblies installation is completed, use dial gauge 380000228 (1) fitted with base 380000364 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block.

Protrusion shall be 0.28 - 0.52 mm (0.011 - 0.020 in).

BACD04APH143ASA

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Flywheel - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

1.

Insert tool 380000988 (2) into flywheel housing (1) to keep the flywheel (3) from rotating.

2.

Loosen two bolts opposite each other and place two guide pins (2)in place of the bolts.

3.

Remove the remaining bolts securing the flywheel (1) to the crankshaft.

4.

Remove the flywheel locking tool from the flywheel housing.

5.

Insert two bolts of medium length into the threaded holes (4) at the top of the flywheel to sling the flywheel with a hoist.

6.

Remove the flywheel (1) from it’s housing.

Next operation: Flywheel - Check (B.10.A)

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FLYWHEELH

1

FLYWHEEL2H

2

POWER PRODUCTION - ENGINE

Flywheel - Check F4CE9484, F4HE9484, F4CE9684, F4HE9684

Prior operation: Flywheel - Remove (B.10.A) 1.

Check the supporting surface of the clutch plate (1) and if it is scratched, it is necessary to carry out turning.

2.

Check ring gear teeth (2), if breakage or excessive wear is found, remove the ring gear from the engine flywheel using a suitable hammer.

3.

Heat the ring gear to 150 °C (302 °F)for 15 to 20 minutes.

4.

Install the ring gear with the chamfering on the inside diameter facing the flywheel.

FLYWHEELH3

Next operation: Flywheel - Install (B.10.A)

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Flywheel - Install F4HE9484, F4HE9684

Prior operation: Flywheel - Check (B.10.A) 1.

Install two guide pins (2) having suitable length into crankshaft (3) holes.

2.

Using the proper sling and hoist, install the flywheel (1).

3.

Apply tool 380000988 (2) to the flywheel housing to stop rotation of the flywheel (3).

4.

Tighten the bolts (1) securing the flywheel (3) to the crankshaft (4).

5.

FLYWHEELH4

1

FLYWHEELH5

2

FLYWHEELH6

3

Tighten the flywheel bolts (1) in two stages: 1.

Torque bolts to 26 - 34 Nm (19 - 25 lb ft).

2.

Finish by turning the bolts an additional 55 - 65 °.

NOTE: Torquing to an angle is performed by using the tool 380000304.

Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

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Flywheel - Remove F4DE9484, F4DE9684, F4DE9687

1.

Remove two opposite screws (1) from the area where the guide pins will be introduced.

2.

Loosen the remaining flywheel fixing screws (3) from the driving shaft (2).

3.

Remove the flywheel locking tool (4).

4.

Tighten two screws of medium length into the holes (4) to sling the flywheel with hoist.

5.

Throughout the two guide pins (2) previously screw into the driving shaft holes (3) withdraw the engine flywheel (1) after slinging it with the hoist.

Next operation: Flywheel - Check (B.10.A)

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FLYWHEELD

1

FLYWHEELD2

2

POWER PRODUCTION - ENGINE

Flywheel - Check F4GE9484, F4DE9484, F4GE9684, F4DE9684, F4DE9687

Prior operation: Flywheel - Remove (B.10.A) 1.

Check the supporting surface of the clutch plate (1) and if it is scratched, it is necessary to carry out turning.

2.

Check ring gear teeth (2), if breakage or excessive wear is found, remove the ring gear from the engine flywheel using a suitable hammer.

3.

Heat the ring gear to 150 °C (302 °F)for 15 to 20 minutes.

4.

Install the ring gear with the chamfering on the inside diameter facing the flywheel.

FLYWHEELD3

Next operation: Flywheel - Install (B.10.A)

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Flywheel - Install F4DE9484, F4DE9684, F4DE9687

Prior operation: Flywheel - Check (B.10.A) 1.

Screw two bolt of medium length into the flywheel (1) using holes (4).

2.

Install two guide pins (2) having suitable length into crankshaft holes (3).

3.

Using the proper sling and hoist, install the flywheel (1).

4.

Screw engine flywheel (3) fixing screws (4) on the engine shaft.

5.

Install the tool (1) in the proper hole (2) in order to block engine flywheel rotation.

6.

Tighten the bolts (4) securing the flywheel (3) to the crankshaft.

7.

FLYWHEELD4

1

FLYWHEELD5

2

FLYWHEELD6

3

Tighten the flywheel bolts (2) in two stages: 1.

Torque bolts to 26 - 34 Nm (19 - 25 lb ft).

2.

Finish by turning the bolts an additional 55 - 65 °.

NOTE: Torquing to an angle is performed by using the tool 380000304.

Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

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Flywheel - Remove F4CE9484, F4CE9684

1.

Using tool 380000988, block flywheel (2) rotation.

2.

Loosen the flywheel fixing screws (3) to the engine crankshaft.

3.

Screw out the opposite screws (3) from the ports and introduce the withdrawal pins. (See figure below).

4.

Loosen the remaining flywheel fixing screws (3) to the engine crankshaft.

5.

Remove the flywheel block tool.

6.

Screw up to medium length screws in the ports (4) to sling the flywheel with a hoist.

7.

Throughout two guide pins (2), previously installed into the engine crankshaft ports (3), control the engine flywheel withdrawal by means of a hoist.

Next operation: Flywheel - Check (B.10.A)

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FLYWHEELC

1

FLYWHEELC2

2

POWER PRODUCTION - ENGINE

Flywheel - Install F4CE9484, F4CE9684

Prior operation: Flywheel - Check (B.10.A) 1.

Install two guide pins (2) having suitable length into crankshaft (3) holes.

2.

Using the proper sling and hoist, install the flywheel (1).

3.

Apply tool 380000988 (2) to the flywheel housing (1) to stop rotation of the flywheel (2).

4.

Tighten the bolts (3) securing the flywheel (2) to the crankshaft.

5.

FLYWHEELC2

1

FLYWHEELC

2

FLYWHEELC3

3

Tighten the flywheel bolts (1) in two stages: 1.

Torque bolts to 26 - 34 Nm (19 - 25 lb ft).

2.

Finish by turning the bolts an additional 55 - 65 °.

NOTE: Torquing to an angle is performed by using the tool 380000304.

Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

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Flywheel - Install F4GE9484, F4GE9684

Prior operation: Flywheel - Check (B.10.A) 1.

Screw two hooks or trail rings in the flywheel (1) threaded holes (4) for lifting.

2.

Insert two guide pins (2), having the appropriate length, in the shaft ports (3).

3.

Using a hoist, handle the flywheel (1) to place it in the housing.

4.

Tighten the screws (4) fixing the engine flywheel (3) to the engine crankshaft.

5.

Use tool 380000988 (2) in the flywheel housing (1) to block engine flywheel rotation.

6.

FLYWHEELG

1

FLYWHEELG2

2

FLYWHEELG3

3

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

•

Phase 1 - Use a torque wrench to tighten the bolts to 26 - 34 Nm (19.2 - 25.1 lb ft).

•

Phase 2 - Use tool 380000304 to tighten an additional 55 - 65 °.

NOTE: Before assembly, always check that the threads of the ports and of the screws have no evidence of wear or dirt.

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Vibration damper - Remove Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the bolts (3) securing the vibration dampener (2) and withdrawal the damper (2) and pulley (1).

VIBDAMPENERH

Next operation: Vibration damper - Install (B.10.A)

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1

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Vibration damper - Install F4HE9484, F4HE9684

Prior operation: Vibration damper - Remove (B.10.A) 1.

Attach the vibration damper (2) and the pulley (1) to the crankshaft, and torque the mounting bolts (3) to 61 - 75 Nm (45 - 55 lb ft).

VIBDAMPENERH

Next operation: Fan and drive Belt - Install (B.50.A)

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1

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Vibration damper - Remove F4DE9484, F4DE9684, F4DE9687

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the bolts (1) securing the vibration dampener (2) and withdrawal the damper (2) and pulley (3).

VIBDAMPERD

Next operation: Vibration damper - Install (B.10.A)

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1

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Vibration damper - Install F4DE9484, F4DE9684, F4DE9687

Prior operation: Vibration damper - Remove (B.10.A) 1.

Attach the vibration damper (2) and the pulley (3) to the crankshaft, and torque the mounting bolts (1) to 61 - 75 Nm (45 - 55 lb ft).

VIBDAMPERD

Next operation: Fan and drive Belt - Install (B.50.A)

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1

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Balancer - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Oil pan - Remove (B.60.A) 1.

Remove the screws (1) and withdraw the oil pickup tube.

2.

By means of pin (2) lock the dynamic balancer (3) in the TDC (Top Dead Center) position.

3.

Loosen the fixing screws (4) and remove the dynamic balancer (3).

DYNAMICBALANCER

Next operation: Balancer - Install (B.10.A)

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1

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Balancer - Install F4GE9484, F4GE9684

Prior operation: Balancer - Remove (B.10.A) 1.

Match the marks (A) engraved on the gears for timing.

2.

Once the balancer is mounted on the engine, remove the pin from point (B).

BALANCERG

Next operation: Oil pan - Install (B.60.A)

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Cylinder block Bore - Check Prior operation: Connecting rod and piston - Remove (B.10.A) Once engine is disassembled, clean accurately the cylinder block assembly.

Use the proper rings to handle the cylinder unit.

The engine block shall not show cracks.

Check operating plug conditions and replace them in case of uncertain seal or if rusted.

Inspect cylinder bore surfaces; they shall be free from seizing, scores, ovalization, taper, or excessive wear.

Inspection of cylinder bore to check ovalization, taper, and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder bore diameter.

NOTE: Should a ring gauge not be available, use a micrometer for zero-setting.

BACD04APH104ASA

1

BAIL07APH372AMA

2

Measurements shall be performed on each cylinder at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B).

Maximum wear is usually found on plane (B) in correspondence with the first measurement.

Should ovalization, taper, or wear be found, bore and grind the cylinder bores. Cylinder bore regrinding shall be performed according to the spare piston diameter oversized by 0.4 mm (0.016 in) and to the specified assembling clearance.

NOTE: In case of regrinding, all bores shall have the same oversize 0.4 mm (0.016 in).

Next operation: Cylinder block - Check (B.10.A)

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Cylinder block - Check Prior operation: Crankshaft - Remove (B.10.A)

Main Bearing Housings Check main bearing housings as follows: •

fit the main bearing caps on the supports without bearings

•

tighten the fastening screws to the specified torque

•

use the proper internal gauge to check whether the housing diameter is falling within the specified value.

Replace if a higher value is found.

Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit.

Planarity error shall not exceed 0.075 mm (0.003 in) Check cylinder unit operating plug (1) conditions, replace them in case of uncertain seal or if rusted.

CRIL04J058A01

Next operation: Crankshaft Journal - Clearance (B.10.A)

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1

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Cylinder head - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel injector Electro injector - Remove (B.20.A) 1.

Remove the fastening screws (1) from the cylinder head (2).

NOTE: The highlighted screws are shorter.

2.

CYLHEADF4DF4HE

1

CYLHEADREMOVE

2

Hook brackets (1) with suitable lifting chains and remove the cylinder head (2) from the cylinder block using a hoist.

Next operation: Cylinder head - Check (B.10.A)

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Cylinder head - Check F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Cylinder head - Remove (B.10.A)

Checking cylinder head wet seal This check shall be performed using the proper tools.

1.

Use a pump to fill with water heated to approximately 90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pressure.

2.

Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting.

NOTE: Before refitting, smear the plug surfaces with water repellent sealant.

3.

Replace the cylinder head if leaks are found.

80709

1

70325

2

Checking cylinder head supporting surface 4.

Distortion found along the whole cylinder head shall not exceed 0.20 mm (0.008 in).

If higher values are found, grind the cylinder head according to values and indications shown in the following figure.

5.

The rated thickness (A) for the cylinder head is 104.75 - 105.25 mm (4.124 - 4.144 in). Maximum metal removal shall not exceed thickness (B) by 1 mm (0.039 in).

NOTE: After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

Next operation: Cylinder head - Install (B.10.A)

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Cylinder head - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Cylinder head - Check (B.10.A) 1.

Check the cleanliness of the cylinder head and engine block coupling surface.

2.

Taking care not to foul the cylinder head gasket, set the gasket (1) with the marking "TOP" facing the head.

3.

The arrow shows the point where the gasket thickness is given.

4.

80714

1

PROTRUSION

2

There are two head gasket thicknesses, ( 1.25 mm Type A and 1.15 mm Type B).

To determine the correct head gasket to use, piston protrusion must be measured.

•

For each piston, measure protrusion in two places 180 ° apart, at a distance of 45 mm (1.8 in) from the center of the piston S1 and S2.

Then calculate the average:

•

For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value.

•

For 6 cylinder versions: Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

•

If S is > 0.40 mm (0.016 in) use seal type A.

•

If S is < 0.40 mm (0.016 in) use seal type B.

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5.

Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0.1 mm (0.004 in) the screw can be utilized again; If D1 - D2 > 0.1 mm (0.004 in) the screw must be replaced.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

6.

7.

BACD04APH224ASA

3

CYLHEADREMOVE

4

CYLINDERHEADDH

5

Using a suitable hoist, set the cylinder head on the engine block.

Tighten the cylinder head bolts in the following order using tool 380000304 for the angle tightening procedure.

1.

Tighten with a torque wrench.

•

12x1.75x130 are torqued to 30 - 40 Nm (22 - 30 lb ft).

•

12x1.75x150 are torqued to 50 - 60 Nm (37 - 44 lb ft).

2.

Turn the bolt clockwise 85 - 95 °.

3.

Turn the bolt clockwise an additional 85 - 95 °.

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6-Cylinder Engines

70476

6

Tightening sequence for the 6 cylinder engine.

A = Front of engine

4-Cylinder Engines

BACD04APH085ASA

7

Tightening sequence for the 4 cylinder engine.

A = Front of engine Next operation: Fuel injector Electro injector - Install (B.20.A)

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Cylinder head Valve guide - Clearance F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Valve drive Valve assembly - Remove (B.10.A) 1.

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 0.092 mm (0.002 - 0.004 in).

2.

Turn the valve (2) and check that the centering error is not exceeding 0.03 mm (0.001 in).

3.

80710

1

0B0O200405BACD0

2

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.

Next operation: Valve drive Valve assembly - Install (B.10.A)

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Cylinder head Valve seat - Regrind F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Valve drive Valve assembly - Remove (B.10.A) Should slight scratches or burns be found, go over with the adequate tool (1) according to the inclination values indicated as follows:

80711

70331

2

VALVE SEAT MAIN DATA (4 CYL.) Should valve seats be not reset just by regrinding, replace them with spare ones. Using a suitable tool, remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

1.

Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F) and using the proper punch, fit the new valve seats, previously cooled, into the cylinder head.

2.

Therefore, with an adequate tool, go over the valve seats according to the values stated in the previous figure.

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70332

3

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD 3.

After regrinding, check that the valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial gauge 380000228 (1).

80712

Next operation: Valve drive Valve assembly - Install (B.10.A)

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4

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Cylinder head - Remove F4GE9484, F4GE9684

Prior operation: Fuel injector Mechanical injector - Remove (B.20.A) 1.

Loosen the screws (1) and (2) fixing the cylinder head (3).

2.

Hook the brackets with a suitable lifting device.

3.

With a hoist, withdraw the cylinder head from the block.

4.

Remove the gasket (4).

CYLHEADG

Next operation: Cylinder head - Install (B.10.A)

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Cylinder head - Remove F4CE9484, F4CE9684

Prior operation: Fuel injector Mechanical injector - Remove (B.20.A) 1.

Loosen the screws (1) and (2) fixing the cylinder head (3).

2.

Hook the brackets with a suitable lifting device.

3.

Using a hoist, withdraw the cylinder head from the block.

4.

Remove the gasket (4).

CYLHEADC

Next operation: Cylinder head - Install (B.10.A)

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1

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Cylinder head - Install F4GE9484, F4GE9684

Prior operation: Cylinder head - Remove (B.10.A) 1.

Check the cleanliness of the cylinder head and engine block coupling surface.

2.

Taking care not to foul the cylinder head gasket, set the gasket (1) with the marking "TOP" facing the head.

3.

The arrow shows the point where the gasket thickness is given.

4.

80714

1

PROTRUSION

2

There are two head gasket thicknesses, ( 1.25 mm Type A and 1.15 mm Type B).

To determine the correct head gasket to use, piston protrusion must be measured.

•

For each piston, measure protrusion in two places 180 ° apart, at a distance of 45 mm (1.8 in)from the center of the piston S1 and S2.

Then calculate the average:

•

For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value.

•

For 6 cylinder versions: Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

•

If S is > 0.40 mm (0.016 in) use seal type A.

•

If S is < 0.40 mm (0.016 in) use seal type B.

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5.

Place the head (3) over the block and insert screws (1) and (2).

NOTE: If the valves have been removed, it is necessary to assemble them before installing the head onto the engine block.

6.

3

HEADBOLT

4

TORQUEPATTERNG2

5

Before using the screws again, measure them twice as indicated in the picture.

- if D1 - D2 < 0.1 mm (0.004 in) the screw can be used again.

- if D1 - D2 > 0.1 mm (0.004 in) the screw must be replaced.

7.

Lubricate the head bolts and install them in the head.

8.

Bolts must be torqued starting with the center bolts and moving out. Bolts shall be torqued in the following stages.

9.

CYLHEADG

•

Make all bolts snug then turn 90 °.

•

Turn bolts M12x140 and M12x180 an additional 90 °.

The end result should look like this.

•

M12x70 = 50 Nm (36.9 lb ft) + 90 °.

•

M12x140 = 40 Nm (29.5 lb ft) + 180 °.

•

M12x180 = 70 Nm (51.6 lb ft) + 180 °.

Next operation: Fuel injector Mechanical injector - Install (B.20.A)

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Cylinder head - Install F4CE9484, F4CE9684

Prior operation: Cylinder head - Remove (B.10.A) 1.

Place the gasket (1) over the block. The choice of the gasket thickness shall be made in consideration of the cylinder protrusion measured with the respect to the block’s upper surface.

NOTE: Verify that the engine block is clean.

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

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

2.

HEADGASKETG

1

CYLHEADC

2

HEADBOLT

3

Place the head (3) over the block and insert screws (1) and (2).

NOTE: If the valves have been removed, it is necessary to assemble them before installing the head onto the engine block.

3.

Before using the screws again, measure them twice as indicated in the picture.

- if D1 - D2 < 0.1 mm (0.004 in) the screw can be used again.

- if D1 - D2 > 0.1 mm (0.004 in) the screw must be replaced.

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4.

Lubricate the head bolts and install them in the head.

5.

Bolts must be torqued starting with the center bolts and moving out. Bolts shall be torqued in the following stages.

6.

•

Make all bolts snug then turn 90 °.

•

Turn bolts M12x140 and M12x180 an additional 90 °.

The end result should look like this.

•

M12x70 = 50 Nm (36.9 lb ft) + 90 °.

•

M12x140 = 40 Nm (29.5 lb ft) + 180 °.

•

M12x180 = 70 Nm (51.6 lb ft) + 180 °.

TORQUEPATTERNG2

Next operation: Fuel injector Mechanical injector - Install (B.20.A)

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4

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Cylinder head - Check F4GE9484, F4GE9684

Prior operation: Cylinder head - Remove (B.10.A)

Checking cylinder head wet seal This check shall be performed using the proper tools.

1.

Use a pump to fill with water heated to approximately 90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pressure.

2.

Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting.

NOTE: Before refitting, smear the plug surfaces with water repellent sealant.

3.

Replace the cylinder head if leaks are found.

CYLHEADWETSEAL

1

CYLHEADG2

2

Checking cylinder head supporting surface 4.

Distortion found along the whole cylinder head shall not exceed 0.20 mm (0.008 in).

If higher values are found, grind the cylinder head according to values and indications shown in the following figure.

5.

The rated thickness (A) for the cylinder head is 104.75 - 105.25 mm (4.124 - 4.144 in). Maximum metal removal shall not exceed thickness (B) by 1 mm (0.039 in).

NOTE: After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

Next operation: Cylinder head - Install (B.10.A)

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Cylinder head - Check F4CE9484, F4CE9684

Prior operation: Cylinder head - Remove (B.10.A)

Checking cylinder head wet seal This check shall be performed using the proper tools.

1.

Use a pump to fill with water heated to approximately 90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pressure.

2.

Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting.

NOTE: Before refitting, smear the plug surfaces with water repellent sealant.

3.

Replace the cylinder head if leaks are found.

CYLHEADWETSEAL

1

CYLHEADC2

2

Checking cylinder head supporting surface 4.

Distortion found along the whole cylinder head shall not exceed 0.20 mm (0.008 in).

If higher values are found, grind the cylinder head according to values and indications shown in the following figure.

5.

The rated thickness (A) for the cylinder head is 104.75 - 105.25 mm (4.124 - 4.144 in). Maximum metal removal shall not exceed thickness (B) by 1 mm (0.039 in).

NOTE: After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

Next operation: Cylinder head - Install (B.10.A)

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Cylinder head Valve guide - Clearance F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Valve assembly - Remove (B.10.A) 1.

Use a magnetic base dial gauge (1)set as shown in the figure, the assembling clearance shall be 0.052 0.092 mm (0.002 - 0.004 in).

2.

Turn the valve (2) and check that the centering error is not exceeding 0.03 mm (0.001 in).

3.

VALVEGUIDE

1

VALVEGUIDE2

2

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.

Next operation: Valve drive Valve assembly - Install (B.10.A)

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Cylinder head Valve seat - Regrind F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve drive Valve assembly - Remove (B.10.A) Should slight scratches or burns be found, go over with the adequate tool (1) according to the inclination values indicated as follows:

VALVESEAT

VALVESEAT2

2

VALVE SEAT MAIN DATA (dimensions in mm) Should valve seats be not reset just by regrinding, replace them with spare ones. Using a suitable tool, remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

1.

Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F) and using the proper punch, fit the new valve seats, previously cooled, into the cylinder head.

2.

Therefore, with an adequate tool, go over the valve seats according to the values stated in the previous figure.

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1

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VALVESEAT3

3

VALVE SEAT HOUSING MAIN DATA (dimensions in mm) 3.

After regrinding, check that the valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial gauge 380000228 (1).

VALVESINK

Next operation: Valve drive Valve assembly - Install (B.10.A)

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4

POWER PRODUCTION - ENGINE

Cylinder head - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

Check the cleanliness of the cylinder head and engine block coupling surface.

2.

Taking care not to foul the cylinder head gasket, set the gasket (1) with the marking "TOP" facing the head.

3.

The arrow shows the point where the gasket thickness is given.

4.

80714

1

PROTRUSION

2

There are two head gasket thicknesses ( 1.25 mm Type A and 1.15 mm Type B).

To determine the correct head gasket to use, piston protrusion must be measured.

•

for each piston measure protrusion in two places 180 ° apart, at a distance of 45 mm (1.8 in)from the center of the piston S1 and S2. Then calculate the average:

•

For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value.

•

For 6 cylinder versions: Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

•

If S is > 0.40 mm (0.016 in) use seal type A.

•

If S is < 0.40 mm (0.016 in) use seal type B.

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5.

Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0.1 mm (0.004 in) the screw can be utilized again; If D1 - D2 > 0.1 mm (0.004 in) the screw must be replaced.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

BACD04APH224ASA

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Valve cover - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

Remove the nuts securing the valve cover to base.

2.

Remove valve cover and gasket.

BACD04APH004ASA

Next operation: Valve cover - Install (B.10.A)

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1

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Valve cover - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Valve cover - Remove (B.10.A) 1.

Install a new gasket (2) on the valve cover (1).

2.

Place the valve cover (1) on its seat, and install the mounting bolts.

VALVECOVER

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1

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Valve cover - Remove F4DE9484, F4DE9684, F4DE9687

1.

Loosen the nuts (1) on top of the valve cover (2).

2.

Remove the valve cover (2) from it’s base.

VALVECOVERF4DE

Next operation: Valve cover - Install (B.10.A)

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1

POWER PRODUCTION - ENGINE

Valve cover - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

2.

Remove the fastening screws (1) from the valve covers (2). Remove the covers (2) and the related gaskets.

VALVECOVERCG

1

VALVECOVERCG2

2

On one of the caps there is a blow-by valve for the lubrication oil vapors. This can be disassembled with the relevant valve cover (2) by removing screws (1).

NOTE: All gaskets should be replaced upon reassembly.

Next operation: Valve cover - Install (B.10.A)

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Valve cover - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Valve cover - Remove (B.10.A) 1.

Assemble the valve covers (2) with new gaskets.

2.

Install the seals on the bolts and tighten the screws to the prescribed torque.

3.

VALVECOVERCG

1

VALVECOVERCG2

2

Install the cover (2) that incorporates the blow-by valve and tighten the screws (1) to the prescribed torque.

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Front cover - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Vibration damper - Remove (B.10.A) 1.

Remove the screws (1) from the front cover. Be sure to remove the two screws (3) underneath the cover.

NOTE: Take note of screw (1) assembling positions since they have different lengths.

2.

Remove the front cover from the cylinder block.

FRONTCOVERH

Next operation: Front cover - Cleaning (B.10.A)

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1

POWER PRODUCTION - ENGINE

Front cover - Cleaning F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Front cover - Remove (B.10.A) 1.

2.

Remove the sealing ring (2) from the front cover (1).

FRONTCOVERH2

1

FRONTCOVERG

2

Clean the sealing surfaces and apply LOCTITE 5205.

Next operation: Front cover - Install (B.10.A)

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Front cover - Install F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Front cover - Cleaning (B.10.A) 1.

Install the front cover (2) and tighten the mounting bolts (1) to the specified torque.

FRONTCOVERD3

Next operation: Vibration damper - Install (B.10.A)

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1

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Front cover - Remove F4DE9484, F4DE9684, F4DE9687

Prior operation: Vibration damper - Remove (B.10.A) 1.

Remove the screws (1) from the front cover (2). Be sure to remove the four screws (3) from underneath the cover (2).

NOTE: Take note of screw assembling positions since that have different lengths.

2.

Remove the front cover (2).

FRONTCOVERD

Next operation: Front cover - Cleaning (B.10.A)

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1

POWER PRODUCTION - ENGINE

Front cover - Cleaning F4DE9484, F4DE9684, F4DE9687

Prior operation: Front cover - Remove (B.10.A) 1.

Disassemble the sealing ring (2) from the front cover (1), clean the coupling surfaces accurately.

FRONTCOVERD2

Next operation: Front cover - Install (B.10.A)

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1

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Front cover - Install F4DE9484, F4DE9684, F4DE9687

Prior operation: Front cover - Cleaning (B.10.A) 1.

2.

Position the front cover seal (1) on the engine block.

FRONTCOVERD4

1

FRONTCOVERD5

2

Install the front cover (1) on the block and tighten the screws (2) to the prescribed torque.

Next operation: Vibration damper - Install (B.10.A)

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Rear cover - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Flywheel - Remove (B.10.A) 1.

Remove the retaining bolts (2) from the rear cover (1) and withdrawal the cover.

NOTE: Take note of the bolt location due to the different lengths. This will aid in ease of assembly.

REARCOVERH3

Next operation: Rear cover - Cleaning (B.10.A)

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1

POWER PRODUCTION - ENGINE

Rear cover - Cleaning F4HE9484, F4HE9684

Prior operation: Rear cover - Remove (B.10.A) 1.

Clean the rear cover and it’s mating surface on the timing gear cover.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (1), a few millimeters thick, to the sealing surface of the cover.

NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes.

REARCOVERH

Next operation: Rear cover - Install (B.10.A)

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1

POWER PRODUCTION - ENGINE

Rear cover - Install F4HE9484, F4HE9684

Prior operation: Rear cover - Cleaning (B.10.A) NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or dirt.

1.

Install the cover (1) onto the timing gear housing and install the bolts in same location that they were removed.

2.

Tighten them to the prescribed torque.

REARCOVERH2

Next operation: Flywheel - Install (B.10.A)

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1

POWER PRODUCTION - ENGINE

Rear cover - Cleaning F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Rear cover - Remove (B.10.A) 1.

Clean the rear cover and it’s mating surface on the timing gear cover.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (1), a few millimeters thick, to the sealing surface of the cover.

NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes.

REARCOVERD

Next operation: Rear cover - Install (B.10.A)

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1

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Rear cover - Install F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Rear cover - Cleaning (B.10.A) NOTE: Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

1.

Install the cover (1) on the engine.

2.

Tighten the fixing screws (2) in the same position from where they have been removed, to the prescribed torque.

REARCOVERC2

Next operation: Flywheel - Install (B.10.A)

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1

POWER PRODUCTION - ENGINE

Rear cover - Remove F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Flywheel - Remove (B.10.A) 1.

Loosen the screws (2) and remove the rear cover (1).

NOTE: Take of the screw assembly position, since the screws have different lengths.

REARCOVERC

Next operation: Rear cover - Cleaning (B.10.A)

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1

POWER PRODUCTION - ENGINE

Rear cover - Cleaning F4GE9484, F4GE9684

Prior operation: Rear cover - Remove (B.10.A) 1.

Clean the rear cover (1) and it’s mating surface on the timing gear cover.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (2), a few millimeters thick, to the sealing surface of the cover.

NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes.

REARCOVERG

Next operation: Rear cover - Install (B.10.A)

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1

POWER PRODUCTION - ENGINE

Rear cover - Install F4GE9484, F4GE9684

Prior operation: Rear cover - Cleaning (B.10.A) NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or dirt.

1.

Install the cover (1) onto the timing gear housing and install the bolts in same location that they were removed.

2.

Tighten them to the prescribed torque.

REARCOVERG2

Next operation: Flywheel - Install (B.10.A)

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POWER PRODUCTION - ENGINE

Wiring harness - Disconnect F4DE9484, F4DE9684, F4DE9687

0B0O200406CRIL0

1

(1) Connections for electro-injectors - (2) Coolant temperature sensor - (3) Fuel pressure sensor - (4) Oil pressure/temperature sensor - (5) Driving shaft sensor - (6) Electro-injector - (7) Air pressure/temperature sensor - (8) Timing system sensor - (9) Fuel temperature sensor - (10) Pressure regulating gauge - (11) EDC 7 electronic module.

1.

Disconnect the engines cable from the connectors (1) to electro-injector (6), air pressure/temperature sensor (7), fuel pressure sensor (3), engine control module (11), high pressure pump sensor (10), timing system sensor (8), coolant temperature sensor (2), driving shaft sensor (5).

2.

Disassemble the harness from the engine block by removing the fixing clamps.

0B0O200406CRIL0

Next operation: Wiring harness - Connect (B.10.A)

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2

POWER PRODUCTION - ENGINE

Wiring harness - Disconnect F4HE9484, F4HE9684

HARNESS

1

(1) Fuel Pressure Sensor - (2) Coolant Temperature Sensor - (3) Engine Oil Temperature Sensor - (4) Crankshaft Speed Sensor - (5) Electro-Injector - (6) Air Pressure/Temperature Sensor - (7) Timing Sensor - (8) Fuel Temperater Sensor - (9) Fuel Pressure Regulator - (10) EDC 7 Electronic Control Unit - (11) Connectors for Electro-Injectors 1.

Disconnect the engine’s cable from the connectors wiring harness to Electro-Injectors (11); Air Pressure/Temperature Sensor; (6) Fuel Pressure Sensor (1); Engine Control Module (10); Timing Sensor (7); Coolant Temperature Sensor (2); Crankshaft Speed Sensor (4).

HARNESS

Next operation: Wiring harness - Connect (B.10.A)

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2

POWER PRODUCTION - ENGINE

Wiring harness - Connect F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Wiring harness - Disconnect (B.10.A) 1.

Reconnect the engine wiring harness to all the sensors, the engine control module and the common rail.

Refer to Wiring harness - Disconnect (B.10.A) for the harness routing and connections.

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POWER PRODUCTION - ENGINE

Electronic control Control module - Remove F4HE9484, F4HE9684

Prior operation: Fuel line Low pressure - Disconnect (B.20.A) 1.

Disconnect the main wiring harness from the electronic control module (2).

2.

Disconnect the low pressure fuel lines that are attached to the control module cooling plate.

3.

Remove the three mounting bolts (1) that secure the control module and the cooling plate to the engine block.

4.

Remove the control module and cooling plate as one unit.

EDC7H

Next operation: Electronic control Control module - Install (B.10.A)

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1

POWER PRODUCTION - ENGINE

Electronic control Control module - Install F4HE9484, F4HE9684

Prior operation: Electronic control Control module - Remove (B.10.A) 1.

Install the electronic control module (2) and cooling plate on the side of the engine block.

2.

Install the mounting bolts (1) and rubber isolators and tighten to the specified torque.

NOTE: If the rubber isolators are cracked or excessively deformed, replace them before installation.

EDC7H

Next operation: Fuel line Low pressure - Connect (B.20.A)

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1

POWER PRODUCTION - ENGINE

Sensing system Position sensor - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

Remove the mounting nut and slide the timing sensor out of the timing gear housing.

Next operation: Sensing system Position sensor - Install (B.10.A)

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POWER PRODUCTION - ENGINE

Sensing system Position sensor - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Sensing system Position sensor - Remove (B.10.A) 1.

Install a new O-ring on the timing sensor.

2.

Slide the sensor over the mounting stud and install the nut. Tighten to the specified torque.

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POWER PRODUCTION - ENGINE

Sensing system Speed sensor - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

Install a new O-ring on the speed sensor (3).

2.

Install the speed sensor (3) on the front cover (1).

3.

Tighten the screw (2) to the specified torque.

SPEEDSENSORH

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1

Index POWER PRODUCTION - B ENGINE - 10.A Auxiliary drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 F4HE9484, F4HE9684

Auxiliary drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 F4CE9484, F4CE9684

Auxiliary drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 F4GE9484, F4GE9684

Auxiliary drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 F4HE9484, F4HE9684

Auxiliary drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 F4GE9484, F4GE9684

Auxiliary drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 F4CE9484, F4CE9684

Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 F4GE9484, F4GE9684

Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 F4GE9484, F4GE9684

Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 F4CE9484, F4CE9684

Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 F4DE9484, F4DE9684, F4DE9687

Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 F4CE9484, F4CE9684

Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Connecting rod and piston - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Connecting rod and piston Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Connecting rod and piston Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Connecting rod Bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Connecting rod Bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Connecting rod Bushing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Crankshaft Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Crankshaft Gear - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Crankshaft Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Crankshaft Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 F4CE9484, F4CE9684

Crankshaft Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Cylinder block - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 F4GE9484, F4GE9684

Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 F4CE9484, F4CE9684

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 F4GE9484, F4GE9684

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 F4CE9484, F4CE9684

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 F4GE9484, F4GE9684

Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 F4CE9484, F4CE9684

Cylinder head Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Cylinder head Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Cylinder head Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Cylinder head Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Electronic control Control module - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Electronic control Control module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 F4HE9484, F4HE9684

Electronic control Control module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Electronic control Control module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 F4HE9484, F4HE9684

ENGINE - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4HE9484, F4HE9684

ENGINE - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DE9484, F4DE9684, F4DE9687

ENGINE - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4CE9484, F4CE9684

ENGINE - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4GE9484, F4GE9684

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4HE9484, F4HE9684

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DE9484, F4DE9684, F4DE9687

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4CE9484, F4CE9684

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4GE9484, F4GE9684

ENGINE - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 F4HE9484, F4HE9684 84250518 09/11/2009

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ENGINE - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 F4DE9484, F4DE9684, F4DE9687

ENGINE - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 F4GE9484, F4GE9684

ENGINE - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 F4CE9484, F4CE9684

ENGINE - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 ENGINE - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 F4DE9484, F4DE9684, F4DE9687

ENGINE - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F4GE9484, F4GE9684

ENGINE - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 F4CE9484, F4CE9684

ENGINE - Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

ENGINE - Service limits Maintenance Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 F4CE9484, F4HE9484, F4CE9684, F4HE9684

Flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 F4GE9484, F4DE9484, F4GE9684, F4DE9684, F4DE9687

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 F4HE9484, F4HE9684

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 F4DE9484, F4DE9684, F4DE9687

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 F4CE9484, F4CE9684

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 F4GE9484, F4GE9684

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 F4DE9484, F4DE9684, F4DE9687

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 F4CE9484, F4CE9684

Front cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Front cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 F4DE9484, F4DE9684, F4DE9687

Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 F4DE9484, F4DE9684, F4DE9687

Front cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Front cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208 F4DE9484, F4DE9684, F4DE9687

Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Rear cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 F4HE9484, F4HE9684

Rear cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Rear cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 F4GE9484, F4GE9684

Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 F4HE9484, F4HE9684

Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 F4GE9484, F4GE9684

Rear cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Rear cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 84250518 09/11/2009

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Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Rocker assembly Shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Sensing system Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 F4HE9484, F4HE9684

Sensing system Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4DE9484, F4DE9684, F4DE9687

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 F4HE9484, F4HE9684

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4DE9484, F4DE9684, F4DE9687

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 F4CE9484, F4CE9684

Sensing system Position sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Sensing system Position sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Sensing system Speed sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 F4HE9484, F4HE9684

Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 F4GE9484, F4GE9684

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 F4HE9484, F4HE9684

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 F4GE9484, F4GE9684

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 F4DE9484, F4DE9684, F4DE9687

Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 F4DE9484, F4DE9684, F4DE9687

Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve drive - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve drive Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Valve drive Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Valve drive Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Valve drive Rocker assembly - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve drive Rocker assembly - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve drive Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve drive Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve drive Rocker assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve drive Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve drive Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Valve drive Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Valve drive Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 F4CE9484, F4GE9484, F4CE9684, F4GE9684 84250518 09/11/2009

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Vibration damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 F4HE9484, F4HE9684

Vibration damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 F4DE9484, F4DE9684, F4DE9687

Vibration damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Vibration damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 F4DE9484, F4DE9684, F4DE9687

Wiring harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Wiring harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 F4DE9484, F4DE9684, F4DE9687

Wiring harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 F4HE9484, F4HE9684

Wiring harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4HE9484, F4HE9684

Wiring harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4DE9684, F4DE9687

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POWER PRODUCTION - B FUEL AND INJECTION SYSTEM - 20.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents POWER PRODUCTION - B FUEL AND INJECTION SYSTEM - 20.A

FUNCTIONAL DATA FUEL AND INJECTION SYSTEM Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4HE9484, F4HE9684

Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4DE9684, F4DE9687

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Regulator valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Relief valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel injection pump Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9684

Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9684

Rotary injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel filter system Water separator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4HE9484, F4HE9684

Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4DE9484, F4DE9684, F4DE9687

High pressure common rail Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4HE9484, F4HE9684

External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4DE9484, F4DE9684, F4DE9687

Pump head and housing - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Priming pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4HE9484, F4HE9684

Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4HE9484, F4HE9684

Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4HE9484, F4HE9684

Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4DE9684, F4DE9687

Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 F4DE9484, F4DE9684, F4DE9687

Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F4DE9484, F4DE9684, F4DE9687

Water sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 F4CE9484, F4CE9684

SERVICE Fuel injection pump Rotary injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Rotary injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 F4GE9484, F4GE9684

Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4GE9484, F4GE9684

Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4GE9484, F4GE9684

Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 F4CE9484, F4CE9684

Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 F4CE9484, F4CE9684

Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 F4CE9484, F4CE9684

Fuel filter system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Fuel filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel injector Fuel Manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel Manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Electro injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Electro injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

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Mechanical injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Mechanical injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 F4CE9484, F4GE9484, F4CE9684, F4GE9684

High pressure common rail Pump head and housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Pump head and housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Priming pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel line High pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F4HE9484, F4HE9684

High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 F4DE9484, F4DE9684, F4DE9687

High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 F4HE9484, F4HE9684

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 F4GE9484, F4GE9684

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 F4CE9484, F4CE9684

High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 F4CE9484, F4GE9484, F4CE9684, F4GE9684

High pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 F4CE9484, F4CE9684

Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 F4GE9484, F4GE9684

Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel connector Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Sensing system Air temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

FUEL AND INJECTION SYSTEM - Dynamic description F4HE9484, F4HE9684

4C0O200406CRILH

1

(1) Electro-Injector - (2) Common Rail - (3) Pressure limiting device for fuel return - (4) Common rail pressure relief valve - (5) Pre-filter mounted on the frame - (6) High-pressure pump - (7) Mechanical vane pump - (8) Fuel filter.

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.

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

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

fuel suction piping from tank to pre-filter

•

pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and pre-filter

•

pipings supplying the high pressure pump through the fuel filter

The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

FUEL AND INJECTION SYSTEM - Plumbing schema F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

The fuel system is a Common Rail injection system with a CP3 high pressure pump.

The pressure regulator, placed upstream of the high pressure pump, adjusts the fuel flow that is necessary on the low pressure system. Afterwards, the high pressure pump takes care of supplying the rail properly. This arrangement, by pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.

Function of the pressure relief valve (2), assembled on the high pressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bar (73 psi). Based on the efficiency the fuel filter.

The pressure relief valve (2) increases fuel flow in the high pressure pump cooling circuit, through inlet and drain piping (16) from piping (8).

The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 - 2 bar (19 - 29 psi).

Two bypass valves are placed in parallel with the mechanical supply pump.

The bypass valve (18) allows fuel to flow from the mechanical pump outlet to it’s inlet, when the fuel filter inlet pressure exceeds the allowed threshold value.

The bypass valve (17) allows filling the supply system through the manual priming pump (10).

FUELSYSTEMSCHEM

1

(1) High-Pressure pump - (2) pressure relief valve on high pressure pump, 5 bar (72.5 psi) - (3) Pressure relief valve assembled on fuel return from injectors, 1.3 - 2 bar (18.9 - 29.0 psi) - (4) Rail overpressure valve (5) Common rail - (6) Pressure sensor - (7) Injector - (8) Return spring - (9) Control unit heat exchanger - (10) Mechanical priming pump - (11) Pre-Filter - (12) Fuel tank - (13) Mechanical supply pump - (14) Fuel filter (15) Pressure regulator - (16) High pressure pump cooling pipe - (17) By-pass valve - (18) By-pass valve.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

FUEL AND INJECTION SYSTEM - Dynamic description F4DE9484, F4DE9684, F4DE9687

4C0O200406CRIL0

1

(1) Injector - (2) Common Rail - (3) Pressure limiter for fuel return - (4) Rail overpressure valve - (5) Prefilter mounted on the block - (6) High pressure pump - (7) Mechanical rotor pump - (8) Fuel filter.

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.

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

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

fuel suction piping from tank to pre-filter

•

pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and pre-filter

•

pipings supplying the high pressure pump through the fuel filter

The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.

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FUEL AND INJECTION SYSTEM - Dynamic description F4CE9484, F4GE9484, F4CE9684, F4GE9684

FUELSYSTEMCG

1

(1) Fuel filter - (2) Feed pipeline from filter to fuel pump - (3) Feed pipeline from priming pump to filter (4) Priming pump.

Description of working principles Fuel is sucked from the tank by the priming pump. This last one is placed on the engine block and is driven by the camshaft.

Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For application to be equipped in cold climate areas, the fuel filter is provided with a heater).

The transfer pump is placed inside the feed pump, and is bladed type. Its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.

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

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

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

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Regulator valve - Overview F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Pressure Regulator The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the pressure regulator is managed by the EDC7 control unit.

Delivery pressure to the rail is modulated between 250 - 1450 bar (3625 - 21025 psi) by the electronic control unit by controlling the pressure regulator solenoid valve.

This component is a N.O. solenoid valve.

The solenoid valve impedance is approximately 3.2 Ω.

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 pressures of 1.3 - 2 bar (19 - 29 psi). By guaranteeing this pressure to the return fuel, the fuel vapor formation inside the injectors is avoided, optimizing fuel spraying and combustion.

BACD04APH176ASA

1

(A) - To Tank (B) - From Injectors

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Relief valve - Overview F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Mounted on the end of the rail, it has the function of protecting the system’s components in case the failure of the rail pressure sensor or the pressure regulator of the CP3 pump causes an excessive pressure increase in the high pressure plant.

When the rail pressure reaches 1800 bar (26100 psi), the valve initially opens in order to allow the fuel to flow and subsequently reduce the pressure within the safety limits and then it mechanically regulates the rail pressure to approximately 800 bar (11600 psi).

This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of the fuel preserving the return pipes to tank.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Overview F4GE9484, F4GE9684

Fuel feed system is composed by: •

Fuel tank (placed on the machine)

•

Fuel delivery and back-flow to tank

•

Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)

•

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

•

Fuel filter (assembled to the engine in different positions according to equipment application and duty)

•

Fuel feed rotary pump

•

Injector feed pipeline (from fuel feed pump to injectors)

•

Injectors

INJECTIONPUMPG

1

(1) Injector feed pipes - (2) Fuel return pipes from injectors - (3) Fuel feed rotary pump - (4) Connector for LDA pressure gauge pipe with suction collector - (5) KSB thermal bulb - Electro-valve - (7) Injector.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Overview F4CE9484, F4CE9684

Fuel feed system is composed by: •

Fuel tank (placed on the machine)

•

Fuel delivery and back-flow to tank

•

Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)

•

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

•

Fuel filter (assembled to the engine in different positions according to equipment application and duty)

•

Fuel feed rotary pump

•

Injector feed pipeline (from fuel feed pump to injectors)

•

Injectors

INJECTIONPUMPC

1

(1) Injector feed pipes - (2) Injector - (3) Electro-valve - (4) KSB thermal bulb - (5) Fuel feed rotary pump - (6) Fuel return pipes from injectors.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Sectional view F4CE9484, F4GE9484, F4CE9684, F4GE9684

Decoding the identification tag V = Distribution rotary plunger E = Pump dimensions 4 = Four cylinder engines (3 = Three cylinder engines and 6 = Six cylinder engines) 12 = Distribution plunger in mm 1150 = Number of pump revolutions per minute LV = Left direction of rotation

PUMPSECTIONCG

1

(1) Diaphragm - (2) Locking nut - (3) Pivot - (4) Drive lever - (5) Speed gauge - (6) Transfer pump - (7) Drive shaft - (8) Cam disk - (9) Advance converter - (10) Distribution plunger - (11) Delivery pipe fitting - (12) Hydraulic head - (13) Drive plate - (14) Gauge pin - (15) Counteracting spring.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel filter system Water separator - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684

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

On the filter cartridge, there is a water dump screw throughout which it is possible to provide regular drainage. For those equipment applications requiring it, a heater can be installed along with a temperature sensor. On some versions, a water presence sensor is mounted to the filtering cartridge.

FUELWATERFILTER

1

(1) Fuel filter base - (2) Filter cartridge - (3) Water dump screw.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Electro injector - Overview F4HE9484, F4HE9684

On NEF TIER III engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power developed by the engine.

Jet

Power

Pressure

DLLA DSLA

Up to 152 kW (207 Hp) 152 kW (207 Hp) and above.

250 - 1600 bar (3625 - 23200 psi) 250 - 1450 bar (3625 - 21025 psi)

The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs.

The injector is composed of two parts: •

actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.

•

control solenoid valve composed of a coil, and pilot valve.

The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

93095366

(1) (2) (3) (4) (5)

Pressure Rod Plunger Nozzle Coil Pilot Valve

1

(6) Ball Shutter (7) Control Area (8) Pressure Chamber (9) Control Volume (10) Control Duct

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(11) Supply Duct (12) Control Fuel Outlet (13) Electrical Connection (14) Spring (15) High Pressure Fuel Inlet

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Injection Start

93095367

2

When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, following fuel injection into the cylinder.

Injection End When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance as to make plunger (2) go back to its closing position and end the injection process.

NOTE: The injector cannot be overhauled and therefore it must not be disassembled.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Electro-Injector Solenoid Valves 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 Ω.

COVERBASE

Reference Connector (1) Pin #1 Pin #2 Pin #3 Pin #4 Connector (2) Pin #1 Pin #2 Pin #3 Pin #4 Connector (3) Pin #1 Pin #2 Pin #3 Pin #4

3

Description

ECU Pin

Cylinder Cylinder Cylinder Cylinder

2 2 1 1

injector injector injector injector

11A 6A 13A 4A

Cylinder Cylinder Cylinder Cylinder

4 4 3 3

injector injector injector injector

14A 3A 12A 5A

Cylinder Cylinder Cylinder Cylinder

6 6 5 5

injector injector injector injector

15A 2A 1A 16A

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Electro injector - Overview F4DE9484, F4DE9684, F4DE9687

On NEF TIER III engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power developed by the engine.

Jet

Power

Pressure

DLLA DSLA

Up to 152 kW (207 Hp) 152 kW (207 Hp) and above

250 - 1600 bar (3625 - 23200 psi) 250 - 1450 bar (3625 - 21025 psi)

The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs.

The injector is composed of two parts: •

actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.

•

control solenoid valve composed of a coil, and pilot valve.

The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

93095366

(1) (2) (3) (4) (5)

Pressure Rod Plunger Nozzle Coil Pilot Valve

1

(6) Ball Shutter (7) Control Area (8) Pressure Chamber (9) Control Volume (10) Control Duct

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(11) Supply Duct (12) Control Fuel Outlet (13) Electrical Connection (14) Spring (15) High Pressure Fuel Inlet

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Injection Start

93095367

2

When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, following fuel injection into the cylinder.

Injection End When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance as to make plunger (2) go back to its closing position and end the injection process.

NOTE: The injector cannot be overhauled and therefore it must not be disassembled.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Electro-Injector Solenoid Valves 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 Ω.

COVERBASE

Reference Connector (1) Pin #1 Pin #2 Pin #3 Pin #4 Connector (2) Pin #1 Pin #2 Pin #3 Pin #4 Connector (3) Pin #1 Pin #2 Pin #3 Pin #4

3

Description

ECU Pin

Cylinder Cylinder Cylinder Cylinder

2 2 1 1

injector injector injector injector

3A 6A 13A 9A

Cylinder Cylinder Cylinder Cylinder

4 4 3 3

injector injector injector injector

5A 14A 12A 4A

Cylinder Cylinder Cylinder Cylinder

6 6 5 5

injector injector injector injector

10A 15A 16A 11A

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

High pressure common rail - Overview F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

FUEL SYSTEM OPERATION The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements at about 2 bar (29 psi).

The amount of fuel supplying the high pressure pump is metered by the pressure regulator placed on the low pressure system. The pressure regulator is controlled by the EDC7 control unit through a PWM signal.

When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, unable to be released, is compressed above the supply pressure value existing in the rail.

The generated pressure makes the exhaust valve open and the compressed fuel reaches the high pressure circuit.

The pumping element compresses the fuel till top dead center of the delivery stroke, is reached. Afterwards, the pressure decreases till the exhaust valve is closed.

The pumping element piston goes back towards bottom dead center and the remaining fuel is decompressed.

When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated.

The delivery valves must always be free in their movements, free from impurities and oxidation.

The rail delivery pressure is modulated between 250 - 1600 bar (3625 - 23200 psi) by the electronic control unit, through the pressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

The radialjet pump disconnection - reconnection time on the engine is greatly 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 be removed or installed, be sure that hands and components are absolutely clean.

RAIL

COMMONRAILOVERV

1

(1) Rail - (2) Fuel inlet from high-pressure pump - (3) Overpressure valve - (4) Pressure sensor.

The rail volume is comparatively small to allow quick pressurization at start-up, at idle and in case of high flow rates.

It has enough volume to minimize system spikes and the use of plenum chambers caused by the opening and closing of the injectors and by the high pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high pressure pump.

A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is feedback information, where the rail pressure value is checked and if necessary, corrected.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

High pressure common rail - External view F4HE9484, F4HE9684

Introduction Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and fuel consumption.

For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at pressures up to 1450 bar (21025 psi).

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

HARNESS

1

(1) Fuel pressure sensor - (2) Coolant temperature sensor - (3) Oil temperature/pressure sensor - (4) Driving shaft sensor - (5) Connection to electro-injectors - (6) Air temperature/pressure sensor - (7) Camshaft sensor - (8) Fuel heater cable and fuel temperature sensor - (9) Pressure gauge cabling - (10) EDC 7 gearbox - (11) Electro-injector

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

High pressure common rail - External view F4DE9484, F4DE9684, F4DE9687

Introduction Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and fuel consumption.

For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at pressures up to 1450 bar (21025 psi).

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

Air pressure/temperature system It is a component integrating a temperature sensor and a pressure sensor. Fitted on the intake manifold, it measures the maximum inlet air capacity to calculate precisely the fuel quantity to inject at every cycle. The outlet voltage is proportional to the pressure or temperature obtained by the sensor.

Engine oil temperature and pressure sensor Same as the air pressure/temperature sensor, it is fitted on the engine oil filter base, in a horizontal position. It measures engine oil temperature and pressure.

Fuel pressure sensor Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The injection pressure value is used to control the pressure and to determine the electric injection control length.

Coolant temperature sensor It is a variable resistance sensor suitable to measure the coolant temperature to provide the control unit with an index of the engine thermal state.

Output shaft sensor It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape.

System functionality The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.

FPT Code recognition The EDC 7 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

0B0O200406CRIL0

1

(1) Connection to electro-injectors - (2) Coolant temperature sensor - (3) Fuel pressure sensor - (4) Oil temperature/pressure sensor - (5) Crankshaft sensor - (6) Electro-injector - (7) Air temperature/pressure sensor - (8) Camshaft sensor - (9) Fuel heater cable and fuel temperature sensor - (10) Pressure gauge cabling - (11) EDC 7 gearbox.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

High pressure common rail Pump head and housing - Sectional view F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

CP3 HIGH PRESSURE PUMP Pump provided with 3 radial pumping elements driven by the timing system gear, no need for timing. The mechanical feeding pump driven by the high pressure pump’s shaft is assembled to the rear side of the high pressure pump.

NOTE: The high pressure pump unit - feeding pump is not subject to overhaul. Do not disassemble or tamper with the retaining bolts.

The only serviceable components are the control gear and pressure regulator.

80719

1

(1) Fuel exhaust collector to rail - (2) High pressure pump - (3) Pressure regulating gauge - (4) Driving gear (5) Connector to fuel entry flowing from filter - (6) Connector to fuel exhaust to filter support - (7) Connector to fuel entry flowing from engine control module heat exchanger - (8) Connector to fuel exhaust flowing from mechanical pump to filter - (9) Mechanical feeding pump

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

HIGH PRESSURE PUMP Inside Structure

80720

2

(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) Pumping elements supplying fuel ducts.

Every pumping unit is composed of: •

A piston actuated by a three-lobe element floating on the pump shaft. The element, which is floating on an offset part of the shaft, uses the highest part of the element to actuate the three pistons alternately.

•

Cap intake valve.

•

Ball delivery valve.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Working Principle

80721

3

(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) Pumping elements supplying fuel ducts The pumping element is oriented towards the pump’s camshaft. During the intake phase, the pumping element is fed through the feeding line. The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge. The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element. During the compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to the common rail, feeding it through the exhaust unit.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

80722

4

(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) Pumping elements supplying fuel ducts The figure shows the fuel runs at low pressure inside the pump. The following elements are clearly visible: the main feeding line to the pumping elements, the feeding lines to the pumping elements, the duct lines run for the pump lubrication, the pressure gauge, the flow limiting valve to 5 bar (73 psi) and the fuel exhaust flue The pump shaft is lubricated by the fuel from the feeding and recovery lines.

The pressure gauge determines the quantity of fuel to feed the pumping elements. The excess fuel flows through the exhaust gallery.

The 5 bar (73 psi) limiting valve, in addition to recovering exhaust fuel as a collector, also functions to keep the pressure at a constant 5 bar (73 psi) limit at gauge entry.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

80723

5

(1) Fuel exhaust flue - (2) Fuel exhaust gallery (3) Fuel exhaust flowing from pump with connector to high pressure pipe for common rail This figure shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel heater - Overview The ECU drives the filter heater at fuel temperature less than our equal to 5 °C (41 °F).

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel transfer pump - Sectional view F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

MECHANICAL FEEDING PUMP Gear pump, placed on the rear part of the high pressure pump, whose function is to feed the high pressure pump. It is driven by the high pressure pump’s shaft.

Ordinary working condition

BACD04APH163ASA

1

(A) Fuel entry flowing from the tank - (B) Fuel exhaust to filter - (1) and (2) By-pass valves in the closed postion

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Overpressure condition in Exhaust unit

BACD04APH164ASA

2

The by-pass valve (1) is activated in case of overpressure on (B) Exhaust unit. The actual pressure, overcoming the resistance of the valve’s spring (1), connects the exhaust with the entry through the gallery (2).

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Jettison condition

BACD04APH165ASA

3

The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system through the priming pump. In this condition the by-pass (1) keeps closed while the dump by-pass valve (2) opens up due to the pressure effect on the entry unit so the fuel flows to the exhaust unit (B).

NOTE: The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the high pressure pump.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Priming pump - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684

This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to the engine block and driven by the camshaft.

PRIMINGPUMPCG

1

(1) Fuel output to the filter - (2) Drive lever - (3) Fuel inlet from the tank

PRIMINGPUMPCG2

2

(1) Priming pump - (2) Drive lever - (3) Camshaft

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Sensing system Air temperature-pressure sensor - Overview F4HE9484, F4HE9684

AIRPRESSTEMP

1

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 for temperature and 33C - 34C for pressure.

The power supply is 5 volts.

Voltage at the sensor output is proportional to the detected pressure or temperature.

Reference

Description

ECU pin

1 2 3 4

Ground NTC signal (temperature) +5 V power input Signal (pressure)

25C 36C 33C 34C

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Sensing system Pressure sensor - Overview F4HE9484, F4HE9684

FUELPRESS

1

Mounted on the 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.

The sensor is connected to the control unit on pins 12C - 14C - 13C. The power supply is 5 Volt.

Reference

Description

ECU pin

1 2 3

Ground Signal Power supply

12C 14C 13C

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Sensing system Temperature sensor - Overview F4HE9484, F4HE9684

FUELTEMPH

1

(1) Fuel Temperature Sensor - (2) Filter heating resistamce

Fuel Temperature Sensor This sensor is identical to the coolant temp 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 (68 °F) is approximately 2.50 Ω.

Reference

Description

ECU pin

1 2

Ground Temperature signal

35C 18C

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Sensing system Air temperature-pressure sensor - Overview F4DE9484, F4DE9684, F4DE9687

AIRPRESSTEMP

1

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 21C - 29C for temperature and 10C - 28C for pressure.

The power supply is 5 volts.

Voltage at the sensor output is proportional to the detected pressure or temperature.

Reference

Description

ECU pin

1 2 3 4

Ground NTC signal (temperature) +5 V power input Signal (pressure)

21C 29C 10C 28C

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Sensing system Pressure sensor - Overview F4DE9484, F4DE9684, F4DE9687

FUELPRESS

1

Mounted on tone 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.

The sensor is connected to the control unit on pins 20C - 27C - 12C. The power supply is 5 Volt.

Reference

Description

ECU pin

1 2 3

Ground Signal Power supply

20C 27C 12C

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Sensing system Temperature sensor - Overview F4DE9484, F4DE9684, F4DE9687

Fuel Temperature Sensor

FUELTEMPD

1

(1) Fuel Temperature Sensor This sensor has a variable resistor able to detect the fuel temperature to provide the engine control module an index of the fuel thermal status.

It is connected to the control module by pin 17C (Earth) and 34C (temperature signal).

The resistor to 20 °C (68 °F) = 2.5 k Ω.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Sensing system Water sensor - Overview F4CE9484, F4CE9684

FUELHEATERC

1

(1) Heater - (2) Water detecting sensor.

On the bottom of the fuel filter cartridge, there is a sensor (2) that detects the presence of water in the system. For the applications in cold climate conditions, a heater (1) may be interposed between the filter base and the filtering cartridge.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fuel line High pressure - Disconnect (B.20.A) 1.

Remove the gear (1) transmitting motion to the injection pump.

2.

Remove the adjustable gear that lies behind the primary drive gear.

TIMINGGEARCG

Next operation: Fuel injection pump Rotary injection pump - Install (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fuel injection pump Rotary injection pump - Remove (B.20.A) 1.

Install the adjustable gear that lies behind the primary drive gear.

2.

Install the gear (1) transmitting motion to the injection pump.

TIMINGGEARCG

Next operation: Fuel line High pressure - Connect (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Disassemble F4GE9484, F4GE9684

Prior operation: Fuel injection pump Rotary injection pump - Remove (B.20.A) NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been disconnected, and the accelerator cable shall also be disconnected.

1.

Remove the starter from the flywheel housing (1) and use tools 380000988 (2) and 380000732 (3) to rotate the flywheel.

FLYWHEELROTATEG

1

NOTE: In the case of pump replacement, the spare part shall be supplied preset. If the pump is to be disassembled and reassembled later on without being repaired, it will be necessary to preset the pump while it is still assembled to the engine and disassembled afterwards.

Finding TDC with the false injector 2.

Remove the rocker cover of the first cylinder.

3.

Remove the injector and place the tool (1) to set the number one cylinder to the TDC (top dead center) position at the end of the compression phase. Preload the gauge.

4.

This condition is obtained by rotating the engine shaft properly until you find the maximum value on the gauge and then checking that the intake and exhaust valves are both closed.

5.

Once TDC is obtained, lock the flywheel by means of tool 380000988.

TDCTOOLING

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2

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Finding TDC with the timing gear blocking pin 6.

Install the pin (1) in the housing on the rear cover.

7.

Turn the flywheel while pushing on the pin (1) until it blocks the gear (2) obtaining TDC of the number one cylinder.

8.

Check that the piston is in the compression phase by making sure the intake and exhaust valves are both closed.

9.

Loosen the side screw (1) that is used to lock the pump shaft and remove the spacer (2). The spacer must be kept. It is recommended to fix it to the pump with a wire or a clip.

10.

Tighten the screw (1) blocking rotation of the pump shaft.

11.

Remove the screws (1) that secure the plate (2) covering the pump drive gear.

12.

Loosen the nut (3) securing the gear to the pump shaft and remove the relating washer.

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TDCTOOLING2

3

LOCKINGSCREW

4

PUMPGEAR

5

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

13.

From the pump side, loosen the nuts (1) without removing them in order to move the pump backwards using the injection pump gear extractor.

14.

Assemble the extractor throughout the two threaded ports (2) and withdraw the gear from the pump shaft.

15.

Properly hold the pump and remove the nuts completely.

16.

Withdraw the pump from its mounting studs, together with the gasket.

NOTE: Hold the pump drive gear to avoid interference or crawling during timing gear rotation.

FEEDPUMP

6

ATTENTION: When the pump is to be installed, the engine must be at TDC of the compression phase on cylinder number one.

Next operation: Fuel injection pump Rotary injection pump - Assemble (B.20.A)

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Assemble F4GE9484, F4GE9684

Prior operation: Fuel injection pump Rotary injection pump - Disassemble (B.20.A) 1.

Assemble the pump in its housing on the engine, while fitting the gear onto the pump shaft.

2.

Tighten the nuts (1) securing the pump to the engine.

NOTE: The gasket removed during disassembly shall not be utilized again. Always use original spare parts.

3.

On the timing side, fit the washer and the fixing nut (3) on the pump shaft.

4.

Torque the nut to 90 - 95 Nm (66.4 - 70.1 lb ft).

5.

Install the plate (2) with new gasket and tighten screws (1).

6.

Loosen the screw (1) that prevents pump shaft rotation and insert spacer (2). By doing this the pump shaft will be able to rotate freely.

7.

Disassemble the flywheel rotation/locking tool 380000988 and install the starter motor.

8.

Connect all pipelines in the fuel system.

9.

Connect the electrical connections to electro-magnets on the hydraulic head and on the KSB.

FEEDPUMP2

1

PUMPGEAR

2

LOCKINGSCREW

3

NOTE: If the engine is installed in the application, connect the accelerator cable.

Next operation: Fuel injection pump Rotary injection pump - Timing adjust (B.20.A)

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Timing adjust F4GE9484, F4GE9684

Prior operation: Fuel injection pump Rotary injection pump - Assemble (B.20.A) 1.

With the injection pump mounted on the engine and the mounting nuts loose, install the dial gauge adapter for pump timing 380001601 (1) and the dial gauge 380000228 (2). Preload the rod by 2.5 mm (0.098 in).

2.

Rotate the engine crankshaft to obtain cylinder number one TDC at the end of the compression phase.

Reset the dial gauges and rotate the engine crankshaft in the opposite direction until obtaining cylinder number one TDC at the end of the compression phase again.

3.

From this position it is necessary to compare the value to the pumping element pre-lift specifications below.

•

4 Cylinder Engines = 0.73 - 0.77 mm (0.029 0.030 in).

•

6 Cylinder Engines = 0.73 - 0.77 mm (0.029 0.030 in).

Next operation: Fuel injection pump Rotary injection pump - Install (B.20.A)

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PUMPTIMING

1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Disassemble F4CE9484, F4CE9684

Prior operation: Fuel injection pump Rotary injection pump - Remove (B.20.A) NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been disconnected, and the accelerator cable shall also be disconnected.

1.

Loosen the screws (1) and remove the starter (2).

2.

Fit the bracket of the tool 380000988 (1) holding the flywheel provided with the rotation coil (2).

3.

Carefully rotate the flywheel in the direction of normal rotation to remove the slack in the gear.

4.

Rotate the flywheel until the pin (4) provide with the tool 380000988 engages in the notch of the flywheel (3).

STARTERC

1

FLYWHEELROTATEC

2

TDCTOOLING

3

Finding TDC with the false injector 5.

Remove the rocker cover of the first cylinder.

6.

Remove the injector and place the tool (1) to set the number one cylinder to the TDC (top dead center) position at the end of the compression phase. Preload the gauge.

7.

This condition is obtained by rotating the engine shaft properly until you find the maximum value on the gauge and then checking that the intake and exhaust valves are both closed.

8.

Once TDC is obtained, lock the flywheel by means of tool 380000988.

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9.

Disconnect the fuel pipes from the priming pump (1).

10.

Loosen the fastening screws (2) and remove the pump (1).

11.

12.

PRIMINGPUMPCG3

4

CAMNOTCH

5

PUMPLOCK

6

PUMPGEAR

7

Check through priming pump hole in the block, that camshaft (1) is in TDC at the compression phase by the visible notches (2) on the camshaft. If the notches are not visible, unlock the flywheel and rotate the engine 360 ° until the notches are visible.

Lock the flywheel.

Loosen the screw (2), remove the "L" spacer (1) and tighten the screw (2) to keep the pump timed with the engine flywheel. The spacer must be kept. It is recommended to fix it to the pump with a wire or a clip.

13.

Remove the screws (1) that secure the plate (2) covering the pump drive gear.

14.

Loosen the nut (3) securing the gear to the pump shaft and remove the relating washer.

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15.

Remove the three nuts (2), (3), and (5) fastening the pump (1) to the housing (4) and withdraw it from the housing.

FEEDPUMP3

Next operation: Fuel injection pump Rotary injection pump - Assemble (B.20.A)

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8

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Assemble F4CE9484, F4CE9684

Prior operation: Fuel injection pump Rotary injection pump - Disassemble (B.20.A) 1.

At the time of assembling the feed pump to the engine it is necessary to ensure that the number one cylinder is at TDC of the compression phase.

2.

Install the pump unit (1), preset, into the gearbox housing (2).

3.

Install the mounting nuts (3) without tightening them.

NOTE: The gasket removed during disassembly shall not be utilized again. Always use original spare parts.

4.

On the timing side, fit the washer and the fixing nut (3) on the pump shaft.

5.

Torque the nut to 90 - 95 Nm (66.4 - 70.1 lb ft).

6.

Install the plate (2) with new gasket and tighten screws (1).

7.

Loosen the screw (1) that prevents pump shaft rotation and insert spacer (2).

8.

Tighten the screw (1) so that it locks the spacer (2) in place. By doing this, the pump shaft will be able to rotate freely.

9.

Remove the flywheel rotation locking tool 380000988 and install the starter.

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FEEDPUMP4

1

PUMPGEAR

2

LOCKINGSCREW2

3

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

10.

Assemble the priming pump (1) to the engine block and tighten the fastening screws (2) to the specified torque.

11.

Connect all pipelines in the fuel system.

12.

Connect the electrical connections to electro-magnets on the hydraulic head and on the KSB.

NOTE: If the engine is installed in the application, connect the accelerator cable.

PRIMINGPUMPCG3

Next operation: Fuel injection pump Rotary injection pump - Timing adjust (B.20.A)

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4

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injection pump Rotary injection pump - Timing adjust F4CE9484, F4CE9684

Prior operation: Fuel injection pump Rotary injection pump - Assemble (B.20.A) 1.

With the injection pump mounted on the engine and the mounting nuts loose, install the dial gauge adapter for pump timing 380001601 (1) and the dial gauge 380000228 (2). Preload the rod by 2.5 mm (0.098 in).

2.

Rotate the engine crankshaft to obtain cylinder number one TDC at the end of the compression phase.

Reset the dial gauges and rotate the engine crankshaft in the opposite direction until obtaining cylinder number one TDC at the end of the compression phase again.

3.

From this position it is necessary to compare the value to the pumping element pre-lift specifications below.

•

4 Cylinder Engines = 0.73 - 0.77 mm (0.029 0.030 in).

•

6 Cylinder Engines = 0.73 - 0.77 mm (0.029 0.030 in).

Next operation: Fuel injection pump Rotary injection pump - Install (B.20.A)

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PUMPTIMING

1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel filter system - Remove Prior operation: Fuel line Low pressure - Disconnect (B.20.A) 1.

Using the tool disassemble the fuel filter (1) and remove it from the support (5).

2.

Disconnect the electrical connections (2) from the support (5) including the one for the fuel heater.

3.

Disconnect the fuel low pressure pipelines (3) from the support (5).

4.

Disconnect pipeline (4) from the support (5).

5.

Remove the sustaining support bracket (5) from the block.

4442596398GHDC

Next operation: Fuel filter system - Install (B.20.A)

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel filter system Fuel filter - Install 1.

Install the bracket and the base of the fuel filter.

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Fuel filter system - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel filter system - Remove (B.20.A) 1.

Assemble the bracket and support (1) of the fuel filter (6).

2.

Proceed connecting in sequence the pipelines (9) (3) (4) (5) of the support (1) to the high pressure pump (8).

3.

Connect the pipeline (7) from the high pressure pump to the common rail.

NOTE: Refer to Fuel connector - Connect (B.20.A) for the proper operation of the clamps on the low pressure fuel lines.

FUELSYSTEMD

Next operation: Fuel line Low pressure - Connect (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Fuel Manifold - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel line High pressure - Disconnect (B.20.A) NOTICE: Make sure the area around the fuel manifold is clean. Once they are removed, there is a greater risk of contaminating the internal components.

1.

Remove the nuts and remove the fuel manifolds.

NOTE: Disassembled fuel manifolds must not be used again. Replace them with new ones during reassembly.

FUELMANIFOLD

Next operation: Fuel injector Fuel Manifold - Install (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Fuel Manifold - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel injector Fuel Manifold - Remove (B.20.A) 1.

Fit a sealing ring (3) lubricated with petroleum jelly on the fuel manifold (2).

2.

Install the fuel manifold (2) into the cylinder head so that the positioning ball (5) is coinciding with the relevant housing (4).

NOTE: After removing fuel manifolds they cannot be used again. Replace them with new ones.

3.

Screw the fastening nuts on without tightening them.

NOTE: During this operation, the injector (1) can be moved so that the manifold (2)can be properly inserted into the inlet hole.

4.

FUELMANIFOLDDH

1

INJMANIFOLDDH

2

After everything is in place, tighten the fuel manifold nuts (2) to 50 Nm (37 lb ft).

NOTICE: Be sure to tighten the screws (1) securing the injector to the specified torque. Refer to Fuel injector Electro injector - Install (B.20.A) for the proper procedure.

Next operation: Fuel line High pressure - Connect (B.20.A)

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Electro injector - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel injector Fuel Manifold - Remove (B.20.A) 1.

Remove the bolts securing the injector to the cylinder head.

2.

Use tool 380001099 (1) to remove the injectors (2) from the cylinder head.

INJECTORREMOVE

Next operation: Fuel injector Electro injector - Install (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Electro injector - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel injector Electro injector - Remove (B.20.A) 1.

Put a new O-ring (2) and sealing washer (3) on the injector (1).

2.

Lubricate the O-ring (2) with petroleum jelly.

3.

4.

ELECTROINJECTOR

1

EINJECTORDH2

2

EINJECTORDH3

3

Install the injectors (1) into the cylinder head directed so the fuel inlet hole (2) is facing the fuel manifold seat (3).

Use tool 380001099 (3) to seat the injector (1) in place.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

5.

Insert the bolts (2) securing the injector (1) without tightening them.

NOTICE: You must install the fuel manifold before tightening the bolts securing the electro-injector. Refer to Fuel injector Fuel Manifold - Install (B.20.A).

6.

EINJECTORDH4

4

INJMANIFOLDDH

5

Use a torque wrench to tighten the injector screws (1) gradually and alternately to a torque of 7.7 - 9.3 Nm (68 - 82 lb in).

NOTICE: Be sure to torque the nut (2) securing the fuel manifold (3) after torquing the injector. Refer to Fuel injector Fuel Manifold - Install (B.20.A) for the proper procedure.

Next operation: Fuel injector Fuel Manifold - Install (B.20.A)

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Mechanical injector - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fuel line High pressure - Disconnect (B.20.A) 1.

Loosen the retaining nut (2) on the mechanical injector.

2.

Remove the injector and seal (1) from its seat in the cylinder head.

INJECTOR3

Next operation: Fuel injector Mechanical injector - Install (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel injector Mechanical injector - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fuel injector Mechanical injector - Remove (B.20.A) 1.

Install the injectors after having replaced the sealing gasket (1).

2.

Verify that the positioning ball is correctly aligned in the head housing.

MECHINJECTORCG

Next operation: Fuel line High pressure - Connect (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

High pressure common rail Pump head and housing - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel line High pressure - Disconnect (B.20.A) Prior operation: Fuel line Low pressure - Disconnect (B.20.A) 1.

Disconnect all fuel lines (4) on the high pressure pump (2).

2.

Remove the mounting nuts (1) and remove the high pressure pump (2) and feed pump (3) together as one unit.

HPPUMPDH

Next operation: High pressure common rail Pump head and housing - Install (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

High pressure common rail Pump head and housing - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: High pressure common rail Pump head and housing - Remove (B.20.A) Prior operation: Fuel line Low pressure - Connect (B.20.A) 1.

Slide the high pressure pump (4) including the feed pump (3) into place on the rear cover.

2.

Install the nuts (1) securing the pump to the rear cover and tighten to the specified torque.

3.

Hook up all fuel lines (4).

HPPUMPDH

Next operation: Fuel line High pressure - Connect (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

High pressure common rail Common rail - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fuel line High pressure - Disconnect (B.20.A) 1.

Install the high pressure fuel rail (2) on the cylinder head.

2.

Tighten the mounting screws (1) to the specified torque.

3.

Connect new fuel pipes (6) to the rail (2) and to the manifold for electro-injectors (5).

4.

Tighten the pipe joints (3) to 20 Nm (14.8 lb ft).

5.

Install the low pressure fuel line (4) to the rail (2).

Refer to Fuel connector - Connect (B.20.A) for the proper procedure.

RAIL

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Priming pump - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fuel line Low pressure - Disconnect (B.20.A) 1.

Loosen the two fixing screws (2) and disassemble the priming pump (1).

PRIMINGPUMPCG3

Next operation: Priming pump - Install (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Priming pump - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Priming pump - Remove (B.20.A) 1.

Assemble the priming pump (1) with a new gasket and tighten the screws (2) to the prescribed torque.

PRIMINGPUMPCG3

Next operation: Fuel line Low pressure - Connect (B.20.A)

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Connect F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

2.

Connect new fuel pipes (1) between high pressure rail (3) and fuel manifolds (2).

HPFUELCONNECT

1

HPFUELTORQUE

2

Pipe connection (1) should be torqued to 20 Nm (15 lb ft) using the proper wrench (4) and torque wrench (3).

Connections should be tighten by holding the flow limiting valve hexagon with the proper wrench.

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Connect F4HE9484, F4HE9684

1.

Connect the pipeline to the pressure limiter.

2.

Connect all the fuel lines between the fuel filter base and the high pressure pump.

3.

Connect the pipeline from the high pressure pump to the engine control module cooling plate.

4.

Connect the pipeline from the high pressure pump to high pressure common rail.

LPFUELCONNECT

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Disconnect F4DE9484, F4DE9684, F4DE9687

1.

Disconnect from the rail (1) the fuel pipe (3). Refer to Fuel connector - Disconnect Low Pressure (B.20.A). Disconnect the fuel pipes (5) from the rail (1) and injector manifolds (4).

2.

Remove the screws (2) and disconnect the rail (1).

COMMONRAILF4DE

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Disconnect F4HE9484, F4HE9684

1.

Disconnect the fuel pipe (4) from the cylinder head Fuel connector - Disconnect Low Pressure (B.20.A). Disconnect the fuel pipes (5) from the rail (2) and injector manifolds (6).

NOTICE: When releasing pipe (5) connections (6) to rail (2), use the proper wrench to avoid rotation of flow limiters (3).

2.

Remove the screws (1) and disconnect the rail (2).

COMMONRAILF4HE

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Disconnect F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

Disconnect the fuel return pressure limiter (1). Refer to Fuel connector - Disconnect (B.20.A).

RETURNLINEF4DEF

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Disconnect F4GE9484, F4GE9684

1.

Place a container under the fuel filter and screw out the condense drain faucet (5) underneath the filter.

Carry out complete drainage of the fuel contained in the filter.

2.

Remove the drain faucet (5) completely and by using the tool 380000670, remove the filter cartridge (2).

3.

Disconnect the fuel pipelines (4) and (3) respectively from priming pump to filter bearing and from the filter bearing to the feed pump. Refer to Fuel connector - Disconnect (B.20.A) for proper removal procedures.

4.

Remove the fuel filter base (1) from the engine cylinder head.

5.

Disconnect the LDA pipe (1) from the engine cylinder head and from the feed pump.

6.

Plug the ends of the pipelines as well as the feed pump and the cylinder head.

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LPFUELLINEG

1

LPFUELLINEG2

2

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Disconnect F4CE9484, F4CE9684

1.

Place a container under the fuel filter (1) and screw out the condense faucet underneath the filter (1).

Carry out complete drainage of the filter.

2.

Screw out completely the faucet and use tool 380000670 to remove the filter cartridge (1).

3.

Disconnect fuel pipelines (2) and (3) respectively from the priming pump to the fuel filter base and from the fuel filter base to the feed pump. Refer to Fuel connector - Disconnect (B.20.A) for proper removal procedures.

4.

Remove the filter base (4) from the engine cylinder head.

5.

Disconnect the LDA pipe (1) from the head and from the feed pump.

6.

Plug the ends of the pipelines as well as the feed pump and the engine cylinder head.

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LPFUELLINEC

1

LPFUELLINEC2

2

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Disconnect F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

Disconnect the pipelines that provide feed (1) and fuel recovery (2) between pump and injectors.

2.

Screw out the nuts fixing the pipes to the pumping elements.

3.

Loosen the fuel recovery pipe (2) collar on the injection pump (3).

4.

Operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery pipeline.

5.

Loosen the screws holding the mounting brackets pipelines (1), (6) and (7).

6.

After removal, plug the ends of the lines to reduce the risk of dirt contamination.

HPFUELLINEG

HPFUELOVERVIEW

2

(1) Rear bracket fixing screw (on suction selector plate) - (2) Fuel recovery pipeline to pump - (3) Rotary feed pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket fixing screw to injection pump side - (7) Front bracket fixing screw (on suction collector plate).

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

Assemble the fastening brackets of the fuel pipes.

2.

Assemble the pipes (1) and (2) providing fuel feed and recovery between the pump and the injectors.

3.

Tighten the locknuts and tighten the screws fixing the fuel recovery manifold.

4.

Assemble the pipes to the injectors and to the brackets securing them.

HPFUELLINEG

HPFUELOVERVIEW

2

(1) Rear bracket fixing screw (on suction selector plate) - (2) Fuel recovery pipeline to pump - (3) Rotary feed pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket fixing screw to injection pump side - (7) Front bracket fixing screw (on suction collector plate).

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1

POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Install F4CE9484, F4CE9684

1.

Assemble the fuel filter support (4) to the engine cylinder head.

2.

Connect the fuel pipelines (2) and (3) respectively from priming pump to filter support, and from the support to the feed pump.

3.

Install the fuel filter (1) using tool 380000670.

NOTE: The filter should be filled with fuel prior to assembly.

This will help facilitate fuel system bleeding.

4.

Connect the electrical connections for the water presence sensor and the fuel heater (If applicable).

LPFUELLINEC

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Install F4GE9484, F4GE9684

1.

Assemble the fuel filter support (1) to the engine cylinder head.

2.

Connect the fuel pipelines (4) and (3) respectively from the priming pump to the filter support and from the support to the fuel feed pump.

3.

Install the fuel filter (2) using tool 380000670.

LPFUELLINEG3

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Bleed F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

Disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the priming pump.

2.

Continue the operation until fuel flows out.

3.

Connect the (1) to the filter.

FUELBLEED

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel connector - Disconnect Low Pressure 1.

Hold down the clasp (1) and release the quick fitting joint.

80628

Next operation: Fuel connector - Connect (B.20.A)

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POWER PRODUCTION - FUEL AND INJECTION SYSTEM

Fuel connector - Connect Low Pressure Prior operation: Fuel connector - Disconnect (B.20.A) 1.

Connect low pressure lines to the fuel rail by inserting the rapid fitting joint into the connection joint and press until the clip (1) fastens securely.

2.

Check proper fuel connection.

80628

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Sensing system Air temperature-pressure sensor - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

Disconnect the wiring harness from the sensor.

2.

Remove the retaining bolt.

3.

Remove the sensor and O-ring.

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Index POWER PRODUCTION - B FUEL AND INJECTION SYSTEM - 20.A FUEL AND INJECTION SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4HE9484, F4HE9684

FUEL AND INJECTION SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4DE9684, F4DE9687

FUEL AND INJECTION SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9684, F4GE9684

FUEL AND INJECTION SYSTEM - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel connector - Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Fuel connector - Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Fuel filter system Fuel filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fuel filter system Water separator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel injection pump Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4GE9484, F4GE9684

Fuel injection pump Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 F4CE9484, F4CE9684

Fuel injection pump Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 F4GE9484, F4GE9684

Fuel injection pump Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 F4CE9484, F4CE9684

Fuel injection pump Rotary injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel injection pump Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9684

Fuel injection pump Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9684

Fuel injection pump Rotary injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel injection pump Rotary injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel injection pump Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4GE9484, F4GE9684

Fuel injection pump Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 F4CE9484, F4CE9684

Fuel injector Electro injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4HE9484, F4HE9684

Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4DE9484, F4DE9684, F4DE9687

Fuel injector Electro injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel injector Fuel Manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel injector Fuel Manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel injector Mechanical injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel injector Mechanical injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel line High pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel line High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 F4DE9484, F4DE9684, F4DE9687

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Fuel line High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 F4HE9484, F4HE9684

Fuel line High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel line High pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel line Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fuel line Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F4HE9484, F4HE9684

Fuel line Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fuel line Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 F4GE9484, F4GE9684

Fuel line Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 F4CE9484, F4CE9684

Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 F4CE9484, F4CE9684

Fuel line Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 F4GE9484, F4GE9684

Fuel transfer pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

High pressure common rail - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4HE9484, F4HE9684

High pressure common rail - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4DE9484, F4DE9684, F4DE9687

High pressure common rail - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

High pressure common rail Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

High pressure common rail Pump head and housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

High pressure common rail Pump head and housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

High pressure common rail Pump head and housing - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Regulator valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4HE9484, F4HE9684

Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4DE9684, F4DE9687

Sensing system Air temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Sensing system Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4HE9484, F4HE9684

Sensing system Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 F4DE9484, F4DE9684, F4DE9687

Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4HE9484, F4HE9684

Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F4DE9484, F4DE9684, F4DE9687

Sensing system Water sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 F4CE9484, F4CE9684

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POWER PRODUCTION - B AIR INTAKE SYSTEM - 30.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents POWER PRODUCTION - B AIR INTAKE SYSTEM - 30.A

FUNCTIONAL DATA AIR INTAKE SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE9684

Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4DE9684, F4DE9687

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Air intake manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4HE9484, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DE9484, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4DE9684, F4DE9687

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9684, F4GE9684

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POWER PRODUCTION - AIR INTAKE SYSTEM

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

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

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the drawn air is then cooled by the radiator and flown through the piston collector.

The turbocharger is equipped with a transforming valve to regulate the pressure. It is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s function is to restrict the exhaust of the emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed pressure.

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

BOOSTDIAGRAM

1

6 cylinder version

BOOSTDIAGRAM2

2

4 cylinder version

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Turbocharger Turbine - Remove F4HE9484, F4HE9684

1.

Remove the turbo oil supply line (3) from the oil filter base and from the pipe fitting (4) to the turbine.

2.

Remove the nuts securing the turbocharger (1) to the exhaust manifold (2)and remove it from its seat.

TURBOF4HE

Next operation: Turbocharger Turbine - Install (B.30.A)

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POWER PRODUCTION - AIR INTAKE SYSTEM

Turbocharger Turbine - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Turbocharger Turbine - Remove (B.30.A) 1.

With a suitable sling, place the turbocharger (1) on the exhaust manifold (2) with a new gasket.

2.

Tighten the mounting screws (3) to the specified torque.

TURBOF4DE

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POWER PRODUCTION - AIR INTAKE SYSTEM

Turbocharger - Remove F4DE9484, F4DE9684, F4DE9687

1.

Unscrew the fixing nuts (3) of the turbocharger (1) on the exhaust manifold (2).

TURBOF4DE

Next operation: Turbocharger - Install (B.30.A)

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POWER PRODUCTION - AIR INTAKE SYSTEM

Turbocharger - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

Loosen the fixing nut (1) and remove the oil supply line from the turbocharger.

2.

Loosen the fixing nut on the other end of the supply line to remove it from the the upper part of the heat exchanger.

3.

Remove the four mounting bolts (2) securing the turbo to the exhaust manifold.

4.

Lift the turbo from it’s seat and remove the mounting gasket.

TURBOCG

Next operation: Turbocharger - Install (B.30.A)

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1

POWER PRODUCTION - AIR INTAKE SYSTEM

Turbocharger - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Turbocharger - Remove (B.30.A) 1.

Install a new gasket for the turbocharger.

2.

Hold the turbocharger and place it on the exhaust manifold.

3.

Install the nuts and bolts (2) securing the turbo to the manifold and tighten them to the prescribed torque.

4.

Install the oil supply line (1) the to turbo. Tighten the opposite end of the line on the upper part of the oil filter support.

TURBOCG

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POWER PRODUCTION - AIR INTAKE SYSTEM

Air intake manifold - Remove F4HE9484, F4HE9684

1.

Loosen the retaining bolts (2) of the intake manifold (1) and disassemble the intake air heater (3) for the cold start aid.

INTAKEF4HE

Next operation: Air intake manifold - Install (B.30.A)

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1

POWER PRODUCTION - AIR INTAKE SYSTEM

Air intake manifold - Install F4HE9484, F4HE9684

Prior operation: Air intake manifold - Remove (B.30.A) 1.

Apply LOCTITE 5999to the mounting surface of the air intake heater (3) on the intake manifold (1).

2.

Install the heater (3) and tighten bolts.

3.

Assemble the manifold and fasten it to the cylinder head using screws (2).

INTAKEF4HE

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1

POWER PRODUCTION - AIR INTAKE SYSTEM

Air intake manifold - Remove F4DE9484, F4DE9684, F4DE9687

1.

Loosen the fixing screws (2) of the intake manifold (1) and disassemble the joint to the air heater for the cold start.

INTAKEF4DE

Next operation: Air intake manifold - Install (B.30.A)

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1

POWER PRODUCTION - AIR INTAKE SYSTEM

Air intake manifold - Install F4DE9484, F4DE9684, F4DE9687

Prior operation: Air intake manifold - Remove (B.30.A) 1.

Apply to the coupling surface of the intake manifold (1) equipped with heater a sufficient coat of LOCTITE 5999.

2.

Tighten the screws (2) to the prescribed torque.

INTAKEF4DE

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POWER PRODUCTION - AIR INTAKE SYSTEM

Air intake manifold - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

Loosen the screws (1) fixing the suction manifold plate (2) to the cylinder head.

2.

Remove the plate (2) and the relative gasket from the cylinder head.

AIRINTAKECG

Next operation: Air intake manifold - Install (B.30.A)

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1

POWER PRODUCTION - AIR INTAKE SYSTEM

Air intake manifold - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Air intake manifold - Remove (B.30.A) 1.

Apply a new gasket to the assembly surface of the intake manifold (2) plate and tighten the screws (1) to the prescribed torque.

2.

If the duct from the intake manifold has been disassembled, reassemble it after fitting the gaskets and heater (if applicable).

AIRINTAKECG

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1

Index POWER PRODUCTION - B AIR INTAKE SYSTEM - 30.A Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4HE9484, F4HE9684

Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4DE9684, F4DE9687

Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4HE9484, F4HE9684

Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DE9484, F4DE9684, F4DE9687

Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4GE9484, F4CE9684, F4GE9684

AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4DE9684, F4DE9687

Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Turbocharger Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE9684

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POWER PRODUCTION - B EXHAUST SYSTEM - 40.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents POWER PRODUCTION - B EXHAUST SYSTEM - 40.A

FUNCTIONAL DATA EXHAUST SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4GE9484, F4CE9684, F4GE9684

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POWER PRODUCTION - EXHAUST SYSTEM

EXHAUST SYSTEM - Overview Exhaust Gas Re-Circulation System (EGR) In the Tier 3 version, the profile of the exhaust cam has been modified in order to allow partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders.

The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitrogen oxides (NOx).

The exhaust gas recirculation system (EGR), reducing the combustion temperature by means of the diminishing of the concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission of NOx. The internal EGR system is not equipped with any electronically controlled elements: the system is always active. It’ configuration does not need additional elements. (i.e. checking valves, piping or heat exchangers.)

The exhaust cam (B) has another lobe apart from the major lobe (A-A) with respects to the configuration without EGR. The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the aspiration phase inside the cylinder.

BAIL07APH368GMA

1

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POWER PRODUCTION - EXHAUST SYSTEM

Exhaust manifold - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Turbocharger Turbine - Remove (B.30.A) 1.

Loosen the bolts (1) and remove the exhaust manifold (2) from the cylinder head.

BAIL06CCM055ASA

Next operation: Exhaust manifold - Install (B.40.A)

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1

POWER PRODUCTION - EXHAUST SYSTEM

Exhaust manifold - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Exhaust manifold - Remove (B.40.A) 1.

Connect the exhaust manifold (2) with new gasket.

Tighten the mounting bolts (1) to the specified torque.

EXHAUSTMANIFOLD

Next operation: Turbocharger Turbine - Install (B.30.A)

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1

POWER PRODUCTION - EXHAUST SYSTEM

Exhaust manifold - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Turbocharger - Remove (B.30.A) 1.

Loosen the fixing screws (2) from the exhaust manifold (1).

2.

Remove the exhaust manifold (1) and the relative gaskets from the cylinder head.

EXHAUSTCG

Next operation: Exhaust manifold - Install (B.40.A)

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1

POWER PRODUCTION - EXHAUST SYSTEM

Exhaust manifold - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Exhaust manifold - Remove (B.40.A) 1.

Assemble the exhaust manifold (1) with new gaskets (2) to the cylinder head.

NOTE: The illustration of the exhaust manifold may not match your model. However, the described procedure is applicable.

EXHAUSTCG2

Next operation: Turbocharger - Install (B.30.A)

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1

Index POWER PRODUCTION - B EXHAUST SYSTEM - 40.A Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4GE9484, F4CE9684, F4GE9684

EXHAUST SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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POWER PRODUCTION - B ENGINE COOLANT SYSTEM - 50.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents POWER PRODUCTION - B ENGINE COOLANT SYSTEM - 50.A

FUNCTIONAL DATA ENGINE COOLANT SYSTEM Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE9684

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9684

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9684

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HE9484, F4HE9684

Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4DE9684, F4DE9687

Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9684, F4GE9684

SERVICE Thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4CE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Water manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4DE9684, F4DE9687

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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4CE9484, F4DE9484, F4HE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4GE9484, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4CE9484, F4CE9684

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4CE9484, F4GE9484, F4CE9684, F4GE9684

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

ENGINE COOLANT SYSTEM - Dynamic description F4HE9484, F4HE9684

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

Expansion Tank - Placement, shape and dimension are subject to change according to the engine’s equipment.

•

Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid which is then ran through the radiator. Application determines placement and dimensions.

•

Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.

Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.

•

Heat Exchanger - Cools the lubrication oil. Also application specific.

•

Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.

•

Thermostat - regulates the circulation of the cooling liquid.

•

If applicable, the circuit may be extended to the compressor.

ZEIL06EN0105G0B

1

6 cylinder version 84250518 09/11/2009

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

ENGINE COOLANT SYSTEM - Dynamic description F4DE9484, F4DE9684, F4DE9687

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

Expansion Tank - Placement, shape and dimension are subject to change according to the engine’s equipment.

•

Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid which is then ran through the radiator. Application determines placement and dimensions.

•

Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.

Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.

•

Heat Exchanger - Cools the lubrication oil. Also application specific.

•

Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.

•

Thermostat - regulates the circulation of the cooling liquid.

•

If applicable, the circuit may be extended to the compressor.

BAIL07CCM266AMA

1

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

ENGINE COOLANT SYSTEM - Dynamic description F4GE9484, F4GE9684

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

Expansion Tank - Placement, shape and dimension are subject to change according to the engine’s equipment.

•

Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid which is then ran through the radiator. Application determines placement and dimensions.

•

Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.

Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.

•

Heat Exchanger - Cools the lubrication oil. Also application specific.

•

Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.

•

Thermostat - regulates the circulation of the cooling liquid.

•

If applicable, the circuit may be extended to the compressor.

COOLINGSYSTEMG

1

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

ENGINE COOLANT SYSTEM - Dynamic description F4CE9484, F4CE9684

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

Expansion Tank - Placement, shape and dimension are subject to change according to the engine’s equipment.

•

Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid which is then ran through the radiator. Application determines placement and dimensions.

•

Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.

Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.

•

Heat Exchanger - Cools the lubrication oil. Also application specific.

•

Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.

•

Thermostat - regulates the circulation of the cooling liquid.

•

If applicable, the circuit may be extended to the compressor.

COOLINGSYSTEMC

1

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Sensing system Coolant temperature - Overview F4HE9484, F4HE9684

COOLANTTEMP

1

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.

The sensor is connected to the control unit on pins 15C - 26C. The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

Reference

Description

ECU pin

1 2

Ground Temperature signal

15C 26C

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Sensing system Coolant temperature - Overview F4DE9484, F4DE9684, F4DE9687

COOLANTTEMP

1

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.

The sensor is connected to the control unit on pins 18C - 36C. The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

Reference

Description

ECU pin

1 2

Ground Temperature signal

18C 36C

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Sensing system Coolant temperature - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684

COOLANTTEMPCG

1

The coolant temp sensor is assembled to the engine head close to the thermostat unit and its duty is to detect engine coolant temperature.

Specifications: •

•

Range of working temperatures •

Connection side: -40 - +150 °C ( -40 - +302 °F) for less than 10 minutes.

•

Bulb side on engine: -40 - +140 °C ( -40 - +284 °F).

•

Working tensions: 6 - 28 V.

Settings: •

80 °C (176 °F) - 304 - 342 Ω.

•

20 °C (68 °F) - 2262 - 2760 Ω.

•

-10 °C (14 °F) - 8244 - 10661 Ω.

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Thermostat - Remove F4GE9484, F4GE9684

1.

Loosen the three screws (1) and disassemble the thermostat housing (2) together with the bracket (3) and the thick rubber seal (4).

2.

Remove the gasket (6) and the thermostat (5).

3.

Assemble the bracket (3) in the original position, fixing it with the screws (1) of the thermostat housing.

86082982

Next operation: Thermostat - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Thermostat - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Thermostat - Remove (B.50.A) 1.

Assemble the thermostat housing (2) including the thermostat (5) and gasket (6).

2.

Install the thick rubber seal (4) inside the bracket (3) and the thermostat housing (2).

3.

Tighten the screws (1) to the prescribed torque.

NOTE: The bracket (3) may not be available on some applications. Always replace the gasket with new upon reassembly.

86082982

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Thermostat - Remove F4CE9484, F4CE9684

1.

Loosen the three screws securing the thermostat housing (2) to the cylinder head.

2.

Remove the housing (2), the thick rubber seal (3), the thermostat (4) and relevant seal (1) from the cylinder head.

86082980

Next operation: Thermostat - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Thermostat - Install F4CE9484, F4CE9684

Prior operation: Thermostat - Remove (B.50.A) 1.

Install the thermostat (2) with the appropriate seal (1).

2.

Install the housing (2) and the thick rubber seal (3) using the screws to secure it to the cylinder head.

86082980

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Thermostat - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

Remove the three screws securing the thermostat housing (1) to the top of the cylinder head.

2.

Remove the thermostat (2) and the seal (3) from the housing (1).

86082981

Next operation: Thermostat - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Thermostat - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Thermostat - Remove (B.50.A) 1.

Install the seal (3) around the flange of the thermostat (2).

2.

Install the thermostat (2) into the housing (1) and secure the assembly to the cylinder head using the three mounting screws.

86082981

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Water pump - Remove Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the retaining bolts and withdrawal the water pump.

BVE0294A

Next operation: Water pump - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Water pump - Install Prior operation: Water pump - Remove (B.50.A) 1.

2.

3.

Apply a new sealing ring (2) on the water pump (1).

BACD04APH220ASA

1

ZEIL06CS0245A0B

2

BACD04APH070ASA

3

Install the water pump (1) into the engine block (2) using the two mounting bolts (3).

Tighten the water pump (1) mounting bolts (2) to the specified torque.

Next operation: Fan and drive Belt - Install (B.50.A)

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Water manifold - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Alternator - Remove (A.30.A) 1.

Remove the screws (2) and disconnect the water manifold (1).

WATERMANIFOLDH

Next operation: Water manifold - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Water manifold - Install F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Water manifold - Remove (B.50.A) 1.

Position the water manifold/alternator support (1) so that the pins (3) and (4) are set against the engine block.

2.

Tighten the mounting bolts (2) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

WATERMANIFOLDH2

Next operation: Alternator - Install (A.30.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Water manifold - Remove F4DE9484, F4DE9684, F4DE9687

Prior operation: Alternator - Remove (A.30.A) 1.

Remove the screws securing the water manifold.

2.

Disconnect the water manifold from the block.

WATERMANIFOLDD2

Next operation: Water manifold - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Water manifold - Install F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Water manifold - Remove (B.50.A) 1.

Install the water manifold (1) onto the block.

2.

Tighten the mounting screws (2) to the specified torque.

WATERMANIFOLDD2

Next operation: Alternator - Install (A.30.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Belt - Remove F4CE9484, F4DE9484, F4HE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684

1.

Release tension on the belt (1) by pulling back on the belt tensioner (2).

2.

Extract the belt (1) from all the pulleys.

BELT

Next operation: Fan and drive Belt - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Belt - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fan and drive Belt - Install (B.50.A) 1.

Turn the belt tensioner and fit the belt on the pulleys.

66070776

1

Belt Configuration (1) - Crankshaft (2) - Fixed Idler Pulley

(3) - Fan (4) - Water Pump

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(5) - Alternator (6) - Tensioner

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Belt tensioner - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the bolt from the center of the belt tensioner and remove the tensioner.

Next operation: Fan and drive Belt tensioner - Install (B.50.A)

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Belt tensioner - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fan and drive Belt tensioner - Remove (B.50.A) 1.

Install the belt tensioner. Tighten the mounting bolt to the specified torque.

Next operation: Fan and drive Belt - Install (B.50.A)

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Idler pulley - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Remove the retaining bolt from the center of the idler pulley.

2.

Remove the idler pulley.

Next operation: Fan and drive Belt - Install (B.50.A)

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Idler pulley - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fan and drive Idler pulley - Remove (B.50.A) 1.

Install the idler pulley and tighten the retaining bolt in the center to the specified torque.

Next operation: Fan and drive Belt - Install (B.50.A)

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive - Remove Support - Remove Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Loosen the fastening screws (3) and remove the pulley controlling the fan (2).

2.

Proceed detaching the support (1).

FANDRIVEC

Next operation: Fan and drive - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive - Install Support - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Prior operation: Fan and drive - Remove (B.50.A) 1.

Re-attach the support, tightening the screws to the prescribed torque.

Next operation: Fan and drive Belt - Install (B.50.A)

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POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Belt - Remove F4CE9484, F4GE9484, F4CE9684, F4GE9684

1.

Loosen the screw (1) and the relevant nut on the alternator bracket (3).

2.

Loosen the screw on the bottom side of the alternator in order to slide out the POLY-V belt (2).

ALTBELTG

Next operation: Fan and drive Belt - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive - Remove -Drive Pulley F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Loosen the screws (1) and disassemble the pulley (2) from the crankshaft.

DRIVEPULLEYCG

Next operation: Fan and drive - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive - Install -Drive Pulley F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fan and drive - Remove (B.50.A) 1.

Fit the pulley (2) on the crankshaft and tighten the screws (1) to the prescribed torque.

DRIVEPULLEYCG

Next operation: Fan and drive Belt - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive - Install F4GE9484, F4GE9684

Prior operation: Fan and drive - Remove (B.50.A) 1.

Assemble the fan pulley support and tighten the screws to the prescribed couple.

2.

Assemble the alternator tensioning bracket.

3.

Mount the fan pulley (3) and secure it to the support using screws (2).

4.

Assemble the idler pulley (1).

5.

Fit the new belt onto the pulleys and guide rollers.

NOTE: If the old belt is to be reused, examine it carefully in order to see if there may be any incisions or evident signs of yielding.

PULLEYSG

Next operation: Fan and drive Belt - Install (B.50.A)

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1

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive - Install F4CE9484, F4CE9684

Prior operation: Fan and drive - Remove (B.50.A) 1.

Assemble the support (1) of the fan pulley using screws (2).

2.

Tighten the screws (2) to the prescribe torque.

3.

Assemble the fan pulley (2) to the support (1) throughout the screws (3) tightening them to the prescribed torque.

4.

Assemble the idler pulley (4).

5.

Assemble the support (3) of the automatic tensioner by fastening the relevant screws.

6.

Tighten the fastening screw (1) and assemble the automatic tensioner (2).

Next operation: Fan and drive Belt - Install (B.50.A) 84250518 09/11/2009

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FANSUPPORTC

1

FANSUPPORTC2

2

BELTTENSIONERC

3

POWER PRODUCTION - ENGINE COOLANT SYSTEM

Fan and drive Belt - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684

Prior operation: Fan and drive Belt - Remove (B.50.A) 1.

Assemble the Poli-V belt (4) on the drive pulley, water pump (5), alternator (1), fan pulley (2) and on the idler pulley (3).

2.

Insert a square drive ratchet into the relative hole on the belt tensioner.

3.

Pull on the tensioner (6) and slide the belt (4) into place.

NOTE: In case the old belt is to be reused, examine it carefully first in order to detect any incision or evidence of stress.

BELTCG

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1

Index POWER PRODUCTION - B ENGINE COOLANT SYSTEM - 50.A ENGINE COOLANT SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE9684

ENGINE COOLANT SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687

ENGINE COOLANT SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9684

ENGINE COOLANT SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9684

Fan and drive - Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4GE9484, F4GE9684

Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4CE9484, F4CE9684

Fan and drive - Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fan and drive - Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fan and drive - Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4CE9484, F4DE9484, F4HE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684

Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Fan and drive Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fan and drive Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Fan and drive Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HE9484, F4HE9684

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4DE9684, F4DE9687

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4CE9684

Thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9684

Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4CE9684

Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4DE9684, F4DE9687

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Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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POWER PRODUCTION - B LUBRICATION SYSTEM - 60.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents POWER PRODUCTION - B LUBRICATION SYSTEM - 60.A

FUNCTIONAL DATA LUBRICATION SYSTEM Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE9684

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9684

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9684

Blowby re-circulation system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HE9484, F4HE9684

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4HE9484, F4HE9684

Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DE9484, F4DE9684, F4DE9687

Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4GE9484, F4CE9684, F4GE9684

SERVICE Oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Oil pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HE9484, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4DE9484, F4DE9684, F4DE9687

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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4GE9484, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4GE9484, F4GE9684

Oil filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Blowby re-circulation system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4HE9484, F4HE9684

Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Oil cooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Oil line Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4HE9484, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 F4GE9484, F4GE9684

Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F4HE9484, F4HE9684

Oil temperature-pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4DE9484, F4DE9684, F4DE9687

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POWER PRODUCTION - LUBRICATION SYSTEM

LUBRICATION SYSTEM - Exploded view F4HE9484, F4HE9684

Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the crankshaft, camshaft and to the valve drive.

4C0O200406CRIL0

1

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POWER PRODUCTION - LUBRICATION SYSTEM

LUBRICATION SYSTEM - Exploded view F4DE9484, F4DE9684, F4DE9687

Lubrication by forced circulation is achieved through oil pump, placed in the front part of the basement. From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive. Lubrication involves the heat exchanger as well, the turbo blower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.

80733

1

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POWER PRODUCTION - LUBRICATION SYSTEM

LUBRICATION SYSTEM - Exploded view F4GE9484, F4GE9684

Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the crankshaft, camshaft and to the valve drive.

LUBEVIEWG

1

LUBRICATION SYSTEM LAYOUT (4 cylinder engine)

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POWER PRODUCTION - LUBRICATION SYSTEM

LUBRICATION SYSTEM - Exploded view F4CE9484, F4CE9684

Lubrication by forced circulation is achieved through oil pump, placed in the front part of the basement. From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive. Lubrication involves the heat exchanger as well, the turbo blower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.

LUBEVIEWC

1

LUBRICATION SYSTEM LAYOUT (6 cylinder engines)

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POWER PRODUCTION - LUBRICATION SYSTEM

Blowby re-circulation system - Dynamic description F4HE9484, F4HE9684

Version with blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual vapors are removed by piping and filtered by the blow-by filter. In the blow-by filter, part of the vapors condense and return to the oil sump. The remaining vapors are put back into circulation.

Version without blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual vapors are conveyed, collected and discharged into the open air through a bleeder.

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POWER PRODUCTION - LUBRICATION SYSTEM

Blowby re-circulation system - Dynamic description F4CE9484, F4GE9484, F4CE9684, F4GE9684

On the valve cover (3) there is a valve (1) whose duty is to condense oil vapor inducing the oil to fall back down to the valve cover because of gravity.

The remaining non-condensed vapors shall be properly conveyed through the breather pipe (2).

BLOWBYSYSTEMCG

1

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POWER PRODUCTION - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Overview F4HE9484, F4HE9684

OILPRESSTEMP

1

This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.

The sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 24C - 28C for temperature and 32C- 27C for pressure.

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.

Reference

Description

ECU pin

1 2 3 4

Ground NTC signal (temperature) +5 V power input Signal (pressure)

24C 28C 32C 27C

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POWER PRODUCTION - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Overview F4DE9484, F4DE9684, F4DE9687

OILPRESSTEMP

1

This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.

The sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 19C - 33C for temperature and 9C- 35C for pressure.

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.

Reference

Description

ECU pin

1 2 3 4

Ground NTC signal (temperature) +5 V power input Signal (pressure)

19C 33C 9C 35C

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POWER PRODUCTION - LUBRICATION SYSTEM

Sensing system Oil pressure - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684

OILPRESSCG

1

The sensor is located on the engine block on the left hand side.

Specifications: •

Working tensions: •

•

Contact closure upon lower pressure: •

•

12 - 24 V. 0.2 bar (2.9 psi).

Contact opening upon higher pressure: •

0.9 bar (13.1 psi).

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil pump Gear driven - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Front cover - Remove (B.10.A) 1.

Remove the retaining bolts (1) and disconnect the oil pump (2) from the engine block.

OILPUMPH

Next operation: Oil pump Gear driven - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil pump Gear driven - Install F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Oil pump Gear driven - Remove (B.60.A) 1.

Install the oil pump (1) into the engine block.

2.

Tighten the bolts (2) to the specified torque.

OILPUMPH2

Next operation: Front cover - Install (B.10.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil pump - Remove F4DE9484, F4DE9684, F4DE9687

Prior operation: Vibration damper - Remove (B.10.A) 1.

Please refer to Front cover - Remove (B.10.A) for oil pump removal instructions.

Next operation: Oil pump - Install (B.60.A)

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil pump - Install F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Oil pump - Remove (B.60.A) 1.

2.

Position the front cover seal (1) on the engine block.

FRONTCOVERD4

1

FRONTCOVERD5

2

Install the front cover (1) on the block and tighten the screws (2) to the prescribed torque.

Next operation: Vibration damper - Install (B.10.A)

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil pan - Remove F4HE9484, F4HE9684

1.

Remove the bolts (2) surrounding the oil sump (1).

2.

Remove the plate (2).

3.

Disconnect the oil sump (1) from the engine block.

NOTE: The shape and dimensions of the oil pan and of the suction tube may vary according to the application of the engine. However, the procedures described are still applicable.

4.

OILPANH

1

OILPICKUPTUBEH

2

Remove the screws (4) and (1) and disassemble the oil suction tube (5). Remove the screws (2) and disassemble the stiffening plate (3).

Next operation: Oil pan - Install (B.60.A)

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil pan - Install F4HE9484, F4HE9684

Prior operation: Oil pan - Remove (B.60.A) 1.

2.

Fit the plate (3), the oil pick up tube (5) and tighten the fastening screws (1), (2) and (4) to the specified torque.

OILPICKUPTUBEH

1

OILPANH2

2

OILPANH

3

Set the gasket on the oil sump.

NOTE: The pictures of the instructions relating to the oil pan and to the suction pipe may not reflect the actual shape and dimensions of your engine equipment. However, the procedures described are still applicable.

3.

Fit the oil sump (1) on the engine block and apply the mounting plate (3). Tighten the bolts (2) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil pan - Remove F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

1.

Remove the screws (2) and disconnect the oil sump (1).

OILPAND

Next operation: Oil pan - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil pan - Install F4DE9484, F4DE9684, F4DE9687

Prior operation: Oil pan - Remove (B.60.A) 1.

Install the oil pan (1) on the engine block.

2.

Fit the screws (2) and tighten them to the prescribed torque.

NOTE: Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

OILPAND

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil pan - Remove F4GE9484, F4GE9684

1.

Turn the engine upside down.

2.

Loosen the screws (2) disassemble the plate (3) remove the oil pan.

NOTE: The shape and dimensions of the pan and of the rose pipe may vary according to the engine application.

The relating illustrations provide general guidelines of the operation to be performed.

OILPANG

1

OILPICKUPTUBEG

2

Version with suction rose type A 3.

Loosen the screws (1) and disassemble the oil suction rose pipe (3).

4.

Loosen the screws (2) and remove the stiffening plate (4).

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POWER PRODUCTION - LUBRICATION SYSTEM

Version with suction rose type B 5.

Remove the screws (1) and (4) and disassemble the suction rose (5).

6.

Remove the screws (2) and disassemble the stiffening plate (3).

OILPICKUPTUBEG2

3

DYNAMICBALANCER

4

Version with additional masses 7.

Remove the screws (1) and withdraw the oil pickup tube.

8.

By means of pin (2) lock the dynamic balancer (3) in the TDC (Top Dead Center) position.

9.

Loosen the fixing screws (4) and remove the dynamic balancer (3).

Next operation: Oil pan - Install (B.60.A)

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil pan - Install F4GE9484, F4GE9684

Prior operation: Oil pan - Remove (B.60.A)

Version with suction rose A 1.

Assemble the plate (1), and the rose pipe (2).

2.

Tighten the fixing screws (3) and tighten them to the prescribed torque.

OILPICKUPTUBEG3

1

OILPICKUPTUBEG4

2

Version with suction rose B 3.

Assemble the fixing plate (3), the suction rose (5) and tighten the fixing screws (1), (2), and (4) to the prescribed torque.

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POWER PRODUCTION - LUBRICATION SYSTEM

Version with additional masses 4.

Fit the additional masses (2) and tighten the screws (3) on the engine block.

5.

Remove the lock pin (1) of the additional masses.

6.

Refer to Balancer - Install (B.10.A) for proper timing procedures.

7.

DYNAMICBALANCEG

3

OILPANH2

4

OILPANG

5

Set the gasket (1) on the oil sump (2).

NOTE: The pictures of the instructions relating to the oil pan and to the suction pipe may not reflect the actual shape and dimensions of your engine equipment. However, the procedures described are still applicable.

8.

Fit the oil sump (1) on the engine block and apply the mounting plate (3). Tighten the bolts (2) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil filter - Remove 1.

Use the tool 380000670 to remove the oil filter.

OILFILTERF4HE

Next operation: Oil filter - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil filter - Install F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Oil filter - Remove (B.60.A) 1.

Lubricate the oil filter O-ring (2) with clean engine oil.

2.

Screw the filter (3) onto the base (1) until contact is made with sealing surface.

3.

Tighten the oil filter an additional 3/4 of a turn.

4.

Apply a new sealing ring on the oil temperature/pressure sensor (4).

5.

Install the sensor (4) onto the filter base (1) and tighten the screws (5) to the specified torque.

OILFILTERH2

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil filter - Remove F4DE9484, F4DE9684, F4DE9687

1.

Use tool 380000670 to remove the oil filter (1).

NOTE: The oil filter is equipped with an internal check valve to minimize the amount oil loss when removing the filter.

OILFILTERF4DE

Next operation: Oil filter - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil filter - Install F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Oil filter - Remove (B.60.A) 1.

Lubricate the oil filter O-ring (2) with clean engine oil.

2.

Screw the filter (1) onto the base (3) until contact is made with sealing surface.

3.

Tighten the oil filter an additional 3/4 of a turn.

OILFILTERD2

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Blowby re-circulation system - Remove F4HE9484, F4HE9684

1.

Loosen the clamp (1)holding the blow-by tube and remove the pipe.

2.

Remove the screws (2)and remove the blow-by filter, if applicable.

86070784_RESIZE

Next operation: Blowby re-circulation system - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Blowby re-circulation system - Install F4HE9484, F4HE9684

Prior operation: Blowby re-circulation system - Remove (B.60.A) 1.

2.

3.

Insert the blow-by filter (1) and tighten the bolts (2).

86070785_RESIZE

1

86070784_RESIZE

2

86070784_RESIZE

3

Install the cover (1) on the blow-by filter housing (2) and tighten the mounting screws (3).

Connect the pipelines (1) and fix the oil vapor pipes with the clamps (2).

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POWER PRODUCTION - LUBRICATION SYSTEM

Piston lubrication Spray nozzle - Remove 1.

Remove the main half bearing (1) to avoid damaging them.

2.

Remove the screws (2) and remove the oil nozzles (3).

BACD04APH046ASA

Next operation: Piston lubrication Spray nozzle - Install (B.60.A)

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POWER PRODUCTION - LUBRICATION SYSTEM

Piston lubrication Spray nozzle - Install Prior operation: Piston lubrication Spray nozzle - Remove (B.60.A) 1.

Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.

CRIL04J066A01

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil cooler - Remove F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Oil filter - Remove (B.60.A) 1.

Unscrew the mounting bolts (1).

2.

Remove the oil filter base (2)oil cooler (3), and all gaskets.

OILCOOLERH

Next operation: Oil cooler - Install (B.60.A)

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil cooler - Install F4GE9484, F4HE9484, F4GE9684, F4HE9684

Prior operation: Oil cooler - Remove (B.60.A) 1.

Place a new gasket (1) on the engine block.

2.

Install the oil cooler (2).

3.

Place a new gasket (3) on the oil cooler.

4.

Install the oil filter base (4).

5.

Tighten the mounting bolts (5) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt

OILCOOLERH2

Next operation: Oil filter - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil cooler - Remove F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Oil filter - Remove (B.60.A) 1.

Unscrew the screws (5) that secure the oil filter base (4) to the block.

2.

Remove the base (4) and the oil cooler (2).

NOTE: Be sure to remove all the relevant gaskets and seals (1) and (3).

OILCOOLERD2

Next operation: Oil cooler - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil cooler - Install F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Prior operation: Oil cooler - Remove (B.60.A) 1.

Place a new gasket (1) on the engine block.

2.

Install the oil cooler (2).

3.

Place a new gasket (3) on the oil cooler.

4.

Install the oil filter base (4).

5.

Tighten the mounting bolts (5) to the specified torque.

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt

OILCOOLERD2

Next operation: Oil filter - Install (B.60.A)

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Oil line - Install F4HE9484, F4HE9684

Oil Fill Tube 1.

Install a new O-ring on the oil fill tube (1).

2.

Attach the oil fill tube (1) to the engine block using the three M12x25 bolts.

OILFILLH2

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POWER PRODUCTION - LUBRICATION SYSTEM

Oil line - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Turbo oil lines 1.

Connect the oil supply line (2) between the turbine (1) and the oil filter base.

2.

Install the oil drain pipe (1) onto the turbo and tighten the fixing screws.

3.

Connect the pipe to the block (2) also.

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OILLINEDH

1

OILLINEDH2

2

POWER PRODUCTION - LUBRICATION SYSTEM

Oil line - Install F4GE9484, F4GE9684

1.

Install the oil drain pipe (1) on the turbo by inserting the one end into the block joint (2).

2.

Install and tighten the two screws (3) underneath the turbo securing the drain pipe.

3.

Install the retaining brackets (4) and (5) which hold the piping to the block.

OILLINEG

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Remove F4HE9484, F4HE9684

1.

Disconnect the wiring harness from the sensor.

OILPRESSTEMPH

2.

Remove the mounting screws and remove the sensor and O-ring from the oil filter base.

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1

POWER PRODUCTION - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

1.

Install a new O-ring on the oil temperature/pressure sensor.

2.

Install the sensor on the oil filter base and tighten the mounting bolts to the specified torque.

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POWER PRODUCTION - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Remove F4DE9484, F4DE9684, F4DE9687

1.

Disconnect the electrical connector (1) from the oil temperature pressure sensor (3).

2.

Unscrew the screws (2) securing the sensor to the oil filter base (4) and remove it from its seat.

OILPRESSTEMPD

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1

Index POWER PRODUCTION - B LUBRICATION SYSTEM - 60.A Blowby re-circulation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HE9484, F4HE9684

Blowby re-circulation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Blowby re-circulation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4HE9484, F4HE9684

Blowby re-circulation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4HE9484, F4HE9684

LUBRICATION SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE9684

LUBRICATION SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687

LUBRICATION SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9684

LUBRICATION SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9684

Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4DE9684, F4DE9687

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4HE9484, F4HE9684

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 F4GE9484, F4GE9684

Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HE9484, F4HE9684

Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4DE9484, F4DE9684, F4DE9687

Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4GE9484, F4GE9684

Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4HE9484, F4HE9684

Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4GE9484, F4GE9684

Oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4DE9484, F4CE9684, F4DE9684, F4DE9687

Oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4DE9684, F4DE9687

Oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9484, F4HE9484, F4GE9684, F4HE9684

Piston lubrication Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Sensing system Oil pressure - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4GE9484, F4CE9684, F4GE9684 84250518 09/11/2009

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Sensing system Oil temperature-pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4HE9484, F4HE9684

Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DE9484, F4DE9684, F4DE9687

Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F4HE9484, F4HE9684

Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4DE9484, F4DE9684, F4DE9687

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POWER PRODUCTION - B STARTING SYSTEM - 80.A

F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684

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Contents POWER PRODUCTION - B STARTING SYSTEM - 80.A

FUNCTIONAL DATA Cold start aid Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4GE9484, F4CE9684, F4GE9684

SERVICE Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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POWER PRODUCTION - STARTING SYSTEM

Cold start aid Grid heater - Overview F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

GRIDHEATER

1

The pre-post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post heating operations. The resistance is powered by a contactor.

The resistance impedance is approximately 0.5 Ω.

The control contactor is connected to the control unit (B) connector.

The contactor is tripped with water and/or fuel temperature below 5 °C (41 °F).

The contactor impedance is approximately 15 Ω.

WARNING This engine is equipped with an intake air (grid) heater. DO NOT use starting fluid on this engine. Use of starting fluid can cause explosion, personal injury or property damage. Failure to comply could result in death or serious injury.

M836

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POWER PRODUCTION - STARTING SYSTEM

Cold start aid Grid heater - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684

HEATRESISTORCG

1

It is a resistor assembled to the intake manifold and is utilized to heat the air during pre-post heating operations. It is fed by a tele-switch usually placed very close to the engine.

Specifications: •

Working voltage: •

•

12 V.

Maximum possible air flow: •

0.034 cm³/sec at a pressure of 138 kPa (20 psi).

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POWER PRODUCTION - STARTING SYSTEM

Sensing system Temperature sensor - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684

Electrical Cold-start Accelerator (KKSB)

1

ELECTROMAGNETCG

(1) Hydraulic head electro-magnet - (2) KKSB electro-magnet.

The KKSB is located on the fuel injection pump. During engine start-up, the KKSB advances the injection pump timing to reduce white smoke and emissions until the cylinders warm to normal operating temperature. By shifting the start of injection in the advanced direction, the KKSB improves the cold-start characteristics of the emissionized engine.

Operation is triggered automatically by means of a temperature sensitive thermostatic switch, which is located in the cylinder head on the engine’s left hand side.

KKSBSENSORCG

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Specifications: •

Working tensions: •

•

12 - 24 V.

Electrical Power load: •

2.5 A (induction) 84250518 09/11/2009

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POWER PRODUCTION - STARTING SYSTEM

• •

5.0 A (resistance)

Settings: •

60 - 66 °C (140 - 151 °F) Contact opening upon increasing temperature.

•

50 - 56 °C (122 - 133 °F) Contact closure upon decreasing temperature.

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POWER PRODUCTION - STARTING SYSTEM

Engine starter - Remove 1.

Disconnect the starter cables from the solenoid and the starter body (2).

2.

Remove the three mounting bolts (3) securing the starter (2) to the flywheel housing (1). Withdraw the starter (2).

STARTERDH

Next operation: Engine starter - Install (B.80.A)

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1

POWER PRODUCTION - STARTING SYSTEM

Engine starter - Install Prior operation: Engine starter - Remove (B.80.A) 1.

Install the starter (2) on the flywheel housing (1) using the three mounting bolts (3).

NOTE: Before any assembly operation verify that the hole and bolt threads have no evidence of wear or dirt.

STARTERDH

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Index POWER PRODUCTION - B STARTING SYSTEM - 80.A Cold start aid Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684

Cold start aid Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4CE9484, F4GE9484, F4CE9684, F4GE9684

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4GE9484, F4CE9684, F4GE9684

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CNH AMERICA LLC Racine, WI 53404 U.S.A.

Printed in U.S.A.