Case F4GE9454H F4GE9454J F4GE9484D F4HE9484A F4HE9484C Backhoe Loader Engine Repair Manual - PDF DOW

ENGINE REPAIR MANUAL BACKHOE LOADER

F4GE9454H F4GE9454J F4GE9484D F4HE9484A F4HE9484C

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01Aug07 Printed in U.S.A. • Book/Form Number 87630273 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer This unit first became available 08-2007 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01Aug07

F4GE9454H, F4GE9454J, F4GE9484D, F4HE9484A, F4HE9484C

87630273 NA

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

ENGINE REPAIR MANUAL

ENGINE REPAIR MANUAL TABLE OF CONTENTS CHAPTER 1

DIAGNOSTICS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CHAPTER 2

445TA ENGINE OVERHAUL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 F4HE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 TORQUE SPECIFICATIONS (F4GE) - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 TORQUE SPECIFICATIONS (F4HE) - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 F4HE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 COUNTER BALANCER - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ENGINE LUBRICATION - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 ENGINE LUBRICATION - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 MECHANICAL INJECTION FEEDING SYSTEM - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . 2-54 KKSB COLD START ADVANCE SYSTEM - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION - F4GE ENGINES . . . . . . . . . . . . . 2-56 HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL) - F4HE ENGINES . . . . . . . . . . . . . . . 2-59 EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 FUEL SUPPLY SYSTEM - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 SPECIAL DISASSEMBLY - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 SPECIAL DISASSEMBLY - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . 2-97 CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 INJECTION PUMP TIMING FIRST PHASE - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 ASSEMBLING COUNTER BALANCER - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131 MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137 87519803 NA

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I

SECTION 1 - ENGINE REPAIR MANUAL

INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD ASSEMBLY - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-138 2-138 2-141 2-144 2-145 2-147 2-149 2-150 2-153 2-153 2-154 2-157 2-158 2-158 2-159

CHAPTER 3

ELECTRICAL, CHARGING AND START-UP TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 LOCATION OF MAIN ELECTRICAL COMPONENTS - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 LOCATION OF MAIN ELECTRICAL COMPONENTS - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

II

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87519803 NA

ENGINE REPAIR MANUAL

CHAPTER 1

445TA TIER III

DIAGNOSTICS

Issued 08-2007 Book/Form Number 87630273 NA Copyright © 2007. CNH America LLC. All Rights Reserved.

Printed in U.S.A. • Bur Source Code No. unknown

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer Revision History Issue First Edition

1-II

Issue Date

Applicable Machines

Remarks

08-2007

F4GE9454H, F4GE9454J, F4GE9484D, F4HE9484A, F4HE9484C

87630273 NA

Issued 04-07

Bur

87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 1

DIAGNOSTICS TABLE OF CONTENTS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Engine Won’t Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Engine Lacks Power and Runs Erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Engine lacks power and runs erratically (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Engine Exhaust Smoke Black or Dark Grey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Engine exhaust smoke black or dark grey (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine Exhaust Smoke Grey (Verging On White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine Exhaust Smoke Light Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine Knocks Irregularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Engine Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Engine Exceeds Max. Revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Engine Won’t Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS

NOTES

1-2

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87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS

TROUBLESHOOTING ENGINE WON’T START No

Batteries fully charged.

Perform the checks described in the electrical section of the shop manual.

Yes Connections to battery terminals are tight and clean.

No

Inspect, clean, tighten nuts or replace terminals if excessively corroded.

No

Perform the checks described in the electrical section of the repair manual.

Yes

Replace.

No

Refuel tank.

No

Check using multi meter replace or repair. Refer to Chapter 3 pages 3-5 and 3-14.

No

Verify timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. Common rail pump bring to certified pump shop.

No

On common rail engines check using Electronic Service Tool (EST). Mechanical injection loosen (crack) injection lines.

Yes

Check and repair air leaks. For mechanical injection see Chapter 2 page 2-56

Yes

Check and clean the fuel system including the fuel tank.

No

Check fuel pump and replace if necessary.

No

Check and replace defective parts. See Chapter 2 page 2-55

No

Check cylinders for proper compression, overhaul engine or make repairs on defective parts,.

Yes Starter motor working properly.

Yes Fuel filters plugged.

No Fuel in tank.

Yes Grid heater system working properly.

Yes Injection pump timed properly.

Yes Injectors working properly.

Yes The fuel system or injection pump shows signs of air in system.

No The fuel system shows traces of water.

No Fuel pump working properly.

Yes Cold start advance solenoid and shut off solenoid both in working order.

Yes Compression good on all cylinders.

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1-3

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS ENGINE OVERHEATS Coolant level correct.

No

Check for leaks, repair leaks and refill to proper level.

Yes Fan working properly.

No

Replace.

No

Replace.

No

Check for leaks, bad bearing, overhaul or replace.

No

Replace.

Yes

Wash down, repair leaks and flush out radiator. If necessary replace radiator.

Yes

Clean or replace faulty parts.

Yes

Clean thoroughly.

No

Check and adjust for correct valve clearance.

No

Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. Common rail pump bring to certified pump shop.

Yes

Replace.

Yes Drive belts serviceable.

Yes Water Pump working properly.

Yes Thermostat working properly.

Yes Radiator plugged or leaking.

No Air to Air Cooler and hoses leaking.

No Openings for coolant flow within the cylinder head and engine block plugged.

No Valve clearance correct.

Yes

Injection pump timed correctly.

Yes Cylinder head gasket leaking.

1-4

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87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS ENGINE LACKS POWER AND RUNS ERRATICALLY Correct tie rod length between hand throttle and accelerator pedal.

No

Adjust rod length.

Yes

Replace.

Yes

Clean or replace filter.

Yes

Check and clean the fuel system including the fuel tank.

No

Replace.

No

Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

No

Check and if defective repair or replace.

Refer to Chapter 2 page 2-55

No

Power to KKSB solenoid repair or replace if defective.

No

Replace.

No

On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

No

Bring to a certified pump shop for repair.

Yes Fuel filters plugged.

No Air filter plugged.

No The fuel system shows impurities and or traces of water.

No Thermostat working properly.

Yes

Injection pump timed correctly

Yes Cold start solenoid (in injection pump) KKSB working properly.

Yes Timing plunger (in injection pump) working properly.

Yes Fuel pump working properly.

Yes Injectors working properly Yes Injection pump rate correct.

Yes Speed governor (in injection pump) in working order at all speeds.

No

Bring to a certified pump shop for repair.

Yes

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1-5

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS Engine lacks power and runs erratically (continued) Circuit and L.D.A.device both in working order.

No

Bring to a certified pump shop for repair.

Yes Injection pump peak adjusted.

No

Bring to a certified pump shop for repair.

No

Adjust clearance for proper value.

No

Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.)

No

Repair or replace unit.

Yes Correct valve clearance.

Yes Compression good on all cylinders.

Yes Turbocharger working properly.

1-6

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Bur

87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS ENGINE EXHAUST SMOKE BLACK OR DARK GREY Fresh clean diesel fuel in tank.

No

Clean the tank and replace the fuel filter.

Yes

Clean replace if necessary, repair leaking hoses.

No

Check using multi meter replace or repair.

Refer to Chapter 3 pages 3-5 and 3-14.

No

Cold start solenoid (KKSB) working properly.

Remove connector measure solenoid 4.8 ± 0.2 ohms. See Chapter 2 page 2-55

No

On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

No

Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

No

Bring to a certified pump shop for repair.

No

Bring to a certified pump shop for repair.

Yes Air filter pluggedand charge air cooler hoses leaking.

No Grid heater system working properly.

Yes KKSB solenoid working properly.

Yes Injectors working properly.

Yes

Injection pump timed correctly.

Yes Circuit and L.D.A.device both in working order.

Yes Injection pump adjusted properly.

Yes

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Bur

1-7

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS Engine exhaust smoke black or dark grey (continued) Injection pipes intact.

No

Check the condition of pipes and replace them if necessary.

No

Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.).

Yes Compression good on all cylinders.

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE) Grid heater working properly.

No

Check using multi meter replace or repair.

Refer to Chapter 3 pages 3-5 and 3-14.

Yes Coolant level correct.

No

Possible flow of coolant into the combustion chamber. Replace the cylinder head gasket or overhaul the engine.

No

On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

No

Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

Yes Injectors working properly.

Yes

Injection pump timed correctly.

Yes Fresh clean diesel fuel in tank.

No

Clean the tank and replace the fuel filter.

ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption.

1-8

Yes

Check: Cylinder compression, leaks into or out of turbocharger, leaks from valve guides.

Overhaul cylinder head or engine if necessary. Oil vapor breather check valve installed see Step 43 on page 2-161.

Issued 08-07

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87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS ENGINE KNOCKS IRREGULARLY

Knock detected in the crankshaft.

Yes

Check the following items: Journal play and out-of -roundness, bolt torque for main journal caps and engine flywheel, oil pressure. Replace the defective parts or overhaul the engine.

No

Knock detected in the connecting rods.

Yes

Check the following items: Rod journal end play and out-of -roundness, bolt torque for connecting rod caps, connecting rod torsion, straightness. Replace defective parts or overhaul the engine.

Yes

Check the following items: Play between the pistons and the cylinder liners, integrity of piston rings, play between the pins and the piston hubs. Replace the defective parts or overhaul the engine.

Yes

Check the following items: Play between the rocker arms and the valves, injection pump timing and valve timing. Adjust to proper specification.

Yes

Check and replace if necessary the gears.

Inspect for broken springs, excessive play between the stems and guides, and the tappets and seats. Adjust the clearance.

Yes

On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

Yes

Replace loose bolts and tighten all bolts to the specified torque and angles.

Yes

Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

No

Knock detected in pistons.

No

Knock detected in the cylinder head.

No

Knock detected in valve gear.

No Knock detected in injectors.

No Knock detected in the engine flywheel.

No

Knock detected in the injection pump.

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Bur

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ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS ENGINE STOPS Fuel in tank.

No

Refuel and drain if necessary.

Yes

Replace.

No

Check the solenoid replace if defective.

No

Check and if defective bring to a certified pump shop for repair. For common rail refer to Chapter 2 page 2-77. For mechanical injection refer to Chapter 2 page 2-53

No

Check and if defective bring to a certified pump shop for repair.

No

Adjust.

No

Adjust play to proper specifications.

No

Replace broken valves.

Yes Fuel filters plugged.

No Fuel Shut Off (FSO) solenoid working properly.

Yes

Regular injection pump rate.

Yes Injection pump controls working properly.

Yes Regular idle speed.

Yes Correct play between the valves and rocker arms.

Yes Valves intact.

EXCESSIVE OR INSUFFICIENT OIL PRESSURE Oil pressure control valve working properly.

No

Check and replace if necessary.

Yes Oil level correct and proper engine oil SAE viscosity.

No

Check to see if contaminated or proper viscosity and fill to proper level if low.

No

Check and replace if necessary.

No

Replace the bearings and reface if necessary the crankshaft.

Yes Oil pump and delivery lines in working properly Yes Main bearings and connecting rod bearings in acceptable condition.

Yes

1-10

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ENGINE REPAIR MANUAL

CHAPTER 1 - DIAGNOSTICS Excessive or Insufficient Oil Pressure continued Low oil pressure caused by fuel dilution.

Yes

Check for leaking shaft seal or leaking injection pump.

No

Replace the bearings and reface, if necessary, the crankshaft.

Yes

Repair leaks (if any) and replace the worn parts.

Yes

Replace.

No

Check and if defective bring to a certified pump shop for repair. For common rail refer to Chapter 2 page 2-77. For mechanical injection refer to Chapter 2 page 2-53

No

On common rail engines check using Electronic Service Tool (EST) . Mechanical injection loosen injection lines.

No

Check and if wrong, adjust to proper value.

No

Check each cylinder for proper compression and overhaul the engine or make repairs on defective parts (valves, piston rings, etc.).

No

Replace.

No

Check and if defective, bring to a certified pump shop for repair.

No Main bearings and connecting rod bearings working properly.

EXCESSIVE FUEL CONSUMPTION Fuel tank and lines leaking.

No Air filter plugged.

No

Injection pump operating properly.

Yes Electronic fuel injection system operating properly.

Yes Valve adjustment correct.

Yes Compression good on all cylinders.

ENGINE WON’T STOP Fuel Shut Off solenoid working properly.

Yes Speed governor working properly.

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NOTES

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ENGINE REPAIR MANUAL

CHAPTER 2

445TA TIER III

445TA ENGINE OVERHAUL

Issued 08-2007 Book/Form Number 87630273 NA Copyright © 2007. CNH America LLC. All Rights Reserved.

Printed in U.S.A. • Bur Source Code No. unknown

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer Revision History Issue First Edition

2-II

Issue Date

Applicable Machines

Remarks

08-2007

F4GE9454H, F4GE9454J, F4GE9484D F4HE9484A, F4HE9484C

87630273 NA

Issued 04-07

Bur

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CHAPTER 2

445TA ENGINE OVERHAUL TABLE OF CONTENTS F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 F4HE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 TORQUE SPECIFICATIONS (F4GE) - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 TORQUE SPECIFICATIONS (F4HE) - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 F4GE9454H and F4GE9454J Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 F4GE9484D Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 F4HE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 F4HE9484A Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EGR Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Control for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Control for F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head for F4GE9454h and f4GE9454J Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head for F4GE9484D Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head for F4HE9484A Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves and Valve Seats for F4GE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves and Valve Seats for- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-24 2-24 2-25 2-25 2-26 2-27 2-28 2-28 2-29 2-30 2-31 2-32 2-33 2-34 2-36 2-37

ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 COUNTER BALANCER - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ENGINE LUBRICATION - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 ENGINE LUBRICATION - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pan (Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Vapor Recirculation for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Vapor Recirculation for- F4HE Engines with Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blow-By Recirulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Vapor Recirculation for- F4HE Engines without Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-41 2-42 2-42 2-42 2-43 2-43 2-44 2-45 2-45 2-46

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 87630273 NA

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Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Boosting Version Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49 Inter-Cooled Engine Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 MECHANICAL INJECTION FEEDING SYSTEM - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 Mechanical Fuel lift Pump- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52 Mechanical Injection Working Principles- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53 ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . . . . . 2-54 KKSB COLD START ADVANCE SYSTEM - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION - F4GE ENGINES . . . . . . . . . . . . . . . . . 2-56 Parts needed for pressure/ vacuum testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57 Normal system operating observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58 HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL) - F4HE ENGINES . . . . . . . . . . . . . . . . . . . 2-59 EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Engine Preheating Element Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Phase Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Injection Pressure Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Pilot and Main Injection Advance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Idle Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Maximum Engine Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Smoke Control Under Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 After Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Control Of Working Speed In Normal Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Recover Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 FUEL SUPPLY SYSTEM - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Fuel Supply System Diagram- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64 Mechanical Feed Pump- Normal Operating Condition- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 Mechanical Feed Pump- Outlet Overpressure Condition In Exhaust Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 Fuel System Bleeding Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 High Pressure Pump Type CP3.3- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67 High Pressure Pump Inside Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69 Operating Principal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71 COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 Injection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74 Electro-Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75 Pressure Limiter for Fuel Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 Low Pressure Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77 Low - Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78 Test On Pressure Relief Valve On Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79 Test On Fuel Backflow From the Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80 SPECIAL DISASSEMBLY - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82 Crank Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84 2-2

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

Removing Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 Removing Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 SPECIAL DISASSEMBLY - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97 CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 Checking Crankcase Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 Checking Eccentric Lift and Bearing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Cam Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Tappets and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-102 2-102 2-103 2-103 2-103

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring Bearing Journals and Connecting Rods Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Oil Pump Drive Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Crankshaft Shoulder Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-105 2-105 2-107 2-107 2-109

PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conditions for Correct Pin/Piston Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Twisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Flexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling Piston To Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Connecting Rod-Piston Assemblies In Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring Crank Pin Assembly Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Piston Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-109 2-111 2-111 2-112 2-113 2-113 2-114 2-114 2-114 2-115 2-116 2-116 2-118

VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 INJECTION PUMP TIMING FIRST PHASE - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 ASSEMBLING COUNTER BALANCER - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121 Counter Balancer Timing- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124 MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Descaling, Check and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Valve Guide Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Seats Regrinding- Replacing Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-131 2-131 2-131 2-132 2-132 2-133 2-134

MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 Installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 87630273 NA

Issued 08-07

Bur

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135 Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135 Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136 Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137 INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137 INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138 INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138 INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141 REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144 Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145 ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145 Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146 CYLINDER HEAD ASSEMBLY - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147 Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147 Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148 Checking Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149 Valve Cleaning, Checks and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149 Checking Valve guide wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150 VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150 Valve Seats- Regrinding, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150 VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153 INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153 Fitting Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154 Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154 INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154 Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156 Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156 LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157 ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158 INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158 INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159 Injector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160 Installing Tappet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-161 Exhaust Manifold/Turbo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-161 Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162 Fuel Filter Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162 Wiring Harness Connections to the Engine- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-163

2-4

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

F4GE - ENGINES

Figure 2-1

BS06N188

F4GE9454H & F4GE9454J ENGINE

Figure 2-2

BS06N189

F4GE9484D ENGINE

The NEF F4GE engines are character ized as naturally aspirated or turbocharged two valves per cylinder engines.

Fuel feed is provided by rotary mechanical injection pump.

87630273 NA

Issued 08-07

Bur

It differs from other applications due to the provision of different power, power take-off, for different collector configurations, boost turbine and after cooler.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

F4HE - ENGINES

Figure 2-3

BS07D071

F4HE9484A / F4HE9484C ENGINE

The NEF F4HE engines are characterized by a four stroke diesel, turbocharged, four valves per cylinder.

They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the fuel efficiency and performance. this also limits emissions as much as possible.

1

BS07D072

Figure 2-4

F4HE9484A / F4HE9484C ENGINE SHOWING THE EDC7UC31 CONTROL BOX (1).

2-6

Issued 08-07

Bur

87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CODING OF SOURCE ENGINES ENGINE MODEL BREAKDOWN DISCRIPTION

F

4

G

E

9

4

8

4

D

*

J

6

1= Common Rail 4 valve 2= Common Rail 2 valve 3= In Line 4 valve 4= In Line 2 valve 5= Rotary 4 valve 6= Rotary 2 valve Emissions Level: J= Tier 3 Approved power rating Application: 4= Agricultural. machinery - Earth moving Fuel / Injection / Induction 0= Diesel injection - naturally aspirated 5= Diesel injection - Turbocharged 8= Diesel injection - Turbo - after cooler Number of Cylinders 4= 4 cylinders 6= 6 cylinders 9= Internal EGR E= Engine Type of crankcase: A= Non-structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter B= Non-structural crankcase 102 mm - 2valves - 3.9 or 5.9 liter C= Structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter D= Structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter E= Structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter F= Structural crankcase 104 mm - 2 valves - 3.9 or 5.9 liter G= Non-structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter H= Non-structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter Engine Family: Includes 4 cylinder and 6 cylinder in both 2 valves and 4 valves per cylinder mechanical and common rail fuel systems

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Issued 08-07

Bur

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

ENGINE PROPERTIES A F4GE9454H F4GE9454H F4GE9454J F4GE9454J F4GE9484D F4GE9484D F4HE9484A F4HE9484C B

*J601

*J602

*J600

*J601

*J601

C

4 Cylinders

D

4485 cm³ (273.7 cubic inches)

E

74 kW (100 h.p.)

2000 rpm

74 kW (100 h.p.)

2000 rpm

66 kW (90 h.p.)

2000 rpm

F

93 kW (126 h.p.)

2200 rpm

* J101

*J101/*J102

93 kW (126 h.p.)

2200 rpm

104 kW (141 h.p.)

2200 rpm

82 kW (110 h.p.)

2200 rpm

Direct Injection

G H

66 kW (90 h.p.)

2000 rpm

*J602

Rotary Injection pump T.C. (Boosted)

High pressure Common rail EDC7UC31 T.A.A.- (Boosted by Intercooler)

A. Type of engine B. Engine model C. Number of cylinders D. Total displacement E. Maximum power currently available F. Type of Injection G. Injection system H. Air supply system

2-8

Issued 08-07

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87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

GENERAL ENGINE FEATURES

1

2

6

3

4

7

5

8

9

10

11 Figure 2-5

BS06K013

REF. NO.

F4GE9454H

ENGINE TYPE

J601

J602

F4GE9454J

F4GE9484D

J600

J601

J602

Boosted

Air

Direct

2

Number of cylinders

3

Bore

104 mm (4.1 in.)

4

Stroke

132 mm (5.2 in)

5

Total displacement

6

Compression ratio

4 in-line

4485cm³ (273.7 cubic inches) 17.5: 1

Maximum power rating (net power at flywheel ISO 14396)

16.5: 1

17.5: 1

74 kW

66 kW

93 kW

104 kW

82 kw

2000 rpm

2000 rpm

2200 rpm

2200 rpm

2200 rpm

100 hp

90 hp

126 hp

141 hp

110 hp

2000 rpm

2000 rpm

2200 rpm

2200 rpm

2200 rpm

400 Nm

375 Nm

510 Nm

608 Nm

516 Nm

1250 rpm

1250 rpm

1250 rpm

1600 rpm

1400 rpm

295 lb.-ft.

277 lb.-ft.

376 lb.- ft.

448 lb.-ft.

381 lb. - ft.

1250 rpm

1250 rpm

1250 rpm

1600 rpm

1400 rpm

8

Maximum Torque

9

No-load idle

950 rpm

10

No-load peak rpm

2430 rpm

11

without intercooler HOLSET HX25

Boosting (type of turbocharger)

87630273 NA

J101 / J102

Boosted by intercooler

Injection

7

J101

4- Stroke diesel engine

Cycle 1

J601

F4HE9484A F4HE9484C

Issued 08-07

Bur

with with intercooler intercooler HOLSET HX25 HOLSET HX27W

???

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

12

13

14

15

16

17

18

19

Figure 2-6

BS06K014

REF. NO.

ENGINE TYPE

Lubrication.

12

Cooling.

F4GE9484D

J601

J601

F4HE9484A

F4HE9494C

J101

J101 / J102

J602

Forced by means of gear pump, pressure relief valve, oil filter.

0.70 bar (10 psi) 4.0 bar (58 psi)

3.50 bar (50 psi)

By centrifugal pump, regulated by thermostat, heat exchanger, intercooler By means of Belt

Water pump drive.

Thermostat start of opening temperature.

14

F4GE9454J J600

J602

Oil pressure with hot engine: at idle rpm.

Oil pressure with hot engine: at peak rpm.

13

F4GE9454H J601

79 to 83° C (174 to 181° F)

Oil capacity engine sump.

Refer to Owners Manual

Oil capacity engine sump + filter.

Refer to Owners Manual

15

Fuel feed type

Rotary Bosch - VE4 / 12 F

High Pressure Common Rail, EDC7UC31

16

Pump setting

0° ± 0.5°

N.A.

17

Start of delivery

0.95 to 1.05 mm (0.0374 to 0.0413 in.)

Type of injector

No information available

18

19

2-10

1 -3 -4 -2

Injection sequence

Injection pressure

N.A. CRIU 2 250 to 1600 bar

N.A.

3626 to 23206 psi

Issued 08-07

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87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

1

2

44

6

5

8

3

7

9

10 Figure 2-7

BS06K015

REF. NO. 1

ENGINE TYPE

Cylinder bore.

F4GE9454H

F4GE9454J

F4GE9484D

J601

J600

J601

J602

J601

F4HE9484A

F4HE9484C

J101

J101 / J102

J602

104.000 to 104.024 mm. (4.0945 to 4.0954 in.)

Pistons: 2

Measurement dimension.

X=

55.90 mm. (2.20 in.)

Outer diameter.

Ø1=

103.714 to 103.732 mm. (4.0832 to 4.0839 in.)

38.010 to 38.016 mm. (1.4965 to 1.4967 in.)

Pin seat.

Ø2=

3

Piston - cylinder liners.

0.252 to 0.294 mm. (0.0099 to 0.0116 in.)

4

Piston diameter.

Ø=

5

Protrusion of pistons from crankcase.

6

Piston pin.

Ø3=

7

Piston pin-Pin seat.

0.01 to 0.022 mm. (0.0004 to 0.0009 in.)

Piston ring grooves (measured on Ø of 99.0mm 3.898 in.)

8 Piston rings (measured 1.5 mm 0.05905 in. away from external Ø).

9 10

Piston rings - Slots.

Piston rings.

87630273 NA

0.4 mm. (0.0157 in.)

0.28 to 0.52 mm (0.01102 to 0.02047 in.)

37.994 to 38.000 mm. (1.4958 to 1.4961 in.)

X1=

2.705 to 2.735 mm. (0.1065 to 0.1077 in.)

X2=

2.44 to 2.46 mm. (0.0961 to 0.0969 in.)

X3=

4.03 to 4.05 mm. (0.1587 to 0.1594 in.)

S1=

2.560 to 2.605 mm. (0.1008 to 0.1026 in.)

S2=

2.350 to 2.380 mm. (0.0925 to 0.0937 in.)

S3=

3.970 to 3.990 mm. (0.1563 to 0.1571 in.)

1=

0.100 to 0.175 mm. (0.0039 to 0.0069 in.)

2=

0.060 to 0.110 mm. (0.0024 to 0.0043 in.)

3=

0.040 to 0.080 mm. (0.0016 to 0.0031 in.)

0.40 mm. (0.0157 in.)

Issued 08-07

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

11

12

14

13

15

17 16 Figure 2-8

BS06K016

REF. NO.

ENGINE TYPE

F4GE9454H

F4GE9454J

F4GE9484D F4HE9484A F4HE9484C

J601

J600

J601

J602

J601

J602

J101

X1=

0.30 to 0.40 mm. (0.0118 to 0.0157 in.)

X2=

0.60 to 0.80 mm. (0.0236 to 0.0315 in.)

X3=

0.30 to 0.55 mm. (0.0118 to 0.0217 in.)

Connecting rod small-end bearing seat.

Ø1=

40.987 to 41.013 mm. (1.6137 to 1.6147 in.)

Connecting rod large-bearing seat.

Ø2=

72.987 to 73.013 mm. (2.8735 to 2.8745 in.)

Inner

Ø3=

38.019 to 38.033 mm. (1.4968 to 1.4974 in.)

Big end half bearings

S=

14

Connecting rod small-end bearing seat.

0.250 to 0.500 mm. (0.0098 to 0.01968 in.)

15

Piston pin - bearing.

0.019 to 0.039 mm. (0.0007 to 0.0015 in.)

11

12

Piston ring gaps in cylinder liner.

J101 / J102

Connecting rod small-end bearing diameter.

13

16

17

2-12

1.955 to 1.968 mm. (0.0770 to 0.0775 in.)

Measurement dimension.

No Information Available

Maximum error on connecting rod axis parallelism.

No Information Available

Bearing journals

Ø1=

82.990 to 83.010 mm. (3.2673 to 3.2681 in.)

Crank pins

Ø2=

68.987 to 69.013 mm. (2.7160 to 2.7170 in.)

Main half bearings (supplied as spares).

S1=

2.456 to 2.464 mm. (0.0967 to 0.0970 in.)

Connecting rod half bearings.

S2=

1.955 to 1.968 mm. (0.0770 to 0.0775 in.)

Numbers 1, 5

Ø3

87.982 to 88.008 mm. (3.4638 to 3.4649 in.)

Numbers 2, 3, 4

Ø3=

87.977 to 88.013 mm. (3.4637 to 3.4651 in.)

Main bearing- journals

Issued 08-07

Bur

87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

18

19

20

22

21

23 Figure 2-9

BS06K017

REF .

NO.

F4GE9454H ENGINE TYPE

J601

J602

F4GE9454J J600

J601

F4GE9484D J601

J602

F4HE9484A

F4HE9484C

J101

J101 / J102

Half bearing- journals.

0.064 to 0.095 mm.

Numbers 1, 5

(0.0025 to 0.0037 in.)

18

0.059 to 0.100 mm.

Numbers 2, 3, 4

(0.0023 to 0.0039 in.)

0.064 to 0.090 mm. (0.0025 to 0.0035 in.)

Half bearing - crank pins.

(0.0025 to 0.0035 in.)

0.041 to 0.119 mm.

(0.0016 to 0.0047 in.)

0.041 to 0.103 mm.

(0.0016 to 0.0041 in.)

0.033 to 0.041 mm.

(0.0013 to 0.0016 in.)

+0.250 mm. (0.0098 in.)

19 Main half bearings Big end connecting rod half bearings. +0.500 mm. (0.0197 in.)

20 Main journal of thrust bearing.

X1= 37.475 to 37.550 mm. (1.4754 to 1.4783 in.)

21 Main bearing housing of thrust bearing.

X2= 32.180 to 32.280 mm. (1.2669 to 1.2709 in.)

22 Shoulder half ring.

X3= 37.280 to 37.380 mm. (1.4677 to 1.4716 in.)

23 Crankshaft shoulder.

0.095 to 0.270 mm. (0.0037 to 0.0106 in.)

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Issued 08-07

Bur

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

VALVE GEAR - CYLINDER ASSEMBLY

1

3

2

5

4

7

6

8 Figure 2-10

BS06K018

REF. NO.

ENGINE TYPE

1

Valve guide seats on cylinder head.

Valves - Intake.

F4GE9454H

F4GE9454J F4GE9484D

F4HE9484A

F4HE9484C

J601

J600 J601 J601 J602

J101

J101 / J102

J602

Ø1= 8.019 to 8.039 mm.

(0.316 to 0.317 in.)

Ø1= 7.042 to 7.062 mm.

(0.277 to 0.278 in.)

Ø4= 7.960 to 7.980 mm.

(0.313 to 0.314 in.)

Ø4= 6.970 to 6.990 mm.

(0.274 to 0.275 in.)

Angle=

60° ± 0.25°

2 Valves - Exhaust.

Angle= 3

4

Ø4= 6.970 to 6.990 mm.

(0.274 to 0.275 in.)

Ø4= 7.960 to 7.980 mm.

(0.313 to 0.314 in.)

45° ± 0.25°

Valve stem and respective guide.

0.059 to 0.086 mm (0.002 to 0.003 in.) 0.052 to 0.092 mm (0.002 to 0.003 in.)

Seat on head for valve seat. Intake.

46.987 to 47.013 mm (1.850 to 1.851 in.)

34.837 to 34.863 mm (1.371 to 1.373 in.)

Seat on head for valve seat. Exhaust.

43.637 to 43.663 mm.

(1.718 to 1.719 in.)

34.837 to 34.863 mm (1.371 to 1.373 in.)

Valve seat outer diameter; angle of valve seats on cylinder head.

5

Ø2= 34.917 to 34.931 mm.

(1.374 to 1.375 in.)

Ø2= 47.063 to 47.089 mm.

(1.853 to 1.8534 in.)

Intake.

angle= 60° Ø2= 34.917 to 34.931 mm.

(1.374 to 1.375 in.)

Ø2= 43.713 to 43.739 mm.

(1.7210 to 1.7220 in.)

Exhaust.

angle= 45° 6

7

8

2-14

1.00 to 1.52 mm. (0.039 to 0.060 in.)

0.59 to 1.11 mm. (0.023 to 0.044 in.)

Recessing. Exhaust valve

1.00 to 1.52 mm. (0.039 to 0.060 in.)

0.59 to 1.11 mm. (0.023 to 0.044 in.)

Between valve seat and headIntake

0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)

Between valve seat and headExhaust

0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)

Recessing.

Valve seats

Intake valve

No Information Available Issued 08-07

Bur

87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

9

11

10

15 18 22

17

16

14

13

12

21

20

19

Figure 2-11

BS06K019

REF. NO.

Valve spring height: 9

F4GE9454H

ENGINE TYPE

J601

Free spring.

H=

F4GE9454J

J602

J600

J601

F4HE9484A

F4HE9484C

J101

J101 / J102

J602

63.5 mm. (2.500 in.)

47.75 mm (1.880 in.)

Under load of: 329 N (74 lbf).

H1=

49.02 mm. (1.930 in.)

35.33 mm (1.391 in.)

Under load of: 641 N (144 lbf).

H2=

38.20 mm. (1.504 in.)

25.2 mm (0.992 in.)

X=

Injector protrusion.

10

F4GE9484D J601

Not Adjustable

Seats camshaft bearing.- number - 1 Ø 7= 59.222 to 59.248 mm. (flywheel side) (2.332 to 2.333 in.)

Seats camshaft bearings.numbers - 2, 3, 4, 5

Ø 1-6= 54.089 to 54.139 mm.

(2.130 to 2.132 in.)

11

Camshaft main bearing journals: 1 through 5

Ø 1, 2, 3, 4, 5 = 53.995 to 54.045 mm.

(2.126 to 2.128 in.)

12

Camshaft bushing outside diameter

Ø= N.A.

13

Camshaft bearing inner diameter.

Ø=54.083 to 54.147 mm. (2.129 to 2.132 in.)

14

Bearing and seats in crankcase.

N.A.

15

Bearing and main journals.

0.038 to 0.162 mm. (0.002 to 0.006 in.)

Useful cam lift- Intake.

10.74 mm. (0.423 in.)

7.5282 mm (0.296 in.)

Useful cam lift- Exhaust.

11.02 mm. (0.434 in.)

6.045 mm (0.238 in.)

Tappet plate seat in crankcase.

Ø1= 16.000 to 16.030 mm. (0.630 to 0.631 in.)

16

Ø2= 15.924 to 15.954 mm. (0.627 to 0.628 in.)

17 Tappet plate outside diameter.

18

15.960 to 15.975 mm (0.628 to 0.629 in.)

Ø3= 15.965 to 15.980 mm.(0.629 to 0.629 in.)

Between tappets and seat.

No Information Available

19

Tappets.

No Information Available

20

Rocker arm shaft.

Ø1= 18.963 to 18.975 mm.

(0.747 to 0.747 in.)

Ø1= 21.965 to 21.977 mm (0.8647 to 0.8652 in.)

21

Rocker arms

Ø2= 19.000 to 19.026 mm. (0.748 to 0.749 in.)

Ø2= 22.001 to 22.027 mm (0.866 to 0.867 in.)

22

Between rocker arm and spindle

0.025 to 0.063 mm.

(0.001 to 0.003 in.)

0.024 to 0.162 mm (0.00094 to 0.0064 in.)

87630273 NA

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

TORQUE SPECIFICATIONS (F4GE) - ENGINES PART ...................................................................................................................................... TORQUE - Nm (lb.-ft.)

Cylinder head fastening bolts.

1st phase. (pre lubricated with oil) Bolts M12x1.75x70 .................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet) Bolts M12x1.75x140 ...............................................................................35 to 45 Nm (25.8 to 33.2 pound-feet) Bolts M12x1.75x180 ...............................................................................65 to 75 Nm (47.9 to 55.3 pound-feet) 2nd phase (additional rotation)..........................................................................................90 degrees ± 5 degrees 3rd phase (only for bolts 140 and 180 mm long additional rotation) .................................90 degrees ± 5 degrees Crankshaft main bearings.

1st phase (pre lubricate with oil). ................................................................44 to 56 Nm (32.5 to 41.3 pound-feet) 2nd phase ...................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet) 3rd phase. (additional rotation). ......................................................................................................90 ± 5 degrees Bolts fastening the pulley on the crankshaft ................................................105 to 115 Nm (77.4 to 84.8 pound-feet) Connecting rod cap bolts.

1st phase. (pre lubricate with oil). ...............................................................27 to 33 Nm (19.9 to 24.3 pound-feet) 2nd phase ...................................................................................................55 to 65 Nm (40.5 to 47.9 pound-feet) 3rd phase. additional rotation ..........................................................................................................60 ± 5 degrees Engine flywheel fastening bolts. M12x1.5 1st phase. (pre lubricate with oil) ................................................................26 to 34 Nm (19.2 to 25.1 pound-feet) 2nd phase. (additional rotation).......................................................................................................60 ± 5 degrees Flywheel housing M12x120 .....................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet) M12x80 .......................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet) M10x80 .......................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) M10x40 .......................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) Assembly rear cover plate to flywheel housing (M8x1.25x16).........................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel injectors. ..................................................................................................55 to 65 Nm (40.6 to 47.9 pound-feet) Sump (oil pan) M8x1.25. .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Sump (oil pan) M18x1.5 ..................................................................................51 to 69 Nm (37.6 to 50.9 pound-feet) Oil pan drain plug ............................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Oil filter............................................................................................................................................ Contact + 3/4 turn Oil bypass valve to lube filter head ..................................................................72 to 88 Nm (53.1 to 64.9 pound-feet) Fuel filter. ........................................................................................................................................ Contact + 3/4 turn Injection pump fastening bolts. ........................................................................20 to 30 Nm (14.8 to 22.1 pound-feet) Injection pump gear (drive gear nut) 1st stage......................................................................................................15 to 20 Nm (11.0 to 14.8 pound-feet) 2nd stage ....................................................................................................85 to 90 Nm (62.7 to 66.4 pound-feet) Valve gear cover and case fastening bolts (front cover). .................................20 to 30 Nm (14.8 to 22.1 pound-feet) Intake manifold fastening bolts. .......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Assembly air intake connection M8x1.25 ........................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel pump fastening bolts M8 bolt...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel pump fastening bolts M6 bolt.........................................................................9 to 11 Nm (6.6 to 8.1 pound-feet) Fuel pump M6 nut..................................................................................................9 to 11 Nm (6.6 to 8.1 pound-feet) Exhaust manifold fastening bolts. .....................................................................37 to 49Nm (27.3 to 36.1 pound-feet) Valve cover fastening nuts. ..............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Rocker arm support fastening bolts.................................................................40 to 56 Nm (29.5 to 41.3 pound-feet) Rocker arm adjusting nut.................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft shoulder plate fastening bolts..........................................................20 to 30 Nm (14.8 to 22.1 pound-feet) Camshaft retaining plate bolts M8 ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet.)

Fan support fastening bolts M10x1.5x20.........................................................28 to 38 Nm (20.7 to 28.0 pound-feet) Fan pulley fastening bolts M6 ....................................................................................................................8 to 12 Nm (5.9 to 8.8 pound-feet) M10 .............................................................................................................37 to 49 Nm (27.3 to 36.1 pound-feet) Turbocharger fastening bolts. ..........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet) Starter motor fastening bolts. ..........................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) 2-16

Issued 08-07

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87630273 NA

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL Alternator fastening bolts.

Alternator to alternator support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Alternator to water inlet M8 bolt ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Alternator lower mount M10 ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Alternator upper pivot M10 bolt ...................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) Alternator mounting hardware M12x1.75x120 .............................................37 to 49Nm (27.3 to 36.1 pound-feet) Alternator wiring M6 nut ....................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Water pump fastening bolts. ............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Water outlet connection M8x1.25x35.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) M8x1.25x70.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Heat exchanger fastening bolts .......................................................................20 to 30 Nm (14.8 to 22.1 pound-feet) Camshaft gear bolt M8 ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet) Rear gear housing assembly M8 ...............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) M10 .............................................................................................................42 to 52 Nm (30.9 to 38.4 pound-feet) M12 .............................................................................................................65 to 89 Nm (47.9 to 65.6 pound-feet) Cylinder lubricating nozzles M8x1.25x10 ..........................................................12 to 18 Nm (8.9 to 13.3 pound-feet) Engine counter balancer................................................................................. 40 to 56 Nm (29.5 to 41.3 pound-feet) Engine coolant temperature sensor fastening bolt ......................................... 17 to 23 Nm (12.5 to 17.0 pound-feet)

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

TORQUE SPECIFICATIONS (F4HE) - ENGINES PART .............................................................................................................................TORQUE - Nm (pound-feet) Camshaft sensor M6 studs....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Feed pump M8 studs .......................................................................................... 10 to 14 Nm (7.4 to 10.3 pound-feet Rear gear case M12 bolts ...............................................................................65 to 89 Nm (47.9 to 65.6 pound-feet) Rear gear case M10 bolts ...............................................................................42 to 52 Nm (31.0 to 38.4 pound-feet) Rear gear case M8 bolts .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft sensor M6 nut .......................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Oil pump M8 bolts 1st stage ..................................................................................................................7 to 9 Nm (5.2 to 6.6 pound-feet) 2nd stage.........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Front cover M8 bolts ........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft gear M8 bolts ..................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet) Crankcase plate M10 bolt................................................................................38 to 48 Nm (28.0 to 35.4 pound-feet) High pressure pump gear M18 nut ..............................................................100 to 110 Nm (73.6 to 81.1 pound-feet) Fuel pump M8 nuts..........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) 1/2 inch plug on cylinder head.........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) 1/4 inch plug on cylinder head.........................................................................31 to 41 Nm (22.9 to 30.2 pound-feet) 3/4 inch plug on cylinder head...........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet) Injector fastening M6 bolts 1st stage ........................................................................................................8.15 to 8.85 Nm (6.0 to 6.5 pound-feet) 2nd stage (additional rotation) ....................................................................................................................... 75 ° ± 5° Injector feed connector fastening nut................................................................ 45 to 55 Nm 33.2 to 40.6 pound-feet) Grid heater grill on intake manifold M6 nut ............................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Intake manifold M8 bolts..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fastening brackets (rear) for engine lifting M12 bolts ......................................65 to 89 Nm (47.9 to 65.6 pound-feet) Fastening brackets (front) for engine lifting M8 bolts .......................................20 to 28 Nm (14.8 to 20.7 pound-feet) Common rail M8 bolts......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) High pressure fuel line connectors M14 ..........................................................18 to 22 Nm (13.3 to 16.2 pound-feet) High pressure fuel line connectors M8 ............................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Cylinder head M12x1.75x130 and 150 1st stage ..........................................................................................................30 to 40 Nm (22.1 to 29.5 pound-feet) 2nd stage (additional rotation) ........................................................................................................................ 90° ± 5° 3rd stage (additional rotation)......................................................................................................................... 90° ± 5° Rocker arm bracket .........................................................................................31 to 41 Nm (22.9 to 30.2 pound-feet) Valve clearance adjusting nuts ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel line from high pressure pump to Common Rail, M14 nut ........................18 to 22 Nm (13.2 to 16.2 pound-feet) Wiring bulkhead M6 bolt ........................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Electrical wiring support for injector feed.........................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Wiring on each injector -nuts ................................................................ 1.25 to 1.75 Nm (11.1 to 15.5 pound-inches) Fuel filter bracket M12 bolts .........................................................................................................69 to 85 Nm (50.9 to 62.7 pound-feet) M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel filter......................................................................................................................................... Contact + 3/4 turn Oil pressure relief valve on oil filter support M22 bolt......................................72 to 88 Nm (53.1 to 64.9 pound-feet) Radiator seal and oil filter support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Oil filter ........................................................................................................................................... Contact + 3/4 turn Connection on oil filter support for turbine lubrication .....................................20 to 28 Nm (14.8 to 20.7 pound-feet) Turbine lubrication pipe M12 nut............................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Engine coolant inlet connection M10 bolt ........................................................37 to 49 Nm (27.3 to 36.1 pound-feet) 90° elbow (if required) to engine coolant inlet connection ...............................20 to 28 Nm (14.8 to 20.7 pound-feet) Line on cylinder head for compressor cooling .................................................20 to 24 Nm (14.8 to 17.7 pound-feet) Engine coolant drain connector M6 bolt ................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Engine block exhaust manifold pin ........................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Exhaust manifold to cylinder head M10 bolt ....................................................48 to 58 Nm (35.4 to 42.8 pound-feet) 2-18

Issued 08-07

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

Damper adapter and damper on crankshaft M12 bolt 1st stage ..........................................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet) 2nd stage (additional rotation) ........................................................................................................................90° ± 5° Crankshaft pulley M10 bolts ............................................................................61 to 75 Nm (45.0 to 55.4 pound-feet) Water pump M8 bolts.......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Auxiliary component control belt tensioner M10 bolt .......................................37 to 49 Nm (27.3 to 36.1 pound-feet) Fixed pulleys for auxiliary component control belt M10 bolts ..........................37 to 49 Nm (27.3 to 36.1 pound-feet) Flywheel housing M10 bolts .........................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet) M12 bolts .........................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) Heat exchanger for EDC7UC31 control unit M6 bolts ....................................................................................................................... 8 to 12 (5.9 to 8.9 pound-feet) M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel inlet-outlet on heat exchanger ...................................................................10 to 14 Nm (7.4 to 10.3 pound-feet) Valve cover fastening nut M8 nut .....................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft sensor M6 bolt.......................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Crankshaft sensor M6 bolt.....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Coolant temperature sensor M14 bolt .............................................................17 to 23 Nm (12.5 to 17.0 pound-feet) Oil pressure/temperature sensor M5 bolt ................................................................5 to 7 Nm (3.7 to 5.2 pound-feet) Fuel pressure sensor fastening bolt......................................... 30 to 40 Nm (22.1 29.5 Nm (22.1 to 29.5 pound-feet) Fuel temperature sensor M14 bolt...................................................................17 to 23 Nm (12.5 to 17.0 pound-feet) Air temperature/pressure sensor on intake manifold ...............................................5 to 7 Nm (3.7 to 5.2 pound-feet) Engine oil level sensor M12 bolt ........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet) Turbine to exhaust manifold M8 pins ....................................................................................................................6 to 8 Nm (4.4 to 5.9 pound-feet) M8 nuts............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Adapter on turbine for lubricant oil lines (inlet) M12 adapter ...........................30 to 40 Nm (22.1 to 29.5 pound-feet) Adapter on line on turbine for lubrication M10 adapter....................................30 to 40 Nm (22.1 to 29.5 pound-feet) Adapter on oil line for turbine lubrication to block M10 adapter.......................37 to 49 Nm (27.3 to 36.1 pound-feet) Oil drain pipe on turbine M8 bolt......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Connector attaching oil return from cylinder head to flywheel housing .................8 to 12 Nm (5.9 to 8.9 pound-feet) Flywheel fastening bolts M12 bolts 1st stage ........................................................................................................... 26 to 34 Nm 19.2 to 25.1 pound-feet) 2nd stage (additional rotation) ........................................................................................................................60° ± 5° Oil pan (sump) M8 bolts ..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Cylinder bore lubricating nozzles M8 bolts ........................................................12 to 18 Nm (8.9 to 13.3 pound-feet) Crankshaft output bearings M12 bolts 1st stage ..........................................................................................................44 to 56 Nm (32.5 to 41.3 pound-feet) 2nd stage.........................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet) 3rd stage (additional rotation).........................................................................................................................90° ± 5° Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft gear M8 bolt ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet) Connecting rod caps M11 bolts 1st stage ........................................................................................................... 55 to 65 Nm 40.6 to 47.9 pound-feet) 2nd stage (additional rotation) .......................................................................................................................60 ° ± 5° Alternator bracket attaching to water feed pipe fitting M10 bolts .....................37 to 49 Nm (27.3 to 36.1 pound-feet) Alternator fastening M10 bolts.........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet) Starter fastening bolts M10 bolts .....................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

SPECIAL TOOLS 380000665............................................................................................... Tool for removing the crankshaft front seal.

380000663................................................................................................ Tool for removing the crankshaft rear seal.

380000671..................................................................................................... Tool for removing mechanical injectors.

380000666..........................................................................................Coupler for installing the crankshaft front seal.

380000664...........................................................................................Coupler for installing the crankshaft rear seal.

380000228........................................................................................................................... Dial indicator (0 - 5 mm).

380001601...........................Dial indicator holder tool for rotary injection pump timing (to be used with 380001004).

380002729..................................................................................................................... Engine TDC positioning tool.

380000979................................................................................................................ Injection pump drive gear puller.

380000158............................................................................................................................. 1 to 6 Nm torque driver.

380001099......................................................................................................... Tool for removing electrical injectors.

2-20

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

F4GE - ENGINES F4GE9454H AND F4GE9454J ENGINE

2

1

3

9 8 7 4 5

6

Figure 2-12

BS06N188 -

1. TURBOCHARGER 2. OIL VAPOR RECIRCULATION VALVE 3. ROTARY INJECTION PUMP

87630273 NA

Issued 08-07

Bur

4. FUEL FILTER 5. PRIMING PUMP 6. CRANKSHAFT PULLEY

7. FIXED GUIDE PULLEY 8. WATER PUMP 9. FAN PULLEY

2-21

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL F4GE9484D ENGINE

2

1

3

9 8 7 4 5

6

Figure 2-13

BS06N189

1. TURBOCHARGER 2. BLOW-BY 3. ROTARY INJECTION PUMP

2-22

4. FUEL FILTER 5. PRIMING PUMP 6. CRANKSHAFT PULLEY

7. FIXED GUIDE PULLEY 8. WATER PUMP 9. FAN PULLEY

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

F4HE - ENGINES F4HE9484A ENGINE

2

1

3

4

5 6

Figure 2-14

BS07D071

1.

2.

3.

4.

5.

6.

7

TURBOCHARGER COMMON RAIL FAN PULLEY FIXED GUIDE PULLEY DAMPING FLYWHEEL WATER PUMP

7.

8.

9.

10.

11.

EDC7UC31 CONTROL UNIT REAR OF CRANKSHAFT FLYWHEEL HIGH PRESSURE PUMP FUEL FILTER

8 11 10 9 Figure 2-15

BS07D072

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Issued 08-07

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2-23

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

DESCRIPTION OF MAIN ENGINE COMPONENTS ENGINE BLOCK

1

5

4 2

3

Figure 2-16

BS06N190

1. CYLINDER BORE 2. SEATS FOR CAMSHAFT BEARINGS AND TAPPETS

3. MAIN BEARING HOUSINGS 4. OIL PUMP

5. WATER PUMP

The engine block consists of a cast iron structure containing the cylinder bores (1), the main bearing housings (3), and the following seats: for camshaft bearings (2), water pump (5), and oil pump (4). The block also incorporates the water jackets for cooling and the oil galleys for lubrication.

2-24

Issued 08-07

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL CRANKSHAFT

4 3

2 1

Figure 2-17

BS06K022

1. FLYWHEEL ATTACHMENT HUB

2. TIMING DRIVE GEAR

The crankshaft is made of steel and rests on five induction hardened bearing journals. Drilled inside the crankshaft are a series of lubricating oil ducts.

The following items are pressed onto the front of the crankshaft: oil pump drive gear (4), phonic wheel, the vibration damper, and auxiliary equipment drive pulley.

3. CRANKSHAFT

4. OIL PUMP DRIVE GEAR

CRANKSHAFT OIL SEALS The front and rear seals are box type with radial seal.

R e m o ve w i t h s p e c i a l t o o l s 3 8 0 0 0 0 6 6 5 a n d 380000663. Install with special tools 380000666 and 380000664.

The following items are pressed onto the rear of the crankshaft: timing gear (2), and the flywheel mounting hub (1).

The main bearing shells are made of steel with a antifriction alloy plating.

One of the main bearing shells is equipped with shoulders to limit crankshaft endplay.

The timing drive gear (2) and the flywheel attachment hub (1) are installed on the rear of the crankshaft with a force-fit and cannot be replaced.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL CONNECTING RODS

Figure 2-18

BS06K023

T h e c o n n e c t i n g r o d s a r e fo r g e d s t e e l , T h e connecting rod crankshaft ends are made with an oblique angle, with separation of rod and cap obtained by means of the innovative fracture splitting system rather than the conventional machining process.

The connecting rod crankshaft bearing shells are made of steel plated with an antifriction alloy.

2-26

Each connecting rod is marked: • By a number on the connecting rod body and on the cap indicating the match and the cylinder in which they are assembled.

• By a letter on the connecting rod body indicating the weight class of the connecting rod installed in production.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL PISTONS

1 2 3 4

Figure 2-19

BS06K024

The piston crown features a high turbulence combustion chamber. The underside of the piston crown is cooled by engine oil delivered by a spray nozzle installed in the crankcase.

The following reference data is engraved into the piston crown:

There are three piston ring grooves with different functions and different geometry.

2. Stamping (facing the crankcase front side) indicating the mounting direction of the piston in the cylinder bore.

1st piston ring with trapezoidal (keystone) section, ceramic chrome plating.

2nd piston ring with torsional conical rectangular section.

1. Spare part number and design modification number.

3. Date of manufacture.

4. Stamping indicating 1st recess insert testing.

3rd piston ring with double oil ring wiper with internal spring.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL CAMSHAFT

NOTE: The camshaft below is a 6 cylinder camshaft.

BS06K025

A D B C D Figure 2-20

BS06K026

A. CRANKSHAFT OUTPUT GEAR

B. JOURNAL

The camshaft is installed on five bearing journals (B) in the engine block.

The front and rear bearing housings are equipped with steel bearings plated with antifriction material assembled by means of a force-fit.

The camshaft is controlled directly by the crankshaft by means of gear (A).

EGR EXHAUST GAS RECIRCULATION SYSTEM In the TIER 3 version, the profile of the exhaust lobe has been modified in order to allow the par tial opening of the exhaust valve during the intake cycle.

The exhaust gases can be partially returned back into the cylinders to lower the maximum combustion temperature which is responsible for the production of nitrogen oxides (NOx).

2-28

C. INTAKE VALVE LOBE

D. EXHAUST VALVE LOBE

The exhaust gas recirculation system (EGR), lowers the combustion temperature by decreasing the concentration of oxygen in the combustion chamber.

Creating an effective system to control the emission of NOx. The internal EGR system exhaust lobe design is not equipped with any electronically controlled elements, the system is always active. Its configuration does not need additional elements such as check valves, piping or heat exchangers.

The exhaust lobe (D) has an additional lobe apart from the major lobe see cross sectional view of exhaust valve (D), as compared to the configuration of a cam without EGR. With the additional lobe during the intake stroke of a cylinder, this lobe permits a brief opening of the exhaust valve. Recirculation is generated in the cylinder during the intake stroke due to the greater pressure of exhaust compared to the intake gases.

Issued 08-07

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL VALVE CONTROL FOR F4GE ENGINES

2

1

9 3 8 7 4

5

6

Figure 2-21

BS06N193

1. ROCKER ARM 2. ROCKER ARM SUPPORT 3. ADJUSTING SCREW

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4. PUSH ROD 5. TAPPET 6. CAM SHAFT

7. SPRING 8. SPRING SEAT 9. VALVE SPRING RETAINER (KEEPERS)

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL VALVE CONTROL FOR F4HE ENGINES

2 1

3

10 9 8 7

4

6

5

Figure 2-22

BS06K027

1.

2.

3.

4.

5.

2-30

ROCKER ARM ROCKER SPINDLE VALVE BRIDGE TAPPET CAMSHAFT

6.

7.

8.

9.

10.

SPRING SPRING SEAT VALVE SPRING RETAINER (KEEPERS) PUSH ROD VALVE LASH ADJUSTER SCREW

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CHAPTER 2 - 445TA ENGINE OVERHAUL CYLINDER HEAD FOR F4GE9454H AND F4GE9454J ENGINES

1

2

6 3

4

5

Figure 2-23

BS06N194

DETAIL OF CYLINDER HEAD FOR F4GE9454H/J ENGINE WITH INSERTED VALVE SEATS 1. EXHAUST MANIFOLD 2. INTAKE MANIFOLD

3. GRID HEATER 4. VALVE SEAT

The cast iron cylinder head is machined to accommodate the following parts: • Valve seats (4).

• Injectors (6).

• Thermostat (5).

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5. THERMOSTAT 6. INJECTOR

The cylinder head is also fitted for the following components to be installed on to the cylinder head.

• Exhaust manifold (1).

• Intake manifold (2) with seat for grid heater (3).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL CYLINDER HEAD FOR F4GE9484D ENGINES

1

2

3

6

4 5

Figure 2-24

BS06N195

DETAIL OF CYLINDER HEAD FOR F4GE9484D ENGINE WITH INSERTED VALVE SEATS 1. EXHAUST MANIFOLD 2. INTAKE MANIFOLD

3. GRID HEATER 4. VALVE SEAT

The cast iron cylinder head is machined to accommodate the following parts: • valve seats (4).

• injectors (6).

• thermostat (5).

2-32

5. THERMOSTAT 6. INJECTOR

The cylinder head is also fitted for the following components to be inserted on to the head.

• exhaust manifold (1).

• intake manifold (2) with seat for grid heater (3).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL CYLINDER HEAD FOR F4HE9484A ENGINES

2

1 3

5

4 6

Figure 2-25

BS07D063

DETAIL OF CYLINDER HEAD FOR F4HE9484A ENGINE WITH INSERTED VALVE SEATS 1. EXHAUST MANIFOLD 2. INTAKE MANIFOLD

3. GRID HEATER 4. VALVE SEAT

5. INJECTOR 6. THERMOSTAT

The cast iron cylinder head is machined to accommodate the following parts: • Valve seats (4).

The cylinder head is also fitted for the following components to be installed on the cylinder head.

• Exhaust manifold (1).

• Injectors (2).

• Thermostat (6).

• Intake manifold (2) with seat for grid heater (3).

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CHAPTER 2 - 445TA ENGINE OVERHAUL VALVES AND VALVE SEATS FOR F4GE ENGINES

2 3 1

4

A

Figure 2-26

BS06N196

1. EXHAUST SIDE 2. EXHAUST VALVE

3. INTAKE VALVE 4. INTAKE SIDE

Valve seats inserted in the head have the following angles: 45° - Exhaust valves.

60° - Intake valves.

NOTE: The exhaust valves (2) differ from the intake valves (3) in that they have only one notch at the stem end.

(A) Shows the oil seals mounted on valve stems.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

Figure 2-27

BS06N197

DETAIL OF VALVE GUIDES AND SEATS F4GE ENGINES

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL VALVES AND VALVE SEATS FOR- F4HE ENGINES

1

4

2

3 Figure 2-28

BS06K030

1. INTAKE VALVES 2. INTAKE SIDE

1

3. EXHAUST SIDE 4. EXHAUST VALVES

2

Valve seats have the following angles:

3 Figure 2-30

BS06K032

Exhaust valves- 45° Intake valves- 60° NOTE: Exhaust valves (4) have a distinctive identification at the center of the head of the valve.

1. 7.042 TO 7.062 MM (0.277 TO 0.278 INCHES) 2. INTAKE VALVE 3. EXHAUST VALVE

The cylinder head does not have guide inserts. The valve guide is machined directly into the head casting.

1 1

2 BS06K031

Figure 2-29

Oil seals (1) installed on valve stems.

Figure 2-31

BS06K033

1. JUMPER 2. PUSH RODS

NOTE: When installing the cylinder head, the orientation of valve bridges must be positioned with marks (1) towards exhaust manifold.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL ENGINE FLYWHEEL The flywheel (2) is not timed to the crankshaft and does not have any stamping, notch or reference hole for sensors or timing.

Equal distance of fastening bolt holes (1) allows it to be installed in any position.

1

2

Figure 2-32

BS06N198

FLYWHEEL FOR- F4GE ENGINES

Figure 2-33

BS07D076

FLYWHEEL FOR- F4HE ENGINES

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

ACCESSORY EQUIPMENT DRIVE 2

3

1

6

5

4

Figure 2-34

BS06K038

1. ALTERNATOR 2. AUTOMATIC BELT TENSIONER

3. FAN PULLEY 4. CRANKSHAFT

5. WATER PUMP 6. POLY-V-BELT

A Poly-V-belt (6) transmits the rotation of the crankshaft (4) to water pump (5), fan pulley, and to the alternator (1). The tension of the belt is controlled by the automatic belt tensioner (2).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

COUNTER BALANCER - F4GE ENGINES

A

1

B

2

10

3

9

4

5

7

8

6 Figure 2-35

BS06N200

COUNTER BALANCER FOR F4GE ENGINES 1.

2.

3.

4.

5.

FASTENING BOLTS SUPPORT FASTENING BOLTS GEAR BALANCING MASS

Inside the oil pan (sump), secured to the cylinder block is the counter balancer.

The counter balancer is timed as shown above.

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6.

7.

8.

9.

10.

HALF BEARINGS COUNTER-ROTATING SHAFT GEAR RING O-RING

Match alignment marks (A) engraved on the gears for timing, insert pin in hole (B) on the balancing mass to stop rotation temporarily.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

ENGINE LUBRICATION - F4GE ENGINES

A B C Figure 2-36

BS06N236

LUBRICATION SYSTEM LAYOUT FOR F4GE ENGINES A. GRAVITY OIL RETURN PATH

B. PRESSURIZED OIL PATH

Pressurized lubrication is performed by the following components: Gerotor oil pump housed in the front of the engine block, is driven by the spur tooth gear force fitted on the crankshaft.

C. OIL SUPPLY

A by-pass valve in case the oil filter becomes clogged. To cut out oil filter, is built into the cooler unit.

The filter is a cartridge- type oil filter.

Water / oil cooler, is housed in the engine block.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

ENGINE LUBRICATION - F4HE ENGINES

1 2 3

4 5

A B 6

Figure 2-37

BS07D132

LUBRICATION SYSTEM LAYOUT FOR- F4HE ENGINES (NOTE: THE ILLUSTRATION IS A 6 CYLINDER) 1. TURBO OIL PRESSURE CONTROL VALVE 2. BY-PASS VALVE 3. CARTRIDGE- TYPE OIL FILTER

4. HEAT EXCHANGER 5. OIL PUMP 6. OIL PAN (SUMP)

A. PRESSURIZED OIL PATH B. GRAVITY OIL RETURN PATH

Pressurized lubrication is done with the following components: • Gerotor oil pump (5) housed in the front of the engine block, driven by the spur tooth gear force fitted on the crankshaft.

• Heat exchanger (4) housed in the engine block, under the oil filter support.

• By-pass valve (2) for clogged oil filter cut off.

• Cartridge type oil filter (3) • Oil pan (sump) (6) 87630273 NA

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL HEAT EXCHANGER

1 2

3

4

Figure 2-38

BS06N237

1. HEAT EXCHANGER BODY 3. WATER / OIL COOLER 2. INNER GASKET 4. GASKET (BETWEEN COOLER AND ENGINE BLOCK)

BY-PASS VALVE

OIL PRESSURE CONTROL VALVE

1 2

3 A Figure 2-40

BS06K042 BS06K041

Figure 2-39

1. 66 MM (2.59 INCHES) 2. 41.25 MM (1.62 INCHES) 3. 136.9 ± 10.5 N (30.8 ± 2.36 LBF)

Calibration at 100° C (212° F) oil temperature.

A. DIRECTION OF FLOW

Blow-by max: 20 cm³/min (.68 oz/min) with 0.83 bar (12 psi) pressure at 26.7° C (80° F) oil temperature.

Minimum pressure 1.2 bar (17.4 psi) Maximum pressure 3.8 bar (55.1 psi) 2-42

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL OIL PAN (SUMP)

OIL PUMP

1

2

Figure 2-41

BS06K043

OIL PUMP

Figure 2-43

BS06N238

OIL PAN (SUMP) FOR F4GE ENGINES

1

1

2

2 Figure 2-42

BS06K044

1. Crankshaft with oil pump drive gear.

Figure 2-44

BS06K045

OIL PAN (SUMP) FOR F4HE ENGINES

2. Oil pump.

The oil pan (sump) (2) is bolted to the cylinder block.

The gasket (1), fitted on the oil pan reduces noise and in addition to improve tightness.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL OIL VAPOR RECIRCULATION FOR F4GE ENGINES

1 2

3

Figure 2-45

BS06N238

Oil vapor recirculation takes place by means of valve (1) placed above the tappet cover (3) on F4GE engines.

2-44

The vapor condensed within the valve falls into the tappet cover (3) due to gravity. The remaining vapor is recovered by vent (2) and recirculated to the engine intake.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITH BLOW-BY FILTER

1

2

3

4

A B Figure 2-46

BS06K048

1. PRE-SEPARATOR 2. RECIRCULATION TO INTAKE

3. BLOW-BY FILTER 4. RETURN TO ENGINE

BLOW-BY RECIRULATION: The rocker cover has a blow-by pre-separator (1), designed to increase the outlet velocity of blow-by oil vapor while condensing them partially. Condensed oil returns to the oil pan (sump) while residual vapors are collected and routed through the blow-by filter (3).

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A. OIL CONDENSATE B. OIL VAPORS

In blow-by filter (3) a portion of the vapors partially condense and return to the oil pan (sump) through line (4), while the remaining is recirculated to the engine intake by line (2).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITHOUT BLOW-BY FILTER

1

2

A B Figure 2-47

BS07D070

The tappet cover houses the pre-separator (1), whose shape and position increases the outlet velocity of the blow-by vapors and condenses part of the vapors at the same time.

The condensed oil returns to the oil pan (sump), where the residual vapor is collected and discharged into the open air through the bleeder on the side (2).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

COOLING SYSTEM

1

2

3

A

C

B Figure 2-48

BS06N240

1. THERMOSTAT 2. HEAT EXCHANGER

3. WATER PUMP A. WATER FLOWING OUT OF THERMOSTAT

The engine cooling system is a closed circuit, forced c i r c u l a t i o n t y p e i n c o r p o r a t i n g t h e fo l l ow i n g components: • Radiator- Dissipates the heat from the engine by circulating coolant through a long row of tubes that has air flowing across them thus decreasing the temperature.

• Expansion tank- Collects the overflow of coolant as it expands and contracts.

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B. WATER RECIRCULATING IN THE ENGINE C. WATER FLOWING INTO WATER PUMP

• Fan- Increases heat dissipating power of the radiator by flowing more air across the radiator.

• Heat exchanger- Cools the lubricating oil.

• Centrifugal water pump- placed on the front of the engine block. Circulates the coolant through the engine and radiator and is driven by a Poly-V belt.

• Thermostat- Regulates the circulation of the coolant.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL WATER PUMP

1

Figure 2-51

BS06K052

Figure 2-49

BS06K050

THERMOSTAT

Engine temperature is controlled by a thermostat.

WATER PUMP

Thermostat opening 79 to 83° C (174 to 181° F).

(1)- This side goes towards engine block.

BS06K051

Figure 2-50 CROSS SECTIONAL VIEW OF WATER PUMP

The water pump is housed in a cavity in the front of the engine block. and is driven by a Poly-V belt. The water pump is sealed to the block by a rubber ring.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

AIR INDUCTION BOOST DIAGRAM BOOSTING VERSION ENGINES

1

2

3

4

Figure 2-52

BS07C435

4 CYLINDER BOOSTED VERSION 1. AIR FILTER

2. TURBOCHARGER

The turbocharger is composed of the following parts: turbine, wastegate valve to regulate the boost pressure, main body, and compressor.

When the engine is running, the exhaust emission flow through the body of the turbine makes the turbine disk rotate.

3. EXHAUST

4. PISTONS

T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure of the compressor, reaches the prescribed pressure value.

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

The compressor rotor connected by a shaft to the turbine disk rotates, compressing the air drawn through the air filter.

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

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

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL INTER-COOLED ENGINE VERSION

2

1

3

4 5

Figure 2-53

BS07C436

4 CYLINDER BOOSTED / INTERCOOLED VERSION 1. AIR FILTER

2. TURBOCHARGER

3. EXHAUST

The turbocharger is composed of the following parts: turbine, wastgate valve to regulate the boost pressure, main body, and compressor.

When the engine is running, the exhaust emission flow through the body of the turbine makes the turbine disk rotate.

4. CHARGE AIR COOLER

5. PISTONS

T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure of the compressor, reaches the prescribed pressure value.

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

The compressor rotor connected by a shaft to the turbine disk rotates, compressing the air drawn through the air filter.

The air is then cooled by the charge air cooler and sent via the intake manifold to the pistons.

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

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

MECHANICAL INJECTION FEEDING SYSTEM - F4GE ENGINES FUEL FILTER

1

2 6 3

4

5

Figure 2-54

BS06N241

FUEL FILTER 1. FUEL FILTER BRACKET 2. AIR BLEEDING SCREW

3. FUEL HEATING RESISTOR 4. WATER DRAIN

5. FUEL FILTER 6. FUEL TEMPERATURE SENSOR

The fuel filter is located close to the feed and priming pump. The fuel filter provides a barrier trap for impurities and to separate water from the fuel.

On the filter bracket base there is a water drain screw. Equipment used in cold climate areas have a heater assembled into the bracket (to prevent the fuel from jelling), and a fuel temperature sensor. On some versions there is a water presence sensor located on the filter cartridge base.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL MECHANICAL FUEL LIFT PUMP- F4GE ENGINES

1

2

3

4

5

6

Figure 2-55

BS06N242

MECHANICAL FUEL PUMP 1. FUEL OUTLET TO FILTER 2. CONTROL LEVER

3. FUEL INLET FROM TANK 4. FUEL PUMP

The fuel pump is mounted on the left side of the engine. It draws fuel from the fuel tank and feeds it to the rotary injection pump. It is driven by the camshaft.

2-52

5. CONTROL LEVER 6. CAMSHAFT

Specifications for fuel lift pump: Static pressure at 1800 r/min. (rpm).

0.47 to 0.61 bar (6.8 to 8.8 psi).

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CHAPTER 2 - 445TA ENGINE OVERHAUL MECHANICAL INJECTION WORKING PRINCIPLES- F4GE ENGINES

1

3

2

4

5

Figure 2-56

BS07D011

1. Fuel filter

3. Feed pipeline from priming pump to filter

2. Feed pipe line from fuel pump to fuel filter

4. Rotary injection pump

5. Fuel pump

Fuel is drawn from the fuel tank by the fuel pump (5) and is driven by the camshaft.

To check fuel pressure for engines with mechanical fuel system.

Fuel flows through pipeline (2) to the fuel filter (1) and is piped to the vacuum chamber of the injection pump via pipeline (3), (for applications to be operated in cold climates the fuel filter is provided with a heater).

The fuel supply pressure specification is 0.27 bar (4 psi) minimum and 0.34 to 0.48 bar (5 to 7 psi) at full load rated rpm. To check fuel pressure, purchase a fuel supply line for the four cylinder engine. Cut the fuel line and install a tee fitting to measure the fuel pressure.

Transfer pump is placed inside the injection pump (4), and is a rotary type. It increases fuel pressure with the increase in the number of engine revolutions.

The fuel arrives to the valve gauging the pressure inside injection pump.

The distribution plunger increases the pressure and delivers fuel throughout the delivery pipe to the injectors.

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

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES

4

3

5

2 1

6

10

7 8 9 Figure 2-57

BS06N243

INJECTION ASSEMBLY 1. INJECTOR 1 FUEL PIPE 2. INJECTOR 2 FUEL PIPE 3. INJECTOR 3 FUEL PIPE

4. INJECTOR 4 FUEL PIPE 5. PIPE FOR FUEL DISCHARGE FROM INJECTORS 6. CONNECTOR FOR MEASURING PRESSURE INSIDE THE L.D.A. INTAKE MANIFOLD

Fuel feed system is composed of:

• Fuel tank (placed on the machine).

• Fuel delivery and back-flow to tank.

• Fuel pre-filter (if available, it is usually placed

7. THERMAL BULB FOR KSB

10. INJECTOR

8. INJECTION PUMP 9. SOLENOID VALVE

• Fuel feed rotary injection pump.

• Injector feed pipeline (from injection pump to injectors).

• Injectors

close to the engine on the machine frame).

• Priming pump, assembled to the engine driven by the camshaft.

• Fuel filter

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CHAPTER 2 - 445TA ENGINE OVERHAUL

KKSB COLD START ADVANCE SYSTEM - F4GE ENGINES

1

3

4

2

Figure 2-58

BS07F331

1. TEMPERATURE SWITCH

2. ADVANCE SOLENOID

Theory of operation: When the engine is cold (coolant temperature below 50° C (122° F), the injection pump is in timing advance state. When engine gets to between 60 and 66° C (140 to 151°F), the thermo switch in the cylinder head opens and system voltage is no longer sent to the solenoid on the injection pump. This allows the timing to retard to "normal" operating position.

Units equipped with the Bosh VE rotary injection pump do not require a relay for the pull in circuit. The pump uses a simple shut off solenoid built into the pump.

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3. FUEL SHUT OFF SOLENOID

4. WIRE HARNESS

There is one wire connected to the main harness that goes to the ignition terminal of the key switch. This wire feeds power to the injection pump shut off s o l e n o i d . A s e c o n d w i r e fe e d s p o w e r t o a temperature switch in the head. A third wire routes from the temperature switch to an additional solenoid on the injection pump.

An additional solenoid ensures that the pump will go to full advance timing during cranking and upon initial cold start up. Once the engine warms to 71° C (160° F), the temperature switch opens and power to the solenoid on the side of the injection pump is removed. This allows the injection pump to retard the timing according to engine rpm.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL To troubleshoot the system: 1. With the engine temperature below 50° C (122° F), and the key switch on, battery voltage should be present at both solenoids on the injection pump. If battery voltage is not present, troubleshoot the temperature switch circuit.

To check the temperature switch: 2. With the engine temperature is below 50° C (122° F), battery voltage should be present at both terminals. Warm the engine to 60 to 66° C (140 to 151° F). Batter y voltage should be present at only one terminal of the temperature switch when engine is warmed to 71° C (160° F) or higher.

3. Disconnect the connector at the temperature switch. Short across the two terminals of the connector with a jumper wire and start engine.

After a short time, remove the jumper wire the engine should change sound and run smoother as the injection pump time is retarded. This signifies that the cold starting advance system is operating properly.

FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION - F4GE ENGINES NOTE: If possible, test the fuel system as described before removing the Bosch VE fuel injection pump for repair. If leakage is too severe, complete the test procedure following the pump repair or replacement.

Failure to test the system may result in continued pump leakage.

To determine if the low pressure fuel supply is restricted, or if air is entering the system, follow these steps.: STEP 1 Install a clear poly-vinyl tube between the outlet of the fuel filter and the inlet of the Bosch VE fuel injection pump. Tee the connector into the test line a pressure gauge which can read both 0 to 762 mm (0 to 30 inches) of Hg vacuum and 0 to 2.07 bar (0 to 30 psi) positive pressure. See figure 2-59 on page 2-57 NOTE: For more information, see further procedures in this section which describe how to build test lines, and describe normal system operating observations.

STEP 2 Run the engine to purge all possible air from the system which was caused by test line installation.

STEP 3 When air is no longer visible in the clear test line, measure and record the operating pressures, while continually observing for air in the fuel, under the following conditions:

• Low idle- apply no load to the engine.

• High idle- apply no load to the engine.

• High idle- apply load to the engine using hydraulics over relief, hydrostatic stall or converter stall, depending upon the unit being tested. Load the engine to its rated engine operating rpm.

• Run multiple tests while observing fuel pressure and looking for air in the fuel.

STEP 4 If the fuel pressure is below 0.276 bar (4.0 psi) at any time during the previous Step 3, check the following, and replace as needed:

• The fuel pre-filter (replace).

NOTE: some applications do not use a fuel pre-filter.

• The primary fuel filter.

• The lines and connections from the fuel supply pump inlet back to the fuel tank, checking for damaged lines (kinks and rub marks) and leakage at the Voss o-ring fittings.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

• Debris in the tank, clean as required.

• The fuel pick-up tube in the fuel tank, checking for

Parts needed for pressure/ vacuum testing

cracks, plugging, or contact with the bottom or side walls of the tank.

2

1

• The fuel tank cap, assuring that a vacuum is not

1

being formed in the fuel tank, which would reduce the fuel supply pressure to the injection pump inlet.

3

NOTE: Vacuum in the fuel tank might not be observed during short-term running.

• These instructions apply only to engines with external electrical fuel shutoff valve assemblies.

Ensure that fuel supplied to and from the valve assembly is properly plumbed. Fuel supplied from the fuel filter enters the shutoff valve at port number 1. Port number 2 supplies fuel to the inlet of the Bosch VE injection pump.

STEP 5 If the checks in Step 4 were made and all necessary corrective actions were taken, Retest. If the pressure is still low, preform the following tests:

• From the gauges previously used to measure pressure, remove one section of test line and a barbed fitting from the tee. Install in there place a gasket and a connector. This will allow installation of the gauges between the supply pump inlet and the fuel supply line from the tank. After installation of the gauges, run the engine and observe the clear tube remaining on the gauges to ensure that air is not entering. The vacuum here should not exceed 50.8 mm (2.0 inches) of Hg under full load.

If the vacuum is greater than that, look for a plugged fuel supply line or debris in the fuel tank.

• An alternative vacuum test method would be to supply fuel from an alternate fuel source, such as a five gallon container, with a known good supply line. Fit it directly to the supply pump inlet fitting, then rerun the test. If the pressures return to normal, check the fuel supply line and tank of the vehicle for leaks or restrictions.

4

5

Figure 2-59

BS07F316

SETUP FOR MEASURING PRESSURE

To build a fuel system test set for pressure testing, obtain the following : NOTE: Voss o-ring type connectors can be obtained either by purchasing the connectors, or by purchasing a fuel line for the application being worked on, then carefully removing the plastic Voss type connectors (1), from the plastic tube for re-use with poly-vinyl tubing.

Quan.

Description

ID #

2

Voss type brass barbed hose connectors

1

1

6.35 mm (1/4 inch)- NPT tee fitting

3

2

6.35 mm (1/4 inch)- NPT to 7.54 mm (5/16 inch) barb connectors

5

1

Five feet of 7.54 mm (5/16 inch) O.D. poly-vinyl tubing

4

1

Dampened compound gauge which will measure 0 to 762 mm (0 to 30 inches) of Hg and 0 to 2.07 bar (0 to 30 psi).

2

• Upon completion of the diagnostic procedures, remove the test line and the gauge, and reinstall the standard fuel line.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL Normal system operating observations 1. Fuel supply pressures between the fuel filter and the inlet to the injection pump should be 0.276 to 0.414 bar (4 to 6 psi) with the engine loaded or unloaded.

1

2. Perform a "wiggle test" on each fuel line. A steady stream of bubbles or foam Should Not be seen moving through the fuel system. Very small random bubbles are allowable.

3. A small, high intensity flashlight can aid in observing air in the fuel lines.

2 Figure 2-60

BS07F317

SETUP FOR MEASURING VACUUM

4. The suction pressure between the inlet of the fuel supply and the tank should not exceed 50.8 mm (2 inches) of Hg vacuum.

To build a fuel system test set for vacuum testing, obtain the following : Quan.

Description

ID #

1

Connector Voss type M12 x 1.5

1

1

Sealing washer between connector (1) and tee fitting

2

NOTE: If the gauges are not equipped with a dampening device, install a small needle valve between the gauge and the test line. the needle valve can be adjusted to control gauge reading fluctuations.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL) - F4HE ENGINES 1 2 3

11 10 9 4 8

7 6 5

Figure 2-61

BS06K053

1.

2.

3.

4.

HARNESS TO INJECTORS ELECTRO- INJECTOR COOLANT TEMP. SENSOR ENGINE OIL AND PRESSURE SENSOR

5.

6.

7.

8.

CRANKSHAFT SENSOR 9. CAMSHAFT SENSOR EDC7UC31 CONTROL UNIT 10. FUEL PRESSURE SENSOR PRESSURE REGULATOR 11. BOOST TEMP. PRESSURE SENSOR FUEL HEATER AND TEMP. SENSOR

Extremely high injection pressures are necessary in order to reduce PARTICULAR emissions.

The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21030 23206 psi), while the injection precision obtained by EDC7UC31 electronic control of the system serves to optimize operation of the engine while limiting emissions and fuel consumption.

NOTE: 6 cylinder version is shown in figure above, operation is the same.

For engines more powerful than 152 kW (203 hp.), the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23206 psi), while engines less powerful than 152 kW (203 hp.) are fitted with DSLA nozzles which work with pressures up to 1450 bar (21030 psi.).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION ENGINE PREHEATING ELEMENT CONTROL Pre-post heating is activated when even just one of the water, air or fuel temperature sensors detects a temperature of less than 5° C (41° F).

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 by controlling the "on time" of the electro-injectors. In some applications, the maximum limiting response consists in stopping the engine.

PHASE RECOGNITION Signals transmitted by the camshaft and crankshaft sensors determine the cylinder which fuel must be injected.

INJECTION CONTROL Information transmitted by the sensors, the control unit determines and regulates pressure and modifies the pre-injection and main injection mode.

INJECTION PRESSURE CLOSED LOOP CONTROL

CUT OFF Fuel cut-off release is managed by the control unit with the following logical interventions:

• deactivation of the electro-injectors.

• reactivation of electro-injectors immediately prior to arrival at idle speed.

• control of fuel pressure regulator.

SMOKE CONTROL UNDER ACCELERATION

Engine load, determined by processing of data transmitted by the various sensors, and the control unit. Governs the regulator to maintain injection pressure at constant optimal values.

With intense load demands, signals received from the boost temperature pressure sensor and the crankshaft 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.

PILOT AND MAIN INJECTION ADVANCE CONTROL

AFTER ENGINE SHUT DOWN

Signals transmitted by various sensors to the control unit, determines the optimum injection point on the basis of internal mapping.

Afte r the engine is stopped, the contro l un it microprocessor saves various parameters to the EEPROM memory, including the fault log so that they will be available the next time the engine is started.

IDLE SPEED CONTROL The control unit processes signals transmitted by the various sensors and adjusts 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.

CONTROL OF WORKING SPEED IN NORMAL OPERATING CONDITIONS Each time work load varies, the control unit adjusts torque to maintain the engine in maximum power conditions. If the load causes a reduction in power, the control unit increases torque i.e. it increases the amount of fuel injected in order to restore the engine to maximum power.

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 intake manifold temperature is the reference temperature.

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CHAPTER 2 - 445TA ENGINE OVERHAUL RECOVER STRATEGIES

• 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 rev 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 safety values, the engine reduces power.

• Synchronism problems In the case of synchronism problems, faulty rev s e n s o r s, t h e s y s t e m c o n t r o l s t h e e n g i n e by increasing the number of revs in order to improve interpretation of the signals.

When the temperature of the supercharging 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 that of the same engine if it were aspirated.

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

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

• Power restrictions as operating temperature increases.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

FUEL SUPPLY SYSTEM - F4HE ENGINES

2 1

3

4 6 D

8 5 7

A B

D

C Figure 2-62

BS06K054

1. ELECTRO-INJECTOR

4. PRE-FILTER

2. PRESSURE RELIEF VALVE FOR 5. FUEL FILTER FUEL RETURN 3. COMMON RAIL PRESSURE 6. COMMON RAIL RELIEF VALVE

The common rail system has a high pressure pump that constantly keeps the fuel supply at a very high pressure, not dependent on the phase of the cylinder that must receive the injection. The high pressure fuel is stored in a pipeline (the common rail) that is shared by all electro- injectors.

This means that there is always a supply of fuel available at the electro- injector inlet at the injection pressure determined by the EDC7UC31 electronic control unit.

When the solenoid valve of an electro- injector is energized by the EDC7UC31 electronic control unit, fuel taken directly from the common rail is injected into the corresponding cylinder.

The fuel system is composed of a low pressure circuit and a high pressure circuit.

2-62

7. LOW PRESSURE GEAR TYPE B. LOW PRESSURE CHARGE PUMP 8. HIGH PRESSURE PUMP

C. FUEL RETURN

A. HIGH PRESSURE

D. HIGH PRESSURE FROM PUMP TERMINAL

The high pressure circuit consists of the following lines:

• Line connecting the high pressure pump outlet to the common rail.

• Lines supplying the electro-injectors from the common rail.

The low pressure circuit is composed of the following lines:

• Fuel line from fuel tank to prefilter.

• Lines supplying the mechanical supply pump through the heat exchanger of the control unit, the manual priming pump and the pre filter.

The fuel system is completed by the fuel return from the common rail, injectors and high pressure pump cooling circuit.

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CHAPTER 2 - 445TA ENGINE OVERHAUL FUEL SUPPLY SYSTEM DIAGRAM- F4HE ENGINES

5

6

7

A B

4

C D

3 18 17

2

8 9

1

10

16 15

13

11

14

12 Figure 2-63

BS06K055

9. EDC7UC31 CONTROL UNIT HEAT EXCHANGER

1. HIGH PRESSURE PUMP

2. PRESSURE RELIEF VALVE ON HIGH 10.

PRESSURE PUMP 3. PRESSURE RELIEF VALVE ON FUEL 11.

RETURN LINE FROM INJECTORS 4. COMMON RAIL SAFETY RELIEF 12.

VALVE 5. COMMON RAIL 13.

6. RAIL PRESSURE SENSOR 14.

7. ELECTRO-INJECTOR 15.

8. RETURN LINE FROM HIGH PRESSURE 16.

PUMP

MANUAL PRIMING PUMP PRE-FILTER

A. DRAIN

FUEL TANK

B. SUCTION

MECHANICAL SUPPLY PUMP FUEL FILTER PRESSURE REGULATOR

C. LOW PRESSURE D. HIGH PRESSURE

HIGH PRESSURE PUMP COOLING PIPING

The fuel system is a Common Rail with a CP3 high pressure pump.

The supply pressure regulator controls the flow of fuel needed in the low pressure system. The high pressure pump supplies the common rail. This pressurization of fuel, improves energy efficiency and limits the heating of the fuel in the system.

Function of low pressure regulator valve (2), installed on the high pressure pump maintains the pressure at a constant level of 5 bars (72 psi.).

Low pressure relief valve (2), operates to increase fuel flow in the high pressure pump cooling circuit through inlet and drain piping (16), from piping (8).

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17. HIGH PRESSURE PUMP BYPASS CHECK VALVE 18. ROTOR PUMP PRESSURE SAFETY BY-PASS

The pressure relief valve (3) installed on the cylinder head. Controls the flow of fuel returning from the electro-injectors at a pressure of 1.3 to 2 bars (19 to 29 psi.).

In parallel with the mechanical supply pump there are two by-pass valves.

The by-pass valve (18) allows fuel to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed limit.

The by-pass valve (17) allows filling the supply system through the manual priming pump (10).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL FUEL FILTER

B

1

D

C

5 4

2

2

D

A A

B

3

C 5 E

Figure 2-64

BS06K056

1.

2.

3.

4.

5.

FUEL FILTER BRACKET FUEL TEMPERATURE SENSOR FUEL FILTER ELECTRIC FUEL HEATER FUEL TEMPERATURE SENSOR

A. B. C. D. E.

OUTLET CONNECTION TO HIGH PRESSURE PUMP COMMON RAIL, CYLINDER HEAD INJECTORS DISCHARGE LINE INLET CONNECTION CONNECTION TO HIGH PRESSURE PUMP DISCHARGE LINE INLET CONNECTION FROM FEED PUMP OUTLET CONNECTION TO FUEL TANK

The fuel filter is installed on the engine cylinder block in the circuit between supply pump and high pressure pump (CP3).

2-64

The heater is activated if the fuel temperature is less than 0° C (32° F) and is heated until the fuel reaches 5° C (41° F). Fuel temperature is monitored by the EDC7UC31 control unit.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL MECHANICAL FEED PUMP- NORMAL OPERATING CONDITION- F4HE ENGINES

1 A

2 B

Figure 2-65

BS06K057

1. PRESSURE SAFETY VALVE 2. PRIMING BY-PASS VALVE IN CLOSED POSITION

The charge gear pump, installed on the rear of the high pressure pump, draws fuel from the tank through the pre-filter and sends it through the main fuel filter to the high pressure pump.

A. FUEL INLET FROM TANK B. FUEL OUTLET TO FILTER

The feed pump is driven by the high pressure pump shaft.

In normal operating conditions the flow in the feed pump enters port (A), flows around the outside of the gears and out through port (B).

MECHANICAL FEED PUMP- OUTLET OVERPRESSURE CONDITION IN EXHAUST UNIT

2

1

A

B

Figure 2-66

BS06K058

1. PRESSURE SAFETY VALVE 2. BY-PASS PORT

Pressure safety valve (1) opens when pump outlet pressure (B), is excessive due to filter restriction or charge pressure regulator malfunction. The pressure of the fuel would then overcome the force exerted by 87630273 NA

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A. FUEL INLET FROM TANK B. FUEL OUTLET TO FILTER

spring (1) allowing fuel to flow to the pump inlet through passage (2).

2-65

ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL FUEL SYSTEM BLEEDING CONDITION

1 A

2 B

Figure 2-67

BS06K059

1. PRESSURE SAFETY VALVE 2. PRIMING BY-PASS VALVE IN CLOSED POSITION

The by-pass valve (2) opens when, the engine is turned off. The supply system has to be filled with the manual priming pump.

2-66

A. FUEL INLET FROM TANK B. FUEL OUTLET TO FILTER

When activating the hand pump the by-pass valve (2) is opened due to inlet pressure, this allows the fuel flow to outlet (B).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL HIGH PRESSURE PUMP TYPE CP3.3- F4HE ENGINES

1 2 8

3

7

6 4

5

Figure 2-68

BS06K060

HIGH PRESSURE PUMP 1.

2.

3.

4.

5.

6.

7.

8.

MECHANICAL GEAR CHARGE PUMP FUEL OUTLET CONNECTION FROM MECHANICAL PUMP TO FILTER FUEL INLET CONNECTION FROM CONTROL UNIT HEAT EXCHANGER FUEL DRAIN RETURN CONNECTION TO FILTER BRACKET FUEL INLET CONNECTION FROM FILTER HIGH PRESSURE REGULATOR HIGH PRESSURE PUMP FUEL OUTLET CONNECTION TO COMMON RAIL

The high pressure pump has 3 radial plungers driven by the cam gear. The pump does not need to be timed.

On the rear of the high pressure pump is the mechanical gear feed pump which is driven by the high pressure pump shaft.

IMPORTANT: The high pressure pump unit can not be overhauled, there are no adjustments.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

1 9

2

8

3

7

4

6 5

Figure 2-69

BS06K061

EXPLODED VIEW OF HIGH PRESSURE PUMP 1. BY-PASS VALVES ON FEED PUMP 2. PUMP SHAFT 3. HIGH PRESSURE PUMP FUEL INLET FROM FILTER

2-68

4. 5 BAR (72 PSI) LOW PRESSURE FUEL REGULATOR VALVE 5. HIGH PRESSURE REGULATOR SOLENOID VALVE

7. HIGH PRESSURE FUEL DELIVERY VALVE TO COMMON RAIL

6. INDIVIDUAL HIGH PRESSURE PUMP PLUNGER (1 OF 3)

9. MECHANICAL GEAR CHARGE FEED PUMP

8. GEAR SET

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CHAPTER 2 - 445TA ENGINE OVERHAUL HIGH PRESSURE PUMP INSIDE STRUCTURE

3 1 6

4

5

Figure 2-72

BS06K161

Figure 2-70

BS06K160

8

BS06K159

7

Figure 2-73

2 Figure 2-71

BS06K158

1. LOW PRESSURE FUEL INLET 2. PUMPING ELEMENTS SUPPLYING FUEL DUCTS 3. CYLINDER 4. THREE LOBE ELEMENT

5. PUMP SHAFT 6. PISTON 7. BALL DELIVERY VALVE 8. CAP INTAKE VALVE

Pumping unit is composed of: • Three pistons (6) which are actuated by a three lobe element (4) on the pump shaft (5) When the shaft (5) rotates the three lobe element (4) actuates the piston (6) pumping high pressure fuel past the ball delivery valve (7) to the common rail.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL OPERATING PRINCIPAL

1

7

2

6 5 4

3

Figure 2-74

BS06K063

Figure 2-75

BS06K160

1. OUTLET FOR RAIL DELIVERY LINE 2. HIGH PRESSURE REGULATOR

3. PRESSURE REGULATOR SUPPLY PASSAGE 4. PLUNGER SUPPLY PASSAGE

High pressure plunger (3) rides on the cam installed on the pump shaft (4). In the intake phase the plunger is supplied with fuel through the supply passage (5). The quantity of fuel supplied to the plunger is determined by pressure regulator (7). The pressure regulator controls high pressure pump outlet flow based on PWM (pulse width modulated) command received from the EDC7UC31 control unit.

2-70

5. PUMP SHAFT

7. RAIL DELIVERY VALVE

6. HIGH PRESSURE PLUNGER

During the plunger compression phase the fuel reaches sufficient pressure to open the common rail delivery valve (2) and is forced through outlet (1) to the common rail.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

2 1 1 2

9

3 8 4 7 5

6

Figure 2-76

BS06K064

1.

2.

3.

4.

5.

6.

7.

8.

9.

INLET TO HIGH PRESSURE PLUNGERS INLET TO HIGH PRESSURE PLUNGERS CHARGE PRESSURE REGULATOR DRAIN PASSAGE CHARGE PRESSURE 5 BAR (72 PSI) REGULATOR VALVE FUEL DISCHARGE FROM HIGH PRESSURE REGULATOR VALVE INLET HIGH PRESSURE REGULATOR VALVE MAIN PLUNGER SUPPLY PASSAGE INLET TO HIGH PRESSURE PLUNGERS PUMP LUBRICATION PASSAGES

3 BS06K065

Figure 2-77

1. FUEL EXHAUST FLUE 2. FUEL EXHAUST GALLERY 3. FUEL EXHAUST FLOWING FROM PUMP WITH CONNECTOR TO HIGH PRESSURE LINE FOR COMMON RAIL

The figure above shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.

THEORY OF OPERATION

The figure above shows the low pressure fuel passages inside the pump. The figure shows the main plungers supply passage (7), the individual plunger supply passages (1, 8, 2), the passages utilized for lubrication of the pump (9), the high pressure regulator (6), the 5 bar (72 psi) pressure regulator valve (4) and the fuel discharge passage (3).

The high pressure regulator (6) determines the quantity of fuel which the high pressure plungers deliver to the common rail. Excess fuel flows out through passage (5).

The regulator valve (4), is designed to maintain a constant pressure of 5 bar (72 psi.) at the high pressure regulator inlet.

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 about 2 bars (29 psi.).

The amount of fuel supplying the high pressure pump is metered by the high pressure regulator. The high pressure regulator is controlled by the EDC7UC31 control unit through a PWM (pulse width modulated) signal.

When fuel is sent to a pumping element, the corresponding piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the fuel in the pumping element chamber, is compressed into 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 the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed.

The pumping element piston goes back towards the bottom dead center and the remaining fuel is decompressed.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated.

The rail delivery pressure is modulated between 250 and 1600 bars (3625 to 23206 psi.) by the EDC7UC31 control unit, through the pressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

The pump replacement time on the engine is highly reduced in comparison with traditional injection pumps, because it does not require timing.

IMPORTANT: If the line between the fuel filter and high pressure pump is to be removed or replaced, be sure that components are absolutely clean.

COMMON RAIL

1

Figure 2-78

BS06K066

COMMON RAIL

The common rail volume is a high pressure fuel storage device. It has a small volume to allow a rapid pressurization at startup, at slow idle and in case of high flow rates.

A fuel rail pressure sensor (1) is screwed into the common rail. The sensor has a feedback signal to the EDC7UC31 control unit in order for the control unit to verify correct rail pressure.

It has enough volume to minimize system spikes caused by injector opening and closings and by the high pressure pump operation. This function is further enhanced by a calibrated orifice between the high pressure pump and the common rail.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

COMMON RAIL PRESSURE RELIEF VALVE

B

A

1

2

3

4

5

6

1

2

3

4

5

6 Figure 2-79

BS06K067

COMMON RAIL PRESSURE RELIEF VALVE 1. DIRECT TANK DISCHARGE 3. BODY 5. SMALL PISTON 2. STOP 4. SPRING 6. SEAT ON RAIL A. NORMALLY, THE TAPERED PISTON (5) END STAYS CLOSED THE DISCHARGE IS DIVERTED TO THE FUEL TANK. B. IF 1750 BAR FUEL PRESSURE IS EXCEEDED IN THE RAIL, THE SMALL PISTON MOVES AND THE EXCESS PRESSURE IS DISCHARGED INTO THE FUEL TANK.

The common rail pressure relief valve is installed at one end of the common rail, it is designed to protect the systems components in case of excessive increase of pressure buildup.

The valve can be single stage (as the ones shown above) or two stage with two working limits for pressure relief 1750 bar and 800 bar (25381 psi. and 11603 psi.).

The relief valve enables engine operation at limited p e r fo r m a n c e, avo i d i n g f u e l ove r h e a t i n g a n d safeguarding the system If the dual stage relief valve opening pressure is reached, the EDC7UC31 control unit stops operation of the pressure regulator. The high pressure pump will then operate at maximum delivery to the common rail, and a failure code will be stored.

In the second case, when the pressure within the high pressure system reaches 1750 bar (25381 psi.), the valve is activated as a single stage one to exhaust the fuel and consequently reduce the pressure until reaching the proper pressure. Then it reduces the pressure into the common rail to approximately 800 bar (11603 psi.).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

ELECTRO-INJECTOR 1

1

14 13

13

3

12

3

4

4 11 11

15

2

15

2 12

14

5

5

6

6 10

10

7

7 9

9

8

8

Figure 2-81

BS06K069

Figure 2-80

BS06K068

INJECTOR IN REST POSITION 1. ELECTRICAL CONNECTION 2. PILOT VALVE 3. CONTROL AREA 4. CONTROL DUCT 5. PRESSURE ROD 6. SUPPLY DUCT 7. PLUNGER 8. NOZZLE

9. PRESSURE CHAMBER 10.

11.

12.

13.

14.

15.

SPRING CONTROL FUEL OUTLET HIGH PRESSURE FUEL INLET COIL BALL SHUTTER CONTROL VOLUME

The injector is similar to the conventional injectors, except for the absence of plunger return springs.

The injector can be considered in terms of two basic parts: • Actuator- spray nozzle composed of pressure rod (5), plunger (7) and nozzle (8).

INJECTION START

When coil (13) is energized, it makes ball shutter (14) move upwards. The control volume (15) fuel flows towards control fuel outlet (11) making a pressure drop occur in control volume (15). Simultaneously the fuel pressure into pressure chamber (9) makes plunger (7) lift, causing injection of fuel into the cylinder.

INJECTION END When coil (13) is de-energized, shutter ball (14) goes back to its closed position to restore a balance of forces to make plunger (7) go back to its closed position and end the injection cycle.

IMPORTANT: The injector has no serviceable parts inside, so it is not repairable.

• Control solenoid valve composed of coil (13) and pilot valve (2).

The solenoid valve controls spray nozzle plunger lift.

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CHAPTER 2 - 445TA ENGINE OVERHAUL ELECTRO-INJECTOR The NEF Tier III engines use Bosch CRIN 2 electroinjectors. The injection jet used are according to power developed by the engine.

1

Figure 2-82

BS06K070

1. JET

Pressures

Injectors

Jet

Power developed

CRIN 2

DLLA

Above 152kW (204 h.p.)

250 bar (3626 psi.)

1600 bar (23206 psi.)

CRIN 2

DSLA

Below 152kW (204 h.p.)

250 bar (3626 psi.)

1450 bar (21030 psi.)

kW / H.P.

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Minimal operating pressure

Nominal operating pressure

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL PRESSURE LIMITER FOR FUEL RETURN

A

BS06K071

B

Figure 2-83

A. TO FUEL TANK B. FROM INJECTORS

The pressure limiter for the fuel return is housed on the rear of the cylinder head, and adjusts the pressure of the fuel returning from injectors at a pressure of 1.3 to 2.0 bars (18.9 to 29 psi.). By maintaining this pressure to the return fuel, the fuel vapor formation inside the injectors is avoided, optimizing fuel spraying and combustion.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

CHECKING THE FUEL SYSTEM LOW PRESSURE SUPPLY TEST

10

9

8

7

4

4

9

9 11

3

2 4

6

12

4

4 5

1 13

Figure 2-84

BS06K214

DIAGRAM OF SET UP OF COMPONENTS FOR SPECIFIC TEST 1.

2.

3.

4.

5.

FUEL TANK PREFILTER LOW-PRESSURE PUMP FUEL DELIVERY CIRCUIT FUEL FILTER

6.

7.

8.

9.

10.

HIGH PRESSURE PUMP HIGH PRESSURE CIRCUIT COMMON RAIL FUEL RECIRCULATION INJECTORS

11. M1 PRESSURE GAUGE 0-15 BAR FUEL FILTER INLET 12. M2 PRESSURE GAUGE FUEL FILTER OUTLET 13. EXTERNAL CONTAINER PLACED 1M (39 IN.) BELOW ENGINE

6 12

11

5

13 Figure 2-85

BS06K215

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL LOW - PRESSURE PUMP

Figure 2-86

BS06K216

The function of the gear pump is to supply the high pressure pump. It is driven by the shaft of the high pressure pump and is installed on the rear portion of the high pressure pump.

Under normal operating conditions, the flow of fuel inside the pump is as shown in the figure above.

With the fuel system pressurized, a fully charged battery and an external fuel supply placed 1m (39 in.) below the engine. The engine must start within 20 seconds of activation of the starter motor. If the pump is not able to draw fuel to the engine and start the engine the low pressure pump is probably defective.

2-78

After starting the engine, check the pressure at 1500 rpm.

On pressure gauge M1- (11) it must be between 6 and 9 bar (87 and 130 psi.)

• If lower than 6 bar (87 psi.) replace pump • If higher than 9 bar (130 psi.) replace the fuel filter.

On pressure gauge M2- (12) it must be greater than 5 bar (72.5 psi.)

• If lower, replace the fuel filter • If the trouble persists, check the seals on the couplings of the fuel filter bracket and the high pressure pump inlet.

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CHAPTER 2 - 445TA ENGINE OVERHAUL TEST ON PRESSURE RELIEF VALVE ON COMMON RAIL

1

Figure 2-87

BS06K217

The pressure relief valve is installed on the end of the common rail, its function is to protect the systems components if any malfunction causes and excessive increase in the pressure of the high pressure system.

Disconnect recirculation line (1) from the pressure relief valve and plug with the VOSS fitting from the test set.

If the valve seeps diesel without a fault code, then replace the valve.

With the common rail pressure sensor disconnected and a fault code is generated, with the rail pressure is at 71 0 bar (1 029 8 psi.) m ea sura ble with th e diagnostic instrument, the trouble is in the wiring and not the component.

No diesel must come out of the valve at any engine speed. If the diagnostic system signals a fault code “Engine - backfill valve control”, it means that the EDC7UC31 control unit has recognized that the value has opened after a significant change in the pressure of the rail greater than 1700 bar (24656 psi.). Since its opening is to be considered a consequence of abnormal increase in pressure, the valve is NOT defective even though a great amount of diesel flows out.

IMPORTANT: Information acquired to date shows that the sensor is rarely defective.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL TEST ON FUEL BACKFLOW FROM THE RETURN

1

Figure 2-89

BS06K219 BS06K218

Figure 2-88

Tests on fuel backflow from the return establishes the operating status of the injectors. The engine speed and power are controlled through the injectors. The power required by the user, through the accelerator, is converted into the quantity of fuel injected per cycle. This in turn is converted into microseconds of injector opening according to the rail pressure.

1. INJECTOR DUCT LOCKING NUT

When the EDC7UC31 control unit warning light comes on during acceleration and/or cold star t trouble, make sure the following check is done.

• Check torque of the nut (1) locking the injector duct on the cylinder head. The torque setting is 45 - 55 Nm (33.2 - 40.6 lb.- ft.).

NOTE: The injectors may have problems of both a mechanical and a electrical nature. Therefore before proceeding with the following analysis, it is wise to rule out the presence of water in the tank and the fuel prefilter.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

2

1

3

4

Figure 2-90

BS06K220

Proceed with the injector fuel backflow tests as follows: • Remove the duct (4) from the cylinder head.

• Plug it (3) • Install a transparent line (2) Make sure that the engine idling speed is correct.

Check the quantity of fuel recirculation from the cylinder head.

The process for measuring the quantity of injector return fuel is: • Engine idling and without air compressor or air conditioner on.

• engine temperature greater than 50°C (122°F).

The quantity of fuel that flows out must be no greater than 80ml. (2.7 oz.) of diesel per minute. Excessive recirculation more than 80ml. (2.7 oz.) of diesel per minute could be caused by: • Incorrect coupling between one or more injectors and the related needles.

• Problem of internal leakage of the injector.

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To identify the defective injector, follow the method as described below: Measure the quantity of fuel flowing out in one minute from the coupling on the cylinder head. If recirculation exceeds 80 ml. (2.7 oz.) per minute, plug the rail outlet of one injector (1) at a time using the rail plugs in the test set.

The defective injector is the one when plugged causes a significant reduction in recirculated fuel.

NOTE: When changing an injector it is necessary to change the duct.

After identifying the injectors / ducts with high fuel recirculation, check the torque of the ducts, 45 - 55 Nm (33.2 - 40.6 pound-feet), if they are loose tighten.

Then check the recirculation values again.

If the torque is correct, remove the line and check the spherical end towards the injector is not out of round, replace if necessary. Recheck recirculation value.

If the duct is not out of shape, replace the injector.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

SPECIAL DISASSEMBLY - F4GE ENGINES STEP 3

DISASSEMBLING ENGINE

1

STEP 1

2

13

3 4

12

5

11

6 7

10

8

9 1 Figure 2-93

BS06N246

Version F4GE9484D BS06N244

Figure 2-91

Drain the engine oil by taking the plug off the oil pan and the oil filling cap of the valve cover.

Remove the fan unit from the fan pulley.

In order to apply the brackets to the engine block to fix it on the stand for overhaul it is necessary to remove electrical wiring (1).

STEP 2

1

2

5

Remove the following:

• • • • • • • • • • •

Grid heater (1).

Intake manifold (2).

Oil recovery pipe from blow-by (3).

Pipe for LDA intake manifold (4).

Piping for LDA system (5).

Quick-couplings pipes (6), (7), (10) see step 4.

Fuel filter (8).

Electrical wiring (9).

Fuel filter support (11).

Grid heater control unit (12).

Tappet covers (13).

STEP 4

4

3

A

B

1 BS06N245

Figure 2-92

Remove the following:

• • • •

Fastening bracket (5) from electrical wiring (1).

Starter (4) turbine lubrication delivery pipe (2).

1

Oil filter (3).

Figure 2-94

BS06K388

IMPORTANT: Push clamp (1), as shown in figure B to disconnect the low pressure fuel lines 6, 7, 10 from the corresponding connections. After disconnecting the line, reset the clamp (1) to position in figure A to prevent distortion to the clamp.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 7

STEP 5

1

2 1

6 5 4

3 Figure 2-95

BS06N247

2 Figure 2-97

BS06N248

• Remove the bolts fastening the turbine, and then

Remove the following:

• Injector feed pipes (3) from injection pump (2).

• Brackets fastening feed pipes (1), (5), (6) on the cylinder head.

remove the turbine (1).

• Remove the exhaust manifold (3).

STEP 8

• Fuel pump (4).

1

STEP 6

9

2 1

3

8

4 5 6

3 2

7 BS06N250

4

Figure 2-98

Remove the following: Figure 2-96

BS06N249

Remove the following:

• Fuel feed pipes from the injectors (1).

• Remove fuel drain pipe (2) from the injectors by removing the bolt (4) and the seal (3).

• • • •

Belt tightener (2).

Poly-V belt (4).

Alternator fastening bracket (1).

Alternator (3), water pump (6), fan pulley (5), and guide pulleys (7).

• pulley support (8).

• Thermostat housing and thermostat (9) from the engine block.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 11

STEP 9

1 2 1

3 2

4

Figure 2-99

BS06N251

Lock the flywheel properly to prevent rotation, remove bolts (2) from pulley (1).

CRANK SEAL REPLACEMENT STEP 10

Figure 2-101

BS06K244

Using the pry bar (3) of Special Tool 380000996 and the lever (4), remove the external seal ring (2) from the front cover STEP 12

A

B 1

1 2 2 3

3 4

4 BS06K243

Figure 2-100

Place Special Tool 380000665 (4) to the front of the crankshaft (2).

Working through the guide holes of Special Tool 380000665 (4), drill into the internal seal ring (1) with a 3.5 mm (9/64 inches) drill bit (A) to a depth of 5 mm (3/16 inch) (B).

Secure Special Tool 380000665 (4) to the ring (1) by screwing down the six bolts supplied with tool to the crankshaft front cover.

Figure 2-102

BS07C437

Remove the following:

• Water pump (1) • Bolts (2) and (4) • Crankcase front cover (3) NOTE: Take note of bolts (2) and (4) position when removing them because they are different lengths.

Now extract seal ring (1) by tightening bolt (3).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 15

STEP 13

2 1

1

Figure 2-103

BS06K246

Figure 2-105

BS06N254

Remove bolts and take off oil pump (1).

LOCKING INJECTION PUMP IN PRESET CONDITION

IMPORTANT: Oil pump (1) cannot be repaired.

REMOVING INJECTION PUMP

To correctly preset the injection pump prior to removing it, loosen bolt (2) and remove the L-shaped spacer (1).

Tighten bolt (2) to 27 to 33 Nm (20 to 24.3 poundfeet) to block rotation of the pump shaft.

STEP 14

IMPORTANT: Keep the L-shaped spacer with the pump so it does not get misplaced (it is needed for installation).

STEP 16

1

A

2

B

2 4

3

Figure 2-104

BS06N253

LOCKING FLYWHEEL

Rotate the crankshaft until the number 1 cylinder reaches top dead center (TDC).

When TDC is obtained lock the flywheel by pushing pin (1) of special tool 380002729 as shown by the arrow.

1 BS06N255

Figure 2-106

Remove cover (1) from gear case (2).

Loosen nut (3) securing the injection pump drive gear (4).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 19

STEP 17

1

1

2 Figure 2-107

BD04A025-01

Attach Special Tool 380000979 (1) to the injection pump drive gear and remove the gear.

Figure 2-109

BS06N257

Remove bolts (1) securing engine flywheel (2) to the crankshaft

STEP 18 STEP 20

1

2

5

3

1 2

4 3 BS06N256

Figure 2-108

Loosen the three nuts (1), (3) and (4) securing the injection pump (2) to the bell housing (5), then take the pump out of its housing.

NOTE: Hold the pump drive gear shaft to prevent it from moving, when removing pump from the engine block.

2-86

Figure 2-110

BS06N258

Screw two pins (2) of adequate length into crankshaft holes (3).

Remove engine flywheel (1) so that it can be harnessed with a hoist and moved out of the way.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 23

STEP 21

A 1 1 2 2

3 4

5 Figure 2-111

BS06N252

REMOVING INNER REAR CRANKSHAFT SEAL

Apply Special Tool 380000663 (3) on crankshaft rear shank (5).

Dr ill inner seal ring (1), through Special Tool 380000663 (3) guide holes, with a 3.5 mm (9/64 inches) drill bit (A). Drill down to a depth of 5 mm (3/16 inches).

Secure Special Tool 380000663 (3) to ring (1) by fastening the 6 bolts (4) provided.

BS06N259

Figure 2-113

Remove bolts (2) and then remove the flywheel housing.

IMPORTANT: Note the installation position of the bolts (2) because they are different lengths.

STEP 24

1

Extract seal ring (1) by tightening bolt (2).

STEP 22

1

2

2 3 BS06N260

Figure 2-114

Turn the engine upside down, remove bolts (2), remove oil pan (1).

STEP 25

4 1 Figure 2-112

BS06K244

REMOVING OUTER REAR CRANKSHAFT SEAL

Using the pry bar (3) and lever (4) remove the outer seal ring (2) as shown in figure above.

Then take the same tool and remove the seal ring from the flywheel cover case in the same manner.

2 3 4 BS06N261

Figure 2-115

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

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 28

STEP 26

1

2 1

3

2 Figure 2-116

BS06N262

REMOVING COUNTER BALANCE

Use pin (1) to lock the counter balance (3) at TDC (top dead center). Remove bolts (2) and remove the counter balance (3).

Figure 2-118

BS06N264

Remove injectors (2) with Special Tool 380000671 (1).

STEP 29 REMOVING ROCKER ARM ASSEMBLY STEP 27

1 2 3 4

1

Figure 2-119

BS06N265

BS06N263

Figure 2-117

For each cylinder, loosen adjusting nuts (3) and unscrew the adjusters (2).

Remove bolts (1) securing the cylinder head to the engine block STEP 30

Remove the bolts (4), remove rocker assembly (1) and the push rods.

1

Figure 2-120

BS06N266

Attach harness to brackets (1), and remove cylinder head from block using a hoist.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

SPECIAL DISASSEMBLY - F4HE ENGINES STEP 4

DISASSEMBLING ENGINE STEP 1 Drain the engine oil by removing the plug from the oil pan (sump).

1

2

STEP 2

1 5 3 4

2 BS06K223

3

Figure 2-123

Disconnect fuel line (1) from common rail and from high pressure pump (2) and remove it by taking out securing bolts (5).

4 5 Figure 2-121

BS06K221

Apply the brackets for fastening the engine to the engine stand as follows (working from the left side of the engine.

• Use a suitable tool to remove fuel filter (5) from the fuel filter bracket (1).

• Disconnect the low pressure lines (2, 3, 4) from

IMPORTANT: When loosing fitting (4) of fuel line (1), it is necessary to use a suitable wrench to prevent fitting (3) of high pressure pump (2) from rotating.

STEP 5 From the Right Side:

1

the fuel filter bracket (1).

• Remove fuel filter bracket (1) from engine block.

STEP 3

2 A

B

1

BS07D073

Figure 2-124

Remove the mounting bolts and remove the oil line (2) from the Turbo-charger (1) from the engine block.

1 Figure 2-122

BS06K222

Remove the starter from the flywheel housing Secure the engine to a engine stand.

Push clamp (1), as shown in figure B to disconnect the low pressure fuel lines (2, 3, 4) from the corresponding connections. After disconnecting the line, reset the clamp (1) to locking position figure (A) to prevent distortion to the clamp.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 6

1

2

11 3

10

4

9 5

6 7 8 Figure 2-125

BS06K225

1. INJECTOR CONNECTIONS

5. FUEL HEATER TEMPERATURE SENSOR

2. INJECTOR

6. HIGH PRESSURE REGULATOR

3. BOOST TEMPERATURE-PRESSURE SENSOR 4. CAMSHAFT SENSOR

9. OIL TEMPERATURE-PRESSURE SENSOR 10. COMMON RAIL FUEL PRESSURE SENSOR 11. ENGINE COOLANT TEMPERATURE SENSOR

7. EDC7UC31 CONTROL UNIT 8. CRANKSHAFT SPEED SENSOR

Disconnect the following connectors from the engine: • Connectors (1) from injector wiring (2)

STEP 7

3

2

• Engine coolant temperature sensor on the thermostat (11)

• • • • • •

Common rail fuel pressure sensor (10)

1

Crankshaft speed sensor (8) Boost pressure / temperature sensor (3)

5

Camshaft sensor (4) High pressure regulator (6)

4

EDC7UC31 control unit (7)

Figure 2-126

BS06K226

Disconnect from the common rail (2): • Fuel line (4) according to procedure on page 2-89

• Fuel lines (3) • Injector manifolds (5) • Remove the bolts (1) and disconnect the common rail (2) 2-90

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 10

STEP 8

1

1

2 5

3 4

2

5 6

3

7

4

8 Figure 2-129

BS06K229

Figure 2-127

BS06K227

Disconnect line (5) from fuel return pressure limiter (1) as shown in step 3 page 2-89.

Remove the nut, loosen the retainer collar and disconnect the oil vapor line (2). Remove bolts (4) and take off the blow-by filter (3).

Loosen tappet adjusting nuts (1) and unscrew the adjusters.

Remove bolts (2), remove the rocker assembly (3), consisting of bracket (6), rockers (4), shafts (5) and remove jumpers (7) from valves. Remove rods (8).

STEP 11

STEP 9

1 1 6

2 5

2

3

4

Figure 2-128

BS06K228

Remove nuts and remove the tappet cover including the gasket.

BS06K230

Remove bolts (1) and disconnect the injector wiring housing (6) complete with gasket.

Remove bolts (3) and detach the boost temperature/ pressure sensor (2).

Figure 2-130

Remove injector fastening bolts. Use Special Tool 380001099 (1) to remove injectors (2) from the cylinder head.

R e m o ve n u t s ( 5 ) a n d r e m o ve t h e f u e l i n l e t connectors (4).

IMPORTANT: Disassembled fuel inlet connectors (4) must not be used again. They must be replaced with new ones.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 14

STEP 12

2

1

3

4 1 2 3

Figure 2-133

BS06K233

Figure 2-131

BS07D075

Disconnect oil line (4) from heat exchanger oil filter bracket and from the line fitting (2) to the turbine.

Remove nuts and detach turbocharger (3) from exhaust manifold (1).

Remove the bolts and take off the ther mostat housing (1) and the thermostat under the housing.

Remove fastening bolts (2) and remove cylinder head (3).

STEP 15

Remove bolts and disconnect the exhaust manifold (1), from the cylinder head.

1

STEP 13

1

2

Figure 2-134

BS06K234

Attach brackets (1) to cylinder head and remove cylinder head from block using a hoist.

STEP 16 BS07D064

1

Figure 2-132

On the opposite side, remove the bolts from the intake manifold (1) and remove grid heater (2).

Figure 2-135

BS06K235

Remove cylinder head gasket (1).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 19

STEP 17

1 1 2 3 Figure 2-136

BS07D068

Remove bolts (2) and disconnect the alternator support (3).

Remove oil filter (1)

Figure 2-138

BS06K238

Remove the bolts and disconnect the EDC7UC31 control unit (1), including the heat exchanger.

STEP 20

STEP 18

1

1

4

2

3

2

4

3 Figure 2-137

BS06K237

Take out bolts and remove the oil temperaturepressure sensor (2).

Take out bolts and then remove heat exchanger/ oil filter bracket (1) and intermediate plate (4) and relevant gaskets.

BS07D069

Figure 2-139

Remove bolts (3) and remove the cap (1). Keep the gasket (2), the power take-off (4) and the second gasket (4).

Remove the oil level sensor (3).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 24

STEP 21

2

1

1

3 2 Figure 2-140

BS06K239

Remove the nut and disconnect the timing sensor (1). Remove the nuts and disconnect the high pressure pump (2) including the feed pump (3).

STEP 22

Figure 2-143

BS06K242

Remove the bolts and disconnect the water pump (1). Remove the bolt and disconnect the engine speed sensor (2).

STEP 25

A

B

1 2 1 3 4 Figure 2-141

BS06K240

Install tool to flywheel housing, loosen bolts on flywheel (1) but do not remove the flywheel.

NOTE: The special tool 380000988 is not shown in figure, see page 2-95 STEP 23

1

Figure 2-144

BS06K243

Place Special Tool 380000665 (4) to the front of the crankshaft (2).

Working through the guide holes of Special Tool 380000665 (4), drill into the internal seal ring (1) with a 3.5mm (9/64 inch.) drill bit (A) to a depth of 5mm (3/16 inch.)

(B).

Secure Special Tool 3800000665 (4) to the ring (1) by screwing down the six bolts supplied with tool to the crankshaft front cover.

2

Now extract seal ring (1) by tightening bolt (3).

3 BS06K241

Figure 2-142

Remove the bolts (3) and take off the damping flywheel (2) and the pulley (1).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 29

STEP 26

1

2

2 3

1

4

3

BS06K247

Figure 2-145

BS06K244

Using the pry bar (3) and the lever (4), remove the external seal ring (2) from the front cover (1).

Figure 2-148

Remove Special tool 380000988 (1), remove bolts securing flywheel (2) to crankshaft (3).

STEP 30 \

STEP 27

1

2 1 3

BS06K248

Figure 2-146

BS06K245

Remove the bolts and take off the front cover (1).

IMPORTANT: Note the installation position of the bolts because they are different lengths.

Figure 2-149

Screw two pins (2) of adequate length into the crankshaft holes (3) slide flywheel out on them.

Attach a harness to flywheel.

Remove the flywheel (1) with a hoist.

STEP 28

1

Figure 2-147

BS06K246

Remove bolts and take off gear oil pump (1).

IMPORTANT: Oil pump (1) can not be repaired.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 33

STEP 31

2 1

1 5

3

4 Figure 2-150

BS06K249

Remove bolts and take off rear cover (1).

IMPORTANT: Note the installation position of the bolts because they are different lengths.

STEP 32 Turn engine upside down

Figure 2-152

BS06K251

Remove the bolts (1 and 3) and remove the oil suction tube (2). Remove the bolts (5) and remove the stiffening plate (4).

Remove bolts (1 and 4) and remove oil suction tube (5). Remove bolts (2) and remove stiffening plate (3).

STEP 34

1 1

2 BS06K250

2 Figure 2-151

Remove the bolts, plate (2) and oil pan (sump) (1).

2-96

Figure 2-153

BS06K254

Remove bolts and take gear (2) off of camshaft (1).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES STEP 36

1

1

2 2

Figure 2-154

BS06N267

Remove bolts (2) and take off timing gear case (1).

IMPORTANT: Note the installation position of the bolts because they are different lengths.

BS06K257

Figure 2-156

Remove bolts (1), and take off main bearing journals (2) STEP 37

STEP 35

1 1 2

2 BS06K258

Figure 2-155

BS06K256

Remove connecting rod cap fastening bolts (1) then take off rod caps (2).

Remove the pistons (complete with connecting rods) from the crankcase by pushing them up thorough the top of the block.

IMPORTANT: Half bearings must be kept in there respective housings. If they are going to be used again, they must be mounted in the same position they had prior to being removed.

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Figure 2-157

The main bearing journal cap (1) and its respective thr ust bear ing (2) have a shoulder to control crankshaft endplay.

IMPORTANT: Take note of the mounting position of the main bearings and thrust bearings. If they have to be reused again, they must be installed in the same position they had prior to being removed.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 41

STEP 38

1

2

1

Figure 2-158

BS06N268

Figure 2-161

BS06K262

Remove crankshaft (2) from engine crankcase by means of a suitable tool (1) and a hoist.

Carefully remove the camshaft (1) from the engine crankcase.

STEP 39

STEP 42

2

1

1

3 Figure 2-162

BS06K263

Figure 2-159

BS06K260

Remove tappets (1) from the engine crankcase.

Take off main half bearings (1).

Remove bolts (2) and take off oil nozzles (3).

STEP 40

1 2

BS06K261

Figure 2-160

Remove bolts (1) and take off camshaft retainer plate (2).

IMPORTANT: Note plate (1) mounting position.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE STEP 44

INSPECTION After the engine has been dismantled, clean the crankcase thoroughly.

Check the crankcase carefully for cracks. Check the condition of freeze plugs. They must be replaced if they are rusty or sealing properties are in doubt.

Inspect the cylinder bore surfaces, they must not show traces of seizing, scoring, out-of-roundness, taper or excessive wear.

1 2

B A

STEP 43

3 1

BS06K265

1

Figure 2-164

Measurements must be taken for each cylinder, at three different heights (1, 2, 3) of the bore and two planes perpendicular to each other. One parallel to the engine longitudinal axis (A), the other perpendicular (B).

2 2

NOTE: the greatest amount of wear is usually found on the (B) axis and during measurement (1) of the vertical plane.

Figure 2-163

BS06K264

CHECKING CYLINDER BORE OUT-OF-ROUNDNESS AND TAPER

Check the cylinder bore inner diameter (in order to measure the amount of out-of-roundness, taper and wear) with a bore gauge (1) equipped with a dial indicator. Set ring gage to zero and check the cylinder bore diameter (2).

When detecting out-of-roundness, taper or wear, the cylinder bores must be bored and resurfaced.

Cylinder bore reconditioning must be done in standard increments of 0.5mm (0.020 inches) of over sized pistons and rings, and to prescribed assembly play.

IMPORTANT: If a bore gage is not available, use a micrometer to perform test.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL CHECKING CRANKCASE CYLINDER HEAD MATING SURFACE

STEP 45

STEP 46

2

1

4 3 2 Figure 2-166

BS06N269

Verify that the crankcase cylinder head mating surface does not show any warping.

BS06K269

Figure 2-165

CYLINDER BORE DIMENSIONS AND SPECIFICATIONS

IMPORTANT: In the case of reconditioning, all the bores must be machined to the same increment of 0.5 mm (0.02 inches).

Check the main bearing seats as follows:

• Mount the bed caps on the supports without

This check can be carried out by taking out dowels (2). With a straight edge (1) and a thickness gauge (4). Measure for warpage. Warpage must not be greater than 0.075 mm (0.0030 inches). If there are any deformed areas greater than the specified value, resurface the block.

IMPORTANT: When the repair work has been completed, check that the protrusion of the piston from the bore is not greater than the specified value.

As shown on page 2-118.

After flattening, restore the bore countersink as shown on page 2-100.

bearings.

• Tighten the fastening bolts to the specified torque.

• Check, with an internal comparator, that the seat diameter is the same as the specified value.

NOTE: If a greater value is found, replace the crankcase.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CAMSHAFT

Figure 2-167

BS06N270

MAIN FEATURES OF CAMSHAFT

The camshaft support journals and lobe surfaces must be perfectly smooth. If they show signs of seizing and scoring, replace the camshaft and respective bearings.

CHECKING ECCENTRIC LIFT AND BEARING SURFACE

For F4HE engines: 6.045 mm (0.238 inches) for Exhaust.

7.528 mm (0.296 inches) for Intake .

If different values are found than specifications, replace the camshaft.

STEP 47

1 2

3

Figure 2-168

BS06K266

Check the camshaft with a micrometer (1). The journal surface (2) must not have greater than 0.04 mm (0.0016 inches) of wear otherwise replace camshaft. Check the diameter of the camshaft bearing journals with a micrometer (1) on two axis perpendicular to each other.

Also check the eccentric (lobe) lift (3) which must be equal to.

For F4GE engines: 11.02 mm (0.434 inches) for Exhaust.

10.74 mm (0.423 inches) for Intake.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

REASSEMBLY BEARINGS

Figure 2-169

BS06N271

MAIN FEATURES OF CAMSHAFT BEARINGS AND RELATED SEATS * DIMENSION TO BE OBTAINED AFTER DRIVING THE BEARING

STEP 48

1

3 2

BS06K267

Figure 2-170

The camshaft bearings (2) must be pressed into their respective seats.

The inner surface must show no traces of internal wear.

Use bore gauge (3) to measure the diameter of rear bearing (2) and camshaft intermediate seats (1).

Measurements must be take on two axis perpendicular to each other.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL REPLACING CAM BEARINGS

INSTALLING TAPPETS AND CAMSHAFT

STEP 49

STEP 51

1

2

1 3

Figure 2-171

BS06K272

To replace front and rear bearings (1), remove and refit them using an acceptable driver (2) and striker (3).

IMPORTANT: When installing bearings (1) it must be aligned so that the lubrication holes are aligned with the holes on the crankcase seat.

BS06K274

Figure 2-173

Lubricate tappets (1) and fit them to there respective seats on the crankcase.

STEP 52

TAPPETS STEP 50

1 BS06K275

Figure 2-174

Lubricate the camshaft support bearings and mount the camshaft (1) taking care not to damage the bearings or support seats.

Figure 2-172

BS06N272

MAIN FEATURES OF TAPPETS AND THEIR RESPECTIVE SEATS ON THE CRANKCASE

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 55

STEP 53

1 1 2 2

Figure 2-175

BS06K276

Place camshaft retaining plate (1) with the slotted hole facing the crankcase upper side and the stamping facing the operator, then torque bolts to 20 to 28 Nm (14.8 to 20.7 pound-feet).

Figure 2-177

BS06K278

Mount nozzles (2) and tighten fastening bolts to 12 to 18 Nm (8.9 to 13.3 pound-feet).

STEP 54

1

BS06K277

Figure 2-176

Check the camshaft end play (1). It must be between 0.13 to 0.23 mm (0.005 to 0.009 inches).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CRANKSHAFT MEASURING BEARING JOURNALS AND CONNECTING RODS JOURNALS

If any traces of seizing, scoring, or out-of-roundness are found on the bearing journals and connecting rod journals, it is necessary to resurface the bearing journals by machining. Prior to resurfacing the bearing journals (2), measure the bearing journals with a micrometer (1) to determine the amount (diameter) by which the bearing journals will have to be reduced.

STEP 56

Reduction in classes are 0.25 and 0.50 mm (0.010 and 0.020 inches) IMPORTANT: It is advisable to write down the measured values on the table on page 2-105

Figure 2-178

BS06K279

IMPORTANT: Bearing journals and connecting rod journals must always be ground to the same reduction class.

The reduction done on the bearing journals and connecting rod journals must be marked with a special stamping made on the side of the crank arm.

For reduced connecting rod journals, use letter M. For reduced bearing journals, use letter B. For reduced connecting rod journals and bearing journals use letters MB

Figure 2-179 DATA ON WHICH CRANKSHAFT BEARING JOURNAL AND CONNECTING ROD JOURNAL MEASURING VALUES ARE TO BE WRITTEN DOWN

BS06N273

* - RATED VALUE

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

1

3

2

4

5

6

7

9

8

Figure 2-180

BS06N274

MAIN TOLERANCES OF DRIVE SHAFT

Tolerance Concerning SHAPE

ORIENTATION

POSITION

OSCILLATION

2-106

Tolerance-Related-Feature

Graphic Symbol

Roundness

1

Cylindrical

2

Parallelism

3

Perpendicularity

4

Straightness

5

Concentricity or Coaxial

6

Circular Oscillation

7

Total Oscillation

8

Taper

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CHAPTER 2 - 445TA ENGINE OVERHAUL

2

1

3

Figure 2-181

BS06K282

1. MAIN BEARING ON TIMING SYSTEM CONTROL SIDE 2. INTERMEDIATE MAIN BEARINGS 3. FIRST MAIN BEARING ON FRONT SIDE

REPLACING OIL PUMP DRIVE GEARS

MOUNTING MAIN BEARINGS

STEP 57

STEP 58

1 1

2 3 BS06K284

Figure 2-182

BS06K283

Verify that the teeth of gear (1) force-fitted on crankshaft (2) are not damaged or worn; otherwise, proceed with removal by means of a suitable extractor (3).

When fitting the new gear, the gear must be heated for 10 minutes at a temperature of 180° C ± 10% (356° F ± 10%).

WARNING: Always wear heat protective gloves to prevent burning your hands when handling heated parts.

Figure 2-183

IMPORTANT: If main bearings do not need replacing, they must be fitted in the same order and positions they were removed.

Main bearings (1) are supplied as spares with incrementally reduced inner diameters by 0.250 - 0.500 mm (0.010 - 0.020 inches).

IMPORTANT: No matching operation must be carried out on bearings.

Thoroughly clean the main half bearings (1) provided with lubrication holes, then fit them into their seats.

The main half bear ings (1) are provided with shoulder half rings.

SM121A

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 61

STEP 59

2 1

3

1

BS06N268

Figure 2-184

Install the crankshaft (2) in the engine crankcase on which gears (1) and (3) are force fitted.

Figure 2-186

BS06K287

Fasten pre-lubricated bolts (1) by tightening them in three phases.

• 1st phase with a torque wrench to 44 to 56 Nm

STEP 60

(32.5 to 41.3 pound-feet).

• 2nd phase with a torque wrench to 74 to 86 Nm (54.6 to 63.4 pound-feet).

1

STEP 62

2 1 3 2 4

BS06K286

Figure 2-185

Check the play between the crankshaft bearing journals and their respective bearings by following the procedure below:

• Thoroughly clean the parts to eliminate any foreign material and oil.

• Place a piece of gauged wire (3) parallel to the axis of the crankshaft pins (4)

Figure 2-187

BS06K288

• 3rd phase with a acceptable tool (1) placed as shown, tighten bolts (2) further to an angle of 90° ± 5°.

• Install the mount caps (1), with half bearings (2), on their respective supports.

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CHAPTER 2 - 445TA ENGINE OVERHAUL CHECKING CRANKSHAFT SHOULDER PLAY

STEP 63

STEP 64

1

2

1

2 3

Figure 2-188

BS06K289

Take the caps off the supports.

Figure 2-189

BS06K290

The play between the main bearings and their respective pins can be measured by comparing the width taken on by the gauged wire (2) at the narrowest point with the scale graduation shown on o the gauge (1) containing the calibrated wire.

The shoulder play is checked by placing a magnetic base indicator (2) on crankshaft (3) as shown in figure.

Normal assembly play is 0.068 to 0.410 mm (.0027 to 0.0161 inches)

The numbers shown on the scale indicate the backlash play in (mm).

If play falls out of the window, replace the main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft and main half bearings.

If the measured play is different than specifications, replace half bearings and repeat the check. Once the specified backlash play has been obtained, lubricate main bearings and mount the supports and torque as described in step 61 and 62.

PISTONS 1

2

8

4

7

3

6 5 Figure 2-190

BS06K291

PARTS MAKING UP THE CONNECTING ROD PISTON ASSEMBLY 1. PISTON 2. PISTON RINGS

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5. HALF BEARINGS 6. BEARING

7. WRIST PIN 8. RETAINING RINGS

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CHAPTER 2 - 445TA ENGINE OVERHAUL

Figure 2-191

BS07D256

MAIN DATA ABOUT PISTON

STEP 67

STEP 65

1

1

2 3

2

Figure 2-192

BS06K292

Figure 2-194

BS06K294

Taking piston rings (1) off piston (2) by using an acceptable tool.

Measure the piston diameter (1) by means of a micrometer (2) to determine the assembly play.

STEP 66

NOTE: The diameter of piston must be measured 8mm (0.315 inches) from the piston skirt base.

1 2 3

BS06K293

Figure 2-193

The retaining rings (1) retaining the piston pin (2) are removed by means of a scribe (3).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 68

CONDITIONS FOR CORRECT PIN/PISTON MATCHING STEP 70

1 1

Figure 2-195

BS06K295

The play between the piston and the cylinder bore can also be measured by means of a thickness gauge (1) as shown in figure.

PISTON PINS STEP 69

BS06K298

Figure 2-197

Lubricate piston pin (1) and its respective seat on piston hubs with engine oil, the pin must be inserted into the piston by pressing with your fingers slightly and must not slide out due to gravity.

STEP 71

2 1 2

1

Figure 2-196

BS06N299

Measure the piston pin diameter (1) by means of a micrometer (2).

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BS06K299

Figure 2-198

Check the thickness of piston rings (2) by means of a micrometer (1).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 74

STEP 72

1

1

2 2 3 3 Figure 2-199

BS06K300

Use a thickness gauge (1) to check the play between the piston rings (3) of the 3rd slot and the respective seats on piston (2).

Figure 2-201

BS06K302

Measure the piston ring gap (2) inserted into cylinder bore (3), by means of a thickness gauge (1).

CONNECTING RODS

STEP 73 STEP 75

1 X

3 2

BS06K301

Figure 2-200

DIAGRAM FOR MEASURING PLAY X FOR THE TRAPEZOIDAL RING

Due to the peculiar shape of the first trapezoidal cross-sectional seal ring, the play between the slot and the ring itself must be measured as follows.

• Allow piston (1) to protrude from the crankcase so that ring (2) comes out of the cylinder bore (3) about half way.

• In this position, check by means of a thickness gauge, the play (X) between the ring and the slot, it must correspond to the specified value.

Figure 2-202

BS06K303

MAIN DATA OF CONNECTING ROD, PISTON PIN BUSHING AND HALF BEARINGS

* Dimension of inner diameter to be obtained after driving into the connecting rod small-end and refacing by means of a reamer. ** This dimension cannot be measured in released condition.

IMPORTANT: The connecting rod, connecting rod cap matching surfaces are knurled to ensure better match.

Therefore, it is recommended not to remove knurls.

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CHAPTER 2 - 445TA ENGINE OVERHAUL BEARINGS

STEP 76

STEP 77 Verify that the bearings in the connecting rod smallend is not loosened and does not show traces of scoring or seizing. If it does replace them.

Removing and reassembling are carried out with the same suitable driver.

When driving the bearings, make sure that the holes allowing oil to flow onto the bear ing and the connecting rod small- end correspond to each other.

Use a reamer to reface the bearing to obtain the required diameter.

CHECKING CONNECTING RODS STEP 78

1 2 3

Figure 2-203

BS06K304

▲ -Production year ● -Production day

4

■ -Weight class IMPORTANT: Each connecting rod is marked as follows: • By a number (on the body and cap) which indicates the connecting rod match and the cylinder on which it is mounted. In case of replacement, it is necessary to number the new connecting rod with the same number as the replaced one.

• By letter (on the connecting rod body) which indicates the weight class of the factoryassembled connecting rod.

V- 1820 to 1860 grams (marked in yellow) W- 1861 to 1900 grams (marked in green) X- 1901 to 1940 grams (marked in blue)

BS06K305

Figure 2-204

Check the centerlines of the connecting rods (1) are parallel using proper device (5) as follows.

• Install connecting rod (1) on tool (5) spindle, then secure it by means of bolt (4).

• Place spindle (3) on V-blocks by putting connecting rod (1) on stop bar (2).

Replacement rods are supplied class W and marked in green.

Material removal is not permitted.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL CHECKING TWISTING

CHECKING FLEXING

STEP 79

STEP 80

1 B

2

1 2

D

C

A

3

5

3

5

4

4

BS06K306

Figure 2-205

Figure 2-206

BS06K307

Check connecting rod torsion (5) by comparing two points (A and B) of pin (3) on the horizontal plane of the connecting rod axis.

Check connecting rod flexing (5) by comparing two points (C) and (D) of pin (3) on the vertical plane of the connecting rod axis.

Place comparator (2) suppor t (1) so that the comparator is preloaded by approximately 0.5mm (.02 inches) on pin (3) at point A, then set comparator (2) to zero. Move spindle (4) with connecting rod (5), then compare the deviation (if any) on opposite side (B) of pin (3). The difference between A and B must not be greater than 0.08mm (0.003 inches).

Place comparator (2) vertical support (1) so that the comparator rests on pin (3) at point (C).

Swing the connecting rod back and forth, looking for the highest position of the pin. Under such condition, set comparator (2) to zero.

Move the spindle with connecting rod (5) and repeat the highest point check on opposite side (D) of pin (3). The difference between points (C) and (D) must not be greater than 0.08 mm (0.003 inches).

ASSEMBLING PISTON TO CONNECTING ROD

1 2 3 4 Figure 2-207

BS06K308

The following reference data is engraved on the piston crown.

1. Part number and design modification number 2. Arrow showing piston assembly direction into cylinder bore, this arrow shall face the front key of the engine block.

3. Manufacture date 4. Marking showing 1st slot insert testing.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL INSTALLING PISTON RINGS

STEP 81

1

STEP 83

2 3

1

4

2

3

Figure 2-208

BS06K309

Connect piston (2) to connecting rod (4) by means of pin (3) so reference inscription (1) for installing piston (2) in the cylinder bore and the numbers stamped on connecting rod (4) can be seen as shown in the figure above.

Figure 2-210

BS06K311

Use a suitable tool (3) to install piston rings (1) on piston (2).

IMPORTANT: The rings must be installed with the writing "TOP" facing upwards and they should be inserted so that the ring gaps are turned so that they are offset to each other by 120°.

STEP 82

2

NOTE: Spare piston rings are supplied in the following dimensions: • Standard, marked with yellow paint.

• Oversized by 0.4mm (0.016 inches), marked with yellow/green paint.

1

STEP 84

Figure 2-209

BS06K310

Insert pin (1) fastening split rings (2)

1

BS06K312

Figure 2-211

Install the half bearings (1) both on the connecting rod and the cap.

IMPORTANT: If connecting rod bearings do not need replacing, they must be installed in the same order and position they had prior to being taken off.

No matching operation must be carried out on half bearings.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL MEASURING CRANK PIN ASSEMBLY PLAY

INSTALLING CONNECTING ROD-PISTON ASSEMBLIES IN CYLINDER BORES

STEP 87 STEP 85

1 2 1 3

2

4 Figure 2-214

BS06K315 BS06K313

Figure 2-212

Lubricate the pistons, including the piston rings and the cylinder bore inside.

Use acceptable tool (2) to install the connecting rodpiston assemblies (1) into the cylinder bores verify that: • The number of each connecting rod corresponds to the cap matching number.

STEP 86

T h e p l ay c a n b e m e a s u r e d by fo l l ow i n g t h e procedure below.

• Thoroughly clean the parts and eliminate any traces of oil.

• Place a piece of gauged wire (2) on crankshaft pins (1).

• Install the connecting rod caps (3) with their respective half bearings (4).

STEP 88

1

2

1 BS06K314

Figure 2-213

SCHEME FOR INSTALLING THE CONNECTING ROD-PISTON ASSEMBLY INTO THE CYLINDER BORE

• The piston ring gaps are offset to each other by 120°.

• All the connecting rod-piston assemblies weigh the same.

Figure 2-215

BS06K316

Tighten bolts (1) previously lubricated with engine oil to the specified torque by means of a torque wrench (2) in three phases.

1st phase- 27 to 33 Nm (19.9 to 24.3 pound-feet) 2nd phase- 55 to 65 Nm (40.5 to 47.9 pound-feet)

• The writing stamped on the piston crown (1) faces the engine block front side, the notch on the piston skirt corresponds to the position of oil nozzles.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 89

STEP 91

1 2 2

1 Figure 2-216

BS06K317

Use an acceptable tool (1) on the socket wrench, then tighten bolts (2) fur ther in a cr isscross sequence.

BS06K319

Figure 2-218

If the measured play is different from the specified, replace half bearings and repeat the check.

Once the specified play has been obtained, lubricate the connecting rod half bearings and install them by tightening the connecting rod cap fastening bolts to specified torque

3rd phase additional rotation- 60° ± 5°.

STEP 90

2

1st phase- 27 to 33 Nm (19.9 to 24.3 pound-feet) 2nd phase- 55 to 65 Nm (40.5 to 47.9 pound-feet) 3rd phase additional rotation- 60° ± 5° IMPORTANT: Prior to installing the connecting rod cap fastening bolts, verify that the diameter measured at the middle of the thread length is not smaller than 0.1mm (0.004 inches) of the diameter measured at about 10mm (0.39 inches) from the bolt end.

1 Figure 2-217

BS06K318

Take off the cap and calculate the existing play by comparing the width of gauged wire (1) with the scale (2) graduation shown on the wire envelope.

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Manually check that connecting rods (1) slide axially on the crankshaft pins, and that the end play measured by means of a thickness gauge (2) is 0.10 to 0.33mm (0.004 to 0.013 inches)

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 94

CHECKING PISTON PROTRUSION STEP 92

2 1

3

Figure 2-219

BS06K320

After the connecting rod-piston assemblies have been installed, check with a dial indicator (1) equipped with base (2), the protrusion of pistons (3) at the top dead center relative to the engine block upper plane. Protrusion shall be 0.28 - 0.52 mm (0.011 - 0.0205 inches)

VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY

Figure 2-221

BS07D079

Install gear box case to the crankcase.

Install the bolts in the same positions they had prior to being taken off, then torque the bolts to: M8-

20 to 28 Nm (14.8 to 20.7 pound-feet)

M10-

42 to 52 Nm (30.9 to 38.4 pound-feet)

M12-

65 to 89 Nm (47.9 to 65.6 pound-feet)

STEP 95

STEP 93

1

1

2

Figure 2-222

BS06K323

Figure 2-220

BS07D078

SEALANT APPLICATION AREA

Thoroughly clean timing gear box case and the engine block. To obtain a good seal the surface must be clean. Apply a bead of LOCTITE 5205 to the case a few millimeters in diameter (1). It should be uniform in size without air bubbles, thin areas or voids. Any imperfection should be corrected as soon as possible. Avoid the use of excessive sealant to seal the joint. Excessive sealant could come out from the joint sides and cause lubrication passage clogging.

After applying the sealant, the joint should be assembled within (10 - 20 minutes).

2-118

Mark, with a felt tip pen, the tooth of drive gear (1) mounted on crankshaft (2) having the mark (→) on the side surface.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 97

STEP 96

1

1

3

2

2

4

3

Figure 2-223

BS06N304

Turn crankshaft (4) and camshaft (2) so drive gear (1) on the camshaft and the stamped marks on gears (1 and 3) align with each other.

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BS06K325

Figure 2-224

Tighten gear (2) fastening bolts (1) to camshaft (3), tighten them to 32 to 40 Nm (23.6 to 29.5 poundfeet).

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CHAPTER 2 - 445TA ENGINE OVERHAUL

INJECTION PUMP TIMING FIRST PHASE - F4GE ENGINES

STEP 100

1

STEP 98

2

1 2 Figure 2-227

BS06N308

BS06N305

Figure 2-225

Bring cylinder 1 to top-dead-center (TDC). When this occurs push pin (1) it is housed in the seat in the camshaft drive gear (shown by arrow) to lock the camshaft in the TDC position.

Force-fit the injection pump drive gear (1), then tighten nut (2) by hand.

NOTE: Be sure not to move the shaft for the injection pump when installing the pump.

STEP 99

1 2

3

BS06N306

Figure 2-226

Mount the injection pump body (1) in the gearbox seat (2), then secure it by means of bolts (3). Tighten to 20 to 30 Nm (14.8 to 20.7 pound-feet).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

ASSEMBLING COUNTER BALANCER F4GE ENGINES STEP 101

1 3

2

Figure 2-228

BS06N307

Turn engine over and install the counter balancer (2) and tighten the bolts (3) to 40 to 56 Nm (29.5 to 41.3 pound-feet) Remove the counter balancer locking pin (1).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL COUNTER BALANCER TIMING- F4GE ENGINES

1

2

B 3

A

4

Figure 2-229

BS06N309

COUNTER BALANCER GEAR ALIGNMENT 1. INJECTION PUMP GEAR 2. CAMSHAFT CONTROL GEAR

3. INJECTION PUMP CONTROL GEAR 4. COUNTER BALANCER UNIT

Make the marks (A) on the timing gears align, insert counter balancer locking pin into hole (B) on the counter balancer.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

FLYWHEEL

STEP 103

STEP 102

1

1 2 Figure 2-231

BS06N311

FLYWHEEL BELL HOUSING BOLT TORQUE SPECIFICATION Figure 2-230

BS06N310

SEALANT APPLICATION AREA TO FLYWHEEL BELL HOUSING

Thoroughly clean bell housing (1) and the engine block. To obtain a good seal the surface must be clean. Apply a bead of LOCTITE 5205 to the case a few millimeters in diameter. It should be uniform in size without air bubbles, thin areas or voids. Any imperfection should be corrected as soon as possible. Avoid the use of excessive sealant to seal the joint. Excessive sealant could come out from the joint sides and cause lubrication passage clogging.

After applying the sealant, the joint should be assembled within (10 - 20 minutes).

Install bell housing (1) on to the crankcase, install bolts (2) in the positions they had prior to being removed. Then tighten to the specified torque.

M12 x 120-

75 to 95 Nm (55.3 to 70.1 pound-feet)

M12 x 80-

75 to 95 Nm (55.3 to 70.1 pound-feet)

M10 x 80-

44 to 54 Nm (32.5 to 39.8 pound-feet)

M10 x 40-

75 to 95 Nm (32.5 to 39.8 pound-feet)

Rear cover plate to bell housing M8x1.25x16 - 20 to 28 Nm (14.8 to 20.7 pound-feet) NOTE: Tighten the bolts in the bell housing in a crisscross cross pattern.

STEP 104

1

2

7 6 5 4 BS06K328

3 Figure 2-232

Apply p ar t (4 ) o f Special tool 3 8000 0664 o n crankshaft rear shank (3), secure it with bolts (5) and force-fit the new seal ring (6) on to the rear shank.

Position part (1) on part (4), then screw nut (7) to fully mount seal ring (6) in flywheel bell housing case (2).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL ENGINE FLYWHEEL

STEP 106

STEP 105

1

2

2

1

3

Figure 2-233

BS06N312

FLYWHEEL FOR F4GE ENGINES

2 1

Figure 2-235

BS06N314

Screw two pins (2) of adequate length into the shaft holes (3), then install the engine flywheel (1) by means of suitable harness and a hoist into the flywheel bell housing.

STEP 107

1

Figure 2-236

BS06N313

Figure 2-234

BS07D076

FLYWHEEL FOR F4HE ENGINES

Remove the two pins and install the flywheel bolts (1) to the drive shaft.

Check contact surface of the flywheel and turn it if scoring is detected.

Check the condition of ring gear (2) teeth. If breaks or excessive tooth wear is found, remove the ring gear from the flywheel (1) by using a suitable tool. then mount the new ring gear after previously heating it to 150° C (302° F) for 15 to 20 minutes. Chamfering on the ring gear inside diameter must face the engine flywheel.

WARNING: Always wear heat protective gloves to prevent burning your hands when handling heated parts.

SM121A

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 110

STEP 108

1

Figure 2-237

BS06N315

Tighten flywheel bolts in two separate phases: 1st phase- 26 to 34 Nm (19.2 to 25.1 pound-feet)

2

BS06K334

Figure 2-239

Apply a new seal ring (2) onto the water pump (1).

STEP 111

2nd phase- 60° ± 5° NOTE: Before assembly check the threads of the ports and of the bolts to make sure there is no evidence of wear or dirt.

MOUNTING THE OIL AND WATER PUMP STEP 109

1

2 BS06K335

Figure 2-240

Mount water pump (1).

1

Install bolts (2) and torque them to

2

M8 bolts-20 to 28 Nm (14.8 to 20.7 pound-feet) STEP 112 Figure 2-238

BS06N319

Install oil pump (1).

Install bolts (2) and tighten them to specified torque: 1st stage- 7 to 9 Nm (5.2 to 6.6 pound-feet).

1

2nd stage- 20 to 28 Nm (14.8 to 20.7 pound-feet).

2

BS06K336

Figure 2-241

Take seal ring (2) off front cover (1), clean sealing surface thoroughly and apply Loctite 5205 sealant to the surface.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 115

STEP 113

1 3 2

1 2

Figure 2-244

BS06K341

Figure 2-242

BS06K337

FOR F4HE ENGINES

Thoroughly clean the mating surface of the front cover and install the front cover (2).

Install stiffner plate (3), oil pick up tube (1) and tighten fastening bolts (2). Torque to:

Fasten bolts (1) and torque them to

Stiffner plate M10- 38 to 48 Nm (28 to 35 pound-feet)

M8 bolts- 20 to 30 Nm (14.8 to 22.1 pound-feet).

Pick up tube- M8- 20 to 28 Nm (14.8 to 20.7 poundfeet).

STEP 114

STEP 116

1

1

2 3

1

4 2 5 Figure 2-245

BS06N320 BS06K338

Figure 2-243

Apply part (5) of tool 380000666 on crankshaft front shank (6), secure it by means of bolts (4) and force-fit the new seal ring (3) on the front shank.

OIL PAN (SUMP) FOR F4GE ENGINES

Position part (1) on part (5), then screw nut (2) to fully mount seal ring (3) in front cover (7).

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CHAPTER 2 - 445TA ENGINE OVERHAUL

1 4

1

5

2

2

3 Figure 2-246

BS06K343

6 Figure 2-248

BS06K344

OIL PAN (SUMP) FOR F4HE ENGINES

FOR F4HE ENGINES

Install phonic wheel (1) and hub (2) on the crankshaft.

Install a new oil pan gasket.

Mount the oil pan (1).

Torque bolts to:

Fasten bolts (2) and torque them to

1st stage- 45 to 55 Nm (33.2 to 40.6 pound-feet).

M8x1.25- 20 to 28 Nm (14.8 to 20.7 pound-feet).

2nd stage- 90° ± 5°

STEP 117

3

1 2 3

4

4

Figure 2-247

BS06N321

FOR F4GE ENGINES

Force-fit pulley (1) complete with spacer (2) onto the crankshaft, then torque the bolts to 105 to 115 Nm (77.4 to 84.8 pound-feet) Install guide pulleys (4) to the front cover by means of bolts (3) and tighten to: 37 to 49 Nm (27.3 to 36.1 pound-feet)

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 120

STEP 118

1 1

2

2

3

4

Figure 2-249

BS06K345

FOR F4HE ENGINES

Figure 2-251

BS06N323

Install a new seal ring on RPM sensor (2).

Install RPM sensor (2) on front cover (1) Torque bolt to 6 to 10 Nm (4.4 to 7.4 pound-feet).

Install alternator support (1) in such a way that pins (2) and (3) are placed against the crankcase. Fasten bolts (4) and tighten them to specified torque.

Alternator Torque Specifications:

STEP 119

Support M8 - 20 to 28 Nm (14.8 to 20.7 lb.-ft.)

1

Lower mount M10- 20 to 28 Nm (14.8 to 20.7 lb.-ft.)

2

Upper pivot M10- 44 to 54 Nm (32.5 to 39.8 lb.-ft.)

Alternator wiring M6 nut- 8 to 12 Nm (5.9 to 8.9 lb.-ft.)

3 4

Mounting hardware M12- 37 to 49 Nm (27.3 to 36.1 lb.-ft.)

5

Alternator to water inlet M8- 20 to 28 Nm (14.8 to 20.7 lb.-ft.)

STEP 121

Figure 2-250

BS06N322

INSTALLING WATER/OIL HEAT EXCHANGER

Install the following items on the crankcase:

2

A new gasket between the exchanger unit and crankcase (1), heat exchanger (2), new inner gasket (3), heat exchanger body (4). Fasten bolts (5) and tighten to specified torque of.

1

20 to 30 Nm (14.8 to 22.1 pound-feet).

Figure 2-252

BS06N324

Install alternator (1) on support (2) and connect associated hardware. Tighten to specified torque information listed above in step 120.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

CYLINDER HEAD FOR F4GE ENGINES STEP 124

REMOVING THE VALVES STEP 122

1 2 3

1

4

BS06N327

Figure 2-253

BS06N325

Valves can be removed by means of acceptable tools (1), by pressing slightly spring seat (3) so that keepers (2) can be removed by compressing spring (4). Then remove spring seat (3) and spring (4).

Figure 2-255

In addition to the head dimensions, the exhaust valves differ from the intake valves in that they are equipped with a additional notch (1) located on the stem of the intake valves.

Repeat the above procedure on all the valves.

STEP 123

1

Figure 2-254

BS06N326

Take off seals (1) fitted to the valve stems.

To remove the valves, turn the head upside down.

IMPORTANT: Mark the exhaust and intake valves prior to removing them.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 127

STEP 125

1 2

Figure 2-256

BS07C593

Remove the thermostat housing (1) and thermostat (2) from the cylinder head.

STEP 126

1

Figure 2-258

BS06N329

MAIN FEATURES OF CYLINDER HEAD

Nominal thickness (A) of the cylinder head is 95 ± 0.25 mm (3.740 ± 0.0099 inches) max. Material removal shall not exceed thickness (B) 0.13 mm (0.005 inches) IMPORTANT: After resurfacing, check valve sinking and regrind valve seats if required, to obtain the required value.

CHECKING CYLINDER HEAD WATER SEAL STEP 128

3

BS06N328

C h e ck t h e wa t e r s e a l by m e a n s o f s u i t a bl e equipment. Use a pump to feed water heated to approximately 90° C (194° F) at a pressure of 2 to 3 bar (29 to 43.5 psi).

2 Figure 2-257

The plane of the supporting surface of the cylinder head (1) is checked by means of a straight edge (2) and a thickness gauge (3).

The warpage found on the entire length of the cylinder head must not be greater than 0.20 mm (0.008 inches).

If leaks are detected from the freeze plugs, they must be replaced by using a suitable beater for removal and reassembling operations.

IMPORTANT: Prior to mounting the freeze plugs, apply water repellent sealant to the freeze plugs.

If leaks are found from the cylinder head the cylinder head must be replaced.

If greater values are found, resurface the cylinder head according to the values in figure on page 2-130.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

VALVES

STEP 130

1

2

BS06K360

Figure 2-261

Use a micrometer (2) to measure valve stem (1), which must be equal to 7.943 to 7.963 mm (0.313 to 0.314 inches) Figure 2-259

BS06N330

MAIN DATA OF INTAKE AND EXHAUST VALVES

VALVE DESCALING, CHECK AND GRINDING

CHECKING VALVE GUIDE WEAR STEP 131

STEP 129

1 2

BS06N332

Figure 2-260

BS06K359

Remove the carbon deposits from the valves by means of the special metal brush.

Verify that the valves do not show traces of seizing, scoring or burns.

Adjust if required, the valve seats with the proper grinder, removing the least amount of material possible.

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Figure 2-262

Check can be made by means of a magnetic dial indicator (1) placed as shown. Assembly play must be equal to 0.056 to 0.096 mm (0.002 to 0.004 inches).

Check, by turning valve (2) and making sure that the centering error does not exceed 0.03 mm (0.001 inches).

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL VALVE SEATS REGRINDING- REPLACING VALVE SEATS

VALVE GUIDE STEP 132

STEP 133

1

2

BS06N331

Figure 2-263

Use a bore gauge to measure the valve guide inner diameter, which must be equal to the value shown in the figure above.

2-132

Figure 2-264

BS06N333

Check valve seats (2). If slight scoring or burrs are found, regrind seats with tool (1) according to the angle values shown in figure on page 2-133.

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CHAPTER 2 - 445TA ENGINE OVERHAUL VALVE SEATS

Figure 2-265

BS07E175

VALVE SEAT DIMENSIONS

If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By using the same tool (1) in (figure 2-262) and taking care not to indent the cylinder head.

Remove as much material as possible from the valve seats until the seat can be taken off the cylinder head by using a punch.

STEP 134

Heat the cylinder head to 80 to 100° C (176 to 212° F), then mount the new valve seats (previously cooled) into the heated cylinder head by means of a suitable beater.

3

Recondition the valve seats with tool (1) in (figure 2-262), according to values shown in (figure 2-263).

1 2

BS06N336

Figure 2-266

After regrinding, check that valve (3) recess value is as specified by using the base and dial indicator.

WARNING: Always wear heat protective gloves to prevent burning your hands when handling heated parts.

SM121A

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CHAPTER 2 - 445TA ENGINE OVERHAUL VALVE SPRINGS

MOUNTING CYLINDER HEAD

STEP 135

STEP 136

1 2 3 Figure 2-267

BS06N337

MAIN DATA FOR INTAKE / EXHAUST VALVE SPRING CHECK

Prior to installing, check the valve spring flexibility by means of the proper tool. Compare the elastic strain and load data with the existing springs to the new springs shown in the table below.

Height in mm / inches

Under a load of N / lbf

Figure 2-268

BS06N338

Lubr icate the va lve stem and inser t into the respective valve guide according to the position marked when disassembling.

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

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

No Load

H (Free)

63.50 (2.50)

H1

49.02 (1.93)

P1

329 (73.96)

H2

38.20 (1.50)

P2

641 (144.10)

INSTALLING VALVES STEP 137

2 3

1

4

Figure 2-269

BS06K369

Position spring (4) and spring seat (3) on the cylinder head. Use acceptable tool (1) to compress spring (4) and lock the par ts to the valve by means of the keepers (2).

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 138

RODS AND TAPPETS STEP 140

A

B

Figure 2-270

BS06K370

Verify that the cylinder head and the crankcase mating surfaces are both clean.

Take care not to damage the cylinder head gasket.

The gasket thickness to be used, will have to take in consideration of the cylinder protrusion measured with respect to the crankcase upper surface Set the head gasket with writing "TOP" facing the head.

The arrow shows the point where the gasket thickness is given.

IMPORTANT: Prior to reusing the cylinder head bolts, verify that they do not show traces of wear, corrosion or deformation. If they do STEP 139

Figure 2-272

BS06K378

A. BAD PUSH ROD B. GOOD PUSH ROD

Prior to inserting the pushrods, verify their conditions:

• The push rods should not be distorted • The ball seats in contact with the rocker arm adjusting screw and tappet (arrows) must not show traces of seizing or wear, otherwise they must be replaced

• Intake and exhaust pushrods are identical and therefore interchangeable.

ROCKER ARM ASSEMBLY STEP 141

4

1 2 1

Figure 2-271

BS06N341

Lubricate cylinder head bolts prior to installing them.

Mount the cylinder head on the crankcase by fastening bolts (1), WITHOUT tightening them.

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3 Figure 2-273

BS06N342

PARTS MAKING UP THE ROCKER ARM ASSEMBLY 1. SUPPORT

2. ROCKER ARM

3. ARBOR

4. BOLTS

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CHAPTER 2 - 445TA ENGINE OVERHAUL TORQUING CYLINDER HEAD

STEP 142

STEP 144

Figure 2-274

BS06N343

Figure 2-276

BS06N345

MAIN DATA OF ARBOR-ROCKER ARM

Verify that the arbor/rocker arm matching surfaces do not show excessive wear or damage.

Install lubricated bolts into the cylinder head.

NOTE: install in the same position that they came out. There are three different length bolts used.

STEP 143

2 1

Figure 2-277

BS06N346 BS06N344

Figure 2-275

TIGHTENING SEQUENCE FOR CYLINDER HEAD BOLTS F4GE ENGINES

Verify that the tappet adjusters are unscrewed to prevent the tappet from crawling on the rods when the rocker arm assembly (1) is mounted.

Pre lubricated bolts

Mount the rocker arm assembly made up of the arbors and rocker arm support, then secure them to the head WITHOUT tightening the bolts (2).

M12x1.75x140 mm- 1, 2, 7, 8, 9, 10, 15, 16, 17, 18.

M12x1.75x70 mm- 3, 6, 11, 14.

M12x1.75x180 mm - 4, 5, 12, 13.

1st phase: 70 mm bolts- 45 to 55 Nm (33.2 to 40.6 pound-feet).

140 mm bolts- 35 to 45 Nm (25.8 to 33.2 pound-feet).

180 mm bolts- 65 to 75 Nm (47.9 to 55.3 pound-feet).

2nd phase: 90° ± 5°.

3rd phase: Only for 140 and 180 mm long bolts.

An additional 90° ± 5°.

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CHAPTER 2 - 445TA ENGINE OVERHAUL ADJUSTING TAPPETS

INSTALLING THE INJECTORS

STEP 145

STEP 146

2

1

1

2

3

3 Figure 2-278

BS06N347

Adjust the play between rocker arms and valves using allen wrench (1), box end wrench (3) and feeler gauge (2).

Correct play is:

BS06N348

Figure 2-279

Mount a new seal ring (2) lubricated with clean engine oil and a new seal washer (3) on injector (1).

Mount the injectors on their seats on the cylinder head, then tighten them to the following torque.

55 to 65 Nm (40.6 to 47.9 pound-feet).

Intake valves- 0.2 to 0.3 mm (0.008 to 0.012 inches).

STEP 147

Exhaust valves-0.2 to 0.3 mm (0.008 to 0.012 inches).

1

NOTE: 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 Top Dead Center (TDC) at the end of compression stroke and adjusting the clearance of both valves on the cylinder. See procedure on page 2-157.

4

3 BS06N349

2 Figure 2-280

Mount the injector feeding pipe assembly (1). Mount the pipes for fuel discharge (2) from injectors, by using gaskets (4) and by tightening bolts (3).

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CHAPTER 2 - 445TA ENGINE OVERHAUL

INSTALLING EXHAUST MANIFOLD, TURBOCHARGER

STEP 148

1 2 6

STEP 149

1

5

4

3 Figure 2-281

BS06N350

Mount the injection pump (2), injector feeding pipes (3), then secure brackets (1), (5), (6) fastening the pipe assembly onto the cylinder head.

Mount priming pump(4).

Torque spec for fuel pump: M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet).

M6 bolts- 9 to 11 Nm (6.6 to 8.1 pound-feet).

M6 nut-

2

Figure 2-282

BS06N371

• Install exhaust manifold (2).

Tighten to specified torque of: M10 bolts- 37 to 49 Nm (27.3 to 36.1 pound-feet).

• Install turbine (1).

Tighten to specified torque of: M10 bolts- 37 to 49 Nm (27.3 to 36.1 pound-feet).

9 to 11 Nm (6.6 to 8.1 pound-feet).

NOTE: Be sure and not turn the injector pump drive shaft when installing injector pump. do not torque injector pump bolts yet.

Injector pump drive shaft to be connected later.

INSTALLING INTAKE MANIFOLD STEP 150

1 6 2 3 4 5 Figure 2-283

BS06N372

APPLICATION FOR F4GE9454H AND F4GE9454J ENGINES

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 152

1

A

2

B

6 3

1

4 5 1

Figure 2-284

BS06N373

APPLICATION FOR F4GE9484D ENGINES

BS06K388

Figure 2-286

The intake manifold is made up of manifold (5) on the cylinder head, cover (6), seal gaskets (2) and (4), grid heater (3) and elbow (1).

Press the clamp (1) in direction of arrow (figure B) and connect the pipe.

Apply Loctite 5205 sealant between cover (6) and intake manifold (5), then tighten the bolts to the specified torque.

STEP 153

Reset the clamp to the initial locking position (A).

M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet) STEP 151

1

12

2

3 4

11

5

10

6

9

7

1

BS06N376

Figure 2-287

Assemble the wire harness (1).

8 Figure 2-285

BS06N376

• • • • • • •

Install valve covers (12).

Install the grid heater (2).

Install intake manifold elbow (1).

Install grid heater control unit (11).

Install fuel filter bracket (10).

Install fuel filter (7).

Attach quick coupling pipes (5,6,9) by following installation in figure 2-199.

• Install electric wiring (8) • Install L.D.A. system piping (4) • Install engine oil vapor recovery pipe to blow-by (3).

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 154

STEP 156

1 1

2 2

4

3

3

BS06N377

Figure 2-288

• Install turbine lubricating oil return piping (1) and fastening bracket (4).

• Install turbine lubricating oil delivery pipe and engine oil pipes to water/oil cooler (2).

• Install the starter motor tighten bolts to specified torque.

Figure 2-290

BS06N380

Install fan pulley (2) on support (1) tighten bolts (3) to specified torque.

M6 bolts-

8 to 12 Nm (5.9 to 8.8 pound-feet)

M10 bolts- 37 to 49 Nm (27.3 to 36.1 pound-feet) STEP 157

M10 bolts- 44 to 54 Nm (32.5 to 39.8 pound-feet).

1

STEP 155

1

2 2 3 3

6

4

4 5 6

5

Figure 2-291

BS06N381

BS06N378

Figure 2-289

• Install the thermostat housing (1) to the cylinder head (5) and tighten bolts (6) to specified torque.

Install Polly-V belt (3) on pulley (4) crankshaft pulley, guide pulley (6), water pump (5) and on the alternator (2). Then loosen the automatic belt tensioner (2) and release onto the belt.

M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet)

• Install water temperature sensor (2) and tighten to specified torque.

17 to 23 Nm (12.5 to 17.0 pound-feet)

• Install the fan pulley support (3) on the head (5) by means of bolt (4), and tighten to specified torque.

M10 bolts- 28 to 38 Nm (20.7 to 28.0 pound-feet).

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CHAPTER 2 - 445TA ENGINE OVERHAUL

INJECTION PUMP TIMING

STEP 160

The following two steps (step 158, 159) are two ways of finding Top Dead Center (TDC) STEP 158

1

1 Figure 2-294

BS06N316

Tighten the already installed lock washer and nut (1) on the back side of the injector pump drive shaft.

Tighten to specified torque.

2 Figure 2-292

BS06N305

SEARCHING FOR TDC WITH GEAR BLOCKING PIN

Turn the flywheel until, the pin (1) can be inserted into the gear (2). This will put the engine at Top Dead Center (TDC) of the number 1 cylinder.

1st phase- 15 to 20 Nm (11 to 14.8 pound-feet) 2nd phase- 90 to 95 Nm (66 to 70 pound-feet) NOTE: Make sure that the injector pump drive shaft does not move when tightening the nut.

WARNING: Be careful not to drop the nut and washer inside engine.

STEP 159

STEP 161

A

1

1

BS06N317

Figure 2-293

BS07C720

FINDING TDC WITH FALSE INJECTOR

Remove the rocker cover from the number one cylinder, remove the number one injector and place dial indicator (1) to set the number one cylinder to TDC (end of compression stroke). Pre-load the dial indicator.

B 2

Figure 2-295

Apply Loctite 5205 sealant (1) as shown in figure (A).

Then install the cover (2) and tighten bolts to specified torque.

M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet).

Rotate engine until you find the maximum value on the dial indicator, and then check that both the intake and exhaust valves are closed (both exhaust and intake pushrods should be loose).

Once TDC has been obtained lock the flywheel with acceptable tool to prevent engine from turning.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 163

STEP 162

1

1

2

2 BS07C719

Figure 2-296

Loosen bolt (2) that prevents pump shaft rotation and insert spacer (1). Tighten bolt (2) so it locks spacer (1), now the injection pump drive shaft will be able to rotate freely. Disengage flywheel locking pin see, step 158 on page 2-141.

Figure 2-297

BS07C721

• Locate the timing plug at the center of the four injection lines and remove it with a 12mm socket.

• Install adapter (1) CAS2458 and insert dial indicator (2) into the timing hole.

• Preload the gauge approximately 2.5 mm.

• Turn the engine counterclockwise from TDC until dial indicator needle stops moving.

• Turn the engine clockwise until the TDC is reached again.

• Note the timing prelift shown on the gauge.

The timing prelift specification is: 0.95 to 1.10 mm (0.037 to 0.043 inches) STEP 164 If the pre-lift timing meets specification then tighten the nuts to the following torque specification: 20 to 30 Nm (14.8 to 22.1 pound-feet) NOTE: Use a 38 mm (15 inches) socket extension minimum to tighten the back bolt so that the gauge reading will not be altered.

STEP 165 Remove dial indicator and adaptor, install timing plug cap.

STEP 166 If timing prelift is out of specification, do the following procedures.

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 167

STEP 174

With engine at TDC and dial indicator installed. Make sure the three nuts that secure pump to housing are still loose.

STEP 168 Rotate the pump in a counter clockwise direction if the stroke is shorter or in a clockwise direction if the stroke is longer.

1

STEP 169 When proper prelift is obtained, tighten the mounting nuts to the following torque specification: 20 to 30 Nm (14.8 to 22.1 pound-feet)

Figure 2-299

BD04A025-01

NOTE: Use a 38 cm (15 inches) socket extension minimum to tighten the back bolt so that the gauge reading will not be altered.

Attach Special Tool 380000979 (1) to the injection pump drive gear and loosen the nut and lock washer.

STEP 175

STEP 170

Turn the engine back to TDC (Top Dead Center).

NOTE: If the timing prelift can not be achieved by rotating the pump do the following procedures.

STEP 176

STEP 171 Make sure the pump housing nuts are tight.

STEP 172

1

Turn the engine over until the prelift reads, 1.00 to 1.10 mm (0.039 to 0.043 inches) STEP 173

BS06N316

Figure 2-300

Tighten the lock washer and nut (1) to the back side of the injector pump drive shaft, to specified torque.

1

2

1st phase- 15 to 20 Nm (11 to 14.8 pound-feet) 2nd phase- 90 to 95 Nm (66 to 70 pound-feet) NOTE: Make sure that the injector pump drive shaft does not move when tightening the nut.

Figure 2-298

BS07C719

WARNING: Be careful not to drop the nut and washer inside engine.

Lock the injection pump by removing the slotted plate (1) and tightening the bolt (2).

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CHAPTER 2 - 445TA ENGINE OVERHAUL

REPLACING THE INJECTORS

STEP 177

A 1

B

REMOVAL

2

STEP 1

2

3

1

BS06N317

Figure 2-301

Apply Loctite 5205 sealant (1) as shown in figure (A).

Then install the cover (2) and tighten bolts to specified torque.

M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet).

STEP 178 Verify that the pump prelift is within specifications: 0.95 to 1.10 mm (0.037 to 0.043 inches).

STEP 179 Remove dial indicator and adaptor. Install timing plug cap back on injection pump.

4

Figure 2-302

BS06N382

Lift engine compar tment cover, disconnect the battery cables and proceed as follows:

• Disconnect engine oil vapor recovery pipe (1) from blow-by.

• Take off tappet cover (3) by removing nut (2).

• Disconnect the fuel manifold pipes from injectors (4).

NOTE: Always replace tappet cover gaskets during assembly STEP 2

1

2 Figure 2-303

BS06N383

Remove injectors (2) with Special Tool 380000671 (1) and take out of the cylinder head.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

ROCKER ARM REMOVAL / ASSEMBLY

REASSEMBLING STEP 3

REMOVAL STEP 1

1 2 1

3 4

2 Figure 2-304

BS06N379

Install a new seal ring (2) lubricated with clean engine oil on the injector.

BS06N345

Install injector, verify that the locator pin (1) is correctly positioned in the cylinder head.

Loosen tappet adjuster fastening nuts (3), then unscrew adjusters (2).

Tighten the injectors to the specified torque:

Remove bolts (4) and remove rocker arm assembly (1) made up of the rocker arm support and arbors, then remove valves.

55 to 65 Nm (40.6 to 47.9 pound-feet).

STEP 4

Figure 2-306

ASSEMBLY

1

2

Verify that the tappet adjusters are unscrewed to prevent tappets from crawling on the push rods when the rocker arm assembly is installed.

Mount the rocker arm assemblies made up of rocker arm support and arbors, then secure them to the cylinder head by tightening bolts to the specified torque.

Rocker arm fastening bolts: M8 bolts- 36 Nm (26.5 pound-feet).

Figure 2-305

BS06N384

• Mount new seal rings (2) on fuel manifolds (1).

• Connect the manifolds to the injectors, by tightening the tightening nuts to specified torque of: 50 Nm (37 pound-feet).

• Re-connect the engine oil vapor recovery pipe to the blow-by.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL ADJUSTING TAPPETS STEP 2

1

3

2

BS06N347

Figure 2-307

Adjust the play between rocker arms and valves using allen wrench (1), box end wrench (2) and feeler gauge (3).

Correct play is: Intake valves- 0.2 to 0.3 mm (0.008 to 0.012 inches).

Exhaust valves-0.2 to 0.3 mm (0.008 to 0.012 inches).

NOTE: 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 Top Dead Center (TDC) at the end of compression stroke and adjusting the clearance of both valves on the cylinder. See procedure on page 2-157.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL

CYLINDER HEAD ASSEMBLY - F4HE ENGINES STEP 3

STEP 1

3

1 3

1

2

2 4 5 4 Figure 2-310

BS07D069

Figure 2-308

BS06K350

Install the high pressure pump (4) including the feed pump (5) and tighten the nuts to the specified torque.

M8 nuts- 20 to 28 Nm (14.8 to 20.7 pound-feet) Install the support (3) with a new sealing ring, the timing sensor (2) with a new sealing ring and tighten the fastening nut (1), to specified torque.

Insert the power take-off (4) equipped with the gasket (2) the cover (1) and its gasket (2).

Tighten the bolts (3) to the general bolt torque specifications.

REMOVING THE VALVES STEP 4

M6 nut- 6 to 10 Nm (4.4 to 7.4 pound-feet)

A

1

STEP 2

2

1 2

3

B BS06K352

Figure 2-311

Intake (1) and exhaust (2) valves have heads with the same diameter.

Figure 2-309

BS06K351

Install the EDC7UC31 electronic control unit (3) including the heat exchanger to the engine block and tighten the bolts (2), to: M6 bolts- 8 to 12 Nm (5.9 to 8.9 pound-feet).

M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet).

The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.

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

A = Intake side B = Exhaust side

IMPORTANT: Replace the vibration damper elements (1) if they are cracked or excessively deformed.

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CHAPTER 2 - 445TA ENGINE OVERHAUL CHECKING CYLINDER HEAD WATER SEAL

STEP 5

2

1

STEP 7

3

4

5 1 BS06K353

Figure 2-312

Va l ve s c a n b e r e m o ve d w i t h a va l ve s p r i n g compressor tool (1) by pressing slightly on collar (3) so that lock cones (2) can be removed by compressing springs (4).

Then remove collar (3) and springs (4).

Repeat the operation on all valves.

Turn the head upside down and remove the valves (5).

STEP 6

Figure 2-314

BS06K355

C h e ck t h e wa t e r s e a l by m e a n s o f s u i t a bl e equipment.

Use pump to feed water heated to 90° C (194° F) at a pressure of 2 to 3 bar (29 to 43 psi.)

If leaks are detected from the freeze plugs, they must be replaced by using a suitable tool for removal and reassembling operations.

IMPORTANT: Prior to installing the freeze plugs, apply water repellent sealant to them.

If leaks are detected from the cylinder head, the cylinder head must be replaced.

2

CHECKING CYLINDER HEAD MATING SURFACE STEP 8

1

BS06K354

2

Figure 2-313

3

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

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

Sealing rings (2) for exhaust valves are green.

1 Figure 2-315

BS06K356

The plane of the supporting surface of the head (1) to cylinder cluster is checked by means of a straight edge (2) and a thickness gauge (3).

The warping found on the entire length of the cylinder head must not be greater than 0.20mm (0.008 inches).

If greater values are found, reface the cylinder head according to values given in the next step.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 9

VALVE CLEANING, CHECKS AND GRINDING STEP 10

Figure 2-316

BS06K357

The rated thickness "A" of the cylinder head is 105 ± 0.25mm (4.134 ± 0.0099 inches). Maximum allowed metal removal must not exceed thickness "B" by 0.13 mm (0.005 inches).

IMPORTANT: After grinding, check valve sinking.

Regrind the valve seats if necessary, to obtain the specified value

VALVES

Figure 2-318

BS06K359

Remove the carbon deposits from the valves by means of a special metal brush.

Verify that the valves do not show traces of seizing, scoring or cracking.

Reface if necessary the valve seats by grinding, removing as little material as necessary.

STEP 11

1

2

Figure 2-317

BS06K358

INTAKE AND EXHAUST VALVE MAIN DATA

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BS06K360

Figure 2-319

Use a micrometer (2) to measure valve stem (1), which must be equal to 6.97 to 6.99 mm (0.2744 to 0.2751 inches)

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CHAPTER 2 - 445TA ENGINE OVERHAUL CHECKING VALVE GUIDE WEAR

VALVE SEATS- REGRINDING, REPLACING

STEP 12

STEP 14

1 2

BS06K361

Figure 2-320

Use a magnetic dial indicator (1) placed as shown.

Assembly play must be equal to 0.052 to 0.092 mm (0.0020 to 0.0036 inches) Turn valve (2) and check that the centering error is not exceeding 0.03 mm (0.0011 inches)

Figure 2-322

BS06K363

Check valve seats (2). If slight scoring or burrs are found, regrind seats with tool (1) according to the angle values shown on page 2-151 figure 2-321.

VALVE GUIDES STEP 13

BS06K362

Figure 2-321

Use a bore gauge to measure the valve guide inner diameter, which must be equal to 7.042 to 7.062 mm (0.2772 to 0.2780 inches).

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CHAPTER 2 - 445TA ENGINE OVERHAUL

Figure 2-323

BS07D077

MAIN DATA ON VALVE SEATS ON CYLINDER HEAD F4HE ENGINES

Figure 2-324

BS06K365

MAIN DATA ON VALVE SEATS

If the valve seats cannot be reseated, just by grinding, replace them with replacement parts. By using tool (1, in step 14) to remove as much material as possible from the valve seats (taking care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

Heat the cylinder head to 80° to 100° C (176° to 212° F) and using the proper beater, install the new valve seats (previously cooled) into the heated cylinder head.

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Recondition the valve seats with tool (1 in step 14) according to the values shown on page 2-151 figure 2-321 .

WARNING: Always wear heat protective gloves to prevent burning your hands when handling heated parts.

SM121A

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 15

1 2 3

BS06K366

Figure 2-325

After the reconditioning operations, verify by means of a base (2) and dial indicator (1), that the valve recess (3) corresponds to the specified value.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

VALVE SPRINGS STEP 16

Figure 2-326

BS06K367

MAIN DATA FOR INTAKE AND EXHAUST VALVE SPRING CHECK

Height

Under a force of

mm/ inches

N/ pound-force (lbf)

H

47.75 (1.88 inches)

Free

H1

35.33 (1.39 inches)

P

339.8 ± 19 N (76.2 ± 4.27 lbf.)

H2

25.20 (0.992 inches)

P2

741 ± 39 N (166.6 ± 8.77 lbf.)

INSTALLING CYLINDER HEAD

STEP 18

STEP 17

1

2 3

3 1 2

4 5

BS06K369

Figure 2-327

Lubricate the valve stem (1) and insert into the respective valve guide according to the position marked when disassembling.

Figure 2-328

Position spring (4) and upper collar (3) on the cylinder head. Use tool (1) to compress spring (4) and lock the parts to the valve by means of lock cones (2).

Install seal rings (2 and 3) into the valve guide.

IMPORTANT: Seal rings (2) for intake valves are yellow. Seal rings (3) for exhaust valves are green.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 21

FITTING CYLINDER HEAD STEP 19

1

Figure 2-331

BS06N346

Cylinder head fastening bolt tightening sequence: Figure 2-329

BS06K370

Verify that the cylinder head and the engine block mating surfaces are both clean.

Take care not to damage the cylinder head gasket.

Set the cylinder head gasket (1) with the writing "TOP" (1) facing the head.

The arrow shows the point where the gasket thickness is given.

IMPORTANT: Prior to reusing the cylinder head fastening bolts, verify that they do not show traces of wear, deformations or corrosion. If they do replace them.

Pre lubricated bolts 1st phase: 130mm bolts- 30 to 40 Nm (22.1 to 29.5 pound-feet) 150 mm bolts- 50 to 60 Nm (36.9 to 44.3 pound-feet) 2nd phase: Angle tighten- 90° ±5° 3rd phase: Angle tighten an additional- 90° ± 5°

INSTALLING INJECTORS STEP 22

TORQUING CYLINDER HEAD STEP 20

1

3

2

3

1

2 Figure 2-332

BS06K373

Install a new sealing ring (2) lubricated with vaseline and a new sealing washer (3) on injector (1).

BS06K371

Figure 2-330

Install cylinder head (1), attach bolts (2) and tighten them in three successive steps according to the procedure in (step 21) on page 2-154.

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 25

STEP 23

1

1

2

2

3

5 3

4 Figure 2-333

BS06K374

Install injectors (1) on the cylinder head seats, directed so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side STEP 24

Figure 2-335

BS06K376

Install a new sealing ring (4) lubricated with vaseline on the fuel manifold (5) and install it into the cylinder head seat so that the positioning ball (3) is lined up with the notch in the housing (2).

IMPORTANT: Disassembled fuel manifolds (5) must not be reused, they need to be replaced with new ones.

1

IMPORTANT: During this operation, the injector (1) shall be moved so that the manifold (5) is properly inserted into the fuel inlet hole.

STEP 26

2

1

Figure 2-334

BS06K375

Use Special Tool 380001099 (1) to install the injector (2) into its seat.

Screw injector fastening bolts without tightening them.

2 BS06K377

3 Figure 2-336

Use a torque wrench to tighten gradually and alternating the injector fastening bolts (1) to: 1st stage- 7.7 - 9.3 Nm (5.7 - 6.9 lbf ft.).

2nd stage- 75° ± 5° Screw the fastening nuts (2) on the fuel manifold (3) without locking them.

Tighten the fuel manifold (3) fastening nuts (2) to 45 to 55 Nm (33.2 to 40.6 lbf ft.) of torque.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL RODS AND TAPPETS

STEP 28

STEP 27

A

B

Figure 2-339

BS06K380

MAIN DATA OF ARBOR-ROCKER ARM BS06K378

Figure 2-337

A. BAD PUSH ROD B. GOOD PUSH ROD

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

Prior to inserting the pushrods, verify their conditions:

STEP 29

• The push rods should not be distorted • The ball seats in contact with the rocker arm

1

adjusting screw and tappet (arrows) must not show traces of seizing or wear, otherwise they must be replaced

• Intake and exhaust pushrods are identical and therefore interchangeable.

ROCKER ARM ASSEMBLY

2 1

4 BS06K379

Figure 2-340

BS06K381

2

Install the push rods (2).

3

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

4 Figure 2-338

PARTS MAKING UP THE ROCKER ARM ASSEMBLY 1.

2.

3.

4.

BOLTS SUPPORT ROCKER ARM ARBOR

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CHAPTER 2 - 445TA ENGINE OVERHAUL

LOCATING TOP DEAD CENTER (TDC)

STEP 30

IMPORTANT: Due to the additional lobe for the Internal EGR, each cylinder must cylinder must be adjusted by taking it to the TDC. (top dead center) and adjusting the clearance of both valves on every cylinder.

1 2 3

STEP 31

4 5 Figure 2-341

BS06K382

Check tappet adjusters (1) that they are loose to prevent their balking on the rods (2) when installing the rocker assembly.

1

Then install the rocker assembly consisting of: bracket (5), rockers (3), shafts (4), and secure them to the cylinder head by tightening the fastening bolts (2) to the specified torque.

2 Figure 2-342

BS06K345

1. ENGINE BLOCK

M8 bolts- 36 Nm (26.5 lbf ft.)

2. TONE WHEEL

• Remove the injector from the number one cylinder.

• Rotate engine over using Special Tool 380000988 to bring the number one cylinder to the highest point using a dial indicator. Check to see if push rods are loose, if they are not rotate the engine 360° now they should be loose.

• Put a reference mark on tone wheel (1) and the engine block (2) this is (Cylinder 1).

STEP 32 Measure the circumference of the tone wheel and divide by 2. Starting from the reference mark on tone wheel put on in step 31. Put the other mark of the calculated length on the tone wheel. Once these marks are installed, adjust the corresponding cylinder valves (Cylinder 1).

Rotate engine to the next mark, and adjust valves for corresponding cylinder in firing order (Cylinder 3).

Next rotate engine to the next mark and adjust the valves for the next cylinder in the firing order (Cylinder 4). Repeat sequence for next cylinder (Cylinder 2) NOTE: Firing order is (1, 3, 4, 2) NOTE: You will need to rotate the crankshaft two complete rotations in order to adjust all the valves.

NOTE: Before adjusting make sure the valves on each cylinder are loose. If they are not, you are on the wrong cylinder 87630273 NA

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CHAPTER 2 - 445TA ENGINE OVERHAUL

INSTALLING INTAKE MANIFOLD STEP 34

ADJUSTING VALVE PLAY STEP 33

1

3 1 2

2 3 BS06N347

Figure 2-343

Adjust the play between rocker arms and valves using allen wrench (1), box end wrench (2) and feeler gauge (3).

Correct play is:

Figure 2-344

BS07D064

Apply Loctite 5999 to the contact surfaces of intake manifold (1) and install the intake manifold and grid heater (3) to the cylinder head. Install air intake (2) with a new gasket and tighten to general bolt torque specifications.

Intake valves- 0.2 to 0.3 mm (0.008 to 0.012 inches).

Tighten intake manifold bolts to:

Exhaust valves- 0.45 to 0.55 mm (0.018 to 0.022 inches).

Tighten grid heater cover plate nuts to:

M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet).

M6 nuts- 6 to 10 Nm (4.4 to 7.4 pound-feet).

NOTE: 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 Top Dead Center (TDC) at the end of compression stroke and adjusting the clearance of both valves on the cylinder.See page 2-157.

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CHAPTER 2 - 445TA ENGINE OVERHAUL

INSTALLING FUEL SYSTEM

STEP 37

3

STEP 35

1 4 2

1

3

2

4 5 Figure 2-347

BS06K387

Figure 2-345

BS06K385

Install the rail (2) and tighten the bolts (1) to the general bolt torque specifications in the repair manual. Connect the ground cable (3) to the intake manifold (4) and tighten the fastening nut (5) to 20 to 30 Nm (14.8 to 22.1 lb.- ft.) of torque.

Connect the fuel line (4) to rail (2) following the procedure shown in the following figure (step 38).

IMPORTANT: Fuel line (4) connections shall be tighten to 20 Nm (14.8 lb.-ft.) of torque, using the proper box wrench and the torque wrench 380000158 (3).

STEP 38

STEP 36

B

A

1 2

1

3

1 BS06K388

Figure 2-346

BS06K386

Figure 2-348

Connect new fuel lines (1) to rail (3) and injector manifolds (2).

Press the clamp (1) in arrow direction (Figure B) and connect the line to the rail, reset the clamp to the initial locking position (Figure A).

IMPORTANT: When fuel lines (1) are removed they should always be replaced with new ones

IMPORTANT: Check for proper fuel line connection.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 41

INJECTOR WIRING STEP 39

4

1 1

2

2 3

5

4

BS06K389

3

Figure 2-351

BS06K391

Figure 2-349

Check wir ing cable (2) condition, replace it if damaged, by cutting the support (5) clamps and removing the bolts (3) that secure it to connectors (4). Install a new gasket (1) on the support (5).

Connect the electrical cables (1) to the injectors (3) and use Special Tool 380000158 torque wrench (4) to tighten the fastening nuts (2) to the general bolt torque specifications in the repair manual.

STEP 40

1

2

BS06K390

Figure 2-350

Install the wiring support (2) and tighten the bolts (1) to the general bolt torque specifications in the repair manual.

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 44

INSTALLING TAPPET COVER STEP 42

1

2

1

2 BS06K393

Figure 2-352

BS06K392

Install a new gasket (2) on the tappet cover (1).

Figure 2-355

Install the tappet cover (1) and tighten the nuts (2) to 20 to 30 Nm (14.8 to 22.1 lb.-ft.) the specified torque.

EXHAUST MANIFOLD / TURBO INSTALLATION

STEP 43

STEP 45

1 4

1 Figure 2-353

BS07G387

2

3

1. BLOW-BY FILTER

BS07D073

Figure 2-356

Re-attach exhaust manifold (3) with new gaskets.

Install bolts and tighten them to: M10 bolts- 48 to 58 Nm (35.4 to 42.8 pound-feet).

2

Re-attach turbo-charger (1) to exhaust collector, with a new gasket and tighten nuts to: M8 nuts- 20 to 30 Nm (14.8 to 22.1 pound-feet).

Connect the oil pipeline (4) to the support of the heat exchanger. Attach the oil line to the line fitting on the turbocharger (2) tighten nut to:

Figure 2-354 2. CHECK VALVE INSTALLED IN THE BLOW-BY FILTER

BS07G388

M12 nut- 8 to 12 Nm (5.9 to 8.9 pound-feet).

Make sure the check valve (2) is installed in the blowby filter (1) located in the tappet cover. If not replace the filter.

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ENGINE REPAIR MANUAL

CHAPTER 2 - 445TA ENGINE OVERHAUL STARTER INSTALLATION

STEP 46

STEP 48

1 2 6 3 4

1 2 3

5

4 Figure 2-357

BS06K396

If present, insert the blow-by filter (4) tightening the bolts to the general bolt torque specifications.

Connect the line (2) and attach the oil vapor recovery line with clamp (3).

Connect the line (6) to the pressure-limiter device (1) by the figure below (step 46).

Figure 2-359

BS06K399

Install the starter (5) to the flywheel housing (4) and tighten the bolts to: 37 to 49 Nm (27.3 to 36.1 pound-feet).

Install the oil line (3) with a new sealing ring into the engine block and secure it to the turbo charger (1) by the bolts (2) and tighten to

STEP 47

A

5

B

20 to 30 Nm (14.8 to 22.1 pound-feet).

1

FUEL FILTER BRACKET INSTALLATION STEP 49

1 1 BS06K388

2 Figure 2-358

Press the clamp (1) in arrow direction (Figure B) and connect the line. Reset the clamp to the initial locking position (Figure A).

3

IMPORTANT: Check for proper fuel line connection.

Figure 2-360

BS06K400

Install the bracket (2) including the fuel filter bracket (1) to the engine block, tighten bolts (3) to: M12 bolts- 69 to 85 Nm (50.9 to 62.7 pound-feet).

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CHAPTER 2 - 445TA ENGINE OVERHAUL WIRING HARNESS CONNECTIONS TO THE ENGINE- F4HE ENGINES STEP 50

1

6

2 7

3 8 4 9 10 11 5 Figure 2-361

BS06K398

1. CONNECTIONS FOR ELECTRO-INJECTORS

5. CRANKSHAFT SENSOR

2. ENGINE COOLANT TEMPERATURE SENSOR

6. ELECTRO-INJECTOR

3. COMMON RAIL FUEL PRESSURE SENSOR 4. OIL TEMPERATURE-PRESSURE SENSOR

7. BOOST TEMPERATURE AND PRESSURE SENSOR 8. CAMSHAFT SENSOR

Re-attach engine cable by connecting electroinjectors (6) wiring connectors (1), boost pressure/ temperature sensor (7), common rail pressure sensor (3), EDC7UC31 electronic control unit (11), high pressure pump sensor (10), camshaft sensor (8), engine coolant temperature sensor on thermostat (2), crankshaft sensor (5).

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9. FUEL HEATER AND TEMP SENSOR 10. HIGH PRESSURE REGULATOR 11. EDC7UC31 CONTROL UNIT

Apply rocker lever to engine lifting hooks, hook the rocker lever to a hoist and detach the engine from rotating stand. Remove brackets.

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 52

STEP 51

A

2 1

B

1

5 4 BS06K401

1 3 Figure 2-362

By hand screw on the fuel filter (3) to the bracket (1).

Tighten the fuel filter 3/4 of a turn after the gasket makes contact with the bracket. Connect the fuel lines (2, 4, 5) to the relevant support connections (1) as shown in step 51.

2-164

Figure 2-363

BS06K388

Press the clamp (1) in arrow direction (Figure B) and connect the line. Reset the clamp to the initial locking position (Figure A).

NOTE: When installation is complete, fill engine with the proper lubricating oil.

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ENGINE REPAIR MANUAL

CHAPTER 3

445TA TIER III

ELECTRICAL, CHARGING AND START-UP

Issued 08-2007 Book/Form Number 87630273 NA Copyright © 2006. CNH America LLC. All Rights Reserved.

Printed in U.S.A. • Bur Source Code No. unknown

ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer Revision History Issue First Edition

3-II

Issue Date

Applicable Machines

Remarks

08-2007

F4GE9454H, F4GE9454J, F4GE9484D F4HE9484A, F4HE9484C

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ENGINE REPAIR MANUAL

CHAPTER 3

ELECTRICAL, CHARGING AND START-UP TABLE OF CONTENTS LOCATION OF THE MAIN ELECTRICAL COMPONENTS FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . 3-3 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Rotary Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 KSB Water Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 EDC7UC31 Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Cabling Connector Pinout On Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Connector (A) Injectors Pinout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Connector (C) Sensors Pinout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Crankshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Camshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Boost Temperature - Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Engine Oil Temperature - Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Common Rail Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Intake Air Pre-post Resistance Heater And Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 High Pressure Pump - Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Quick Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Quick Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

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CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP

NOTES

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP

LOCATION OF MAIN ELECTRICAL COMPONENTS - F4GE ENGINES 1

2

3 A

7

B

6

5

4 Figure 3-1

BS07C722

Below are listed the electrical components which are present on F4GE9454H, F4GE9454J, F4GE9484D engines.

1. STARTER 2. KKSB- WATER TEMPERATURE SENSOR 3. ELECTROMAGNETS ASSEMBLED TO INJECTION PUMP (A)- ON HYDRAULIC HEAD UNIT (B)- ON KSB

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4.

5.

6.

7.

OIL PRESSURE SENSOR GRID HEATER- (FOR COLD START UP) ALTERNATOR COOLANT TEMPERATURE SENSOR

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP ROTARY INJECTION PUMP

COOLANT TEMPERATURE SENSOR

1

2 Figure 3-3

BS07C726

1. Hydraulic head Electro-magnet.

2. KKSB Electro-magnet.

C

Cold start advance system (KKSB)

A B

B C

A

Figure 3-2

BS07C723

Coolant temperature sensor is installed on the engine cylinder head close to the thermostat unit, it detects engine coolant temperature.

When engine is cold (coolant temp. is below 50° C 122° F), the injection pump is in timing advanced state. When engine reaches 60 to 66° C (140 to 151°F), the thermo switch in the cylinder head opens and the system voltage is no longer sent to the solenoid on the injection pump. This allows the timing to retard to "normal" operating position.

KKSB WATER TEMPERATURE SENSOR

Specifications: Range of working temperatures: Connection side: -40 to +150 °C for < 10 minutes.

-40 to +302 °F for < 10 minutes.

Bulb side on engine: -40 to +140 °C -40 to + 284 °F Working voltages: 6 to 28 volts Resistance readings at temperatures: 80 °C (176 °F)-

304 to

342 Ohms.

20 °C (68 °F)-

2262 to 2760 Ohms.

-10 °C (14 °F)-

8244 to 10661 Ohms.

Figure 3-4

BS07C725

KKSB water temperature sensor is installed on the cylinder head on the left hand side of the engine.

Specifications: Working voltage 12 to 24 volts Electrical power load:

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CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP GRID HEATER

OIL PRESSURE SENSOR

BS07C729

Figure 3-5

BS07C727

Oil pressure sensor is installed to the engine crankcase on the engines left hand side.

Figure 3-6

Grid heater is a resistor installed in the intake manifold. It is used to heat the intake air during cold weather starting.

The grid heater is controlled by the grid heater control unit located very close to the engine. Which is activated when temperature is below 5° C (41° F)

Specifications: Working voltage: 12 to 24 volts Contact closure Upon lower pressure: 0.2 bar (2.9 psi) Contact opening Upon higher pressure: 0.9 bar (13 psi)

Specifications: Working voltage: depending on equipment 12 volt or 24 volt.

Maximum air flow: 2cc / min Pressure: 138 kPa (20 psi) Impedance : Approximately 0.5 Ohm.

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CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP

LOCATION OF MAIN ELECTRICAL COMPONENTS - F4HE ENGINES 3 1

2

4

5 12

6

11

8

9

10

7 Figure 3-7

BS06K072

Below are listed the electrical components which are present on F4HE9484A / F4HE9484C engines.

1.

2.

3.

4.

5.

6.

COOLANT TEMPERATURE SENSOR ELECTRO-INJECTOR FUEL RAIL PRESSURE SENSOR BOOST TEMPERATURE/PRESSURE SENSOR STARTER MOTOR CAMSHAFT SENSOR

T h e e n g i n e i s c o n t r o l l e d by t h e E D C 7 U C 3 1 electronic control module. The control module is installed on flexible mounts to reduce vibration transmitted by the engine. The fuel heat exchanger removes heat from the controller due to the high voltages needed for firing the injectors. It removes the heat from the controller and loses it in the fuel cooler. It also picks up some engine heat when it is returned from the cylinder head. The unit is supplied with a 20 amp fuse. The main relay used to supply the power to the system is located inside the control unit.

3-6

7.

8.

9.

10.

11.

12.

SOLENOID VALVE FOR PRESSURE REGULATOR FUEL TEMPERATURE SENSOR EDC7UC31 ELECTRONIC CONTROL UNIT CRANKSHAFT SENSOR ENGINE OIL PRESSURE/TEMPERATURE SENSOR HEATING ELEMENT FOR PRE-POST HEATING

Through the engine control module, it is possible to verify the correct operations of the engine and also help troubleshoot problems with error codes generated from the EDC7UC31 control module.

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP EDC7UC31 ELECTRONIC CONTROL UNIT

C

A

B

Figure 3-8

BS06K073

EDC7UC31 ELECTRONIC CONTROL UNIT A. CONNECTOR TO INJECTORS B. CONNECTOR FOR POWER INPUT AND FUNCTIONS PROVIDED FOR IN THE APPLICATION C. CONNECTOR TO SENSORS

NOTE: Ensure you replace the electronic control unit (EDC7UC31) with the correct model. The previous controller model EDC7 has similar connectors but with different wiring.

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP CABLING CONNECTOR PINOUT ON ENGINE

A

C

10

1

9

2

8 7 3 6 4 5

Figure 3-9

BS07D157

CONNECTOR / CABLING DIAGRAM A. B. C. 1.

2.

3.

4.

CONNECTOR A (INJECTORS) EDC7UC31 ECU (POWER) 5.

CONNECTOR B NOT SHOWN (SEE NOTE BELOW) 6.

CONNECTOR C (SENSORS) EDC7UC31 ECU (SIGNAL) 7.

INJECTORS FOR CYLINDERS 1-2 8.

INJECTORS FOR CYLINDERS 3-4 9.

CRANKSHAFT SENSOR 10.

CAMSHAFT SENSOR

OIL PRESSURE AND TEMPERATURE SENSOR FUEL TEMPERATURE COOLANT TEMPERATURE SENSOR BOOST AIR TEMPERATURE AND PRESSURE SENSOR COMMON RAIL PRESSURE SENSOR FUEL HIGH PRESSURE REGULATOR SENSOR

NOTE: Connector B is not shown because it is specific to the machine application see the particular machine schematic.

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CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP CONNECTOR (A) INJECTORS PINOUT DIAGRAM EDC7UC31 ECU PIN

FUNCTION

CONNECTOR (C) SENSORS PINOUT DIAGRAM EDC7UC31 ECU PIN

FUNCTION

1.

Not Used

1.

Not Used

2.

Not Used

2.

Not Used

3.

Cylinder 4 injector

3.

Not Used

4.

Cylinder 1 injector

4.

Not Used

5.

Cylinder 3 injector

5.

Not Used

6.

Cylinder 2 injector

6.

Not Used

7.

Not Used

7.

Not Used

8.

Not Used

8.

Not Used

9.

High pressure regulator with fuel metering

9.

Camshaft speed sensor - Signal

10.

High pressure regulator with fuel metering

10.

Camshaft speed sensor - Ground

11.

Cylinder 2 injector

11.

Not Used

12.

Cylinder 3 injector

12.

13.

Cylinder 1 injector

Common rail temperature and pressure sensor - Ground

14.

Cylinder 4 injector

13.

15.

Not Used

Common rail temperature and pressure sensor - Positive

16.

Not Used

14.

Common rail temperature and pressure sensor - Signal

15.

Coolant temperature sensor - Signal

16.

Not Used

17.

Not Used

18.

Fuel temperature sensor - Signal

19.

Crankshaft speed sensor - Ground

20.

Not Used

21.

Not Used

22.

Not Used

23.

Crankshaft speed sensor - Signal

24.

Engine oil pressure and temperature sensor Ground

25.

Boost intake pressure sensor - Ground

26.

Coolant temperature sensor - Ground

27.

Oil pressure sensor - Signal

28.

Oil temperature sensor- Signal

29.

Not Used

30.

Not Used

31.

Not Used

32.

Engine oil pressure and temperature sensor Positive

33.

Boost intake pressure sensor - Positive

34.

Boost intake pressure sensor - Signal

35.

Fuel temperature sensor - Signal

36.

Boost intake temperature sensor - Signal

NOTE: Connector B is not shown because it is specific to the machine application see the particular machine schematic.

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP CRANKSHAFT SENSOR

Figure 3-10

BS06K075

CRANKSHAFT SENSOR

The crankshaft sensor is connected to the EDC -7 control unit on pins 19C - 23C. The sensor impedance is approximately 900 Ohms.

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

CAMSHAFT SENSOR

A

3

2

1 1

B

C

2 3 Figure 3-11

BS06K076

A. CAMSHAFT SENSOR

Reference

Description

B. CONNECTOR

EDC7UC31 ECU Crankshaft sensor

Camshaft sensor

1

Signal

19C

10C

2

Signal

23C

9C

3

Shield

3-10

C. WIRING DIAGRAM

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP BOOST TEMPERATURE - PRESSURE SENSOR This component incorporates a temperature sensor and a pressure sensor all in one unit.

I n s t a l l e d o n t h e i n t a ke m a n i fo l d , t h e s e n s o r measures the temperature and boost pressure, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle.

The sensor is connected to the EDC7UC31 electronic control unit on pins 25C - 36C - 33C - 34C. The sensor is supplied with 5 volts.

Voltage at the sensor output is proportional to the detected pressure or temperature.

• Pin 25C - 36C Temperature • Pin 33C - 34C Pressure ENGINE OIL TEMPERATURE - PRESSURE SENSOR

Figure 3-12

BS06K077

PRESSURE - TEMPERATURE SENSOR

This component incorporates a temperature sensor and a pressure sensor all in one unit.

1

2

3

4

The engine oil temperature-pressure sensor is installed on the engine oil filter bracket in a vertical position. This sensor measures the engine oil temperature and pressure.

The sensor is connected to the EDC7UC31 electronic control unit on pins 24C - 28C - 32C - 27C. The sensor is supplied with 5 volts. The pressure signal is transmitted to the EDC7UC31 electronic control unit which in turn, sends a signal to the instrument panel gauge and low pressure warning light.

The oil temperature is not displayed on any gauges this value is used exclusively by the control unit.

Pin 24C - 28C

Temperature

Pin 32C - 27C

Pressure

Reference

Description

Figure 3-13

BS06K078

EDC7UC31 Control unit pin number Oil

Air

1

Ground

24C

25C

2

EDC7UC31 control unit- Signal (temperature)

28C

36C

3

+5 volt power supplied to sensor

32C

33C

4

Signal (pressure)

27C

34C

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP COMMON RAIL FUEL PRESSURE SENSOR

2 3

1

Figure 3-14

BS06K079

COMMON RAIL FUEL PRESSURE SENSOR CONNECTOR

Reference

Description

EDC7UC31 control unit pin

1

Ground

12C

2

Signal

14C

3

Power supply

13C

The fuel rail pressure sensor is installed on one end of the common rail, this sensor measures the internal fuel pressure and feeds back this information to the EDC7UC31 control unit.

This sensor is connected to the EDC7UC31 control unit on pins 12C - 14C - 13C. The power supplied to sensor is 5 volts.

The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical pulse for the injection command.

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP ELECTRO-INJECTORS

Figure 3-15

BS07D158

INJECTOR WIRE HARNESS LAYOUT

Figure 3-16

BS06K081

INJECTOR WIRE HARNESS (NOTE 6 CYLINDER HARNESS SHOWN)

The electro-injectors are a normally Closed (N.C.) solenoid valve.

The impedance of the coil of each injector is 0.56 0.57 Ohms.

Each injector is connected to the EDC7UC31 control unit on connector A. Reference

CONNECTOR 1

CONNECTOR 2

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Description

EDC7UC31 control unit pin

1

Cylinder 2 injector

11A

2

Cylinder 2 injector

6A

3

Cylinder 1 injector

13A

4

Cylinder 1 injector

4A

1

Cylinder 4 injector

14A

2

Cylinder 4 injector

3A

3

Cylinder 3injector

12A

4

Cylinder 3 injector

5A

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP GRID HEATER AND CONTROL RELAY

A

Figure 3-18

BS06K083

GRID PLATE HEATER CONTROL RELAY

Figure 3-17

BS06K082

GRID PLATE HEATER

The pre-post grid plate heater is located on the intake manifold.

The control relay is connected to the EDC7UC31 control unit B connector.

T h e r e l ay i s t r i p p e d w h e n wa t e r a n d o r f u e l temperature below 5° C (41° F).

The relay impedance is approximately 15 Ohms.

The purpose of the grid plate heater is to heat the air in pre-post heating operations. The grid plate heater is powered by a relay on the chassis.

The impedance of the grid plate heater is approximately 0.5 Ohm. WARNING: Starting fluids or aids, such as ether, must not be used to help start this engine. The use of these starting fluids or aids will cause severe internal damage to the engine and can also cause personal injury.

50-41

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CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP COOLANT TEMPERATURE SENSOR

Figure 3-19

BS06K209

COOLANT TEMPERATURE SENSOR

The coolant temperature sensor is a variable resistance sensor able to read the coolant temperature in order to provide the EDC7UC31 control unit with an indication of the temperature status of the engine.

The same signal is utilized by the control unit to drive an instrument panel gauge, if present.

This sensor is connected to the EDC7UC31 control unit on pins 15C - 26C. Resistance readings at various temperatures for sensor: 80 °C (176 °F)-

304 to

342 Ohms.

20 °C (68 °F)-

2262 to 2760 Ohms.

-10 °C (14 °F)-

8244 to 10661 Ohms.

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP FUEL TEMPERATURE SENSOR

This sensor detects the fuel temperature so the EDC7UC31 control unit can precisely inject the fuel required.

The fuel temperature sensor is connected to the EDC7UC31 control unit on pins 35C - 18C. Resistance readings at various temperatures for sensor: 80 °C (176 °F)-

304 to

342 Ohms.

20 °C (68 °F)-

2262 to 2760 Ohms.

-10 °C (14 °F)-

8244 to 10661 Ohms.

1 2

Figure 3-20

BS06K210

1. FUEL TEMPERATURE SENSOR 2. FILTER HEATER RELAY

1

2 Figure 3-21

BS06K211

FILTER HEATER RELAY

The EDC7UC31 control unit activates the filter heater relay when fuel temp drops below 5° C (41° F) Reference

Description

EDC7UC31 Control unit Pin Coolant

Fuel

1

Ground

15C

35C

2

Temperature Signal

26C

18C

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP HIGH PRESSURE PUMP - PRESSURE REGULATOR

A

Figure 3-22

BS06K212

A. PRESSURE REGULATOR

The quantity of fuel supplied to the high pressure pump is controlled by the supply pressure regulator solenoid valve. The high pressure regulator is controlled by the EDC7UC31 control unit.

Delivery pressure to the common rail is modulated between 250 and 1600 bar (3626 and 23206 psi) by the EDC7UC31 control unit by controlling the high pressure regulator solenoid valve.

• This component is a Normally Open solenoid valve.

• The solenoid is connected to the EDC7UC31 control unit on pins 9A - 10A.

• The solenoid valve impedance is approximately 3.2 ohms.

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP

STARTER MOTOR

Starter is usually controlled by a switch on the vehicle dashboard, which in turn energizes the solenoid assembled to the starter.

Depending on equipment: Manufacture- BOSCH - 24 Volt - 4kW Manufacture- BOSCH - 12 Volt - 3kW

Figure 3-23

BS07C724

QUICK DIAGNOSIS Fault

Cranking power insufficient

Cranking power sufficient, but the engine won’t start Pinion won’t engage

3-18

Possible Causes

Remedy

1. - Batteries run down

Recharge or Replace

2. - Circuit connections oxidized or loose

Clean or replace the component

3. - Brushes damaged or worn

Replace defective component

4. - Short-circuit in field windings

Replace defective component

5. -Open or short circuit in armature

Replace defective component

6. - Out of round bushings

Replace defective component

Starter bendix or solenoid Bevelled ring gear or flywheel

Replace defective component

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ENGINE REPAIR MANUAL

CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP

ALTERNATOR

Alternator is installed on the front right side of the engine and is driven by a belt.

Specifications: Working voltage: Depending on equipment 12 volt or 24 volt.

Current delivered: 90 amps at 6000 rpm Direction of rotation: Clockwise

Figure 3-24

BS07C728

QUICK DIAGNOSIS Fault

No charge

Low charge

Excessive charging

87630273 NA

Possible causes

Remedy

1. Open in recharge circuit (warning light, fuse, connector, etc.)

Check the recharge circuit connections. Clean and tighten the cable terminals on the alternator and battery.

2. Voltage regulator not working

Replace the component

3. Open rotor winding

Replace the component

4. Worn brushes

Replace the component

1. Loose belt

Check automatic belt tensioner

2. Faulty voltage regulator

Replace the component

3. Excessive wear of rotor rings or brushes

Replace the component

4. Short-circuited diodes

Replace the component

5. Short-circuited rotor windings

Replace the component

1. Loose circuit connections

Check the connections to terminals and cable terminals of batteries, starter motor and alternator

2. Voltage regulator not working

Replace component

3. Faulty ground

Check ground connections

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CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP

NOTES

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