Kobelco SK210-9 Hydraulic Excavator Engine Manual – PDF DOWNLOAD

51. ENGINE

51. ENGINE 51

51-1

Contents INTRODUCTION HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS A ELECTRICAL POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30.A

ENGINE AND PTO IN ................................................................... B ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.A FUEL AND INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.20.A AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.30.A EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.A ENGINE COOLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.50.A EXHAUST SYSTEM Emissions control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.40.B LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.60.A STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.80.A

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Contents INTRODUCTION Foreword - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Basic instructions - How To Use and Navigate Through This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Foreword - Ecology and the environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances which are required by advanced technology, sound judgement should govern the use and disposal of products of a chemical and petrochemical nature.

NOTICE: The following are recommendations which may be of assistance: •

Become acquainted with and ensure that you understand the relative legislation applicable to your country.

•

Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these substances.

•

Agricultural consultants will, in many cases, be able to help you as well.

HELPFUL HINTS •

Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems which may cause considerable spillage.

•

In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which may be harmful to your health.

•

Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

•

Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

•

Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil but should be collected and disposed of properly.

•

Do not open the air-conditioning system yourself. It contains gases which should not be released into the atmosphere. Your CNH dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

•

Repair any leaks or defects in the engine cooling or hydraulic system immediately.

•

Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

•

Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

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Safety rules Personal safety

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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Torque Component

Size

Specification

Cylinder Head and Components Plug

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

¼" ½" ¾" M6 Nut M8 Screw

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

M12 M8 M12x1.75x130 mm

65 - 89 Nm (47.9 - 65.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 85 - 95 ° 85 - 95 °

M12x1.75x150 mm

M8 Nut

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

M8 M8 M8 M8

Screw Nut Screw Nut

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

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

M12 Screw M10 Screw M8 Screw M10 M12

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

Front Case Front Cover

Rear Case Gear Case

Flywheel Housing

Cylinder Block and Crankshaft Components

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

Size M8 Screw M8 Screw M10 Screw M12

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

M10 M12

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

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

M8 M8 M22 M8 Screw

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

1 ⅛" M12 Nut M12

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

M8

Electrical Components Camshaft Sensor

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

M6 M6 M6 M6 M8

Studs Nut Screw Screw Screw

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

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

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Component

Size

Specification

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

M8 Studs M18 Nut M8 Nut

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

M6 Screw M6 Screw

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

M8 Screw M14 Fitting M8 Screw M12 Screw M8 Screw

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

M10 Screw 90 ° Elbow

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

M6 Screw M8 Screw M10 M10

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Basic instructions - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools.

Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages.

The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.

In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries.

In case of questions, refer to your CNH Sales and Service Networks.

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Basic instructions - How To Use and Navigate Through This Manual Technical Information This manual has been produced by a new technical information system. This new system is designed to deliver technical information electronically through Web delivery, DVD and in paper manuals. A coding system called SAP has been developed to link the technical information to other Product Support functions, e.g., Warranty.

Technical information is written to support the maintenance and service of the functions or systems on a customer’s machine. When a customer has a concern on his machine it is usually because a function or system on his machine is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the technical information in this manual to resolve that customer’s concern, you will find all the information classified using the SAP coding, according to the functions or systems on that machine. Once you have located the technical information for that function or system then you will find all the mechanical, electrical or hydraulic devices, components, assemblies and sub assemblies for that function or system. You will also find all the types of information that have been written for that function or system, the technical data (specifications), the functional data (how it works), the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.).

By integrating SAP coding into technical information , you will be able to search and retrieve just the right piece of technical information you need to resolve that customer’s concern on his machine. This is made possible by attaching 3 categories to each piece of technical information during the authoring process.

The first category is the Location, the second category is the Information Type and the third category is the Product: •

LOCATION - is the component or function on the machine, that the piece of technical information is going to describe e.g. Fuel tank.

•

INFORMATION TYPE - is the piece of technical information that has been written for a particular component or function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount of fuel held by the Fuel tank.

•

PRODUCT - is the model for which the piece of technical information is written.

Every piece of technical information will have those 3 categories attached to it. You will be able to use any combination of those categories to find the right piece of technical information you need to resolve that customer’s concern on his machine.

That information could be: •

the description of how to remove the cylinder head

•

a table of specifications for a hydraulic pump

•

a fault code

•

a troubleshooting table

•

a special tool

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How to Use this Manual This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the end of a Chapter. Page number references are included for every piece of technical information listed in the Chapter Contents or Chapter Index.

Each Chapter is divided into four Information types: •

Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and, assemblies.

•

Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and assemblies.

•

Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or hydraulic devices, components and assemblies.

•

Service Data (remove disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices, components and assemblies.

Sections Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This table illustrates which Sections could be included in a manual for a particular product.

SECTION A - Hydraulic – Pneumatic – Electrical – Electronic Systems B - Engine and PTO In C - Transmission, Drive and PTO Out D - Axles, Brakes and Steering E - Frame and Cab F - Frame Positioning G - Tool Positioning H - Hitch and Working Tool J - Excavating and Landscaping K - Crop Processing L - Field Processing PRODUCT Tractors Vehicles with working arms: backhoes, excavators, skid steers, .....

Combines, forage harvesters, balers, ....

Seeding, planting, floating, spraying equipment, ....

Mounted equipment and tools, .....

X X X X X X X X

X X X X X

X X

X X

X X X X X X X X

X X X X X X

X

X X

X X X

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X

X X

INTRODUCTION

Section Contents SECTION HYDRAULIC – PNEUMATIC – ELECTRICAL – ELECTRONIC SYSTEMS ENGINE AND PTO IN

LETTER A

B

TRANSMISSION, C DRIVE AND PTO OUT

AXLES, BRAKES AND D STEERING

FRAME AND CAB

E

FRAME POSITIONING F

TOOL POSITIONING

G

HITCH AND WORKING TOOL

H

EXCAVATING AND LANSCAPING

J

CROP PROCESSING

K

FIELD PROCESSING

L

DESCRIPTION This Section covers the main systems that interact with most of the functions of the product. It includes the central parts of the hydraulic, electrical, electronic, pneumatic, lighting and grease lubrication systems. The components that are dedicated to a specific function are listed in the Chapter where all the technical information for that function is included.

This Section covers all the functions related to the production of power to move the machine and to drive various devices.

In the case of a pulled-type machine, this Section covers the power take-off function where power is provided from the towing machine.

This Section covers all the functions related to the transmission of power from the engine to the axles and to internal or external devices. This Section also covers the power take-off function where power is provided to the pull-type machine and additional Process Drive functions.

This Section covers all the functions related to moving the machine, including tracks, wheels, steering and braking. It covers all the axles; both driven axles and non-driven axles, including any axle suspension.

This Section covers all the main functions and systems related to the structure and the body of the machine, including the frame, the shields, the operators cab and the platform. The functions related to the positioning of the machine frame are included in Section F, Frame Positioning.

This Section covers all the main functions and systems related to positioning of the machine frame or to positioning the attachment on the supporting machine frame.

This Section covers all the functions related to the final and/or automatic positioning of the tool once the tool is positioned using the Working Arm or the machine frame.

This Section covers all the functions related to the articulated or single arms mounted on the front or rear of the machine. A working arm can have various tools and quick couplers mounted on to it. The tools and quick couplers are included in Section J, Excavating and Landscaping.

This Section covers all the functions related to the specific tools that mount on the front, rear or beside the machine. The tools described here can be mounted with the positioning systems (lifting, side shift, swing) listed in Section G Tool Positioning. This Section covers all the quick coupling systems, located between the tool and the positioning system. The tools used for field preparation, soil preparation and treatment, planting and seeding are included.

This Section covers all the functions related to crop processing.

Examples of crop processing include threshing, baling, windrowing, cutting and conditioning.

This Section covers all the field processing functions of the machine. Examples of field process include seeding, fertilizer application, seedbed preparation and chemical application.

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This manual contains these Sections: Contents INTRODUCTION HYDRAULIC – PNEUMATIC – ELECTRICAL – ELECTRONIC SYSTEMS ENGINE AND PTO IN FRAME POSITIONING CROP PROCESSING

A B F K

Chapters Each Chapter is identified by a letter and number combination e.g. Engine B.10.A The first letter is identical to the Section letter i.e. Chapter B.10 is inside Section B, Engine and PTO In. CONTENTS The Chapter Contents lists all the technical data (specifications), functional data (how it works), service data (remove, install adjust, etc..) and diagnostic data (fault codes and troubleshooting) that have been written in that Chapter for that function or system on the machine.

Contents ENGINE AND PTO IN ENGINE _ 10.A TECHNICAL DATA ENGINE - General specification (B.10.A) FUNCTIONAL DATA ENGINE - Dynamic description (B.10.A) SERVICE ENGINE - Remove (B.10.A) DIAGNOSTIC ENGINE - Troubleshooting (B.10.A)

INDEX The Chapter Index lists in alphabetical order all the types of information (called Information Units) that have been written in that Chapter for that function or system on the machine.

Index ENGINE AND PTO IN - B ENGINE ENGINE - Dynamic description (B.10.A) ENGINE - General specification (B.10.A) ENGINE - Remove (B.10.A) ENGINE - Troubleshooting (B.10.A)

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Information Units and Information Search Each chapter is composed of information units. Each information unit has the SAP code shown in parentheses which indicates the function and the type of information written in that information unit. Each information unit has a page reference within that Chapter. The information units provide a quick and easy way to find just the right piece of technical information you are looking for.

Example information unit Information Unit SAP code SAP code classification

Stack valve - Sectional View (A.10.A.18) A 10.A Primary hydraulic power Hydraulic – Pneumatic – Electrical – Electronic Systems

CRIL03J033E01A

18 Stack valve

1

Navigate to the correct information unit you are searching for by identifying the function and information type from the SAP code.

•

(1) Function and (2) Information type.

•

(A) corresponds to the sections of the repair manual.

(B) corresponds to the chapters of the repair manual.

(C) corresponds to the type of information listed in the chapter contents, Technical Data, Functional Data, Diagnostic or Service.

(A) and (B) are also shown in the page numbering on the page footer.

THE REST OF THE CODING IS NOT LISTED IN ALPHANUMERIC ORDER IN THIS MANUAL. You will find a table of contents at the beginning and end of each section and chapter.

You will find an alphabetical index at the end of each chapter.

• •

By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly find the information you are looking for.

Page Header and Footer The page header will contain the following references: •

Section and Chapter description

The page footer will contain the following references: •

Publication number for that Manual, Section or Chapter.

•

Version reference for that publication.

•

Publication date

•

Section, chapter and page reference e.g. A.10.A / 9

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Basic instructions - Shop and Assembly SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated on each shim.

ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: •

before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.

•

thoroughly clean the shaft and check that the working surface on the shaft is not damaged.

•

position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will deviate the fluid towards the inner side of the seal.

•

coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease.

•

insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a hammer or mallet.

•

whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes contact with the thrust element, if required.

•

to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.

O-RING SEALS Lubricate the O-RING seals before inserting them in the seats, this will prevent them from overturning and twisting, which would jeopardise sealing efficiency.

SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or LOCTITE® RTV 598 or LOCTITE® INSTANT GASKET 587 BLUE. Before applying the sealing compound, prepare the surfaces as directed on product container or as follows: •

remove any incrustations using a metal brush.

•

thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts cleaner.

SPARE PARTS Only use "CNH Original Parts" or " CNH Parts".

Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same parts that are assembled during standard production. Only "CNH Original Parts" or " CNH Parts" can offer this guarantee.

When ordering spare parts, always provide the following information: •

machine model (commercial name) and serial number

•

part number of the ordered part, which can be found in the "Microfiches" or the "Service Parts Catalogue", used for order processing

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PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR WELDING To avoid damage to the electronic/electrical systems, always observe the following: 1. Never make or break any of the charging circuit connections, including the battery connections, when the engine is running.

2. Never short any of the charging components to ground.

3. Always disconnect the ground cable from the battery before arc welding on the combine or on any header attached to the combine.

•

position the welder ground clamp as close to the welding area as possible

•

if welding in close proximity to a computer module, then the module should be removed from the combine

•

never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress

4. Always disconnect the negative cable from the battery when charging the battery in the combine with a battery charger.

NOTICE: If welding must be performed on the unit, either the combine or the header (if it is attached), the battery ground cable must be disconnected from the combine battery. The electronic monitoring system and charging system will be damaged if this is not done.

Remove the battery ground cable. Reconnect the cable when welding is completed.

WARNING Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetables oil. Call physician immediately. EYES: flush with water for 15 minutes and get prompt medical attention.

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TOOLS The tools that CNH suggests and illustrate in this manual have been: •

specifically researched and designed for use with CNH machines

•

essential for reliable repair operations

•

accurately built and rigorously tested so as to offer efficient and long-lasting operation

By using these tools, repair personnel will benefit from: •

operating in optimal technical conditions

•

obtaining the best results

•

saving time and effort

•

working in safe conditions

NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from the rear, facing in the direction of travel of the machine during operation.

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INTRODUCTION

Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE CLASS 8.8 BOLT and CLASS 8 NUT UNPLATED M4 M5 M6 M8

2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft)

PLATED W/ZnCr 2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT UNPLATED

LOCKNUT CL.8 W/CL8.8 BOLT

LOCKNUT CL.10 W/CL10.9 BOLT

PLATED W/ZnCr

3.2 N·m (28 lb 4.2 N·m (37 lb in) in) 6.4 N·m (57 lb 8.5 N·m (75 lb in) in) 11 N·m (96 lb 15 N·m (128 lb in) in) 26 N·m (234 lb 35 N·m (311 lb in) in) 70 N·m (51 lb 52 N·m (38 lb ft) ft) 121 N·m (90 lb 91 N·m (67 lb ft) ft) 225 N·m (166 lb 301 N·m (222 ft) lb ft) 440 N·m (325 lb 587 N·m (433 ft) lb ft) 762 N·m (560 lb 1016 N·m (750 ft) lb ft)

2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft)

2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft)

NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet.

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INTRODUCTION

METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT

UNPLATED M4 M5 M6 M8

2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in)

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft)

PLATED W/ZnCr 3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED

IDENTIFICATION Metric Hex head and carriage bolts, classes 5.6 and up

1

1. Manufacturer’s Identification 2. Property Class

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LOCKNUT CL.10 W/CL10.9 BOLT

2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in)

PLATED W/ZnCr

3.5 N·m (31 lb 4.6 N·m (41 lb in) in) 7.0 N·m (62 lb 9.4 N·m (83 lb in) in) 12 N·m (105 lb 16 N·m (141 lb in) in) 29 N·m (257 lb 39 N·m (343 lb in) in) 77 N·m (56 lb 57 N·m (42 lb ft) ft) 100 N·m (74 lb 134 N·m (98 lb ft) ft) 248 N·m (183 lb 331 N·m (244 ft) lb ft) 484 N·m (357 lb 645 N·m (476 ft) lb ft) 838 N·m (618 lb 1118 N·m (824 ft) lb ft)

20083680

LOCKNUT CL.8 W/CL8.8 BOLT

37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft)

226 N·m (167 lb ft) 440 N·m (325 lb ft)

INTRODUCTION

Metric Hex nuts and locknuts, classes 05 and up

20083681

2

1. Manufacturer’s Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer’s Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

8 N·m (71 lb in) 17 N·m (150 lb in) 30 N·m (22 lb ft) 48 N·m (36 lb ft) 74 N·m (54 lb ft) 107 N·m (79 lb ft) 147 N·m (108 lb ft) 261 N·m (193 lb ft) 420 N·m (310 lb ft) 630 N·m (465 lb ft)

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER 11 N·m (97 lb in) 23 N·m (204 lb in) 40 N·m (30 lb ft) 65 N·m (48 lb ft) 98 N·m (73 lb ft) 142 N·m (105 lb ft) 196 N·m (145 lb ft) 348 N·m (257 lb ft) 561 N·m (413 lb ft) 841 N·m (620 lb ft)

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (31 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 150 N·m (111 lb ft) 208 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD 16 N·m (142 lb in) 32 N·m (283 lb in) 57 N·m (42 lb ft) 91 N·m (67 lb ft) 139 N·m (103 lb ft) 201 N·m (148 lb ft) 277 N·m (204 lb ft) 491 N·m (362 lb ft) 791 N·m (584 lb ft) 1187 N·m (875 lb ft)

12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in)

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 76 N·m (56 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft)

111 N·m (82 lb ft)

NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet.

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INTRODUCTION

INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE UNPLATED or PLATED SILVER 1/4

9 N·m (80 lb in)

5/16

19 N·m (168 lb in)

3/8

33 N·m (25 lb ft)

7/16

53 N·m (39 lb ft)

1/2

81 N·m (60 lb ft)

9/16 5/8 3/4 7/8 1

117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

PLATED W/ZnCr GOLD

UNPLATED or PLATED SILVER

PLATED W/ZnCr GOLD

12 N·m (106 lb in) 25 N·m (221 lb in) 44 N·m (33 lb ft) 71 N·m (52 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb ft) 216 N·m (159 lb ft) 383 N·m (282 lb ft) 617 N·m (455 lb ft) 925 N·m (682 lb ft)

13 N·m (115 lb in) 26 N·m (230 lb in) 47 N·m (35 lb ft) 75 N·m (55 lb ft) 115 N·m (85 lb ft) 165 N·m (122 lb ft) 228 N·m (168 lb ft) 405 N·m (299 lb ft) 653 N·m (482 lb ft) 979 N·m (722 lb ft)

17 N·m (150 lb in) 35 N·m (310 lb in) 63 N·m (46 lb ft) 100 N·m (74 lb ft) 153 N·m (113 lb ft) 221 N·m (163 lb ft) 304 N·m (225 lb ft) 541 N·m (399 lb ft) 871 N·m (642 lb ft) 1305 N·m (963 lb ft)

LOCKNUT GrF W/ Gr5 BOLT

8 N·m (71 lb in) 17 N·m (150 lb in)

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in)

30 N·m (22 lb ft) 43 N·m (32 lb ft) 48 N·m (35 lb ft) 68 N·m (50 lb ft) 74 N·m (55 lb ft) 106 N·m (78 lb ft) 147 N·m (108 lb ft) 261 N·m (193 lb ft) 421 N·m (311 lb ft) 631 N·m (465 lb ft)

104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

IDENTIFICATION Inch Bolts and free-spinning nuts

20083682

3

Grade Marking Examples 1 2 3

Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks

SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120 ° Apart 6 Grade 8 Nut - Marks 60 ° Apart

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INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

4

Grade Identification Grade Grade A Grade B Grade C

Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches

Flats Marking Method (2) No Mark Letter B Letter C

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Clock Marking Method (3) No Marks Three Marks Six Marks

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

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

Remove the cables from the back of the alternator.

2.

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

3.

Remove the alternator (1).

ALTERNATOR

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

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1

HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM

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

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

2.

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

ALTERNATOR

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

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1

Index HYDRAULIC, PNEUMATIC, ELECTRICAL, ELECTRONIC SYSTEMS - A ELECTRICAL POWER SYSTEM - 30.A Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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ENGINE AND PTO IN - B ENGINE - 10.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B ENGINE - 10.A

TECHNICAL DATA ENGINE General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

FUNCTIONAL DATA ENGINE Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Valve drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connecting rod and piston Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Wiring harness Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Electronic control Control module - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Control module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

SERVICE ENGINE Service instruction Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Valve drive Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rocker assembly - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Rocker assembly Shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Auxiliary drive Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Crankshaft Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 84392428 15/03/2011

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Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Gear - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Connecting rod Bushing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Connecting rod Bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Connecting rod Bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Vibration damper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Balancer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Valve cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Front cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A 84392428 15/03/2011

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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Rear cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Wiring harness Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Electronic control Control module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Control module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Position sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Position sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Speed sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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ENGINE - General specification F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

F4HECOMPLETE

1

The NEF F4HFE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder.

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

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

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

4 Cylinders

6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 UC31 CRIN 2 DLLA 1-3-4-2 1-5-3-6-2-4 250 - 1600 bar (3625 - 23200 psi) Intercooled Holset HX35

Honeywell GT25 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt)

Belt Driven 79 - 83 °C (174 - 181 °F)

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Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels 104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) Oversize 103.739 - 103.757 mm (4.084 - 4.085 in) (*) Pistons Skirt Height 49.5 mm (1.949 in) (*) Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in) Piston (oversize) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) Protrusion 37.994 - 38.000 mm (1.496 - 1.496 in) Pin Piston Pin - Pin Housing 0.01 - 0.022 mm (0.0004 - 0.001 in) Piston ring landings 2.705 - 2.735 mm (0.106 - 0.108 in) Combustion 2.420 - 2.440 mm (0.095 - 0.096 in) (*) Intermediate 4.030 - 4.050 mm (0.159 - 0.159 in) Oil Control Piston Rings 2.560 - 2.605 mm (0.101 - 0.103 in) Combustion 2.350 - 2.380 mm (0.093 - 0.094 in) Intermediate 3.970 - 3.990 mm (0.156 - 0.157 in) Oil Control Piston Ring and Ring Landing Clearance 0.100 - 0.175 mm (0.004 - 0.007 in) Combustion 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) Intermediate 0.040 - 0.080 mm (0.002 - 0.003 in) Oil Control Piston Ring End Gap 0.30 - 0.40 mm (0.012 - 0.016 in) Combustion 0.60 - 0.80 mm (0.024 - 0.031 in) Intermediate 0.30 - 0.55 mm (0.012 - 0.022 in) Oil Control Connecting Rod Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in) Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in) Small end bushing Inside 38.019 - 38.033 mm (1.497 - 1.497 in) Diameter Big end bearing shell 1.955 - 1.968 mm (0.077 - 0.077 in) thickness Piston Pin and Bushing 0.019 - 0.039 mm (0.001 - 0.002 in) Clearance Oversize Big end bearing 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) Shells Crankshaft 82.99 - 83.01 mm (3.267 - 3.268 in) Main Journals 68.987 - 69.013 mm (2.716 - 2.717 in) Crankpins Main Bearing Shell Thickness 2.456 - 2.464 mm (0.097 - 0.098 in) Big end Bearing Shell 1.955 - 1.968 mm (0.077 - 0.078 in) Thickness Main Bearing Bore 87.982 - 88.008 mm (3.464 - 3.465 in) No. 1,5 / 1,7 87.977 - 88.013 mm (3.464 - 3.465 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance 0.041 - 0.119 mm (0.002 - 0.005 in) No. 1,5 / 1,7 0.041 - 0.103 mm (0.002 - 0.004 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin 0.033 - 0.041 mm (0.001 - 0.002 in) Clearance 37.475 - 37.545 mm (1.475 - 1.478 in) Thrust Journal Thrust Bearing Bore 32.180 - 32.280 mm (1.267 - 1.271 in) 84392428 15/03/2011

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Clearance Data Thrust Bearing Crankshaft End Play

37.28 - 37.38 mm (1.468 - 1.472 in) 0.095 - 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 7.042 - 7.062 mm (0.277 - 0.278 in) Valve Guide Bore Intake Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.052 - 0.092 mm (0.002 - 0.004 in) Clearance Valve Seat Bore 34.837 - 34.863 mm (1.372 - 1.373 in) Intake 34.837 - 34.863 mm (1.372 - 1.373 in) Exhaust Valve seat Outside Diameter: 34.917 - 34.931 mm (1.375 - 1.375 in) Intake 34.917 - 34.931 mm (1.375 - 1.375 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 0.59 - 1.11 mm (0.023 - 0.044 in) Intake 0.96 - 1.48 mm (0.038 - 0.058 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.054 - 0.094 mm (0.002 - 0.004 in) Intake 0.054 - 0.094 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 47.75 mm (1.880 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 35.33 mm (1.391 in) lb) Under a load equal to: 25.2 mm (0.992 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 53.995 - 54.045 mm (2.126 - 2.128 in) 1-5 / 1-7 Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in) Bushing and Journal Clearance 0.038 - 0.162 mm (0.001 - 0.006 in) Cam Lift 7.582 mm (0.299 in) Intake 6.045 mm (0.238 in) Exhaust Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in) Tappet outside diameter Top 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) Middle 15.924 - 15.954 mm (0.627 - 0.628 in) Bottom 0.025 - 0.070 mm (0.001 - 0.003 in) Tappets and Bore Clearance 21.965 - 21.977 mm (0.865 - 0.865 in) Rocker shaft 22.001 - 22.027 mm (0.866 - 0.867 in) Rockers 0.024 - 0.162 mm (0.001 - 0.006 in) Rockers and Shaft Clearance 84392428 15/03/2011

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ENGINE - General specification F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

F4DECOMPLETE

1

The NEF F4DFE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder.

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

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

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

4 Cylinders

6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 UC31 CRIN 2 DLLA 1-3-4-2 1-5-3-6-2-4 250 - 1600 bar (3625 - 23200 psi) Intercooled Holset HX35

Honeywell GT25 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt)

Belt Driven 79 - 83 °C (174 - 181 °F)

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Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings Combustion Intermediate Oil Control Piston Rings Combustion Intermediate Oil Control Piston Ring and Ring Landing Clearance Combustion Intermediate Oil Control Piston Ring End Gap Combustion Intermediate Oil Control Connecting Rod Small end housing Big end housing Small end bushing Inside Diameter Big end bearing shell thickness Piston Pin and Bushing Clearance Oversize Big end bearing Shells Crankshaft Main Journals Crankpins Main Bearing Shell Thickness Big end Bearing Shell Thickness Main Bearing Bore No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin Clearance Thrust Journal Thrust Bearing Bore

104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.739 - 103.757 mm (4.084 - 4.085 in) 49.5 mm (1.949 in) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in) 2.705 - 2.735 mm (0.106 - 0.108 in) 2.420 - 2.440 mm (0.095 - 0.096 in) 4.030 - 4.050 mm (0.159 - 0.159 in) 2.560 - 2.605 mm (0.101 - 0.103 in) 2.350 - 2.380 mm (0.093 - 0.094 in) 3.970 - 3.990 mm (0.156 - 0.157 in) 0.100 - 0.175 mm (0.004 - 0.007 in) 0.040 - 0.090 mm (0.002 - 0.004 in) 0.040 - 0.080 mm (0.002 - 0.003 in) 0.30 - 0.40 mm (0.012 - 0.016 in) 0.60 - 0.80 mm (0.024 - 0.031 in) 0.30 - 0.55 mm (0.012 - 0.022 in) 40.987 - 41.013 mm (1.614 - 1.615 in) 72.987 - 73.013 mm (2.874 - 2.875 in) 38.019 - 38.033 mm (1.497 - 1.497 in) 1.955 - 1.968 mm (0.077 - 0.077 in) 0.019 - 0.039 mm (0.001 - 0.002 in) 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) 2.456 - 2.464 mm (0.097 - 0.098 in) 1.955 - 1.968 mm (0.077 - 0.078 in) 87.982 - 88.008 mm (3.464 - 3.465 in) 87.977 - 88.013 mm (3.464 - 3.465 in) 0.041 - 0.119 mm (0.002 - 0.005 in) 0.041 - 0.103 mm (0.002 - 0.004 in) 0.033 - 0.041 mm (0.001 - 0.002 in) 37.475 - 37.545 mm (1.475 - 1.478 in) 32.180 - 32.280 mm (1.267 - 1.271 in) 84392428 15/03/2011

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Clearance Data Thrust Bearing Crankshaft End Play

37.28 - 37.38 mm (1.468 - 1.472 in) 0.095 - 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 7.042 - 7.062 mm (0.277 - 0.278 in) Valve Guide Bore Intake Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.052 - 0.092 mm (0.002 - 0.004 in) Clearance Valve Seat Bore 34.837 - 34.863 mm (1.372 - 1.373 in) Intake 34.837 - 34.863 mm (1.372 - 1.373 in) Exhaust Valve seat Outside Diameter: 34.917 - 34.931 mm (1.375 - 1.375 in) Intake 34.917 - 34.931 mm (1.375 - 1.375 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 0.59 - 1.11 mm (0.023 - 0.044 in) Intake 0.96 - 1.48 mm (0.038 - 0.058 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.054 - 0.094 mm (0.002 - 0.004 in) Intake 0.054 - 0.094 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 47.75 mm (1.880 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 35.33 mm (1.391 in) lb) Under a load equal to: 25.2 mm (0.992 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 53.995 - 54.045 mm (2.126 - 2.128 in) 1-5 / 1-7 Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in) Bushing and Journal Clearance 0.038 - 0.162 mm (0.001 - 0.006 in) Cam Lift 7.582 mm (0.299 in) Intake 6.045 mm (0.238 in) Exhaust Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in) Tappet outside diameter Top 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) Middle 15.924 - 15.954 mm (0.627 - 0.628 in) Bottom 0.025 - 0.070 mm (0.001 - 0.003 in) Tappets and Bore Clearance 21.965 - 21.977 mm (0.865 - 0.865 in) Rocker shaft 22.001 - 22.027 mm (0.866 - 0.867 in) Rockers 0.024 - 0.162 mm (0.001 - 0.006 in) Rockers and Shaft Clearance 84392428 15/03/2011

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ENGINE - Component localisation F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Location of main electrical components

CRIL04D081G01

(1) Coolant Temperature Sensor (2) Electro-Injector (3) Rail Pressure Sensor (4) Air Temperature/Pressure Sensor (5) Engine Starter (6) Timing Sensor (7) Solenoid Valve for Pressure Regulator

1

(8) Fuel Temperature Sensor (9) EDC7 UC31 (10) Crankshaft Sensor (11) Oil Level Sensor (12) Engine Oil Temperature/Pressure Sensor (13) Heating Element for Pre-Post Heating

The NEF F4HFE engines are fully driven by the electronic engine control module, which is assembled directly to the engine by means of a heat exchanger enabling it’s cooling, utilizing rubber buffers to reduce vibration originated by the engine.

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

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ENGINE - Component localisation F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Location of main electrical components

ELECCOMPD

(1) (2) (3) (4) (5) (6)

Coolant temperature sensor Electro-injector Starter Fuel pressure sensor Air pressure/temperature sensor Timing sensor

1

(7) fuel temperature sensor (8) EDC7 electronic control module (9) Crankshaft speed sensor (10) Engine oil pressure/temperature sensor (11) Pre-post heating resistor

The NEF F4DFE engines are fully driven by the electronic engine control module, which is mounted remotely on the unit utilizing rubber buffers to reduce vibration originated by the engine.

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

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Valve drive - Overview Rocker Assembly Components

ROCKERCOMPONENT

(1) Bolts

(2) Bracket

1

(3) Shafts

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(4) Rockers

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Connecting rod and piston - Overview

1

BAPH04APH144ASA

(1) (2) (3) (4)

Stop rings Pin Piston Split rings

(5) (6) (7) (8)

Bolts Half bearings Connecting rod Bushing

NOTE: The pistons are supplied spare with the following sizes: - Standard - 0.4 mm (0.016 in) oversize.

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Wiring harness - Electrical schema F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

ELECSCHEMH

(1) Injectors cylinders 1 and 2 (2) Injectors cylinders 3 and 4 (3) Injectors cylinders 5 and 6 (4) Engine RPM sensor (5) Timing sensor

1

(6) Engine oil pressure/temperature (7) Fuel temperature (8) Coolant temperature (9) Air pressure/temperature (10) Fuel pressure

(11) Pressure regulator (12) Connector C - Sensors (13) Connector A - Injectors

Connector A - Injectors Function

EDC pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Pressure Regulator Pressure Regulator Cylinder 2 injector Cylinder 3 injector Cylinder 1 injector Cylinder 4 injector Cylinder 6 injector Cylinder 5 injector

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

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

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Wiring harness - Electrical schema F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

CONNECTORA

1

Connector A - Injectors Wire color

EDC pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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

Function Injector Injector Injector Injector Earth Injector Injector Injector Injector Injector Injector Injector Injector

Cylinder Cylinder Cylinder Cylinder

2 3 4 2

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

1 6 5 3 1 4 6 5

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CONNECTORB

2

Connector B - Vehicle EDC pin # 1 2 3 4 7 8

Wire # 8150 0087 0000 8885/0159 8150 7777

9 12/13 14/15 16 19 20 27 28 31 32 36 37 39 44 45 46 49 50 52 53 55 62 63 64 72 73 78 81 83

0000 8150 0000 0094 0150 8153 0156 5535 2298 8837 8888 8051 9905 9906 5553 5584 0158 6109 6108 5158 0160 5503 0535 0159 0159 8162 0157 5157

Function Positive driven by battery Negative for switch of fuel filter heater/starter Earth Positive for pre-post heating resistor Positive driven by battery Positive for blink-code button, low oil pressure LED, pre-heating LED, Air conditioner switch (if available), EDC Earth Positive driven by battery Earth Negative for post-heating resistor Negative start/stop push buttons from eng./accelerator pressed Positive from change over switch to key in starting phase (+50) Positive from blink-code button Positive for EDC diagnostic LED K line for diagnostic connector, 30 poles (pin 2) Negative for multi-switch couple-limiter Positive for fuel heating switch Positive for starter Positive from key switch/ L line for diagnosis connector, 30 poles (pin 11) Negative from starter push button from engine Negative from engine stop push button from engine Negative for pre-heating LED in on position Diagnosis connector (pin 28) Negative from accelerator push button pressed CAN Line (if equipped), diagnosis connector (pin 22) CAN Line (if equipped), diagnosis connector (pin 22) Positive for sensor of foot accelerator pedal pos. / Earth multi-switch Negative for clutch sensor Negative for low engine oil pressure LED Negative for EDC diagnosis LED Positive from pressed accelerator push button / multi-switch signal Positive redundant from pressed accelerator push button Positive air conditioner device (if equipped) Negative sensor of foot accelerator pedal pos. / Earth Multi-switch Signal from sensor of foot accelerator pedal pos. / Signal Multi-switch 84392428 15/03/2011

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EDC pin #

Wire # -

87

Function Positive for couple multi-switch limiter

CONNECTORC

3

Connector C - Sensors Wire color C V MN CR HN BL CV GV BZ GN R B R RV LN BH B GR CN NS BG

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

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

Color legend Symbol C A B L G H M

Color Orange Sky Blue White Blue Yellow Gray Brown

Symbol N W S R V Z

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Color Black Light Brown Pink Red Green Purple

ENGINE AND PTO IN - ENGINE

Electronic control Control module - Detailed view EDC7 UC31

CONTROLMODULE

(A) Injector connector

1

(B) Vehicle connector

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(C) Sensor connector

ENGINE AND PTO IN - ENGINE

Electronic control Control module - Overview EDC7 UC31 OPERATION Engine preheating element control Pre-post heating is activated when any of the following requirements are met. Water, air, or fuel temperature sensors detect a temperature less than or equal to 5 °C (41 °F).

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

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

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

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

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

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

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

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

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

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

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

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

Deactivation of the electro-injectors.

•

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

•

Control of fuel pressure regulator.

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

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

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

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

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

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

•

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

•

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

•

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

•

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

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

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Sensing system Crankshaft sensor - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

CRANKSENSOR

1

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

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

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Sensing system Camshaft speed sensor - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

CAMSENSOR

1

This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal.

Although it is similar to the flywheel sensor, these two devices are no interchangeable because of the different external shape.

The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance is ~900 Ω.

Description

Reference 1 2 3

Signal Signal Shield

EDC pin 10C 9C -

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Sensing system Crankshaft sensor - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

CRANKSENSOR

1

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

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

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

The resistance value of the sensor is about 900 Ω.

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Sensing system Camshaft speed sensor - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

CAMSENSOR

1

This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal.

Although it is similar to the flywheel sensor, these two devices are no interchangeable because of the different external shape.

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

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ENGINE - Service instruction Maintenance procedures WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer’s instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

CAUTION Burn hazard!

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.

Failure to comply could result in minor or moderate injury.

C0043A

WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

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

Draw off the rod from it’s slot and check that the level is within the etched tags of minimum and maximum level.

Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no contamination and put it back in it’s slot. Draw it off again and check the level.

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

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

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

OILFILLH

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1

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

The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head.

Special attention must be paid to the connections on the high pressure pipelines.

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

Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips.

Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.

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

NOTE: In case of new filling, proceed bleeding the system, through the bleeds on the engine.

If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.

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

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

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

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

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

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

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

86070785_RESIZE

2

VALVEADJUST

3

Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.

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

Valve clearance •

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

•

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

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

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

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

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

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

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

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

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

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

For the cartridge replacement use the tool 380000670.

NOTE: The engine oil filter has an internal volume of about 1 l (0.3 US gal).

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

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

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

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

However the following operations are valid for all applications.

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

Unscrew the cartridge by using the 380000670.

Collect the eventual fuel inside the filtering cartridge.

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

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

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

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

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

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

Replace the worn belt with a new one.

Place the belt on the pulleys and guide rollers.

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

Check proper position in the races of the pulleys.

ALTBELT

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ENGINE - Service instruction Maintenance Procedures F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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

Draw off the rod from it’s slot and check that the level is within the etched tags of minimum and maximum level.

Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no contamination and put it back in it’s slot. Draw it off again and check the level.

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

OILFILLD

1

OILFILLD2

2

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

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

M1159

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

The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head.

Special attention must be paid to the connections on the high pressure pipelines.

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

B071

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

Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips.

Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.

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

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

SB023

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

NOTE: In case of new filling, proceed bleeding the system, through the bleeds on the engine.

If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.

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

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

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

M1159

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

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

Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.

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

Valve clearance •

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

•

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

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

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

VALVEADJUST

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

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

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

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

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

M1159

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

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

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

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

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

For the cartridge replacement use the tool 380000670.

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

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

M1159

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

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

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

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

However the following operations are valid for all applications.

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

Unscrew the cartridge by using the 380000670.

Collect the eventual fuel inside the filtering cartridge.

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

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

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

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

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

M411

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

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

Replace the worn belt with a new one.

Place the belt on the pulleys and guide rollers.

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

Check proper position in the races of the pulleys.

ALTBELT

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

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

2.

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

3.

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

ROCKERHOUSING

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

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

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

2.

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

3.

VALVEBASEDH

1

VALVEBASEDH2

2

VALVEBASEDH3

3

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

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

4.

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

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

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

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

2.

Remove the rocker shaft mounting bolts (2).

3.

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

4.

Remove the valve bridges (7).

5.

Remove the push rods (8).

BACD04APH020ASA

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

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

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

SHAFTMEASURE

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

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

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

2.

Install the rocker assembly consisting of:

3.

•

Bracket (5).

•

rockers (3).

•

shafts (4).

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

ROCKERASSEMDH

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

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

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

2.

Set the clearance to the following specifications.

•

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

•

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

BACD04APH162ASA

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

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Camshaft Gear - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

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

2.

Withdrawal the camshaft gear (3).

CAMGEARH

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

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Camshaft Gear - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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

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

CAMGEARD

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

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

1.

2.

3.

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

BACD04APH064ASA

1

BACD04APH065ASA

2

BACD04APH066ASA

3

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

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

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

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

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

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

2.

BACD04APH047ASA

1

BACD04APH048ASA

2

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

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

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

Set the camshaft on the tailstock using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm (0.002 in), otherwise replace the camshaft.

2.

Check cam lift; found values shall be: 6.045 mm (0.238 in) for exhaust cams and 7.582 mm (0.299 in) for intake cams, in case of different values replace the camshaft.

3.

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

BACD04APH117ASA

BAIL07APH360FSA

1

2

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

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

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

2.

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

CRIL04J056A01

1

CRIL04J064A01

2

Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque.

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

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

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

CRIL04J065A01

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

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

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

2.

Install the push rods (2).

3.

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

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

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PUSHROD

1

BACD04APH093ASA

2

ENGINE AND PTO IN - ENGINE

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

Withdraw the tappets (1) from the engine block.

BACD04APH049ASA

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

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

BAIL07APH361FSA

1

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

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

CRIL04J063A01

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

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

Camshaft bushing (2) shall be pressed into its housing. Internal surface must not show seizing or wear.

Use bore dial gauge (3) to measure camshaft bushings (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axis’.

CRIL04J060A01

BAIL07APH367FMA

2

*Height to be obtained after installing the bushing.

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

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Camshaft Bushing - Replace Prior operation: Valve drive Camshaft - Measure (B.10.A) Remove and install the bushing (1) using the beater (2) and the hand-grip 380000145 (3).

NOTICE: When installing the bushing , take note of orientation to make sure the lubricating holes coincide with the holes on the block housing.

ZEIL06EN0048A0B

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

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

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

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

A = intake side - S = exhaust side

2.

Valve removal shall be performed using tool 380000302 (1) and pressing the cap (3) so that when compressing the springs (4) the keepers (2) can be removed. Then remove the cap (3) and the springs (4).

3.

Repeat this operation for all the valves.

4.

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

5.

BACD04APH145ASA

1

BACD04APH146ASA

2

BACD04APH147ASA

3

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

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

Sealing rings (2) for exhaust valves are green.

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

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

VALVE

1

INTAKE AND EXHAUST VALVE MAIN DATA 1.

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

BAPH04APH152ASA

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

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

Remove carbon deposits from valves using the proper metal brush.

2.

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

3.

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

BAPH04APH151ASA

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

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

50676

Height (H) - 47.75 mm (1.880 in) (H1) - 35.33 mm (1.391 in) (H2) - 25.2 mm (0.992 in)

Weight applied None (P) - 320.8 - 358.8 N (72.1 - 80.7 lb) (P1) - 702 - 780 mm (27.6 - 30.7 in)

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

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

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

2.

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

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

3.

80713

1

BACD04APH146ASA

2

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

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

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Auxiliary drive - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Unscrew the cover bolts (3) and remove the cover (1). Save the cover gasket (4).

2.

Remove the power take-off adapter (2). Save the gasket (4).

AUXDRIVEH

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Auxiliary drive - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Insert the power take-off adapter (2) with gaskets (4) and cover (1).

2.

Tighten the bolts (3) to the specified torque.

AUXDRIVEH

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Crankshaft Front seal - Remove Prior operation: Vibration damper - Remove (B.10.A) 1.

2.

Remove the ring sealing the engine’s driving shaft from the front cover (6). Use the tool (4) to operate on the front bar hold of the driving shaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).

Fix the tool to the ring tightening the six screws (5) provided with the equipment. Then proceed removing the ring (2) by tightening the screw (3).

MAINSEALDH

1

EXHOLDRINGDH

2

Using the specific tie rod (3) of the tool 380000669 and the ancillary lever (4), remove the external holding ring (2) from the front cover (1).

Next operation: Crankshaft Front seal - Install (B.10.A)

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Crankshaft Front seal - Install Prior operation: Crankshaft Front seal - Remove (B.10.A) 1.

Apply tool (4) to the front crankshaft tang (6) and secure it by screws (5) and install the new sealing ring (7). Position part (2) on part (4), tighten nut (3) until completing installation of the sealing ring (7) into the front cover (1).

BACD04APH074ASA

Next operation: Vibration damper - Install (B.10.A)

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Crankshaft Rear seal - Remove Prior operation: Flywheel - Remove (B.10.A) 1.

Remove the holding ring of the flywheel cover box using the tool (3) to operate on the driving shaft’s back bar hold (5).

2.

Through the steering holes of the tool, perforate the inside holding ring with a straight way drill bit with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in).

3.

Fix the tool (3) to the ring tighten the six screws (4) provided with the equipment.

4.

Then proceed removing the ring (1) by tightening the screw (2).

5.

REARMAINSEALDH

1

EXHOLDRINGDH

2

Using a specific tie rod (3) of the tool 380000669 and an ancillary lever (4), remove the external holding ring (2)from the rear cover (1).

Next operation: Flywheel - Remove (B.10.A)

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Crankshaft Rear seal - Install Prior operation: Crankshaft Rear seal - Remove (B.10.A) 1.

Apply tool (6), to the rear crankshaft tang (5), secure it by screws (4) and install the new sealing ring (3).

Position part (1) on part (5), tighten nut (2) until completing installation of the sealing ring (3) into the flywheel housing (7).

BACD04APH219ASA

Next operation: Flywheel - Install (B.10.A)

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Crankshaft Main bearing - Remove Prior operation: Oil pan - Remove (B.60.A) 1.

2.

Remove the screws (1) and the main bearing caps (2).

BACD04APH043ASA

1

BACD04APH044ASA

2

The second to last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).

NOTE: Take note of the lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.

Next operation: Crankshaft Main bearing - Install (B.10.A)

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Crankshaft Main bearing - Install Prior operation: Crankshaft Main bearing - Remove (B.10.A) NOTE: Refit the main bearings that have not been replaced, in the same position found at removal.

Main bearings (1) are supplied spare with 0.250 - 0.500 mm (0.010 - 0.020 in) undersize on the internal diameter.

Clean accurately the main half bearings (1) having the lubricating and fit them into their housings.

The second last main half bearing (1) is fitted with shoulder half rings.

BACD04APH056ASA

NOTICE: Do not try to adapt the bearings.

Next operation: Oil pan - Install (B.60.A)

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Crankshaft - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Crankshaft Main bearing - Remove (B.10.A) 1.

Use tool 380000362 (2) and hoist to remove the crankshaft (1) from the block.

BACD04APH057ASA

Next operation: Crankshaft Main bearing - Install (B.10.A)

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Crankshaft - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Crankshaft Main bearing - Remove (B.10.A) 1.

Use tool 380000362 (1)and hoist to remove the crankshaft (2) from the block.

CRANKSHAFTD

Next operation: Crankshaft Main bearing - Install (B.10.A)

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Crankshaft - Measure Prior operation: Crankshaft - Remove (B.10.A) Grind journals and crank pins if seizing, scoring or excessive ovalization are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.

NOTE: It is recommended to insert the found values in the table below.

NOTICE: Journals and crank pins shall always be ground to the same undersize class.

Journals and crank pins undersize shall be marked on the side of the crank arm No.1.

For undersized crank pins: letter M For undersized journals: letter B For undersized crank pins and journals: letters MB.

BACD04APH108ASA

Measuring journals and crank pins

BACD04APH186FSA

2

Fill this table with crankshaft journal and crank pin measured values * Rated value

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ZEIL06EN0183F0B

3

Crankshaft tolerances * Measured on a radius greater than 45.5 mm (1.791 in) ** 0.500 mm (0.020 in) between adjacent main journals Tolerances Shape

Direction Position Oscillation

Tolerance Characteristic

Graphic Symbol

Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation Levels of importance for product characteristics

Critical Important Secondary Next operation: Crankshaft Journal - Clearance (B.10.A)

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Graphic Symbol

ENGINE AND PTO IN - ENGINE

Crankshaft Gear - Replace Check that gear toothing (1) is not damaged or worn, otherwise remove it from the crankshaft (2) using the proper puller (3).

When installing the new gear, heat it to 180 °C (356 °F) for 10 minutes in an oven and then key it to the crankshaft.

CRIL04J068A01

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Crankshaft Journal - Clearance Prior operation: Crankshaft - Measure (B.10.A) 1.

Install the crankshaft (1).

2.

Check the backlash between crankshaft main journals and the relevant bearings as follows:

3.

Clean accurately the parts and remove any trace of oil.

4.

Position a piece of calibrated wire (3) on the crankshaft pins (4) so that it is parallel to the longitudinal axis;

5.

Fit caps (1), including the half bearings (2) on the relevant supports.

BACD04APH057ASA

1

BACD04APH112ASA

2

80621

3

NOTE: Before using the fixing screws again, measure them twice as indicated in the picture, checking (D1) and (D2) diameters: if (D1)- (D2) < 0.1 mm (0.004 in) the screw can be utilized again; if (D1)- (D2) > 0.1 mm (0.004 in) the screw must be replaced.

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6.

7.

Tighten the pre-lubricated screws (1) in the following three successive stages: STAGE 1: with torque wrench to 44 - 56 Nm (32.5 41.3 lb ft).

STAGE 2: with torque wrench to 74 - 86 Nm (54.6 63.4 lb ft).

BACD04APH058ASA

4

BACD04APH113ASA

5

BACD04APH114ASA

6

BACD04APH115ASA

7

STAGE 3: with tool 380001001 (1) set as shown, tighten the screws (2) with 85 - 95 ° angle.

8.

Remove the caps from the supports.

9.

The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire.

The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described.

Checking crankshaft end play 10.

This check is performed by setting a magnetic base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 - 0.41 mm (0.003 0.016 in).

If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft pins and main half bearings.

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Timing gear housing - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Remove the screws (2) and disconnect the timing gear case (1) from the engine block.

NOTE: Mark locations of mounting screws (2) since they are different sizes. This will make assembly much easier.

TIMINGGEARHOUSI

Next operation: Timing gear housing - Cleaning (B.10.A)

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1

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Timing gear housing - Cleaning F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Timing gear housing - Remove (B.10.A) 1.

Clean the timing gear housing (1) and it’s mating surface on the engine block.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (2), a few millimeters thick, to the sealing surface of the housing.

NOTE: After applying the sealant, the housing should be assembled within 10 to 20 minutes.

GEARCASESEAL

Next operation: Timing gear housing - Install (B.10.A)

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Timing gear housing - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Timing gear housing - Cleaning (B.10.A) NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.

1.

Install the housing (1) on the engine block.

2.

Insert the fastening bolts in the same position found upon disassembly and tighten them to the prescribed torque.

GEARCASEINSTALL

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Timing gear housing - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Disconnect the high pressure pump stroke sensor (3).

2.

Remove the screws (2) and remove the timing gear housing (1) from the engine block.

GEARHOUSING

Next operation: Timing gear housing - Cleaning (B.10.A)

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Connecting rod and piston - Remove Prior operation: Oil pan - Remove (B.60.A) 1.

Loosen the fixing screws (1) and remove the rod caps (2).

2.

Withdraw the piston including the connecting rod from the top of the engine block.

3.

Repeat these steps for the remaining cylinders.

NOTE: Keep the half bearings into their housing since in case of use they shall be fitted in the same position found at removal.

BACD04APH042ASA

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod and piston Piston - Measure Prior operation: Connecting rod and piston Piston - Remove (B.10.A) 1.

2.

Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.

BAPH04APH123ASA

1

BACD04APH124ASA

2

The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Connecting rod and piston Connecting rod - Measure

BACD04APH131BSA

1

* Value for the inside diameter to be obtained after driving in connecting rod small end and grinding.

NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recommended not to smooth the knurls.

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CRIL04D023F

2

NOTE: Every connecting rod is marked as follows: (1) - On the body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement, it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.

(2) - On the body with a letter showing the weight of the connecting rod assembled at production: - V - 1820 - 1860 g (64.2 - 65.6 oz) (yellow marking) - W - 1861 - 1900 g (65.6 - 67.0 oz) (green marking) - X - 1901 - 1940 g (67.1 - 68.4 oz) (blue marking) Spare connecting rods are of the - W - class with a green marking. Material removal is not allowed.

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Connecting rod Bushing - Service instruction Prior operation: Piston Pin - Remove (B.10.A) 1.

Check that the bushing in the connecting rod small end is free from scoring or seizing and that it is not loose. Otherwise replace.

2.

Removal and refitting shall be performed using the proper beater.

3.

When refitting take care to make the oil holes in the bushing coincide with the holes in the connecting rod small end.

4.

Grind the bushing to obtain the specified diameter.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Piston Ring - Remove Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Remove the split rings (1) from the piston (3) using pliers 380000324 (2).

ZEIL06EN0060A0B

Next operation: Piston Ring - Measure (B.10.A)

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Piston Ring - Measure Prior operation: Connecting rod and piston Piston - Remove (B.10.A) 1.

2.

3.

4.

Use a micrometer (1) to check split ring (2) thickness.

BAPH04APH127ASA

1

BAPH04APH128ASA

2

BAPH04APH129ASA

3

BACD04APH130ASA

4

Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1).

Since the first sealing ring is trapezoidal, the clearance between the slot and the ring shall be measured as follows: Make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3). In this position, use a feeler gauge to check the clearance (X) between ring and slot.

Found value shall be the specified one.

Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).

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Next operation: Connecting rod and piston Piston - Install (B.10.A)

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Piston Ring - Install Prior operation: Connecting rod and piston Piston - Remove (B.10.A) 1.

Use pliers 380000221 (3) to fit the split rings (1) on the piston (2).

NOTICE: Split rings shall be fitted with the marking "TOP" (4) facing upwards and their openings shall be displaced with each other by 120 °.

NOTE: Split Rings are supplied spare with the following sizes: - standard - 0.4 mm (0.016 in) oversize.

MID0330A

Next operation: Connecting rod and piston Piston - Install (B.10.A)

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Piston Pin - Remove Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Remove the piston pin (1) by extracting the stop rings (2) using a scriber (3).

BACD04APH121ASA

Next operation: Piston Pin - Measure (B.10.A)

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Piston Pin - Measure Prior operation: Piston Pin - Remove (B.10.A) 1.

2.

To measure the piston pin (1) diameter, use a micrometer (2).

BAPH04APH125ASA

1

BAPH04APH126ASA

2

Lubricate the pin (1) and its seat on the piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.

Next operation: Connecting rod and piston - Assemble (B.10.A)

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Connecting rod and piston - Assemble Prior operation: Piston Pin - Remove (B.10.A) 1.

2.

3.

The piston crown is marked as follows: 1.

Part number and design modification number.

2.

Arrow showing piston assembling direction into cylinder.

3.

Manufacturing date.

4.

Stamp indicating the ring carrier US inspection.

BACD04APH136ASA

1

BACD04APH137ASA

2

BACD04APH138ASA

3

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (4) are read as shown in the figure.

Position the piston (3) on the connecting rod according to the diagram shown in the figure and fit the pin (1) and stop at the stop rings (2).

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod Bearing - Install Prior operation: Connecting rod and piston - Remove (B.10.A) 1.

Fit the half-bearings (1) on the connecting rod and cap.

NOTE: Refit the bearings that have not been replaced in the same position found at removal. Do not relocate the half-bearings.

BAPH04APH059ASA

Next operation: Connecting rod and piston - Install (B.10.A)

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Connecting rod and piston - Install Prior operation: Connecting rod and piston Connecting rod - Install (B.10.A) 1.

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside.

2.

Use band 380000325 (1) to fit the connecting rod - piston assembly (2) into the cylinder barrels and checking the following:

MID0332A

1

BACD04APH061ASA

2

The number of each connecting rod shall correspond to the cap coupling number.

Split ring openings shall be displaced with each other by 120 °.

Connecting rod - piston assemblies shall have the same weight.

The arrow (1) marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.

Next operation: Connecting rod and piston Connecting rod - Install (B.10.A)

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Connecting rod Bearing - Clearance Prior operation: Connecting rod and piston - Install (B.10.A) 1.

Clean the parts accurately and remove any trace of oil.

2.

Set a piece of calibrated wire (2) on the crank pins (1).

3.

Fit the connecting rod caps (3) with the relevant half bearings (4).

NOTE: Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the center of the thread length is not < 0.1 mm (0.004 in) than the diameter measured at approximately 10 mm (0.394 in) from the screw end.

4.

5.

BAPH04APH139ASA

1

BACD04APH140ASA

2

0B00200405BACD0

3

BACD04APH141ASA

4

Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench (2).

Apply tool 380001001 (1) to the socket wrench and tighten screws (2) to 60 °.

6.

Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).

7.

If a different clearance value is found, replace the half bearings and repeat the check.

8.

Once the specified clearance has been obtained, lubricate the half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.

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9.

Check manually that the connecting rods (1) are sliding axially on the crank pins and that their end float, measured with a feeler gauge (2) is 0.10 - 0.33 mm (0.004 - 0.013 in).

BACD04APH142ASA

Next operation: Connecting rod and piston Piston - Check (B.10.A)

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Connecting rod and piston Piston - Check 1.

Once connecting rod - piston assemblies installation is completed, use dial gauge 380000228 (1) fitted with base 380000364 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block.

Protrusion shall be 0.28 - 0.52 mm (0.011 - 0.020 in).

BACD04APH143ASA

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Flywheel - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Insert tool 380000988 (2) into flywheel housing (1) to keep the flywheel (3) from rotating.

2.

Loosen two bolts opposite each other and place two guide pins (2) in place of the bolts.

3.

Remove the remaining bolts (4) figure 1 securing the flywheel (1) to the crankshaft.

4.

Remove the flywheel locking tool from the flywheel housing.

5.

Insert two bolts of medium length into the threaded holes (4) at the top of the flywheel to sling the flywheel with a hoist.

6.

Remove the flywheel (1) from it’s housing.

Next operation: Flywheel - Check (B.10.A)

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FLYWHEELH

1

FLYWHEEL2H

2

ENGINE AND PTO IN - ENGINE

Flywheel - Check F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

Check the supporting surface of the clutch plate (1) and if it is scratched, it is necessary to carry out turning.

2.

Check ring gear teeth (2), if breakage or excessive wear is found, remove the ring gear from the engine flywheel using a suitable hammer.

3.

Heat the ring gear to 150 °C (302 °F)for 15 to 20 minutes.

4.

Install the ring gear with the chamfering on the inside diameter facing the flywheel.

FLYWHEELH3

Next operation: Flywheel - Install (B.10.A)

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Flywheel - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Flywheel - Check (B.10.A) 1.

Install two guide pins (2) having suitable length into crankshaft (3) holes.

2.

Using the proper sling and hoist, install the flywheel (1).

3.

Apply tool 380000988 (2) to the flywheel housing to stop rotation of the flywheel (3).

4.

Tighten the bolts (1) securing the flywheel (3) to the crankshaft (4).

5.

FLYWHEELH4

1

FLYWHEELH5

2

FLYWHEELH6

3

Tighten the flywheel bolts (1) in two stages: 1.

Torque bolts to 26 - 34 Nm (19 - 25 lb ft).

2.

Finish by turning the bolts an additional 55 - 65 °.

NOTE: Torquing to an angle is performed by using the tool 380000304.

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

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Flywheel - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Remove two opposite screws (1) from the area where the guide pins will be introduced.

2.

Loosen the remaining flywheel fixing screws (3) from the driving shaft (2).

3.

Remove the flywheel locking tool (4).

4.

Tighten two screws of medium length into the holes (4) to sling the flywheel with hoist.

5.

Throughout the two guide pins (2) previously screw into the driving shaft holes (3) withdraw the engine flywheel (1) after slinging it with the hoist.

Next operation: Flywheel - Check (B.10.A)

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FLYWHEELD

1

FLYWHEELD2

2

ENGINE AND PTO IN - ENGINE

Flywheel - Check F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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

Check the supporting surface of the clutch plate (1) and if it is scratched, it is necessary to carry out turning.

2.

Check ring gear teeth (2), if breakage or excessive wear is found, remove the ring gear from the engine flywheel using a suitable hammer.

3.

Heat the ring gear to 150 °C (302 °F)for 15 to 20 minutes.

4.

Install the ring gear with the chamfering on the inside diameter facing the flywheel.

FLYWHEELD3

Next operation: Flywheel - Install (B.10.A)

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Flywheel - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Flywheel - Check (B.10.A) 1.

Screw two bolt of medium length into the flywheel (1) using holes (4).

2.

Install two guide pins (2) having suitable length into crankshaft holes (3).

3.

Using the proper sling and hoist, install the flywheel (1).

4.

Screw engine flywheel (3) fixing screws (4) on the engine shaft.

5.

Install the tool (1) in the proper hole (2) in order to block engine flywheel rotation.

6.

Tighten the bolts (4) securing the flywheel (3) to the crankshaft.

7.

FLYWHEELD4

1

FLYWHEELD5

2

FLYWHEELD6

3

Tighten the flywheel bolts (2) in two stages: 1.

Torque bolts to 26 - 34 Nm (19 - 25 lb ft).

2.

Finish by turning the bolts an additional 55 - 65 °.

NOTE: Torquing to an angle is performed by using the tool 380000304.

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

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Vibration damper - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

Remove the bolts (3) securing the vibration dampener (2) and withdrawal the damper (2) and pulley (1).

VIBDAMPENERH

Next operation: Vibration damper - Install (B.10.A)

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1

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Vibration damper - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Vibration damper - Remove (B.10.A) 1.

Attach the vibration damper (2) and the pulley (1) to the crankshaft, and torque the mounting bolts (3) to 61 - 75 Nm (45 - 55 lb ft).

VIBDAMPENERH

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

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Vibration damper - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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

Remove the bolts (1) securing the vibration dampener (2) and withdrawal the damper (2) and pulley (3).

VIBDAMPERD

Next operation: Vibration damper - Install (B.10.A)

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Vibration damper - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Vibration damper - Remove (B.10.A) 1.

Attach the vibration damper (2) and the pulley (3) to the crankshaft, and torque the mounting bolts (1) to 61 - 75 Nm (45 - 55 lb ft).

VIBDAMPERD

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

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Balancer - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Oil pan - Remove (B.60.A) 1.

Remove the bolts (1) and withdraw the oil pickup tube.

2.

By means of pin (2) lock the dynamic balancer (3) in the Top Dead Center (TDC) position.

3.

Loosen the bolts (4) and remove the dynamic balancer (3).

DYNAMICBALANCER

Next operation: Balancer - Install (B.10.A)

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Balancer - Install 1.

Place the balancer on the engine, install and tighten the mounting bolts.

2.

Install and tighten the oil sump.

3.

Remove the retaining bolt previously installed during the timing adjustment.

4.

Install the oil pan on the engine, fill the engine with oil.

5.

Pull the timing lock pin from the cam gear.

6.

Start and run engine, check for excessive vibration and oil leaks.

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RCPH10TLB003BAL

1

RCPH10TLB004BAL

2

ENGINE AND PTO IN - ENGINE

Cylinder block Bore - Check Prior operation: Connecting rod and piston - Remove (B.10.A) Once engine is disassembled, clean accurately the cylinder block assembly.

Use the proper rings to handle the cylinder unit.

The engine block shall not show cracks.

Check operating plug conditions and replace them in case of uncertain seal or if rusted.

Inspect cylinder bore surfaces; they shall be free from seizing, scores, ovalization, taper, or excessive wear.

Inspection of cylinder bore to check ovalization, taper, and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder bore diameter.

NOTE: Should a ring gauge not be available, use a micrometer for zero-setting.

BACD04APH104ASA

1

BAIL07APH372AMA

2

Measurements shall be performed on each cylinder at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B).

Maximum wear is usually found on plane (B) in correspondence with the first measurement.

Should ovalization, taper, or wear be found, bore and grind the cylinder bores. Cylinder bore regrinding shall be performed according to the spare piston diameter oversized by 0.4 mm (0.016 in) and to the specified assembling clearance.

NOTE: In case of regrinding, all bores shall have the same oversize 0.4 mm (0.016 in).

Next operation: Cylinder block - Check (B.10.A)

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Cylinder block - Check Prior operation: Crankshaft - Remove (B.10.A)

Main Bearing Housings Check main bearing housings as follows: •

fit the main bearing caps on the supports without bearings

•

tighten the fastening screws to the specified torque

•

use the proper internal gauge to check whether the housing diameter is falling within the specified value.

Replace if a higher value is found.

Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit.

Planarity error shall not exceed 0.075 mm (0.003 in) Check cylinder unit operating plug (1) conditions, replace them in case of uncertain seal or if rusted.

CRIL04J058A01

Next operation: Crankshaft Journal - Clearance (B.10.A)

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Cylinder head - Remove Prior operation: Fuel injector Electro injector - Remove (B.20.A) 1.

Remove the fastening screws (1) from the cylinder head (2).

NOTE: The highlighted screws are shorter.

2.

CYLHEADF4DF4HE

1

CYLHEADREMOVE

2

Hook brackets (1) with suitable lifting chains and remove the cylinder head (2) from the cylinder block using a hoist.

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

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

Checking cylinder head wet seal This check shall be performed using the proper tools.

1.

Use a pump to fill with water heated to approximately 90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pressure.

2.

Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting.

NOTE: Before refitting, smear the plug surfaces with water repellent sealant.

3.

Replace the cylinder head if leaks are found.

80709

1

70325

2

Checking cylinder head supporting surface 4.

Distortion found along the whole cylinder head shall not exceed 0.20 mm (0.008 in).

If higher values are found, grind the cylinder head according to values and indications shown in the following figure.

5.

The rated thickness (A) for the cylinder head is 104.75 - 105.25 mm (4.124 - 4.144 in). Maximum metal removal shall not exceed thickness (B) by 1 mm (0.039 in).

NOTE: After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

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

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

Check the cleanliness of the cylinder head and engine block coupling surface.

2.

Taking care not to foul the cylinder head gasket, set the gasket (1) with the marking "TOP" facing the head.

3.

The arrow shows the point where the gasket thickness is given.

4.

5.

80714

1

PROTRUSION

2

BACD04APH224ASA

3

There are two head gasket thicknesses, ( 1.25 mm Type A and 1.15 mm Type B).

To determine the correct head gasket to use, piston protrusion must be measured.

•

For each piston, measure protrusion in two places 180 ° apart, at a distance of 45 mm (1.8 in) from the center of the piston S1 and S2.

Then calculate the average:

•

Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

•

If S is > 0.40 mm (0.016 in) use seal type A.

•

If S is < 0.40 mm (0.016 in) use seal type B.

Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0.1 mm (0.004 in) the screw can be utilized again; If D1 - D2 > 0.1 mm (0.004 in) the screw must be replaced.

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

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6.

7.

Using a suitable hoist (1), set the cylinder head (2) on the engine block.

CYLHEADREMOVE

4

CYLINDERHEADDH

5

Tighten the cylinder head bolts (2) in the following order using tool 380000304 for the angle tightening procedure.

1.

Tighten with a torque wrench.

•

12x1.75x130 are torqued to 30 - 40 Nm (22 - 30 lb ft).

•

12x1.75x150 are torqued to 50 - 60 Nm (37 - 44 lb ft).

2.

Turn the bolt clockwise 85 - 95 °.

3.

Turn the bolt clockwise an additional 85 - 95 °.

70476

6

Tightening sequence for the 6 cylinder engine.

A = Front of engine Next operation: Fuel injector Electro injector - Install (B.20.A)

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Cylinder head Valve guide - Clearance Prior operation: Valve drive Valve assembly - Remove (B.10.A) 1.

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 0.092 mm (0.002 - 0.004 in).

2.

Turn the valve (2) and check that the centering error is not exceeding 0.03 mm (0.001 in).

3.

80710

1

0B0O200405BACD0

2

Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.

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

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Cylinder head Valve seat - Regrind Prior operation: Valve drive Valve assembly - Remove (B.10.A) Should slight scratches or burns be found, go over with the adequate tool (1) according to the inclination values indicated as follows:

80711

70331

2

VALVE SEAT MAIN DATA (4 CYL.) Should valve seats be not reset just by regrinding, replace them with spare ones. Using a suitable tool, remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

1.

Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F) and using the proper punch, fit the new valve seats, previously cooled, into the cylinder head.

2.

Therefore, with an adequate tool, go over the valve seats according to the values stated in the previous figure.

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70332

3

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD 3.

After regrinding, check that the valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial gauge 380000228 (1).

80712

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

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Valve cover - Remove 1.

Remove the nuts securing the valve cover to base.

2.

Remove valve cover and gasket.

BACD04APH004ASA

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

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

Install a new gasket (2) on the valve cover (1).

2.

Place the valve cover (1) on its seat, and install the mounting bolts.

VALVECOVER

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Valve cover - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Loosen the nuts (1) on top of the valve cover (2).

2.

Remove the valve cover (2) from it’s base.

VALVECOVERF4DE

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

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Front cover - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Vibration damper - Remove (B.10.A) 1.

Remove the screws (1) from the front cover. Be sure to remove the two screws (3) underneath the cover.

NOTE: Take note of screw (1) assembling positions since they have different lengths.

2.

Remove the front cover from the cylinder block.

FRONTCOVERH

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

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Front cover - Cleaning F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

2.

Remove the sealing ring (2) from the front cover (1).

FRONTCOVERH2

1

FRONTCOVERG

2

Clean the sealing surfaces and apply LOCTITE 5205.

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

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Front cover - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Front cover - Cleaning (B.10.A) 1.

Install the front cover (2) and tighten the mounting bolts (1) to the specified torque.

FRONTCOVERD3

Next operation: Vibration damper - Install (B.10.A)

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Front cover - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Vibration damper - Remove (B.10.A) 1.

Remove the screws (1) from the front cover (2). Be sure to remove the four screws (3) from underneath the cover (2).

NOTE: Take note of screw assembling positions since that have different lengths.

2.

Remove the front cover (2).

FRONTCOVERD

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

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Front cover - Cleaning F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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

Disassemble the sealing ring (2) from the front cover (1), clean the coupling surfaces accurately.

FRONTCOVERD2

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

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Front cover - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Front cover - Cleaning (B.10.A) 1.

2.

Position the front cover seal (1) on the engine block.

FRONTCOVERD4

1

FRONTCOVERD5

2

Install the front cover (1) on the block and tighten the screws (2) to the prescribed torque.

Next operation: Vibration damper - Install (B.10.A)

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Rear cover - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

Remove the retaining bolts (2) from the rear cover (1) and withdrawal the cover.

NOTE: Take note of the bolt location due to the different lengths. This will aid in ease of assembly.

REARCOVERH3

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

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Rear cover - Cleaning F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

Clean the rear cover and it’s mating surface on the timing gear cover.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (1), a few millimeters thick, to the sealing surface of the cover.

NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes.

REARCOVERH

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

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Rear cover - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Rear cover - Cleaning (B.10.A) NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or dirt.

1.

Install the cover (1) onto the timing gear housing and install the bolts in same location that they were removed.

2.

Tighten them to the prescribed torque.

REARCOVERH2

Next operation: Flywheel - Install (B.10.A)

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Rear cover - Cleaning F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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

Clean the rear cover and it’s mating surface on the timing gear cover.

NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant.

Excessive sealant could squeeze out the sides and cause blockage of lubrication passages.

2.

Apply a thin bead of LOCTITE 5205 (1), a few millimeters thick, to the sealing surface of the cover.

NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes.

REARCOVERD

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

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Rear cover - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Rear cover - Cleaning (B.10.A) NOTE: Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

1.

Install the cover (1) on the engine.

2.

Tighten the fixing screws (2) in the same position from where they have been removed, to the prescribed torque.

REARCOVERC2

Next operation: Flywheel - Install (B.10.A)

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Wiring harness - Disconnect F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

0B0O200406CRIL0

(1) Connections for electro-injectors (2) Coolant temperature sensor (3) Fuel pressure sensor (4) Oil pressure/temperature sensor

1

(5) Driving shaft sensor (6) Electro-injector (7) Air pressure/temperature sensor (8) Timing system sensor

1.

Disconnect the engines cable from the connectors (1) to electro-injector (6), air pressure/temperature sensor (7), fuel pressure sensor (3), engine control module (11), high pressure pump sensor (10), timing system sensor (8), coolant temperature sensor (2), driving shaft sensor (5).

2.

Disassemble the harness from the engine block by removing the fixing clamps.

(9) Fuel temperature sensor (10) Pressure regulating gauge (11) EDC 7 UC31

0B0O200406CRIL0

Next operation: Wiring harness - Connect (B.10.A)

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Wiring harness - Disconnect F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

HARNESS

(1) Fuel pressure Sensor (2) Coolant temperature sensor (3) Engine oil temperature sensor (4) Crankshaft speed sensor 1.

1

(5) Electro-injector (6) Air pressure/temperature sensor (7) Timing sensor (8) Fuel temperature sensor

(9) Fuel pressure regulator (10) EDC 7 UC31 (11) Connectors for electro-injectors

Disconnect the engine’s cable from the connectors wiring harness to Electro-Injectors (11); Air Pressure/Temperature Sensor; (6) Fuel Pressure Sensor (1); Engine Control Module (10); Timing Sensor (7); Coolant Temperature Sensor (2); Crankshaft Speed Sensor (4).

HARNESS

Next operation: Wiring harness - Connect (B.10.A) 84392428 15/03/2011

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Wiring harness - Connect Prior operation: Wiring harness - Disconnect (B.10.A) 1.

Reconnect the engine wiring harness to all the sensors, the engine control module and the common rail.

Refer to Wiring harness - Disconnect (B.10.A) for the harness routing and connections.

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Electronic control Control module - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Fuel line Low pressure - Disconnect (B.20.A) 1.

Disconnect the main wiring harness from the electronic control module (2).

2.

Disconnect the low pressure fuel lines that are attached to the control module cooling plate.

3.

Remove the three mounting bolts (1) that secure the control module and the cooling plate to the engine block.

4.

Remove the control module and cooling plate as one unit.

EDC7H

Next operation: Electronic control Control module - Install (B.10.A)

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Electronic control Control module - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Electronic control Control module - Remove (B.10.A) 1.

Install the electronic control module (2) and cooling plate on the side of the engine block.

2.

Install the mounting bolts (1) and rubber isolators and tighten to the specified torque.

NOTE: If the rubber isolators are cracked or excessively deformed, replace them before installation.

EDC7H

Next operation: Fuel line Low pressure - Connect (B.20.A)

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Sensing system Position sensor - Remove 1.

Remove the mounting nut and slide the timing sensor out of the timing gear housing.

Next operation: Sensing system Position sensor - Install (B.10.A)

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Sensing system Position sensor - Install Prior operation: Sensing system Position sensor - Remove (B.10.A) 1.

Install a new O-ring on the timing sensor.

2.

Slide the sensor over the mounting stud and install the nut. Tighten to the specified torque.

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Sensing system Speed sensor - Install 1.

Install a new O-ring on the speed sensor (3).

2.

Install the speed sensor (3) on the front cover (1).

3.

Tighten the screw (2) to the specified torque.

SPEEDSENSORH

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Index ENGINE AND PTO IN - B ENGINE - 10.A Auxiliary drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Auxiliary drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Camshaft Bushing - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Camshaft Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Camshaft Gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Camshaft Gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Camshaft Tappet - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Camshaft Tappet - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Camshaft Tappet - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Connecting rod and piston - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Connecting rod and piston Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Connecting rod and piston Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Connecting rod Bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Connecting rod Bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Connecting rod Bushing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Crankshaft Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Crankshaft Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Crankshaft Gear - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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Crankshaft Main bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Crankshaft Main bearing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Crankshaft Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Crankshaft Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Cylinder block - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Cylinder block Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Cylinder head Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Cylinder head Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Electronic control Control module - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Electronic control Control module - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Electronic control Control module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Electronic control Control module - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

ENGINE - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

ENGINE - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

ENGINE - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

ENGINE - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

ENGINE - Service instruction Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Front cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Front cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Front cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Front cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A 84392428 15/03/2011

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Front cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Rear cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Rear cover - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Rear cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Rear cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Rocker assembly Housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rocker assembly Housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Rocker assembly Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Rocker assembly Shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Sensing system Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Camshaft speed sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Sensing system Position sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Sensing system Position sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Sensing system Speed sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Valve assembly Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Valve assembly Valve - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Valve assembly Valve - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Valve drive - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Valve drive Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 84392428 15/03/2011

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Valve drive Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Valve drive Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Valve drive Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Valve drive Rocker assembly - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Valve drive Rocker assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Valve drive Valve assembly - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Valve drive Valve assembly - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Vibration damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Vibration damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Vibration damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Vibration damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Wiring harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Wiring harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Wiring harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Wiring harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Wiring harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A

FUNCTIONAL DATA FUEL AND INJECTION SYSTEM Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Regulator valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Relief valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

High pressure common rail Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Gear pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Fuel heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Fuel transfer pump Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

SERVICE Fuel filter system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fuel filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Fuel injector Fuel Manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fuel Manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electro injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Electro injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

High pressure common rail Gear pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Gear pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fuel line High pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Fuel connector Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Sensing system Air temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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FUEL AND INJECTION SYSTEM - Dynamic description F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1

4C0O200406CRILH

(1) Electro-injector (2) Common rail (3) Pressure limiting device for fuel return (4) Common rail pressure relief valve

(5) (6) (7) (8)

Pre-filter mounted on the frame High-pressure pump Mechanical vane pump Fuel filter

The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.

Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.

The hydraulic system is implemented by a low pressure circuit and a high pressure circuit The high pressure circuit is composed of the following pipings: •

piping connecting high pressure pump outlet to rail

•

pipings supplying injectors from rail

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

fuel suction piping from tank to pre-filter

•

pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and pre-filter

•

pipings supplying the high pressure pump through the fuel filter 84392428 15/03/2011

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The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.

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FUEL AND INJECTION SYSTEM - Dynamic description F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1

4C0O200406CRIL0

(1) (2) (3) (4)

Injector Common rail Pressure limiter for fuel return Rail overpressure valve

(5) (6) (7) (8)

Prefilter mounted on the block High pressure pump Mechanical rotor pump Fuel filter

The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.

Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.

The hydraulic system is implemented by a low pressure circuit and a high pressure circuit The high pressure circuit is composed of the following pipings: •

piping connecting high pressure pump outlet to rail

•

pipings supplying injectors from rail

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

fuel suction piping from tank to pre-filter

•

pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and pre-filter

•

pipings supplying the high pressure pump through the fuel filter

The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.

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FUEL AND INJECTION SYSTEM - Plumbing schema The fuel system is a Common Rail injection system with a CP3 high pressure pump.

The pressure regulator, placed upstream of the high pressure pump, adjusts the fuel flow that is necessary on the low pressure system. Afterwards, the high pressure pump takes care of supplying the rail properly. This arrangement, by pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.

Function of the pressure relief valve (2), assembled on the high pressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bar (73 psi). Based on the efficiency the fuel filter.

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

The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 - 2 bar (19 - 29 psi).

Two bypass valves are placed in parallel with the mechanical supply pump.

The bypass valve (18) allows fuel to flow from the mechanical pump outlet to it’s inlet, when the fuel filter inlet pressure exceeds the allowed threshold value.

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

FUELSYSTEMSCHEM

(1) High-pressure pump (2) Pressure relief valve on high pressure pump (3) Pressure relief valve assembled on fuel return from injectors (4) Rail overpressure valve (5) Common rail

1

(7) Injector (8) Return spring

(13) Mechanical supply pump (14) Fuel filter

(9) Control unit heat exchanger

(15) Pressure regulator

(10) Mechanical priming pump (11) Pre-filter

(16) High pressure pump cooling pipe (17) By-pass valve

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(6) Pressure sensor

(12) Fuel tank

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(18) By-pass valve

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Regulator valve - Overview Pressure Regulator The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the pressure regulator is managed by the EDC7 control unit.

Delivery pressure to the rail is modulated between 250 - 1450 bar (3625 - 21025 psi) by the electronic control unit by controlling the pressure regulator solenoid valve.

This component is a N.O. solenoid valve.

The solenoid valve impedance is approximately 3.2 Ω.

Pressure Limiter for Fuel Return It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at pressures of 1.3 - 2 bar (19 - 29 psi). By guaranteeing this pressure to the return fuel, the fuel vapor formation inside the injectors is avoided, optimizing fuel spraying and combustion.

BACD04APH176ASA

1

(A) - To Tank (B) - From Injectors

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Relief valve - Overview

93101562

1

Mounted on the end of the rail, it has the function of protecting the system’s components in case the failure of the rail pressure sensor or the pressure regulator of the CP3 pump causes an excessive pressure increase in the high pressure plant.

When the rail pressure reaches 2000 bar (29000 psi), the valve initially opens in order to allow the fuel to flow and subsequently reduce the pressure within the safety limits and then it mechanically regulates the rail pressure to approximately 1000 bar (14500 psi).

This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of the fuel preserving the return pipes to tank.

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Fuel injector Electro injector - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

On NEF TIER IV engines, BOSCH - CRIN2 electro-injectors with 8 hole DLLA type jets with a flow rate of 550 CCM / 30 SEC @ 100 bar (1450 psi).

The injector is similar as construction to the tier 3 injectors, apart from the absence of the plunger return springs.

The injector is composed of two main parts: •

Actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.

•

Control solenoid valve composed of a coil, and pilot valve.

The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

93095366

(1) (2) (3) (4) (5)

Pressure Rod Plunger Nozzle Coil Pilot Valve

1

(6) Ball Shutter (7) Control Area (8) Pressure Chamber (9) Control Volume (10) Control Duct

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(11) Supply Duct (12) Control Fuel Outlet (13) Electrical Connection (14) Spring (15) High Pressure Fuel Inlet

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Injection Start

93095367

2

When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, following fuel injection into the cylinder.

Injection End When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance as to make plunger (2) go back to its closing position and end the injection process.

NOTE: The injector cannot be overhauled and therefore it must not be disassembled.

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Electro-Injector Solenoid Valves The electro-injectors are effectively N.O. solenoid valves.

Each injector is connected to the EDC control unit on connector A. The Impedance of the coil of each injector is 0.56 - 0.57 Ω.

COVERBASE

Description

Reference Connector (1) Pin #1 Pin #2 Pin #3 Pin #4 Connector (2) Pin #1 Pin #2 Pin #3 Pin #4 Connector (3) Pin #1 Pin #2 Pin #3 Pin #4

3

EDC pin

Cylinder Cylinder Cylinder Cylinder

2 2 1 1

injector injector injector injector

11A 6A 13A 4A

Cylinder Cylinder Cylinder Cylinder

4 4 3 3

injector injector injector injector

14A 3A 12A 5A

Cylinder Cylinder Cylinder Cylinder

6 6 5 5

injector injector injector injector

15A 2A 1A 16A

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Fuel injector Electro injector - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

On NEF TIER IV engines, BOSCH - CRIN2 electro-injectors with 8 hole DLLA type jets with a flow rate of 550 CCM / 30 SEC @ 100 bar (1450 psi).

The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs.

The injector is composed of two main parts: •

Actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.

•

Control solenoid valve composed of a coil, and pilot valve.

The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

93095366

(1) (2) (3) (4) (5)

Pressure Rod Plunger Nozzle Coil Pilot Valve

1

(6) Ball Shutter (7) Control Area (8) Pressure Chamber (9) Control Volume (10) Control Duct

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(11) Supply Duct (12) Control Fuel Outlet (13) Electrical Connection (14) Spring (15) High Pressure Fuel Inlet

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Injection Start

93095367

2

When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, following fuel injection into the cylinder.

Injection End When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance as to make plunger (2) go back to its closing position and end the injection process.

NOTE: The injector cannot be overhauled and therefore it must not be disassembled.

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Electro-Injector Solenoid Valves The electro-injectors are effectively N.O. solenoid valves.

Each injector is connected to the EDC control unit on connector A. The Impedance of the coil of each injector is 0.56 - 0.57 Ω.

COVERBASE

Description

Reference Connector (1) Pin #1 Pin #2 Pin #3 Pin #4 Connector (2) Pin #1 Pin #2 Pin #3 Pin #4 Connector (3) Pin #1 Pin #2 Pin #3 Pin #4

3

EDC pin

Cylinder Cylinder Cylinder Cylinder

2 2 1 1

injector injector injector injector

3A 6A 13A 9A

Cylinder Cylinder Cylinder Cylinder

4 4 3 3

injector injector injector injector

5A 14A 12A 4A

Cylinder Cylinder Cylinder Cylinder

6 6 5 5

injector injector injector injector

10A 15A 16A 11A

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High pressure common rail - Overview Fuel system operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements at about 2 bar (29 psi).

The amount of fuel supplying the high pressure pump is metered by the pressure regulator placed on the low pressure system. The pressure regulator is controlled by the EDC7 control unit through a PWM signal.

When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, unable to be released, is compressed above the supply pressure value existing in the rail.

The generated pressure makes the exhaust valve open and the compressed fuel reaches the high pressure circuit.

The pumping element compresses the fuel till top dead center of the delivery stroke, is reached. Afterwards, the pressure decreases till the exhaust valve is closed.

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

When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated.

The delivery valves must always be free in their movements, free from impurities and oxidation.

The rail delivery pressure is modulated between 250 - 1600 bar (3625 - 23200 psi) by the electronic control unit, through the pressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

The radialjet pump disconnection - reconnection time on the engine is greatly reduced in comparison with traditional injection pumps, because it does not require setting.

If the pipe between fuel filter and high pressure pump is to be removed or installed, be sure that hands and components are absolutely clean.

Rail

COMMONRAILOVERV

(1) Rail

(2) Fuel inlet from high-pressure pump

1

(3) Overpressure valve

(4) Pressure sensor

The rail volume is comparatively small to allow quick pressurization at start-up, at idle and in case of high flow rates.

It has enough volume to minimize system spikes and the use of plenum chambers caused by the opening and closing of the injectors and by the high pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high pressure pump.

A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is feedback information, where the rail pressure value is checked and if necessary, corrected.

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High pressure common rail - External view F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Introduction Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and fuel consumption.

The CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23200 psi).

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

HARNESS

(1) Fuel pressure sensor (2) Coolant temperature sensor (3) Oil temperature/pressure sensor (4) Driving shaft sensor

1

(5) Connection to electro-injectors (6) Air temperature/pressure sensor (7) Camshaft sensor (8) Fuel heater cable and fuel temperature sensor

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(9) Pressure gauge cabling (10) EDC7 UC31 Control unit (11) Electro-injector

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

High pressure common rail - External view F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Introduction Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and fuel consumption.

For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at pressures up to 1450 bar (21025 psi).

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

Air pressure/temperature system It is a component integrating a temperature sensor and a pressure sensor. Fitted on the intake manifold, it measures the maximum inlet air capacity to calculate precisely the fuel quantity to inject at every cycle. The outlet voltage is proportional to the pressure or temperature obtained by the sensor.

Engine oil temperature and pressure sensor Same as the air pressure/temperature sensor, it is fitted on the engine oil filter base, in a horizontal position. It measures engine oil temperature and pressure.

Fuel pressure sensor Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The injection pressure value is used to control the pressure and to determine the electric injection control length.

Coolant temperature sensor It is a variable resistance sensor suitable to measure the coolant temperature to provide the control unit with an index of the engine thermal state.

Output shaft sensor It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape.

System functionality The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.

FPT Code recognition The EDC 7 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent.

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0B0O200406CRIL0

1

(1) Connection to electro-injectors

(5) Crankshaft sensor

(2) Coolant temperature sensor (3) Fuel pressure sensor (4) Oil temperature/pressure sensor

(6) Electro-injector (7) Air temperature/pressure sensor (8) Camshaft sensor

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(9) Fuel heater cable and fuel temperature sensor (10) Pressure gauge cabling (11) EDC 7 UC31

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

High pressure common rail Gear pump - Dynamic description CP3 high pressure pump Pump provided with 3 radial pumping elements driven by the timing system gear, no need for timing. The mechanical feeding pump driven by the high pressure pump’s shaft is assembled to the rear side of the high pressure pump.

NOTE: The high pressure pump unit - feeding pump is not subject to overhaul. Do not disassemble or tamper with the retaining bolts.

The only serviceable components are the control gear and pressure regulator.

80719

(1) Outlet to rail (2) High pressure pump (3) Pressure regulator valve

1

(4) Drive gear (5) Inlet from filter (6) Return to filter

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(7) Inlet (8) Outlet to filter (9) Transfer pump

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Inside structure

80720

(1) (2) (3) (4)

Cylinder Three-lobe element Cap intake valve Ball delivery valve

2

(5) Piston (6) Pump shaft (7) Low pressure fuel inlet (8) Pumping elements supplying fuel ducts

Every pumping unit is composed of: •

A piston actuated by a three-lobe element floating on the pump shaft. The element, which is floating on an offset part of the shaft, uses the highest part of the element to actuate the three pistons alternately.

•

Cap intake valve.

•

Ball delivery valve.

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Working principle

80721

(1) (2) (3) (4)

Cylinder Three-lobe element Cap intake valve Ball delivery valve

3

(5) Piston (6) Pump shaft (7) Low pressure fuel inlet (8) Pumping elements supplying fuel ducts

The pumping element is oriented towards the pump’s camshaft. During the intake phase, the pumping element is fed through the feeding line. The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge. The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element. During the compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to the common rail, feeding it through the exhaust unit.

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80722

(1) (2) (3) (4)

Cylinder Three-lobe element Cap intake valve Ball delivery valve

4

(5) Piston (6) Pump shaft (7) Low pressure fuel inlet (8) Pumping elements supplying fuel ducts

The figure shows the fuel runs at low pressure inside the pump. The following elements are clearly visible: the main feeding line to the pumping elements, the feeding lines to the pumping elements, the duct lines run for the pump lubrication, the pressure gauge, the flow limiting valve to 5 bar (73 psi) and the fuel exhaust flue The pump shaft is lubricated by the fuel from the feeding and recovery lines.

The pressure gauge determines the quantity of fuel to feed the pumping elements. The excess fuel flows through the exhaust gallery.

The 5 bar (73 psi) limiting valve, in addition to recovering exhaust fuel as a collector, also functions to keep the pressure at a constant 5 bar (73 psi) limit at gauge entry.

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

80723

(1) Fuel exhaust galley

5

(2) Fuel exhaust galley

(3) Fuel outlet to rail

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

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Fuel heater - Overview The ECU drives the filter heater at fuel temperature less than our equal to 5 °C (41 °F).

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Fuel transfer pump - Sectional view Gear pump, placed on the rear part of the high pressure pump, whose function is to feed the high pressure pump. It is driven by the high pressure pump’s shaft.

Normal operating condition

BACD04APH163ASA

1

- - and (A) Fuel entry flowing from the tank (B) Fuel exhaust to filter

(1) By-pass valve in the closed position (2) By-pass valve in the closed position

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Overpressure condition

BACD04APH164ASA

2

The by-pass valve (1) is activated in case of overpressure on (B) Exhaust unit. The actual pressure, overcoming the resistance of the valve’s spring (1), connects the exhaust with the entry through the gallery (2).

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Jettison condition

BACD04APH165ASA

3

The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system through the priming pump. In this condition the by-pass (1) keeps closed while the dump by-pass valve (2) opens up due to the pressure effect on the entry unit so the fuel flows to the exhaust unit (B).

NOTE: The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the high pressure pump.

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Sensing system Air temperature-pressure sensor - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

AIRPRESSTEMP

1

This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle.

The sensor is connected to the control unit on pins 25C - 36C for temperature and 33C - 34C for pressure.

The power supply is 5 volts.

Voltage at the sensor output is proportional to the detected pressure or temperature.

Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 25C 36C 33C 34C

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Pressure sensor - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

FUELPRESS

1

Mounted on the end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command.

The sensor is connected to the control unit on pins 12C - 14C - 13C. The power supply is 5 Volt.

Reference 1 2 3

Description Ground Signal Power supply

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EDC pin 12C 14C 13C

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Temperature sensor - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

FUELTEMPH

(1) Fuel Temperature Sensor

1

(2) Filter heating resistance

This sensor is identical to the coolant temp sensor.

This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.

The fuel temperature sensor is connected to the control unit on pins 35C - 18C. The sensor impedance at 20 °C (68 °F) is approximately 2.50 Ω.

Reference 1 2

Description Ground Temperature signal

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EDC pin 35C 18C

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Air temperature-pressure sensor - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

AIRPRESSTEMP

1

This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle.

The sensor is connected to the control unit on pins 21C - 29C for temperature and 10C - 28C for pressure.

The power supply is 5 volts.

Voltage at the sensor output is proportional to the detected pressure or temperature.

Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 21C 29C 10C 28C

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Pressure sensor - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

FUELPRESS

1

Mounted on tone end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command.

The sensor is connected to the control unit on pins 20C - 27C - 12C. The power supply is 5 Volt.

Reference 1 2 3

Description Ground Signal Power supply

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EDC pin 20C 27C 12C

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Temperature sensor - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Fuel Temperature Sensor

FUELTEMPD

1

(1) Fuel Temperature Sensor This sensor has a variable resistor able to detect the fuel temperature to provide the engine control module an index of the fuel thermal status.

It is connected to the control module by pin 17C (Earth) and 34C (temperature signal).

The resistor to 20 °C (68 °F) = 2.5 k Ω.

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Fuel filter system - Remove Prior operation: Fuel line Low pressure - Disconnect (B.20.A) 1.

Using the tool disassemble the fuel filter (1) and remove it from the support (5).

2.

Disconnect the electrical connections (2) from the support (5) including the one for the fuel heater.

3.

Disconnect the fuel low pressure pipelines (3) from the support (5).

4.

Disconnect pipeline (4) from the support (5).

5.

Remove the sustaining support bracket (5) from the block.

4442596398GHDC

Next operation: Fuel filter system - Install (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel filter system Fuel filter - Install 1.

Install the bracket and the base of the fuel filter.

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Fuel filter system - Install Prior operation: Fuel filter system - Remove (B.20.A) 1.

Assemble the bracket and support (1) of the fuel filter (6).

2.

Proceed connecting in sequence the pipelines (9) (3) (4) (5) of the support (1) to the high pressure pump (8).

3.

Connect the pipeline (7) from the high pressure pump to the common rail.

NOTE: Refer to Fuel connector - Connect (B.20.A) for the proper operation of the clamps on the low pressure fuel lines.

FUELSYSTEMD

Next operation: Fuel line Low pressure - Connect (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injector Fuel Manifold - Remove Prior operation: Fuel line High pressure - Disconnect (B.20.A) NOTICE: Make sure the area around the fuel manifold is clean. Once they are removed, there is a greater risk of contaminating the internal components.

1.

Remove the nuts (1) and remove the fuel manifolds (2).

NOTE: Disassembled fuel manifolds must not be used again. Replace them with new ones during reassembly.

FUELMANIFOLD

Next operation: Fuel injector Fuel Manifold - Install (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injector Fuel Manifold - Install Prior operation: Fuel injector Fuel Manifold - Remove (B.20.A) 1.

Fit a sealing ring (3) lubricated with petroleum jelly on the fuel manifold (2).

2.

Install the fuel manifold (2) into the cylinder head so that the positioning ball (5) is coinciding with the relevant housing (4).

NOTE: After removing fuel manifolds they cannot be used again. Replace them with new ones.

3.

Screw the fastening nuts on without tightening them.

NOTE: During this operation, the injector (1) can be moved so that the manifold (2)can be properly inserted into the inlet hole.

4.

FUELMANIFOLDDH

1

INJMANIFOLDDH

2

After everything is in place, tighten the fuel manifold nuts (2) to 50 Nm (37 lb ft).

NOTICE: Be sure to tighten the screws (1) securing the injector to the specified torque. Refer to Fuel injector Electro injector - Install (B.20.A) for the proper procedure.

Next operation: Fuel line High pressure - Connect (B.20.A)

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ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injector Electro injector - Remove Prior operation: Fuel injector Fuel Manifold - Remove (B.20.A) 1.

Remove the bolts securing the injector to the cylinder head.

2.

Use tool 380001099 (1) to remove the injectors (2) from the cylinder head.

INJECTORREMOVE

Next operation: Fuel injector Electro injector - Install (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel injector Electro injector - Install Prior operation: Fuel injector Electro injector - Remove (B.20.A) 1.

Put a new O-ring (2) and sealing washer (3) on the injector (1).

2.

Lubricate the O-ring (2) with petroleum jelly.

3.

4.

ELECTROINJECTOR

1

EINJECTORDH2

2

EINJECTORDH3

3

Install the injectors (1) into the cylinder head directed so the fuel inlet hole (2) is facing the fuel manifold seat (3).

Use tool 380001099 (1) to seat the injector (2) in place.

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5.

Insert the bolts (2) securing the injector (1) without tightening them.

NOTICE: You must install the fuel manifold before tightening the bolts securing the electro-injector. Refer to Fuel injector Fuel Manifold - Install (B.20.A).

6.

EINJECTORDH4

4

INJMANIFOLDDH

5

Use a torque wrench to tighten the injector screws (1) gradually and alternately to a torque of 7.7 - 9.3 Nm (68 - 82 lb in).

NOTICE: Be sure to torque the nut (2) securing the fuel manifold (3) after torquing the injector. Refer to Fuel injector Fuel Manifold - Install (B.20.A) for the proper procedure.

Next operation: Fuel injector Fuel Manifold - Install (B.20.A)

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High pressure common rail Gear pump - Remove Prior operation: Fuel line High pressure - Disconnect (B.20.A) Prior operation: Fuel line Low pressure - Disconnect (B.20.A) 1.

Disconnect all fuel lines (4) on the high pressure pump (2).

2.

Remove the mounting nuts (1) and remove the high pressure pump (2) and feed pump (3) together as one unit.

HPPUMPDH

Next operation: High pressure common rail Gear pump - Install (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

High pressure common rail Gear pump - Install Prior operation: High pressure common rail Gear pump - Remove (B.20.A) Prior operation: Fuel line Low pressure - Connect (B.20.A) 1.

Slide the high pressure pump (2) including the feed pump (3) into place on the rear cover.

2.

Install the nuts (1) securing the pump to the rear cover and tighten to the specified torque.

3.

Hook up all fuel lines (4).

HPPUMPDH

Next operation: Fuel line High pressure - Connect (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

High pressure common rail Common rail - Install Prior operation: Fuel line High pressure - Disconnect (B.20.A) 1.

Install the high pressure fuel rail (2) on the cylinder head.

2.

Tighten the mounting screws (1) to the specified torque.

3.

Connect new fuel pipes (6) to the rail (2) and to the manifold for electro-injectors (5).

4.

Tighten the pipe joints (3) to 20 Nm (14.8 lb ft).

5.

Install the low pressure fuel line (4) to the rail (2).

Refer to Fuel connector - Connect (B.20.A) for the proper procedure.

RAIL

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Connect 1.

2.

Connect new fuel pipes (1) between high pressure rail (3) and fuel manifolds (2).

HPFUELCONNECT

1

HPFUELTORQUE

2

Pipe connection (1) should be torqued to 20 Nm (15 lb ft) using the proper wrench (4) and torque wrench (3).

Connections should be tighten by holding the flow limiting valve hexagon with the proper wrench.

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Fuel line Low pressure - Connect F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Connect the pipeline to the pressure limiter.

2.

Connect all the fuel lines between the fuel filter base and the high pressure pump.

3.

Connect the pipeline from the high pressure pump to the engine control module cooling plate.

4.

Connect the pipeline from the high pressure pump to high pressure common rail.

LPFUELCONNECT

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Disconnect F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Disconnect from the rail (1) the fuel pipe (3). Refer to Fuel connector - Disconnect Low Pressure (B.20.A). Disconnect the fuel pipes (5) from the rail (1) and injector manifolds (4).

2.

Remove the screws (2) and disconnect the rail (1).

COMMONRAILF4DE

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line High pressure - Disconnect F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Disconnect the fuel pipe (4) from the cylinder head Fuel connector - Disconnect Low Pressure (B.20.A). Disconnect the fuel pipes (5) from the rail (2) and injector manifolds (6).

NOTICE: When releasing pipe (5) connections (6) to rail (2), use the proper wrench to avoid rotation of flow limiters (3).

2.

Remove the screws (1) and disconnect the rail (2).

COMMONRAILF4HE

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel line Low pressure - Disconnect 1.

Disconnect the fuel return pressure limiter (1). Refer to Fuel connector - Disconnect (B.20.A).

RETURNLINEF4DEF

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel connector - Disconnect Low Pressure 1.

Hold down the clasp (1) and release the quick fitting joint.

80628

Next operation: Fuel connector - Connect (B.20.A)

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Fuel connector - Connect Low Pressure Prior operation: Fuel connector - Disconnect (B.20.A) 1.

Connect low pressure lines to the fuel rail by inserting the rapid fitting joint into the connection joint and press until the clip (1) fastens securely.

2.

Check proper fuel connection.

80628

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1

ENGINE AND PTO IN - FUEL AND INJECTION SYSTEM

Sensing system Air temperature-pressure sensor - Remove 1.

Disconnect the wiring harness from the sensor.

2.

Remove the retaining bolt.

3.

Remove the sensor and O-ring.

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Index ENGINE AND PTO IN - B FUEL AND INJECTION SYSTEM - 20.A FUEL AND INJECTION SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

FUEL AND INJECTION SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

FUEL AND INJECTION SYSTEM - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel connector - Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Fuel connector - Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Fuel filter system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Fuel filter system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fuel filter system Fuel filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Fuel injector Electro injector - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Fuel injector Electro injector - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Fuel injector Electro injector - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Fuel injector Fuel Manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Fuel injector Fuel Manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fuel line High pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Fuel line High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Fuel line High pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Fuel line Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Fuel line Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fuel transfer pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 High pressure common rail - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

High pressure common rail - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

High pressure common rail - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 High pressure common rail Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 High pressure common rail Gear pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 High pressure common rail Gear pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 High pressure common rail Gear pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Regulator valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Air temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Sensing system Air temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Sensing system Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A

FUNCTIONAL DATA AIR INTAKE SYSTEM Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Air intake manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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ENGINE AND PTO IN - AIR INTAKE SYSTEM

AIR INTAKE SYSTEM - Overview The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure, one main body and one compressor.

During engine working process, the exhaust emissions flow through the body of the turbine, causing the turbine disk wheel’s rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the drawn air is then cooled by the radiator and flown through the piston collector.

The turbocharger is equipped with a transforming valve to regulate the pressure. It is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s function is to restrict the exhaust of the emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed pressure.

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

BOOSTDIAGRAM

1

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Turbocharger Turbine - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Remove the turbo oil supply line (3) from the oil filter base and from the pipe fitting (4) to the turbine.

2.

Remove the nuts securing the turbocharger (1) to the exhaust manifold (2)and remove it from its seat.

TURBOF4HE

Next operation: Turbocharger Turbine - Install (B.30.A)

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Turbocharger Turbine - Install Prior operation: Turbocharger Turbine - Remove (B.30.A) 1.

With a suitable sling, place the turbocharger (1) on the exhaust manifold (2) with a new gasket.

2.

Tighten the mounting screws (3) to the specified torque.

TURBOF4DE

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Turbocharger - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Unscrew the fixing nuts (3) of the turbocharger (1) on the exhaust manifold (2).

TURBOF4DE

Next operation: Turbocharger - Install (B.30.A)

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Turbocharger - Install 1.

Set the turbocharger (1) on the exhaust manifold (2).

2.

Torque the nuts (3) to 35 N·m (26 lb ft) then torque to 46 N·m (34 lb ft).

TURBOF4DE

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Air intake manifold - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Loosen the retaining bolts (2) of the intake manifold (1) and disassemble the intake air heater (3) for the cold start aid.

INTAKEF4HE

Next operation: Air intake manifold - Install (B.30.A)

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Air intake manifold - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Air intake manifold - Remove (B.30.A) 1.

Apply LOCTITE 5999to the mounting surface of the air intake heater (3) on the intake manifold (1).

2.

Install the heater (3) and tighten bolts.

3.

Assemble the manifold and fasten it to the cylinder head using screws (2).

INTAKEF4HE

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Air intake manifold - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Loosen the fixing screws (2) of the intake manifold (1) and disassemble the joint to the air heater for the cold start.

INTAKEF4DE

Next operation: Air intake manifold - Install (B.30.A)

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Air intake manifold - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Air intake manifold - Remove (B.30.A) 1.

Apply to the coupling surface of the intake manifold (1) equipped with heater a sufficient coat of LOCTITE 5999.

2.

Tighten the screws (2) to the prescribed torque.

INTAKEF4DE

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1

Index ENGINE AND PTO IN - B AIR INTAKE SYSTEM - 30.A Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Air intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Air intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

AIR INTAKE SYSTEM - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Turbocharger Turbine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Turbocharger Turbine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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ENGINE AND PTO IN - B EXHAUST SYSTEM - 40.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B EXHAUST SYSTEM - 40.A

SERVICE Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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ENGINE AND PTO IN - EXHAUST SYSTEM

Exhaust manifold - Remove Prior operation: Turbocharger Turbine - Remove (B.30.A) 1.

Loosen the bolts (1) and remove the exhaust manifold (2) from the cylinder head.

BAIL06CCM055ASA

Next operation: Exhaust manifold - Install (B.40.A)

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ENGINE AND PTO IN - EXHAUST SYSTEM

Exhaust manifold - Install Prior operation: Exhaust manifold - Remove (B.40.A) 1.

Connect the exhaust manifold (2) with new gasket.

Tighten the mounting bolts (1) to the specified torque.

EXHAUSTMANIFOLD

Next operation: Turbocharger Turbine - Install (B.30.A)

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Index ENGINE AND PTO IN - B EXHAUST SYSTEM - 40.A Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A

FUNCTIONAL DATA ENGINE COOLANT SYSTEM Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

SERVICE Thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 84392428 15/03/2011

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Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

ENGINE COOLANT SYSTEM - Dynamic description F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: •

Expansion Tank - Placement, shape and dimension are subject to change according to the engine’s equipment.

•

Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid which is then ran through the radiator. Application determines placement and dimensions.

•

Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.

Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.

•

Heat Exchanger - Cools the lubrication oil. Also application specific.

•

Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.

•

Thermostat - regulates the circulation of the cooling liquid.

•

If applicable, the circuit may be extended to the compressor.

ZEIL06EN0105G0B

1

6 cylinder version 84392428 15/03/2011

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

ENGINE COOLANT SYSTEM - Dynamic description F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: •

Expansion Tank - Placement, shape and dimension are subject to change according to the engine’s equipment.

•

Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid which is then ran through the radiator. Application determines placement and dimensions.

•

Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.

Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.

•

Heat Exchanger - Cools the lubrication oil. Also application specific.

•

Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.

•

Thermostat - regulates the circulation of the cooling liquid.

•

If applicable, the circuit may be extended to the compressor.

BAIL07CCM266AMA

1

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Sensing system Coolant temperature - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

COOLANTTEMP

1

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine.

The same signal is utilized by the control unit to drive an instrument panel gauge, if present.

The sensor is connected to the control unit on pins 15C - 26C. The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

Reference 1 2

Description Ground Temperature signal

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EDC pin 15C 26C

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Sensing system Coolant temperature - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

COOLANTTEMP

1

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine.

The same signal is utilized by the control unit to drive an instrument panel gauge, if present.

The sensor is connected to the control unit on pins 18C - 36C. The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

Reference 1 2

Description Ground Temperature signal

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ECU pin 18C 36C

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Thermostat - Remove 1.

Remove the three screws securing the thermostat housing (1) to the top of the cylinder head.

2.

Remove the thermostat (2) and the seal (3) from the housing (1).

86082981

Next operation: Thermostat - Install (B.50.A)

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Thermostat - Install Prior operation: Thermostat - Remove (B.50.A) 1.

Install the seal (3) around the flange of the thermostat (2).

2.

Install the thermostat (2) into the housing (1) and secure the assembly to the cylinder head using the three mounting screws.

86082981

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

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

Remove the retaining bolts and withdrawal the water pump.

BVE0294A

Next operation: Water pump - Install (B.50.A)

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Water pump - Install Prior operation: Water pump - Remove (B.50.A) 1.

2.

3.

Apply a new sealing ring (2) on the water pump (1).

BACD04APH220ASA

1

ZEIL06CS0245A0B

2

BACD04APH070ASA

3

Install the water pump (1) into the engine block (2) using the two mounting bolts (3).

Tighten the water pump (1) mounting bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

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

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Water manifold - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

Remove the screws (2) and disconnect the water manifold (1).

WATERMANIFOLDH

Next operation: Water manifold - Install (B.50.A)

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Water manifold - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Water manifold - Remove (B.50.A) 1.

Position the water manifold/alternator support (1) so that the pins (3) and (4) are set against the engine block.

2.

Tighten the mounting bolts (2) to the specified torque.

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

WATERMANIFOLDH2

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

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Water manifold - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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

Remove the bolts (2) securing the water manifold (1).

2.

Disconnect the water manifold from the block.

WATERMANIFOLDD2

Next operation: Water manifold - Install (B.50.A)

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Water manifold - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Water manifold - Remove (B.50.A) 1.

Install the water manifold (1) onto the block.

2.

Tighten the mounting screws (2) to the specified torque.

WATERMANIFOLDD2

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

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Fan and drive Belt - Remove 1.

Release tension on the belt (1) by pulling back on the belt tensioner (2).

2.

Extract the belt (1) from all the pulleys.

BELT

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

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

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

Turn the belt tensioner and fit the belt on the pulleys.

66070776

1

Belt Configuration (1) - Crankshaft (2) - Fixed Idler Pulley

(3) - Fan (4) - Water Pump

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(5) - Alternator (6) - Tensioner

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

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

Remove the bolt from the center of the belt tensioner and remove the tensioner.

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

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

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

Install the belt tensioner. Tighten the mounting bolt to the specified torque.

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

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

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

Remove the retaining bolt from the center of the idler pulley.

2.

Remove the idler pulley.

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

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

Fan and drive Idler pulley - Install Prior operation: Fan and drive Idler pulley - Remove (B.50.A) 1.

Install the idler pulley and tighten the retaining bolt in the center to the specified torque.

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

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ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

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

Loosen the fastening screws (3) and remove the pulley controlling the fan (2).

2.

Proceed detaching the support (1).

FANDRIVEC

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

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1

ENGINE AND PTO IN - ENGINE COOLANT SYSTEM

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

Re-attach the support, tightening the screws to the prescribed torque.

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

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Index ENGINE AND PTO IN - B ENGINE COOLANT SYSTEM - 50.A ENGINE COOLANT SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

ENGINE COOLANT SYSTEM - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Fan and drive - Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Fan and drive - Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fan and drive Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fan and drive Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fan and drive Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Fan and drive Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fan and drive Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fan and drive Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Coolant temperature - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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ENGINE AND PTO IN - B EXHAUST SYSTEM Emissions control - 40.B

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B EXHAUST SYSTEM Emissions control - 40.B

FUNCTIONAL DATA Selective Catalytic Reduction (SCR) Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Supply module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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ENGINE AND PTO IN - EXHAUST SYSTEM Emissions control

Selective Catalytic Reduction (SCR) - Overview

93101563

(1) (2) (3) (4)

SCR catalyst DEF/AdBlue® injection unit DEF/AdBlue® tank Supply module/DCU

1

(5) DEF/AdBlue® tank level/temperature sensor (6) Upstream exhaust gas temperature sensor (7) Downstream exhaust gas temperature sensor (8) NOx sensor

Your CNH machine is equipped with additional components to comply with national and local exhaust emissions requirements. The main components of the SCR system include the SCR catalyst (1), the Diesel Exhaust Fluid (DEF)/AdBlue® injection unit (2), the DEF/AdBlue® tank (3), and the DEF/AdBlue® Dosing Control Unit (DCU) (4).

During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue® solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx molecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue® solution.

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ENGINE AND PTO IN - EXHAUST SYSTEM Emissions control

Selective Catalytic Reduction (SCR) Supply module - Overview The supply module integrates a pump, valves, filters, sensors, pressure controller and the Dosing Control Unit (DCU) within an environmentally secure box.

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Index ENGINE AND PTO IN - B EXHAUST SYSTEM Emissions control - 40.B Selective Catalytic Reduction (SCR) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Selective Catalytic Reduction (SCR) Supply module - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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ENGINE AND PTO IN - B LUBRICATION SYSTEM - 60.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B LUBRICATION SYSTEM - 60.A

FUNCTIONAL DATA LUBRICATION SYSTEM Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Blowby re-circulation system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

SERVICE Oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A 84392428 15/03/2011

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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Blowby re-circulation system Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Oil cooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil line Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil temperature-pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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LUBRICATION SYSTEM - Exploded view F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the crankshaft, camshaft and to the valve drive.

4C0O200406CRIL0

1

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LUBRICATION SYSTEM - Exploded view F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Lubrication by forced circulation is achieved through oil pump, placed in the front part of the basement. From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive. Lubrication involves the heat exchanger as well, the turbo blower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.

80733

1

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Blowby re-circulation system - Dynamic description F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

93101561

1

Version with blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual vapors are removed by piping and filtered by the blow-by filter. In the blow-by filter, part of the vapors condense and return to the oil sump. The remaining vapors are put back into circulation.

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93101560

2

Version without blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil sump and the residual vapors are conveyed, collected and discharged into the open air through a bleeder.

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Sensing system Oil temperature-pressure sensor - Overview F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

OILPRESSTEMP

1

This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.

The sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 24C - 28C for temperature and 32C- 27C for pressure.

The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light).

The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 24C 28C 32C 27C

ENGINE AND PTO IN - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Overview F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

OILPRESSTEMP

1

This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.

The sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 19C - 33C for temperature and 9C- 35C for pressure.

The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light).

The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 19C 33C 9C 35C

ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil pump Gear driven - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

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

Remove the retaining bolts (1) and disconnect the oil pump (2) from the engine block.

OILPUMPH

Next operation: Oil pump Gear driven - Install (B.60.A)

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Oil pump Gear driven - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Oil pump Gear driven - Remove (B.60.A) 1.

Install the oil pump (1) into the engine block.

2.

Tighten the bolts (2) to the specified torque.

OILPUMPH2

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

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Oil pump - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Vibration damper - Remove (B.10.A) 1.

Please refer to Front cover - Remove (B.10.A) for oil pump removal instructions.

Next operation: Oil pump - Install (B.60.A)

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Oil pump - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Oil pump - Remove (B.60.A) 1.

2.

Position the front cover seal (1) on the engine block.

FRONTCOVERD4

1

FRONTCOVERD5

2

Install the front cover (1) on the block and tighten the screws (2) to the prescribed torque.

Next operation: Vibration damper - Install (B.10.A)

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Oil pan - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Remove the bolts (2) surrounding the oil sump (1).

2.

Remove the plate (2).

3.

Disconnect the oil sump (1) from the engine block.

NOTE: The shape and dimensions of the oil pan and of the suction tube may vary according to the application of the engine. However, the procedures described are still applicable.

4.

OILPANH

1

OILPICKUPTUBEH

2

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

Next operation: Oil pan - Install (B.60.A)

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Oil pan - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Oil pan - Remove (B.60.A) 1.

2.

Fit the plate (3), the oil pick up tube (5) and tighten the fastening screws (1), (2) and (4) to the specified torque.

OILPICKUPTUBEH

1

OILPANH2

2

OILPANH

3

Set the gasket on the oil sump.

NOTE: The pictures of the instructions relating to the oil pan and to the suction pipe may not reflect the actual shape and dimensions of your engine equipment. However, the procedures described are still applicable.

3.

Fit the oil sump (1) on the engine block and apply the mounting plate (3). Tighten the bolts (2) to the specified torque.

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

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Oil pan - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Remove the screws (2) and disconnect the oil sump (1).

OILPAND

Next operation: Oil pan - Install (B.60.A)

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Oil pan - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Oil pan - Remove (B.60.A) 1.

Install the oil pan (1) on the engine block.

2.

Fit the screws (2) and tighten them to the prescribed torque.

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

OILPAND

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Oil filter - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Use the tool 380000670 to remove the oil filter.

OILFILTERF4HE

Next operation: Oil filter - Install (B.60.A)

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Oil filter - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Oil filter - Remove (B.60.A) 1.

Lubricate the oil filter O-ring (2) with clean engine oil.

2.

Screw the filter (3) onto the base (1) until contact is made with sealing surface.

3.

Tighten the oil filter an additional 3/4 of a turn.

4.

Apply a new sealing ring on the oil temperature/pressure sensor (4).

5.

Install the sensor (4) onto the filter base (1) and tighten the screws (5) to the specified torque.

OILFILTERH2

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Oil filter - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Use tool 380000670 to remove the oil filter (1).

NOTE: The oil filter is equipped with an internal check valve to minimize the amount oil loss when removing the filter.

OILFILTERF4DE

Next operation: Oil filter - Install (B.60.A)

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Oil filter - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Oil filter - Remove (B.60.A) 1.

Lubricate the oil filter O-ring (2) with clean engine oil.

2.

Screw the filter (1) onto the base (3) until contact is made with sealing surface.

3.

Tighten the oil filter an additional 3/4 of a turn.

OILFILTERD2

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Blowby re-circulation system - Remove - External filter F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Loosen the clamp (1)holding the blow-by tube and remove the pipe.

2.

Remove the screws (2)and remove the blow-by filter, if applicable.

86070784_RESIZE

Next operation: Blowby re-circulation system - Install (B.60.A)

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Blowby re-circulation system - Install - External filter F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Blowby re-circulation system - Remove (B.60.A) 1.

2.

3.

Insert the blow-by filter (1) and tighten the bolts (2).

86070785_RESIZE

1

86070784_RESIZE

2

86070784_RESIZE

3

Install the cover (1) on the blow-by filter housing (2) and tighten the mounting screws (3).

Connect the pipelines (1) and fix the oil vapor pipes with the clamps (2).

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Blowby re-circulation system - Remove - Internal filter 1.

Pull the plastic fitting (1) out of the top of the valve cover.

NOTE: The fitting is held in place by a rubber O-ring.

2.

Remove the valve cover.

3.

Lift the valve cover off of the cylinder head.

4.

Remove the plastic retaining nut (2) from the top of the valve cover.

5.

93110964

1

93110965

2

Pull the filter (3) out of the bottom side of the valve cover.

NOTE: There may be a slight resistance when pulling the filter from the valve cover due to the O-ring seal.

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Blowby re-circulation system - Install - Internal filter 1.

Lubricate the O-ring seal on the filter.

2.

Install the filter (1) into the bottom side of the valve cover.

NOTE: Be sure to connect the hose (2) between the filter (1) and pressure regulator (3).

3.

93110965

1

93110964

2

Install the retaining nut (4) on the top side of the valve cover.

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Piston lubrication Spray nozzle - Remove 1.

Remove the main half bearing (1) to avoid damaging them.

2.

Remove the screws (2) and remove the oil nozzles (3).

BACD04APH046ASA

Next operation: Piston lubrication Spray nozzle - Install (B.60.A)

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Piston lubrication Spray nozzle - Install Prior operation: Piston lubrication Spray nozzle - Remove (B.60.A) 1.

Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.

CRIL04J066A01

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Oil cooler - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Oil filter - Remove (B.60.A) 1.

Unscrew the mounting bolts (1).

2.

Remove the oil filter base (2)oil cooler (3), and all gaskets.

OILCOOLERH

Next operation: Oil cooler - Install (B.60.A)

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil cooler - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Prior operation: Oil cooler - Remove (B.60.A) 1.

Place a new gasket (1) on the engine block.

2.

Install the oil cooler (2).

3.

Place a new gasket (3) on the oil cooler.

4.

Install the oil filter base (4).

5.

Tighten the mounting bolts (5) to the specified torque.

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

OILCOOLERH2

Next operation: Oil filter - Install (B.60.A)

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil cooler - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Oil filter - Remove (B.60.A) 1.

Unscrew the screws (5) that secure the oil filter base (4) to the block.

2.

Remove the base (4) and the oil cooler (2).

NOTE: Be sure to remove all the relevant gaskets and seals (1) and (3).

OILCOOLERD2

Next operation: Oil cooler - Install (B.60.A)

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil cooler - Install F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Prior operation: Oil cooler - Remove (B.60.A) 1.

Place a new gasket (1) on the engine block.

2.

Install the oil cooler (2).

3.

Place a new gasket (3) on the oil cooler.

4.

Install the oil filter base (4).

5.

Tighten the mounting bolts (5) to the specified torque.

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

OILCOOLERD2

Next operation: Oil filter - Install (B.60.A)

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil line - Install F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil Fill Tube 1.

Install a new O-ring on the oil fill tube (1).

2.

Attach the oil fill tube (1) to the engine block using the three M12x25 bolts.

OILFILLH2

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Oil line - Install Turbo oil lines 1.

Connect the oil supply line (2) between the turbine (1) and the oil filter base.

2.

Install the oil drain pipe (1) onto the turbo and tighten the fixing screws.

3.

Connect the pipe to the block (2) also.

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OILLINEDH

1

OILLINEDH2

2

ENGINE AND PTO IN - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Remove F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

1.

Disconnect the wiring harness from the sensor.

OILPRESSTEMPH

2.

Remove the mounting screws and remove the sensor and O-ring from the oil filter base.

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ENGINE AND PTO IN - LUBRICATION SYSTEM

Sensing system Oil temperature-pressure sensor - Install 1.

Install a new O-ring on the oil temperature/pressure sensor.

2.

Install the sensor on the oil filter base and tighten the mounting bolts to the specified torque.

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Sensing system Oil temperature-pressure sensor - Remove F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

1.

Disconnect the electrical connector (1) from the oil temperature pressure sensor (3).

2.

Unscrew the screws (2) securing the sensor to the oil filter base (4) and remove it from its seat.

OILPRESSTEMPD

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1

Index ENGINE AND PTO IN - B LUBRICATION SYSTEM - 60.A Blowby re-circulation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Blowby re-circulation system - Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Blowby re-circulation system - Install - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Blowby re-circulation system - Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Blowby re-circulation system - Remove - Internal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 LUBRICATION SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

LUBRICATION SYSTEM - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A 84392428 15/03/2011

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Oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Piston lubrication Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Piston lubrication Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Sensing system Oil temperature-pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Oil temperature-pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4HFE613K*A, F4HFE613J*A, F4HFE613H*A, F4HFE613G*A, F4HFE613R*A, F4HFE613P*A, F4HFE613Y*A, F4HFE613X*A, F4HFE6131*A

Sensing system Oil temperature-pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4DFE613D*A, F4DFE613C*A, F4DFE613A*A, F4DFE613B*A, F4DFE613L*A, F4DFE613K*A, F4DFE613J*A, F4DFE613H*A, F4DFE613G*A

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ENGINE AND PTO IN - B STARTING SYSTEM - 80.A

F4DFE613A*A , F4DFE613B*A , F4DFE613C*A , F4DFE613D*A , F4DFE613G*A , F4DFE613H*A , F4DFE613J*A , F4DFE613K*A , F4DFE613L*A , F4HFE6131*A , F4HFE613G*A , F4HFE613H*A , F4HFE613J*A , F4HFE613K*A , F4HFE613P*A , F4HFE613R*A , F4HFE613X*A , F4HFE613Y*A

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Contents ENGINE AND PTO IN - B STARTING SYSTEM - 80.A

FUNCTIONAL DATA Cold start aid Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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ENGINE AND PTO IN - STARTING SYSTEM

Cold start aid Grid heater - Overview

GRIDHEATER

1

The pre-post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post heating operations. The resistance is powered by a contactor.

The resistance impedance is approximately 0.5 Ω.

The control contactor is connected to the control unit (B) connector.

The contactor is tripped with water and/or fuel temperature below 5 °C (41 °F).

The contactor impedance is approximately 15 Ω.

WARNING This engine is equipped with an intake air (grid) heater. DO NOT use starting fluid on this engine. Use of starting fluid can cause explosion, personal injury or property damage. Failure to comply could result in death or serious injury.

M836

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ENGINE AND PTO IN - STARTING SYSTEM

Engine starter - Remove 1.

Disconnect the starter cables from the solenoid and the starter body (2).

2.

Remove the three mounting bolts (3) securing the starter (2) to the flywheel housing (1). Withdraw the starter (2).

STARTERDH

Next operation: Engine starter - Install (B.80.A)

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1

ENGINE AND PTO IN - STARTING SYSTEM

Engine starter - Install Prior operation: Engine starter - Remove (B.80.A) 1.

Install the starter (2) on the flywheel housing (1) using the three mounting bolts (3).

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

STARTERDH

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1

Index ENGINE AND PTO IN - B STARTING SYSTEM - 80.A Cold start aid Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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SPECIAL TOOL INDEX IU

Genuine 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000145 [Camshaft Bushing Remover/Installer Tool for use with Cursor 7.8L Engines] 380000302 [Cylinder Head Valve Spring Compressor] 380000302 [Cylinder Head Valve Spring Compressor] 380000669 [Gasket Extraction Tool] 380000669 [Gasket Extraction Tool] 380000362 [Crankshaft Lifting Hook] 380000362 [Crankshaft Lifting Hook] 380001001 [Motore NEF Vedi Allegato] 380000324 [110-150 Diameter Piston Ring Pliers] 380000221 [Piston Ring Pliers (65 - 110 mm)] 380000325 [90-175 Diameter Piston Assembly Band Clamp] 380001001 [Motore NEF Vedi Allegato] 380000228 [Dial Gauge (0 - 5 mm)] 380000364 [Piston Protrusion Check, Gauge Base] 380000988 [Flywheel Locking Adapter Plate] 380000988 [Flywheel Locking Adapter Plate] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)]

PAGE

ENGINE - Service instruction Maintenance procedures

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ENGINE - Service instruction Maintenance procedures

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ENGINE - Service instruction Maintenance procedures

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ENGINE - Service instruction Maintenance procedures

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ENGINE - Service instruction Maintenance Procedures

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ENGINE - Service instruction Maintenance Procedures

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ENGINE - Service instruction Maintenance Procedures

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ENGINE - Service instruction Maintenance Procedures

B.10.A / 40

Camshaft Bushing - Replace

B.10.A / 59

Valve drive Valve assembly - Remove

B.10.A / 60

Valve drive Valve assembly - Install

B.10.A / 64

Crankshaft Front seal - Remove

B.10.A / 67

Crankshaft Rear seal - Remove

B.10.A / 69

Crankshaft - Remove

B.10.A / 73

Crankshaft - Remove

B.10.A / 74

Crankshaft Journal - Clearance

B.10.A / 79

Piston Ring - Remove

B.10.A / 89

Piston Ring - Install

B.10.A / 92

Connecting rod and piston - Install

B.10.A / 97

Connecting rod Bearing - Clearance

B.10.A / 98

Connecting rod and piston Piston - Check

B.10.A / 100

Connecting rod and piston Piston - Check

B.10.A / 100

Flywheel - Remove

B.10.A / 101

Flywheel - Install

B.10.A / 103

Flywheel - Install

B.10.A / 103

Flywheel - Install

B.10.A / 106

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IU

Genuine 380000304 [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 380000364 [Piston Protrusion Check, Gauge Base] 380000228 [Dial Gauge (0 - 5 mm)] 380001099 [Fuel Injector Extractor] 380001099 [Fuel Injector Extractor] 380000670 [Oil Filter Removal Tool (NH F5C)] 380000670 [Oil Filter Removal Tool (NH F5C)]

PAGE

Cylinder head - Install

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Cylinder head Valve seat - Regrind

B.10.A / 121

Cylinder head Valve seat - Regrind

B.10.A / 121

Fuel injector Electro injector - Remove

B.20.A / 41

Fuel injector Electro injector - Install

B.20.A / 42

Oil filter - Remove

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Oil filter - Remove

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