New Holland LB90.B LB95.B LB110.B LB115.B Engines Repair Manual - PDF DOWNLOAD

REPAIR MANUAL FOR CNH U.K. ENGINES F4GE0454C -- F4GE0484G The following models are to integrate repair manuals: NEW HOLLAND LB90.B -- LB95.B -- LB110.B -- LB115.B

F4GE0454C

F4GE0484G Every information, illustration and specification contained in the present manual is based on the most recent informa-tion available at the time of printing.

NEW HOLLAND reserves the right, to modify the text at any time without prior communication.

NEW HOLLAND PRINT NO. 604.13.612 Edition – April 2006

2

WE

MOTORI

2

IN--1

INTRODUCTION

TO THE READER - This manual was written for a skilled technician and contains all the technical information needed to repair this vehicle.

- Read this manual carefully for the information concerning repairing operations.

- For any question or comment, or should you no-tice any mistake concerning the content of this manual, please contact: NEW HOLLAND Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax ++39 011 0077357

FURTHER REFERENCES PAGE NUMBER - Every page carries a number on the top right corner. Every page contains the following information:

Example:: T 1 -- 2 -- 3

Progressive page number for each group Group number (if any) Section number S:

Safety rules

T:

Technical section

W:

Instruction section for excavator repairing

EW:

Instruction section for engine repairing

Operation principle Performance tests Fault diagnosis

SYMBOLS This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.

!

This symbol regards safety.

Use great care when you see this symbol because possible injuries to the personnel may occur.

Strictly observe the precautions marked with this symbol.

The safety warning symbol is used also to draw attention on the weight of a component or an element.

Make sure you are always using the right equipment and lifting techniques when handling heavy loads, in order to prevent injuries or damages.

IN--2

INTRODUCTION

UNIT OF MEASURE This manual adopts the units of measure based on the International System.

The MKSA system units of measure are indicated within brackets after the units of measure of the International System.

Example: 24.5 Mpa (250 kgf/cm2).

The following table converts the International System units of measure in some of the main units belonging to other systems.

Quantity Length Volume Mass Force Torque

To convert from (IS) mm mm L L m3 kg N N N.m N.m

in (Others) in ft US gal US qt yd3 lb kgf lbf kgf.m lbf.ft

Multiply by 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 0.10197 0.7375

Quantity Pressure Power Temperature Speed Capacity

To convert from (IS) MPa MPa kW kW °C km/h min--1 L/min mL/rev

in (Others) kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply by 10.197 145.0 1.360 1.341 °C x 1.8 + 32 0.6214 1.0 0.2642 1.0

REPAIR MANUAL

ENGINES

INDEX OF SECTIONS

Section 1 -- Diagnostics

EW--1--1

Section 2 -- Engines overhaul: -- F4GE0454C -- F4GE0484G

EW--2--1

Section 3 -- Recharging and start--up

EW--3--1

4

WE

MOTORI

SECTION 1

DIAGNOSTICS

INDEX Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3 Main engine operating anomalies . . . EW--1--3

INDICE

EW--1--3

DIAGNOSTICS MAIN ENGINE OPERATING ANOMALIES 1 -2 -3 -4 -5 --

1

6 -7 -8 -9 -10 -11 -12 --

Engine won’t start; Engine overheats; Engine lacks power and works erratically; Engine exhaust smoke black or dark grey; Engine exhaust smoke grey (verging on white);

Engine exhaust smoke light blue; Engine knocks irregularly; Engine stops; Engine exceeds max. revs number; Excessive or insufficient oil pressure; Excessive fuel consumption; Engine won’t stop.

ENGINE WON’T START

Connections to battery terminals are in working order

NO

Clean, check, tighten or replace clamp nuts.

YES

Batteries in working order NO

Carry out the checks described in the “Electric system” repair manual.

NO

Carry out the checks described in the “Electric system” repair manual.

YES

Starter motor in working order

YES

Thermal starter in working order

Replace.

NO

YES

Injection pump timed NO

Verify correct timing as described in the relevant chapter.

(to be continued)

EW--1--4

DIAGNOSTICS

Injectors in working order

Check operation and adjust.

NO

YES

The feeding circuit or injection pump does not show air penetration

Check and blow off.

NO

YES

The feeding circuit or pump does not show traces of water

NO

Check and clean the feeding circuit (including the tank).

YES

Prescribed compression ratio NO

Overhaul the engine or make repairs only on concerned parts (valves, piston rings, etc.).

YES

Fuel filters in working order

Replace.

NO

YES

Automatic advance variator and electric STOP device both in working order

Check and replace the concerned parts.

NO

YES

Fuel pump fed correctly

Check and replace (if necessary) the fuel pump.

NO

YES

Fuel tank supplied correctly

Refuel.

NO

EW--1--5

DIAGNOSTICS

2

ENGINE OVERHEATS

Coolant level correct

Check for leaks and restore the level.

NO

YES

Fan and water pump drive belts in working order

Check for leaks and restore the level.

NO

YES

Water pump in working order

Overhaul or replace the unit.

NO

YES

Thermostat in working order

Replace.

NO

YES

Radiator in working order NO

Wash down thoroughly, check for fluid leaks, re-place (if necessary) the part.

YES

Air filter and circuit piping both in working order

Clean or replace faulty parts.

NO

YES

Openings for coolant flow to the head in working order

Wash down thoroughly.

NO

EW--1--6

DIAGNOSTICS

Valve timing correct

NO

Check and perform correct timing.

YES

Injection pump timed

NO

Check correct timing as described in the relevant paragraph.

YES

Cylinder head gasket in working order

Replace.

NO

YES

Fan in working order

Replace.

NO

3

ENGINE LACKS POWER AND WORKS ERRATICALLY

Air filter in working order NO

Clean the unit and replace (if necessary) the filter element.

NO

Replace by following the instructions given in the “Owner Handbook”.

NO

Check and make (if necessary) the required re-pairs.

YES

Fuel filters in working order

YES

Feeding circuit in working order

(to be continued)

EW--1--7

DIAGNOSTICS

The feeling circuit does not show impurities and/ or traces of water

NO

Take off the pipes and injection pump, clean them thoroughly, then clean (if necessary) and dry the fuel tank.

YES

Thermostat in working order

Replace.

NO

YES

Fuel pump in working order

Replace.

NO

YES

Injectors in working order

Check operation and adjust them.

NO

YES

Injection pump timed NO

Check correct timing as described in the relevant paragraph.

YES

Automatic advance variator (in injection pump) in working order

Check and bench--adjust the injection pump.

NO

YES

Distributing plunger (in injection pump) in work-ing order

Check and bench--adjust the injection pump.

NO

(to be continued)

EW--1--8

DIAGNOSTICS

Injection pump rate correct

Check and bench--adjust the injection pump.

NO

YES

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

Check and bench--adjust the injection pump.

NO

YES

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

NO

Check.

YES

Injection pump with peak adjusting--screw fine-tuned

Fine--tune the peak adjusting--screw.

NO

YES

Correct play between the valves and rocker arms NO

Adjust the play between the valves and rocker arms.

YES

Prescribed compression ratio

Check and bench--adjust the injection pump.

NO

YES

Turbocharger in working order

Repair or replace the unit.

NO

YES

Correct tie rod length between the accelerator and injection pump

Adjust the tie rod length.

NO

EW--1--9

DIAGNOSTICS

4

ENGINE EXHAUST SMOKE BLACK OR DARK GREY

Air filter in working order

NO

Replace.

YES

Thermal starter in working order

Replace.

NO

YES

Automatic addition device comes into operation

Check and replace (if necessary).

NO

YES

Injectors in working order

Check operation and adjust them as described.

NO

YES

Injection pump timed NO

Check correct timing as described in the relevant paragraph.

YES

L.D.A. device in working order

Ad just the L.D.A. device.

NO

YES

Injection pump adjusted as prescribed

Check and bench--adjust the injection pump.

NO

(to be continued)

EW--1--10

DIAGNOSTICS

Injection pipes intact

NO

Check the condition of pipes and replace them (if necessary).

NO

Check by means of a Motometer 75301430 tool and carry out the necessary operations.

YES

Prescribed compression ratio

YES

High--quality diesel fuel

Clean the tank and replace the diesel oil filter.

NO

5

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

The thermostat comes into operation correctly

Replace.

NO

YES

Injectors in working order NO

Check operation and adjust as described in S.I. 1094.

NO

Check correct timing as described in the relevant paragraph.

YES

Injection pump timed

YES

Coolant level correct NO

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

(to be continued)

EW--1--11

DIAGNOSTICS

High--quality diesel oil

Clean the tank and replace the diesel oil filters.

NO

6

ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption

7

YES

Check the oil vapour vent and cylinder compres-sion. Overhaul, if necessary, the cylinder head or engine.

ENGINE KNOCKS IRREGULARLY

Knock detected in the injection pump YES

Perform correct timing of injection pump on the engine.

NO

Knock detected in the drive shaft YES

Check the following items: journal play and out-of--roundness; screw fastening for bed caps and engine flywheel; oil pressure. Replace the parts or overhaul the engine.

NO

Knock detected in the connecting rods YES

Check the following items: crankpin play and out--of--roundness; screw fastening for connect-ing rod caps; connecting rod squaring. Replace the parts or overhaul the engine.

YES

Check the following items: play between the pis-tons and the cylinder liners; integrity of piston rings; play between the pins and the piston hubs.

Replace the parts or overhaul the engine.

NO

Knock detected in pistons

(to be continued)

EW--1--12

DIAGNOSTICS

Knock detected in the cylinder head YES

Check the following items: operation play be-tween the rocker arms and the valves; injection pump timing; valve timing. Adjust.

YES

Check and replace (if necessary) the gears; moreover, check for broken springs, for excess-ive play between the stems and guides, the tappets and seats. Adjust the play between the valves and rocker arms.

NO

Knock detected in the valve gear

NO

Knock detected in injectors YES

Check and adjust as described in S.I. 1094, then replace.

YES

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

NO

Knock detected in the engine flywheel

NO

Knock detected in the fuel piping YES

8

Clean the pipes and replace the pipes that show evident dents; clean (if necessary) the injection pump.

ENGINE STOPS

Fuel tank filled

Refuel and drain (if necessary).

NO

YES

Fuel filters in working order

Replace.

NO

(to be continued)

EW--1--13

DIAGNOSTICS

Feeling circuit in working order

Check the circuit and drain.

NO

YES

Regular idle speed

Adjust.

NO

YES

Regular injection pump rates

Bench--check the flow rates.

NO

YES

Injection pump controls in working order

Replace worn parts and adjust.

NO

YES

Correct play between the valves and rocker arms NO

Ad just the play between the valves and rocker arms.

YES

Intact valves

Replace the valves.

NO

9

ENGINE EXCEEDS MAX. REVS NUMBER

Speed governor in working order

NO

Check and replace (if necessary) the worn parts.

EW--1--14

DIAGNOSTICS

10

EXCESSIVE OR INSUFFICIENT OIL PRESSURE

Pressure control valve in working order

Check and replace (if necessary).

NO

YES

Oil pump and delivery pipes both in working or-der

Check and replace (if necessary).

NO

YES

Main bearings and connecting rod bearings both in working order

NO

Replace the bearings and reface (if necessary) the drive shaft.

NO

Replace the engine oil with equivalent of ad-equate viscosity.

NO

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

YES

Engine oil SAE viscosity conforming to stan-dards

11

EXCESSIVE FUEL CONSUMPTION

Fuel tank and pipes in working order

YES

Air filter in working order

Replace.

NO

(to be continued)

EW--1--15

DIAGNOSTICS

Correct injector adjustment

Check operation and adjust them.

NO

YES

Correct injection pump adjustment

Check and bench--adjust.

NO

YES

L.D.A. device in working order

Adjust the L.D.A. device.

NO

YES

Injection pump timed

Check static force--fit of the injection pump.

NO

12

ENGINE WON’T STOP

Cut--off electromagnet in working order

NO

Replace the electromagnet.

YES

Speed governor in working order at all speeds NO

Overhaul the injection pump and bench--adjust it according to the relevant adjustment table.

EW--1--16

DIAGNOSTICS

NOTES

SECTION 2

ENGINES F4GE0454C F4GE0484C F4GE0484G OVERHAUL INDEX Engines F4GE0454C . . . . . . . . . . . . . . . . EW--2--3 Engines F4GE0484G . . . . . . . . . . . . . . . EW--2--3 Coding of source engines . . . . . . . . . . EW--2--4 Main engines features . . . . . . . . . . . . . . EW--2--5 General engines features . . . . . . . . . . . EW--2--6 Assembling play -- specifications . . . EW--2--8 Tightening torque . . . . . . . . . . . . . . . . . . EW--2--14 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15 Graphic indications and symbols . . . EW--2--16 General remarks . . . . . . . . . . . . . . . . . . . EW--2--17 F4GE0454C engine . . . . . . . . . . . . . . . . . EW--2--17 F4GE0484G engine . . . . . . . . . . . . . . . . . EW--2--18 Description of main mechanic engine components . . . . . . . . . . . . . . . . EW--2--19 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--20 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--21 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--22 Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--23 Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--2--24 Cylinder head (F4GE0454C engine) . . . EW--2--25 Cylinder head (F4GE0484G engines) . . . . . . . . . . . . . . . EW--2--26 Valves and valve seats . . . . . . . . . . . . . . . EW--2--27 Valve guides . . . . . . . . . . . . . . . . . . . . . . . . EW--2--28 Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--2--29 Auxiliary component drive . . . . . . . . . . . . EW--2--30 Additional masses . . . . . . . . . . . . . . . . . EW--2--31 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . EW--2--32 Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--2--33 Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--35 Engines F4GE0454C*D660 -- F4GE0454C*D603 -F4GE0484G*D660 -- F4GE0484G*D606 EW--2--35 Engine F4GE0484G*D655 -F4GE0484G*605 . . . . . . . . . . . . . . . . . . . . EW--2--35 Oil vapour recirculation . . . . . . . . . . . . . . . EW--2--36 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--37 Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--2--38 Mechanic injection feeding system . . EW--2--39 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--39 Mechanic fuel pump . . . . . . . . . . . . . . . . . EW--2--40 Injection assembly . . . . . . . . . . . . . . . . . EW--2--41 Engine bench--overhaul . . . . . . . . . . . . EW--2--42 Disassembling the engine . . . . . . . . . . . . EW--2--42 O--ring replacement . . . . . . . . . . . . . . . . . EW--2--44

Removing the injection pump . . . . . . . . .

Removing the rocker arm assembly . . .

Repair work on cylinder cluster . . . . .

Checks and measurements . . . . . . . . . . .

Checking the surface supporting the head on the cylinder cluster . . . . . . .

Checking the eccentric lift and the pin alignment . . . . . . . . . . . . . . . . . . . .

Valve gear . . . . . . . . . . . . . . . . . . . . . . . . .

Distributing shaft . . . . . . . . . . . . . . . . . . . .

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the bushings . . . . . . . . . . . . . .

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

Mounting the tappets – Distributing shaft Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . .

Measuring the journals and crankpins . .

Replacing the oil pump drive gears . . . .

Mounting the main bearings . . . . . . . . . .

Measuring the journal assembling play .

Checking the drive shaft shoulder play .

Connecting rod--piston assembly . . . . . .

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

Measuring the piston diameter . . . . . . . .

Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . .

Conditions for correct pin/piston matching . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston rings . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rods . . . . . . . . . . . . . . . . . . . .

Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the connecting rods . . . . . . . . .

Checking the torsion . . . . . . . . . . . . . . . . .

Checking the flexion . . . . . . . . . . . . . . . . .

Mounting the connecting rod--piston assembly . . . . . . . . . . . . . . . . .

Connecting rod--piston match . . . . . . . . .

Mounting the piston rings . . . . . . . . . . . . .

Mounting the connecting rod/piston assemblies in the cylinder liners . . . . . . .

Measuring the crankpin assembling play Checking piston protrusion . . . . . . . . . . .

Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . .

Distribution gearbox case . . . . . . . . . . . .

Valve timing . . . . . . . . . . . . . . . . . . . . . . . .

Injection pump – 1st phase . . . . . . . . . . .

Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembling the additional masses . . . . .

Flywheel cover case . . . . . . . . . . . . . . . . .

EW--2--45 EW--2--47 EW--2--50 EW--2--50 EW--2--51 EW--2--52 EW--2--52 EW--2--52 EW--2--53 EW--2--54 EW--2--54 EW--2--54 EW--2--55 EW--2--55 EW--2--58 EW--2--58 EW--2--58 EW--2--59 EW--2--60 EW--2--61 EW--2--61 EW--2--62 EW--2--62 EW--2--62 EW--2--63 EW--2--64 EW--2--64 EW--2--64 EW--2--64 EW--2--65 EW--2--65 EW--2--65 EW--2--66 EW--2--66 EW--2--67 EW--2--67 EW--2--67 EW--2--68 EW--2--69 EW--2--69 EW--2--69 EW--2--71

INDEX Engine flywheel . . . . . . . . . . . . . . . . . . . .

Replacing the engine flywheel ring gear Injection pump – 2nd phase . . . . . . . . . .

Mounting the injection pump – 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting the oil and water pumps . . . . .

Mounting the water / oil heat exchanger Cylinder head . . . . . . . . . . . . . . . . . . . . . . .

Removing the valves . . . . . . . . . . . . . . . .

Checking the cylinder head supporting surface . . . . . . . . . . . . . . . . . . .

Checking the cylinder head water seal .

Valve descaling, check and grinding . . .

Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve seats . . . . . . . . . . . . . . . . . . . . . . . .

Valve seat reconditioning -- replacement

EW--2--72 EW--2--72 EW--2--73 EW--2--73 EW--2--73 EW--2--75 EW--2--75 EW--2--75 EW--2--76 EW--2--77 EW--2--77 EW--2--77 EW--2--78 EW--2--78

Valve guide . . . . . . . . . . . . . . . . . . . . . . . .

Checking the play between the valve stem, valve guide and valve centring . . .

Valve springs . . . . . . . . . . . . . . . . . . . . . .

Mounting the cylinder head . . . . . . . . . . .

Rocker arm assembly . . . . . . . . . . . . . . . .

Reattaching the cylinder head . . . . . . . . .

Mounting the injectors . . . . . . . . . . . . . . .

Replacing the injectors . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reassembling . . . . . . . . . . . . . . . . . . . . . .

Rocker arm removal/reassembling . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reassembling . . . . . . . . . . . . . . . . . . . . . .

Adjusting the tappets . . . . . . . . . . . . . .

Check priming of the injection pump . . .

EW--2--78 EW--2--78 EW--2--80 EW--2--80 EW--2--81 EW--2--81 EW--2--82 EW--2--85 EW--2--85 EW--2--86 EW--2--86 EW--2--86 EW--2--86 EW--2--87 EW--2--88

EW--2--3

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 1

86607

ENGINES F4GE0454C Figure 2

86608

ENGINES F4GE0484G

EW--2--4

ENGINES F4GE0454C -- F4GE0484G OVERHAUL CODING OF SOURCE ENGINES

F

4

G

E

0

4

8

4

G

*

D

+

Emission level Approved rating Use Feeding / Injection D = TIER 2

Cylinder no.

Cylinder pattern: 0 = 4 strokes, vertical Engine Type of crankcase: B = non--structural

4 = 4--cylinder

Group Engines

8 = Direct injection turbo diesel with intercooler 5 = Direct injection turbo diesel 4 = Earthmovers

X

Y

Y

X = 6 rotary, 2--valve injection pump Y = Engine model

Y

Y

Y

Y

Y

Manufacturing sequence number

Y

EW--2--5

ENGINES F4GE0454C -- F4GE0484G OVERHAUL MAIN ENGINES FEATURES Applications A B C

LB90.B LB95.B

LB90.B LB95.B

LB110.B

LB110.B

LB115.B

LB115.B

F4GE0454C F4GE0454C F4GE0484G F4GE0484G F4GE0484G F4GE0484G *D660

*D603

*D660

*D606

*D655

*D605

82 kW 2200 min--1

82 kW 2200 min--1

82 kW 2200 min--1

D 4485

E F

71 kW 2200 min--1

71 kW 2200 min--1

82 kW 2200 min--1

Net power at flywheel (ISO 14396)

G

Direct injection

H

Rotary injection pump

I

T.C. (Boosted)

T.A.A. (Boosted by intercooler)

Up to chassis no.

N5GH04353

From chassis Up to chassis From chassis Up to chassis From chassis no. no. 031056821 no. 031056822 no. 031056893 no. 031056894 N5GH04354

A B C D E F G H I

Backhoe--loaders Type of engine g Engine model Number of cylinders Total displacement Max. p power currentlyy available Type of injection Injection system Air supply system

EW--2--6

ENGINES F4GE0454C -- F4GE0484G OVERHAUL GENERAL ENGINES FEATURES F4GE0484G Type

*D660

*D655

Cycle

F4GE0484G

F4GE0454C

*D606 *D605 *D660 *D603

4--stroke diesel engine

Feeding

Boosted by intercooler

Injection

Direct

Number of cylinders

Boosted

4 in--line

Bore

mm

104

Stroke

mm

132

Total displacement cm3

4485

Compression ratio

17.5 : 1

Max. rating

kW min --1

82 2200

82 2200

71 2000

Max. torque

Nm min --1

480 (48) 1400

--

398 (39.8) 1400

No--load idle rpm min --1

--

No--load peak rpm min --1

--

BOOSTING Type of turbocompressor: LUBRICATION Oil pressure with hot engine: at idle rpm bar at peak rpm bar

With intercooler HOLSET HX25W

HOLSET HX25W

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

EW--2--7

ENGINES F4GE0454C -- F4GE0484G OVERHAUL F4GE0484G Type

*D660

*D655

COOLING

F4GE0454C

*D606 *D605 *D660 *D603 By fluid

Water pump drive:

By means of belt

Thermostat: Start of opening:

Ambra Mastergold HSP 15W40

F4GE0484G

FILLING Total capacity 1st filling: -- engine sump

81 ± 2

°C

litres kg

--

litres kg

--

-- engine sump + filter litr es kg

VE4 / 12 F

FEEDING Bosch--type injection

1100 L 954

Pump setting

Start of delivery

--

1100 L 956--2

0° ± 0.5°

mm

Type of nozzle

Injection sequence

Injection pressure (bar)

1

DSLA 145 1174

1 -- 3 -- 4 -- 2

245 bar

1100 L 954

EW--2--8

ENGINES F4GE0454C -- F4GE0484G OVERHAUL ASSEMBLING PLAY -- SPECIFICATIONS F4GE0484G Type

mm

∅1

Pistons: supplied with standard spares Measurement dimension X Outer diameter ∅1 Pin seat ∅2 Piston -- cylinder liners Piston diameter

∅1

∅3

Gudgeon pin -- Pin seat

S1* S2 S3

* measured 1,5 mm away from the external ∅ Piston rings – Slots

Piston rings

8 103.714 to 103.732 38.010 to 38.016

0.4

0.28 to 0.52

37.994 to 38.000

0.010 to 0.022

X1* Piston ring slots X2 X3 * measured on ∅ of 101 mm Piston rings

104.000 to 104.024

0.268 to 0.310

Position of pistons from crankcase X

Gudgeon pin

F4GE0454C

*D660 *D655 *D606 *D605 *D660 *D603

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

Cylinder liners

F4GE0484G

1 2 3

2.705 to 2.735 2.44 to 2.46 4.03 to 4.05

2.602 to 2.606 2.35 to 2.38 3.97 to 3.99

0.100 to 0.175 0.060 to 0.110 0.040 to 0.080 0.4

EW--2--9

ENGINES F4GE0454C -- F4GE0484G OVERHAUL F4GE0484G Type

F4GE0484G

*D660 *D655 *D606 *D605 *D660 *D603

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

Piston ring end opening in cylinder liner: X1 X2 X3 Connecting rod small-end bushing seat ∅1 Connecting rod bearing seat ∅2

Connecting rod small-end bushing diameter Outer ∅4 Inner ∅3

mm

0.3 to 0.45 0.6 to 0.8 0.3 to 0.55

40.987 to 41.013 72.987 to 73.013

41.279 to 41.553 38.019 to 38.033

Connecting rod small-end bushing – seat

0.266 to 0.566

Gudgeon pin – Bushing

0.019 to 0.039

Measurement dimension X

--

Max. error on connecting rod axis parallelism = Journals ∅1 Crankpins ∅2 Main half bearings S1* Connecting rod half bearings S2* * supplied with spares Bed supports no.: no. 1--5 no. 2--3--4

F4GE0454C

∅3

--

82.99 to 83.01 68.987 to 69.013 2.456 to 2.464 1.955 to 1.968

87.982 to 88.008 87.977 to 88.013

EW--2--10

ENGINES F4GE0454C -- F4GE0484G OVERHAUL F4GE0484G Type

F4GE0484G

*D660 *D655 *D606 *D605 *D660 *D603

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

mm

Half bearings -- journals: no. 1--5 no. 2--3--4

0.041 to 0.119 0.041 to 0.103

Half bearings -- crankpins

0.033 to 0.041

Main half bearings Connecting rod half bearings

+ 0.250; + 0.500

Shoulder journal

37.475 to 37.545

X1

Shoulder bed support X2

25.98 to 26.48

Shoulder half rings

37.28 to 37.38

Drive shaft shoulder

F4GE0454C

X3

0.095 to 0.265

EW--2--11

ENGINES F4GE0454C -- F4GE0484G OVERHAUL F4GE0484G Type

F4GE0484G

*D660 *D655 *D606 *D605 *D660 *D603

VALVE GEAR – CYLINDER ASSEMBLY

mm

Valve guide seats on cylinder head ∅1

8.019 to 8.039

Valves: ∅4 α ∅4 α Valve stem and respective guide Seat on head for valve seat: ∅1 ∅1 Valve seat outer diameter; inclination of valve seats on cylinder head: ∅2 α ∅2 α Hollow

Between the valve seat and the head

Valve seats

F4GE0454C

7.96 to 7.98 60° 7.96 to 7.98 45° 0.039 to 0.079

46.987 to 47.013 43.637 to 43.663

47.063 to 47.089 60° 43.713 to 43.739 45°

X

1.00 to 1.42

X

1.00 to 1.42 0.050 to 0.102 0.050 to 0.102 --

EW--2--12

ENGINES F4GE0454C -- F4GE0484G OVERHAUL F4GE0484G Type

F4GE0454C

*D660 *D655 *D606 *D605 *D660 *D603

VALVE GEAR – CYLINDER ASSEMBLY Valve spring height: free spring under a load of: 329 N 641 N

F4GE0484G

mm H

63.5

H1 H2

49.02 38.20

X

not adjustable

Injector protrusion

Seats for distributing shaft bushings no. 5 Distributing shaft seats no. 1--2--3--4

Distributing shaft support pins: 1⇒5 ∅

59.222 to 59.248 54.089 to 54.139

53.995 to 54.045

Bushing outer diameter for distributing shaft: ∅ under a load of 3.3 kN

59.222 to 59.248

Bushing inner diameter ∅

54.083 to 54.147

Bushings and seats in crankcase

0.113 to 0.165

Bushings and support pins

0.038 to 0.162

Eccentric working lift: 6.045 7.239

EW--2--13

ENGINES F4GE0454C -- F4GE0484G OVERHAUL F4GE0484G Type

∅2 ∅3 ∅2

Seat for tappet collar in the crankcase

F4GE0454C

*D660 *D655 *D606 *D605 *D660 *D603

VALVE GEAR – CYLINDER ASSEMBLY

∅1

F4GE0484G

mm

∅1

Outer diameter of tappet collar: ∅2 ∅3 Between the tappets and the seats Tappets

16.000 to 16.030

15.929 to 15.959 15.965 to 15.980 0.020 to 0.065 --

∅1 Rocker arm shaft

∅1

18.963 to 18.975

Rocker arms

∅2

19.000 to 19.026

∅2 Between the rocker arm and the shaft

0.025 to 0.063

EW--2--14

ENGINES F4GE0454C -- F4GE0484G OVERHAUL TIGHTENING TORQUE PART Cylinder y head fastening g screw 1st p phase:

2nd p phase: 3rdd phase: p fastening g screws Bed cap

1st

screws M12x1.75x70 screws M12x1.75x140 screws M12x1.75x180 (only for screws 140 and 180 mm long)

phase p 2nd p phase rd 3 phase g rod cap p fastening g screws phase Connecting 1st p 2nd phase g y g screws p g Engine flywheel fastening pre--tighten Angle Injector fastening Fuel filter Injection pump gear cover fastening screw Valve gear cover and case fastening screw Container fastening screw Intake manifold fastening screw Fuel pump fastening screw Exhaust manifold fastening screw Tappet cover fastening nut Rocker arm support fastening screw Nut for rocker arm adjusting screw Screw fastening the pulley on drive shaft pre--tighten Angle Distributing shaft shoulder plate fastening screw Fan support fastening screw Injection pump fastening screw Fan pulley fastening screw Turbocompressor fastening screw Heat exchanger fastening screw Oil pump and front cover fastening screw Starter motor fastening screw Alternator fastening screw Water pump fastening screw Oil filter Belt stretcher fastening screw -- Lubrication with oil

TORQUE Nm (kgm) 50 ± 5 (5 ± 0.5) 40 ± 5 (4 ± 0.5) 70 ± 5 (7 ± 0.5) 90° 90° 50 ± 6 (5 ± 0.6) 80 ± 6 (8 ± 0.6) 90° 50 ± 5 (5 ± 0.5) 60° ± 5° 30 ± 5 (3 ± 0.5) 60° ± 5° 60 ± 5 (6 ± 0.5) contact + 3/4 turn 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 53 ± 5 (5.3 ± 0.5) 25 ± 5 (2.5 ± 0.5) 48 ± 8 (4.8 ± 0.8) 25 ± 5 (2.5 ± 0.5) 50 ± 5 (5 ± 0.5) 90° 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 12 ± 5 (1.2 ± 0.5) 45 ± 5 (4.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) 55 ± 5 (5.5 ± 0.5) 45 ± 5 (4.5 ± 0.5) 25 ± 5 (2.5 ± 0.5) contact + 3/4 turn 45 ± 5 (4.5 ± 0.5)

EW--2--15

ENGINES F4GE0454C -- F4GE0484G OVERHAUL TOOLS 380000977

Tool for checking the top dead centre (to be used with 380001005)

380000978

Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)

380000979

Extractor for the gear linking the injection pump to the engine

380000980

Tool for removing the drive shaft front gasket

380000981

Tool for removing the drive shaft rear gasket

380000982

Injector extracting tool

380000983

Coupler for mounting the drive shaft front gasket

380000984

Coupler for mounting the drive shaft rear gasket

380000985

Cartridge filter removing tool

380000986

Pliers for removing and reassembling the piston rings (65--110 mm)

380000987

Tool for removing and reassembling the engine valves

380000988

Tool for rotating the engine flywheel

380000989

Joint for pressure control in the cylinders (use with 380001006)

380000990

Engine flywheel retaining tool

380000991

Beater for removing and reassembling the distributing shaft bushings (to be used with 380000999)

380000992

Drive shaft lifting tool

380000993

Swing bar for engine detachment and reattachment

380000994

Band for inserting the piston into the cylinder liner (60--125 mm)

380000995

Brackets for fastening the engine to the rotary stand 380000978

380000996

Gasket extracting tool

380000998

Manual pump for pressure and depression measuring

380000999

Handle for interchangeable beaters

380001000

Comparator holder base for miscellaneous measurements (to be used with 380001004)

380001001

Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount

380001004

Comparator (0--5 mm)

380001005

Comparator (0--10 mm)

380001006

Diesel engine cylinder compression control device

380001084

Comparator holder tool for rotary injection pump timing (to be used with 380001004)

380002730

Engine PMS positioning tool

EW--2--16

ENGINES F4GE0454C -- F4GE0484G OVERHAUL GRAPHIC INDICATIONS AND SYMBOLS Detachment Disconnect

Intake

Reattachment Connect

Exhaust

Removing Disassembling

Operation

Mounting Assembling

α

!

ρ

Compression ratio

Torque--tighten

Tolerance Weight difference

Torque--tighten + angular value

Dragging torque

Countersink

Rotation

Adjustment Setting

Angle Angular value

Warning Note

Preload

Visual check Mounting position check

Revs number

Measurement Dimension to be measured Check

Temperature

Equipment

bar

Pressure

Surface to be machined Machining finish

Increase Greater than .....

Maximum

Interference Forced mounting

Decrease Smaller than ....

Minimum

Thickness Play

Selection Classes Increases

Lubricate Moisten Grease

Temperature < 0 °C Cold Winter

Sealant

Temperature < 0 °C Hot Summer

Air bleed

EW--2--17

ENGINES F4GE0454C -- F4GE0484G OVERHAUL GENERAL REMARKS F4GE0454C ENGINE Figure 3

86552

1. Turbosupercharger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Output shaft pulley -6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by

EW--2--18

ENGINES F4GE0454C -- F4GE0484G OVERHAUL F4GE0484G ENGINE Figure 4

86553

1. Turbosupercharger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Output shaft pulley -6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by

EW--2--19

ENGINES F4GE0454C -- F4GE0484G OVERHAUL DESCRIPTION OF MAIN MECHANIC ENGINE COMPONENTS Crankcase It consists of a cast--iron structure in which the following items are realized: cylinder liners (1); bed supports (5) and seats for: distributing shaft bushings (3), tappets, water pump (2) and oil pump (4).

It also incorporates the coolant circulation chambers and the engine member lubricating circuit ducts.

Figure 5

86554

EW--2--20

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Drive shaft It is made of steel and rests on five induction--hardened supports.

Inside the drive shaft are the lubricating oil ducts.

The following items are force--fitted on the rear shank: distributing shaft (2) drive gear and engine flywheel (5) mounting hub.

The following items are force--fitted on the front shank: oil pump (1) drive gear, phonic wheel, damper flywheel and auxiliary component drive pulley.

The main half bearings are made of steel with anti-friction alloy coating.

The second main half bearing is equipped with a shoulder to restrain the drive shaft end play.

Parts (2) and (5) cannot be replaced.

Figure 6

84207

1. Oil pump control gear -- 2. Camshaft control gear -3. Main half bearings -- 4. Shoulder half bearings -- 5. Engine flywheel hub

EW--2--21

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Connecting rods They are steel--stamped, of the oblique cut type, with separation of the cap obtained by an advanced technology (fracture split) instead of mechanic machining.

The connecting rod half bearings are made of steel, with anti--friction alloy coating.

Figure 7

84038

EW--2--22

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Pistons The combustion chamber is found on the piston crown. The crown is cooled by the engine oil delivered by the nozzle fitted to the crankcase.

1st

The slots housing the piston rings are three; the slot is obtained by a cast iron insert with trapezoidal section.

The following references are marked on the piston crown:

1. Part no., spare no, and design modification no.

2. Arrow showing piston assembly mark into cylinder barrel, it shall be directed towards the front side of the cylinder block.

3. Date of manufacture.

4. Marking showing 1st slot insert testing.

Figure 8

86549

EW--2--23

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Distributing shaft The distributing shaft rests on five supports in the crankcase.

The supports (front and rear) are equipped with steel bushings mounted in an interfering manner and coated with anti--friction material; two control eccentrics are provided for each cylinder.

A. Intake valve control B. Exhaust valve control The camshaft is directly controlled by the output shaft through the gear (C).

Gear (D) transmits motion to the injection pump.

Figure 9

86556

EW--2--24

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Valve control Figure 10

86557

1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring – 8. Tappet – 9. Distributing shaft

EW--2--25

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Cylinder head (F4GE0454C engine) The seats of the following parts are obtained from the cast--iron cylinder head: - inserted valve seats (4); - injector (6); - thermostat (5);

Moreover, the following components are inserted on the heads: - single--block exhaust manifold (1); - intake manifold (2) with seat for cold start air heater (3).

Figure 11

86558

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--26

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Cylinder head (F4GE0484G engines) The seats of the following parts are obtained from the cast--iron cylinder head:

Moreover, the following components are inserted on the heads:

- inserted valve seats (4);

- single--block exhaust manifold (1); - intake manifold (2) with seat for cold start air heater (3).

- injector (6); - thermostat (5); Figure 12

86559

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

EW--2--27

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Valves and valve seats Figure 13

2 S

1

A

84241

1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side The valve seats inserted on the cylinder head have the following inclination: - 45° (exhaust valves) - 60° (intake valves).

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

Figure 14

84242

Figure 14 shows the oil seals mounted on valve stems.

EW--2--28

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Valve guides Figure 15

INTAKE

EXHAUST 84046

DETAIL OF VALVE GUIDES AND SEATS

EW--2--29

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Engine flywheel The flywheel (1) does not need being positioned in a fixed manner on the drive shaft, since it does not bear any stamping, notch or reference hole for sen-

sors or timing. The equidistance of fastening screw holes (2) allows it to be mounted in any position.

Figure 16

86560

EW--2--30

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Auxiliary component drive A Poly--V belt (4) transmits the motion of drive shaft (5) to water pump (1), alternator (2) and fan (6).

The belt is stretched by means of automatic belt stretcher (3).

Figure 17

86561

1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan pulley

EW--2--31

ENGINES F4GE0454C -- F4GE0484G OVERHAUL ADDITIONAL MASSES Inside the oil sump, secured to the cylinder block are located the additional masses.

The additional masses shall be timed with each other as shown below.

Make coincide marks (A) on gears for timed masses, insert hole pin (B) on the balancing mass to stop rotation temporarily.

Figure 18

80354

1. Fastening screws -- 2. Support -- 3. Fastening screws -- 4. Gear -- 5. Balancing mass -6. O--Ring -- 7. Ring -- 8. Gear -- 9. Counter--rotating shaft -- 10. Half bearings

EW--2--32

ENGINES F4GE0454C -- F4GE0484G OVERHAUL LUBRICATION Forced circulation lubrication is performed by the following components:

- water / oil cooler, housed in cylinder block; - oil pressure relief valve built into the cooler unit;

- rotor--equipped oil pump housed in the crankcase front part, controlled by the straight--tooth gear force--fitted on the drive shaft shank;

- by–pass valve to cut out clogged oil filter, built into the cooler unit; - cartridge oil filter.

Figure 19

Oil return drop--type path Pressure oil path Oil supply 86562

EW--2--33

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Heat exchanger Figure 20

1 2 3

4

86458

1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -4. Gasket between exchanger unit and engine block

EW--2--34

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Oil pump Figure 21

84052

Figure 22

70150

1. Drive shaft with oil pump drive gear

EW--2--35

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Oil sump The oil sump (1) is bolted to the cylinder block by means of a plate (2).

The plate (2), fitted on the oil sump outline reduces noise in addition to improve tightness.

Engines F4GE0454C*D660 -- F4GE0454C*D603 -- F4GE0484G*D660 -- F4GE0484G*D606 Figure 23

86563

Engine F4GE0484G*D655 -- F4GE0484G*605 Figure 24

86564

EW--2--36

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Oil vapour recirculation Oil vapour recirculation takes place by means of valve (1) placed above the tappet cover (2).

The vapour condensed therein fall below the tappet cover (2) due to gravity, whereas the remaining vapour is recovered by vent (3) and properly conveyed to the intake phase.

Figure 25

114063

EW--2--37

ENGINES F4GE0454C -- F4GE0484G OVERHAUL COOLING The engine cooling system is of the forced, closed-circuit circulation type and is made up of the following components:

- centrifugal water pump, housed in the crankcase front part;

- heat exchanger, to cool the lubricating oil;

- thermostat, to regulate coolant flow.

Figure 26

86565

Water flowing out of the thermostat

Water recirculating in the engine

Water flowing into the pump

EW--2--38

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Water pump The water pump is housed in a seat obtained from the crankcase and is controlled by means of a poly--V belt.

The nearly total absence of outer pipes, sleeves and clamps eliminates many connections, thus reducing possible leak points.

The engine temperature is controlled by a thermostat.

The coolant flows also in the oil heat exchanger.

Figure 27

84058

Figure 28

84059

EW--2--39

ENGINES F4GE0454C -- F4GE0484G OVERHAUL MECHANIC INJECTION FEEDING SYSTEM Fuel filter The support (1) incorporates fuel temperature sensor (5), heater resistor (2), water drain screw (3), air bleeding screw (6) and filter (4).

Degree of filtration of cartridge: 6 micron.

Maximum working pressure: 5 bar.

Working temperature: – 40 °C to + 90 °C.

Figure 29

86566

EW--2--40

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Mechanic fuel pump Displacement pump mounted on the engine left side; it is used to feed the injection pump and is controlled by the distributing shaft.

Figure 30

84249

1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank Figure 31

84250

1. Pump -- 2. Control lever -- 3. Distributing shaft

EW--2--41

ENGINES F4GE0454C -- F4GE0484G OVERHAUL INJECTION ASSEMBLY Figure 32

84251

1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake manifold -- 7. Thermal bulb for KSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector

EW--2--42

ENGINES F4GE0454C -- F4GE0484G OVERHAUL ENGINE BENCH--OVERHAUL

Figure 35

Disassembling the engine Figure 33

86568

86567

Drain the engine oil by taking the cap off the sump and the oil filling cap off the head cover.

F4GE0484G versions

Remove the fan unit from the fan pulley.

- disconnect the engine oil vapour recovery pipe from blow--by (1);

In order to be able to fit bracket 380000995 (which fastens the engine to the overhaul stand) to the crankcase, it is necessary to: - remove electric wiring (1).

- take off intake manifold (3);

- take off tappet covers (4); - disconnect electric wiring (8); - take off fuel filter (9); - take off container (2); - take off container control unit (5); - disconnect the piping from L.D.A. system (13);

Figure 34

- disconnect quick--coupling pipes (7), (10), (11) and (13), by following the indications given in Figure 36; - take off fuel filter support (6).

5

4

Figure 36

86463

In order to be able to fit bracket 380000995 to the crankcase on the right side, it is necessary to remove: - fastening bracket (2) from electric wiring (1); - electric wiring (1); - the starter motor (3).

Secure the engine to rotary stand 380000978.

- take off turbine lubrication delivery pipe (7); - remove the oil filter (4).

70126

Act on fork (1) as shown in the figure (detail A), then remove the adapter. To avoid damaging the same, bring fork (1) back to the locking position (detail B) after the adapter has been removed.

EW--2--43

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 37

Figure 39

84255

- Remove injector (5) feed pipes (5) from injection pump (6); remove the rackets fastening the pipe unit (1), (2) and (3) on the cylinder head.

- Remove the priming pump (4).

86570

- Remove the screws (3) and then remove the turbine (1).

- Remove the exhaust manifold (2).

Figure 40

Figure 38

86571

- Remove the belt tightener (2).

- Remove the auxiliary component belt (4) operating the alternator fastening bracket (1).

86569

- Remove the feed pipe unit from injectors (1).

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

- Remove the alternator (3), the water pump (6), the fan pulley (5) and the guide pulleys (7).

- Remove the pulley support (8).

- Remove the engine cooling system connection from the cylinder block.

EW--2--44

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 41

Figure 43

84259

78257

Lock the flywheel properly to prevent rotation, loosen the fastening screws (1) from pulley (2).

Apply the proper tension rod (3) of tool 380000996 to outer seal ring (2) as shown in the figure, then take the same off front cover (1) by means of lever (4).

Remove the front cover.

O--ring replacement Figure 42

Figure 44

78256

Apply tool 380000980 (4) on drive shaft front shank (2).

Drill inner seal ring (1), through tool 380000980 (4) guide holes, with an inset (∅ 3.5 mm) down to a depth of 5 mm.

Secure tool 380000980 (4) to ring (1) by screwing the 6 screws (5) provided.

Take off ring (1) by fastening screw (3).

84237

Remove gear oil pump (1).

IMPORTANT -- Oil pump (1) cannot be reconditioned.

EW--2--45

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Removing the injection pump

Figure 47

Figure 45

84071

Unlock the engine flywheel.

Rotate the drive shaft until it reaches the condition of 1° cylinder at top dead centre.

Such condition is obtained when (after removing the closing plug), by pushing pin 380002730 (1) shown by the arrow, it is housed in its own seat obtained on distributing shaft drive gear (2).

86573

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

- Lock the engine flywheel.

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

Figure 46

Figure 48

84260

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

Fasten again screw (2) to its abutting end.

IMPORTANT -- Carefully store the L--shaped spacer with the pump body.

84261

Loosen the three nuts (2) (4) (5) securing the injection pump (1) to the flywheel covering case (3), then take the pump out of its housing by means of tool 380000979 through proper application to gear (4) in NO TAG.

EW--2--46

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 49

Figure 51

86574

Remove screws (1) securing engine flywheel (2) to the drive shaft.

78258

Apply tool 380000981 (3) on drive shaft rear shank (5).

Drill inner seal ring (1), through tool 380000981 (3) guide holes, with an inset (∅ 3.5 mm) down to a depth of 5 mm.

Secure tool 380000981 (3) to ring (1) by fastening the 6 screws (4) provided.

Take off ring (1) by fastening screw (2).

Figure 52

Figure 50

86575

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

Remove tool 380000990 (2).

Take out engine flywheel (1) so that it can be harnessed by means of a hoist and placed into its own container.

78257

Apply the proper torsion bar (3) of tool 380000996 to outer seal ring (2) as shown in the figure, then take the same off flywheel cover case (1) by means of lever (4).

EW--2--47

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 53

Figure 55

86576

Remove screws (2) and then remove the flywheel housing (1).

IMPORTANT -- Take note of the mounting position of screws (2), due to the different size of the latter.

86608

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

Figure 56

86578

Use pin (1) to lock the additional masses (2) at T.D.C. Loosen the fastening screws (3) and remove the additional masses (2).

Figure 54

Removing the rocker arm assembly Figure 57

86577

Turn the engine upside down, remove screws (2), take off oil sump (1).

84081

For each cylinder, remove rocker arm assembly (1), loosen adjusting nuts (3), unscrew registers (2) and remove screws (4).

EW--2--48

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 58

Figure 61

1

2

84082

Take out injectors (2) by means of tool (1) 380000982.

86609

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

Figure 59

IMPORTANT -- Take note of the mounting position of screws (2), due to the different size of the latter.

86579

Figure 62

Remove screws (1) securing the head to the crankcase.

Figure 60

70158

Remove connecting rod cap (2) fastening screws (1), then take off the caps.

Remove the pistons (complete with connecting rods) from the crankcase upper part.

86580

Hook the wire ropes to brackets (1) and (2), then separate the cylinder head from the crankcase by means of a hoist.

IMPORTANT -- Half bearings must be kept in their respective housings; in fact, if they have to be used again, they must be mounted in the same position they had prior to being taken off.

EW--2--49

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 63

Figure 66

70159

Remove screws (1) and take off bed caps (2).

70162

Take off main half bearings (1).

Figure 64

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

Figure 67

70160

The penultimate bed cap (1) and its respective support have half bearing (2) provided with shoulder.

IMPORTANT -- Take note of the mounting position of lower and upper half bearings; in fact, if they have to be used again, they must be mounted in the same position they had prior to being taken off.

70163

Remove screws (1) and take off distributing shaft (3) retaining plate (2).

IMPORTANT -- Take note of plate (2) mounting position.

Figure 65 Figure 68

70161

Remove drive shaft (2) from crankcase by means of tool 380000992 (1) and a hoist.

70164

Carefully remove the distributing shaft from the crankcase.

EW--2--50

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 69

Figure 70

70165

Remove tappets (1) from the engine crankcase.

70166

The check of cylinder liner inner diameter (in order to measure the amount of out--of--roundness, taper and wear) is carried out by means of bore gauge (1) equipped with a comparator previously reset on the ring gauge (2) of the cylinder liner diameter.

NOTE – If no ring gauge is available, use a micrometer to perform reset.

REPAIR WORK ON CYLINDER CLUSTER

Figure 71

Checks and measurements After the engine has been dismantled, clean the crankcase--cylinder cluster thoroughly.

Use proper rings to move the cylinder cluster.

Check the crankcase carefully for cracks.

Check the condition of working caps. They must be replaced if they are rusty or their sealing properties are in doubt.

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

70167

Measurements must be taken for each single cylinder, at three different heights of the liner and on two planes perpendicular to each other: one parallel to the engine longitudinal axis (A), the other perpendicular (B); the greatest amount of wear is usually found on the latter plane and during the first measurement.

When detecting out--of--roundness, taper or wear, the cylinder liners must be bored and refaced. Cylinder liner reconditioning must be performed with regard to the spare piston diameter increased by 0.5 mm of the rated value, and to the prescribed assembling play.

EW--2--51

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Checking the surface supporting the head on the cylinder cluster

Figure 72

Figure 73

70170

Verify that the head supporting plane on the cylinder cluster does not show deformations.

This check can be carried out by taking off dowels (4) by means of a gauged rule (2) and thickness gauge (3).

After detecting the deformed areas, flatten the supporting surface by means of a grinder.

The flatness error must not be greater than 0.075 mm.

80585

IMPORTANT -- In case of reconditioning, all the liners must be machined to the same increase (0.5 mm).

Check the main bearing seats as follows: - mount the bed caps on the supports without bearings; - tighten the fastening screws to the specified torque; - check, by means of an adequate internal comparator, that the seat diameter is the same as the specified value.

If a greater value is found, replace the crankcase.

NOTE -- Crankcase flattening may be carried out only after making sure, when the repair work has been completed, that the protrusion of the piston from the cylinder liner is not greater than the specified value.

Check the condition of cylinder cluster working caps (1); they must be replaced if they are rusty or their sealing properties are in doubt.

After flattening, restore the cylinder liner countersink, as shown in Figure 72.

EW--2--52

ENGINES F4GE0454C -- F4GE0484G OVERHAUL VALVE GEAR Distributing shaft Figure 74

86581

MAIN FEATURES OF DISTRIBUTING SHAFT The features given below refer to the normal diameter of pins The shaft support pin and eccentric surfaces must be perfectly smooth; if, on the contrary, they show traces of seizing and scoring, it is advisable to replace the shaft and its respective bushings.

Figure 75

Checking the eccentric lift and the pin alignment Place the shaft on back centres and check, by means of a centesimal comparator placed on the middle support, that the alignment error is not greater than 0.04 mm; otherwise, replace the shaft.

70171

Check the diameter of distributing shaft support pins (2) by means of a micrometer (1) on two axes perpendicular to each other.

EW--2--53

ENGINES F4GE0454C -- F4GE0484G OVERHAUL BUSHINGS

Figure 76

The distributing shaft bushing (2) must be force--fitted into their respective seats.

The inner surface must show no traces of seizing or wear.

Use bore gauge (3) to measure the diameter of rear bushing (2) and of distributing shaft intermediate seats (1).

Measurements must be taken on two axes perpendicular to each other.

70172

Figure 77

sec. A-A

107399

MAIN FEATURES OF DISTRIBUTING SHAFT BUSHING AND THEIR RESPECTIVE SEATS * Dimension to be obtained after driving the bushing

EW--2--54

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Mounting the tappets – Distributing shaft

Replacing the bushings

Figure 80

Figure 78

70174

To replace rear bushing (1), use beater 380000991 (2) and handle 380000999 (3) to remove and reassemble the bushing.

70176

Lubricate tappets (1) and fit them to their respective seats of the crankcase.

IMPORTANT -- Bushing (1) must, upon mounting, be turned in such a way that the lubricating holes match with the holes available on the crankcase seats.

Tappets Figure 79

Figure 81

84053

MAIN FEATURES OF TAPPETS AND THEIR RESPECTIVE SEATS ON THE CRANKCASE

70164

Lubricate the distributing shaft support bushing and mount distributing shaft taking care not to damage the bushing or supporting seats during operation.

EW--2--55

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 82

Figure 84

70238

Place distributing shaft (3) retaining plate (1) with the slotted hole facing the crankcase upper side and the stamping facing the operator, then fasten screws (2) to the specified torque.

70180

Mount nozzles (2) and tighten fastening screws (1) to the specified torque.

DRIVE SHAFT Measuring the journals and crankpins Figure 85

Figure 83 70182

If traces of excessive seizing, scoring or out--of-roundness are found on journals and crankpins, it is necessary to reface the pins by grinding. Prior to grinding pins (2), measure the journals by means of a micrometer (1) so as to determine the amount (diameter) by which the pins have to be reduced.

NOTE -- It is advisable to write down the measured values on a table.

See Figure 86.

70179

Check the distributing shaft end play (1).

EW--2--56

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Reduction classes are 0.250 and 0.500 mm.

IMPORTANT -- Journals and crankpins must always be ground to the same reduction class.

The reduction carried out on journals and crankpins must be marked with a special stamping made on the side of crank arm 1.

For reduced crankpins, use letter M. For reduced journals, use letter B. For reduced crankpins and journals, use letters MB.

Figure 86

108487

DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE WRITTEN DOWN * Rated value

EW--2--57

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 87

70183

MAIN TOLERANCES OF DRIVE SHAFT TOLERANCES CONCERNING: SHAPE ORIENTATION POSITION OSCILLATION

TOLERANCE--RELATED FEATURE Roundness Cylindricality Parallelism Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES CRITICAL IMPORTANT SECONDARY

GRAPHIC SYMBOL f /f/ //

GRAPHIC SYMBOL ©

EW--2--58

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Measuring the journal assembling play

Replacing the oil pump drive gears Figure 88

Figure 90

70184

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

70161

Mount the drive shaft (1) on which gears (2) and (3) are force--fitted.

When fitting the new gear, the latter must be heated for 10 minutes in a small furnace at a temperature of 180 °C and force--fitted onto the drive shaft by putting the key in between.

Mounting the main bearings Figure 89

Figure 91

70185

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

Main bearings (1) are supplied as spares reduced on their inner diameter by 0.250 – 0.500 mm.

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

Clean thoroughly the main half bearings (1) provided with lubrication holes, then fit them to their seats.

The penultimate main half bearing (1) is provided with shoulder half rings.

70186

Check the play between the drive shaft journals and their respective bearings by following the procedure below: - clean thoroughly the parts and eliminate traces (if any) of oil; - place a piece of gauged wire (3) (parallel to the longitudinal axis) on drive shaft pins (4); - mount caps (1), complete with half bearings (2), on their respective supports.

EW--2--59

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 92

Figure 94

70187

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

- 1st phase with a torque wrench at 50 ± 6 Nm. - 2nd phase with a torque wrench at 80 ± 6 Nm.

70189

- Take the caps off the supports.

The play between the main bearings and their respective pins can be measured by comparing the width taken on by gauged wire (2) at the point where it is flattened most, with the scale graduation shown on gauged wire envelope (1).

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

If the measured play is different from the specified one, replace half bearings and repeat the check; once the prescribed play has been obtained, lubricate main bearings and mount the supports definitely by tightening the fastening screws as described above.

Checking the drive shaft shoulder play Figure 93

Figure 95

α

70188

- 3rd phase with tool 380001001 (1) placed as shown in the figure: tighten screws (2) further to an angle of 60° ± 5°.

70190

The shoulder play is checked by placing a magnetic comparator (2) on drive shaft (3) as shown in the figure: normal assembling play is 0.068 to 0.410 mm.

If a greater play is found, replace the main thrust half bearings of the penultimate support (1), then check again the play between the drive shaft pins and the main half bearings.

EW--2--60

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Connecting rod--piston assembly Figure 96

70191

PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY 1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod -8. Bushing NOTE -- Pistons are supplied as spares increased by 0.4 mm.

Figure 97

Figure 98

84093

Taking piston rings (1) off piston (2) by means of pliers 380000986 (3).

84094

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

EW--2--61

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 99

86497

MAIN DATA ABOUT PISTON

Pistons Measuring the piston diameter Figure 100

Figure 101

84096

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

NOTE -- The diameter must be measured 8 mm far from the piston skirt base.

70192

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

EW--2--62

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Gudgeon pins

Figure 105

Figure 102

84097

Measuring the gudgeon pin diameter (1) by means of a micrometer (2).

Conditions for correct pin/piston matching

84100

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

Figure 103

Figure 106 84098

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

Piston rings Figure 104

84101

84099

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

SCHEME FOR MEASURING PLAY X FOR THE TRAPEZOIDAL RING Due to the peculiar shape of the first trapezoidal cross-sectioned seal ring, the play between the slot and the ring itself must be measured as follows; allow piston (1) to protrude from the crankcase so that ring (2) at issue comes out of about half from cylinder liner (3).

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

EW--2--63

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 107

Figure 109

70194

Measuring the play between the ends of piston rings (2) inserted into cylinder liner (3), by means of a thickness gauge (1).

Connecting rods Figure 108

114314

Y Production year D Production day H Weight class

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

86498

MAIN DATA OF CONNECTING ROD, GUDGEON PIN BUSHING AND HALF BEARINGS * Dimension of inner diameter to be obtained after driving into the connecting rod small--end and refacing by means of a reamer. ** This dimension cannot be measured in a free state.

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

Therefore, it is recommended not to remove knurls.

- By a letter (on the connecting rod body) which indicates the weight class of the factory--assembled connecting rod: -- V, 1560 to 1600 (marked in yellow); -- W, 1601 to 1640 (marked in green); -- X, 1641 to 1680 (marked in blue); Replacement rods are supplied class W and marked in green.

Material removal is not permitted.

EW--2--64

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Bushings

Checking the torsion

Verify that the bushing in the connecting rod small-end is not loosened and does not show traces of scoring or seizing. Otherwise, replace it.

Figure 111

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

When driving, take the greatest care that the holes allowing oil to flow onto the bushing and the connecting rod small--end correspond to each other. Use a reamer to reface the bushing so as to obtain the required diameter.

Checking the connecting rods Figure 110

61694

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

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

Checking the flexion Figure 112

61696

Check parallelism of the axles of the connecting rods (1) with a suitable device (5) as follows: - assemble the connecting rod (1) on the proper tool chuck (5) and lock it with the screw (4); - place spindle (3) on V--shaped block squares by putting connecting rod (1) on stop bar (2).

61695

Check connecting rod flexion (5) by comparing two points C and D of pin (3) on the vertical plane of the connecting rod axis. Place comparator (2) vertical support (1) so that the comparator rests on pin (3) at point C. Swing the connecting rod to and fro, looking for the highest position of the pin; under such condition, set comparator (2) to zero. Move the spindle with connecting rod (5) and repeat the highest point check on opposite side (D) of pin (3). The difference between points C and D must not be greater than 0.08 mm.

EW--2--65

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Mounting the connecting rod--piston assembly Connecting rod--piston match Figure 113

Mounting the piston rings Figure 116

86550

The following reference data are engraved on the piston crown: 1. Spare part number and design modification number; 2. Arrow showing piston assembly mark into cylinder barrel, it shall be directed towards the front side of the cylinder block.

3. Date of manufacture.

4. Marking showing 1st slot insert testing.

Figure 114

84093

Use pliers 380000986 (3) to fit piston rings (1) on piston (2).

IMPORTANT -- Spare piston rings are supplied in the following dimensions: -- standard, marked with yellow paint; -- increased by 0.4 mm, marked with yellow/green paint;

Figure 117

86551

Connect piston (2) to connecting rod (4) by means of pin (3) so that reference inscription (1) for mounting piston (2) in the cylinder liner and the numbers (5) stamped on connecting rod (4) cen be seen as shown in the figure.

Figure 115 70200

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

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

Insert pin (1) fastening piston rings (2).

72705

No matching operation must be carried out on half bearings.

EW--2--66

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Mounting the connecting rod/piston assemblies in the cylinder liners

Measuring the crankpin assembling play Figure 120

Figure 118

70201

70203

Lubricate thoroughly the pistons, including the piston rings and the cylinder liner inside.

The play can be measured by following the procedure below:

Use band 380000994 (2) to mount the connecting rod--piston assemblies (1) into the cylinder liners.

- clean thoroughly the parts and eliminate any trace of oil; - place a piece of gauged wire (2) on drive shaft pins (1); - mount the connecting rod caps (3) with their respective half bearings (4); Figure 121

Figure 119

70204

- tighten screws (1) (previously lubricated with engine oil) to the specified torque by means of a torque wrench (2).

Figure 122 α 80612

SCHEME FOR MOUNTING THE CONNECTING ROD--PISTON ASSEMBLY INTO THE TUNNEL - the piston ring apertures are offset to each other by 120°; - all the connecting rod/piston assemblies weigh the same; - the arrow (1) stamped on the piston crown faces the crankcase front side, or the notch obtained on the piston skirt corresponds to the position of oil nozzles.

70205

- Apply tool 380001001 (1) on the compass wrench, then tighten screws (2) further in a criss-cross sequence.

EW--2--67

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Checking piston protrusion Figure 125

Figure 123

70206

- Take off the cap and calculate the existing play by comparing the width of gauged wire (1) with the scale graduation shown on the wire envelope (2).

70208

After the connecting rod--piston assemblies have been mounted, check, by means of comparator 380001004 (1) equipped with base 380001000 (2), the protrusion of pistons (3) at the top dead centre relative to the crankcase upper plane.

Said protrusion must be 0.28 to 0.52 mm.

Valve gear Distribution gearbox case

Figure 124

Figure 126

70207

If the measured play is different from the specified one, replace half bearings and repeat the check.

Once the specified play has been obtained, lubricate the connecting rod half bearings and mount them definitely by tightening the connecting rod cap fastening screws as described.

IMPORTANT -- Prior to mounting the connecting rod cap fastening screws definitely, verify that the diameter of the same (as measured at the middle of the thread length) is not smaller than 0.1 mm of the diameter measured at about 10 mm from the screw end.

Check manually that connecting rods (1) run axially on the drive shaft pins, and that the end play of the same (as measured by means of a thickness gauge (2) is 0.10 to 0.33 mm.

86582

SCHEME FOR SEALANT LOCTITE 5205 APPLICATION AREA Clean thoroughly distribution gearbox case (1) and the engine crankcase.

Cleaning the surface to be sealed is necessary and unavoidable in order to ensure optimum seal.

Apply sealant LOCTITE 5205 on the case so as to make a bead with a diameter of a few millimetres.

The bead must be smooth (no lumps) and free from air bubbles, thin areas or gaps.

Any defect must be corrected as soon as practicable.

Avoid using excess material to seal the joint.

An excessive amount of sealant tends to come out on both sides of the joint and obstruct lubricant flowing passages.

After completing sealant application, the joints must be mounted immediately (within 10 -- 20 minutes).

EW--2--68

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 127

Figure 129

86610

SCHEME FOR REAR GEARBOX CASE FASTENING SCREW TIGHTENING SEQUENCE Reassemble case to the crankcase.

Tighten the fastening screws in the same positions they had prior to being taken off, then fasten the screws to the specified torque.

86611

Turn drive shaft (4) and distributing shaft (2) in such a direction that when mounting driven gear (1) on the distributing shaft, the stamped marks on gears (1 and 3) correspond to each other.

Valve timing Figure 128

Figure 130

70211

Mark, with a felt--tip pen, the tooth of drive gear (1) mounted on drive shaft (2), the side surface of which bears a stamped notch (→) for timing.

86612

Tighten gear (2) fastening screws (1) to distributing shaft (3), then fasten them to the specified torque.

EW--2--69

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Injection pump – 1st phase

Figure 133

Timing Figure 131

86613 84071

Bring cylinder 1 to the top dead centre. This condition occurs when pin 380002730 (1) (shown by an arrow) is housed in the seat available on the distributing shaft drive gear (2).

Force--fit gear (1) transmitting the motion to the pump, then fasten nut (2) by hand.

Turn the engine and then assemble the additional masses.

Assembling the additional masses Figure 134

Figure 132

86578

84273

Mount the injection pump body (1) in the gearbox seat (2), then secure it by means of screws (3).

Assemble the additional masses (2) and tighten the screws (3) on the cylinder block.

Remove the additional masses locking pin (1).

EW--2--70

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Additional masses timing Make the marks (A) on the timing gears coincide, insert the pin into the hole (B) set on the balancing mass.

Figure 135

86614

1. Injection pump gear -- 2. Camshaft control gear-3. Injection pump control gear -- 4. Additional mass unit

EW--2--71

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Flywheel cover case

Figure 137

Figure 136

α

86576 86583

SCHEME FOR SEALANT LOCTITE 5205 APPLICATION AREA Clean thoroughly the attaching surfaces of flywheel case (1) and distribution gearbox.

SCHEME FOR FLYWHEEL COVER CASE FASTENING SCREW TIGHTENING SEQUENCE Fit case back to the crankcase, tighten the fastening screws (2) in the positions they had prior to being taken off, then fasten them to the specified torque.

Screws:

Cleaning the surface to be sealed is necessary and unavoidable in order to ensure optimum seal.

- M12 x 1.75 x 100

80 ± 10 Nm

- M16 x 1.50 x 80

200 ± 20 Nm

Apply sealant LOCTITE 5205 on the case (1) so as to make a bead with a diameter of a few millimetres.

- M16 x 1.50 x 100 - M12 x 1.75 x 78

200 ± 20 Nm 80 ± 10 Nm

The bead must be smooth (no lumps) and free from air bubbles, thin areas or gaps.

Any defect must be corrected as soon as practicable.

Avoid using excess material to seal the joint.

An excessive amount of sealant tends to come out on both sides of the joint and obstruct lubricant flowing passages.

Figure 138

After completing sealant application, the joints must be mounted immediately (within 10 -- 20 minutes).

70216

Apply part (5) of tool 380000984 on drive shaft rear shank (6), secure it by means of screws (4) and force--fit the new seal ring (3) on the same.

Position part (1) on part (5), then screw nut (2) to fully mount seal ring (3) in flywheel cover case (7).

EW--2--72

ENGINES F4GE0454C -- F4GE0484G OVERHAUL ENGINE FLYWHEEL

Figure 141

Figure 139

2

1

86574

86584

Check the clutch disc supporting surface and turn it if scoring is detected.

Tighten screws (2) fastening engine flywheel (3) to the drive shaft.

NOTE -- The rated thickness of the engine flywheel is 70.5 mm.

Replacing the engine flywheel ring gear Check the condition of ring gear (2) teeth. If breaks or excessive tooth wear is found, remove the ring gear from the engine flywheel (1, NO TAG) by using a normal beater, then mount the new gear ring after previously heating it to 150 °C for 15’ to 20’; the countersink made on the gear ring inner diameter must face the engine flywheel.

Figure 142 α

Figure 140

86585

Tighten engine flywheel (2) fastening screws (1) in two separate phases: - 1st phase: tighten to a torque of 30 ± 5 Nm by means of a torque wrench; 86575

Screw down two pins (2) of adequate length into the shaft holes (3), then remove the engine flywheel (1) by means of suitable harnesses and a hoist.

- 2nd phase: tighten to an angle of 60° ± 5°.

IMPORTANT -- Angle tightening is carried out by means of tool 380001001.

EW--2--73

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Injection pump – 2nd phase Mounting the injection pump – Figure 143

2nd

Mounting the oil and water pumps Figure 146

phase

86586

Torque--tighten nut (1) by means of torque wrench (2).

70220

Mount oil pump (1).

Screw down fastening screws (2) and tighten them to the specified torque.

Figure 144

Figure 147

86587

Apply sealant (1) as shown in the figure, then put on small cover (2) and tighten screws to the specified torque.

70221

Apply a new seal ring (2) onto water pump (1).

Figure 145 Figure 148

84260

Remove plug (1) from the distribution gear seat Figure 45.

Remove presetting screw (2) and insert L--shaped spacer (1). Fasten again the screw to its abutting end.

70222

Mount water pump (1).

Fasten screws (2) and tighten them to the specified torque.

EW--2--74

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 149

Figure 152

70223

Take seal ring (2) off front cover (1), clean thoroughly the attaching surface and apply sealant LOCTITE 5205 onto the same.

86577

Mount oil sump (1).

Fasten screws (2) and tighten them to the specified torque.

Figure 150

70224

Clean thoroughly the surface of front cover (2) attaching base, then mount front cover (2).

Fasten screws (1) and tighten them to the specified torque.

Figure 153 Figure 151

α

70225

Apply part (5) of tool 380000983 on drive shaft front shank (6), secure it by means of screws (4) and force-fit the new seal ring (3) on the same.

Position part (1) on part (5), then screw nut (2) to fully mount seal ring (3) in front cover (7).

86588

Force--fit pulley (1) complete with spacer (2) onto the drive shaft, then torque--tighten and angle--tighten the screws by means of tool 380001001.

Secure guide pulleys (4) to the front cover by means of screws (3).

EW--2--75

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Mounting the water / oil heat exchanger

Figure 156

Figure 154

84175

Mount the following items on the crankcase: a new gasket (1), heat exchanger (2), a new gasket (3), and oil filter support (4). Fasten screws (5) and tighten them to the specified torque.

Applicare la nuova cartuccia filtro olio.

86589

Fit alternator (1) back to alternator support.

Cylinder head Removing the valves Figure 157 Figure 155

84179

84177

Position alternator support (1) in such a way that pins (3 and 4) are placed against the engine crankcase.

Fasten screws (2) and tighten them to the specified torque.

Valves can be removed by means of tool 380000987 (1) by pressing slightly on collar (3) so that lock cones (2) can be removed by compressing springs (4). Then remove collar (3) and springs (4).

Repeat the procedure on all valves.

EW--2--76

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 158

Figure 160

86590

84282

Take off oil seals (1) fitted to the valve stems.

To remove the valves, properly turn the head upside down.

Remove the thermostat unit (2) and brackets (1) and (3).

IMPORTANT -- Mark the exhaust and intake valves prior to removing them.

Checking the cylinder head supporting surface Figure 161

Figure 159

INTAKE

EXHAUST 84181

In addition to the head dimensions, the exhaust valves differ from intake valves in that they are equipped with a supplementary notch (1) obtained on the stem for intake valves.

84183

The plane of the supporting surface of head (1) to cylinder cluster is checked by means of a ruler (2) and a thickness gauge (3).

The deformation found on the entire length of the cylinder head must not be greater than 0.20 mm.

If greater values are found, reface the cylinder head according to the values and instructions given in the next figure.

EW--2--77

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Checking the cylinder head water seal

VALVES

Check the water seal by means of suitable equipment.

Use a pump to feed water heated to ∼ 90 °C at a pressure of 2 to 3 bar.

Figure 163 EXHAUST VALVE

INTAKE VALVE

If leaks are detected from the caps, the latter must be replaced by using a suitable beater for disassembling/ assembling operations.

IMPORTANT -- Prior to mounting the caps, apply water--repellent sealant on the sealing surface of the same.

If leaks are detected from the cylinder head, the latter must be replaced.

84185

MAIN DATA OF INTAKE AND EXHAUST VALVES

Figure 162

Valve descaling, check and grinding Figure 164

84284

Nominal thickness A of the cylinder head is 95 ± 0.25 mm, max. admitted metal removal shall not exceed thickness B, i.e. 0.13 mm.

IMPORTANT -- After regrinding, check valve sinking and regrind valve seats if required, to obtain the required value.

84186

Remove the carbon deposits from the valves by means of the special metal brush.

Verify that the valves do not show traces of seizing, crimping or burns.

Adjust, if required, the valve seats with the proper grinder, removing the least amount of material possible.

EW--2--78

ENGINES F4GE0454C -- F4GE0484G OVERHAUL VALVE GUIDE

Figure 165

Figure 167

84187

Use a micrometer (2) to measure valve stem (1), which must be equal to 7.96 to 7.98.

INTAKE

EXHAUST 84046

Use a bore gauge to measure the valve guide inner diameter, which must be equal to the value shown in the figure.

VALVE SEATS

Checking the play between the valve stem, valve guide and valve centring

Valve seat reconditioning -- replacement Figure 168

Figure 166

84188

Check can be made by means of a magnetic comparator (1) placed as shown. Assembling play must be equal to 0.039 to 0.079 mm.

Check, by making valve (2) rotate, that the centring error is not greater than 0.03 mm.

84189

Check valve seats (2). Check by reading the scorings and burns, use the tool (1) over it again according to the tilting values indicated on the Figure 169.

EW--2--79

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 169

INTAKE

EXHAUST

84190

VALVE SEAT DIMENSIONS Figure 170

EXHAUST

INTAKE

86591

VALVE SEAT HOUSING DIMENSIONS If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By using the same proper tool (1, Figure 168) and taking care not to indent the cylinder head, remove as much material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.

Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by means of a suitable beater.

Recondition the valve seats by means of the proper tool, according to the values shown in Figure 169.

EW--2--80

ENGINES F4GE0454C -- F4GE0484G OVERHAUL MOUNTING THE CYLINDER HEAD

Figure 171

Figure 173

84192

After the reconditioning operations, verify, by means of base 380001000 (2) and comparator 380001004 (1), that valve hollow (3) corresponds to the specified value.

84282

Lubricate the valve stem and insert into the respective valve guide according to the position marked upon disassembling.

Mount seal rings (1) onto the valve guide.

VALVE SPRINGS Figure 172

84193

Figure 174

MAIN DATA FOR INTAKE AND EXHAUST VALVE SPRING CHECK Prior to mounting, check the valve spring flexibility by means of the proper tool. Compare the elastic strain and load data with those relative to the new springs shown in the table below.

Height mm H(Free) 63.50 H1 49.02 H2 38.20

Under a load of N No load P1 329 P2 641

84179

Position spring (4) and upper collar (3) on the cylinder head: use tool 380000987 (1) to compress spring (4) and link the parts to the valve by means of lock cones (2).

EW--2--81

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Reattaching the cylinder head

Figure 177

Figure 175

84113

Verify that the cylinder head attaching plane and the crankcase attaching plane are both clean.

Do not spoil the cylinder head gasket.

IMPORTANT -- Prior to reusing the cylinder head fastening screws, verify that they do not show traces of wear or deformations; otherwise, replace them.

84209

Prior to inserting the pushrods, verify their state of preservation: the spherical seats in contact with the rocker arm adjusting screw and tappet (arrows) must not show traces of seizing or wear; otherwise, the seats must be replaced. The rods controlling the intake and exhaust valves are identical and, therefore, they are interchangeable.

Rocker arm assembly Figure 178

84195

PARTS MAKING UP THE ROCKER ARM ASSEMBLY: 1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws Figure 176

Figure 179

84265

Mount the cylinder head on the crankcase by fastening screws (1) without torque--tightening them.

84196

MAIN DATA OF ARBOUR--ROCKER ARM Verify that the arbour/rocker arm matching surfaces do not show excessive wear or damages.

EW--2--82

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 183

Figure 180

84197

Verify that the tappet adjusters are unscrewed to prevent the latter from crawling on the rods when the rocker arm assembly (1) is mounted.

Mount the rocker arm assembly made up of the arbours and rocker arm support, then secure them to the head without torque--tightening screws (2) and (3).

Figure 181

84200

Ad just the play between the rocker arms and the valves by means of an Allen wrench (2), box wrench (3) and thickness gauge (1).

The operation play is: -- intake valves: 0.25 ± 0.05 mm -- exhaust valves: 0.50 ± 0.05 mm.

Take the cylinder where clearance must be adjusted to the bursting phase; its valves are closed while balancing the symmetric cylinder valves.

Symmetric cylinders are 1--4 and 3--2.

FIRING ORDER 1--3--4--2 Adjusting cylinder valve no.

Adjusting clearance of cylinder valve no.

1

3

4

2

4

2

1

3

Mounting the injectors Figure 184 84198

Fasten the head screws according to the instructions given in Figure 182.

Figure 182

α

84285

Scheme of cylinder head fastening screw tightening sequence: - 1st phase: pre--fastening by means of a torque wrench: screw M12 x 1.75 x 70 [ ]50 Nm ± 5 Nm; screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm; screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm; - 2nd phase: angle tightening: 90° - 3rd phase: angle tightening only for screws 140 and 180 mm long: 90°.

84201

Mount a new seal ring (2) lubricated with petrolatum and a new seal washer (3) on injector (1).

Mount the injectors on their seats on the cylinder head, then tighten them by means of a torque wrench.

EW--2--83

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 185

Figure 187

86615

Mount the injector feeding pipe assembly (1). Mount the pipes for fuel discharge (2) from injectors, by using gaskets (3) and by tightening screws (4).

86570

- Mount exhaust manifold (2).

- Mount turbine (1) by means of screws (3).

Figure 188

86592

APPLICATION ON F4GE0454C

Figure 186

86593

APPLICATION ON F4GE0484G

84255

Mount the injection pump (6) injector feeding pipes (5), then secure brackets (1), (2) and (3) fastening the pipe assembly onto the cylinder head.

Mount priming pump (4).

The intake manifold unit is made up of manifold (6) on the cylinder head, cover (5), seal gaskets (2) and (4), cold--start heater (3) and elbow (1).

Apply sealant LOCTITE 5205 between cover (5) and manifold (6), then tighten the screws to the specified torque.

EW--2--84

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Figure 189

Figure 191

84252 86568

- Assemble the wiring harness (1).

- Mount tappet covers (4).

- Assemble the heater (2).

- Assemble the intake manifold elbow (3).

- Mount container control unit (5).

- Mount fuel filter support (6).

- Mount fuel filter (9).

- Attach quick coupling pipes (7), (10), (11) and (12) by following the indications given in Figure 190.

- Mount electric wiring (8).

- Mount L.D.A. system piping (13).

- Connect the engine oil vapour recovery pipe to blow--by (1).

Figure 192 Figure 190

5

4

86463

70126

Press the clamp (1) in arrow direction (Figure B) and connect the pipe.

Reset the clamp to the initial locking position A.

- Mount the starter motor (3).

- Mount turbine lubricating oil return piping with its respective fastening bracket.

- Mount turbine lubricating oil delivery pipe and engine oil pipes and to water / oil heat exchanger unit.

EW--2--85

ENGINES F4GE0454C -- F4GE0484G OVERHAUL REPLACING THE INJECTORS

Figure 193

Removal Figure 196

86594

- Assemble the thermostat unit (1) to the cylinder head (3) and tighten the screws (2) to torque.

- Assemble the water temperature sensor (5) and tighten it using the torque wrench.

- Assemble the fan pulley support (6) on the head (3) by means of screws (4), tighten the screws to torque.

Figure 194

86596

Place the vehicle in safe conditions.

Lift the engine compartment cover, disconnect the battery cables and proceed as follows: - disconnect engine oil vapour recovery pipe (2) from blow--by; - take off tappet cover (1); - disconnect the fuel manifold pipes from injectors (3).

86595

Mount fan pulley (2) on support (1) by torque--tightening screws (3) to the prescribed torque.

Figure 197

Figure 195

86571

Mount Poli--V belt (4) on pulley (5), drive shaft pulley, guide pulleys (2), water pump (6) and on alternator (3); then, stretch the belt by acting on automatic belt stretcher (3).

84082

Remove injectors (2) by means of tool 380000982 (1) and take them off the cylinder head.

EW--2--86

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Reassembling

ROCKER ARM REMOVAL/REASSEMBLING

Figure 198

Removal Figure 200

84081

Loosen tappet adjuster fastening nuts (3), then unscrew adjusters (2).

84201

Mount a new seal ring (2) lubricated with petrolatum and a new seal washer (3) on injector (1).

Mount the injectors on their seats on the cylinder head, then tighten them by means of a torque wrench.

Remove screws (4) and dismount rocker arm assembly (1) made up of the rocker arm support and arbours, then take off valves.

Reassembling Verify that the tappet adjusters are unscrewed to prevent the latter from crawling on the rods when the rocker arm assembly is mounted.

Mount the rocker arm assemblies made up of rocker arm support and arbours, then secure them to the cylinder head by tightening the fastening screws to a torque of 36 Nm. Ad just the tappets as described above.

Figure 199

84290

Mount new seal rings (1) on fuel manifolds (2).

Connect the manifolds to the injectors, by tightening the fastening nuts to a torque of 50 Nm. Reassemble the tappet cover.

Re--connect the engine oil vapour recovery pipe to the blow--by.

EW--2--87

ENGINES F4GE0454C -- F4GE0484G OVERHAUL ADJUSTING THE TAPPETS Figure 201

84200

Ad just the play between the rocker arms and the valves by means of an Allen wrench (2), box wrench (3) and thickness gauge (1).

The operation play is: --

± 0.05 mm

–

intake valves: 0.25 ± 0.05 mm

--

exhaust valves: 0.50 ± 0.05 mm.

Take the cylinder where clearance must be adjusted to the bursting phase; its valves are closed while balancing the symmetric cylinder valves.

Symmetric cylinders are 1--4 and 3--2.

FIRING ORDER 1--3--4--2 Adjusting cylinder valve no.

Adjusting clearance of cylinder valve no.

1

3

4

2

4

2

1

3

EW--2--88

ENGINES F4GE0454C -- F4GE0484G OVERHAUL Turn the engine shaft counter clockwise of a few degrees and then turn again in the opposite direction until the P.M.S. is determined.

Check priming of the injection pump Figure 202

In this position, on the comparator (2) you will read the pumping element pre--lift value prescribed.

Turn the pump counter clockwise if the stroke is lower, or clockwise if the stroke is higher until the stroke prescribed is achieved.

Then lock the pump with the fixing nuts to the couple prescribed.

88141

Turn the engine shaft unit the piston of the 1st cylinder near the P.M.S. and close the relevant valves (compression stage).

Assemble tool 380000977 (1) and with the comparator (2) in the seat of the injector of the 1str cylinder, preload the comparator (2).

Figure 203

87720

With the injection pump inserted in the relevant seat and the fixing screws loosened, assemble the comparator 380001004 (2) and its holder 380001084 (1), preloading the rod of 2.5 mm.

Turn the engine shaft properly in order to determine the exact PMS of the piston of the 1st cylinder and of the injection pump pumping element, zero the comparators (2, Figure 202 and 2, Figure 203).

SECTION 3

RECHARGING AND START--UP

INDEX Starter motor . . . . . . . . . . . . . . . . . . . . . . EW--3--3

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--5

Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--3

Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW--3--5

Bosch 24 V -- 4 kW . . . . . . . . . . . . . . . . . . EW--3--4

Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--3--6

INDEX

EW--3--3

RECHARGING AND START--UP STARTER MOTOR

BOSCH -- 24 V -- 4 kW

Quick diagnosis Fault

Possible causes

Remedy

Dragging torque insufficient

1. Batteries run down

Restore

2. Circuit connections oxidized or loose

Replace the component

3. Brushes not in working order

Replace the component

4. Short--circuited field windings

Replace the component

5. Interruptedor short circuited ar-mature

Replace the component

6. Out--of--round collector

Replace the component

Dragging torque sufficient, but the engine won’t start.

1. Free wheel or faulty electro--ma-gnet

Replace the component

Pinion won’t engage.

1. Bevelled ring gear

Restore

EW--3--4

RECHARGING AND START--UP Bosch 24 V -- 4 kW 6--pole type with series excitation and engagement by means of a fork controlled by an electromagnet.

Clockwise direction of rotation Rated voltage 24 V Power 4 kW

84262

84267

WIRING DIAGRAM

3/4 VIEW

84268

CHARACTERISTIC CURVES

84269

PINION ADJUSTER

EW--3--5

RECHARGING AND START--UP ALTERNATOR

BOSCH

NCBI 28 V 35--70 A

Quick diagnosis Fault

Possible causes

Remedy

No recharge

1. Interruption of recharge circuit (warning light, fuse, connector, etc.)

Check the recharge circuit con-nections, clean and tighten the cable terminals on the alterna-tor and battery

2. Voltage regulator not in wor-king order

Replace the component

3. Interrupted rotor winding

Replace the component

4. Worn brushes

Replace the component

1. Loose belt

Apply correct tension

2. Faulty voltage regulator

Replace the component

3. Excessive wear of rotor rings or brushes

Replace the component

4. Short--circuited diodes

Replace the component

5. Short--circuited rotor winding(s)

Replace the component

1. Loose circuit connections

Check the connections to ter-minals and cable terminals of batteries, starter motor and al-ternator

2. Voltage regulator not in wor-king order

Replace the component

3. Earth fault

Check earth connections

Poor recharge

Excessive recharge

EW--3--6

RECHARGING AND START--UP Bosch NCBI 28 V 35--70 A Thrre--phase type, claw--type rotor, 11--diode rectifier and electronic voltage regulator.

Direction of rotation (control side) clockwise Current delivered at 6.000 min--1 ≥ 55A Rated voltage 28,5V

84270

WIRING DIAGRAM

3/4 VIEW

84272

CHARACTERISTIC CURVES OF CURRENT DELIVERY

84271

84274

CHARACTERISTIC CURVES OF VOLTAGE REGULATOR