Tigercat FPT N45 & N67 ENGINE SERVICE & REPAIR MANUAL - PDF DOWNLOAD

Tigercat FPT N45 and N67 ENGINE SERVICE AND REPAIR MANUAL

PRELIMINARY ISSUE JANUARY, 2015

Tigercat Industries Inc.

42069AENG

P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

This publication provides unit and relevant component repair data, specifications, instructions and methodologies.

This publication has been drawn up for qualified and specialised personnel.

Before performing any operation check that the part relevant to the unit on which you must work is available along with all safety devices for accident-prevention, such as, goggles, helmet, gloves, shoes, etc. and hoisting and transporting equipment.

Operations are to be performed by following the indications included here, using the special equipment indicated and assuring proper repair, compliance with schedule and operator’s safety requirements.

Each repair must aim to restore operating efficiency and safety in compliance with the FPT provisions.

FPT cannot be held liable for modifications, alterations or other interventions non authorised by FPT on the vehicle and if the unit is warranted the above mentioned interventions will cause its expiration.

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the interventions and all the instructions that are not included on this publication.

Data included in this publication may not be up-to-date therefore subject to Manufacturer’s modifications that can be added at any time for technical or commercial purposes and also to meet new law regulations in other Countries.

If issues on this publication differ from what is actually noticed on the unit, please get in touch with the FPT network before starting any intervention”.

It is forbidden to copy this text or any of its parts and all illustrations included.

Publication edited by FPT Industrial S.p.A. Via Puglia, 15 10156 Torino (Italia) Print P2D32N019 E - 2nd Ed. 03.2012 1st Updating 09.2012

2

Base - March 2012

SERIES NEF TIER 4i

Print P2D32N019 E

SERIES NEF TIER 4i

INTRODUCTION

1

Introduction Page PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Service operations . . . . . . . . . . . . . . . . . . . . . .

3

GENERAL WARNINGS . . . . . . . . . . . . . . . . . . .

5

GENERAL WARNINGS ON THE ELECTRIC SYSTEM . . . . . . . . . . . . .

7

- Bonding and screening . . . . . . . . . . . . . . . . . . .

8

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS . . . . . . . . . . . . . . . .

9

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . .

9

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES . . . . . . . . . . . . . . . . . . .

Print P2D32N019 E

10

Base - March 2012

2

INTRODUCTION

Base - March 2012

SERIES NEF TIER 4i

Print P2D32N019 E

SERIES NEF TIER 4i

INTRODUCTION

3

PREFACE Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents.

The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.

The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the control units peculiar to the electric system.

Section 1 describes the engines illustrating its features and working in general.

Section 2 describes the fuel supply type and engine operation.

Section 3 is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the basis of their specific use.

Section 4 describes scheduled maintenance and specific overhauling.

Section 5 describes troubleshooting for those who require simple and direct indications in order to locate the cause of the faults while performing technical assistance.

Section 6 deals with removal and refitting of the main engine components.

Section 7 describes general mechanical servicing of the engine on the revolving stand.

Section 8 gives engine technical characteristics such as data, installation clearances and tightening torques.

Section 9 is about the tools necessary for performing these operations.

The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order to prevent serious accidents taking place.

The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.

SYMBOLS - Warnings Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

Danger of serious damage for the assembly Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may sometimes cause the warranty to become null and void.

!

General danger It includes the dangers of above described signals.

Environment protection Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect the environment as much as possible.

NOTE

It indicates an additional explanation for a piece of information.

Service operations Example ∅1

Ø 1 = Seat of small end bush Ø 2 = Seat of connecting rod bearings.

∅2

Print P2D32N019 E

Close applying the required torque Close applying the required torque + angular α value

Base - March 2012

4

INTRODUCTION

Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly

α

ρ

Compression ratio

Tighten to torque

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation Adjustment

Angle Angular value

Visual inspection Fitting position check

Number of revolutions

Measurement Value to find Check

Temperature

Equipment

Base - March 2012

SERIES NEF TIER 4i

bar

Pressure

Surface for machining Machine finish

Oversized Higher than….

Maximum, peak

Interference Strained assembly

Undersized Less than….

Minimum

Thickness Clearance

Selection Classes Oversizing

Lubrication Damp Grease

Temperature < 0 °C Cold Winter

Sealant Adhesive

Temperature > 0 °C Hot Summer

Air bleeding

Preload

Print P2D32N019 E

SERIES NEF TIER 4i

INTRODUCTION

5

GENERAL WARNINGS

!

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described.

Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check.

The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path.

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.

In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position.

Keep personnel not authorised to operations clear of working area.

You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly follow all the safety indications found on the assembly.

Do not leave the running assembly unattended when making repairs.

When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist.

When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document, as well as all the specific safety standards provided for.

Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out.

Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.

Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers.

Worn out, damaged or consumable parts must be replaced by original spares.

During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.

Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

Print P2D32N019 E

Base - March 2012

6

INTRODUCTION

SERIES NEF TIER 4i

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc.

Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

Clean the assemblies and carefully verify that they are intact prior to overhauling.

Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.

Self-locking nuts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding: - Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding) and detach connectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80 °C (dryer ovens), disassemble drive electronic central units.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

Base - March 2012

Print P2D32N019 E

SERIES NEF TIER 4i

INTRODUCTION

7

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

!

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.

Before connecting the batteries to the system, make sure that the system is well isolated.

Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals.

Do not cause sparks to be generated in checking if the circuit is energised.

Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.

Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.

Measurements in drive electronic central units, plugged connections and electric connections to components can only be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers, clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which would later cause contact problems.

To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special truck.

A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries) can cause them to be destroyed.

Disconnect the batteries from the system during their recharging with an external apparatus.

On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque.

Before disconnecting the junction connector from an electronic central unit, isolate the system.

Do not directly supply electronic central units servo components at nominal vehicle voltage.

Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according to original arrangement.

Print P2D32N019 E

Base - March 2012

8

INTRODUCTION

SERIES NEF TIER 4i

Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M).

Further, following warnings are to be compulsorily observed for electronic components: -

Electronic central units must be connected to system bonding when they are provided with a metallic shell.

-

Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.

-

Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.

Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

-

Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

-

If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

-

Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

Figure 1

1.

NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

2.

SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE ! 0

Base - March 2012

Print P2D32N019 E

SERIES NEF TIER 4i

INTRODUCTION

9

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling directives issued by FPT. It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel.

It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular, the data interconnection line between central units (CAN line) is to be considered inviolable.

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power 1 kW 1 kW 1 metric HP 1 metric HP 1 HP 1 HP

= = = = = =

1.36 metric HP 1.34 HP 0.736 kW 0.986 HP 0.746 kW 1.014 metric HP

Torque 1 Nm 1 kgm

= =

0.1019 kgm 9.81 Nm

OF

THE

Revolutions per time unit 1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602 Pressure 1 bar 1 kg/cm2 1 bar

= = =

1.02 kg/cm2 0.981 bar 105 Pa

Where accuracy is not particularly needed: - Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1 1 kgm

=

10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1 1 kg/cm2

=

1 bar.

Temperature 0 °C = 32 °F 1 °C = (1 x 1.8 + 32) °F

Print P2D32N019 E

Base - March 2012

10

INTRODUCTION

SERIES NEF TIER 4i

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of vehicle

Printout number

Base - March 2012

Section title

Language Publication

Page number

Basic edition referred to month - year editorial phase closing

When month - year update is present (revi) to the basic edition

Print P2D32N019 E

1

F4HFE ENGINES

Part 1 F4HFE ENGINES Section General specifications

1

Operational diagrams

2

Electrical equipment

3

Scheduled maintenance

4

Diagnostics

5

Removal - refitting of main components

6

General mechanical overhauling

7

Technical specifications

8

Tools

9

Safety prescriptions

Print P2D32N019 E

Appendix

Base - March 2012

2

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

3

F4HFE ENGINES

UPDATING Section 7

Print P2D32N019 E

Description

Page

Date of revision

General mechanical overhauling

42

Revi - September 2012

Base - March 2012 Revi - September 2012

4

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

1

SECTION 1 - GENERAL SPECIFICATIONS

SECTION 1 General specifications

Page

Print P2D32N019 E

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE . . . . . . . . . . . . .

3

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .

4

- Engines F4HFE413A - F4HFE413D - F4HFE413L F4HFE413M . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .

7

- Engines F4HFE6133 - F4HFE6134 - F4HFE613H

7

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .

10

- Engines F4HFE6135 - F4HFE6136 F4HFE613C*A004 - F4HFE613L*A003 . . . . .

10

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .

13

- Engines F4HFE6132 - F4HFE6139 - F4HFE613A F4HFE613C*A002/3 - F4HFE613L*A001/2 . .

13

GENERAL CHARACTERISTICS . . . . . . . . . . . . .

16

- 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . .

16

- 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . .

18

Base - March 2012

2

SECTION 1 - GENERAL SPECIFICATIONS

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

3

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

Technical Code F4HFE413L*A002 F4HFE413A*A003 F4HFE413D*A003 F4HFE413M*A003 F4HFE6132*A002 F4HFE6133*A001 F4HFE6133*A002 F4HFE6134*A001 F4HFE6135*A001 F4HFE6136*A001 F4HFE6139*A001 F4HFE6139*A002 F4HFE613A*A001 F4HFE613A*A002 F4HFE613C*A002 F4HFE613C*A003 F4HFE613C*A004 F4HFE613H*A005 F4HFE613L*A001 F4HFE613L*A002 F4HFE613L*A003

Print P2D32N019 E

Commercial Code

N45 ENT

N67 ENT

Base - March 2012

4

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

ENGINE VIEWS Engines F4HFE413A - F4HFE413D - F4HFE413L - F4HFE413M Figure 1

166691

LEFT-HAND SIDE VIEW Figure 2

166692

RIGHT-HAND SIDE VIEW Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

5

Figure 3

166693

FRONT VIEW Figure 4

166694

REAR VIEW Print P2D32N019 E

Base - March 2012

6

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

Figure 5

166695

TOP VIEW

Figure 6

166696

PERSPECTIVE VIEW Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

7

ENGINE VIEWS Engines F4HFE6133 - F4HFE6134 - F4HFE613H Figure 7

165359

LEFT-HAND SIDE VIEW

Figure 8

165362

RIGHT-HAND SIDE VIEW Print P2D32N019 E

Base - March 2012

8

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

Figure 9

165360

FRONT VIEW Figure 10

165358

REAR VIEW Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

9

Figure 11

165361

TOP VIEW

Figure 12

166097

PERSPECTIVE VIEW Print P2D32N019 E

Base - March 2012

10

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

ENGINE VIEWS Engines F4HFE6135 - F4HFE6136 - F4HFE613C*A004 - F4HFE613L*A003 Figure 13

165364

LEFT-HAND SIDE VIEW

Figure 14

165367

RIGHT-HAND SIDE VIEW Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

11

Figure 15

165365

FRONT VIEW Figure 16

165363

REAR VIEW Print P2D32N019 E

Base - March 2012

12

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

Figure 17

165366

TOP VIEW

Figure 18

166098

PERSPECTIVE VIEW Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

13

ENGINE VIEWS Engines F4HFE6132 - F4HFE6139 - F4HFE613A - F4HFE613C*A002/3 - F4HFE613L*A001/2 Figure 19

165369

LEFT-HAND SIDE VIEW Figure 20

165372

RIGHT-HAND SIDE VIEW Print P2D32N019 E

Base - March 2012

14

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

Figure 21

165370

FRONT VIEW Figure 22

165368

REAR VIEW Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

15

Figure 23

165371

TOP VIEW

Figure 24

162249

PERSPECTIVE VIEW Print P2D32N019 E

Base - March 2012

16

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

GENERAL CHARACTERISTICS 4-cylinder engines Type

ρ

F4HFE413L*A002

Compression ratio Maximum power

17 : 1 kW (hp) rpm

Maximum torque

Nm (kgm) rpm

Idle speed

F4HFE413A*A003

125 (170) 2200

110 (150) 2200

700 (71) 1500

676 (69) 1500

rpm 800

Maximum engine speed Bore x stroke

rpm

Total displacement

cm3

104 x 132

TURBOCHARGING Turbocharger

2375

4485 With intercooler

type

GARRETT Forced by gear pump, pressure relief valve, oil filter

LUBRICATION Oil pressure with engine hot: bar

- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening

bar bar

ºC ºC

0.7 3.5 Liquid cooled Belt driven 79 ± 2 95

FILLING - engine sump

litres

11.5

15W40 ACEA E7/API CI-4 - engine sump 10W30 ACEA E7/API CI-4* + filter 10W40 ACEA E9/API CJ-4**

litres

14.4

* For ambient temperature < -15 °C ** Alternatively

NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.

Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

Type

ρ

F4HFE413D*A003

Compression ratio Maximum power

kW (HP)

Nm (kgm) rpm

Idle speed

F4HFE413M*A003

17 : 1

rpm Maximum torque

17

89 (121) 2200

75 (102) 2200

549 (56) 1500

472 (48) 1400

rpm 800

Maximum engine speed Bore x stroke

rpm

Total displacement

cm3

104 x 132

TURBOCHARGING Turbocharger

2375

4485 With intercooler

type

GARRETTT Forced by gear pump, pressure relief valve, oil filter

LUBRICATION Oil pressure with engine hot: bar

- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening

bar bar

ºC ºC

0.7 3.5 Liquid cooled Belt driven 79 ± 2 95

FILLING - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**

litres

11.5

litres

14.4

* For ambient temperature < -15 °C ** Alternatively

NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.

Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

Print P2D32N019 E

Base - March 2012

18

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

6-cylinder engines F4HFE6133*A001 F4HFE6133*A002

Type

ρ

Compression ratio Maximum power

17 : 1 kW (hp) rpm

Maximum torque

F4HFE6134*A001 F4HFE613H*A005

Nm (kgm) rpm

210 (286) 2200

181 (247) 2200

1143 (116) 1500

1120 (114) 1500

Idle speed

rpm

850

Maximum engine speed Bore x stroke

rpm

2375

Total displacement

cm3

104 x 132

TURBOCHARGING Turbocharger

6728 With intercooler

type

CCM HOLSET HX35W Forced by gear pump, pressure relief valve, oil filter

LUBRICATION Oil pressure with engine hot: bar

- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening

bar bar

ºC ºC

0.7 3.5 Liquid cooled Belt driven 79 ± 2 95

FILLING - engine sump

litres

15.2

15W40 ACEA E7/API CI-4 - engine sump 10W30 ACEA E7/API CI-4* + filter 10W40 ACEA E9/API CJ-4**

litres

17.2

* For ambient temperature < -15 °C ** Alternatively

NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.

Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE6135*A001 F4HFE613L*A003

Type

ρ

Compression ratio Maximum power

F4HFE6136*A001 F4HFE613C*A004 17 : 1

kW (HP) rpm

Maximum torque

Nm (kgm) rpm

151 (206) 2200

129 (176) 2200

960 (98) 1500

810 (83) 1500

Idle speed

rpm

850

Maximum engine speed Bore x stroke

rpm

2375

Total displacement

cm3

104 x 132

TURBOCHARGING Turbocharger

19

6728 With intercooler

type

WLO HOLSET HX35 Forced by gear pump, pressure relief valve, oil filter

LUBRICATION Oil pressure with engine hot: bar

- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening

bar bar

ºC ºC

0.7 3.5 Liquid cooled Belt driven 79 ± 2 95

FILLING - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**

litres

15.2

litres

17.2

* For ambient temperature < -15 °C ** Alternatively

NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.

Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

Print P2D32N019 E

Base - March 2012

20

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE ENGINES

Type

ρ

Compression ratio Maximum power

Maximum torque

F4HFE6139*A001 F4HFE6139*A002

F4HFE6132*A002

17 : 1 kW (HP) rpm

122 (166) 2200

162 (221) 2200

Nm (kgm)

726 (74)

rpm

1500

960 (98) 1500

Idle speed

rpm

850

Maximum engine speed

rpm

2375

Bore x stroke Total displacement

104 x 132 cm3

TURBOCHARGING Turbocharger

6728 With intercooler

type

CEX HOLSET HX35 Forced by gear pump, pressure relief valve, oil filter

LUBRICATION Oil pressure with engine hot: bar

- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening

bar bar

ºC ºC

0.7 3.5 Liquid cooled Belt driven 79 ± 2 95

FILLING Total capacity - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**

litres

15.2

litres

17.2

* For ambient temperature < -15 °C ** Alternatively

NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.

Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

F4HFE613C*A002 F4HFE613A*A001 F4HFE613L*A001 F4HFE613C*A003 F4HFE613A*A002 F4HFE613L*A002

Type

ρ

Compression ratio

17 : 1

Maximum power

kW (HP) rpm

129 (176) 2200

140 (191) 2200

151 (206) 2200

Maximum torque

Nm (kgm) rpm

810 (83) 1500

866 (88) 1500

960 (98) 1500

Idle speed

rpm

850

Maximum engine speed

rpm

2375

Bore x stroke Total displacement

104 x 13 cm3

TURBOCHARGING Turbocharger

21

6728 With intercooler

type

CEX HOLSET HX35 Forced by gear pump, pressure relief valve, oil filter

LUBRICATION Oil pressure with engine hot: bar

- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening

bar bar

ºC ºC

2.0 4.0 Liquid cooled Belt driven 79 ± 2 95

FILLING - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**

litres

15.2

litres

17.2

* For ambient temperature < -15 °C ** Alternatively

NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements.

Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.

Print P2D32N019 E

Base - March 2012

22

SECTION 1 - GENERAL SPECIFICATIONS

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

1

SECTION 2 Operational diagrams

Page

Print P2D32N019 E

HIGH PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL) . . . . . . . . . . . . . .

3

- General Specifications . . . . . . . . . . . . . . . . . . .

3

ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . .

3

- Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- System functionality . . . . . . . . . . . . . . . . . . . . .

4

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . .

5

- Fuel system layout . . . . . . . . . . . . . . . . . . . . . .

7

FUEL SUPPLY SYSTEM COMPONENTS . . . . . .

8

- Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . .

8

- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

- Mechanical supply pump . . . . . . . . . . . . . . . . .

9

- CP3 high-pressure pump . . . . . . . . . . . . . . . . .

10

- Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Overpressure valve . . . . . . . . . . . . . . . . . . . . .

14

- Electro-injector . . . . . . . . . . . . . . . . . . . . . . . .

15

- Pressure limiter for fuel return . . . . . . . . . . . . .

16

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

17

- 4-cylinder engine version . . . . . . . . . . . . . . . . .

17

- 6-cylinder engine version . . . . . . . . . . . . . . . . .

18

- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .

19

- Oil pressure relief valve . . . . . . . . . . . . . . . . . .

21

OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . .

22

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .

23

- 4-cylinder engine version . . . . . . . . . . . . . . . . .

23

- 6-cylinder engine version . . . . . . . . . . . . . . . . .

24

- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Base - March 2012

2

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Page TURBOCHARGING SYSTEM . . . . . . . . . . . . . . .

26

- Description . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- 4-cylinder engine version . . . . . . . . . . . . . . . .

26

- 6-cylinder engine version . . . . . . . . . . . . . . . .

26

- Turbocharger . . . . . . . . . . . . . . . . . . . . . . . .

27

- Waste gate (only for F4HFE413A/3D/3L/3M F4HFE6133/34/3H engines) . . . . . . . . . . . . .

28

DeNOx 2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

29

- General Information . . . . . . . . . . . . . . . . . . .

29

- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

- Ad Blue fluid level gauge control . . . . . . . . . .

31

- Pump module . . . . . . . . . . . . . . . . . . . . . . . .

31

- Dosing module . . . . . . . . . . . . . . . . . . . . . . .

31

- SCR pipes . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

- Exhaust gas temperature sensor . . . . . . . . . .

32

- Humidity detecting sensor . . . . . . . . . . . . . . .

33

- Nitric oxide sensor . . . . . . . . . . . . . . . . . . . .

34

- Pin out DCU 15 D2-2 . . . . . . . . . . . . . . . . . .

35

- Scheduled Maintenance . . . . . . . . . . . . . . . . .

38

- DEF/AdBlue circuit filters (dosing system DeNOx 2) . . . . . . . . . . . . . . . . . . . . . . . . . .

38

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

3

SECTION 2 - OPERATIONAL DIAGRAMS

HIGH PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL) General Specifications In order to reduce PARTICULATES emissions, very high injection pressures are required.

The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision, obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.

ELECTRIC SYSTEM

Figure 1

107246

1. Injectors connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Crankshaft sensor - 6. EDC7UC31 control unit - 7. Fuel flow rate regulator - 8. Fuel heater and fuel temperature sensor - 9. Camshaft sensor - 10. Air pressure/temperature sensor - 11. Injector.

Sensors Through the sensors, present on the engine, the ECU controls the engine operation.

Air pressure/temperature sensor It is a component integrating a temperature sensor and a pressure sensor.

The outlet tension is proportional to the pressure or temperature obtained by the sensor.

Engine oil temperature and pressure sensor Same as air pressure/temperature sensor, it is fitted on the engine oil filter, in a horizontal position.

It measures engine oil temperature and pressure.

Fitted on the intake manifold, it measures the max. inlet air capacity to calculate precisely the fuel quantity to inject at every cycle.

Print P2D32N019 E

Base - March 2012

4

SECTION 2 - OPERATIONAL DIAGRAMS

Fuel pressure sensor Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure.

The injection pressure value is used to control the pressure and to determine the electric injection control length.

Fuel temperature sensor It is a sensor that is equal to the previous one.

It measures fuel temperature to provide the control unit with an index of the diesel fuel thermal state.

Coolant temperature sensor It is a variable-resistance sensor suitable to measure the coolant temperature to provide the control unit with an index of the engine thermal state.

Crankshaft sensor It is an inductive sensor placed on the front engine part. Signals generated through the magnetic flow that is closed on the phonic wheel, change their frequencies depending on output shaft rotation speed.

Timing sensor It is an inductive sensor placed on the engine rear left part.

It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal.

Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape.

System functionality Self-diagnosis The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.

Engine pre-heating resistance check The pre-post heating is activated when even only one of the water, air or fuel temperature sensors signals a temperature that is less than 5 °C. Timing recognition By means of signals coming from camshaft sensor and flywheel sensor, the cylinder on which fuel must be injected is recognised upon startup.

F4HFE ENGINES

Injection control The control unit, depending on information coming from sensors, controls the flow rate regulator, and changes pre-injection and main injection modes.

Closed-loop control for injection pressure Depending on engine load, measured by processing signals coming from various sensors, the control unit controls the regulator in order to always have the optimum pressure.

Pilot and main injection spark advance control The control unit, depending on signals coming from various sensors, computes the optimum injection point according to an internal mapping.

Idle speed control The control unit processes signals coming from various sensors and adjusts the amount of injected fuel.

It controls the pressure regulator and changes the injection time of injectors.

Within certain thresholds, it also takes into account the battery voltage.

Maximum speed limiting Approaching the peak rpm, the ECU limits the fuel flow by reducing the opening time of the electro-injectors.

The peak rpm of the engines is 2375 revs/min. Above this rate the ECU deactivates the electro-injectors.

Cut Off Fuel cut off upon release is controlled by the control unit performing the following logics: - it cuts off injectors supply; - it re-activates the injectors shortly before idle speed is reached; - it controls fuel flow rate regulator.

Smoke control upon acceleration With strong load requests, the control unit, depending on signals received by air inlet meter and engine speed sensor, controls the flow rate regulator and changes the injectors actuation time, in order to avoid exhaust smokes.

Fuel temperature control When the fuel temperature exceeds 78 °C (measured by the sensor placed on fuel filter) the control unit intervenes by reducing injection pressure.

If the temperature exceeds 90 °C, the power is reduced to 60%.

After Run The control unit microprocessor allows storing certain EPROM data, among which failure memory and Immobilizer information, in order to make them available upon the following startup.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

5

SECTION 2 - OPERATIONAL DIAGRAMS

HYDRAULIC SYSTEM The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.

Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.

When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place in the related cylinder.

The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.

The high-pressure circuit is composed of the following pipings: - piping connecting high-pressure pump outlet to rail; - pipings supplying injectors from rail.

Figure 2 (D)(*)

(Demonstration)

High Pressure Low Pressure Fuel outlet

166061

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump 6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.

Print P2D32N019 E

Base - March 2012

6

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

The low-pressure circuit is composed of the following pipings: - fuel suction piping from tank to prefilter; - pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter; - pipings supplying the high-pressure pump through the fuel filter.

The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

Figure 3 (**)

High Pressure Low Pressure Fuel outlet 166062

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump 6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

Fuel system layout The flow rate regulator (15), placed upstream of the highpressure pump, adjusts the fuel flow that is necessary on the low-pressure system. Afterwards, the high-pressure pump takes care of supplying the rail properly. This arrangement, by pressurising the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.

Function of the pressure relief valve (2), assembled on the high-pressure pump, is keeping the pressure, at the flow rate regulator inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream.

7

SECTION 2 - OPERATIONAL DIAGRAMS

The pressure relief valve (2) intervention brings about a fuel flow increase in the high-pressure pump cooling circuit, through inlet and drain piping (16) from piping (8).

The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 to 2 bars.

Two by-pass valves are placed in parallel with the mechanical supply pump.

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

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

Figure 4

EXHAUST INTAKE (LOW PRESSURE) HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE) HIGH PRESSURE

108608

1. High-pressure pump - 2. Pressure relief valve on high-pressure pump, 5 bars - 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars - 4. Rail overpressure valve - 5. Common Rail - 6. Pressure sensor - 7. Injector 8. Return piping - 9. Control unit heat exchanger - 10. Mechanical priming pump - 11. Prefilter assembled on chassis 12. Fuel tank - 13. Mechanical supply pump - 14. Fuel filter - 15. Flow rate regulator 16. High-pressure pump cooling piping - 17. By-pass valve - 18. By-pass valve.

Print P2D32N019 E

Base - March 2012

8

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

FUEL SUPPLY SYSTEM COMPONENTS Fuel prefilter

Figure 6 (D)(*)

Figure 5

99231

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 7 (**)

70494

The fuel filter is of the high water separation type, is assembled on the vehicle chassis, and has the sensor (4) for detecting water in fuel placed on the cartridge (3) base.

Manual priming pump (5) and air bleeding screw (2) from system are located on filter support.

The presence of condensate into filter is signalled by sensor (4) when a warning light on the instrument panel is lit.

If the warning light is on, it is necessary to immediately operate to remove its cause; the common rail system components are quickly damaged by the presence of water or impurities in the fuel.

Fuel filter It is located on engine block in the circuit between feed pump and high pressure pump (CP3).

On the support there are located: fuel temperature sensor and heater resistances.

Fuel temperature, signalled by relating sensor to EDC7UC31 central unit, enables a very accurate calculation of the flow rate of fuel to be injected into the cylinders.

The electric heater is activated when the fuel temperature is less than 0 °C and deactivated when the fuel temperature exceeds 5 °C. Base - March 2012

166063

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 1. Fuel filter support - 2. Fuel temperature sensor 3. Electric fuel heater - 4. Fuel filter - 5. Adapter 6. Heater connector - 7. Gasket A. Fitting for fuel drain outlet to tank B. Fitting for outlet to high pressure pump C. Fitting for drain from high pressure pump D. Fitting for fuel drain inlet from rail E. Fitting for inlet from feed pump

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

9

Bleeding conditions

Mechanical supply pump Feed mechanical pump is a gear pump, mounted on high pressure pump rear side, having the task of feeding high pressure pump. It is driven by high pressure pump shaft.

Figure 10

Normal operating conditions Figure 8

72594

72592

A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass valves in close position

The by-pass valve (2) cuts in when, with engine off, the fuel system shall be filled through the priming pump. In this situation the by-pass valve (1) stays closed whereas by-pass valve (2) opens due to inlet pressure, and fuel is drained out through B.

Overpressure condition at outlet NOTE The mechanical supply pump cannot be replaced individually, therefore it cannot be removed from the high pressure pump.

Figure 9

72593

The by-pass valve (1) cuts in when overpressure is generated at outlet B. The existing pressure, overcoming valve spring (1) elastic strength, makes inlet and outlet communicating through duct (2).

Print P2D32N019 E

Base - March 2012

10

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

CP3 high-pressure pump CP3 high pressure pump is a pump with 3 radial plungers which is driven through a timing system gear. High pressure pump does not require timing. On high pressure pump rear side, feed mechanical pump is mounted, driven by high pressure pump shaft.

NOTE The following work must be carried out on the feed pump / high-pressure pump assembly: - replacing the drive gear; - replacing the fuel flow rate regulator.

Figure 11

72595

1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Fuel flow rate regulator - 4. Control gear - 5. Fuel inlet fitting from filter - 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from supply pump to filter - 9.Mechanical supply pump

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

11

High-pressure pump - inside structure Figure 12

Sec. B-B

Sec. C-C

70498

1. Cylinder - 2. Three-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft 7. Low-pressure fuel inlet - 8. Plungers supplying fuel ducts.

Each plunger is made up of: - one piston (5) driven by a three-lobe element (2) floating on pump shaft (6). Element (2) is floating on a misaligned side of shaft (6). Therefore, during shaft rotation, the element is not turning together with the shaft, but is just translated, according to a circular movement, to a wider radius. It results that the three pumping assemblies are driven alternatively; - one cap intake valve (3); - one delivery ball valve (4).

Print P2D32N019 E

Base - March 2012

12

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Operating principle Figure 13

Sec. B — B

Sec. D — D

72597

1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply duct - 6. Pressure regulator supply duct - 7. Flow rate regulator.

Plunger (3) is oriented towards the cam that is present on pump shaft (4). During suction stroke, the plunger is fed through feed duct (5). The quantity of fuel to be sent to the plunger is set by flow rate regulator (7). Flow rate regulator, on the basis of PWM command received by control unit, partialises fuel inflow to the plunger. During plunger compression stroke, fuel reaches such a pressure that valve delivering the fuel to common rail (2) is opened and common rail is fed by the plunger through outlet (1).

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

Figure 14

Sec. C — C

Figure 15

72598

1. Plunger inlet - 2. Pump lubrication ducts - 3. Plunger inlet - 4. Main plunger supply duct - 5. Flow rate regulator - 6. Plunger inlet - 7. Regulator exhaust duct 8. 5 bar pressure relief valve - 9. Fuel drain from regulator inlet.

Figure 14 shows low pressure fuel paths inside the path and highlights: main plunger supply duct (4), plunger supply ducts (1 — 3 — 6), pump lubrication ducts (2), flow rate regulator (5), 5 bar pressure relief valve (8) and fuel drain duct (7).

Pump shaft is lubricated by fuel through delivery and return ducts (2).

Flow rate regulator (5) establishes the fuel amount to send to plungers; excess fuel is drained out through duct (9).

5 bar pressure relief valve acts as fuel return regulator and keeps 5 bar constant pressure at regulator inlet.

Print P2D32N019 E

13

SECTION 2 - OPERATIONAL DIAGRAMS

72601

Sec. A — A 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet from pump with high pressure pipe fitting for common rail.

Figure 15 shows high pressure fuel flow through plunger outlet ducts.

Replacing the pressure regulator - Greatest cleanliness must be ensured; - avoid letting impurities into the pump pressure channels; - replace the O-rings and moisten them with Vaseline; - tighten to the specified torque of 8 ÷ 12 Nm.

Base - March 2012

14

SECTION 2 - OPERATIONAL DIAGRAMS

Operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the plungers (about 2 bars).

F4HFE ENGINES

Rail Figure 16

(Demonstration)

The amount of fuel supplying the high-pressure pump is metered by the flow rate regulator, placed on the low-pressure system; the flow rate regulator is controlled by the EDC7UC31 control unit through a PWM signal.

When fuel is sent to a plunger, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the plunger chamber, not being able to come out, is compressed above the supply pressure value existing in the rail.

The thereby-generated pressure makes the exhaust valve open and the compressed fuel reaches the high-pressure circuit.

The plunger compresses the fuel till the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed.

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

When the plunger chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated.

The delivery valves must always be free in their movements, free from impurities and oxidation.

The pressure of fuel delivered to rail is modulated by electronic control unit through flow rate regulator solenoid valve.

107422

1. Rail - 2. Pressure sensor - 3. Fuel inlet from high-pressure pump - 4. Overpressure valve.

The rail volume is of reduced sizes to allow a quick pressurisation at startup, at idle and in case of high flow-rates. It anyway has enough volume as to minimise use of plenum chambers caused by injectors openings and closings and by the highpressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump. A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.

The pump is lubricated and cooled by the fuel.

The radialjet pump removal — refitting time on the engine is highly reduced in comparison with traditional injection pumps, because it does not require setting.

If the pipe between fuel filter and high-pressure pump is to be removed-refitted, be sure that hands and components are absolutely clean.

Base - March 2012

Overpressure valve Overpressure valve is mounted at one rail end. Overpressure valve task is to protect system components should rail pressure sensor or CP3 pump pressure regulator malfunctioning cause a pressure excessive increase in high pressure system.

When pressure in rail is reaching 1800 bar, the valve at start operates in order to make fuel flow and consequently decrease pressure to safety values, then mechanically regulates pressure in rail. The valve enables to operate engine for long times with limited performance and prevents fuel excessive overheating, so preserving pipes for fuel return to tank.

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

Electro-injector

15

Injection start

The injector is similar as construction to the traditional ones, apart from the absence of plunger return springs.

The injector can be deemed as composed of two parts: - actuator — spray nozzle composed of pressure rod (1), plunger (2) and nozzle (3); - control solenoid valve composed of coil (4) and pilot valve (5).

The solenoid valve controls spray nozzle plunger lift.

Figure 18

Injector in rest position Figure 17

15

15

70506

1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball shutter - 7. Control area - 8. Pressure chamber - 9. Control volume - 10. Control duct 11. Supply duct - 12. Control fuel outlet - 13. Electric connection - 14. Spring - 15. High-pressure fuel inlet.

70505

1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball shutter - 7. Control area - 8. Pressure chamber - 9. Control volume - 10. Control duct 11. Supply duct - 12. Control fuel outlet - 13. Electric connection - 14. Spring - 15. High-pressure fuel inlet.

When coil (4) is energised, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, with following fuel injection into the cylinder.

Injection end When coil (4) is de-energised, shutter (6) goes back to its closing position, in order to re-create such a force balance as to make plunger (2) go back to its closing position and end the injection.

NOTE The injector cannot be overhauled and therefore it must not be disassembled.

Print P2D32N019 E

Base - March 2012

16

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Pressure limiter for fuel return It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at a pressure 1.3 and 2 bars. By guaranteeing this pressure to the return fuel, the fuel vapours formation inside injectors is avoided, optimising fuel spraying and combustion.

Figure 19

70507

A

To tank — B From injectors

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

LUBRICATION 4-cylinder engine version Lubrication by forced circulation is achieved through oil rotary expansion pump, placed in the front part of the basement, driven by the straight-tooth gear splined to the shaft’s bar hold.

17

Lubrication involves the heat exchanger as well, the turboblower and the eventual compressor for any eventual compressed air system.

All these components may often vary according to the specific duty and will therefore be examined in the specific section.

From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.

Figure 20

(Demonstration)

Oil recover from the turbo-blower

To the exchanger and to the turbo-blower

Routing of oil under pressure

108511

Routing of oil return by gravity to sump Introduction of oil

LUBRICATION SYSTEM LAYOUT 4-cylinder engines Print P2D32N019 E

Base - March 2012

18

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

6-cylinder engine version Even for the 6 cylinders version lubrication is obtained by forced circulation and achieved through an oil rotary expansion pump similar to the 4 cylinders’ one.

Figure 21

Also in this case, the components such as the oil exchanger, the turbo-blower and the eventual compressor are specifically studied and made out to suit the equipment or the duty for which the engine has been developed.

(Demonstration)

Oil recover from the turbo-blower To the exchanger and to the turbo-blower

Routing of oil under pressure 108512

Routing of oil return by gravity to sump Introduction of oil

LUBRICATION SYSTEM LAYOUT 6-cylinder engines Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

Oil pump

SECTION 2 - OPERATIONAL DIAGRAMS

19

Figure 22

NOTE Since the oil pump cannot be overhauled. It shall be replaced when damaged.

70576

Heat exchanger Figure 23 (D)(*)

166064

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 1. Heat exchanger body with filter bracket and oil filter - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.

Print P2D32N019 E

Base - March 2012

20

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Clean accurately the heat exchanger components Always replace the sealing gaskets.

Figure 24 (**)

166065

(**)F4HFE6132/39/3A/3C*A002-3/3L*A001-2 1. Heat exchanger body with oil filter - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

21

Oil pressure relief valve Figure 25

Loosen the plug (1), withdraw the spring (2) and the relief valve (3) from the support (4).

Check whether the valve (3) is not scored and is sliding smoothly into its seat. The spring (2) shall not be broken or yielded.

Pressure regulation at 100 °C oil temperature: - 1.2 bar min pressure; - 3.8 bar max. pressure Figure 26

107418

By-pass valve (5) to cut out clogged oil filter.

Figure 27

Flow

70482 107419

MAIN DATA TO CHECK OIL PRESSURE RELIEF VALVE SPRING Print P2D32N019 E

Max blow-by: 20 cm3/1’ at 0.83 bar pressure and at 26.7 °C oil temperature.

Base - March 2012

22

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

OIL VAPOUR RECYCLING Figure 28

70484

Oil condensate Oil vapours 1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine.

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and condenses a part of vapours at the same time.

Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).

In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again through pipe (2).

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

23

The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:

- Viscous pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development.

- Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment.

- Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment.

- Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.

- Centrifugal water pump, placed in the front part of the engine block.

COOLING SYSTEM 4-cylinder engine version

Figure 29

- Thermostat regulating the circulation of the cooling liquid.

- The circuit may eventually be extended to the compressor, if this is included in the equipment.

(Demonstration) Expansion tank

Expansion tank

Heater (optional)

Radiator

Radiator

Water coming out from thermostat Water recirculating in engine Water coming into pump 74194

COOLING SYSTEM LAYOUT 4-cylinder engines Print P2D32N019 E

Base - March 2012

24

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

6-cylinder engine version The engine cooling system, closed circuit forced circulation type, is of a similar design as the 4 cylinders engine.

It incorporates necessary components such as the radiator, the heat exchanger, the expansion tank and some ancillary components such as the heater or the compressor for the compressed air.

Such components always vary according to the engine’s equipment and duty.

Figure 30

(Demonstration) Expansion tank

Expansion tank

Heater (optional)

Radiator

Radiator

Water coming out from thermostat Water recirculating in engine Water coming into pump 166066

COOLING SYSTEM LAYOUT 6-cylinder engines Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

25

The water pump is located in a hollow obtained in the cylinder block and is driven by and a poly-V belt.

Water Pump Figure 31

An automatic tensioner keeps the belt tension.

Thermostat Figure 32

79458

Sec. A-A

Print P2D32N019 E

70486

The bypass thermostat (1) is housed in the cylinder head and needs no adjustment.

Whenever there are doubts as to its condition, replace it.

The thermometric switch/transmitter and coolant temperature sensor are mounted on the thermostat body.

A = travel start at 77 ÷ 81 °C; B = travel at 95 °C ≥ 7.5 mm

Base - March 2012

26

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

TURBOCHARGER Description The turbocharging system is composed of: air filter, turbocharger and intercooler.

The air cleaner is a dry type composed of a filtering cartridge that is periodically changeable.

The function of the turbocharger is to use the energy of the engine’s exhaust gas to deliver pressurized air to the cylinders.

The intercooler is composed of a radiator applied to the engine coolant radiator, with the function of lowering the turbocharger output air temperature before it is sent to the cylinders.

Figure 33

4-cylinder engine version

TURBOCHARGER

AIR FILTRE

EXHAUST

INTERCOOLER

6-cylinder engine version

TURBOCHARGER

AIR FILTRE

EXHAUST

INTERCOOLER 74195

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

Turbocharger Figure 34

27

Figure 36 (**)

(D)

intake air compressed air exhaust

166697

(D) F4HFE413A/3D/3L/3M GARRETT TURBOCHARGER

intake air compressed air exhaust

166068

(**) F4HFE6135/36/3C*A004/3L*A003

Figure 35 (*)

WLO HOLSET HX35 TURBOCHARGER Figure 37 (***)

intake air compressed air exhaust

166067

(*) F4HFE6133/34/3H CCM HOLSET HX35W TURBOCHARGER

intake air compressed air exhaust

166069

(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 CEX HOLSET HX35 TURBOCHARGER

The turbocharger is composed of the following main parts: - a central body in which a shaft is housed, supported by bushings, the ends of which are connected to: the turbine rotor and the compressor rotor; - a turbine casing and a compressor casing mounted on the end of the central body; - a boost-pressure regulation valve (when present) fitted on the turbine casing.

During engine operation, the exhaust gases pass through the turbine body spinning the turbine rotor.

The compressor rotor is connected by a shaft to the turbine rotor, which it spins and in doing so compresses the air taken in through the air filter.

The air is then cooled by the intercooler and sent to the cylinders via the intake manifold.

The engine oil is used to cool and lubricate the turbocharger and the bearings.

On F4HFE413A/3D/3L/3M and F4HFE6133/34/3H engines, the turbocharger is fitted with a pressure regulation valve, mounted on the exhaust manifold before the turbine and controlled by a pneumatic actuator, connected via a pipe to the intake manifold.

Its job is to limit the quantity of exhaust gas acting on the turbine by sending part of it directly into the exhaust pipe when the boost pressure downstream of the compressor reaches the maximum value set.

Print P2D32N019 E

Base - March 2012

28

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

NOTE Verifying an anomalous operation of the engine, due to the booster system, it is recommended, before performing controls on the turbosupercharger, to check the efficiency of the sealing gaskets and the fixing of the connection sleeves, making sure of clogging absence inside intake sleeves, air cleaner or inside radiators. If the turbosupercharger damage is due to a lack of lubrication, check that the oil circulation pipes are not broken or obstructed, in such case replace them or eliminate the trouble.

Bearing end play check Position the tracer point of the magnetic-base dial gauge on the turbocharger shaft end and set to zero the dial gauge.

Move the turbocharger shaft axially and check that the clearance is not higher than the prescribed value.

Apply the magnetic-base dial gauge (2) on the exhaust gas inlet flange in the turbine.

Position the tracer point of the gauge (2) on the tie rod (3) end and set to zero the gauge (2).

Through the pump (1) let in compressed air, in the actuator (6), at the prescribed pressure and make sure that such value is kept constant for the whole check time, otherwise replace the actuator (6).

In the above-mentioned conditions, the tie rod must have carried out the prescribe stroke.

NOTE During the operation, beat slightly the actuator (6) in order to eliminate possible sticking of the actuator internal spring.

If a different value is found, loosen the nut (5) and operate properly the knurled ring nut (4).

Replace the turbocharger if a different value is found.

Waste gate (only for F4HFE413A/3D/3L/3M F4HFE6133/34/3H engines)

Actuator replacement Figure 39

Check and adjustment Figure 38

5

4

3

2

1 166070

Remove the elastic clip (4) and withdraw the tie rod (3) from the lever (5).

62873

Cover the air, exhaust gas and lubrication oil inlets and outlets.

Carry out an accurate external cleaning of the turbosupercharger, using the anticorrosive and antioxidant solution and perform the check on the actuator (6).

Remove the nuts (2) and remove the actuator (1) from the supporting bracket. Fit the new actuator following the removal operations in reverse order and fitting a new clip (4), tighten the nuts (2) to 5.6 — 6.8 Nm torque.

Check and adjust the actuator (1), if required, as described in the relevant chapter.

Clamp the turbosupercharger in a vice.

Then, paint the nut (6) with safety paint.

Disconnect the pipe of the actuator (6) and apply to the actuator union, the pipe of pump 99367121 (1).

Before refitting the turbocharger on engine, fill the central body with engine oil.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

29

DeNOx 2 SYSTEM General Information To limit the nitrogen oxide exhaust gas values (NOx) within the limits required by Tier 4i, with low fuel consumption, the vehicles have been equipped with a post-treatment system for these substances contained in the exhaust gas, which is essentially an electronically controlled oxidative catalyst.

Using the Selective Catalytic Reduction (SCR) process, the system transforms the nitrogen oxide (NOx) into inert compounds: free nitrogen (N2) and water vapour (H2O).

The SCR process is based on a series of chemical reactions that, due to the reaction of ammonia with the oxygen in the exhaust gas, lead to the reduction of nitrogen oxides (NOx) contained in the exhaust gas.

The system essentially comprises: - a tank (5) of reagent solution (water - urea: Ad Blue) with a level indicator; - a pump module (1); - a mixing and injection module (6); - a catalytic converter; - two temperature sensors (9 and 10) at the exhaust gas inlet and outlet to the catalytic converter; - a humidity sensor fitted on the engine air intake pipe downstream of the air filter.

The SCR system is electronically managed by the DCU (Dosing Control Unit) incorporated in the pump module (1), which according to the number of engine revs, the torque delivered, the exhaust temperature, the amount of nitrogen oxides and humidity in the incoming air, adjusts the flow rate of the Ad Blue solution to be put into the system.

The pump module (1) picks up the reagent solution from the tank (5) and sends it under pressure to the mixing and injection module (6) to be injected into the exhaust pipe upstream of the catalytic converter.

The first phase of the process takes part in the first part of the catalytic converter: due to the effect of the exhaust gas temperature, the reagent solution evaporates instantly and, by hydrolysis, converts into ammonia (2NH3) and carbon dioxide (CO2).

Evaporation of the solution causes lowering of the exhaust gas temperature, bringing it closer to the optimum temperature required by the process.

The exhaust fumes, additioned with ammonia and at the reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gasses the ammonia is converted into free nitrogen (N2) and water vapour (H2O).

Print P2D32N019 E

Base - March 2012

30

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Figure 40

148514

1. Pump module - 2. Tank level sensor - 3. Tank temperature sensor - 4. Ad Blue tank - 5. Prefilter - 6. Return flow valve 7. Dosing module - 8. MV2 - 9. Exhaust gas temperature sensor - 10. Catalyst - 11. Exhaust gas temperature sensor 12. NOx detection sensor - 13. Ad Blue pressure sensor - 14. Filter - 15. Diaphgram pump - 16. Reverting valve 17. Ad Blue temperature sensor

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

31

Pump module

Tank Figure 41

Figure 43

108508

The tank with the level indicator command (1) contains the reducing substance necessary for the SCR process, comprising a solution of 35% urea and water, known as Ad Blue.

148510

1. DCU control unit connector - 2. Pressure compensattion - 3. Ad Blue solution infeed - 4. Prefilter - 5. Ad Blue solution outlet - 6. Ad Blue return pipe from dosing module - 7. Ad Blue l tank return - 8. Filter

Dosing module Figure 44

Ad Blue fluid level gauge control Figure 42

108129

1. Ad Blue infeed - 2. Electrical connection 3. Ad Blue outlet Has the job of dosing the Ad Blue solution to be sent into the exhaust pipe upstream of the catalytic converter.

SCR pipes 116181

1. Ad Blue fluid intake pipe - 2. Ad Blue fluid return pipe 3. Inlet pipe for hot engine coolant fluid - 4. NTC sensor 5. Outlet pipe for hot engine coolant fluid - 6. Float 7. AdBlue liquid heating coil (only versions equipped with 08277 optional) - 8. AdBlue breather

Print P2D32N019 E

NOTE The SCR pipe harnesses complete with the VOSS are only available for production.

In case of repair operations, for the replacement of each component (cooling water pipes, AdBlue pipes, fittings, corrugated pipes, sectioning plates, etc.) refer to the supplied spare accessories.

Base - March 2012

32

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Exhaust gas temperature sensor Figure 45

102303

Figure 46

102304

FUNCTIONAL WIRING DIAGRAM 1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Earth cable (white) - 6. Sensor.

The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to calculate the amount of urea to be injected into the system.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

33

Humidity detecting sensor Figure 47

102311

1. Temperature - 2. Earth - 3. Humidity percent value - 4. Power supply.

This sensor is located on the air filter output conveyor, and is used to inform the control unit of the amount (percentage) of humidity found in sucked air, to determine the calculation of nitric oxide emissions.

Figure 48

102312

ELECTRIC BLOCK DIAGRAM 1. Earth - 2. Temperature - 3. Power supply unit - 4. Humidity percent value - A. Sample frequency generator B. Reference oscillator - C. NTC temperature sensor - D. Amplifier lowpass filter

Print P2D32N019 E

Base - March 2012

34

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Nitric oxide sensor Figure 49

102302

1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare This sensor has the function to communicate the dosing of AdBlue liquid (Urea) and the catalyst conditions to the control unit.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

35

Pin out DCU 15 D2-2 Figure 50

UDS DCU15

113576

Pin No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Print P2D32N019 E

Abbrev

Name

V_V_BAT+R V_V_BAT+R V_V_BAT+ V_V_BAT+ B_D_CANH1 B_D_CANL1 B_D_CANH2 B_D_CANL1 dnc O_S_CLH O_S_RAMV O_V_RAMV dnc G_G_BATG_G_BATdnc G_R_CATTSPRE I_A_RALS G_R_RALS

Battery + via main relay (output) Battery + via main relay (output) Battery plus Battery plus Controller Area Network 1 (high) Controller Area Network 1 (low) Controller Area Network 2 (high) Controller Area Network 2 (low) do not connect Compensation line heating Reduction agent metering valve Reduction agent metering valve supply (BAT+ ) do not connect Battery minus Battery minus do not connect Catalyst temperature sensor ground (upstream) Reduction agent level sensor signal Reduction agent level sensor ground/Reduction agent tank temperature sensor ground

Base - March 2012

36

SECTION 2 - OPERATIONAL DIAGRAMS

Pin No 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Base - March 2012

Abbrev

Name

dnc O_S_SVS O_S_HH1 O_S_RATH I_S_T15 G_R_CATTSPOST I_A_CATTSPOST dnc I_A_CATTSPRE I_A_TRATS V_V_5VRALS B_D_ISOK O_S_HH3 dnc O_S_HH4 O_S_HH2

do not connect Service soon available Hose heating 1 (Suction line heating) Reduction agent tank heating Terminal 15 (switched BAT+) Post-catalyst temperature sensor ground (downstream) Post-catalyst temperature sensor signal (downstream) do not connect Catalyst temperature sensor signal (upstream) Reduction agent tank temperature sensor signal Reduction agent level sensor supply ISO-K interface Hose heating 3 (Pressure line heating) do not connect Hose heating 4 (Back flow to supply module line heating) Hose heating 2 (Back flow to tank line heating)

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

SECTION 2 - OPERATIONAL DIAGRAMS

37

Figure 51

148515

Print P2D32N019 E

Base - March 2012

38

SECTION 2 - OPERATIONAL DIAGRAMS

F4HFE ENGINES

Scheduled Maintenance DEF/AdBlue system test through PT-Box

Every 1800 hours or every 2 years

DEF/AdBlue circuit filters (dosing system DeNOx 2) FILTER

TYPE

POSITION

MAINTENANCE

Tank mesh filter

-

DEF/AdBlue tank

Clean (if necessary).

Filter on the DEF/AdBlue feeder line 100 µm (Voss)

Between the tank and feeder Clean at every oil change. module

Feeder module prefilter

-

Feeder module

No maintenance to be carried out.

Feeder module filter (Bosch)

10 µm

Feeder module

Replacement before 3600 hours (or 2 years) of activity.

100 µm

Dosing module entry

No maintenance to be carried out.

100 µm

Dosing module exit

No maintenance to be carried out.

Dosing module prefilter

NOTE The data are only valid if the fitter observes all the installation regulations provided by FPT.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

1

SECTION 3 - ELECTRICAL EQUIPMENT

SECTION 3 Electrical equipment

Page

Print P2D32N019 E

LOCATION OF THE MAIN ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .

3

ENGINE CABLE . . . . . . . . . . . . . . . . . . . . . . . . .

4

- 4-cylinder engine version . . . . . . . . . . . . . . . . .

4

- 6-cylinder engine version . . . . . . . . . . . . . . . . .

5

ECU ELECTRONIC CONTROL UNIT (EDC7UC31) . . . . . . . . . . . . . . . . . . . . . . . . .

6

- Electroinjectors connector (A) . . . . . . . . . . . .

7

- Sensors connector (C) . . . . . . . . . . . . . . . . . .

8

FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS

9

- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . .

9

- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . .

9

- Supercharging air pressure - temperature sensor

10

- Engine oil temperature-pressure sensor . . . . .

10

- Fuel temperature and pressure sensor . . . . . .

11

- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . .

12

- Pre-post heating resistance and contactor (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

- Coolant temperature sensor . . . . . . . . . . . . . .

14

- Fuel temperature sensor . . . . . . . . . . . . . . . . .

15

- High pressure pump - fuel flow rate regulator

16

Base - March 2012

2

SECTION 3 - ELECTRICAL EQUIPMENT

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

3

LOCATION OF THE MAIN ELECTRICAL COMPONENTS Figure 1

(Demonstration)

108641

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

The electrical and electronic components of the engine are listed here following:

Through the engine control module it is possible to verify the correct working of the engine. (See SECTION 5 Diagnostics).

3. RAIL pressure sensor.

1. Coolant temperature sensor.

2. Electro-injector.

4. Air temperature/pressure sensor.

5. Starter motor.

6. Timing sensor.

7. Fuel flow rate regulator solenoid valve.

8. Fuel temperature sensor.

9. EDC electronic control unit.

10. Crankshaft sensor.

11. Engine oil pressure/temperature sensor.

12. Heating element for pre-post heating.

Print P2D32N019 E

Base - March 2012

4

SECTION 3 - ELECTRICAL EQUIPMENT

F4HFE ENGINES

ENGINE CABLE 4-cylinder engine version All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary version, in other words at the approval stage.

Figure 2

166698

1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 4. Engine rpm sensor 5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor 8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor 11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

5

6-cylinder engine version All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary version, in other words at the approval stage.

Figure 3

0051064t

1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor 5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor 8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor 11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).

Print P2D32N019 E

Base - March 2012

6

SECTION 3 - ELECTRICAL EQUIPMENT

F4HFE ENGINES

ECU ELECTRONIC CONTROL UNIT (EDC7UC31) Figure 4

102373

A. Injector connector - B. Frame connector (refer to the vehicle which the engine is fitted to) C. Sensor connector

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

7

SECTION 3 - ELECTRICAL EQUIPMENT

Electroinjectors connector (A) Figure 5

12

16

11

6

50350

Colour legend C ORANGE A LIGHT BLUE B WHITE L BLUE G YELLOW H GREY M BROWN N BLACK W LIGHT BROWN S PINK R RED V GREEN Z PURPLE Pin Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1

4-cylinder engines Cable colour HN HR MB HV V C BL HG MN MV

Description Cylinder 3 injector Cylinder 2 injector Cylinder 1 injector Cylinder 4 injector Fuel flow rate regulator Fuel flow rate regulator Cylinder 4 injector Cylinder 1 injector Cylinder 2 injector Cylinder 3 injector

5

6-cylinder engines Cable colour Description LR (*) - CL (**) Cylinder 5 injector BC Cylinder 6 injector BL (*) - CN (**) Cylinder 4 injector MB Cylinder 1 injector MV Cylinder 3 injector HR Cylinder 2 injector V Fuel flow rate regulator C Fuel flow rate regulator MN Cylinder 2 injector HN Cylinder 3 injector HG Cylinder 1 injector HV (*) - VB (**) Cylinder 4 injector VN Cylinder 6 injector RG (*) - VG (**) Cylinder 5 injector

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 (**)F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Print P2D32N019 E

Base - March 2012

8

SECTION 3 - ELECTRICAL EQUIPMENT

F4HFE ENGINES

Sensor connector (C) Figure 6

6

8

16

9

15

22

1

3

23 30

36

29

Colour legend C A B L G H M N W S R V Z

ORANGE LIGHT BLUE WHITE BLUE YELLOW GREY BROWN BLACK LIGHT BROWN PINK RED GREEN PURPLE

Description

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

4 5

Signal from sensor of engine revolution counter on timing (phase sensor) Ground of sensor of engine revolution counter on timing (phase sensor) Fuel pressure sensor ground Fuel pressure sensor power supply Fuel pressure sensor signal Water temperature sensor signal Fuel temperature sensor ground Engine revolution counter sensor ground Signal from engine revolution counter sensor Oil pressure / temperature sensor ground Air pressure / Temperature ground Water temperature sensor ground Oil pressure sensor signal Oil temperature sensor signal Oil pressure / temperature sensor supply Air pressure / Temperature sensor supply Air pressure sensor signal Fuel temperature sensor signal Air temperature sensor signal

Base - March 2012

50350

Cable colour code B R BN HN RV CV CN B R GV GN BG GR NS MN CL LN BL BR Print P2D32N019 E

F4HFE ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

9

FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS Crankshaft sensor This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft.

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

Figure 7

50319

Crankshaft sensor

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

Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.

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

Figure 8

50320

Timing sensor Figure 9 3

2

1

50342

50288

Connector Ref. 1 2 3

Print P2D32N019 E

Wiring diagram Description

Ground Signal Shield

ECU pin Camshaft sensor 19C 23C

Timing sensor 10C 9C

Base - March 2012

10

SECTION 3 - ELECTRICAL EQUIPMENT

F4HFE ENGINES

Supercharging air pressure - temperature sensor This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle.

The sensor is connected to the control unit on pins 25C - 36C - 33C - 34C. The power supply is 5 Volt Voltage at the sensor output is proportional to the detected pressure or temperature.

Pin 36C Pin 34C

Temperature signal Pressure signal

Engine oil temperature-pressure sensor This component is analogous to the air temperature-pressure sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position.

This sensor measures the engine oil temperature and pressure.

The sensor is connected to the control unit on pins 24C - 28C - 32C - 27C. The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light).

The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

Pin 28C Pin 27C

Temperature signal Pressure signal

Figure 10

50324

50344

Wiring diagram

Ref. 1 2 3 4

Base - March 2012

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

ECU Pin Oil 24C 28C 32C 27C

Air 25C 36C 33C 34C

Print P2D32N019 E

F4HFE ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

11

Fuel temperature and pressure sensor Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback).

The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command.

This sensor is connected to the control unit on pins 12C - 14C- 13C. The power supply is 5 Volt.

Figure 11

0051065t

Fuel pressure sensor connector

Ref. 1 2 3

Print P2D32N019 E

Description Ground Signal Power supply

ECU pin 12C 14C 13C

Base - March 2012

12

SECTION 3 - ELECTRICAL EQUIPMENT

F4HFE ENGINES

Electro-injectors The electro-injectors are effectively N.O. solenoid valves.

Each injector is connected to the EDC control unit on connector A. The impedance of the coil of each injector is 0.56 - 0.57 Ω.

4-cylinder engine version Ref. CONNECTOR 1

CONNECTOR 2

1 2 3 4 1 2 3 4

Description

ECU pin 15 A 2A 13 A 4A 5A 12 A 1A 16 A

Description

ECU pin 11 A 6A 13 A 4A 14 A 3A 12 A 5A 15 A 2A 1A 16 A

Cylinder 2 injector Cylinder 2 injector Cylinder 1 injector Cylinder 1 injector Cylinder 4 injector Cylinder 4 injector Cylinder 3 injector Cylinder 3 injector

6-cylinder engine version Ref. CONNECTOR 1

CONNECTOR 2

CONNECTOR 3

1 2 3 4 1 2 3 4 1 2 3 4

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

Figure 12

50343

Figure 13

50349

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

13

SECTION 3 - ELECTRICAL EQUIPMENT

Pre-post heating resistance and contactor (if present) The pre-post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor.

The resistance impedance is approximately 0.5 Ω.

Figure 14 B

A

108909

A. - B. Connection terminals

Figure 15

002371t

A. Control contactor

The control contactor is connected to the control unit B connector.

The contactor is tripped with water and/or fuel temperature below 5 °C. The contactor impedance is approximately 15 Ω.

Do not use flammable gases or liquids to provoke the engine ignition.

These substances in contact with the resistance could easily become inflamed creating situations of serious danger.

Print P2D32N019 E

Base - March 2012

14

SECTION 3 - ELECTRICAL EQUIPMENT

F4HFE ENGINES

Coolant temperature sensor This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine.

The same signal is utilized by the control unit to drive an instrument panel gauge, if present.

This sensor is connected to the control unit on pins 15C - 26C. The impedance of the coolant temperature sensor at 20 °C is approximately 2.50 Ω.

Figure 16

107471

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 3 - ELECTRICAL EQUIPMENT

15

Fuel temperature sensor This sensor is identical to the coolant temperature sensor.

This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel.

The fuel temperature sensor is connected to the control unit on pins 35C -18C. The sensor impedance at 20 °C is approximately 2.50 Ω.

Figure 17 (D)(*)

Figure 18 (**)

166060

166092

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 (**)F4HFE6132/39/3A/3C*A002-3/3L*A001-2 1. Fuel temperature sensor - 2. Filter heating resistance.

The ECU drives the filter heater contactor at fuel temperature ≤ 5 °C. Figure 19

107799

107798

Connector

Ref. 1 2

Print P2D32N019 E

Description Ground Temperature signal

ECU Pin Coolant 26C 15C

Fuel 18C 35C

Base - March 2012

16

SECTION 3 - ELECTRICAL EQUIPMENT

F4HFE ENGINES

High pressure pump - fuel flow rate regulator Pump with 3 radial pistons controlled by the timing gears, requiring no phase adjustment, with rotor type feed pump fitted to the back.

Figure 20

166091

1. Fuel flow rate regulator.

The flow rate regulator is located at the inlet of the high-pressure pump on the low-pressure circuit; its function is to modulate the quantity of fuel to feed to the high-pressure pump on the basis of commands received from the electronic control unit.

It basically consists of the following parts: - trapezoidal section shutter; - valve control pin; - pre-charging spring; - coils.

In the absence of the control signal, the flow rate regulator is normally open, and hence the high pressure pump is in its maximum delivery conditions.

The control unit modulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying the fuel to the high pressure pump.

This component cannot be replaced individually and hence it cannot be taken down.

The quantity of fuel supplied to the high pressure pump is metered by the flow rate regulator on the low pressure system; the flow rate regulator is managed by the EDC7 control unit.

Delivery pressure to the rail is modulated between 250 and 1600 bar by the electronic control unit by controlling the flow rate regulator solenoid valve.

- This component is a N.O. solenoid valve.

- The solenoid is connected to the control unit on pins 9A - 10A. - The solenoid valve impedance is approximately 3.2 Ω.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 4 - SCHEDULED MAINTENANCE

1

SECTION 4 Scheduled maintenance

Page

Print P2D32N019 E

SCHEDULED MAINTENANCE . . . . . . . . . . . . .

3

- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Regular maintenance and inspection planning .

3

- Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . .

4

MAINTENANCE PROCEDURES . . . . . . . . . . . .

4

- Checks and inspections . . . . . . . . . . . . . . . . . .

4

Base - March 2012

2

SECTION 4 - SCHEDULED MAINTENANCE

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

SECTION 4 - SCHEDULED MAINTENANCE

3

SCHEDULED MAINTENANCE Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates.

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

It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run.

In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure, immediately intervene in order to find the causes.

We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident prevention standards for the safety of maintenance personnel in charge.

Regular maintenance and inspection planning

Checks and periodical inspections (*) Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . .

Inspection presence of water in fuel filter or pre-filter Checking tappet clearance EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the engine oil and oil filter . . . . . . . . . . . . .

Fuel pre-filter replacement . . . . . . . . . . . . . . . . . . . .

Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . .

Replacement of blow by filter . . . . . . . . . . . . . . . . . .

Changing the alternator belt . . . . . . . . . . . . . . . . . . .

Frequency (hours) ..................... ...................... . . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . .

Daily Daily 2400 When anomaly occurs 500 500 500 1500 1000

(*) For maintenance operations concerning the DEF/AdBlue circuit filters (dosing system DeNOx 2) please consult the relevant chapter under Section 2.

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

The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

Print P2D32N019 E

Base - March 2012

4

SECTION 4 - SCHEDULED MAINTENANCE

F4HFE ENGINES

Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.

- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.

- Notify the maintenance if any inconvenience is detected of if any filling is necessary.

After engine start and while engine is running, proceed with the following checks and controls: - check presence of any eventual leakage from the fuel, cooling and lubricating circuits.

- Verify absence of noise or unusual rattle during engine working.

- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.

- Visual check of fumes (colour of exhaust emissions) - Visual check of cooling liquid level, in the expansion tank.

MAINTENANCE PROCEDURES Checks and inspections Engine oil level check The check must be executed when the engine is disconnected and possibly cool.

Figure 1

The check can be made using the specially provided flexible rod.

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

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

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

Always ensure the oil added has the same characteristics of the oil contained in the sump.

Mixing is not allowed as this would not guarantee correct lubrication of the internal parts of the engine.

166058

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

The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water and detergent.

Adequately protect the skin and the eyes, operate in full compliance with safety regulations.

Disposal must be carried out properly, and in full compliance with the law and regulations in force.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

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

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

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

Due to the high pressure within the pipelines running from the high-pressure pump to the rail diffuser and from this last one to the electro-injectors, special attention must be aid also in checking presence of any leakage or blow-by.

Protect the eyes and the skin from any eventual high pressure jet: these may deeply penetrate under the skin surface provoking serious poisoning.

SECTION 4 - SCHEDULED MAINTENANCE

5

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

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

The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water and detergent.

Adequately protect the skin and the eyes, operate in full compliance with safety regulations.

Disposal must be carried out properly, and in full compliance with the law and regulations in force.

Inspection of water presence within fuel filter or pre-filter

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

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

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

Due to the high temperatures achieved by the system, do not operate immediately after the engine’s disconnection, but wait for the time deemed necessary for the cooling.

Protect the eyes and the skin from any eventual high pressure jet of cooling liquid.

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

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

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

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

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

Check of belt’s tear and wear status Carefully verify the belt’s surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing; check end and surface grinding.

Danger: if the engine is switched off but is still hot, unexpected motion of the belt may occur.

Wait for engine temperature cooling as a precaution in order to avoid serious danger injury.

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

Print P2D32N019 E

Base - March 2012

6

SECTION 4 - SCHEDULED MAINTENANCE

F4HFE ENGINES

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

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

Figure 2

NOTE In order to perform the rocker arm - valve clearance adjustment more quickly, proceed as follows: 4-cylinder engines - Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked by the asterisk as shown in the tables below:

cylinder no. intake exhaust

1 -

2 *

3 * -

4 *

- Rotate the crankshaft, balance the valves of cylinder no. 4 and adjust the valves marked by the asterisk as shown in the tables below:

1

2 74188

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

cylinder no. intake exhaust

1 * *

2 * -

3 *

4 -

6-cylinder engines - Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked by the asterisk as shown in the tables below:

cylinder no. intake exhaust

1 -

2 *

3 * -

4 *

5 * -

6 * *

- Rotate the crankshaft, balance the valves of cylinder no. 6 and adjust the valves marked by the asterisk as shown in the tables below: cylinder no. intake exhaust

Inspection tappet clearance Figure 3

1 * *

2 * -

3 *

4 * -

5 *

6 -

166059

Check the clearance between the rocker arms and valves using a feeler gauge (1).

Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

Oil motor and oil filter replacement

Warning: We recommend to wear proper protections because of high motor service temperature.

The motor oil reaches very high temperature: you must always wear protection gloves.

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

SECTION 4 - SCHEDULED MAINTENANCE

7

Whereas you replace the lubrication oil, it is necessary to replace the filter.

According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

- The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the 9936076-tool.

Warning: the oil filter contains inside a quantity of oil of about 1 kg.

Place properly a container for the liquid.

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

Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water.

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

The motor oil is very pollutant: it must be disposed of according to the rules.

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

The oil motor is very pollutant and harmful.

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

In case of contact with the skin, wash with much water and detergent.

- Tighten further using tool 99360076 to a torque of 20 ± 2 Nm.

Protect properly skin and eyes: operate according to safety rules.

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

Dispose of the residual properly following the rules.

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

!

Use only the recommended oil or oil having the requested features for the corrrect motor functioning.

In case of topping up, don’t mix oils having different features.

If you don’t comply with theses rules, the service warranty is no more valid.

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

Print P2D32N019 E

Base - March 2012

8

SECTION 4 - SCHEDULED MAINTENANCE

Fuel filter replacement

F4HFE ENGINES

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

During this operation don’t smoke and don’t use free flames.

Avoid to breathe the vapors coming from filter.

Warning: with switched off motor (but still hot) the belt can operate without advance notice.

According to the applications the filters position and the quantity can change.

Wait for the motor temperature lowering to avoid very serious accidents.

However the following operations are valid for all applications.

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

- Unscrew the cartridge by using the 99360076-tool.

- Collect the eventual fuel inside the filtering cartridge.

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

For applications with automatic belt stretcher, the procedure is the following: Figure 4

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

- Tigthen through the 99360076-tool at 20 ± 2 Nm torque.

108545

- Operate on the tightener (1) and withdraw the belt (2) from the alternator and water pumps from pulleys and from the returns pumps.

- Replace the worn belt with a new one.

- Place the belt on the pulleys and the guide rollers.

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

- Further adjustments are not required.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

1

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

SECTION 6 Removal and installation of main components Page

Print P2D32N019 E

REMOVAL AND INSTALLATION AUXILIARY DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

ALTERNATOR REMOVAL AND INSTALLATION

3

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

COOLANT PUMP REMOVAL AND INSTALLATION

4

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

THERMOSTAT REMOVAL AND INSTALLATION

5

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

REMOVAL AND INSTALLATION STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

ENGINE CABLE REMOVAL AND INSTALLATION

6

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

REMOVAL AND INSTALLATION LOW-PRESSURE FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . .

7

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Base - March 2012

2

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

F4HFE ENGINES

Page

Page REMOVAL AND INSTALLATION FUEL HOSE FROM HIGH PRESSURE PUMP TO COMMON RAIL 8 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

INJECTOR REMOVAL AND INSTALLATION . .

17

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

TURBOCHARGER REMOVAL AND INSTALLATION 19 ENGINE CONTROL UNIT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .

9

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

EXHAUST MANIFOLD REMOVALINSTALLATION . . . . . . . . . . . . . . . . . . . . . . .

20

FUEL FILTER REMOVAL AND REFITTING . . . . .

9

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

9

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

9

FUEL FILTER REMOVAL AND REFITTING . . . . .

9

INTAKE MANIFOLD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .

21

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

REMOVAL AND INSTALLATION COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

COLD START AIR HEATER REMOVAL AND INSTALLATION (only for F4HFE6132/39/3A/ 3C*A002-3/3L*A001-2 ENGINES) . . . . . . . . .

22

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

OIL VAPOUR RECIRCULATION (BLOW-BY) SYSTEM REMOVAL AND INSTALLATION . .

12

CYLINDER HEAD REMOVAL AND INSTALLATION 22

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

TAPPET COVER REMOVAL AND INSTALLATION

13

ENGINE OIL FILTER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .

24

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

INJECTOR WIRING SUPPORT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .

14

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

REMOVAL AND INSTALLATION ENGINE OIL HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . .

25 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

REMOVAL AND INSTALLATION ROCKER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

OIL SUMP REMOVAL AND INSTALLATION . .

26

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

3

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

REMOVAL AND INSTALLATION AUXILIARY DRIVE BELT Removal

ALTERNATOR REMOVAL AND INSTALLATION Removal Disconnect the electrical connections of the alternator.

Figure 1

Remove the auxiliary components drive belt as described in the relative procedure.

Figure 2

108545

Operate on the belt tensioner (1) and extract the belt (2) from the alternator pulleys, the coolant pump and the return pumps.

166099

Undo the screws (1) and disconnect the alternator (2).

Installation Turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers.

Installation Place the alternator (2) in position, fasten the screws (1) and tighten them to the specified torque.

Install the auxiliary components drive belt as described in the relative procedure.

Connect the alternator electrical connections.

Print P2D32N019 E

Base - March 2012

4

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

COOLANT PUMP REMOVAL AND INSTALLATION Removal

F4HFE ENGINES

Figure 5

Position a suitable container to catch any coolant.

Remove the auxiliary components drive belt as described in the relative procedure.

Figure 3

166100

Place the coolant pump (2) in position, fasten the screws (1) and tighten them to the specified torque.

Install the auxiliary components drive belt as described in the relative procedure.

166100

Undo the screws (1) and remove the water pump (2).

Installation Figure 4

70221

Apply a new seal ring (2) to the coolant pump (1).

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

THERMOSTAT REMOVAL AND INSTALLATION Removal

5

REMOVAL AND INSTALLATION STARTER MOTOR Removal Disconnect the starter motor electrical connections.

Figure 6 (D)

Figure 8

1

2 166699

(D)

4-cylinder engine

74166

Unscrew the flywheel cover fastening screws (1) and remove the starter motor (2).

Figure 7 (*)

Installation Position the starter motor (2) on the internal part of the flywheel cover (1).

Screw down the retaining screws and tighten them to the specified torque.

Connect the starter motor electrical connections.

166624

(*) 6-cylinder engine Unscrew the fastening screws (1) and remove the coolant outlet coupling (2).

Then remove the thermostat (3) with its gasket.

Installation Place the thermostat in position.

Place the coolant outlet coupling (1) in position with a new gasket, screw in the retaining screws and tighten them to the specified torque.

Print P2D32N019 E

Base - March 2012

6

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

F4HFE ENGINES

ENGINE CABLE REMOVAL AND INSTALLATION Removal Figure 9

107246

1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature sensor - 9. Timing phase sensor - 10. Air temperature and pressure sensor - 11. Electro-injector

Disconnect the engine cable from the connectors: (1) electro-injector wiring; (10) air pressure/temperature sensor; (3) fuel pressure sensor; (6) EDC7 control unit; (9) camshaft timing sensor; (7) fuel flow rate sensor; (8) fuel temperature sensor; (2) engine coolant temperature sensor on thermostat; (4) engine oil temperature and pressure sensor; (5) engine speed sensor.

Open the straps holding the engine cable to the engine block and remove it completely.

Installation Place the engine cable in position, close the retaining straps and connect the sensor, control unit and electro-injector connectors (refer to Figure 9).

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

REMOVAL AND INSTALLATION LOWPRESSURE FUEL LINES Removal

7

Figure 12 (**)

Figure 10 (D)

166626

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

173236

(D) F4HFE413A/3D/3L/3M

1. Hose from fuel pre-filter to heat exchanger on engine control unit - 2. Hose from heat exchanger on engine control unit to fuel pump - 3. Hose from fuel pump to fuel filter support - 4. Hose from fuel filter support to high pressure pump intake - 5. Fuel return Hose from common rail outlet and pressure limiter on cylinder head to filter support - 6. Fuel return hose from high pressure fuel pump outlet to filter support - 7. Fuel return hose from filter support to fuel tank

Figure 11 (*) Figure 13

116237

Position a suitable container to catch any fuel.

166625

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 1. Hose from fuel pre-filter to heat exchanger on engine control unit - 2. Hose from heat exchanger on engine control unit to fuel pump - 3. Hose from fuel pump to fuel filter support - 4. Hose from fuel filter support to high pressure pump intake - 5. Fuel return Hose from common rail outlet and pressure limiter on cylinder head to filter support - 6. Fuel return hose from high pressure fuel pump outlet to filter support - 7. Fuel return hose from filter support to fuel tank

To disconnect the low pressure fuel hose from the relevant connecting joint, you need to keep the clasp (1) pressed, and release the quick fitting joint (2).

Installation To connect the low pressure fuel hose to the connection fitting, insert the quick-fit coupling (2) in the connection fitting and push it in until the catch (3) engages.

NOTE Check proper fuel hose connection.

Print P2D32N019 E

Base - March 2012

8

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

REMOVAL AND INSTALLATION FUEL HOSE FROM HIGH PRESSURE PUMP TO COMMON RAIL Removal

F4HFE ENGINES

Figure 16 (**)

Position a suitable container to catch any fuel.

Figure 14 (D)

166633

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Unscrew the fuel hose (2) couplings (1) from the common rail and high pressure pump, open the fastening straps and remove it from the engine block.

Installation 173237

(D) F4HFE413A/3D/3L/3M

Position a new fuel supply hose (2) and tighten its couplings (1) to the high pressure pump and common rail to the specified torque.

NOTE The high pressure fuel hose must always be replaced with a new one whenever it is removed.

The hose couplings must be tightened to 20 Nm torque using spanner 99317915 and torque wrench 99389829.

Figure 15 (*)

166632

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

9

ENGINE CONTROL UNIT REMOVAL AND INSTALLATION Removal

FUEL FILTER REMOVAL AND INSTALLATION Removal

Disconnect the engine cable from the engine control unit electrical connections, as described in the relative section.

Position a suitable container to catch any fuel.

Position a suitable container to catch any fuel.

Figure 18 (D)

Disconnect the fuel hoses from the engine control unit heat exchanger, as described in the relative section.

Figure 17

1 173238

(D) F4HFE413A/3D/3L/3M Figure 19 (*)

2

74174

Remove the retaining screws (1) and disconnect the ECU (2) including the heat exchanger.

Installation Position the ECU, (2) including the heat exchanger, on the crankcase and tighten the screws (1) to the specified torque.

166627

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 20 (**)

NOTE Replacing the elastic support elements is recommended.

Connect the fuel hoses to the engine control unit heat exchanger, as described in the relative procedure.

Connect the engine cable to the engine control unit electrical connections, as described in the relative procedure.

166628

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Using tool 99360076, unscrew the fuel filter (1) from its support (2) and remove it.

Installation Fully screw the fuel filter onto the connection on its support by hand, then further tighten to a torque of 20±2 Nm.

Print P2D32N019 E

Base - March 2012

10

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

F4HFE ENGINES

INJECTION PUMP REMOVAL AND INSTALLATION Removal

REMOVAL AND INSTALLATION COMMON RAIL Removal

Position a suitable container to catch any fuel.

Position a suitable container to catch any fuel.

Disconnect the low pressure fuel hose from the mechanical fuel pump and the high-pressure pump as described in the relative procedure.

Disconnect the fuel pressure sensor connector as described in the procedure regarding the engine cable.

Remove the fuel hose from the high pressure pump to the common rail as described in the relative procedure.

Disconnect the low pressure fuel return hose from the common rail, as described in the relative procedure.

Remove the fuel hose from the high pressure pump to the common rail as described in the relative procedure.

Figure 21 Figure 22 (D)

166629

Remove the three retaining nuts (1) and remove the high pressure pump (2) complete with the fuel supply pump (3).

Installation Position the high pressure pump (2) complete with the fuel supply pump (3) and tighten the three retaining nuts (1) to the specified torque.

Install the fuel hose from the high pressure pump to the common rail as described in the relative procedure.

173239

(D) 4-cylinder engine

Figure 23 (*)

Connect the low pressure fuel hose to the mechanical fuel pump and the high-pressure pump as described in the relative procedure.

166634

(*) 6-cylinder engine Disconnect the high pressure hose couplings (1) from the common rail (2) and injector manifolds (3), then remove them.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

Figure 24 (D)

11

Figure 26 (D)

173240

173241

(D) 4-cylinder engine (D) 4-cylinder engine Figure 27 (*) Figure 25 (*)

166636

(*) 6-cylinder engine 166635

(*) 6-cylinder engine Remove the intake manifold retaining screws (1) and remove the common rail (2).

Installation Place the common rail (2) in position and tighten the screws (1) fastening it to the intake manifold to the prescribed torque.

Place the new high pressure fuel hoses (1) in position and tighten the couplings to the electro-injector collectors (3) and the common rail (2) to the specified torque.

NOTE The hoses (1), as they are subject to high pressure, must be replaced every time they are removed.

The hose couplings must be tightened to a torque of 24 ± 4 Nm, using spanner 99317915 (4) and torque wrench 99389829 (5).

Install the fuel hose from the high pressure pump to the common rail as described in the relative procedure.

Connect the low pressure fuel return hose to the common rail, as described in the relative procedure.

Connect the fuel pressure sensor connector as described in the procedure regarding the engine cable.

Print P2D32N019 E

Base - March 2012

12

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

OIL VAPOUR RECIRCULATION (BLOWBY) SYSTEM REMOVAL AND INSTALLATION Removal Figure 28

F4HFE ENGINES

Installation Place the blow-by filter (6) in position and tighten the fastening screws.

Place the pipe (5) in position with new copper washers in the tappet cover and timing case couplings (4). Then tighten the couplings (4) to the specified torque.

Place the blow-by pipe (3) into the coupling located on the timing case and secure it with the elastic strap (2).

Insert the upper coupling of the new blow-by pipe (5), with a new seal ring, into the tappet cover and tighten the screw (1).

166631

166631

Undo the screw (1). Loosen the elastic strap (2) and remove the blow-by pipe (3).

Unscrew the couplings (4) and remove the pipe (5).

Undo the screws and remove the blow-by filter (6).

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

TAPPET COVER REMOVAL AND INSTALLATION Removal

13

Figure 31

Figure 29

166630

Install the tappet cover (7) and tighten the nuts (6) to the specified torque.

166630

Undo the screw (1). Loosen the elastic strap (2) and remove the blow-by pipe (3).

Unscrew the couplings (4) and remove the pipe (5).

Remove the nuts (6) and take off the tappet cover (7) complete with seal.

Place the pipe (5) in position with new copper washers in the tappet cover and timing case couplings (4). Then tighten the couplings (4) to the specified torque.

Place the blow-by pipe (3) into the coupling located on the timing case and secure it with the elastic strap (2).

Insert the upper coupling of the new blow-by pipe (5), with a new seal ring, into the tappet cover and tighten the screw (1).

Installation Figure 30

74757

Fit a new gasket (2) on the tappet cover (1).

Print P2D32N019 E

Base - March 2012

14

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

INJECTOR WIRING SUPPORT REMOVAL AND INSTALLATION Removal

F4HFE ENGINES

Figure 34

Remove the tappet cover as described in the relative section.

Disconnect the engine cable from the injector wiring connections, as described in the relative section.

Figure 32

99227

Fit the wiring bracket (2) and tighten the screws (1) to the specified torque.

NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting.

166637

Remove the nuts (1) and disconnect the electrical cables from the injectors (2).

Figure 35

Take out the screws (3) and remove the injector wiring bracket (4) together with the gasket.

Installation Figure 33

99228

Connect the electrical cables (1) to the injectors (3) and use the torque wrench 99389834 (4) to tighten the retaining nuts (2) to the specified torque.

74756

Check the condition of the electrical cables (5), if they are damaged replace them by cutting the straps (2) securing them to the bracket and removing the screws (4) securing the connectors to this (3).

Connect the engine cable to the injector wiring connections, as described in the relative procedure.

Install the tappet cover as described in the relative section.

Fit a new gasket (1) on the bracket (2).

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

REMOVAL AND INSTALLATION ROCKER ARM ASSEMBLY Removal

15

Figure 38

Remove the tappet cover as described in the relative section.

Remove the injector wiring support as described in the relative section.

Figure 36

70343

ROCKER ARM ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rocker arms Figure 39

70132

Loosen the tappet adjuster retaining nuts (1) and unscrew the adjusters.

Unscrew the screws (2) and remove the rocker arm assembly (3), composed of: bracket (6), rocker arms (4), shafts (5).

Remove the bridges (7) from the valves and extract the rods (8).

Installation

70344

Figure 37

SHAFT-ROCKER MAIN DATA Check that shaft/rocker arm coupling surfaces are not excessively worn or damaged.

Figure 40

122587

The control rods of the rocker arms must have no deformations; the spherical seats for contact with the rocker arm adjustment screw and with the tappets (arrows) must show no trace of seizure or wear; if they do, replace them.

The intake and exhaust valve control rods are identical and are therefore interchangeable.

74765

Fit the rods (2).

Position the bridges (1) on the valves with the marks (→) facing the exhaust manifold.

Print P2D32N019 E

Base - March 2012

16

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

Figure 41

F4HFE ENGINES

NOTE In order to perform the rocker arm - valve clearance adjustment more quickly, proceed as follows: 4-cylinder engines - Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked by the asterisk as shown in the tables below:

cylinder no. intake exhaust

1 -

2 *

3 * -

4 *

- Rotate the crankshaft, balance the valves of cylinder no. 4 and adjust the valves marked by the asterisk as shown in the tables below: 70346

Check that tappet adjusters (1) are loosened to prevent their catching on the rods (2, Figure 40) when refitting the rocker arm assembly.

Then install the rocker assembly consisting of the bracket (5), rockers (3) and shafts (4), securing them to the cylinder head by tightening the retaining screws to 36 ± 5 Nm.

Figure 42

cylinder no. intake exhaust

1 * *

2 * -

3 *

4 -

6-cylinder engines - Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked by the asterisk as shown in the tables below:

cylinder no. intake exhaust

1 -

2 *

3 * -

4 *

5 * -

6 * *

- Rotate the crankshaft, balance the valves of cylinder no. 6 and adjust the valves marked by the asterisk as shown in the tables below: cylinder no. intake exhaust

1 * *

2 * -

3 *

4 * -

5 *

6 -

70520

Adjust the clearance between the rocker arms and valves using Allen key (1), box wrench (3) and feeler gauge (2).

The operating clearance is:

Install the injector wiring support as described in the relative section.

Install the tappet cover as described in the relative section.

- 0.25 ± 0.05 mm for the intake valves - exhaust valves 0.51 ± 0.05 mm.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

INJECTOR REMOVAL AND INSTALLATION Removal

17

Figure 45

Remove the tappet cover as described in the relative section.

Remove the injector wiring support as described in the relative section.

Remove the rocker arm assembly as described in the relative section.

Position a suitable container to catch any fuel.

Figure 43 70133

Remove the injector fastening screws and use tool 99342101 (1) to remove the injectors (2) from the cylinder head.

Installation Figure 46

166638

Disconnect the high pressure hose couplings (1) from the common rail (2) and injector manifolds (3), then remove them.

70338

Fit a new seal ring (2) lubricated with vaseline and a new washer (3) on the injector (1).

Figure 44

Figure 47

166630

Unscrew the nuts (1) and remove the fuel manifolds (2).

70339

Place the injectors (1) in position on the cylinder head seats so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side.

Print P2D32N019 E

Base - March 2012

18

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

Figure 48

F4HFE ENGINES

Figure 50

70342

Gradually and alternately tighten injector fixing screws (1) in four stages: 70133

Use tool 99342101 (1) to fit the injector (2) into position.

Screw in the injector fastening screws without tightening them.

- 1st stage, tightening to 3.5 ± 0.35 Nm torque with dynamometric wrench.

- 2nd stage, tightening to 25° ± 1° angle; - 3rd stage, tightening to 25° ± 1° angle; - 4th stage, tightening to 25° ± 1° angle.

NOTE Tightening to angle is performed using tool 99395216.

Figure 49

Tighten the fuel manifold (3) retaining nuts (2) to 50 ± 5 Nm. Figure 51

91572

Fit a new seal ring (3), lubricated with Vaseline, onto a new fuel manifold (2).

Position the fuel manifold in place on the cylinder head seat so that the positioning balls (5) coincide with the relevant housing (4).

NOTE Fuel manifolds (2) must not be reused after removal but rather replaced with new ones.

Screw on the fastening nuts (2, Figure 50) without tightening them fully.

NOTE During this operation, manoeuvre the injector (1) so that the manifold (2) is properly inserted into the injector fuel inlet hole (2, Figure 47).

Base - March 2012

166640

Place the new high pressure fuel hoses (1) in position and tighten the couplings to the electro-injector collectors (3) and the common rail (2) to the specified torque.

NOTE The hoses (1), as they are subject to high pressure, must be replaced every time they are removed.

The hose couplings must be tightened to a torque of 24 ± 4 Nm, using spanner 99317915 (4) and torque wrench 99389829 (5).

Install the rocker arm assemblies, the injector wiring support and the tappet cover as described in the relative sections.

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

19

TURBOCHARGER REMOVAL AND INSTALLATION Removal Figure 52 (D)

Figure 54 (**)

166642

(**) F4HFE6135/36/3C*A004/3L*A003 Figure 55 (***) 173242

(D) F4HFE413A/3D/3L/3M Figure 53 (*)

166643

(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 166641

(*) F4HFE6133/34/3H Undo the retaining screws and remove the oil return pipe (1) from the engine block.

Unscrew the couplings on the heat exchanger/oil filter and on the turbocharger and remove the oil supply pipe (2) from the turbocharger.

Undo the nuts (3) and remove the turbocharger (4) from the exhaust manifold (5).

Installation Place the turbocharger (4) in position on the exhaust manifold (5), after fitting a new gasket.

Screw down the retaining nuts (3) and tighten them to the specified torque.

Place the oil supply pipe (2) in position on the turbocharger, after fitting a new gasket and tighten the couplings on the heat exchanger/oil filter bracket and on the turbocharger to the specified torque.

Place the pipe (1) in position on the engine block, after fitting a new gasket and tighten the retaining screws (1) to the specified torque.

Print P2D32N019 E

Base - March 2012

20

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

EXHAUST MANIFOLD REMOVAL AND INSTALLATION Removal

F4HFE ENGINES

Figure 58 (**)

Remove the turbocharger as described in the relative section.

Figure 56 (D)

166645

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Undo the retaining screws (1) and remove the exhaust manifold (2) from the cylinder head.

173243

(D)

F4HFE413A/3D/3L/3M

Installation Place the exhaust manifold (2) with new gaskets in position.

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

Install the turbocharger as described in the relative section.

Figure 57 (*)

166644

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

INTAKE MANIFOLD INSTALLATION Removal

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

REMOVAL

AND

21

Figure 61 (**)

Remove the common rail as described in the relative section.

Disconnect the cold-start heater electrical connections (if fitted).

Figure 59 (D)

166648

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Undo the retaining screws (1) and remove the intake manifold (2) complete with the cold-start heater (if fitted).

Installation Apply a sufficient layer of LOCTITE 5999 to the contact surface of the intake manifold (2) complete with the cold-start heater (if fitted).

173244

Place the intake manifold (2) in position and tighten the retaining screws (1) to the specified torque.

Install the common rail as described in the relative section.

(D) F4HFE413A/3D/3L/3M

Connect the cold-start heater electrical connections (if fitted).

Figure 60 (*)

166647

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

Print P2D32N019 E

Base - March 2012

22

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

F4HFE ENGINES

COLD START AIR HEATER REMOVAL AND INSTALLATION (only for F4HFE6132/39/3A/ 3C*A002- 3/3L*A001-2 engines) Removal

CYLINDER HEAD REMOVAL AND INSTALLATION Removal

Disconnect the air heater electrical connections.

Remove the thermostat as described in the relative section.

Remove the engine cable as described in the relative section.

Remove the common rail as described in the relative section.

Remove the rocker arm assembly as described in the relative section.

Figure 62

Remove the injectors as described in the relative section.

Remove the turbocharger as described in the relative section.

Remove the exhaust manifold as described in the relative section.

Remove the intake manifold as described in the relative section.

166646

Undo the retaining screws (1) and remove the air heater (2) from the intake manifold (3).

Figure 63

Retrieve the gasket (4).

Installation Fit the air heater (2) with a new gasket (4) in position on the intake manifold (3) and tighten the retaining screws (1) to a torque of 13 ± 3 Nm. Connect the air heater electrical connections.

74779

Undo the retaining screws, hook metal cables onto the brackets (1) and remove the cylinder head (2) from the engine block using a hoist.

Remove the head gasket.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

Installation

23

Figure 66

Figure 64

75703

NOTE Before re-using retaining screws (1) measure diameters D1 and D2 as shown in the figure: - if D1-D2 < 0.1 mm the screw can be reused - if D1-D2 > 0.1 mm the screw must be replaced 70335

Clean the cylinder head and engine block contact surfaces.

There are two types of head gasket: -

Type A 1.25 mm thick

-

Type B 1.15 mm thick

Check the average projection S of the pistons as indicated on page 29 of Section 7.

NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting.

If S > 0.40 mm use gasket type A. If S ≤ 0.40 mm use gasket type B. Take care not to get the cylinder head gasket dirty.

Figure 67

Arrange a new cylinder head gasket (1) on the engine block with the marking ”TOP” facing the head.

The arrow shows the point where the gasket thickness is marked.

Figure 65 α

74766

Insert the cylinder head (1) retaining screws (2) and tighten them in three stages, following the order and method shown in the figure below.

NOTE The external screws are the shortest.

74779

Position the cylinder head (2), supported by the brackets (1), on the seal.

Print P2D32N019 E

NOTE Use tool 99395216 (3) for angle tightening.

Base - March 2012

24

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

ENGINE OIL FILTER INSTALLATION Removal

Figure 68 (D)

F4HFE ENGINES

REMOVAL

AND

Position a suitable container to catch any engine oil.

Figure 70 (D)(*) α

A 70337

(D) 4-cylinder engine Figure 69 (*)

A α 166649 70476

(*) 6-cylinder engine Diagram of the tightening sequence for the cylinder head fixing screws:

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 71 (**)

- 1st pre-tightening stage, with torque wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm - 2nd re-tightening stage, with torque wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm - 3rd tightening stage to a 90º ± 2º angle - 4th tightening stage to a 90º ± 2º angle A = Front side NOTE The double tightening is due to the special type of highly pliable strip. Therefore, at the end of the pre-tightening stage, the internal screws (tightened first) will be loose.

166650

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Install the intake manifold as described in the relative section.

Use tool 99360076 to remove the oil filter (1).

Install the exhaust manifold as described in the relative section.

Installation

Install the turbocharger as described in the relative section.

Install the injectors as described in the relative section.

Install the rocker arm assemblies as described in the relative chapter.

Install the common rail as described in the relative section.

Install the thermostat as described in the relative section.

Install the engine cable as described in the relative section.

Base - March 2012

Lubricate the seal ring (2) with engine oil and set it on the oil filter (1).

Screw the oil filter (1) all the way on to the support connection (3) by hand and then tighten to 18±2 Nm. Run the engine for a few minutes and then check the level using the dipstick: the level must be near the MAX mark on the dipstick.

If it is much below this level, top up with the necessary quantity.

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

REMOVAL AND INSTALLATION ENGINE OIL HEAT EXCHANGER Removal

25

Installation Figure 74 (D)(*)

Remove the auxiliary components drive belt as described in the relative procedure.

Remove the alternator as described in the relative section.

Position a suitable container to catch any engine oil.

Remove the engine oil filter as described in the relative section.

Figure 72 (D)(*) 107275

(D)

F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 75 (**)

166651

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 73 (**) 166089

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Fit the following on the engine block: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter bracket (4).

Tighten the screws (5) to the specified torque.

NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting.

166087

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Unscrew the coupling (1) and remove the turbocharger oil delivery pipe (2).

Remove the screws (3) and the oil pressure / temperature sensor (4).

Remove the screws (5) and disassemble the oil filter / heat exchanger bracket (6), intermediate plate (6) and relative gaskets.

Print P2D32N019 E

Base - March 2012

26

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

Figure 76 (D)(*)

F4HFE ENGINES

OIL SUMP REMOVAL AND INSTALLATION Removal Place a suitable container under the oil sump drain plug to catch the oil.

Open the oil filler on the cylinder head and remove the dipstick to aid the flow of oil.

Unscrew the drain plug and let the oil in the sump drain completely.

166652

NOTE It is recommended to drain the oil when the engine is hot.

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 77 (**)

Figure 78 (D)(*)

74775

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 166088

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Place the oil temperature/pressure sensor (2) in position on the bracket (1) with a new seal ring then screw in the retaining screws (3) and tighten them to the specified torque.

Figure 79 (**)

Install the oil delivery pipe (1), screwing on the coupling (2).

Install the engine oil filter as described in the relative section.

Install the alternator as described in the relative section.

Install the auxiliary components drive belt as described in the relative procedure.

Check the oil level with the dipstick: the level must be near the MAX mark on the dipstick.

If it is much below this level, top up with the necessary quantity.

166653

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Undo the screws (2) then remove the plate (3) and oil sump (1), retaining the gasket.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

Installation

27

Figure 82 (D)(*)

Figure 80 (D)(*)

74775 74770

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 83 (**)

Figure 81 (**)

166653

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 166654

Place the oil sump (1) in position and apply the plate (3) to it.

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

Tighten the screws (2) to the specified torque.

Set the gasket (1) on the oil sump (2).

Screw on the drain plug with a new washer and proceed to fill with clean oil.

NOTE If it does not show any signs of damage the gasket can be reused.

Use only recommended oils or those with the required characteristics to ensure correct operation of the engine.

Failure to observer these requirements shall void the guarantees.

Check the oil level with the dipstick: the level must be near the MAX mark on the dipstick.

If it is much below this level, top up with the necessary quantity.

Print P2D32N019 E

Base - March 2012

28

SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

SECTION 7 - GENERAL MECHANICAL OVERHAULING

1

SECTION 7 General mechanical overhauling Page

Print P2D32N019 E

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . .

3

FITTING THE ENGINE TO THE ROTATING STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

REMOVAL OF MAIN COMPONENTS . . . . . . .

5

BENCH ENGINE BLOCK DISASSEMBLY . . . . .

14

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

- Controls and measurements . . . . . . . . . . . . . .

16

- Checking head supporting surface on cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

17

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

- Cam lift check and pin alignment check . . . . .

18

BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

- Bush replacement . . . . . . . . . . . . . . . . . . . . . .

19

TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

- Fitting tappets — camshaft . . . . . . . . . . . . . . . .

20

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

21

- Measuring journals and crankpins (4-cylinder) .

21

- Measuring journals and crankpins (6-cylinder) .

23

CONNECTING ROD — PISTON ASSEMBLY . .

25

- Connecting rod-piston assembly removal . . . .

25

- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .

28

Base - March 2012

2

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Page

Page - Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

- Fitting connecting rod-piston assembly . . . .

29

REMOVING THE ENGINE FROM THE ROTATING STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

- Connecting rod-piston assembling . . . . . . .

29

COMPLETING ENGINE ASSEMBLY . . . . . . . . .

54

- Fitting split rings . . . . . . . . . . . . . . . . . . . . .

29

CHECKS AND INSPECTIONS . . . . . . . . . . . . . .

56

BENCH ENGINE BLOCK ASSEMBLY . . . . . . . .

30

- Replacing oil pump control gear . . . . . . . . .

30

- Fitting main bearings . . . . . . . . . . . . . . . . . .

30

- Crankshaft installation . . . . . . . . . . . . . . . . .

30

- Checking crankshaft end float . . . . . . . . . . .

31

- Fitting connecting rod half bearings . . . . . .

32

- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . .

32

- Checking piston protrusion . . . . . . . . . . . . .

33

CYLINDER HEAD DISMANTLING . . . . . . . . . .

34

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

34

- Checking cylinder head wet seal . . . . . . . . .

34

- Checking cylinder head supporting surface .

35

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

35

- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . .

36

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

36

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

- Regrinding - replacing the valve seats . . . . .

36

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

38

ASSEMBLING CYLINDER HEAD . . . . . . . . . . . .

39

REFITTING MAIN COMPONENTS . . . . . . . . . .

40

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

INTRODUCTION

3

Figure 2 (*)

The following description covers general mechanical overhaul starting from the engine which has been removed from the vehicle.

NOTE Refer to the specific publication for removing the engine from the vehicle.

Engine removal operations, as with overhauling, must be carried out by specialised personnel with specific equipment.

166072

This section contains: - the operations to perform for mounting the engine on the rotating stand, - the sequence of removal operations for the main components,

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 3 (**)

- overhaul of the engine block and the cylinder head, - the sequence of refitting operations for the main components, - operations required for completing engine assembly after removal from the rotating stand, - final checks and tests.

Part of the operations covered in this section can be performed directly on the engine still fitted in the vehicle, in relation to their accessibility in the engine compartment and on the vehicle version; these are listed in Section 6 - Removal-refitting of main engine components.

166073

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

FITTING THE ENGINE TO THE ROTATING STAND Figure 1 (D)

To apply the brackets 99361037 to the engine block for fastening the engine to the overhaul stand, proceed as follows, working from the left side of the engine: - Position a suitable container to catch any fuel.

- Using tool 99360076, remove the fuel filter (1) from its support.

- Unplug the fuel temperature sensor and the camshaft timing sensor electrical connections (2).

- Disconnect the low-pressure fuel hoses (3) from the filter support.

- Unscrew the fastening screws and remove the fuel filter support (4) complete with the bracket, if fitted, from the engine block.

- Unscrew the couplings, disconnect the high-pressure fuel hose (5) from the common rail and high-pressure pump, open the fastening straps and remove it from the engine block.

173245

(D) F4HFE413A/3D/3L/3M Print P2D32N019 E

Base - March 2012

4

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

- Disconnect the low-pressure fuel hose (6) supplying the mechanical pump connected to the high pressure pump via the electronic control unit heat exchanger.

Figure 6 (*)

- Remove the oil delivery pipe, if present, unscrewing and removing the retaining screws. Remove the O-ring from the pipe.

NOTE Because of the high pressure in the hoses running from the high pressure pump to the rail and from this to the injectors, you must absolutely avoid: -

Disconnecting the hoses when the engine is running

-

Reusing hoses after they have been removed

166074

(*) F4HFE6133/34/3H Figure 7 (**)

Figure 4

16675 116237

To disconnect the low pressure fuel hose from the relevant connecting joint, you need to keep the clasp (1) pressed, and release the quick fitting joint (2).

(**) F4HFE6135/36/3C*A004/3L*A003 Figure 8 (***)

Figure 5 (D)

166076

(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

173246

From the right of the engine, unscrew the retaining screws and remove the oil outlet pipe (1) from the turbocharger (2) and the engine block.

(D) F4HFE413A/3D/3L/3M Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

5

Unscrew the flywheel cover retaining screws (1) and remove the starter motor (2).

Figure 9

1

Fit brackets 99361037 to the engine block and use these to secure the engine to the rotating stand 99322205.

Drain the oil from the engine by removing the plug from the oil sump.

Remove the fan from the crankshaft pulley.

Dispose of the oil according to applicable laws.

2 74166

REMOVAL OF MAIN COMPONENTS Figure 10

107246

1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature sensor - 9. Camshaft timing sensor - 10. Air temperature and pressure sensor - 11. Electro-injector.

Disconnect the following engine cable connectors: (1) electro-injector wiring; (10) air pressure/temperature sensor; (3) fuel pressure sensor; (6) EDC7 control unit; (9) camshaft timing sensor; (7) fuel flow rate regulator; (8) fuel temperature sensor; (2) engine coolant temperature sensor on thermostat; (4) engine oil temperature and pressure sensor; (5) engine speed sensor.

Open the straps holding the engine cable to the engine block and remove it completely.

Print P2D32N019 E

Base - March 2012

SECTION 7 - GENERAL MECHANICAL OVERHAULING

6

F4HFE ENGINES

Figure 11 (D)

Figure 13

173247

(D)

4-cylinder engine

Figure 12 (*) 166077

Disconnect the pipe (2) from the fuel return pressure relief valve (1), as described in Figure 4.

Unscrew the screw (3), loosen the retaining strap (4) and remove the blow-by pipe (5).

Unscrew the couplings (7) and remove the pipe (6).

Undo the screws and remove the blow-by filter (8).

Unscrew the nuts (10) and remove the tappet cover (9).

Figure 14 107247

(*) 6-cylinder engine Disconnect the fuel hose (3) from the rail (2) according to the procedures described in Figure 3. Disconnect the fuel hose (5) from the rail (2) and from the injector manifolds (4).

Remove the screws (1) and remove the rail (2).

74744

Remove the nuts (7) and disconnect the electrical cables from the electro-injectors (8).

Undo the screws (1) and remove the injector wiring support (2), complete with gasket.

Remove the screws (5) and detach the air temperature/pressure sensor (6).

Undo the nuts (3) and remove the fuel manifolds (4).

NOTE Fuel manifolds (4) must not be reused after removal but rather replaced with new ones.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 15

7

Figure 17

70132

Loosen the tappet adjuster retaining nuts (1) and unscrew the adjusters.

Remove screws (2), disassemble the rocker unit (3) including support (6), rocker arms (4),and shafts (5) and remove the bridges (7) from the valves.

Remove the rods (8).

108545

Operate on the belt tensioner (1) and extract the belt (2) from the alternator pulleys, the coolant pump and the return pumps.

Unscrew the fastening screw and remove the belt tensioner (1).

Unscrew the screws fastening the alternator to its bracket and remove it.

Figure 16

70133

Undo the injector fastening screws and use tool 99342101 (1) to remove the injectors (2) from the cylinder head.

Print P2D32N019 E

Base - March 2012

SECTION 7 - GENERAL MECHANICAL OVERHAULING

8

F4HFE ENGINES

Figure 18 (D)

Figure 21 (***)

173248

(D)

166080

F4HFE413A/3D/3L/3M (***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

Unscrew the couplings on the heat exchanger/oil filter support and on the turbine, disconnect the oil supply pipe (3) and remove it.

Figure 19 (*)

Remove the retaining nuts and disconnect the turbocharger (1) from the exhaust manifold (2).

Undo the screws and remove the exhaust manifold (2) from the cylinder head.

166078

(*) F4HFE6133/34/3H Figure 20 (**)

166079

(**) F4HFE6135/36/3C*A004/3L*A003

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 22 (D)

9

Figure 25

74779

173249

Undo and remove the cylinder head retaining screws.

Hook metal cables onto the brackets (1) and remove the cylinder head (2) from the engine block using a hoist.

(D) F4HFE413A/3D/3L/3M Figure 23 (*)

Figure 26 (D)(*)

166081

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

166083

(D)

F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

Figure 24 (**)

Figure 27 (**)

166082

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 From the opposite side, undo the intake manifold (1) retaining screws and remove it, complete with the cold-start heater (if fitted).

166084

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Undo the screws (1) and remove the alternator bracket (2).

Use tool 99360076 to remove the oil filter (3).

Print P2D32N019 E

Base - March 2012

10

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 28 (D)(*)

Figure 31

1

4

3

2 166085

(D)

F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

74176

Undo the screws (3) and remove the cover (1). Retrieve the gasket (4), the PTO (2) and the second gasket (4).

Figure 29 (**) Figure 32

166086

70145 166086

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

Remove nut (1) and detach the timing sensor (2).

Remove the screws (1) and the oil pressure / temperature sensor (2).

Remove the nuts (3) and disconnect the high pressure pump (4) including the fuel supply pump (5).

Undo the screws (3) and remove the oil filter / heat exchanger support (4), intermediate plate (5) and relative gaskets.

Figure 33

Figure 30

1

2

70146 74174

Remove the screws (1) and disconnect the electronic control unit (2) complete with heat exchanger.

Base - March 2012

Apply the tool 99360351 (2) to the flywheel housing (1), to stop the flywheel (3) from rotating.

Unscrew the screws (4).

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 34

11

Figure 37

108548

Undo the screws (3) and remove the damper (2) and the pulley (1).

The flywheel blocking device can help aid removal of the damper (2) fitted to the pulley (1).

00904t

Fit the appropriate tie-rod (3) of tool 99363204 onto the external seal (2) as illustrated in the figure and, using the lever (4), extract it from the front cover (1).

Figure 35 Figure 38

116241

Undo the screws (1) and remove the coolant pump (2).

Undo the screws (3) and remove the roller (4).

Undo the screw (5) and remove the engine speed sensor (6).

116242

Remove screws (1 and 3) and take off the front cover (2).

NOTE Note down the installation positions of the screws (1) since they are of different lengths.

Figure 36

00900t

Extract the crankshaft front cover seal. Fit the tool 99340055 (4) onto the front shank (2) of the crankshaft. Through the guide holes in the tool, perforate the internal seal (1) with a drill bit (Ø 3.5 mm) to a depth of 5 mm.

Secure the tool to the ring (1) with the 6 screws provided.

Then extract the ring by screwing in the screw (3).

Print P2D32N019 E

Base - March 2012

12

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 39

Figure 42

Undo the screws (1) and remove the oil pump (2).

Figure 40

00903t

Extract the flywheel housing seal ring by fitting tool 99340056 (3) on the rear shank (5) of the drive shaft.

Through the guide holes of the tool, perforate the internal seal ring with a drill bit (Ø 3.5 mm) to a depth of 5 mm.

Fix tool 99340056 (3) to the ring (1) by means of the 6 screws (4) provided.

Proceed to remove the ring (1) by screwing in the screw (2).

Fit the appropriate tie-rod of tool 99363204 onto the flywheel housing external seal and extract it using the lever.

70151

Remove the two opposing screws (1) where the extraction pins will be inserted (2, Figure 41).

Undo the remaining screws fastening the flywheel (3) to the drive shaft (4).

Remove flywheel blocking tool 99360351.

Figure 43

Figure 41

70153

Undo the screws (2) and remove the flywheel housing (1).

70152

NOTE Note down the installation positions of the screws (2) since they are of different sizes.

Screw two medium-length screws into the holes (4) in order to sling the flywheel with a hoist.

Remove the flywheel (1) using the hoist, guided by the two guide pins (2) previously screwed into the holes in the drive shaft (3).

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 44 (D)(*)

13

Figure 46

74775

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

86516

Undo the screws (1 and 4) and remove the oil suction strainer (5).

Undo the screws (2) and remove the stiffening plate (3).

NOTE The stiffening plate (4) has a single part in the engines.

Figure 45 (**) Figure 47

166653

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Turn the engine over.

Remove the screws (2), disassemble the frame (3) and remove the oil sump (1).

70156

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

Figure 48

NOTE The size and shape of the sump and suction strainer vary depending on the engine use.

The illustrations therefore provide a general outline of the procedure to be performed.

The procedures described are applicable in any case.

70157

Undo the screws (2) and remove the timing gear case (1).

NOTE Note down the installation positions of the screws (2) since they are of different sizes.

Print P2D32N019 E

Base - March 2012

14

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

BENCH ENGINE BLOCK DISASSEMBLY

Figure 51

Figure 49

70160

70158

Remove and remove the connecting rod cap (2) fixing screws (1).

Extract the pistons together with the connecting rods from the top of the crankcase.

NOTE Maintain the half-bearings in their relevant seats because, in the event of use, they should be mounted in the position detected when disassembling.

The second-last-main cap (1) and its relevant support have the half-bearing (2) equipped with shoulder.

NOTE Write down the upper and lower half-bearing assembling position, in the event of use, they should be mounted in the position detected when disassembling.

Figure 52 (D)

Figure 50

70161

(D) 4-cylinder engine Figure 53 (*)

70159

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

74774

(*) 6-cylinder engine Remove the crankshaft (2) from the block by means of tool 99360500 (1) and hoister.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

15

zs

Figure 54

Figure 56

70164

70162

Carefully withdraw the camshaft (1) from the crankcase.

Remove the main half-bearings (1).

Remove the screws (2) and remove the oil nozzles (3).

Figure 57 Figure 55

70163 70165

Remove the screws (1) and remove the camshaft (3) check plate (2) Withdraw the tappets (1) from crankcase.

NOTE Write down the plate (2) assembling position.

Print P2D32N019 E

Base - March 2012

16

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

CRANKCASE Controls and measurements

Figure 60

Figure 58 (D)

s

70167

70166

( D)

4-cylinder engine

The measurements must be performed for each individual cylinder at three different heights from the barrel and on two perpendicular surfaces: one parallel to the longitudinal engine axis (A) and the other one perpendicular (B); usually the max wear is detected on this latter surface and in correspondence with the first measurement.

If you detect any ovalization, taper or wear, ream and grind the cylinders. The cylinder barrel regrinding must be performed in relation to the diameter of the spare pistons oversized of 0.4 or 0.8 mm in respect of the nominal value and prescribed assembling clearance.

Figure 59 (*)

Figure 61

75386

(*) 6-cylinder engine Carefully clean the crankcase, when performed the engine disassembly.

α

Use the proper rings to transfer the crankcase.

Carefully check that the block does not present any cracks.

Check the plug conditions. Replace them if they are rusty or in case of doubt about their conditions.

Examine the cylinder bore surfaces; they must not present any seizing, scoring, ovalization, taper, and excessive wearing traces.

The internal diameter check of the cylinder bore, to verify the ovalization, taper and wearing entity, is performed by means of bore meter (1) equipped with dial gange previously set to zero on the ring gauge (2) of the cylinder barrel diameter.

107804

NOTE If you do not have at your disposal the ring gauge, use a micrometer for the zero setting operation.

Base - March 2012

NOTE In the event of grinding operation, all the cylinders must result of the same oversize (0.4 or 0.8 mm)

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Check the main bearing seats, proceeding as follows: - mount the main caps on the supports without bearings; - tighten the fixing screws to the torque prescribed; - by means of an adequate gauge, verify that the internal diameter of the seats correspond to the value prescribed.

If you detect a higher value, replace the crankcase.

17

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

Planarity error shall not exceed 0.075 mm.

Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.

TIMING SYSTEM Camshaft Figure 62

70169

CAMSHAFT MAIN DATA (4 cylinders) Specified data refer to pin standard diameter

Figure 63

84089

MAIN DATA ABOUT CAMSHAFT PINS (6 cylinders) Specified data refer to pin standard diameter Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft and the bush.

Print P2D32N019 E

Base - March 2012

18

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Checking cam lift and pin alignment

BUSH

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

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

Figure 65

Figure 64

70172

70171

Camshaft bush (2) shall be pressed into its housing.

Internal surface must not show seizing or wear.

Use bore dial gauge (3) to measure camshaft bush (2) and intermediate housing (1) diameter.

Measurements shall be performed on two perpendicular axes.

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

Figure 66

Sec. A-A

107399

CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.) * Value to be obtained after driving the bush.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

19

Figure 67

162246

CAMSHAFT BUSH AND HOUSING MAIN DATA (6 cyl.) * Value to be obtained after driving the bush.

Bush replacement

TAPPETS

Figure 68

Figure 69

70174

To replace rear bushing (1), use, for dismounting and mounting it, beater 99360362 (2) and handgrip 99370006 (3).

NOTE

112890

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK

Bushing (1), on mounting, must be oriented in such a way that lubrication holes match the holes present on block seat.

Print P2D32N019 E

Base - March 2012

20

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Fitting tappets — camshaft

Figure 73

Figure 70

70179

70176

Lubricate the tappets (1) and fit them into the relevant housings on the engine block.

Check camshaft end float (1).

It shall be 0.23 ± 0.13 mm.

Figure 74

Figure 71

70180

70164

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

Lubricate the bushing and other timing system shaft support seats and mount camshaft (1) taking care that, during the operation, the bushing or support seats are not being damaged.

Figure 72

70238

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

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

CRANKSHAFT Measuring journals and crankpins (4-cylinder)

NOTE

21

It is recommended to insert the found values in the proper table. See next Figure.

Figure 75 Undersize classes are:

NOTE Journals and crankpins shall always be ground to the same undersize class.

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

For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB.

70182

Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.

Figure 76

108487

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.) *Rated value

Print P2D32N019 E

Base - March 2012

22

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 77

measured on > 45.5 mm radius between adjacent journals 70183

OUTPUT SHAFT MAIN TOLERANCES Figure 78 MAIN BEARING ON TIMING SYSTEM CONTROL SIDE

INTERMEDIATE MAIN BEARINGS

FIRST MAIN BEARING ON FRONT SIDE

70237

TOLERANCES SHAPE DIRECTION POSITION OSCILLATION

TOLERANCE CHARACTERISTIC Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL ○ /○/ //

GRAPHIC SYMBOL

CRITICAL

©

IMPORTANT

⊕

SECONDARY

⊝

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Measuring journals and crankpins (6-cylinder)

NOTE

23

It is recommended to insert the found values in the proper table. See next Figure.

Figure 79 Undersize classes are: 0.250 — 0.500 mm

NOTE

Journals and crankpins shall always be ground to the same undersize class.

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

For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB

70182

Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the journals (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.

Figure 80

107269

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (6 CYL.) *Rated value

Print P2D32N019 E

Base - March 2012

24

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 81

* **

Measured on a radius greater than 45.5 mm ↗ 0.500

70577

between adjacent main journals MAIN CRANKSHAFT TOLERANCES

Figure 82 MAIN BEARING ON TIMING SYSTEM CONTROL SIDE

INTERMEDIATE MAIN BEARINGS

FIRST MAIN BEARING ON FRONT SIDE

70237

TOLERANCES SHAPE DIRECTION POSITION OSCILLATION

TOLERANCE CHARACTERISTIC Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL ○ /○/ //

GRAPHIC SYMBOL

CRITICAL

©

IMPORTANT

⊕

SECONDARY

⊝

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

CONNECTING ROD — PISTON ASSEMBLY Connecting rod-piston assembly removal

25

Figure 84

Figure 83

32613

70191

Remove split rings (1) from piston (2) using pliers 99360183 (3).

CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.

NOTE

Figure 85

Pistons are supplied spare with 0.4 or 0.8 mm oversize.

32614

Piston pin (1) split rings (2) are removed using a scriber (3).

Figure 86 1.5

*

2.560 2.605

2.350 2.380

3.970 3.990

2.705 2.735

2.420 2.440

2º±20’

38.010 38.016

37.994 38.000 114797

MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS * Value measured on 101 mm diameter Print P2D32N019 E

Base - March 2012

26

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Pistons

Gudgeon pins

Measuring piston diameter Figure 87

Figure 89

32615

18857

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

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

Conditions for proper pin-piston coupling

Figure 88

Figure 90

70192

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

Base - March 2012

32619

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

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Piston rings

27

Figure 93

Figure 91

16552

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

41104

DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).

Figure 92

In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.

Figure 94

32620

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

70194

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

Print P2D32N019 E

Base - March 2012

28

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Connecting rods

Figure 96

Figure 95 CONNECTING ROD BODY CONN. WEIGHT ROD Nr.

CAP CONN. ROD Nr.

*

CONNECTING ROD CAP

F

88607

MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS

DAY

YEAR F = 2003 G = 2004 H = 2005 I = 2006

70196

NOTE Every connecting rod is marked as follows: - On body and cap with a number showing their coupling and the corresponding cylinder.

In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.

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

NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling.

Therefore, it is recommended not to smooth the knurls.

- On body with a letter showing the weight of the connecting rod assembled at production:

S

V, 1560 to 1600 g (yellow marking);

S

W, 1601 to 1640 g (green marking);

S

X, 1641 to 1680 g (blue marking);

Spare connecting rods are of the W class with green marking *.

Material removal is not allowed.

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

Removal and refitting shall be performed using the proper beater.

When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Fitting connecting rod-piston assembly Connecting rod-piston assembling

29

Figure 99

Figure 97 FLYWHEEL SIDE

126312

FAN SIDE 162243

The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block (fan side); 3. Marking showing 1st slot insert testing; 4. Manufacturing date; 5. Product traceability

Position the piston on the connecting rod according to the diagram shown in the figure, fit the pin and stop it by the split rings (2).

Fitting split rings Figure 100

Figure 98

126311

Use pliers 99360183 (1) to fit the split rings on the piston (2).

Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°.

162244

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

Print P2D32N019 E

NOTE Split rings are supplied spare with the following sizes: -

standard;

-

0.4 mm oversize;

-

0.8 mm oversize.

Base - March 2012

30

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Crankshaft installation

BENCH ENGINE BLOCK ASSEMBLY Replacing oil pump control gear

Figure 103 (D)

Figure 101

70161

(D) 4-cylinder engine 70184

Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3).

Figure 104 (*)

On mounting the new gear, the gear has to be heated for 10’ at 180 ºC temperature and keyed on engine shaft by putting the key in between.

Fitting main bearings Figure 102

74774

(*) 6-cylinder engine Refit the output shaft (2).

70185

NOTE Refit the main bearings that have not been replaced, in the same position found at removal.

Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter.

NOTE

Do not try to adapt the bearings.

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

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

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 105

31

Figure 107

α

70188 128169

-

2nd stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90° ± 2° angle.

- Clean accurately the parts and remove any trace of oil; - fit caps (1), including the half bearings (2) on the relevant supports.

Checking crankshaft end float Figure 108 NOTE

Before reusing the fastening screws (1), perform two diameter measurements as shown in figure, registering diameters D1 and D2: if D1-D2 < 0.1 mm the screw may be reused if D1-D2 > 0.1 mm the screw must be replaced

75703 70190

This check is performed by setting a magnetic-base dial gauge (2) on the crankshaft (3) as shown in the figure.

Figure 106

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

70187

Tighten the pre-lubricated screws (1) in the following two successive stages: - 1st stage, with torque wrench to 80 ± 6 Nm.

Print P2D32N019 E

Base - March 2012

32

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Fitting connecting rod half bearings

Figure 111

Figure 109

162245 70200

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

DIAGRAM FOR INSTALLING CONNECTING ROD PISTON ASSEMBLY INTO CYLINDER (viewed from front) - split ring openings shall be displaced with each other by 120°;

NOTE Refit the main bearings that have not been replaced, in the same position found at removal.

Do not try to adapt the half bearings.

- connecting rod-piston assemblies shall have the same weight; - the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.

Fitting connecting rod-piston assembly into cylinder barrels Figure 112

Figure 110

70201 128170

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

Use band 99360605 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number.

Base - March 2012

- Clean the parts accurately and remove any trace of oil; - install the big end caps (1) with the relative half-bearings (2).

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

33

Checking piston protrusion

Figure 113

Figure 116

70204

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

166655

Once connecting rod-piston assemblies refitting is over, use dial gauge 99395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block, carrying out the following operations:

Figure 114 - measure the protrusions S1 and S2 of piston no. 1 from the top surface of the engine block at a distance of 45 mm from the centre of the piston and then calculate the average protrusion:

α

S cil1 = S1 + S2 2

70205

- apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60° ± 2°.

- For 4-cylinders versions: repeat the operation to calculate the average protrusion of pistons 2, 3 and 4, then calculate the average value of the protrusions: S + S cil2 + S cil3 + S cil4 S = cil1 4 - For 6-cylinders versions: repeat the operation to calculate the average protrusion of pistons 2, 3, 4, 5 and 6, then calculate the average value of the protrusions:

Figure 115

S=

S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6 6

70207

Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.10 — 0.33 mm.

Print P2D32N019 E

Base - March 2012

34

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

CYLINDER HEAD DISMANTLING Removing the valves

Figure 119

Figure 117

70322

70319

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

Intake (1) and exhaust (2) valves have heads with the same diameter.

The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.

NOTE

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

A = intake side — S = exhaust side

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

Sealing rings (2) for exhaust valves are green.

Checking cylinder head wet seal Figure 120

Figure 118

70323

This check shall be performed using the proper tools.

70321

Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4).

Repeat this operation for all the valves.

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

Use a pump to fill with water heated to approx. 90 °C and 2 to 3 bar pressure.

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

NOTE Before refitting, smear the plug surfaces with waterrepellent sealant.

Replace the cylinder head if leaks are found.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Checking cylinder head supporting surface

35

VALVES

Distortion found along the whole cylinder head shall not exceed 0.20 mm.

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

Figure 122 EXHAUST VALVE

INTAKE VALVE

Figure 121

162247

INTAKE AND EXHAUST VALVE MAIN DATA 70325

The rated thickness A for the cylinder head is 105 ± 0.25 mm, max. metal removal shall not exceed thickness B by 0.13 mm.

Removing carbon deposits, checking and grinding valves Figure 123

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

18625

Remove carbon deposits from valves using the proper metal brush.

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

Regrind the valve seats, if required, removing as less material as possible.

Print P2D32N019 E

Base - March 2012

36

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

VALVE GUIDES

Figure 124

Figure 126

18882

Check the valve stem (1) using a micrometer (2), it shall be 6.990 ± 7.010 mm.

Checking clearance between valve stem and valve guide and valve centering Figure 125

INTAKE

EXHAUST 79457

Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.

VALVE SEATS Regrinding — replacing the valve seats Figure 127

70327

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.032 ± 0.072 mm.

Turn the valve (2) and check that the centering error is not exceeding 0.03 mm.

70330

Check the valve seats (2). If slight scoring or burnout is found, regrind seats using tool (1) according to the angle values shown in Figure 128.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

37

Figure 128

INTAKE

EXHAUST

107281

MAIN DATA OF ENGINE VALVE SEATS The valve seats are cast in the cylinder head and machined.

Figure 129

EXHAUST

INTAKE

107282

If the valve seats cannot be restored by only regrinding, it is possible to mount the inserts supplied as spares.

In this case, it is necessary to make the seats on the cylinder head with the dimensions shown in the figure and to mount the valve seats.

Print P2D32N019 E

To mount the valve seats in the cylinder head it is necessary to heat the cylinder head to 80 - 100 °C and, using a suitable drift, mount the new valve seats (2) in them after they have been cooled.

Then use the specific tool to grind the valve seats to the values given in Figure 130.

Base - March 2012

38

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 130

EXHAUST

INTAKE

162248

MAIN VALVE SEAT DATA

VALVE SPRINGS

Figure 131

Figure 132

50676

70333

After regrinding, check with the base 99370415 (2) and the dial gauge 99395603 (1) that the valve recessing (3) is as prescribed.

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Prior to assembly, check valve spring flexibility using a suitable tool. Compare the elastic deformation and load data with those for new springs given in the following table.

H H1 H2

Base - March 2012

Height mm 35.33 35.33 25.2

Under a load of N Free P1 339.8 ± 9 P2 741 ± 39

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

39

ASSEMBLING CYLINDER HEAD Figure 133

70334

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

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

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

Figure 134

770321

Position on the cylinder head: the spring (4) and upper plate (3): using tool 99360268 (1), compress the spring (4) and fasten the plate (3) to the valve (5) with the cotters (2).

Print P2D32N019 E

Base - March 2012

40

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

REFITTING MAIN COMPONENTS

Figure 136

Figure 135

70210 70209

LOCTITE 5205 SEALANT APPLICATION AREAS Clean accurately the timing gear case (1) and the engine block.

NOTE Perfect seal is only obtained by cleaning accurately the surface to seal.

Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter.

It shall be uniform (no clots), without air bubbles, thin areas or discontinuities.

Any imperfection shall be corrected as soon as possible.

Avoid to use excess material to seal the joint.

Excessive sealant could come out from joint sides and cause lubricant passage clogging.

After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).

DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR CASE FASTENING SCREWS Refit the case (1) to the engine block.

Screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 65 to 89 Nm Screws M8 20 to 28 Nm Screws M10 42 to 52 Nm NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

Figure 137

70211

With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the side surface of which a groove has been created for the ignition timing.

NOTE Fasten screwing of the two pins to facilitate the operation of engine driving shaft rotation.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 138

41

NOTE Perfect seal is only obtained by cleaning accurately the surface to seal.

Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter.

It shall be uniform (no clots), without air bubbles, thin areas or discontinuities.

Any imperfection shall be corrected as soon as possible.

Avoid to use excess material to seal the joint.

Excessive sealant could come out from joint sides and cause lubricant passage clogging.

After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).

114791

Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).

Figure 141

Figure 139

70215

70213

Tighten the screws (1) fastening gear (2) to camshaft (3) to the specified torque.

Figure 140

SEQUENCE FOR TIGHTENING THE FLYWHEEL HOUSING FASTENING SCREWS Refit the housing (1) to the engine block and screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 75 to 95 Nm Screws M10 44 to 53 Nm

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

70214

LOCTITE 5205 SEALANT APPLICATION AREAS Print P2D32N019 E

Base - March 2012

42

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 142

Figure 144

70152

0901t

Apply tool 99346253 part (6) to the rear output shaft tang (5), secure it by screws (4) and fit the new sealing ring (3).

Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into flywheel housing (7).

Screw two pins (2) having suitable length into shaft holes (3) and remove the engine flywheel (1) using proper sling and hoister.

Figure 145

Figure 143

Apply tool 99360339 (2) to the flywheel housing to stop engine flywheel (3) rotation. Tighten the screws (1) fastening the engine flywheel (3) to the output shaft.

Figure 146

70217

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

α

70219

Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1, Figure 142) using a suitable hammer and fit the new one, previously heated to 150 °C for 15 to 20 minutes.

Chamfering on ring gear inside diameter shall be facing the engine flywheel.

Base - March 2012 Revi - September 2012

Tighten engine flywheel (2) fastening screws (1) in two stages: - 1st stage, tightening to 50 ± 5 Nm torque with dynamometric wrench; - 2nd stage, tightening to 60 ± 2° angle.

NOTE Tightening to angle is performed using tool 99395216.

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

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 147

43

Figure 150

106549 70220

Fit the oil pump (1).

Tighten the fastening screws (2) to the specified torque.

Remove the sealing ring (2) from the front cover (1), clean accurately the coupling surfaces and smear them with LOCTITE 5205.

Figure 151

Figure 148

106550 70221

Clean accurately the front cover (2) surface and refit it.

Tighten the screws (1) to the specified torque.

Apply a new sealing ring (2) to the water pump (1).

Figure 152 Figure 149

00902t 70222

Fit the water pump (1).

Tighten the screws (2) to the specified torque.

Print P2D32N019 E

Apply tool 99346252 part (4) to the front output shaft tang (6), secure it by screws (5) and fit the new sealing ring (7).

Position part (2) on part (4), screw nut (3) until completing sealing ring (7) fitting into front cover (1).

Base - March 2012

44

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 156 ((D)(*)

Figure 153

74775

108553

Fit the plate (1), the oil pick up tube (2) and tighten the fastening screws (3) to the specified torque.

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 157 (**)

Figure 154 (D)(*)

166653

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 74770

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

Place the oil sump (1) in position and apply the plate (3) to it.

Tighten the screws (2) to the specified torque.

Figure 155 (**) NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting Figure 158

166654

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Set the gasket (1) on the oil sump (2).

NOTE If it does not show any signs of damage the gasket can be reused.

Base - March 2012

108548

Fit the pulley (1) and the damper flywheel (2) onto the crankshaft.

Tighten the fastening screws (3) to 68 ± 7 Nm torque.

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

45

Figure 162 (D)(*)

Figure 159

116245

Fit a new seal ring on the speed sensor (3).

Fit the speed sensor (3) on the front cover (1) and tighten the retaining screw (2) to the specified torque.

Figure 160

108578

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

(D)(*)

Figure 163 (**)

108576

(D) F4HFE413A/3D/3L/3M (*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 161 (**) 166090

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Lubricate the seal ring (2) with engine oil and place it on the oil filter (3).

Screw the oil filter (3) all the way on to the bracket connection (1) by hand and then tighten the oil filter (3) to 18 ± 2 Nm. Apply a new seal ring to the oil temperature/pressure sensor (4) and fit it on the support (1).

Tighten the screws (5) to the specified torque.

166089

Fit a new seal ring (6) in the engine block seat.

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Fit the following on the engine block: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter bracket (4).

Tighten the screws (5) to the specified torque.

NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting.

Print P2D32N019 E

Base - March 2012

46

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 164

Figure 166

114793 70234

Position the alternator support (1) so that pins (3 and 4) are set against the engine block.

Tighten the screws (2) to the specified torque.

Refit the automatic belt tensioner (2).

Tighten the screw (3) to the specified torque using a wrench, turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers.

Figure 167

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

Figure 165

70145

Refit the high pressure pump (6) including the feed pump (5) and tighten the nuts (3) to the specified torque. Fit the support (4) with a new sealing ring, the timing sensor (2) with a new sealing ring and tighten the relevant fastening nut (1) to the specified torque.

Figure 168

1

4

3

114792

Refit the alternator (1).

Tighten the screw (2) to the specified torque.

2 74176

Insert the power take-off (2) equipped with the gasket (4), the cover (I) and its gasket (4).

Tighten the screws (3) to the prescribed matching couple.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 169

47

Figure 171

1

2

74174

Assemble the electronic gearbox (2) equipped with the exchanger to the engine, fixing it with the screws (1).

In case the rubber buffers are cracked or excessively deformed, provide replacing them.

74779

Direct the output shaft (4) and the camshaft (2) so that when fitting the driven gear (1) on the camshaft the marks on the gears (1 and 3) are coinciding.

NOTE Before reusing the fastening screws (1), perform two diameter measurements as shown in figure, registering diameters D1 and D2: if D1-D2 < 0.1 mm the screw may be reused if D1-D2 > 0.1 mm the screw must be replaced

Figure 170

D2

D1

75703

Figure 172

70335

Check cleanness of cylinder head and engine block coupling surface.

There are two types of head gasket: -

Type A - 1.25 mm thick

-

Type B - 1.15 mm thick

Check the average protrusion S of the pistons as indicated on page 33.

If S > 0.40 mm use gasket type A. If S ≤ 0.40 mm use gasket type B.

α

70336

Assemble cylinder head (1), tighten the screws (2) in three following steps, following order and mode shown in the figure below.

Do not get the cylinder head gasket dirty.

Place the gasket (1) in position with the marking “TOP” (1) facing the head.

NOTE The angle tightening is carried out through tool 99395216 (3).

The arrow shows the point where the gasket thickness is given.

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

Print P2D32N019 E

Base - March 2012

SECTION 7 - GENERAL MECHANICAL OVERHAULING

48

F4HFE ENGINES

Figure 173 (D)

Figure 176

α

A 70337

(D) 4-cylinder engine Figure 174 (*) 70339

Fit injectors (1) on the cylinder head seats, directed so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side.

A

α

Figure 177

70476

(*) 6-cylinder engine Tightening order layout for cylinder head fastening screws: - 1st step pre-tightening with dynamometric wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm - 2nd re-tightening stage, with torque wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm - 3rd step tightening with a 90 ± 2° angle - 4th step tightening with a 90 ± 2° angle A = Front side

70133

Use tool 99342101 (1) to fit the injector (2) into its seat.

NOTE The double tightening is due to the special type of highly pliable strip. Therefore, at the end of the pre-tightening stage, the internal screws (tightened first) will be loose.

Screw injector fastening screws without tightening them.

Figure 175

70338

Fit a new sealing ring (2) lubricated with petroleum jelly and a new sealing washer (3) on injector (1).

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 178

49

NOTE Tightening to angle is performed using tool 99395216.

Tighten the fuel manifold (3) fastening nuts (2) to 50 ± 5 Nm torque.

Carry out the assembly of the equalisers’ unit , after previous check of the components.

Figure 180 (D)

91572

Fit a new sealing ring (3) lubricated with petroleum jelly on the fuel manifold (2) and fit it into the cylinder head seat so that the positioning ball (5) is coinciding with the relevant housing (4).

NOTE Disassembled fuel manifolds (2) must not be used again. Replace with new items.

The fuel manifolds (2) for engines have 2 positioning spheres.

173249

(D) F4HFE413A/3D/3L/3M Figure 181 (*)

1

Screw the fastening nuts (2, Figure 179) without locking them.

NOTE During this operation, the injector (1) shall be moved so that the manifold (2, Figure 176) is properly inserted into the fuel inlet hole (2, Figure 178).

Figure 179

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003

166081

Figure 182 (**)

70342

Tighten gradually and alternately the injector fastening screws (1) in four stages: - 1st stage, tightening to 3.5 ± 0.35 Nm torque with dynamometric wrench.

- 2nd stage, tightening to 25° ± 1° angle; - 3rd stage, tightening to 25° ± 1° angle; - 4th stage, tightening to 25° ± 1° angle.

Print P2D32N019 E

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

166082

Apply to the coupling surface of the intake manifold (1) with the cylinder head, a sufficient coat of LOCTITE 5999.

Place the intake manifold (1), complete with the cold-start heater (if fitted), in position and tighten the retaining screws to the specified torque.

Base - March 2012

50

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 183 (D)

Figure 186 (***)

166080 173248

(D) F4HFE413A/3D/3L/3M

(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 Place the exhaust manifold (2) in position with new gaskets and tighten the retaining screws to the specified torque.

Sling the turbocharger (1) and position it above the exhaust manifold after fitting it with a new gasket, tighten the fastening nuts to the specified torque.

Place the the oil supply pipe (3) in position on the turbocharger and tighten the couplings on the turbocharger and on the heat exchanger/oil filter bracket to the specified torque.

Figure 184 (*)

Figure 187

166078

(*) F4HFE6133/34/3H Figure 185 (**)

70343

ROCKER ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.

166079

(**) F4HFE6135/36/3C*A004/3L*A003

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 188

51

Figure 191

SHAFT-ROCKER MAIN DATA Check that shaft/rocker coupling surfaces are not showing excessive wear or damages.

70346

Check that tappet adjusters (1) are loose to prevent their balking on the rods (2, Figure 190) when refitting the rocker assembly.

Then refit the rocker assembly consisting of: bracket (5), rockers (3), shafts (4) and secure them to the cylinder head by tightening the fastening screws (2) to 36 ± 5 Nm torque.

Figure 189

122587

Figure 192

Rocker control rods shall not be distorted; the ball seats in touch with the rocker adjusting screw and with tappets (arrows) shall not show seizing or wear; otherwise replace them. Intake and exhaust valve control rods are identical and are therefore interchangeable.

Figure 190

70520

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

Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.

70345

Fit the rods (2).

Position jumpers (1) on valves with marks (→) facing the exhaust manifold.

Print P2D32N019 E

Base - March 2012

52

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 196 (*)

Figure 193 (D)

173250

(D)

4-cylinder engine

Figure 194 (*)

166640

(*) 6-cylinder engine Place the new high pressure fuel hoses (1) in position and tighten the couplings to the electro-injector collectors (3) and the common rail (2) to the specified torque.

NOTE

The hoses (1), as they are subject to high pressure, must be replaced every time they are removed.

The hose couplings must be tightened to a torque of 24 ± 4 Nm, using spanner 99317915 (5) and torque wrench 99389829.

107286

(*) 6-cylinder engine Fit the rail (2) and tighten the screws (1) to the specified torque, connect the ground cable (3) to the intake manifold (4) and tighten the fastening nut to the specified torque.

Figure 197

Figure 195 (D)

70352

Check the condition of the electrical cables (5), if they are damaged replace them by cutting the straps (2) securing them to the bracket and removing the screws (4) securing the connectors to this (3).

Fit a new gasket (1) on the bracket (2).

173251

(D)

4-cylinder engine

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

Figure 198

53

Figure 201

108570

Fit the wiring support (2) and tighten the screws (1) to the specified torque.

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

Figure 199

166077

Fit the tappet cover (9) and tighten the nuts (10) to the specified torque.

Place the blow-by filter (8) in position and tighten the fastening screws.

Place the pipe (6) in position with new copper washers in the tappet cover and timing case couplings (7). Then tighten the couplings (7) to the specified torque.

Place the blow-by pipe (5) into the coupling located on the timing case and secure it with the elastic strap (4).

Insert the upper coupling of the new blow-by pipe (5), with a new seal ring, into the tappet cover and tighten the screw (3).

Connect the fuel return pipe (2) to the pressure limiter (1) and common rail as shown in following figure.

Figure 202 108571

Connect the electrical cables (1) to the injectors (3) and use the torque wrench 99389834 (4) to tighten the fastening nuts (2) to the specified torque.

Figure 200

116237

To connect the low pressure fuel hose to the connection fitting, insert the quick-fit coupling (2) in the connection fitting and push it in until the catch (3) engages.

NOTE Check proper fuel hose connection.

70355

Fit a new gasket (2) on the tappet cover (1).

Print P2D32N019 E

Place the engine cable in position, close the retaining straps and connect the sensor, control unit and electro-injector connectors (refer to Figure 8 on page 5).

Base - March 2012

54

SECTION 7 - GENERAL MECHANICAL OVERHAULING

REMOVING THE ENGINE ROTATING STAND

FROM

F4HFE ENGINES

THE

Figure 205 (*)

Support the engine appropriately with a hoist, disconnect it from the rotating stand, remove brackets 99341009 and place it on a suitable support to complete engine assembly.

COMPLETING ENGINE ASSEMBLY Refit the fan to the crankshaft pulley.

Figure 203

1 166074

(*) F4HFE6133/34/3H Figure 206 (**)

2 74166

Position the starter motor (2) on the internal part of the flywheel cover (1).

Screw down the retaining screws and tighten them to the specified torque.

Figure 204 (D) 166075

(**) F4HFE6135/36/3C*A004/3L*A003

Figure 207 (***)

173246

(D) F4HFE413A/3D/3L/3M 166076

(***) F4HFE6132/39/3A/3C*A002-3/3L*A001-2 From the right-hand side of the engine, place the oil drain pipe (1) in position and tighten the screws fastening it to the turbocharger and engine block to the specified torque.

Base - March 2012

Print P2D32N019 E

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

55

Perform the following operations from the left-hand side of the engine:

Figure 208 (D)

173245

(D) F4HFE413A/3D/3L/3M

-

Place the oil delivery tube in position, if present, with a new o-ring, and tighten the retaining screws.

-

Connect the low-pressure fuel hose (6) supplying the mechanical pump connected to the high pressure pump via the electronic control unit exchanger.

-

Connect a new high-pressure fuel hose (5) between the high-pressure pump and the common rail, tighten the couplings to the specified torque and fasten it to the engine block with the respective clamps

NOTE Due the high pressures in the hoses running from the high pressure pump to the rail and from this to the injectors, reuse of these hoses after removal must absolutely be avoided.

Figure 209 (*) -

Place the fuel filter support (4) in position together with the bracket, if present, and tighten the retaining screws to the specified torque.

-

Connect the low-pressure fuel hoses (3) to the filter support.

-

Connect the fuel temperature sensor and camshaft timing sensor electrical connections (2).

-

Fully screw the fuel filter onto the connection on its support by hand, then further tighten to a torque of 20 ± 2 Nm.

166072

(*) F4HFE6133/34/3H/35/36/3C*A004/3L*A003 Figure 210 (**)

166073

(**) F4HFE6132/39/3A/3C*A002-3/3L*A001-2

Print P2D32N019 E

Base - March 2012

56

SECTION 7 - GENERAL MECHANICAL OVERHAULING

F4HFE ENGINES

CHECKS AND INSPECTIONS NOTE The following checking inspections must be carried out after the engine assembly on the vehicle .

Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check: - that there are no water leaks from the connecting sleeves of engine cooling circuit pipes and cab internal heating pipes, tighten the clamping collars if required; - check carefully the connection between the low pressure fuel pipes and the relevant connectors; - that there are no oil leaks between the cover and the cylinder head, between oil sump and engine block, between heat exchanger oil filter and the relevant housings and between the different pipes in the lubricating circuit; - that there are no fuel leaks from the fuel pipes; - that there are no air leaks from pneumatic pipes (if fitted); - check also proper operation of the warning lights set on the instrument panel and of the equipment disconnected when engine was removed.

- Carefully check and bleed the engine cooling equipment by repeated draining operations.

Base - March 2012

Print P2D32N019 E

F4HFE ENGINES

SECTION 8 - TECHNICAL SPECIFICATIONS

1

SECTION 8 Technical specifications

Page

Print P2D32N019 E

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

3

CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .

4

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .

10

Base - March 2012

2

SECTION 8 - TECHNICAL SPECIFICATIONS

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

SECTION 8 - TECHNICAL SPECIFICATIONS

3

GENERAL SPECIFICATIONS Type

4 CYLINDERS

6 CYLINDERS

Cycle

Four-stroke diesel engine

Power

Turbocharged with intercooler

Injection

Direct

Number of cylinders

4

6

∅

+

+

Bore

mm

104

Stroke

mm

132

+.. = Total displacement

cm3

4485

6728

TIMING start before T.D.C. end after B.D.C.

A B

18.5º 29.5º

start before B.D.C. end after T.D.C.

D C

67º 35º

Checking timing mm

-

mm

-

mm

0.20 to 0.30

mm

0.45 to 0.55

Bosch

high pressure common rail EDC7 ECU

X X

Checking operation X

FUEL FEED Injection Type:

Injector

CRIN2

Nozzle type

DLLA

Injection sequence

1-3-4-2

1-5-3-6-2-4

bar

Injection pressure

Print P2D32N019 E

bar

250 - 1600

Base - March 2012

4

SECTION 8 - TECHNICAL SPECIFICATIONS

F4HFE ENGINES

CLEARANCE DATA

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1

104.000 to 104.024

∅1

0.4 - 0.8

Size Outside diameter Pin housing

X ∅1 ∅2

12 103.851 ÷ 103.865 38.010 ÷ 38.016

Piston diameter

∅1

0.4 - 0.8

X X ∅2

mm

∅1

Cylinder barrels

∅1

6 CYLINDERS

Spare pistons type:

Piston - cylinder liners

0.135 to 0.173

X

∅ 3

Piston protrusion

X

Piston pin

∅3

Piston pin — pin housing

Base - March 2012

0.28 to 0.52

37.994 to 38.000 0.010 to 0.022

Print P2D32N019 E

F4HFE ENGINES

SECTION 8 - TECHNICAL SPECIFICATIONS

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S 2 S 3

X1 X2

∅ 2

Print P2D32N019 E

6 CYLINDERS mm 2.705 to 2.735 2.420 to 2.440 4.030 to 4.050

* measured on 101 mm 2.560 to 2.605 2.350 to 2.380 3.970 to 3.990

Split rings

S 1* S2 S3

Split rings - slots

1 2 3

0.100 to 0.175 0.040 to 0.090 0.040 to 0.080

Split rings

1 2 3

0.4 - 0.8 0.4 - 0.8 0.4 - 0.8

Split ring end opening

X3

∅1

X1* X2 X3

Split ring slots

5

Small end bush housing Big end bearing housing

X1 X2 X3

0.30 to 0.40 0.60 to 0.80 0.30 to 0.55

∅1

40.987 to 41.013

∅2

72.987 to 73.013

∅ 3

Small end bush diameter

S

Inside Big end half bearings

∅3 S

38.019 to 38.033 1.955 to 1.968

Piston pin — bush

0.019 to 0.039

Big end half bearings

0.250 - 0.500

Base - March 2012

6

SECTION 8 - TECHNICAL SPECIFICATIONS

F4HFE ENGINES

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS

6 CYLINDERS mm

X Size

X

Max. tolerance on connecting rod axis alignment

-

-

∅2

∅1

S 1

S 2

∅ 3

Journals Crankpins

∅1 ∅2

82.990 to 83.010 68.987 to 69.013

Main half bearings Big end half bearings

S1 S2

2.456 to 2.464 1.955 to 1.968

Main bearings No. 1 - 7 No. 2 - 3 - 4 - 5 - 6

∅3 ∅3

87.982 to 88.008 87.977 to 88.013

Half bearings — Journals No. 1 - 7 No. 2 - 3 - 4 - 5 - 6

0.044 to 0.106 0.039 to 0.111

Half bearings - Crankpins

0.033 to 0.041

Main half bearings Big end half bearings

0.250 - 0.500

Shoulder journal

X1

37.475 to 37.545

Shoulder main bearing

X2

32.180 to 32.280

Shoulder half-rings

X3

37.28 to 37.38

X 1

X 2 X 3

Output shaft shoulder

Base - March 2012

0.095 to 0.265

Print P2D32N019 E

F4HFE ENGINES

SECTION 8 - TECHNICAL SPECIFICATIONS

Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM ∅ 1

6 CYLINDERS mm

Valve guide seats on cylinder head

∅ 4

7

∅1

7.042 to 7.062

∅4 α

6.990 to 7.010 60o ± 0.25o

∅4 α

6.990 to 7.010 45o ± 0.25o

Valves:

α Valve stem and guide

0.032 to 0.072

Housing on head for valve seat:

∅ 1

34.837 to 34.863

∅1

34.837 to 34.863

Valve seat outside diameter; valve seat angle on cylinder head: ∅2 α

∅ 2

∅2 α

α

X

Sinking Between valve seat and head Valve seats

Print P2D32N019 E

∅1

34.917 to 34.931 60o 34.917 to 34.931 45o

X

0.59 to 1.11

X

0.96 to 1.48 0.054 to 0.094 0.054 to 0.094 -

Base - March 2012

8

SECTION 8 - TECHNICAL SPECIFICATIONS

F4HFE ENGINES

Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

6 CYLINDERS mm

Valve spring height: free spring H

H1

H 2 under a load equal to: 339.8 ± 9 N 741 ± 39 N Injector protrusion

H

47.75

H1 H2

35.33 25.2

X

-

X Camshaft bush housings No. 1 (flywheel side) ∅ ∅ ∅ 1 23 4 5 ∅ 2

∅ 1

59.222 to 59.248

Camshaft pin seats No. 2-3-4-5-6-7

∅

54.083 to 54.147

Camshaft journals: 1⇒7

∅

53.995 to 54.045

Bush inside diameter

∅

54.083 to 54.147

∅ 3 ∅

Bushes and journals

0.038 to 0.152

Cam lift: H

Base - March 2012

H

6.045

H

7.582

Print P2D32N019 E

F4HFE ENGINES

SECTION 8 - TECHNICAL SPECIFICATIONS

Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

9

6 CYLINDERS mm

∅1 Tappet cap housing on block ∅2 ∅ 3

Tappet cap outside diameter:

∅2

∅1

16.000 to 16.030

∅2 ∅3

15.924 to 15.954 15.960 to 15.975

Between tappets and housings Tappets

0.025 to 0.070 -

∅ 1 Rocker shaft

∅1

21.965 to 21.977

Rockers

∅2

22.001 to 22.027

∅ 2 Between rockers and shaft

Print P2D32N019 E

0.024 to 0.062

Base - March 2012

10

SECTION 8 - TECHNICAL SPECIFICATIONS

F4HFE ENGINES

TIGHTENING TORQUE TORQUE

COMPONENT M12x1.75 screw fastening rear gear case M10x1.50 screw fastening rear gear case M8x1.25 screw fastening rear gear case M8x1.25 screw fastening oil pump

1st stage 2nd stage

M8x1.25 screw fastening front cover M8x1.25 screw fastening camshaft longitudinal retaining plate M8x1.25 screw fastening camshaft gear M10x1.50 screw fastening crankcase plate M18x1.50 nut fastening high pressure pump gear M8x1.25 nuts fastening fuel pump ½ inch plug on cylinder head ¾ inch plug on cylinder head ¼ inch plug on cylinder head M6x1 screw fastening injectors

M22x1.5 fastening nut injector feed connector M8x1.25 screw fastening intake manifold M12x1.75 screw fastening rear brackets for engine lifting M8x1.25 screws fastening Common Rail M12x1.75x130 screw fastening cylinder head M12x1.75x150 screw fastening cylinder head

1st stage 2nd stage 3rd stage 4th stage

} 12

st stage/ nd stage

Nm 77 ± 12 47 ± 5 24 ± 4 8±1 24 ± 4 24 ± 4 24 ± 4 36 ± 2 43 ± 5 105 ± 5 24 ± 4 24 ± 4 36 ± 5 12 ± 2 3.5 ± 0.35 25º ± 1º 25º ± 1º 25º ± 1º 50 ± 5 24 ± 4 77 ± 12 36 ± 5 35 ± 5

5 ± 0.5 2.4 ± 0.4 7.7 ± 1.2 3.6 ± 0.5 3.5 ± 0.5

55 ± 5

5.5 ± 0.5

3rd

90º ± 2º 90º ± 2º

stage 4th stage

M8x1.25 screw fastening rocker bracket Valve clearance adjusting nuts M8x1.25 M14x1.5 nuts fastening fuel pipes from high pressure pump to Common Rail M8 screw fastening high pressure pipe connector M6 screw fastening wiring bulkhead M8 screw fastening electric wiring support for injector feed Nuts M4 fastening wiring on each injector M12x1.75 screw fastening fuel filter bracket (industrial) M8 screw fastening fuel filter holder (agricultural) Fuel filter M22 screw fastening oil pressure relief valve on oil filter support M27x2 coupling fastening oil filter 11/8 inch connection on filter support for turbine lubrication M12 nut fastening turbine lubrication pipe M10 screw fastening engine coolant inlet connection

Base - March 2012

kgm 7.7 ± 1.2 4.7 ± 0.5 2.4 ± 0.4 0.8 ± 0.1 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 3.6 ± 0.2 4.3 ± 0.4 10.5 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 3.6 ± 0.5 1.2 ± 0.2 0.35 ± 0.035

36 ± 5 24 ± 4 24 ± 4 24 ± 4 10 ± 2 24 ± 4 1.5 ± 0.25 80 ± 8 32.5 ± 2.5 20 ± 2 80 ± 8 20 ± 2 24 ± 4 10 ± 2 43 ± 6

3.6 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 1 ± 0.2 2.4 ± 0.4 0.15 ± 0.025 8 ± 0.8 3.25 ± 0.25 2 ± 0.2 8 ± 0.8 2 ± 0.2 2.4 ± 0.4 1 ± 0.2 4.3 ± 0.6

Print P2D32N019 E

F4HFE ENGINES

SECTION 8 - TECHNICAL SPECIFICATIONS

TORQUE

COMPONENT M10x1.5 screw fastening exhaust manifold on cylinder head M12 screw fastening damper adapter 1st stage and damper on output shaft 2nd stage M10x1,25 screw fastening pulley on output shaft M8x1.25 screw fastening water pump M10x1.50 screw fastening auxiliary component control belt tensioners M10x1.50 screw fastening fixed pulleys for auxiliary component control belt M12x1,75 screw fastening flywheel housing M10x1.50 screw fastening flywheel housing Nut M8x1.25 fastening valve cover M6x1 screw fastening camshaft sensor M6x1 screw fastening crankshaft sensor M14x1.5 screw fastening coolant temperature sensor M6x1 screw fastening oil pressure/temperature sensor Screw fastening fuel pressure sensor M14 screw fastening fuel temperature sensor M6x1 screw fastening air temperature/pressure sensor on intake manifold M12x1.5 screw fastening engine oil level sensor pins M10 Turbine fixing to exhaust manifold 6-cyl. nuts M10x1.5 M16 couplings fastening oil delivery pipe to turbocharger Pipe fixing on adapter M10 for turbine lubrication Oil pipe fixing on adapter M10 for turbine lubrication to block M8x1.25 screws fastening oil drain pipe to turbine Screw M12x1.25 screws fastening engine flywheel 1st stage 2nd stage M8x1.25 screws fastening front bracket for engine lifting M8x1.25 screws fastening engine oil sump M8 screws fastening cylinder barrel lubricating nozzles M12 screws fastening crankshaft caps 1st stage 2nd stage

{

M10x1.25 screw fastening connecting rod caps Alternator M10x1.5 screw bracket fixing on water feed pipefitting M10x1.5 screw alternator locking Starter M10x1.5 nut fastening starter motor

Print P2D32N019 E

11

1st stage 2nd stage

Nm 53 ± 5 50 ± 5

kgm 5.3 ± 0.5 5 ± 0.5 90º ± 5º

68 ± 7 24 ± 4 43 ± 6 43 ± 6 85 ± 10 49 ± 5 24 ± 4 10 ± 2 10 ± 2 24 ± 4 10 ± 2 35 ± 5 25 ± 2 10 ± 2 10 ± 2 7±1 43 ± 6 36 ± 5 35 ± 5 43 ± 6 24 ± 4 50 ± 5

6.8 ± 0.7 2.4 ± 0.4 4.3 ± 0.6 4.3 ± 0.6 8.5 ± 1 4.9 ± 0.5 2.4 ± 0.4 1 ± 0.2 1 ± 0.2 2.4 ± 0.4 1 ± 0.2 3.5 ± 0.5 2.5 ± 0.2 1 ± 0.2 1 ± 0.2 0.7 ± 0.1 4.3 ± 0.6 3.6 ± 0.5 3.5 ± 0.5 4.3 ± 0.6 2.4 ± 0.4 5 ± 0.5 60º ± 2º

36 ± 5 24 ± 4 15 ± 3 80 ± 6

3.6 ± 0.5 2.4 ± 0.4 1.5 ± 0.3 8 ± 0.6 90º ± 2º

60 ± 5

6 ± 0.5 60º ± 2º

43 ± 6 43 ± 6

4.3 ± 0.6 4.3 ± 0.6

43 ± 6

4.3 ± 0.6

Base - March 2012

12

SECTION 8 - TECHNICAL SPECIFICATIONS

COMPONENT M8x1.25 screws fastening heat exchanger and oil filter support M8x1.25 screws fastening housing M8x1.25 screws fastening suction strainer M10x1.5 screws fastening suction strainer bracket M18x1.5 heat exchanger valve cap M18x1.5 nut (left-handed) fastening compressor drive gear M12x1.75 nuts fastening compressor M8x1.25 screws fastening compressor support bracket M6x1 screws fastening thermostat cover M18x1.5 caps to engine block M10x1.5 screws fastening rail tube bracket M18x1.5 couplings M6x1 screws fastening plate M10x1.5 screws fastening power steering pump 3/4” coupling M6x1 screws fastening breather plate M6x1 screw fastening breather plate to tappet cover M12x1.5 breather fastening couplings M8x1.25 screws fastening dipstick M6x1 screws fastening dipstick clamp M12x1.5 coupling on cylinder head M8 screw fastening the fuel filter retaining bracket (agricultural) Fuel filter adapter Oil filter adapter M7x1 screws fastening intake elbow M8x1.25 screws fastening intake elbow bracket M8x1.25 screws fastening control unit M10x1 cap M6x1 screws fastening control unit to bracket M12x1.5 coupling on control unit bracket M8x1.25 nuts fastening heater

Base - March 2012

F4HFE ENGINES

TORQUE Nm 26 ± 4 24 ± 4 24 ± 4 43 ± 5 60 ± 9 165 ± 10 67 ± 2 24 ± 4 10 ± 2 24 ± 4 40 ± 5 24 ± 4 24 ± 4 43 ± 6 36 ± 4 10 ± 2 10 ± 2 20 ± 4 24 ± 4 10 ± 2 22 ± 2 30.5 ± 2.5 30 ± 2 80 ± 8 13 ± 2 24 ± 4 24 ± 4 24 ± 4 10 ± 2 12 ± 2 13 ± 3

kgm 2.6 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 4.3 ± 0.5 6.0 ± 0.9 16.5 ± 1.0 6.7 ± 0.2 2.4 ± 0.4 1.0 ± 0.2 2.4 ± 0.4 4.0 ± 0.2 2.4 ± 0.4 2.4 ± 0.4 4.3 ± 0.6 3.6 ± 0.4 1.0 ± 0.2 1.0 ± 0.2 2.0 ± 0.4 2.4 ± 0.4 1.0 ± 0.2 2.2 ± 0.2 3.05 ± 0.25 3.0 ± 0.2 8.0 ± 0.8 1.3 ± 0.2 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 1.0 ± 0.2 1.2 ± 0.2 1.3 ± 0.2

Print P2D32N019 E

8

SECTION 9 - TOOLS

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

APPENDIX

1

Appendix Page

Print P2D32N019 E

SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . .

3

- Standard safety prescriptions . . . . . . . . . . . . . .

3

- Prevention of injury . . . . . . . . . . . . . . . . . . . . .

3

- During maintenance . . . . . . . . . . . . . . . . . . . .

3

- Respect of the Environment . . . . . . . . . . . . . .

4

Base - March 2012

2

APPENDIX

Base - March 2012

F4HFE ENGINES

Print P2D32N019 E

F4HFE ENGINES

APPENDIX

3

SAFETY PRESCRIPTIONS Standard safety prescriptions

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

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

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

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

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

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

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

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

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

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

Prevention of injury - Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion.

- Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed: ≤ 2 bar)

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

During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50 ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids.

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

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

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

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

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

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

- Do not utilize fast screw-tightening tools.

- Never disconnect batteries when the engine is running.

- Disconnect batteries before any intervention on the electrical system.

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

- Disconnect batteries from system aboard to load them with the battery loader.

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

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

- Use protection cream for hands.

- Change wet cloths as soon as possible - In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections.

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

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

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

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

Non fulfillment of these prescriptions may cause serious injury and poisoning.

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

Print P2D32N019 E

Base - March 2012

4

APPENDIX

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

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

- Do not modify cable wires: their length shall not be changed.

- Do not connect any user to the engine electrical equipment unless specifically approved.

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

For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox.

- Remove electronic gearbox in case of any intervention requiring heating over 80 ºC temperature.

F4HFE ENGINES

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

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

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

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

- Do not paint the components and the electronic connections.

- Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.

Base - March 2012

Print P2D32N019 E