580 m series 3 f4c engine service training manual 0407 87630273

REPAIR MANUAL

F4GE9454H

F4GE9454J

F4GE9484D

F4HE9484A

Issued 04-2007 - Service Training EditsBook/Form Number 87630273 NA

Copyright 2007. CNH America LLC. All Rights Reserved.Printed in U.S.A. Bur

Source Code No. unknown

ENGINE REPAIR MANUAL

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision HistoryIssue Issue Date Applicable Machine Remarks

First Edition 04-2007 F4GE9454H, F4GE9454J, F4GE9484D, F4HE9484A 87630273 NA


ENGINE REPAIR MANUALTABLE OF CONTENTS

CHAPTER 1DIAGNOSTICS

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

CHAPTER 2445TA ENGINE OVERHAUL

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . 2-54KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION FOR F4GE ENGINES . . . . . . . . . . 2-56HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . 2-59EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . 2-97CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137IIssued 04-07 Bur87519803 NA

SECTION 1 - ENGINE REPAIR MANUAL

INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159

CHAPTER 3ELECTRICAL, CHARGING AND START-UP

TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-3LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-6STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19II Issued 04-07 Bur 87519803 NA

CHAPTER 1


DIAGNOSTICS

Issued 04-2007Book/Form Number 87630273 NA



445TATIER III

CHAPTER 1 - DIAGNOSTICSENGINE REPAIR MANUAL

1-II Issued 04-07 Bur 87630273 NA


Revision HistoryIssue Issue Date Applicable Machines Remarks

First Edition 04-2007 F4GE9454H, F4GE9454J, F4GE9484D, F4HE9484A 87630273 NA


CHAPTER 1DIAGNOSTICS

TABLE OF CONTENTS

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Engine Wont Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Engine Lacks Power and Runs Erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Engine lacks power and runs erratically (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Engine Exhaust Smoke Black or Dark Grey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Engine exhaust smoke black or dark grey (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Engine Exhaust Smoke Grey (Verging On White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Engine Exhaust Smoke Light Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Engine Knocks Irregularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Engine Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Engine Exceeds Max. Revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Engine Wont Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111-1Issued 04-07 Bur87630273 NA


NOTES1-2 Issued 04-07 Bur 87630273 NA


TROUBLESHOOTING

ENGINE WONT START

Batteries fully charged. No Perform the checks described in the electrical section of the shop manual.

Yes

Connections to battery terminals are tight and clean. No Inspect, clean, tighten nuts or replace terminals if excessively corroded.

Yes

Starter motor working properly. No Perform the checks described in the electrical section of the repair manual.

Yes

Grid heater system working properly. No Check using multi meter replace or repair. Refer to Chapter 3 pages 3-5 and 3-14.

Yes

Fuel in tank. No Refuel tank.

Yes

Fuel filters plugged. Yes Replace.

No

Injection pump timed properly. No Verify timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. Common rail pump bring to certified pump shop.

Yes

Injectors working properly. No On common rail engines check using Electronic Service Tool (EST). Mechanical injection loosen (crack) injection lines.

Yes

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

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

No

The fuel system shows traces of water. Yes Check and clean the fuel system including the fuel tank.

No

Fuel pump working properly. No Check fuel pump and replace if necessary.

Yes

Cold start advance solenoid and shut off solenoid both in working order. No

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

Yes

Compression good on all cylinders. No Check cylinders for proper compression, overhaul engine or make repairs on defective parts,.1-387630273 NA Issued 04-07 Bur


ENGINE OVERHEATS

Coolant level correct. No Check for leaks, repair leaks and refill to proper level.

Yes

Fan working properly. No Replace.

Yes

Drive belts serviceable. No Replace.

Yes

Water Pump working properly. No Check for leaks, bad bearing, overhaul or replace.

Yes

Thermostat working properly. No Replace.

Yes

Radiator plugged or leaking. Yes Wash down, repair leaks and flush out radiator. If necessary replace radiator.

No

Air to Air Cooler and hoses leaking. Yes Clean or replace faulty parts.

No

Openings for coolant flow within the cylinder head and engine block plugged. Yes Clean thoroughly.

No

Valve clearance correct. No Check and adjust for correct valve clearance.

Yes

Injection pump timed correctly. No Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. Common rail pump bring to certified pump shop.

Yes

Cylinder head gasket leaking. Yes Replace.

1-4 Issued 04-07 Bur 87630273 NA


ENGINE LACKS POWER AND RUNS ERRATICALLY

Correct tie rod length between hand throttle and accelerator pedal. No Adjust rod length.

Yes


No

Air filter plugged. Yes Clean or replace filter.

No

The fuel system shows impurities and or traces of water. Yes

Check and clean the fuel system including the fuel tank.

No

Thermostat working properly. No Replace.

Yes

Injection pump timed correctly No Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

Yes

Cold start solenoid (in injection pump) KKSB working properly. No

Check and if defective repair or replace. Refer to Chapter 2 page 2-55

Yes

Timing plunger (in injection pump) working properly. No

Power to KKSB solenoid repair or replace if defective.

Yes

Fuel pump working properly. No Replace.

Yes

Injectors working properly No On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

Yes

Injection pump rate correct. No Bring to a certified pump shop for repair.Yes

Speed governor (in injection pump) in working order at all speeds. No Bring to a certified pump shop for repair.

Yes 1-587630273 NA Issued 04-07 Bur


Engine lacks power and runs erratically (continued)

Circuit and L.D.A.device both in working order. No Bring to a certified pump shop for repair.

Yes

Injection pump peak adjusted. No Bring to a certified pump shop for repair.Yes

Correct valve clearance. No Adjust clearance for proper value.Yes

Compression good on all cylinders. No Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.)

Yes

Turbocharger working properly. No Repair or replace unit.1-6 Issued 04-07 Bur 87630273 NA


ENGINE EXHAUST SMOKE BLACK OR DARK GREY

Fresh clean diesel fuel in tank. No Clean the tank and replace the fuel filter.

Yes

Air filter plugged. Yes Clean replace if necessary.

No

Grid heater system working properly. No Check using multi meter replace or repair. Refer to Chapter 3 pages 3-5 and 3-14.

Yes

KKSB solenoid working properly. No Cold start solenoid (KKSB) working properly. Remove connector measure solenoid 4.8 0.2 ohms. See Chapter 2 page 2-55

Yes

Injectors working properly. No On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

Yes

Injection pump timed correctly. No Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

Yes

Circuit and L.D.A.device both in working order. No Bring to a certified pump shop for repair.

Yes

Injection pump adjusted properly. No Bring to a certified pump shop for repair.Yes 1-787630273 NA Issued 04-07 Bur


Engine exhaust smoke black or dark grey (continued)

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

ENGINE EXHAUST SMOKE LIGHT BLUE

Injection pipes intact. No Check the condition of pipes and replace them if necessary.Yes

Compression good on all cylinders. No Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.).

Grid heater working properly. No Check using multi meter replace or repair. Refer to Chapter 3 pages 3-5 and 3-14.

Yes

Coolant level correct. No Possible flow of coolant into the combustion chamber. Replace the cylinder head gasket or overhaul the engine.

Yes

Injectors working properly. No On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

Yes

Injection pump timed correctly. No Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

Yes

Fresh clean diesel fuel in tank. No Clean the tank and replace the fuel filter.

Excessive oil consumption. Yes

Check: oil vapor breather, cylinder compression. Leaks into or out of turbocharger. Leaks from valve guides. Overhaul cylinder head or engine if necessary.1-8 Issued 04-07 Bur 87630273 NA


ENGINE KNOCKS IRREGULARLY

Knock detected in the crankshaft. Yes

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

No

Knock detected in the connecting rods. Yes

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

No

Knock detected in pistons. Yes

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

No

Knock detected in the cylinder head. Yes Check the following items: Play between the rocker arms and the valves, injection pump timing, valve timing. Adjust to proper specification.

No

Knock detected in valve gear. Yes Check and replace if necessary the gears. Inspect for broken springs, excessive play between the stems and guides, and the tappets and seats. Adjust the clearance.

No

Knock detected in injectors. Yes On common rail engines check using Electronic Service Tool (EST) .Mechanical injection loosen (crack) injection lines.

No

Knock detected in the engine flywheel. Yes Replace loose bolts and tighten all bolts to the specified torque and angles.

No

Knock detected in the injection pump. Yes Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.1-987630273 NA Issued 04-07 Bur


ENGINE STOPS

EXCESSIVE OR INSUFFICIENT OIL PRESSURE

Fuel in tank. No Refuel and drain if necessary.

Yes


No

Fuel Shut Off (FSO) solenoid working properly. No Check the solenoid replace if defective.

Yes

Regular injection pump rate. No Check and if defective bring to a certified pump shop for repair.For common rail refer to Chapter 2 page 2-77. For mechanical injection refer to Chapter 2 page 2-53

Yes

Injection pump controls working properly. No Check and if defective bring to a certified pump shop for repair.Yes

Regular idle speed. No Adjust.Yes

Correct play between the valves and rocker arms.

No Adjust play to proper specifications.

Yes

Valves intact. No Replace broken valves.

Oil pressure control valve working properly. No Check and replace if necessary.

Yes

Oil level correct and proper engine oil SAE viscosity. No

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

Yes

Oil pump and delivery lines in working properly No Check and replace if necessary.

Yes

Main bearings and connecting rod bearings in acceptable condition. No

Replace the bearings and reface if necessary the crankshaft.

Yes1-10 Issued 04-07 Bur 87630273 NA


Excessive or Insufficient Oil Pressure continued

EXCESSIVE FUEL CONSUMPTION

ENGINE WONT STOP

Low oil pressure caused by fuel dilution. Yes Check for leaking shaft seal or leaking injection pump.No

Main bearings and connecting rod bearings working properly. No

Replace the bearings and reface if necessary the crankshaft.

Fuel tank and lines leaking. Yes Repair leaks (if any) and replace the worn parts.No

Air filter plugged. Yes Replace.

No

Injection pump operating properly. No Check and if defective bring to a certified pump shop for repair.For common rail refer to Chapter 2 page 2-77. For mechanical injection refer to Chapter 2 page 2-53

Yes

Electronic fuel injection system operating properly. No

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

Yes

Valve adjustment correct. No Check and if wrong adjust to proper value.Yes

Compression good on all cylinders. No Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.).

Fuel Shut Off solenoid working properly. No Replace.

Yes

Speed governor working properly. No Check and if defective bring to a certified pump shop for repair.1-1187630273 NA Issued 04-07 Bur


NOTES1-12 Issued 04-07 Bur 87630273 NA

CHAPTER 2


445TA ENGINE OVERHAUL

Issued 04-2007Book/Form Number 87630273 NA



445TATIER III

CHAPTER 2 - 445TA ENGINE OVERHAULENGINE REPAIR MANUAL

2-II Issued 04-07 Bur 87630273 NA


Revision HistoryIssue Issue Date Applicable Machines Remarks

First Edition 04-2007 F4GE9454H, F4GE9454J, F4GE9484DF4HE9484A 87630273 NA


CHAPTER 2445TA ENGINE OVERHAUL

TABLE OF CONTENTS

F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

F4GE9454H and F4GE9454J Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21F4GE9484D Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23F4HE9484A Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25Crankshaft Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28EGR Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28Valve Control for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29Valve Control for F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30Cylinder Head for F4GE9454h and f4GE9454J Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31Cylinder Head for F4GE9484D Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32Cylinder Head for F4HE9484A Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33Valves and Valve Seats for F4GE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34Valves and Valve Seats for- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43Oil Pan (Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43Oil Vapor Recirculation for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44Oil Vapor Recirculation for- F4HE Engines with Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45Blow-By Recirulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45Oil Vapor Recirculation for- F4HE Engines without Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-462-187630273 NA Issued 04-07 Bur

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

87630273 NA


Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

Boosting Version Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49Inter-Cooled Engine Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51Mechanical Fuel lift Pump- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52Mechanical Injection Working Principles- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . . . . . 2-54KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55MECHANICAL INJECTION FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION . . . . . . . . . 2-56

Parts needed for pressure/ vacuum testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57Normal system operating observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . 2-59EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Engine Preheating Element Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Phase Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Injection Pressure Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Pilot and Main Injection Advance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Idle Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Maximum Engine Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Smoke Control Under Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60After Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Control Of Working Speed In Normal Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60Recover Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62Fuel Supply System Diagram- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64Mechanical Feed Pump- Normal Operating Condition- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65Mechanical Feed Pump- Outlet Overpressure Condition In Exhaust Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65Fuel System Bleeding Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66High Pressure Pump Type CP3.3- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67High Pressure Pump Inside Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69Operating Principal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71

COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

Injection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74Electro-Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75Pressure Limiter for Fuel Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77Low Pressure Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77Low - Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78Test On Pressure Relief Valve On Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79Test On Fuel Backflow From the Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80

SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-822-2 Issued 04-07 Bur 87630273 NA

Crank Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84


Removing Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85Removing Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89

CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99Checking Crankcase Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101Checking Eccentric Lift and Bearing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102Replacing Cam Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103Installing Tappets and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105Measuring Bearing Journals and Connecting Rods Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105Replacing Oil Pump Drive Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107Mounting Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107Checking Crankshaft Shoulder Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109

PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111Conditions for Correct Pin/Piston Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113Checking Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113Checking Twisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114Checking Flexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114Assembling Piston To Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115Installing Connecting Rod-Piston Assemblies In Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116Measuring Crank Pin Assembly Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116Checking Piston Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118

VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121

Counter Balancer Timing- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123

Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129

Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131Valve Descaling, Check and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131Checking Valve Guide Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132Valve Seats Regrinding- Replacing Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134

MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1342-387630273 NA Issued 04-07 BurInstalling valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134


Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137

INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145

ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146

CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148Checking Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149Valve Cleaning, Checks and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149Checking Valve guide wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150

VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150Valve Seats- Regrinding, Replacing, Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153

Fitting Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154

INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156

LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159

Injector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160Installing Tappet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160Exhaust Manifold/Turbo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-161Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162Fuel Filter Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162Wiring Harness Connections to the Engine- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1632-4 Issued 04-07 Bur 87630273 NA


F4GE- ENGINES

BS06N188 Figure 2-1F4GE9454H & F4GE9454J ENGINE

BS06N189 Figure 2-2F4GE9484D ENGINE

The NEF F4GE engines are characterized by a fourstroke atmospheric or turbocharged two valves percylinder.Fuel feed is provided by rotary mechanical injection

It differs from other applications because of theprovision of different power, power take-off, fordifferent collector configurations, boost turbine andafter cooler.2-587630273 NA Issued 04-07 Bur

pump.

CHAPTER 2 - 445TA ENGINE OVERHAUL ENGINE REPAIR MANUAL

F4HE- ENGINES

BS07D071 Figure 2-3F4HE9484A ENGINE

BS07D072 Figure 2-4F4HE9484A ENGINE SHOWING THE EDC7UC31

CONTROL BOX (1).

The NEF F4HE engines are characterized by a fourstroke diesel, turbocharged, four valves per cylinder.They have high pressure injection fueling (common rail) and are entirely electronically driven inorder to optimize the fuel efficiency and performance.Also limiting emissions as much as possible.

12-6 Issued 04-07 Bur 87630273 NA


CODING OF SOURCE ENGINES

ENGINE MODEL BREAKDOWN DISCRIPTION

F 4 G E 9 4 8 4 D J * 61= Common Rail 4 valve2= Common Rail 2 valve3= In Line 4 valve4= In Line 2 valve5= Rotary 4 valve6= Rotary 2 valve

Emissions Level: J= Tier 3Approved power rating

Application:4= Agricultural. machinery - Earth moving

Fuel / Injection / Induction0= Diesel injection - naturally aspirated5= Diesel injection - Turbocharged8= Diesel injection - Turbo - after cooler

Number of Cylinders4= 4 cylinders6= 6 cylinders

9= Internal EGRE= Engine

Type of crankcase: A= Non-structural crankcase 102 mm - 4 valves - 3.9 or 5.9 literB= Non-structural crankcase 102 mm - 2valves - 3.9 or 5.9 literC= Structural crankcase 104 mm - 2 valves - 4.5 or 6.8 literD= Structural crankcase 104 mm - 4 valves - 4.5 or 6.8 literE= Structural crankcase 102 mm - 4 valves - 3.9 or 5.9 literF= Structural crankcase 104 mm - 2 valves - 3.9 or 5.9 literG= Non-structural crankcase 104 mm - 2 valves - 4.5 or 6.8 literH= Non-structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter

Engine Family: Includes 4 cylinder and 6 cylinder in both 2 valves and 4 valves per cylindermechanical and common rail fuel systems2-787630273 NA Issued 04-07 Bur


ENGINE PROPERTIES

A. Type of engineB. Engine modelC. Number of cylindersD. Total displacementE. Maximum power currently availableF. Type of InjectionG. Injection systemH. Air supply system

A F4GE9454H F4GE9454H F4GE9454J F4GE9454J F4GE9484D F4GE9484D F4HE9484AB *J601 *J602 *J600 *J601 *J601 *J602 * J101C 4 CylindersD 4485 cm (273.7 cubic inches)

E74 kW

(100 h.p.)2000 rpm

74 kW(100 h.p.)2000 rpm

66 kW(90 h.p.)2000 rpm

66 kW(90 h.p.)2000 rpm

93 kW(126 h.p.)2200 rpm

93 kW(126 h.p.)2200 rpm

104 kW(141 h.p.)2200 rpm

F Direct Injection

G Rotary Injection pumpHigh pressure Common rail EDC7UC31

H T.C. (Boosted) T.A.A.- (Boosted by Intercooler)2-8 Issued 04-07 Bur 87630273 NA


GENERAL ENGINE FEATURES

BS06K013 Figure 2-5

REF. NO. ENGINE TYPE

F4GE9454H F4GE9454J F4GE9484D F4HE9484AJ601 J602 J600 J601 J601 J602 J101

1Cycle 4- Stroke diesel engineAir Boosted Boosted by intercoolerInjection Direct

2 Number of cylinders 4 in-line3 Bore 104 mm (4.1 in.)4 Stroke 132 mm (5.2 in)5 Total displacement 4485cm (273.7 cubic inches)6 Compression ratio 17.5: 1 16.5: 1

7 Maximum power rating (net power at flywheel ISO 14396)

74 kW 66 kW 93 kW 104 kW2000 rpm 2000 rpm 2200 rpm 2200 rpm

100 hp 90 hp 126 hp 141 hp2000 rpm 2000 rpm 2200 rpm 2200 rpm

8 Maximum Torque

400 Nm 375 Nm 510 Nm 608 Nm1250 rpm 1250 rpm 1250 rpm 1600 rpm295 lb.-ft. 277 lb.-ft. 376 lb.- ft. 448 lb.-ft.1250 rpm 1250 rpm 1250 rpm 1600 rpm

9 No-load idle 10 No-load peak rpm

11 Boosting (type of turbocharger) without intercoolerHOLSET HX25with intercoolerHOLSET HX25

with intercooler HOLSET HX27W

1

9

4 5

10 11

2 3

6 7 82-987630273 NA Issued 04-07 Bur


BS06K014 Figure 2-6



12Lubrication. Forced by means of gear pump, pressure relief valve, oil filter.Oil pressure with hot engine: at idle rpm. 0.70 bar (10 psi)Oil pressure with hot engine: at peak rpm. 3.50 bar (50 psi) 4.0 bar (58 psi)

13Cooling. By centrifugal pump, regulated by thermostat, heat exchanger, intercoolerWater pump drive. By means of BeltThermostat start of opening temperature. 79 to 83 C (174 to 181 F)

14Oil capacity engine sump. Refer to Owners ManualOil capacity engine sump + filter. Refer to Owners Manual

15 Fuel feed type Rotary Bosch - VE4 / 12 FHigh Pressure Common Rail, EDC7UC31

16 Pump setting 0 0.5 N.A.17 Start of delivery 0.95 to 1.05 mm (0.0374 to 0.0413 in.) N.A.

Type of injector N.A. CRIU 218 Injection sequence 1 -3 -4 -2

19 Injection pressure N.A.250 to 1600 bar

3626 to 23206 psi

16 17

141312

18 19

152-10 Issued 04-07 Bur 87630273 NA


CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

BS06K015 Figure 2-7


F4GE9454H F4GE9454J F4GE9484D F4HE9484A

J601 J602 J600 J601 J601 J602 J101

1 Cylinder bore. 104.000 to 104.024 mm. (4.0945 to 4.0954 in.)

2

Pistons: Measurement dimension. X = 55.90 mm. (2.20 in.)Outer diameter. 1= 103.714 to 103.732 mm. (4.0832 to 4.0839 in.)Pin seat. 2= 38.010 to 38.016 mm. (1.4965 to 1.4967 in.)

3 Piston - cylinder liners. 0.252 to 0.294 mm. (0.0099 to 0.0116 in.)4 Piston diameter. = 0.4 mm. (0.0157 in.)5 Protrusion of pistons from crankcase. 0.28 to 0.52 mm (0.01102 to 0.02047 in.)6 Piston pin. 3= 37.994 to 38.000 mm. (1.4958 to 1.4961 in.)7 Piston pin-Pin seat. 0.01 to 0.022 mm. (0.0004 to 0.0009 in.)

8

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

X1= 2.705 to 2.735 mm. (0.1065 to 0.1077 in.)X2= 2.44 to 2.46 mm. (0.0961 to 0.0969 in.)X3= 4.03 to 4.05 mm. (0.1587 to 0.1594 in.)

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

S1= 2.560 to 2.605 mm. (0.1008 to 0.1026 in.)S2= 2.350 to 2.380 mm. (0.0925 to 0.0937 in.)S3= 3.970 to 3.990 mm. (0.1563 to 0.1571 in.)

9 Piston rings - Slots.1= 0.100 to 0.175 mm. (0.0039 to 0.0069 in.)2= 0.060 to 0.110 mm. (0.0024 to 0.0043 in.)3= 0.040 to 0.080 mm. (0.0016 to 0.0031 in.)

10 Piston rings. 0.40 mm. (0.0157 in.)

421

8

65

103 7 9

42-1187630273 NA Issued 04-07 Bur


BS06K016 Figure 2-8



11 Piston ring gaps in cylinder liner.X1= 0.30 to 0.40 mm. (0.0118 to 0.0157 in.)X2= 0.60 to 0.80 mm. (0.0236 to 0.0315 in.)X3= 0.30 to 0.55 mm. (0.0118 to 0.0217 in.)

12Connecting rod small-end bearing seat. 1= 40.987 to 41.013 mm. (1.6137 to 1.6147 in.)Connecting rod large-bearing seat. 2= 72.987 to 73.013 mm. (2.8735 to 2.8745 in.)

13Connecting rod small-end bearing diameter.Inner 3= 38.019 to 38.033 mm. (1.4968 to 1.4974 in.)Big end half bearings S= 1.955 to 1.968 mm. (0.0770 to 0.0775 in.)

14 Connecting rod small-end bearing seat. 0.250 to 0.500 mm. (0.0098 to 0.01968 in.)15 Piston pin - bearing. 0.019 to 0.039 mm. (0.0007 to 0.0015 in.)

16

Measurement dimension. No Information AvailableMaximum error on connecting rod axis parallelism. No Information AvailableBearing journals 1= 82.990 to 83.010 mm. (3.2673 to 3.2681 in.)Crank pins 2= 68.987 to 69.013 mm. (2.7160 to 2.7170 in.)Main half bearings (supplied as spares). S1= 2.456 to 2.464 mm. (0.0967 to 0.0970 in.)Connecting rod half bearings. S2= 1.955 to 1.968 mm. (0.0770 to 0.0775 in.)

17 Main bearing- journalsNumbers 1, 5 3 87.982 to 88.008 mm. (3.4638 to 3.4649 in.)Numbers 2, 3, 4 3= 87.977 to 88.013 mm. (3.4637 to 3.4651 in.)

11 12 13

1516

17

142-12 Issued 04-07 Bur 87630273 NA


BS06K017 Figure 2-9



18

Half bearing- journals.

Numbers 1, 50.064 to 0.095 mm. (0.0025 to 0.0037 in.) 0.041 to 0.119 mm. (0.0016

to 0.0047 in.)

Numbers 2, 3, 40.059 to 0.100 mm. (0.0023 to 0.0039 in.) 0.041 to 0.103 mm. (0.0016

to 0.0041 in.)

Half bearing - crank pins.0.064 to 0.090 mm. (0.0025 to 0.0035 in.) 0.033 to 0.041 mm. (0.0013

to 0.0016 in.)

19 Main half bearingsBig end connecting rod half bearings.

+0.250 mm. (0.0098 in.)+0.500 mm. (0.0197 in.)

20 Main journal of thrust bearing. X1= 37.475 to 37.550 mm. (1.4754 to 1.4783 in.)21 Main bearing housing of thrust bearing. X2= 32.180 to 32.280 mm. (1.2669 to 1.2709 in.)22 Shoulder half ring. X3= 37.280 to 37.380 mm. (1.4677 to 1.4716 in.)23 Crankshaft shoulder. 0.095 to 0.270 mm. (0.0037 to 0.0106 in.)

2019

232221

182-1387630273 NA Issued 04-07 Bur


VALVE GEAR - CYLINDER ASSEMBLY

BS06K018 Figure 2-10



1 Valve guide seats on cylinder head. 1= 8.019 to 8.039 mm. (0.316 to 0.317 in.)7.042 to 7.062 mm.(0.277 to 0.278 in.)

2

Valves - Intake.4= 7.960 to 7.980 mm. (0.313 to 0.314 in.)

6.970 to 6.990 mm.(0.274 to 0.275 in.)

angle= 60 0.25 60 0.25

Valves - Exhaust.4= 7.960 to 7.980 mm. (0.313 to 0.314 in.)

6.970 to 6.990 mm.(0.274 to 0.275 in.)

Angle= 45 0.25 Angle= 45 0.253 Valve stem and respective guide. 0.059 to 0.086 mm (0.002 to 0.003 in.) 0.052 to 0.092 mm (0.002 to 0.003 in.)

4Seat on head for valve seat. - Intake. 46.987 to 47.013 mm (1.850 to 1.851 in.)

34.837 to 34.863 mm(1.371 to 1.373 in.)

Seat on head for valve seat. - Exhaust. 43.637 to 43.663 mm. (1.718 to 1.719 in.)34.837 to 34.863 mm(1.371 to 1.373 in.)

5

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

Intake.2= 47.063 to 47.089 mm. (1.853 to 1.8534 in.)

34.917 to 34.931 mm.(1.374 to 1.375 in.)

angle= 60 angle= 60

Exhaust.2= 43.713 to 43.739 mm. (1.7210 to 1.7220 in.)

34.917 to 34.931 mm.(1.374 to 1.375 in.)

angle= 45 angle= 45

6 Recessing. Intake valve 1.00 to 1.52 mm. (0.039 to 0.060 in.) 0.59 to 1.11 mm. (0.023 to 0.044 in.)Recessing. Exhaust valve 1.00 to 1.52 mm. (0.039 to 0.060 in.) 0.59 to 1.11 mm. (0.023 to 0.044 in.)

7 Between valve seat and head- Intake 0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)Between valve seat and head- Exhaust 0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)

8 Valve seats No Information Available

1 4

5 6 7 8

322-14 Issued 04-07 Bur 87630273 NA


BS06K019 Figure 2-11



9

Valve spring height: Free spring. H= 63.5 mm. (2.500 in.) 47.75 mm (1.880 in.)Under load of: 329 N (74 lbf). H1= 49.02 mm. (1.930 in.) 35.33 mm (1.391 in.)Under load of: 641 N (144 lbf). H2= 38.20 mm. (1.504 in.) 25.2 mm (0.992 in.)Injector protrusion. X= Not Adjustable

10

Seats camshaft bearing.- number - 1 (flywheel side)

7= 59.222 to 59.248 mm. (2.332 to 2.333 in.)

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

1-6= 54.089 to 54.139 mm. (2.130 to 2.132 in.)

11 Camshaft main bearing journals: 1 through 5

1, 2, 3, 4, 5 = 53.995 to 54.045 mm. (2.126 to 2.128 in.)

12 Camshaft bushing outside diameter = N.A.13 Camshaft bearing inner diameter. =54.083 to 54.147 mm. (2.129 to 2.132 in.)14 Bearing and seats in crankcase. N.A.15 Bearing and main journals. 0.038 to 0.162 mm. (0.002 to 0.006 in.)

16Useful cam lift- Intake. 10.74 mm. (0.423 in.) 7.5282 mm (0.296 in.)Useful cam lift- Exhaust. 11.02 mm. (0.434 in.) 6.045 mm (0.238 in.)

17

Tappet plate seat in crankcase. 1= 16.000 to 16.030 mm. (0.630 to 0.631 in.)

Tappet plate outside diameter.2= 15.924 to 15.954 mm. (0.627 to 0.628 in.)3= 15.965 to 15.980 mm.(0.629 to 0.629 in.) 15.960 to 15.975 mm (0.628 to 0.629 in.)

18 Between tappets and seat. No Information Available19 Tappets. No Information Available

20 Rocker arm shaft. 1= 18.963 to 18.975 mm. (0.747 to 0.747 in.)21.965 to 21.977 mm (0.8647 to 0.8652 in.)

21 Rocker arms 2= 19.000 to 19.026 mm. (0.748 to 0.749 in.) 22.001 to 22.027 mm (0.866 to 0.867 in.)22 Between rocker arm and spindle 0.025 to 0.063 mm. 0.024 to 0.162 mm

13 14

201917

9 10 11

1615 18 22 21

122-1587630273 NA Issued 04-07 Bur

(0.001 to 0.003 in.) (0.00094 to 0.0064 in.)


TORQUE SPECIFICATIONS FOR (F4GE)- ENGINESPART ...................................................................................................................................... TORQUE - Nm (lb.-ft.)Cylinder head fastening bolts.

1st phase. (pre lubricated with oil)Bolts M12x1.75x70 .................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet)Bolts M12x1.75x140 ...............................................................................35 to 45 Nm (25.8 to 33.2 pound-feet)Bolts M12x1.75x180 ...............................................................................65 to 75 Nm (47.9 to 55.3 pound-feet)

2nd phase (additional rotation)..........................................................................................90 degrees 5 degrees3rd phase (only for bolts 140 and 180 mm long additional rotation) .................................90 degrees 5 degrees

Crankshaft main bearings.1st phase (pre lubricate with oil). ................................................................44 to 56 Nm (32.5 to 41.3 pound-feet)2nd phase ...................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet)3rd phase. (additional rotation). ......................................................................................................90 5 degrees

Bolts fastening the pulley on the crankshaft ................................................105 to 115 Nm (77.4 to 84.8 pound-feet)Connecting rod cap bolts.

1st phase. (pre lubricate with oil). ...............................................................27 to 33 Nm (19.9 to 24.3 pound-feet)2nd phase ...................................................................................................55 to 65 Nm (40.5 to 47.9 pound-feet)3rd phase. additional rotation..........................................................................................................60 5 degrees

Engine flywheel fastening bolts. M12x1.51st phase. (pre lubricate with oil) ................................................................26 to 34 Nm (19.2 to 25.1 pound-feet)2nd phase. (additional rotation).......................................................................................................60 5 degrees

Flywheel housingM12x120 .....................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet)M12x80 .......................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet)M10x80 .......................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)M10x40 .......................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)

Assembly rear cover plate to flywheel housing (M8x1.25x16).........................20 to 28 Nm (14.8 to 20.7 pound-feet)Fuel injectors. ..................................................................................................55 to 65 Nm (40.6 to 47.9 pound-feet)Sump (oil pan) M8x1.25. .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Sump (oil pan) M18x1.5 ..................................................................................51 to 69 Nm (37.6 to 50.9 pound-feet)Oil pan drain plug ............................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Oil filter............................................................................................................................................ Contact + 3/4 turnOil bypass valve to lube filter head ..................................................................72 to 88 Nm (53.1 to 64.9 pound-feet)Fuel filter. ........................................................................................................................................ Contact + 3/4 turnInjection pump fastening bolts. ........................................................................20 to 30 Nm (14.8 to 22.1 pound-feet)Injection pump gear (drive gear nut)

1st stage......................................................................................................15 to 20 Nm (11.0 to 14.8 pound-feet)2nd stage ....................................................................................................85 to 90 Nm (62.7 to 66.4 pound-feet)

Valve gear cover and case fastening bolts (front cover). .................................20 to 30 Nm (14.8 to 22.1 pound-feet)Intake manifold fastening bolts. .......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Assembly air intake connection M8x1.25 ........................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Fuel pump fastening bolts M8 bolt...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Fuel pump fastening bolts M6 bolt.........................................................................9 to 11 Nm (6.6 to 8.1 pound-feet)Fuel pump M6 nut..................................................................................................9 to 11 Nm (6.6 to 8.1 pound-feet)Exhaust manifold fastening bolts. .....................................................................37 to 49Nm (27.3 to 36.1 pound-feet)Valve cover fastening nuts. ..............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Rocker arm support fastening bolts. ................................................................40 to 56 Nm (29.5 to 41.3 pound-feet)Rocker arm adjusting nut.................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Camshaft shoulder plate fastening bolts..........................................................20 to 30 Nm (14.8 to 22.1 pound-feet)Camshaft retaining plate bolts M8 ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet.)Fan support fastening bolts M10x1.5x20.........................................................28 to 38 Nm (20.7 to 28.0 pound-feet)Fan pulley fastening bolts

M6 ....................................................................................................................8 to 12 Nm (5.9 to 8.8 pound-feet)M10 .............................................................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)

Turbocharger fastening bolts. ..........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)2-16 Issued 04-07 Bur 87630273 NA

Starter motor fastening bolts. ..........................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)


Alternator fastening bolts.Alternator to alternator support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Alternator to water inlet M8 bolt ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Alternator lower mount M10 ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Alternator upper pivot M10 bolt ...................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)Alternator mounting hardware M12x1.75x120 .............................................37 to 49Nm (27.3 to 36.1 pound-feet)Alternator wiring M6 nut ....................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)

Water pump fastening bolts. ............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Water outlet connection

M8x1.25x35.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)M8x1.25x70.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)

Heat exchanger fastening bolts .......................................................................20 to 30 Nm (14.8 to 22.1 pound-feet)Camshaft gear bolt M8 ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)Rear gear housing assembly

M8 ...............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)M10 .............................................................................................................42 to 52 Nm (30.9 to 38.4 pound-feet)M12 .............................................................................................................65 to 89 Nm (47.9 to 65.6 pound-feet)

Cylinder lubricating nozzles M8x1.25x10 ..........................................................12 to 18 Nm (8.9 to 13.3 pound-feet)Engine counter balancer................................................................................. 40 to 56 Nm (29.5 to 41.3 pound-feet)Engine coolant temperature sensor fastening bolt ......................................... 17 to 23 Nm (12.5 to 17.0 pound-feet)2-1787630273 NA Issued 04-07 Bur


TORQUE SPECIFICATIONS FOR (F4HE)- ENGINESPART .............................................................................................................................TORQUE - Nm (pound-feet)Camshaft sensor M6 studs....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet)Feed pump M8 studs.......................................................................................... 10 to 14 Nm (7.4 to 10.3 pound-feetRear gear case M12 bolts ...............................................................................65 to 89 Nm (47.9 to 65.6 pound-feet)Rear gear case M10 bolts ...............................................................................42 to 52 Nm (31.0 to 38.4 pound-feet)Rear gear case M8 bolts .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Camshaft sensor M6 nut .......................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)Oil pump M8 bolts1st stage ..................................................................................................................7 to 9 Nm (5.2 to 6.6 pound-feet)2nd stage.........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Front cover M8 bolts ........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Camshaft gear M8 bolts ..................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)Crankcase plate M10 bolt................................................................................38 to 48 Nm (28.0 to 35.4 pound-feet)High pressure pump gear M18 nut ..............................................................100 to 110 Nm (73.6 to 81.1 pound-feet)Fuel pump M8 nuts..........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)1/2 inch plug on cylinder head.........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)1/4 inch plug on cylinder head.........................................................................31 to 41 Nm (22.9 to 30.2 pound-feet)3/4 inch plug on cylinder head...........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)Injector fastening M6 bolts1st stage ........................................................................................................8.15 to 8.85 Nm (6.0 to 6.5 pound-feet)2nd stage (additional rotation) .......................................................................................................................75 5Injector feed connector fastening nut................................................................ 45 to 55 Nm 33.2 to 40.6 pound-feet)Grid heater grill on intake manifold M6 nut ............................................................6 to 10 Nm (4.4 to 7.4 pound-feet)Intake manifold M8 bolts..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Fastening brackets (rear) for engine lifting M12 bolts......................................65 to 89 Nm (47.9 to 65.6 pound-feet)Fastening brackets (front) for engine lifting M8 bolts .......................................20 to 28 Nm (14.8 to 20.7 pound-feet)Common rail M8 bolts......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)High pressure fuel line connectors M14 ..........................................................18 to 22 Nm (13.3 to 16.2 pound-feet)High pressure fuel line connectors M8 ............................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Cylinder head M12x1.75x130 and 1501st stage ..........................................................................................................30 to 40 Nm (22.1 to 29.5 pound-feet)2nd stage (additional rotation) ........................................................................................................................90 53rd stage (additional rotation).........................................................................................................................90 5Rocker arm bracket .........................................................................................31 to 41 Nm (22.9 to 30.2 pound-feet)Valve clearance adjusting nuts ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Fuel line from high pressure pump to Common Rail, M14 nut ........................18 to 22 Nm (13.2 to 16.2 pound-feet)Wiring bulkhead M6 bolt ........................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)Electrical wiring support for injector feed.........................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Wiring on each injector -nuts ................................................................ 1.25 to 1.75 Nm (11.1 to 15.5 pound-inches)Fuel filter bracket M12 bolts .........................................................................................................69 to 85 Nm (50.9 to 62.7 pound-feet)M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Fuel filter......................................................................................................................................... Contact + 3/4 turnOil pressure relief valve on oil filter support M22 bolt......................................72 to 88 Nm (53.1 to 64.9 pound-feet)Radiator seal and oil filter support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Oil filter ........................................................................................................................................... Contact + 3/4 turnConnection on oil filter support for turbine lubrication .....................................20 to 28 Nm (14.8 to 20.7 pound-feet)Turbine lubrication pipe M12 nut............................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)Engine coolant inlet connection M10 bolt ........................................................37 to 49 Nm (27.3 to 36.1 pound-feet)90 elbow (if required) to engine coolant inlet connection ...............................20 to 28 Nm (14.8 to 20.7 pound-feet)Line on cylinder head for compressor cooling .................................................20 to 24 Nm (14.8 to 17.7 pound-feet)Engine coolant drain connector M6 bolt ................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)Engine block exhaust manifold pin ........................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)2-18 Issued 04-07 Bur 87630273 NA

Exhaust manifold to cylinder head M10 bolt ....................................................48 to 58 Nm (35.4 to 42.8 pound-feet)


Damper adapter and damper on crankshaft M12 bolt1st stage ..........................................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet)2nd stage (additional rotation) ........................................................................................................................90 5Crankshaft pulley M10 bolts ............................................................................61 to 75 Nm (45.0 to 55.4 pound-feet)Water pump M8 bolts.......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Auxiliary component control belt tensioner M10 bolt .......................................37 to 49 Nm (27.3 to 36.1 pound-feet)Fixed pulleys for auxiliary component control belt M10 bolts ..........................37 to 49 Nm (27.3 to 36.1 pound-feet)Flywheel housingM10 bolts .........................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet)M12 bolts .........................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)Heat exchanger for EDC7UC31 control unit M6 bolts ....................................................................................................................... 8 to 12 (5.9 to 8.9 pound-feet)M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)Fuel inlet-outlet on heat exchanger ...................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)Valve cover fastening nut M8 nut.............................................................

580 m series 3 f4c engine service training manual 0407 87630273

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