manual de reparacion motores iveco F4GE

N SERIES F4G TIER 3 Agricultural Agricultural applications applications (Hyundai) (Hyundai)

F4GE9484F*J608 F4GE9454J*J604

Technical and Repair manual

This public publicati ation on contai contains ns data, data, featur features, es, instru instructio ctions ns and methods for performing repair interventions on the assembly and its components. This publication is addressed to qualified, specialised personnel. Check that you have the publication related to the assembly on which you are about to work available before you start. Make sure that you have all the necessary safety apparatuses, such such as, for example example,, protect protective ive eyewear eyewear,, helmet, helmet, gloves gloves,, footfootwear, etc. Check that the working, lifting and transport equipment etc. is available available and in working working order. order. Make sure that the group is prepared and secured. Proceed Proceed by carefully observing observing the instructions instructions contained herein and use the indicated specific tools to ensure correct repair procedures, observance of time schedules and safety of operators. All repair interventions interventions are aimed at restoring restoring the conditions conditions of operation, efficiency and safety contemplated by FPT. All on-group interventions, aimed at implementing changes, alterations or other not authorised by FPT will relieve FPT from responsibility. responsibility. Specifically, Specifically, the warranty warranty (where applicable) will be immediately cancelled. FPT cannot be held responsible for repair interventions. FPT is available to provide any additional information needed for performing the inventions and indications in the cases and situations not contemplated in this publication. The data contained in this publication may not be up-to-date ifchange ifchangess are are made made bythe manu manufa fact ctur urerat erat any any time time for for techn techniical cal or comm commer erci cial al reas reason onss or if requ requir ired ed to meet meet lega legall requ requir ireements of countries worldwide. Contac Contactt a FPTdealershi FPTdealership p before before proceed proceedingin ingin the event event of difdifferences between the contents of this publication and the actual assembly. Reproduction, even partial, of this text and the illustrations contained herein is prohibited.

Produced by: Publication edited by FIAT Powertrain Technologies Mkt. Advertising & Promotion Viale dell’Industria, 15/17 20010 Pregnana Milanese Milano (Italy) Print P2D32N010 Print P2D32N010 E - 1st Ed. 02.2009

B.U. TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio, 15/19 10156 Turin - Italy

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INTRODUCTION

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Introduction Page PREFACE TO USER’S GUIDELINE MANUAL . . . .

3

SYMBOLS

...............................

5

-

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

-

Service operations . . . . . . . . . . . . . . . . . . . . . .

3

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

5

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

7

-

8

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

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES . . . . . . . . . . . . . . . . . . . . .

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INTRODUCTION

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PREFACE PREFACE TO USER’S GUIDELINE GUIDELINE MANUAL MANUAL 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 indicated in the general table of contents. contents. The sectio sections ns dealin dealingg with with things things mechan mechanic ic introdu introduce ce the specif specifica icatio tions, ns, tighten tightening ing torque torque values, values, tool tool lists, lists, assemb assembly ly 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 control units peculiar peculiar to the electric system. Section Section 1 describes the engine illustrating illustrating its features and working in general. general. Section 2 describes the type of fuel feed. Section 3 relates to the specific duty and is divided in four separate parts: 1. Mechani Mechanical cal part, part, related related to the engine engine overhaul overhaul,, limited limited to those those compon components ents with differ different ent charac character terist istics ics based based on the relatin relatingg specific duty. 2. Electrical part, concerning wiring harness, electrical and electronic equipment equipment with different characteristics based based on the relating specific duty. 3. Maintenance planning and specific overhaul. 4. Troubl Troublesh eshooti ooting ng part part dedica dedicated ted to the operat operators ors who, who, being being entitl entitled ed to provid provide e technic technical al assist assistanc ance, e, shall shall have have simple simple and and direct direct instructions instructions to identify identify the cause of the major inconveniences inconveniences.. Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such operations. The appendix contains a list of the general safety regulations to be respected by all all installation and maintenance engineers in order to prevent serious accidents taki ng 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 w arnings 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 sometimes cause the warranty warranty to become become null and void.

!

General danger It includes the dangers of above described signals.

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

It indicates an additional additional explanation explanation for a piece of informatio information. n.

Service Service operations Example ∅1

Ø 1 = housing for connecting rod small end bush

α

∅

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Tighten to torque torque Tighten to torque + angular value

2 Ø 2 = housing for connecting rod bearings

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Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting Fitting in place Assembly Tighten to torque torque

Compression ratio

ρ

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation Adjustment

Angle Angular value

α

Visual inspection Fitting position check

Preload

Measurement Value to find Check

Number of revolutions

Equipment

Temperature

Surface for machining Machine finish

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bar

Pressure

Interference Strained assembly

Oversized Higher than…. Maximum, peak

Thickness Clearance

Undersized Less than…. Minimum

Lubrication Damp Grease

Selection Classes Oversizing

Sealant Adhesive

Temperature Temperature < 0 °C Cold Winter

Air bleeding

Temperature Temperature > 0 °C Hot Summer

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INTRODUCTION

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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 specific and general-purp general-purpose ose toolings according to the prescriptions prescriptions contained in respective respective use and maintenance maintenance handbooks. handbooks. Check use state and suitability suitability of tools not subjected subjected to regular 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 Handling by mechanical mechanical means must be with hoisters proper proper as for weight as well as for shape and volume. Hoisters, Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily compulsorily permitted to authorised personnel personnel only. Stay duly clear of the load, and, anyhow, anyhow, never under it. In disassembl disassembling ing operations, operations, always observe observe provided provided prescriptions; prescriptions; prevent mechanical 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 dangerous for the co-operator co-operator because of lack of visibility visibility or of his/her his/her not correct 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 prior to operating on the latter. Strictly follow all the safety indications indications found on the assembly. assembly. Do not leave the running assembly 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, stands, and that the manual/automatic manual/automatic safety devices devices have been actuated in the event that the assembly 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 standards provided provided for. Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Inflam Inflammab mable le fuel fuel andall inflam inflammab mable le fluidsand fluidsand liquid liquidss must must be handledwith handledwith care, care, accord according ing to whatcontainedon whatcontainedon harmfu harmfull materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks sparks in order order to prevent prevent sudden sudden fires/ fires/bur bursts sts.. Adequa Adequatel telyy store store inflam inflammab mable, le, corros corrosive ive and pollut polluting ing fluids fluids andliquids andliquids 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 During worksh workshop op activit activity, y, always always keep keep the work work place place clean; clean; timely timely clear clear or clean clean floors floors from from accide accidenta ntall liquidor liquidor oil spots. spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

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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 Avoid to breathe breathe fumes coming coming from from heating heating or from from paint welding welding becaus because e they can cause cause damages damages to health; health; operat operate e 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. containers. Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking 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: Disconnec nectt all electro electronic nic central central units, units, take take power power cable cable off batter batteryy positi positive ve termin terminal al (connec (connectt it to chassis chassis bondin bonding) g) - Discon and detach connectors. - Remove paint by using proper solvents solvents or paint removers removers and clean relevant surfices with soap and water.

about 15 minutes before before welding. - Await about - 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 temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central units.

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

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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, disconnect, as a first one, the chassis chassis bonding cable from batteries negative terminal. 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 checking circuit continuity, but only use proper control apparatuses. 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 testing lines with special special plugs and plug bushes. bushes. Never use improper means means like wires, screwdriver screwdrivers, s, clip clipss and and the the like like in orde orderr to avoi avoid d the the dang danger er of caus causinga inga shor shortt circ circui uit, t, as well well as of dama damagi ging ng plug plugge ged d conn connec ectio tions ns,, which which would later cause contact problems.

To star startt up the the engi engine,do ne,do not not use use fast fast char charge gers rs.. Star Startt up must must only only be perf perfor ormedwitheith medwitheither er sepa separa rate te batte batteri ries es or speci special al 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 Disconnect the batteries batteries from the system during their recharging with an external apparatus. apparatus. On connecting, only screw up connector connector (temperature (temperature sensors, sensors, pressure sensors etc.) nuts at prescribed prescribed tightening tightening torque. Before Before disconnectin disconnectingg the junction connector from an electronic electronic central unit, isolate 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.

NOTE

Connec Connector torss presen presentt must must be seen seen from from cable cable side. side. Connec Connector torss views views contai containedin nedin the manual manual arerepresen arerepresentati tative ve of cable cable side.

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Bonding and screening Negati Negative ve leads leads connec connected ted to a system system bonded bonded point point must be both as short short and possi possible ble and “star““star“-con connec nected ted to each each other, trying 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 Electronic central central units must be connected connected to system system bonding bonding when they are provided provided with with a metallic shell. shell.

-

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

-

Analog bonding bonding (sensors (sensors), ), although not connected connected to battery battery negative negative system/term system/terminal inal bonding, bonding, must have optimal optimal isolation. isolation. Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

-

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

-

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

-

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

Figure 1

1.

NEGATIVE CABLES “STAR “ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

2.

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

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INTRODUCTION

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

Power 1 kW 1 kW 1 metr metric ic HP 1 metr metric ic HP 1 HP 1 HP

= = = = = =

1.36 metric HP 1.34 HP 0.73 0.736 6 kW 0.98 0.986 6 HP 0. 0 .746 kW 1.014 metric HP

Torque 1 Nm 1 kgm

= =

0.1019 kgm 9.81 Nm

OF

9

T HE

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/cm 2 0.98 0.981 1 bar bar 5 10 Pa

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

1 kgm

=

10 Nm;

- bar unit is for the sake of simplicity simplicity converted converted into kg/cm 2 according according to ratio 1:1

1 kg/cm2

=

1 bar.

Temperature 0° C = 3 2 ° F 1° C = (1 x 1.8 + 32)

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°

F

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KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of vehicle

Printout number

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Section title

Language Publication

Basic edition referred to month - year editorial editorial phase closing

Page number

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

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Part 1 F4GE N SERIES Section General specifications

1

Fuel

2

Agricultural applications

3

Overhaul and technical specifications

4

Tools

5

Safety prescriptions

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Appendix

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UPDATING Section

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Description

Page

Date of revision

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SECTION 1 - GENERAL SPECIFICATIONS

1

SECTION 1 General Specifications

Page LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

OIL VAPOUR RECIRCULATING SYSTEM . . . . . . .

4

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

5

AIR INDUCTION BOOST DIAGRAM . . . . . . . . . .

6

-

Boosting version engines . . . . . . . . . . . . . . . . .

6

-

Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

-

Inter-cooled engine version . . . . . . . . . . . . . . .

7

-

Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

EXHA EXHAUS UST T GAS GAS RE-CI RE-CIRC RCUL ULAT ATIO ION N SYST SYSTEM EM (EGR (EGR))

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3

LUBRICATION

Lubric Lubricati ation on involv involves es the heat exchang exchanger er and the turbob turboblowe lower. r.

Lubric Lubricati ation on by forced forced circul circulati ation on is achiev achieved ed through through oil rotary rotary expansion pump, placed in the front part of the basement, driven driven by the straigh straight-t t-toot ooth h gearsplined gearsplined to the shaft’ shaft’ss barhold.

All these these compon components ents may often often vary vary accord according ing to the specif specific ic duty.

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

Figure 1

Routing of oil under pressure Routing of oil return by gravity to sump 132102

Introduction of oil

LUBRICATION SYSTEM LAYOUT 1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Oil rotary expansion pump - 4. Oil filter.

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OIL VAPOUR RECIRCULATING SYSTEM Figure 2

1

2

3

3240t

1. Valve - 2. Breather Breather pipe - 3. Tappet Tappet Cap On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity, to the Tappet cap underneath. u nderneath. The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example (connection towards towards these vapours vapours shall be designed designed by the Engineer).

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COOLING SYSTEM SYSTEM The engine cooling system, closed circuit forced circulation type, generally incorporates t he following components: - Expansion Expansion tank; placement, placement, shape and dimensions dimensions are subject subject to change according according to the engine’s equipment. equipment.

5

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

Centrifugal water pump, placed placed in the front part of the - Centrifugal engine block. - Thermos Thermostat tat regula regulatingthe tingthe circul circulati ation on of the coolingliqui coolingliquid. d.

Radiato tor, r, whic which h has has the duty duty to diss dissip ipate ate the the heat heat - Radia subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipm equipment ent develo developed ped,, both both for what concer concerns ns the placement and the dimensions. - Visc pusher fan, having the duty to increase the heat dissipating dissipating power of the radiator. radiator. This component component as well will will be specif specifica ically lly equipp equipped ed based based on the engine’s engine’s development.

Figure 3 TO RADIATOR

FROM RADIATOR

Water coming out from thermostat t hermostat Water recirculating in engine 127129

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AIR INDUCTION BOOST DIAGRAM Boosting Boosting version version engines Figure 4

AIR FILTER

TURBOCHARGER

EXHAUST

88208

Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation. The compre compresso ssorr rotor, rotor, being being connect connected ed by shaft shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing compressing the sucked air through the air filter.

The turbocharger is equipped with a transforming valve to regulate regulate the pressure pressure , that is is located located on the exhaust exhaust collector collector before the turbine and connected by piping to the induction collector. It’sdutyis It’sdutyis tochoke tochoke the the exhau exhaust st ofthe emiss emissio ions, ns, relea releasi sing ng part part of them directly to the exhaust tube when the boost boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication lubrication of the turbocharger turbocharger and of the bearings is made by the oil of the engine.

The air coming out of the compressor is sent via the intake manifold directly to the pistons. Base - Februar 2009

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Inter-cooled Inter-cooled engine version Figure 5

AIR FILTER

TURBOCHARGER

EXHAUST

RADIATOR 74195

4 cylinders version

Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding feeding pressure , one main body and one compressor. compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation. The compre compresso ssorr rotor, rotor, being being connec connected ted by shaft shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing compressing the sucked air through through the air filter. filter. The above mentioned air is then cooled by the radiator and flown through the piston induction collector.

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The turbocharger is equipped with a transforming valve to regulate regulate the pressur pressure e , that is located on the exhaust exhaust collector collector before before the turbine and connected connected by piping piping to the induction induction collector. It’s It’s duty duty isto chok choke e the the exha exhaus ustt ofthe emis emissi sion onss , rele releas asin ingg part part of them directly to the exhaust tube when the boost feeding feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

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EXHAUST EXHAUST GAS RE-CIRCULAT RE-CIRCULATION ION SYSTEM SYSTEM (EGR) In the TIER 3 version, the profile of the exhaust cam has been modified modified in order to allow the partial opening of the relative relative valve valve during during the aspira aspiratio tion n phase phase (re-ci (re-circu rculat lation ion of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders. The The exhaus exhaustt gase gasess can can part partia iallllyy be re-di re-dire rect cted ed into into the cyli cylind nder erss so as to redu reduce ce the the maxi maximu mum m comb combus usti tion on temperature values responsible for the production of nitric acid (NOx). The exhaust gas re-circulation system (EGR), reducing the combustion temperature by means of the diminishing of the conc concen entr trat atio ion n of oxyg oxygen en in the the comb combus usti tion on cham chambe ber, r, repres represents ents therefo therefore re an effici efficient ent contro controll system system of the emission of NO x .

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The The inte intern rnal al EGR EGR syst system em is not not equi equipp pped ed with with any any electro electronica nically lly contro controlle lled d elements elements:: the system system is always always active. active. Its Its conf config igur urat atio ion n does does not not need need addi additi tion onal al elem element entss i.e.checking valves, piping or heat exchangers. The exhaust cam (B) has another lobe apart from the major lobe (see Section. A-A fig.) with respects to the configuration without EGR. The additio additional nal lobe, lobe, during during the aspira aspiratio tion n phase phase in the cylind cylinder er in questi question, on, allows a brief brief openin openingg of the exhaust exhaust valve valve generat generating ing re-cir re-circula culatio tion n dueto the intake intake of the exhaustgases exhaustgases caused by depression which is created in the aspiration phase inside the cylinder.

Figure 6

114789

A. Aspiration Aspiration valve valve control - B. Exhaust valve control. control. Base - Februar 2009

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SECTION 2 - FUEL

1

SECTION 2 Fuel Page

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4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP . . . . . . . . . . . .

3

-

General information . . . . . . . . . . . . . . . . . . . . .

3

-

Description of working principles . . . . . . . . . . .

4

FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

-

Example of identification . . . . . . . . . . . . . . . . .

5

PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

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SECTION SECTION 2 - FUEL

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SECTION 2 - FUEL

4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter pre-filter (if available, available, it is usually placed close to the engine on the machine machine frame) - Priming pump, assembled assembled to the engine and driven by the camshaft - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed rotary pump - Injector feed pipeline (from fuel feed pump to injectors) - Injectors

Figure 1

2 1 4

7

5 3 6

74168

1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector Connector for LDA pressure gauge pipe within suction collector collector - 5. KSB thermal bulb - 6. Electro-valve Electro-valve - 7. Injector.

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4

SECTION 2 - FUEL

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Figure 2

3 2

1

4

75807

1. Fuel filter - 2. Feed pipeline pipeline from filter to fuel pump - 3. Feed pipeline pipeline from priming pump to filter - 4. Priming pump. pump.

Description of working principles Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft. Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For applications to be equipped equipped in cold climate areas, the fuel filter is provided provided with heater).

The fuel arrives therefore to the valve gauging the pressure inside feed pump. The distribution plunger further increases this pressure and delive delivers rs fuel throughou throughoutt the deliver deliveryy pipe pipe fittin fittingg to the injectors. The fuel drawing from the injectors is recovered and delivered to the tank again.

Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase i ncrease fuel pressure in correspondence c orrespondence with the increase increase of the number of revolutions. revolutions.

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F4GE N SERIES

5

SECTION 2 - FUEL

FEED PUMP The rotary type pump is driven by a gear mating the camshaft’s one.

Example of identification V

=

Distr Distrib ibuti ution on rota rotary ry plun plunge ger r

E

=

Pum Pump dim dimensi ension onss

4

=

4 cyli cylind nder erss engi engine ne

12 =

Distrib Distributi ution on plunge plungerr in mm. mm.

1150

=

LV =

Left Left direct direction ion of rotati rotation on

N°. of pump revolutions per minute

Figure 3

1 15 2 14 3 4

5 13 12 6

7 8

9 11 10 30454

Injection pump longitudinal section 1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk 9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate 14. Gauge pin - 15. Counteracting Counteracting spring. Print P2D32N010 E

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6

SECTION 2 - FUEL

F4GE N SERIES

PRIMING PUMP This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to the engine basement and driven by the camshaft.

Figure 4

88209

1. Priming pump - 2. Drive lever - 3. Camshaft.

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F4GE N SERIES

7

SECTION 2 - FUEL

FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing bearing for those equipment equipment applications applications requiring requiring it (cold climate areas), areas), there can be a heater assembled assembled to and a temperat temperature ure sensor. sensor. On some versions, versions, a water presence presence sensor is present present at filtering filtering cartridge base.

Figure 5

1 5 1

2

4 4

3 3 3243t

3244t

1. Fuel filter bearing- 2. Heater - 3. Water dump screw- 4. Filter cartridge 5. Temperature sensor.

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8

SECTION 2 - FUEL

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F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION

1

SECTION 3

Agricultural application Page

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

3

CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . .

4

PART ONE MECHANICAL COMPONENTS . . . . . . . . . . .

7

OVERHAUL OF THE ENGINE . . . . . . . . . . . . . . .

9

- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

- Engine setting operations operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Disass sse embly of app applica licati tion on com compone onents nts . . . . . - Disa

11

- Installation of rear components . . . . . . . . . . . .

19

- Flywheel installation . . . . . . . . . . . . . . . . . . . . .

22

- Installation of front components . . . . . . . . . . .

23

- Completion of engine . . . . . . . . . . . . . . . . . . .

33

pump disassembly and assembly pro- Rotary feed pump cedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

- Power take-off take-off disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

- Feed system bleed procedure . . . . . . . . . . . . .

38

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

39

PART TWO ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . .

41

ELECTRICAL COMPONENT LAYOUT . . . . . . . .

43

- Cooling liquid temperature sensor . . . . . . . . .

44

- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

- KSB Water temperature sensor . . . . . . . . . . .

44

- Elec Electr trom omag agne nets ts asse assem mbled led to feed eed pump ump . . . .

45

- Oil pressure sensor . . . . . . . . . . . . . . . . . . . . .

45

- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

- Pre-post heating resistor . . . . . . . . . . . . . . . . .

45

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F4GE N SERIES

Page

PART THREE - TROUBLESHOOTING . . . . . . . .

47

PART FOUR MAINTENANCE PLANNING . . . . . . . . . . . . .

55

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . .

57

- Checks not included in maintenance planning-daily planning-daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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

58

- Checks and controls . . . . . . . . . . . . . . . . . . . .

58

- Engine oil level check . . . . . . . . . . . . . . . .

58

- Check of fuel system . . . . . . . . . . . . . . . .

59

- Cooling system check . . . . . . . . . . . . . . .

59

- Lubricating system check . . . . . . . . . . . . .

59

water presence presence within fuel fuel filter or - Check of water pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . .

59

- Check of drive belt tensioning . . . . . . . . .

60

- Che Check of belt’s tear and wear status . . . .

60

Check ck and and sett settin ingg of tapp tappet et clea cleara ranc nce e ... - Che

60

- Oil motor and filter replacement . . . . . . .

60

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

61

- Alternator belt replacement . . . . . . . . . . .

62

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3

GENERAL INFORMATION Figure 1

132103

NEF engines engines have have been been designe designed d and develope developed d by FPT specifically for transportation by land and farming equipment in general. general. They are characteristed by diesel cycle 4 stroke atmospheric or supercharged 4 and 6 cylinders each with 2 valves. Feed is provid provided ed by rotary rotary mechanica mechanicall pump pump or on line line according to the equipment application. It differ from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine NOTE

The pictur picture e shows shows applic applicati ation on design designed ed for 4 cylinders version, 2 valves per cylinder, having fuel feed mechanical pump.

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NOTE Data, technical technical specificati specifications ons and performanc performances es gran grantedsha tedshallll bevalid bevalid only only if the the Sett Setter er will will follo follow w and comply with all installation prescriptions provided by FPT. Further Furthermor more, e, the expand expanders ers assemb assembled led by the Setter must always comply with couple, power and number of revolutions based on which the engine has been designed. The sectio section n herein herein descri described bed is compos composed ed or four four direct directori ories: es: directory of mechanical mechanical overhaul overhaul prescribed prescribed in in accordanaccordan- directory ce to the engine’s specific duty, illustrating all necessary operations operations to remove remove and assembly assembly the external external compocomponents of the engine, including cylinder heads, gearbox gearbox of the timing system and of the front part cover; - electrical directory, directory, describing describing the connections connections of the different components, of the pre-post heating gearbox (only for some versions) and of the sensors assembled to the engine; - troubleshooting directory; - directory directory of preventive and regular maintenance maintenance opera tions, providing instructions for the execution of the main operations. Base - Februar 2009

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F4GE N SERIES

CLEARANCE DATA

F4GE9454J*604

Type

ρ

Compression ratio Max. output

Max. torque

2200

Nm (kgm) rpm

400 (40.0) 1250

Loadless engine idling

rpm

Loadless engine peak rpm

rpm

Bore x stroke Disp isplace laceme ment nt

mm cm3

Turbocharger type

LUBRICATION

950

2430 104 X 132 4485 without intercooler Direct injection HOLSET HX25 Forced Forced by gear pump, relief valve single action oil filter

Oil pressure (warm engine) - idling - peak rpm COOLING

ACEA: E3, E5, E7 URANIA LD7

66 (90)

kW (HP) rpm

SUPERCHARGING

bar

17.5:1

bar bar

Water pump control Thermostat - start of openin openingg ºC FILLING

engine sump* 20W40: 0°C to 40°C liters (Very (Very hot countr countries ies,, heavy heavy mission) filter* 15W40: -10°C to 40°C engine sump + filter* liters (Europa/Nor (Europa/Nord d American American mission)

> 0.70 3.1 By centrifugal pump, regulating thermostat, heat exchanger, intercooler Through belt 81 ± 2

13

14

10W30: -28°C to 35°C (Cold mission) * First filling operation

NOTE

Data, features and performances 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.

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F4GE9484F*J608

Type

ρ

Compression ratio

17.5:1

Max. output

kW (HP)

74 (101)

rpm Nm (kgm)

2200 430 (43.0)

rpm

1250

idling

rpm

800

Loadless engine peak rpm

rpm

Bore x stro troke Disp isplace laceme ment nt

mm cm3

Max. torque

5

Loadless engine

SUPERCHARGING

With intercooler

Turbocharger type

HOLSET HX25 Forced by gear pump, relief valve single action oil filter

LUBRICATION bar

Oil pressure (warm engine) - idling - peak rpm COOLING

ACEA: E3, E5, E7 URANIA LD7

2430 104 X 132 4485

bar bar

Water pump control Thermostat - start of opening ºC FILLING

engine sump* 20W40: 0°C to 40°C liters (Very (Very hot countr countries ies,, heavy heavy mission) filter* 15W40: -10°C to 40°C engine sump + filter* liters (Europa/No (Europa/Nord rd American American mission)

> 0.70 3.1 By centrifugal pump, regulating thermostat, heat exchanger, intercooler Through belt 81 ± 2

13

14

10W30: -28°C to 35°C (Cold mission) * First filling operation

NOTE

Data, features and performances 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.

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7

PART ONE - MECHANICAL COMPONENTS

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8


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9


OVERHAUL OF THE ENGINE

Figure 3

Preface Part of the operations illustrated within this section can be partia partially lly execute executed d while while the engine is assemb assembled led on the vehicle, depending on the room available for access to the engine and on the equipment application as well. 2 NOTE With regard to the engine disassembly operations, please apply for information consulting the specific manual manual.. All operat operation ionss of engine engine disasse disassemb mbly ly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required.

3

The following information information relate to the engine overhaul overhaul operations operations only for what concerns concerns the different different components components customising customising the engine, engine, according according to its specific duties.

4

NOTE For specific application exigencies, some units can be assembled to the engine in different positions.

1

Within ”General overhaul” section, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.

5

Engine setting operations operations for the assembly assembly on turning stand

75671

- disa disassem ssemble ble lubrica lubricatio tion n oil exhaus exhaustt pipe pipe from from the turbo-blower: Underneath the turbo-blower loosen the two screws (2), loosen the screw (3) fixing the pipe throughout the stop collar collar (4) fixing the block; finally finally loosen loosen and remove remove the union (5) from the block; plug the pipe ends and the exhaust of the turbo-blower.

Figure 2

Figure 4 3

116386

In orde orderr to apply apply the bracke brackets ts 99361037 99361037 to the engi engine ne block block to fix it on to the stand 99322205 for the overhaul, it is necessary to perform the following operations: On the right hand side: - disass disassem embl ble e pipe pipess (1) (1) from from the the union union (2) fitt fitting ing the lubrica lubricatio tion n oil filter filter (assemb (assembled led on the opposit opposite e side): side): unlock unlock the nuts fixing the pip pipes es (1) and remove remove them them from from the union (2); drain the oil eventual eventually ly still still inside inside the pipes pipes and plug them properly in order to avoid impurity inlet.

2

1 NOTE

For For some some versio versions, ns, the oil filter (3) is direct directly ly assembled assembled on to the heat exchanger: exchanger:in in such case it shall be disassembled using tool 99360076. Warning: the oil filter contains inside aprx. 1 kg. of engine oil. Provide for oil recovery and disposal in compliance compliance with the law and regulations regulations in force. force.

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75672

- Disassemble the starter; Proper Properly ly hold hold the starte starterr (2) and loosen loosen the fixing fixing screws screws (1); assemble the supporting bracket (99361037) using the threaded ports on the basement. Base - Februar 2009

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F4GE N SERIES

Figure 5

Figure 6 1 3 4 5 1

2 75673 75674

On the left hand side: - Disasse Disassemb mble le oil filter filter (1) andbracket andbracket as well well (for (for version versionss with engine oil filter not directly assembled on to the exchanger); Using tool 99360076 operate on oil filter; Loosen the screws (3) removing the bracket together with the filter bearing (4 and 5).

Warning: the oil filter contains inside aprx. 1 kg. of engine oil. Provide tank with sufficient capacity to contain the liquid.

- Assemb Assemble le the second second bracke brackett 9936103 99361037 7 throug throughou houtt the screw-threaded ports (1). - Lift the engine using the rocker arm 99360595 99360595 and put it on the turning stand 99322205. - Drain the oil through the cap underneath underneath the plug. plug.

Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance compliance with the law and regulations regulations in force. force.

Warning: avoid contact of engine oil with the skin: in case of skin contamination rinse in running water. Engine oil is highly pollutant: pollutant: provide provide for disposal disposal in compliance compliance with the law and regulations regulations in force. force.

- The plug and the oil filler pipe (for versions with the engine oil filter fitted directly on the heat exchanger). - Seal Seal the the open openin ingg to prev preven entt fore foreig ign n bodi bodies es from from entering. - Remove Remove the oil level rod together with guide pipe (2); (loosen the guide pipe disassembling from the block); properly pipe the screw-threaded port to avoid inlet of foreign matters.

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Disassembly of application components

11

filter and screw out the - Place a container under the fuel filter condense drain faucet underneath said filter. Carry out complete drainage of the fuel contained therein.

Figure 7 1

completely the faucet and, and, using equipment equipment - Screw out completely 99360076 disassemble oil filter (1). - Disconnect fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump. - Remove the fuel filter filter bearing (4) from the bracket fixed to the engine head.

75675

Proceed disassembling the supercharger: - loosen loosen the fixing fixing nut (1) and remove remove the lubric lubricati ation on pipe pipe from the supercharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger.

screw nuts fixing the supercharger supercharger on the - Loosen the screw exhaust manifold.

Figure 9

- Hold up the supercharger and after lifting it remove the gasket.

Figure 8

70126

disconnect fuel pipelines (2 and 3, Figure 8), in NOTE To disconnect low pressure from the relating pipe fittings, it is Neces Necessar saryy to press press the locking locking fastener fastener (1) as shown in picture B. After having disconnected the pipeline, reset the locking fastener (1) in lock position as shown in. picture A, to avoid avoid any possible possible deformat deformation ion of the fastener itself. 123024

NOTE In some some versi version ons, s, the the fuel fuel filt filter er has has a heat heater er interposed interposed between filter filter support support and filtering filtering cartridge. For For the the versi version onss requ requir irin ingg it, disco disconn nnec ectt the the elect lectrrical ical conn connec ecti tio ons of such such elect lectrrical ical component before removing the fuel filter.

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F4GE N SERIES

BOSCH VE 4/12 F Pump

Figure 11

Figure 10 1

1

2 1

75679 75677

- Disconnect Disconnect the LDA pipe (1) from the head and from the feed pump. Pipe the ends of the pipelines as well as the feed pump and the engine head.

- Disconnect Disconnect the pipelines pipelines (1) and (2) that provide provide feed and fuel recovery between pump and injectors; screw out the nuts fixing the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery recovery pipeline; pipeline; loosen the screws holding the fixing brackets of such pipelines pipelines (1,6, and 7, Figure 12); pipe the pipeline ends. - Disassemble the injectors and remove them from their slot: remove the gaskets.

Figure 12

1

2

3 7

4 6

5

75680

1. Rear bracket bracket fixing screw (on suction collector collector plate) plate) - 2. Fuel recovery recovery pipeline pipeline to pump - 3. Rotary Rotary feed pump 4. Connection Connection nut to pumping elements elements - 5. Injector - 6. Bracket fixing screw to injection injection pump side- 7. Front bracket bracket fixing screw (on suction collector plate).

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Figure 13

13

Figure 15

87409 88102

- Loosen Loosen the two fixing fixing screws screws (2) and disassem disassemble ble priming pump (1).

- Disassemble suction and exhaust manifolds: loosen the 8 screws (1) fixing the suction manifold plate to the cyli cylind nder er head head (two (two of them them have have alre alread adyy been been screw screwed ed-ou -outt since since fixi fixing ng the the pipe pipe brack bracket etss to the the injectors); from the exhaust manifold side; loosen the (2) fixing screws; remove the gaskets.

Figure 14

Figure 16

87406

- Remove tappet caps: Loosen the four fixing screws (1) and lift the caps (2); remove the gaskets. 125114

NOTE On the the cap cap ther there e is a blow blow-b -byy valv valve e for for the the lubrication oil vapours. All the gasket gasketss shall shall always always be replace replaced d during during assembly.

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- Disassemble rocker arm bearings; loosen the two fixing screws screws (2) andremove andremove the comple complete te rocker rocker armbearing armbearing;; withdraw withdraw tappet tappet rods. Repeat Repeat the operation operation for all the remaining rocker arm bearings. - Disassemble water temperature temperature transmitter (1).

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F4GE N SERIES

Figure 17

Figure 19

1

2

123023

- Disassemble Disassemble thermostat thermostat unit; loosen the three fixing screws screws (1) and disasse disassemb mble le the thermo thermostat stat unit unit (2) together with the bracket (5); remove the gasket (3) and the thermostat (4). - Assemb Assemble le the bracke brackett in the origin original al positi position on fixing fixing it with with the screws of the thermostat unit.

75686

- Properly hold the alternator (1) separating it from its bearing by loosening the screw (2); remove screw nut and washer.

NOTE The shape and the size of the thermostat casing vary according to the usage of the engine. The illustr illustrati ations ons theref therefore ore provid provide e a genera generall guideline guideline for the operation operation to be carried carried out. The procedures procedures described described are therefore therefore applicabl applicable. e.

Figure 18

Figure 20

108545

Release Release on the drive belt tensioner tensioner (1) and extract the belt (2) (2) from from the the belt belt pulle pulleys ys from from the the wate waterr pumpone pumponess and and from from the belt rebound pulleys.

88555

Unscrew Unscrew the fixing screws (1) and disassemble disassemble the pipeline pipeline union (2).

Disassemble the belt tensioner (1). Loosen the screws fixing the alternator to the support and disassemble it.

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15


Figure 21

Figure 23

1 107275

- Loosen Loosen the screws screws (5) (5) and disassem disassemble ble the oil oil filter/heat filter/heat (2) exchan exchanger ger beari bearing ng (4), (4), interl interlaye ayerr plate plate (3) and relating gaskets (1). - Disassembl Disassemble e injection injection pump (see specific specific procedure) procedure) and the power take-off underneath.

88140

Fit tool tool 99360330 99360330 (2) in the the start starter er motor motor hous housing ing to be able able to rotate the flywheel.

Figure 24

Figure 22 1 2

3 84071

Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2).

4

Figure 25 75688

- Disassemble cylinder head; head; loose loosen n the the screw screwss (1) (1) and and (2) (2) fixi fixing ng the the cylin cylinde derr head(3); head(3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.

90504

Loosen the screws (1) and disassemble disassemble the pulley (2). - Loosen Print P2D32N010 E

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F4GE N SERIES

Figure 28

Figure 26

116242

- Loose Loosen n the the screw screwss (1 and and 3) and and remo remove ve the the fron frontt cove cover r (2). 78256

- Remove the engine drive shaft fixing ring from the front cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3).

NOTE Takenoteof Takenoteof the the screw(1 screw(1 and and 3) assem assembl blyy posit position ion,, since the screws have different length.

Figure 29

75811

Figure 27

- Loosen the screws (1) and remove remove oil pump (2).

Figure 30 1

2

75695

00904t

- Using the specially provided tie rod (3) for the tool 9936320 99363204 4 and the lever lever (4), (4), withdr withdraw aw the extern external al holding ring (2) from the front cover (1). Base - Februar 2009

Screw out out theoppos theopposit ite e screw screwss (2) (2) fromthe fromthe port portss wher where e - Screw the withdrawal pins shall be introduced (see picture following). - Loosen Loosen remain remaining ing flywhee flywheell fixing fixing screws screws (1) to the engine drive shaft. - Remove the flywheel block tool (2). Print P2D32N010 E

F4GE N SERIES

Figure 31 1


(Demonstrative)

17

Figure 33 4

2

3 84077

75690

- Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.

- Loosen Loosen the screws (2) and remove the flywheel flywheel cover box (1).

NOTE Take Take note note of the screw screw (1) assemb assembly ly positi position,since on,since the screws have different length.

Figure 34

Figure 32

132104

- Turn the engine upside-down. upside-down. - Loosen the screws (2), disassemble the plate (3) and remove the oil pan (1).

NOTE The shape and the size of the sump vary according to the usage of the engine. 00903t

- Remove the flywheel cover box fixing ring using the tool 99340056 (3) to operate on the back tang (5) of the engine drive shaft. Throughout the tool guide ports, drill the internal internal holding holding ring using Ø 3,5 mm drill drill for a 5mm depth. - Fix the tool 99340056 (3) to the ring (1) tightening the 6 screws specially specially provided provided (4). - Proceed with drawing the ring (1) tightening the screw (2). - Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring of the flywheel cover box.

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F4GE N SERIES

Figure 36

Figure 35

99222

- Loosen the screws screws (1) and disassemble disassemble the oil suction rose pipe (3). - Loose Loosen n the the screw screwss (2) (2) and and remo remove ve the the stiff stiffen enin ingg plate (4).

87655

- Remove the gear (1) transmitting motion to the ignition pump and the relevant support.

Figure 37

87424

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

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19

Installation of rear components

Figure 38

Figure 39

70157

Loosen the screws screws (2) and disassem disassemble ble the timing timing - Loosen gearbox (1). 70210

DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX

NOTE Take Take note note of the screw screw (2) assemb assembly ly positio position, n, since since the screws have different length.

- Accurately clean the timing gearbox (1) and the engine block. - Reassemble Reassemble to box (1) to the engine block. block. - Tighten Tighten the fixing fixing screws in the same position position as found out during disassembly and fix the screws to the locking couples listed here below, following the order as shown in the picture.

Screws M8 Screws M10

!

20 ÷ 28 Nm 44 ÷ 54 Nm

It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal.

NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

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F4GE N SERIES

Figure 42

Figure 40

87653

70211

fitted - Use a felt pen to mark the driving gear (1) tooth fitted on the output shaft (2) having the mark ( →) for timing on the side surface.

- Place the dial gauge (1) on the timing timing gear (2) and check that the slack sl ack between the gears (2) and (3) is included in the range range between between 0,076 ÷ 0,280 mm.

Figure 43

NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.

87654

- Fit Fit the the screw screwss (1) (1) faste fasteni ning ng thegears thegears (2) (2) to the the cams camsha haft ft (3) and tighten them to the prescribed pair.

Figure 41

Figure 44

116355

distribution shaft (4) - Turn the engine shaft (3) and the distribution so that by mounting the bevel gear on the latter (1) the stencil stencilledmark ledmark on the gear gear (1) coincid coincides es with with the the groove groove on the gear tooth (2). Base - Februar 2009

87655

- Spline the gear (1) transferring motion to the ignition pump. Print P2D32N010 E

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Figure 46

Figure 45

122588

DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform(no uniform(no crumbs) crumbs),, with with no air bliste blisters,thinn rs,thinner er or irregular irregular zones. zones.

84077

(1) to the engine basement. - Re-assemble the box (1) Tighten the fastening screws (2) to the same position position - Tighten detected before disassembly.

NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

Any eventual eventual imperfection imperfection shall shall be correct correct as soon as possible. Avoid Avoid using using mater material ial in excess excess to seal seal the joint. joint. Too much much sealin sealingg materi material al would would drop drop out on both both sides of the joint and obstruct lubricant lubricant passages. passages.

Figure 47

Couplings must be assembled within 10 minutes after completing the sealing operation.

87659

- Appl Applyy to to the the rear rear tong tongss hold hold (3) of the the engi engine ne driv drive e shaft shaft the part (6) of the tool 99346253, fix it with the screws (1) and spline the new tight ring to it (2). - Place the the part part (5) on the the part part (6), tighten tighten the nut (4) until tight ring assembly (2) into the flywheel box is completed.

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Flywheel installation (Demonstration) Figure 48 1

Figure 50

4

2

3

75690

- Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling .

Usinga hoist hoist,, hand handle le the the flywh flywhee eell to placeit placeit in its its housi housing ng - Usinga inside the flywheel cover box.

84071

Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2).

- Screw up to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine engine flywhee flywheell (1) prope properly rly placing placing it inside inside theflywheel theflywheel cover box. - Tighten Tighten the screws screws (4) fixing the engine flywheel flywheel (3) to the engine engine shaft. shaft.

Figure 49

Figure 51 α

1

2

75695

1 Tighten the engine flywheel (1) fixing screws (2) in two phases: 88140

Fit tool tool 9936033 99360330 0 (2) in the the starte starterr motor motor housi housing ng to be be able able to rotate the flywheel.

- 1st phase; phase; tightening tightening by means means of dynamom dynamometric etric wrench to couple 30 ± 4 Nm; - 2nd phase, 60º ± 5º angle dwell with tool 99395216.

NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Base - Februar 2009

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Installation of front components Figure 52

23

Figure 55

106549

- Remove the fixing ring (2) from the front cover (1), accurately accurately clean the plug surface. surface. 70220

- Assemble oil pump pump (1). - Tighte Tighten n fixing fixing screws screws (2) and lock lock them them to the prescri prescribe bed d couple.

Figure 53

Figure 56

70221

- Apply Apply to the water pump pump (1) a new fixing ring (2).

Figure 54

75710

- Assemble the water pump (1).

76112

- Tighten the screws (2) and lock them to the prescribed couple. Print P2D32N010 E

- Accurat Accurately ely clean clean the contact contact surfac surface e of engine engine bloc blockk and apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs.

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Figure 59

Figure 57

106550

- Assemble Assemble the front cover (2) to the block and tighten tighten the screws (1) fixing them to the prescribed couple.

99222

- Assemble the plate (4), the rose pipe (3), tighten the fixing screws (1, 2 and 4) and fix them to the prescribed couple.

Figure 58

00902t

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Figure 60

25

Figure 62

119123

Set the gasket (1) on the oil sump (2). 3 NOTE The shape and the size of the sump vary according to the usage of the engine.

1

2 75697

- Assemble Assemble the pulley (1) to the engine engine drive shaft , and the distance ring (3). - Tighten Tighten the fixing screws (2) and lock them to the 110 ± 5 Nm couple.

Figure 63 Figure 61

107275 132104

- Assemble oil pan (1), apply the plate over it (2). Tighten the screws sc rews (2) and lock them to the prescribed couple.

NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Print P2D32N010 E

Assemble le the following following element elementss to the block: block: new - Assemb gasket gasket (1), heat exchanger exchanger (2), new gasket gasket (3), oil filter bearing (4). Tighten the screws (5) and lock them to the prescribed couple. NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Base - Februar 2009

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Figure 64

Figure 66 1

2

75686

122589

Lubricate the fixing ring (4) using engine oil and place it - Lubricate on the oil filter (2).

- Connect Connect the alternator alternator (1) to the support. - Tighten Tighten the screw without locking it (2).

- Tighten Tighten the oil filter filter (2) manually on the connector for the support (1) until it is in the end of travel position, tighten the oil filter (2) a further ¾ of a turn (for versions with with the engine engine oil filter fitted fitted direct directly ly on the heat exchanger). - Place a new fixing fixing ring on the block housing (3). (3).

Figure 67

Figure 65

87759

- Place the gasket gasket (1) over the block. The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface.

NOTE Verify that the engine block stand is clean. 88587

Assemble Assemble pipeline pipeline union (1) and tighten tighten screws screws (2) up to to the prescribed torque.

NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Base - Februar 2009

Do not grease the gasket. It is recommended to keep the gasket inside packaging until assembly to the cylinder head. Gasket Gasket assemb assembly ly shall shall be made made follow following ing the direction direction of wording wording printed printed on the gasket gasket itself so that this will be readable as indicated in the picture.

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Figure 68

Figure 70 1

4

2 1 3 3 2 2 3

1 4

75705

75688

- Place the head head (3) over the block and insert insert screws (1) and (2).

NOTE If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.

- Carry Carry out the assemb assembly ly of the rocker rocker arms arms after after previo previous us check of the components.

ROCKER ARM UNIT COMPONENTS: 1. Elastic ring - 2. Spacer- 3. Rocker arms4. Support.

Figure 71

18.975 18.963

NOTE Before using the fixing screws again, measure measure them twice as indicated in the picture, checking checkin g D1 and D2 diameters: if D1- D2< 0,1 0,1 mmthe mmthe scre screw w can can beutili beutilise sed d agai again; n; if D1 - D2 > 0,1 mm the screw must be replace replaced. d.

D2

D1 19.000 19.026

75703

19.000 19.026 75704

SHAFT AND ROCKER ARM BASIC DATA

Figure 69

α

10

4

1

5

11

13

7

2

8

14

9

3

6

Check Check the couplingsurfac couplingsurfaces es of bearin bearingg andshaft: no evide evidence nce of excessive wear shall be detected or damages. Replace if necessary.

Figure 72

12 76115

- Lubricate Lubricate cylinder head bolts bolts and install to head. - Bolts must be torqued using stitching pattern starting with with the the centr centre e bolts bolts and and movi moving ng out. out. Bolts Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degree degreess rotati rotation on for all bolts. bolts. Then a furthe furtherr 90 degrees for the M12 x 140 and M12 x 180.

M12 x 70 M12 x 140 M12 x 180

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50 Nm + 90 deg’s 40 Nm + 180 deg’s 70 Nm + 180 deg’s

13.00 11.00 116391

ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. Tigh Tighte ten n thescrewthescrew-th thre read aded ed nut nut (1) (1) to the the i 4 ÷ 6 Nmcouple Nmcouple..

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Figure 73

Figure 76 2

1 3

122587

Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Rocker Arm adjustment adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable.

Figure 74

75806

On TIER TIER 3 engi engine nes, s, due due to the the addi additi tion onal al lobe lobe for for the the INTER INTERNA NAL L E.G.R. E.G.R.,, it is not possib possible le to use the valve valve cleara clearance nce adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder cylinder must must be checked checked by taking taking it to the T.D.C. T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.

D2

D1

75703

- Insert the tappet driving rods and the Rocker Arm unit. Before Before using using the fixing fixing screws screws again, again, measur measure e them them twice twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 0,1 mm mm the the screw screw can be utili utilised sed again; again; if D1 - D2 D2 > 0,1 mm the the screw screw must must be repl replace aced; d;

Remove Remove the rocker rocker covers covers of the cylinde cylinder; r; remove remove the injector and place the tool 99395097(see Figure 98) to set the cylinder top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft shaft proper properly ly until until you find find the maximum maximum value value on the comparator and then checking that the intake and exhaust valves are both closed. Adjust Adjust theslack betwe between en rocker rocker arms arms andvalves andvalves using using socket socket wrench (1), point wrench (3) and feeler gauge (2). Correct Correct slack is: - suction valves 0.25  0.05 mm - exhaust exhaust valves valves 0.50  0.05 mm.

Figure 75 IGNITION SEQUENCE: 1 - 3 - 4 - 2

Bilance valves cylinder n°

Adjust intake and exhaust valves clearance cylinder n°

1° al PMS

1

1

180°

3

3

180°

4

4

180°

2

2

Engine shaft starting and rotation

125114

- Tighten the screws (2) to the prescribed couple and assemble water temperature sensor (1). Base - Februar 2009

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Figure 77

29

Figure 79

1 75707

- Assem Assemble ble injecto injectors rs after after having having replace replaced d the sealing sealing gasket (1).

NOTE During During assemb assembly ly of injecto injectors, rs, verify verify that that theinjector theinjector sphere sphere is correc correctly tly positione positioned d on the head head housing housing..

Figure 78

(Demonstrative)

123025

- Assemble Assemble exhaust manifold manifold (1) providing providing new gaskets (2).

NOTE The illustration of exhaust manifold may be not matc matchi hing ng your your model odel.. Anyh Anyhow ow,, desc descri ribe bed d procedure is applicable.

Figure 80

123023

- Assemble Assemble thermostat thermostat unit (2) including thermostat thermostat (4) and gasket (3). - Tighten the screws to the prescribed couple. 87406

- Assemb Assemble le cylinde cylinderr covers covers (2) with with the respe respectiv ctive e gaskets gaskets;; - Fit the seal nods and tighten the screws fixing them to the prescribed couple.

NOTE The screws (1) have been have been utilised to fix the bracket (3). Disa Disass ssem embl ble e the the brac bracke kett and and reas reasse sem mble ble components from 1 to 5 as shown in the picture. The gasket must be new.

NOTE Always replace the gaskets using new ones. Check the threads threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. In such case provide for replacement with new nods.

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NOTE The shape and the size of the thermostat casing vary according to the usage of the engine. The illust illustrat ration ionss theref therefore ore provid provide e a genera generall guideline for the operation to be carried out. The procedure proceduress described described are therefore therefore applicable applicable..

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Figure 81

Figure 82 1

7

2 6 5 4 3 75701

86571

Assemble thepulley fan beari bearing ng (8) tighte tightenin ningg thescrews thescrews - Assemble to the prescribed couple.

- Apply Apply on the surface joining joining the suction manifold plate plate (1) a sufficient coat of Loctite 5999 and provide. fixing the screws to the prescribed couple.

- Assemble the alternator (1) tensioning bracket.

- If the the duct duct (6) (6) fromthe fromthe inta intake ke mani manifo foldplat ldplate e (1) (1) has has been been removed, refit it after having fitted a new gasket (5) and components (3) and (4).

- Mount pulley pulley (5) and secure secure it to suppo support rt throug through h screws.

- Tighten Tighten the screws (7) to the prescribed prescribed couple. couple.

pulley (7). - Assemble the transmission pulley automatic belt tensioner (2), tightening the - Refit the automatic fixing bolt to the recommended torque. - Assemble belt Poli-V Poli-V (4) on the pulley (5) of the engine shaft, on the jockey pulley, on the water pump (6) and on the alternator (3), tighten (syn.: tension) the belt by means of the automatic belt tensioner (2).

NOTE If the old belt is to be reassembled examine it carefully carefully in order order to see if there may may be incisions incisions or evident evident signs of yielding yielding..

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Figure 83

Figure 84

2

1

88102

- Assemble Assemble priming priming pump (1) providing providing new gasket and tighten the screws (2) to the prescribed couple.

specific procedure) and - Also assemble feed pump (see specific the power take-off underneath.

NOTE Pump Pump mount mountin ingg requ requir ires es spec specif ific ic proce procedu dure re contained contained in this section. 75700

- Assemble the brackets (1) fixing the fuel pipelines to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture.

BOSCH VE 4/12 F pump Figure 85

1

2

3 7

4 6

5

75680

1. Rear bracket bracket fixing screw (on suction collector collector plate) plate) - 2. Fuel recovery recovery pipeline pipeline to pump - 3. Rotary Rotary feed pump 4. Connection Connection nut to pumping pumping elements elements - 5. Injector - 6. Bracket fixing screw to injection injection pump side- 7. Front Front bracket fixing screw (on suction collector plate).

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Figure 86

1

Figure 88

1

2

75679

- Assemble Assemble the pipes pipes (1) and (2) providing providing fuel feed and recovery between pump and injectors; Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold; fix the pipes to the injectors throughout the brackets previously assembled.

123024

- Assemble the fuel filter bearing (4) to the bracket fixed to the engine head. - Connect Connect the fuel pipelines pipelines (2 and 3) respectively respectively from priming pump to filter bearing and from this last one to feed pump. - Using 99360076 equipment assemble fuel filter (1). (1).

NOTE The filter shall be priory filled with fuel to facilitate feed system bleed operations.

Figure 89

Figure 87

1

70126

75677

- Fix the LDA pipeline pipeline (1) to the engine engine head and to the feed pump.

Base - Februar 2009

NOTE To connect fuel pipelines (3 and 4, Figure 89) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B. After After having having connect connected ed the pipeli pipeline, ne, reset reset the faste fastene nerr (1) into into bloc blockk posi positi tion on as shown shown in pictur A.

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Completion of engine Figure 91

Figure 90 1

75675

116386

Proceed assembling the turbocharger:

On the right hand side:

- Hold the turbochar turbocharger ger and place place it on the exhaust exhaust manifold after having interposed the gasket.

- reassemble the pipes (1) from the union (2) to the lubrication lubrication oil filter filter (placed (placed on the opposite opposite side): side): tighten tighten the pipe rings (1) and connect them to t o the union

- Screw up the fixing nuts of the turbocharger to the exhaus exhaustt manifo manifold ld tighte tightenin ningg them them to the prescri prescribed bed couple. - Tighten Tighten the lubrication lubrication pipe fixing fixing ring. Operate in the same way on the other end of the pipe. Connect it to the upper part of the heat exchanger.

To complete engine assembly it is necessary to remove it from the turning stand.

NOTE In some cases, the oil filter (3) is directly placed on the heat exchanger: in this case it shall be assembled using tool 99360076.

Figure 92

- Using rocker arm 99360595 hold the engine and loosen the screws fixing the brackets to the turning stand 99322205. - Disassemble the brackets 99361037 from the engine after having properly put it on a wooden bearing.

2

3 4

1 5

75671

- Reassemble the lubrication oil exhaust pipeline pipeline (1) from the turbocharger: from underneath the turbocharger tighten the two screws (2); tighten the screw (3) fixing the pipeline to the block throughout the fixing collar (4) to the block; finally tighten the union (5) to the block.

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Figure 93

Figure 94

3 4 5 1

2 75673

On the left hand side: 87712

- Reassemble the starter; prope properly rly hold hold thestarter thestarter (2) andtighten andtighten the fixingscrews fixingscrews (1) to the prescribed couple.

- Assemble oil filter (1) together with bracket (for the versions versions with engine oil filter filter not directly assembled assembled to the exchanger); tighten the screws (3) assembling the bracket (4) including filter bearing (5). Using tool 99360076 screw up oil filter; - The plug and the oil filler pipe (for versions with the engine oil filter fitted directly on the heat exchanger); - Assemble oil level rod together together with guide pipe (2).

engine oil. - Fill up engine Installll the the engi engine ne on the the machi machine ne (for (for insta installllat atio ion n - Insta operations please apply to specific issue).

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Rotary feed pump disassembly and assembly procedure

Find the top dead centre with the tool (99395097) - False injector Figure 96

NOTE This procedure prescribes that: pumping elements to - the fuel pipes (from the pumping the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed; - the the elec electr tric ical al disconnected.

conn connec ecti tion onss

have have

been been

disconnected. - Accelerator cable shall be disconnected.

1

Figure 95

88141

Remove Remove the the rocker rocker cover coverss of the 1 st cylinder; cylinder; remove remove the 1st st inje inject ctor or and and plac place e the the tool tool (1) (1) to set set the the 1 cylinde cylinderr topdead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed.

1

Figure 97

88140

Disassemble the starter from the flywheel box and use tool 99360330 99360330 to rotate the flywheel. flywheel. In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part. On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine and disassemble it only afterwards. The following following procedure procedure analyses analyses this second hypothesis hypothesis since it is the more complex. 84071

Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2) obtaining the TDC of the 1 ° cylinder.

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BOSCH VE 4/12 F Pump

Figure 100

Figure 98

1

2

1

75694 75721

- Unscr Unscrew ew the the side side screw screw that that locks locks the pump pump shaft shaft part partia iallllyy (1) (1) and and remo remove ve spac spacer er (2). (2). This This must must be kepton kepton a side (we recommend to fix it on the pump with a wire or a clip). - Tighten the lateral screw (1) blocking rotation of the pump shaft.

- From the the pump side, loosen the fixing nuts (1) without removing them in order to enable moving the pump backwards using 99340035 extractor. - Assemble Assemble the 99340035 99340035 extractor throughout throughout the two threaded ports (4, Figure 99) and withdraw the gear from the pump shaft. - Properly hold the feed pump pump and loosen completely the fixing nuts. - Withdraw Withdraw the pump from the studs, together together with the gasket.

When the supply pump is to be assembled on the engine the P.M.S. conditions at compression end stage cylinder No. 1 must be carried carried out.

Figure 99 1

4

2

3

NOTE Hold the pump driving gear to avoid interference or crawling crawling during during timing timing gear gear rotatio rotation. n.

75693

- From timing side, remove the cover (2) loosening the screw screwss (1) (1) in order order to have have acces accesss to the the unio union n fixing fixing nut nut (3) to the pump driving gear. - Loosen Loosen the the fixi fixing ng nut (3) and and remo remove ve the the rela relati ting ng washer.

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Figure 101

37

Figure 103 1

1

2

75721 75694

pre-set in its housing on the engine, - Assemble the pump pre-set fitting the shaft into the gear port (not provided with wrench). Tighten the the fixing nuts (1) locking the pump flange in the the - Tighten slot centre.

NOTE The gasket gasket remove removed d during during pump pump disasse disassemb mbly ly shall shall not be utilised utilised again. Always use original spare parts.

prevents pump shaft rotation and - Loosen screw (1) that prevents insert spacer (2). Tighten screw (1)so that it locks spacer (2): in this way the supply pump shaft will be able to rotate freely. - Assemble Assemble the cover (2, Figure 102) including gasket and tighten tighten the screws (1, Figure Figure 102). - Disassemble Disassemble the flywheel rotation/locking rotation/locking tool 99360330; arrange the starting motor in its seat. - Connect all pipelines (from pumping pumping elements to injectors, bleedi bleeding ng recover recoveryy pipes pipes from from injector injectorss to pump, pump, LDA pipeline and feed provided by priming pump). - Connect Connect electrical connections connections to electro-magnets electro-magnets on the hydraulic head and on KSB. NOTE

If the pump has been removed removed with the engine mounted, mounted, connect connect the accelerator accelerator cable, cable, if present present in the application.

Ignition pump control and timing Figure 104

Figure 102

1

4

2

3

(Demonstration)

87720 75693

- On the timing side, throughout the specially appointed port port,, fit fit the the wash washerand erand scre screw w up the the fixi fixing ng nut nut (3) (3) to the the pump shaft. Lock the nut to the 90-95 Nm couple.

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- With With the the inje injecti ction on pump pump inser inserte ted d in relati relating ng seat seat andsecurandsecuring screws screws loosene loosened, d, mount mount compar comparato atorr 99395603 99395603 (2) and 99395100 gauge tool (1), preloading the rod by 2.5 mm. - Rotate the engine derive derive shaft to shift from the condition condition of the first cylinder to TDC end of compression phase. Reset the dial gauges and rotate the engine drive shaft into the opposit opposite e directi direction on until until recove recoverin ringg the conditio condition n of the 1st 1st cyli cylind nder er to TDC TDC in phas phase e of comp compre ress ssio ion n (see (see Figure 97). From From this this positio position n on the compar comparato atorr applied appliedon on the pump pump it must be possible to read the value listed on the pumping pumping element pre-lift table. Section 4. - Rotate the pump in anti-clockwise anti-clockwise direction direction if the stroke is shorter shorter or in clockw clockwise ise directi direction on ifif the stro stroke ke is longer longer,, until until obtaining the stroke prescribed. - Checkin Checkingg these these conditio conditions, ns, lock the pump pump by tighten tightening ing the relevant nuts to the prescribed pair. Base - Februar 2009

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Feed system bleed procedure

Powe Powerr take take-o -off ff disa disasse ssembl mbly y and and asse assemb mbly ly procedure

Figure 105

Figure 106 1

76211

In case any operation operation has been executed executed on the components components of the feed circuit, it is necessary to execute bleeding of air within the system. - Loosen the air bleed screw (3) on the fuel filter (1) and oper operat ate e the the blee bleed d leve leverr for for the the prim priming ing pump pump (2) (2) repeatedly. - Continue executing executing this operation operation until when fuel drains drains from the bleeder vent screw. - Tighten the air bleed screw (3) to a torque torque of 7 ÷ 9 Nm.

2

(Demonstration) 4

3

75720

Where designed, there is a power take-off able to transmit motion to different auxiliary parts. Disa Disasse ssemb mbly ly of such such mecha mechanis nism m shall shall be execu execute ted d as following: Loosen the two screws screws (3) and after after having having remove removed d the - Loosen cover (1) with a specially provided extractor, withdraw the power take-off (2). two gask gasket etss (4) (4) shall shall be repl replace aced d in phase phase of - The two reassemble. - Vary out the assembly fitting the power take-off in its housing housing,, provid providing ing new gasket gasket and checkin checkingg the sprock sprocket et gear meshing. - Assemblecover Assemblecover and gasket gasket andtighten andtighten the screws screws to the prescribed couple.

Base - Februar 2009

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39

Checks and inspections NOTE The follow following ing tests tests shall shall be made made after after engine engine assembly assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.

Start Start the engine, engine, let it run at revolu revolutio tion n regime regimen n slightly higher than idling and wait that the cooling liquid liquid tempe temperat rature ure reache reachess the value value enabli enabling ng thermostat opening, then check that:

- The There re is no wate waterr blee bleedi ding ng from from the the mani manifo fold ldss connecting connecting engine cooling cooling circuit pipeline pipeliness and cabin internal heating, eventually providing to further tighten the locking rings. - Care Carefu fully lly check check the the fuel fuel conne connecti ction on pipe pipess to the the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings. - There is no fuel leakage leakage from fuel pipelines. pipelines. - There is no blow-by from pneumatic pneumatic pipes (if provided). - Veri Verify fy corr correc ectt work workin ingg of the the ligh lighti ting ng leds leds of the the dash dashbo boar ard d conta containi ining ng the the tools tools as well well as of the the equi equipm pmen entt that that was was disco disconne nnecte cted d duri during ng engi engine ne disconnection. - Check and and blow by with care the engine engine cooling system, system, carrying out frequent drainage.

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41

PART TWO ELECTRICAL EQUIPMENT

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ELECTR ELECTRICA ICAL L COMPONE COMPONENT NT LAYOUT LAYOUT

Figure 107

132105

Below there are listed the electric components which are present on F4GE94--- engines. 1.

Cooling Cooling liquid liquid temperature temperature sensor; sensor;

2.

Alte Altern rnat ator or;;

3.

Star Starte ter; r;

4.

(A) Engine Engine STOP STOP sole solenoi noid, d, (B) KSB electromagnet;

5.

Oil press pressure ure sensor sensor;;

6.

Fuel heater (where provided provided for);

7.

KSB Water temperature temperature sensor; sensor;

8.

Resist Resistanc ance e for cold cold start start up; up;

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Cooling liquid temperature sensor

Starter

Figure 108

Figure 109

88314

Starter Starter is usually usually driven by starting starting unit placed placed on the vehicle dashbo dashboard ard and provid provides es positiv positive e tension tension to the tele-sw tele-switc itch h assembled sembled to the starter itself.

C

Specifications:

A B

A

B

BOSCH 3 kW - 12V

C KSB Water temperature temperature sensor 75718

Figure 110

It is a component component integrating integrating a temperature temperature sensor. It is asse assemb mble led d to theengine theengine head head clos close e to the the ther thermo most stat at unit unit and its duty is to detect engine cooling cooling liquid liquid temperature. temperature. Specifications: Range of working temperatures: Connection side

-40 ÷ 130 °C/(+150 °C for < 10 min.)

Bulb side on engine:

-40 ÷ 140 °C

Working tensions:

6 ÷ 28 V

Settings: 80 °C

0.304 ÷ 0.342 k Ω

20 °C

2.262 ÷ 2.760 k Ω

-10 °C

8.244 ÷ 10.661 k Ω

75719

It is assembled to the cylinder head on the engine left hand side. Specifications: Working tensions:12 ÷ 24 V

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Electr Electrica icall Power Power load: load:

2.5 A (induc (induction tion)) 5.0 A (resistance)

Setting:

63±3 ºC Contact Contact opening upon increasing temperature 53±3 ºC Contact Contact closure upon decreasing temperature

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Electromagnets assembled to feed pump

45

Alternator

Figure 111

Figure 113

1

75725

It is place front view on the right hand side of the engine, and is driven by tooth belt.

2 75724a

1 - Engine STOP solenoid; solenoid; 2 - KSB Electro-magn Electro-magnet et

Specifications: Working tension:

12 V

Curr Curren entt deli delive vere red: d:

90A 90A (at (at 6000 6000 rpm) rpm)

Absorption in stand-by:

≤

Sens Sense e of rotat otatio ion: n:

cloc clockw kwic ices es

1mA

Oil pressure sensor Pre-post heating resistor resistor

Figure 112

Figure 114

75723 75722

It is assembled to the block on the engine’s left hand side.

It is a resist resistor or assembl assembled ed to the suction suction collec collector tor and is utilis utilised ed to heat the air during pre-post heating operations.

Specifications:

It is fed fed by a teletele-sw swit itch ch usua usuallyplac llyplaced ed very very clos close e to the the engi engine. ne. 12 ÷ 24 V

Specifications:

Contact closure upon upon lowe lowerr pres pressu sure re::

0.6 0.6 bar bar

Contact opening upon upon highe higherr pres pressu sure re::

Working tension: Maximum possible air flow:

0.9 0.9 bar bar

Working tensions:

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12 V 2 cc / min (pressure 138 kPa)

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PART THREE - TROUBLESHOOTING

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. r e l a e d T P F r u o y e e S

. m e t s y s d e e f n i a r D . . p e r e r n p n l n m p t e i h a o f o b o i e m t s m u s i m . b t t c s a h n u u c c l . l t g e r y j a i l r p e p p i e u n c r e a o t e n u n n a n k t n f e i l h v i a t f o r r e u p o r e t i a e i s t o o l o e e h t s h c e m c e t c e h . c l t w R d e t r j r h e e . c i n a j t n d a i e k i e n d y x u r n a t f r e l p n e e n r t u d e h a k c e i e a a Y t f m e s e n i t e h t i R t g h n s h s s e t p a D a h s t . t s t t t l e e a c E b s y e e s c l u m e a n t . h o s o o e d e d o r M g m c t a t p n c h n n l r E r a i o e l f e a l h n e a s . r e m r R a y f t p c a a m h r h c e r h e o i d e h r r e t s r c d e a n g l r c a n n t e d o t f o i c s p a y e n t e i r h t h s m y n r e e o a a t o e n t w b r a d a c r d t w c l e p e n r l x e e e s e n h e r e e t j t e . u a s t c m o t e a n t l a . k a . k v l h a s u i , a . n n a n r k n a f i d i n o e n n p p r o p r c y a b m e e c c p i g a m u u c e l e e n i m f m i m h t s i s e m y e p e e r d v i h r l h c e e u s u l o C p D u D R R O p C f e C h e r a E b f u R C t t t n r o o i t c c e s . . j l p k a n i n m n i a r u t o m p l E r e S s e n t u e U o f n i i l A t y e r c h l C e e t e j t t . E . u n i n f i r a y L t f o b . l r B e t I o t y h u o . e l o S f t . g p a S a t k e m n p i n r s n w i u O o r s a o s m r e P t t s n l i o t t o e r o r l a i n r e l i t a s t f b t c i t l c o s b y e e w s . e o r u r d y u p n o r f p e b t e l t n d p o m t r u o o e c o o i a C a n D B r I N N A u p F

Y t L r a A t s M t o O n N s A e

o d e n i g n e e h T

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e i s l f u l . e r u p o f f m u e e h l p b t n a t e i o i c u t a s l c l e j Y e p e n u R i D f . E h s e t e h M i t r E w u e R l t c a e a l u r f e p e e p r h m r t e o t e c k w a o . c l e s h p r e l t e R a t C . s l l n e a t u o f s c y l e r c b e c a n n t i a i f f s v E a u d a S r n a u k U p f . r y A h o a l t t i p C e c s e s d E w u r l r L d o B e e I c o g h c S g t r n i S o o o l f g O c t n e P e t c i m u i a e v d e r t e s g d p y i n s . o l B . l m S e r o . r u f o K F t m e t w o l t a t r Y t L a A s M t o O n s N e A o d e n i s g e r n e u t a e r h e T p


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. r e . l a m e t e d s y T s P F d r e e u f o y i n a e r e D S r e - r - t e v e e n e l m e o r a t h e t u o n , r m d h s e y i t a m e . e r t . k s a c b r p m e y a e c a s n l m r i r e R . a r i a d p a p e h . l h e D s t t e d l c n l s . s t p e i r . r c n f g r e u g w i a r o m f l n c o s e i a u r e n o d e e i r n w e u k c f n p r c n d y f s a a e d i e e s o l f i . r o c t n s s t d p n a s w a t . s i h n c s l o a e n e e r e e s r d p e t a c e a s r g r k c n l a e e h p b y n o p j , i s R m h t p n a e s t t p a o y m . s s t e a n l r e h e m u m p l t e l i v u o e e j . o p a u c s c e e d e s a r d d a c n o f t f u h f v a . h d f n h a n t o r n e o t i o h a e r a t l e a t h a e s a c t t w i m l h t h h a n i e e n t t t h e e o l e o h j l y g a t c w f n a l c r t r o h e f n i e i n b e t j n e e t t c t c d a k n r c s s s n p a e a o c i w g l l u e u j u s u v m c i n j e j t e m p s h e o e r u l a i d d i n e i e d p s d n c p R h A A D u a w D C h t m t s A R y c t n f a o i h t s c . e s m j a e n . i c . . n s i s p l l e d v o n n l m l e e r a a t u u e l n w v p f e y o e n h u k c t e l f o t a i b p t e h n c i h c m e e t j u r c r . n . n t e p n . i r o s a t e i a w f n r t d e r l a i i o o w o e l f a i e p t l d l p r f c c o w a e o o e l t r o s o l j u o r t f f a n d o i e e r d c . c m n m l t a i i n a t e r , n p r m g e e r u o s u e g k g n s n t r e r e p o r o b a m u e s l l r y m d I r I I C P s B A c B

t . u o s t u c e n i g n e e h T

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c h i t c a u s m o f o t u g a i n h t h c i w r o d e w E t d e T i . r v r r O o e o l r N c a p k e s d c n e o h T i t P c a F , c r i r l e . u p n o p e o i y a i c s v e n n e e e d O t S . . t . e d n h y y l r . r e o e i t a a . f d i b s s p t c e s s p s e a e e m e m u h c u c p t s . u s t e i e p f p y c l e n f n n o s u s . t f i t c h d i e t d s o r t s e i n o e e a t r e f r a c y r c l d c l n o p t a t o e l a n o j c Y l . c e i g h p o n t a t t e g e n i c a D p s r e a e i r t l t r e E r h r r e e a t n u y h c h . s o h i M d t o o t c r t s E n e m t e t e r w d v t d t r e R a k d i r n s g a l t n s e n t a i u o a l e h h j f a . i i f t t n o g t d d g g e a n e t i r n u e e w e a i o i i a a d o l p s e h h r e m d a i t o t t d m h r h i t t h t t h t f y n a e e t p e c c e i c c k k k k f u e n h i n a l a s h c l c c r c - e t e e e c a r b e e p p e h h h o l h e p e a r o o C C R R W f T C C a p s C C r e . d p n i m l . y u p c p e m n h u o t i . p E t n k S c n . i c e s . l t U j a o i g a s n s A t t i . n . p i c s t d C . n g f u l e o n e j o e e o i w E k n m p r o i c i L . r g b l m n f o e o o e B p t i l r I o t e i v o e a t b g S m h t n r o d S u r a n d t i r n b g l n l e i g i n O p o i l l i p e n m y n P r a o i v a e n m e c t c c u t e e o l l i a n d t c t t t p c t c c c i n w n r n g e e e r i a r r r a y n a e l r r r i u l d t t l f l o o o y o a a u a u r c n c c o n e a o n F M F h W C I I D I

Y L A s M t a O e N h r e A v

o e n i g n e e h T

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r r e e l l a a e e D D T T P P F F r r u u o o y y e e e e S S t . s d a l g n n e u t o i g p p e s r p r s e m r . . e r p u r p p o o m m h t t c i a u u n t e r t p p o i o a a t r n n n v c b o i o i e e i l o g j t t a n d c c i c n e e j j d a y n n h i n l t o u c n i c , e e o t n f e s c c r o a a r i s l l t e n o p e p a u r e e c l m r r e a e r p v i r d r o i f u o o n a ; k k k k q c u p r c c e c . e e e e r t h h h h o C C C t o C e s t l . a r o m t a e l c u i r g v o e e t r a d i r d e a e c v e n p a e s v c f d . n r a o a v d a e n l d o o a w i c t c a n i c r t i o i t a b t a l s m . i m g p a c o t o n e t t i u c v n u a e a s o i r i s y . r t t l B c e . n c o u c S . x a u n F K f E I

s k c a l d n a r a l u g e r r i s i n o i t a r e p o r e n e i g w n o E p


52


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. m e t s y s d e e f n i a r d y r a s s e c e n f I

. . r r e e l l a a e e d d T T P P F F r r u u o o y y e e e e S S . d y - l g l y e k e t s o n r r e r n c n n i e i r b o e u e t f a . s . t o a s v n i r i e l t h d a e d . u l s i l t m e e i c e o i n e h e p u l ( s u t t p t d r a f r s g p l m d g a n o n m r e t i e o n l s i e n i s o o s e r m o c a i d c e f u e y p d n g d a r d m c d a h n n . s l h t s m n e i a t e e o d a i i i r o a t t l f r i o e m n u u n a t h l d t t p p c l a n a m u a o e e s e c q f Y e g a e i o l e y h r l o . a t p t u h e r s i . h e r t t l D t l s s c r e r d n f a i t s s f c h , e E f y l o d s o r s t o a a r n . s p e s e r p n o e o u o h o i c i M e e r t s r a d m s u s e a i t E s t t v p c c e e d o h o o a u t e e e n d o t e t e h e t R l t t t u r e j c t ) . r o m c h - a r e k c l a z e r n e e i n a a a z i s j s p h m e e e l h h t o a h r e t r t s a n h o p e l e i p i h c t i p c n e m u t t r t h n t b e e n e h l e s h c t e e o t c d o l a t i t e a c e i a l e r c r n n h . o t r a h b n h y t h o t h h l p t a t t t a n e h t e t p u o a t n g c n c i a f t h s k n t c n k c a t e u k o a a h s r n a e e u , t t c l c d e e c d t o l e r r e i i a a m r e e j c e s p t p i e r d s e e v e h t e e i s a l a h l h d o c v e e n o l n h e p R D p C j e C h t o C C R C C a n a o C i t A l s d r c n e m e j a . a p n l c i o a d . t y d d e p f t t l e n a e s m u a h p j c u i u a l s r v p d e E f . m o a e S r s u a t n f d o r a y c U s . o l r o i e t t t e c A l e A h l . c n c t e e j C z e e D r z j c . e n e r n i E o c n i . d . L i a o w L n r r f f t c f . e B f . e e o o e n o n I t b r g k d i s e S o r a e n n c p r a e S e o k o o c w y h l u o i e i w t t v O g c b a s a t c r t t . l o . a a e l P k j o e e l o e r r p r t c n s m e b s b n e b e e p r n o i e t t s l p e t p s u o c c f i e i b o i t a o o i t s d a e p t e n r l y r e a r l o l y y y s a l t r r i r u l t c l t t l u o l t n r o p n d e o u r u u g e i c c i i a o n a a u t a e i m n n P a I t I a F A F T r F F I s k c a l d n a r a Y l L u g e A r r M i s O i N n o A i t a r e p o r e n e i g w n o E p


g n i k c o n k l a m r o n b a h t i w g n i n n u r e n i g n E

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t - t s o e e r y e n s s s n i v e h h i n i m u u e t t t . p j s r a v . d h e s e i d c r e d l i h e g n a l u a i e n h a c n . d t a t t q t f u e r a r s t n t h e x n r d e d f e a n o g h a t s n o v a s t a . s e i n / a i u t o h m g j f h t e d m d r s c m t n e a d a a s i n k e e h e . a a t s t a h e t t a s w f c i n l s e i s t a e s s d a l g n h a p k c e r a d t n Y r d e e i t r n e n n c c n e i a e v n e l a s p h r D e R e k a r s s a h . u h a d c p E h . d c u w s f e e s m t e . o n y b g b e t j t g t v t M t n b h h h n e i a p i e o t u e E f t n i . c b h u p w s t t e p i h . n r c s t o h R o r t s t o a p e d d w s t n e s , o y n s a o o i u n l e e l s i e e e e l n b a t t b o b i h s r p a n g n a d s , t c a h p r m e w e s t r t p t d i s i s h e e t n e n e e a r e e e e c o e e p w i a n p h g h h l s . r i t r t w d t t e h l h d y c e e d e t p s t o o l t a g a e s r i t n t e u t p c n o n g y s t n m i c c c c c k n a k a b f e e s c e i a h l a l a a l a u t k e o r c r r c l e r t c c l b r e j e f y t p c a l h p p v i s a i l h r o l a l o e e l e p e n e d d a C R r o R n a R t s h a R R t A n a b p a v D i c C o c C - d s e g s c c v . s o i l e n n r s e e u j s i r n c e . f e i l a e x a h . c e h s e e t t g x w m h u o n t e b n y r d t i l . p f t t s g o r o n e i a u E n r g o u n e e d S i r l o n s s i d o y n i r U u o d a p s t a l n u a l A a a s d c i o c e o . u m r r n e d C f h u b b t a d r i s s . l p u e e E a m n e s u a c s d v e o n o h h L h c i t j m s r w f s o n n i B k o a r u s I e r n o e y l o S n m a a f o t m t c a r l b s s t i c S r s g . o i u x s i x o f t O c o p n p n a e p g e u o n P f e v e . f i h n m n t g o n i e m i c s f i o a p s a e u v g n o m m s o . i s u m v r a h e g y g b i . i n n e i n t f i s n s d g c l n k i e k e s e e i y . p l o n s i c y x s r s p h s e a B e n . i e n n h o l a o s o s i c i o e u o a r S r n . x o o o o i v K p o C L M N i b L N E K t T i t r o g n i k k c c a l o B n . k y l l a a m m r r Y o o L n n A b b a M a h s O i t e . k N w e o k A g m o n s i m n e s n n i u y r g r e n e g e n i e k g r h n a E T d

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. r e l a e d o c e v I r u o y e e S

. r e l a e d o c e v I r u o y e e S

l s s . a w n n n e e i e o i n i s v g n f o . r e u o r t h o t . . n s e r e n s . p e i r e o p i h h . . e o d t r m t t e m h t d m u e n t c e a s i l y u p e e i e n t c e j p n a f e l t a . h n m r c i s m e h i e p o p e r t Y t e i r i t l r t . e h e h t e l t i r u i t r a a D c h f d w f t q o p . t f y E e r . e s n s d o j e e e i n r l r . o e o n e M p a n h a i y t o i n e p o t v i E u s l t i s c a t m g u s n g t e c n r r c a b R t n e t e a c j e n e a b e l e c i o e j t c e a l i e h e e h a e r n e t e e t l n l s i a s l i t c i u p c i n e s p d e h n e r h e e e e e t r r t n e g r o h h h h o n h i l l r t h t t t o o r t t t r i s i e t c h t o e u s o u r e e e a t a d o c c k c u c c c o h k h n e e t n a a r a a r w c c r l s l r l l s o c a e e r r e e p c p e e l e v n o p e j e v e e e h d o h p o i n n C R i o C O t R C n a C C R O R R : - f - l r s e e d l a r o o . e d n n o k a e i i t n l a e s a d r . f i d y t e m d u o e d e . o u c i e d u n g k e t t a e m v o e s i k i c f d n t c e . c f s e i o c s e s s t u s e e o l o a n e d p v o g h u p g n . l e j e r l r y i m n b d t g c b b d i d g d o y i o n e a r r i n a t E x ( t a i t t e u t h l e a r p i r S e ; h n a n y e c e e s e l s a u t r g e r r t n o c U n n s s i g e d e r b t u w o e t e h i i n a o n a s n o l i A a i e s i r v w n d i f t t a u s b p r r f p o h g C a e m i d c c r s n m r r n a i s d e e ; o , l e g t i r o j n l e E h y a e o h s d t o d n i n l s d r L p s t h t i n h r g w ( a t o i o b c i t h B m o y k x r i e i e l n I e o o n e s c m l e i e t . t S u l n r f n s s a w i d c e f l r o r . s f a e g y i c r c h . l S p o s . f t l r s o i t i o r n o t r a s o l a r o r s n j l e o l d O n c a r p i a p o k i e b n i s n c e m c . n p w i r t i . P i n a e o o d o e m o r d m w i c f r w l g e e l e v t o ) e r h r o e t t s e n t e o , l o i t n s t o r i j l o n c l o l a e o d e r n b b c o r n y v n v e n e u a e d i a i a j g f e e o c t o o s i . h ) l t r s a e i v e i o y i e e s l e o k n s i n e n l n n e d s . i i c t e u t i n l a u t c e i i o t e f s c k c l B m r s c r l c u a g r g i s . v f m d t e e v g a c e n e n j o n a S e c n i e x h a h h i o u r n n . f y d e E n u e b a L u F e T v T t A L t s w a v U j I d p E K g o E i r o t o k g c n i a l d B n . e y t l a e k m o Y r L o m n s A b M a y e s r O e g . N k e , A o k e m o u l s m b e y n s i y e g r r e n g . e g e , i t k e e r u h h a l T d B w


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PART FOUR - MAINTENANC MAINTENANCE E PLANNING PLANNING

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MAINTENANCE SCHEDULE On purpose to guarantee guarantee the right engine use please please follow the below indicated maintenance maintenance schedule. It is not only only allowe allowed d but recomm recommend ended ed that that the staff staff in charge charge of the mainten maintenanc ance e should should also also carry carry out the necessa necessary ry mainten maintenanc ance e 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.

Maintenance Maintenance operations operations

Frequency (hours)

Visu Visual al che check ck of engi engine ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Chec Checkk of of bel beltt wea wearr sta statu tuss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-

Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3600

Oil and filter filter replacemen replacementt .

600

Fuel filter and prefilter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600

Belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1800

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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 inconveniences,, even serious, serious, during during engine running. running. Such checks are usually up to the operators operators and to the vehicle’s drivers. drivers. - Level controls controls and checks of any eventual eventual leakage leakage from the fuel, cooling cooling and lubricating lubricating circuits. - Notify the maintenance if any inconvenience is detected of if any filling is necessary. After engine start and while engine is running, running, proceed proceed with the following checks and controls: - check presence presence of any eventual leakage from the fuel, cooling and lubricating 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) emissions) - Visual check of cooling liquid level, in the expansion tank.

Figure 116

MAINTENANCE PROCEDURES Checks and controls controls

Engine oil level check The check check must must be executedwhen executedwhen the engine engine is discon disconnec nected ted and possibly cool. The check can be made using the specially provided flexible rod (1). (1).

Figure 115

(Demonstration)

132106

1

MAX

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

MIN

Some Some applic applicati ations ons are equipp equipped ed with with a level level transm transmitt itter er aler alerti ting ng dash dashbo boar ard d inst instru rume ments nts in case case of insu insuff ffic icien ientt lubrication lubrication oil within the pan.

75748

Draw Draw off off the the rod rod fromits fromits slot slot and and chec checkk that that the the levelis levelis with within in 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 case the the level level result resultss being being close close to the the tag showin showingg minimu minimum m level, level, provid provide e filling filling lubric lubricati ation on of the engine’ engine’ss components.

Base - Februar 2009

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 compliance with the law and regulations regulations in force.

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F4GE N SERIES

Check of fuel system The The chec checkk must must be exec execut uted ed both both when when the the engi engine ne disconnected disconnected and when it is running. running. The check operation operation consists in examining examining the fuel pipelines pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the injection pump and to the injectors.


59

Lubricating system check The The chec checkk must must be exec execut uted ed both both when when the the engi engine ne disconnected disconnected and when it is running. 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.

Cooling system check The The chec checkk must must be exec execut uted ed both both when when the the engi engine ne disconnected disconnected and when it is running. running. Check the pipelines from the engine to the radiator, from the expans expansion ion tank tank and vice-v vice-vers ersa. a. Find Find out any blow-b blow-by, y, verify verify the status of the pipes specially 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.

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 compliance with the law and regulations regulations in force. force.

Check of water presence within fuel filter or pre-filter Due Due to the the high high tempe tempera ratur tures es achi achiev eved ed by the the system system,, do not operat operate e immedi immediate ately ly after after the engine’ engine’ss disc discon onnec necti tion on,, but but wait wait for for the time time deeme deemed d necessary for the cooling. Protect the eyes and the skin from any eventual high pressure pressure jet of cooling liquid.

NOTE The components of the system can be damaged very quickly in presence of water or impurity within the fuel. Timely proceed operating operating on the pre-filter pre-filter (not availa available ble on the engine block) block) to carry out the drainage of the water within the feed circuit.

The coolant should be checked every year before the winter, assess assessing ing the densit densityy andit shouldbe shouldbe changedeverytwo changedeverytwo years. years. There is a bleed screw screw at the base of the fuel filter for draining draining any water in the filter. In case case of new fillin filling, g, procee proceed d bleedi bleeding ng system system,, through the bleeds on the engine. If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.

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Place a container underneath the filter and slightly loosen the screw. Drain the water eventually contained in the filter’s bottom. Lock the screw (max 0.5 Nm locking couple) as soon as fuel starts bleeding.

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Check of drive belt tensioning There There is an automat automatic ic tensione tensionerr which which correc corrects ts the belt belt tension. 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.

Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Correct slack is: - suction suction valves valves 0.25  0.05 mm - exhaust valves 0.50  0.05 mm.

IGNITION SEQUENCE: 1 - 3 - 4 - 2 Danger: if the engine is switched off but is still hot, unexpected unexpected motion of the belt may occur. Wait for engine e ngine temperature cooling as a precaution in order to avoid serious danger danger injury.

Bilance valves cylinder n°

Adjust intake and exhaust valves clearance cylinder n°

1° al PMS

1

1

180°

3

3

180°

4

4

180°

2

2

Engine shaft starting and rotation

Check and setting of tappet clearance Figure 117

2

1 3

Oil motor and filter replacement

Warning: We recommend to wear proper protec tions because of high motor service temperature. The motor oil reaches very high temperature: you must always wear protection gloves.

75806

On TIER TIER 3 engi engines nes,, due due to the addi additio tiona nall lobe lobe for for the the INTERNAL INTERNAL E.G.R., E.G.R., it is not possibl possible e to use the valve clearance clearance adjustment adjustment procedure procedure that that requires requires adjusting adjusting the clearance clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance clearance of both valves on the cylinder in question. question. Remove Remove the rocker rocker coversof coversof the cylind cylinder; er; removethe removethe inject injector or andplace the tool tool 9939509 99395097(s 7(see ee Figure Figure 98) to set the cylind cylinder er top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft shaft prope properly rly until you find find the maximum maximum value value on the comparator and then checking that the intake and exhaust valves are both closed.

Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications. We recommend to carry out the oil drainage when the motor is hot. container for the oil collecting under the - Place a proper container pan connected with the drain plug. - Unscrew Unscrew the plug and then take out the control control dipsick dipsick andthe inserti inserting ng plug plug to ease ease the downfl downflow ow of the lubric lubricaa tion oil.

The oil motor is very pollutant and harmful. In caseof caseof conta contactwiththe ctwiththe skin skin,, wash wash with with muchwate muchwater r and detergent. Protect properly skin and eyes: operate according to safety rules. Dispose of the residual properly following the rules.

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F4GE N SERIES

- After After the comple complete te drainag drainage, e, screw screw the plug plug and carry carry out the clean oil filling.


61

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

!

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

Avoid to breathe the vapors vapors coming from filter. filter.

In case of topping up, don’t mix oils having different features. If you you don’ don’tt comp comply ly with with thes theses es rule rules, s, the the serv servic ice e warwarranty is no more valid.

!

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

After After filter filterss replac replacemen ementt the supply supply equipm equipment ent deaeration must be carried out.

Accord According ing to the applic applicati ations ons the filter filterss positio position n and the quanquan tity can change. Howeverthe Howeverthe followi following ng operat operationsare ionsare valid valid for allapplicat allapplication ions. s.

Whereas you replace the lubrication oil, it is necessary nece ssary to replace the filter. 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 car tridge. For the cartridge replacement use the 9936076-tool.

- Drain the fuel inside inside the filter by operating operating the water release screw. screw. Collect the fuel in a container container without impurities. - Unscrew the cartridge by using the 99360076-tool. - Collect Collect the eventual eventual fuel inside inside the filtering filtering cartridge. cartridge. - Clean the gasket seat on the support and oil slightly slightly the gasket on the new filtering cartridge. cartridge. - Screw manually the new filtering cartdrige cartdrige until when the gasket is completely on its seat. - Tigthen through the 99360076-tool at 10-5 Nm torque. torque.

Warning: the oil filter contains inside a quantity of oil of about 1 kg. Place properly a container for the liquid. Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water. The motor oil is very pollutant: it must be disposed of according to the rules.

- Replace Replace the filtering cartidge cartidge with a new one and screw manually until when the gasket is in contact with the support. - Tigthen by means of the 99360076-tool 99360076-tool of three fourth turn. - Oper Operat ate e the the moto motorr for for some some minu minutes tes and and chec checkk the the leve levell through the dipsick again. If it is necessary, carry out a topping ping up to compen compensat sate e the quanti quantity ty of oil used used for the the fillfilling of the filtering cartridge. cartridge.

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Alternator belt replacement

Warning: with switched off motor (but still hot) the belt can operate operate without without advance advance notice. Wait for the motor temperature lowering to avoid very serious accidents.

Figure 118

88544

- By means of a square wrench of proper size act on point point A, indicated on the figure, of the automatic belt tightener (1) and release the pressure. pressure. - Remove the control control belt (2) from the driven and intermediate pulleys. - Replace Replace the worn belt with a new one. - Place the belt on the pulleys pulleys and the guide rollers. rollers. - Place the automatic automatic tightener tightener in order to key the belt in the functioning position. - Check proper proper position in the races of the pulleys. pulleys.

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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

1

SECTION 4 Overhaul and technical specifications Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . .

3

CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . .

4

TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F . . . . . . . . . . . . . .

10

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . .

11

ENGINE REMOVAL AT THE BENCH . . . . . . . . . .

11

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . .

12

CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . .

12

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

12

- Checking Checking head head supporting supporting surface on cylinder cylinder unit 13

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TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Checking cam lift and pin alignment . . . . . . . .

14

BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

- Bush replacement . . . . . . . . . . . . . . . . . . . . . .

16

- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

- Fitting tappets — camshaft . . . . . . . . . . . . . . . .

16

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .

17

- Measuring journals and crankpins . . . . . . . . . .

17

- Replacing oil pump control gear . . . . . . . . . . .

19

- Fitting main bearings . . . . . . . . . . . . . . . . . . . .

19

- Finding journal clearance . . . . . . . . . . . . . . . . .

19

- Check heckin ingg outp output ut shaf shaftt shou should lder er clea cleara ranc nce e ...

20

CONNECTING ROD — PISTO STON ASSE SSEMBL MBLY . . . .

20

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Page

Page

- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .

27

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

27

- Checking cylinder head wet seal . . . . . . . . . . .

28

- Che Check ckin ingg cyli cylind nder er head head supp suppor orti ting ng surf surfac ace e ...

28

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

29

- Condi onditi tion onss for for prop proper er pinpin-pi pist ston on coup coupliling ng . . . .

22

- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .

23

- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Removing carbon carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

- Fitting ing con connect nectiing rod-pi -pisto ston asse ssembly . . . . . .

24

- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . . . . . . .

29

- Connecting rod-piston coupling . . . . . . . . . . . .

24

VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

- Regrinding — replacing the valve seats . . . . . . .

30

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

31

FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . . .

31

- Refitting the cylinder head . . . . . . . . . . . . . . . .

32

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . .

33

- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .

24

- Fitting connecting rod-piston assembly assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - Finding crankpin clearance . . . . . . . . . . . . . . . .

25

- Checking piston protrusion . . . . . . . . . . . . . . .

26

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F4GE N SERIES


3

GENERAL SPECIFICATIONS Type

4 CYLINDERS

Cycle

Four-stroke diesel engine

Power

See properties described in Section 3

Injection

Direct

Number of cylinders

4

∅

+

+

+.. =

Bore

mm

104

Stroke

mm

132

Tota Totall disp displa lace ceme ment nt

cm3

4485

start tart befor efore e T.D T.D.C. .C. end after B.D.C.

A B

18.5 29.5

start before B.D.C. .C. end after T.D.C.

D C

67 35

TIMING

Checking timing

X

mm

0.25 to 0.05

mm

0.50 to 0.05

Bosch

VE 4/12 F

X

FUEL FEED Injection Type:

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Nozzle type

DSLA 145 P

Injection sequence

1-3-4-2

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CLEARANCE DATA

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS

mm

∅1 ∅1

Cylinder barrels X

104.000 to 104.024 0.4

∅1

X ∅2

Spare pistons type: Size Outside diameter Pin housing

X ∅ 1 ∅2

Piston — cylinder barrels Piston diameter

∅

Piston protrusion

X

55.9 103.714 to 103.732 38.010 to 38.016 0.268 to 0.310

1

0.4

X

∅

3

Piston pin Piston pin — pin housing

Base - Februar 2009

0.28 to 0.52

∅3

37.994 to 38.000 0.010 to 0.022

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F4GE N SERIES


Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X1 Split ring slots X2 X3 X2 X3 * measured on a ∅ of 99.00 mm S 1 S 2 S 3

S1 S2 S3

2.560 2.560 to 2.605 2.605 2.350 to 2.380 3.970 to 3.990

Split rings - slots

1 2 3

0.100 to 0.175 0.060 to 0.110 0.040 to 0.080

1

S

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Small end bush housing Big end bearing bearing housing

2 ∅

0.4

X1 X2 X3

X3

∅

2.705 to 2.735 2.440 to 2.460 4.030 to 4.050

Split ring end opening opening in cylinder barrel:

X 2

∅

mm

Split rings

Split rings

X 1

5

3

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

38.019 to 38.033

Small end bush diameter Inside Spare big end half bearings

∅

S

1.955 to 1.968

Piston pin — bush

0.037 to 0.016

Big end half bearings

0.250 to 0.500

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Type

F4GE N SERIES

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS

∅ 1

mm

82.990 68.987

÷

83.010 69.013

Journals Crankpins

∅ ∅

Main half bearings Big Big end end half half bear bearin ings gs

S1 S2

2.456 to 2.464 1.955 to 1.968

Main bearings No. 1 — 5 No. 2 — 3 — 4

∅ ∅

87.982 to 88.008 87.977 to 88.013

1 2

÷

∅ 2

S 1

S

2

∅ 3

3 3

Half bearings — Journals Journals No. 1 — 5 No. 2 — 3 — 4

0.440 to 0.106 0.039 to 0.111

Half bearings - Crankpins

0.038 to 0.116

Main half bearings Big end half bearings

0.250 to 0.500

Shoulder journal

X1

37.475 to 37.550

Shoulder main bearing

X2

32.180 to 32.280

Shoulder half-rings

X3

37.28 to 37.38

X 1

X 2

Output shaft shoulder

Base - Februar 2009

0.095 to 0.270

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F4GE N SERIES


Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM ∅

mm

1 Valve guide seats on cylinder head

4

∅

7

∅

1

8.019 to 8.039

∅ α

4

7.960 to 7.980 60º

∅ α

4

7.960 to 7.980 45º

Valves:

α

Valve stem and guide

0.039 to 0.079

Housing on head for valve seat:

∅

∅

1

∅1

46.987 to 47.013

∅1

43.637 to 43.663

Valve Valve seat seat outside outside diamet diameter; er; valv valve e seat seat angl angle e on cylin cylinde der r head: ∅2

2

α ∅ α

α

X

Sinking Between valve seat and head Valve seats

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2

47.063 to 47.089 60º 43.713 to 43.739 45º

X

0.136 to 0.872

X

0.050 to 0.830 0.050 to 0.102 0.080 to 0.102 -

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8


Type

F4GE N SERIES

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

mm

Valve spring height:

H

H1

H 2

free spring

H

63.50 / 65.69*

under a load equal to: 329 N 641 N

H1 H2

49.02 38.20

Injector protrusion

X

-

X

∅

∅

∅

1 23 4 ∅

Camshaft bush housings housings No. 1-5

59.222 to 59.248

Camshaft housings No. 2-3-4-5

54.089 to 54.139

5

2 Camshaft journals: 1⇒5

∅

1

∅

∅

53.995 to 54.045

3

∅

Bush inside diameter

∅

Bushes and journals

54.083 to 54.147 0.038 to 0.152

Cam lift:

H

*

H

-

H

-

Instal Installed led as an alterna alternativ tive e

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Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM ∅

∅ 2 ∅

3

Tappet cap outside diameter:

2

∅

mm

1 Tappet cap housing on block

∅

9

∅

1

16.000 to 16.030

∅ ∅

2 3

15.929 to 15.959 15.965 to 15.980

Between tappets and housings

-

Tappets

-

1

∅

Rocker shaft

∅

1

18.963 to 18.975

Rockers

∅

2

19.000 to 19.026

2 Between rockers and shaft

Print P2D32N010 E

0.025 to 0.063

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F4GE N SERIES

TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F

-

NOTE

Technical Code

Pre-lift (mm)

F4GE9454F*J604

0.7 ± 0.05

F4GE9484F*J608

0.8 ± 0.05

INJECTION PUMP CALIBRATION Overhaul and calibration interventions are up to BOSCH assistance network. The contra contract ct technic technical al specif specifica icationcontai tioncontainin ningg the data data to calibr calibrate ate the pump pump at the bench bench is identif identifiedby iedby the code code shown shown on injection pump body and is available at BOSCH BOSCH technical assistance assistance network. Otherwise, refer to FPT Technical Assistance Service.

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F4GE N SERIES


ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH

11

Figure 3

The The foll follow owin ingg inst instru ruct ctio ions ns are are pres prescr crib ibed ed on the the understanding that the engine has previously been placed placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well. (See Section 3 of the manual herein). The section section illustr illustrate atess theref therefore ore all the most most import important ant engine overhaul procedures.

Figure 1

70160

The second second last last main main bearin bearingg cap (1) and the relevant relevant support are fitted with shoulder half-bearing (2). NOTE Take Take note note of lowe lowerr and and uppe upperr half half-be -bear arin ingg assembling positions since in case of reuse they shall shall be fitt fitted ed in the the same same posit positio ion n foun found d at removal.

Figure 4 70158

Remove Remove the screws screws (1) fasten fastening ing the connect connecting ing rod caps caps (2) and remove them. Withdraw the pistons including the connecting rods from the top of the engine block. NOTE Keep Keep the half-bearings half-bearings into their housings since in case of use they shall be fitted in the same position found at removal. 70161

Use tool tool 99360500 99360500 (1) and hoist hoist to remove remove the output output shaft (2) from the block.

Figure 2

Figure 5

70159

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

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Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3).

70162

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zs

REPAIR OPERATIONS CYLINDER UNIT Checks and measurements

Figure 6

Figure 9

s

70163

Remove Remove the screws screws (1) and disconn disconnect ect camshaf camshaftt (3)retainin (3)retainingg plate (2). 70166

NOTE Take note of plate (2) assembling position.

Once Once engi engine ne is disa disass ssem embl bled ed,, clea clean n accu accura rate tely ly the the cylinder-block assembly. Use the proper rings to handle the cylinder unit. The engine block shall not show cracks.

Figure 7

Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspec Inspectt cylinde cylinderr barrel barrel surface surfaces; s; they they shall shall be free free from from seizin seizing, g, scores, ovalisation, taper or excessive wear. Inspection of cylinder barrel bore to check ovalisation, taper and wear shall shall be perform performed ed using using the bore dial gauge 9939568 99395687 7 (1) fitted fitted with with the dial dial gauge gauge previo previously usly set to zero zero on the ring gauge (2) of the cylinder barrel diameter. NOTE Shoul Should d the the ring ring gaug gauge e be not not avai availa labl ble, e, use use a micrometer for zero-setting. 70164

Withdraw carefully c arefully the camshaft (1) from the engine block.

Figure 10

Figure 8

70167

Measurements shall be performed on each cylinder, at three diffe iffere rent nt heig height htss in the the barr arrel and and on two two plane laness perp perpen endi dicu cula larr with with each each othe other: r: one one para parallllel el to the the long longit itud udin inal al axis axis of the the engi engine ne (A), (A), and and the the othe other r perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement. 70165

Withdraw the tappets (1) from the engine block. Base - Februar 2009

Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.4 mm and to the specified specified assembling assembling clearance. Print P2D32N010 E

F4GE N SERIES


13

Check main bearing housings as follows:

Figure 11

- fit the main bearing bearingss caps caps on the supports supports without without bearings; - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value.

α

Replace if higher value is found.

Checking Checking head supporting surface on cylinder cylinder unit When finding the distortion areas, replace the cylinder unit. uni t. Planarity error shall not exceed 0.075 mm. Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.

107804

NOTE In case of regrinding, all barrels shall have the same oversize (0.5 mm).

Print P2D32N010 E

Base - Februar 2009

14


F4GE N SERIES

TIMING SYSTEM Camshaft Figure 12

70169

CAMSHAFT MAIN DATA 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 bushes.

BUSHES Figure 14

Checking Checking cam lift and pin alignment Set the camshaft camshaft on the tailstoc tailstockk and using a 1/100 gauge gauge set on the central support, support, check whether whether the alignment error error is not exceeding 0.04 mm, otherwise replace the camshaft.

Figure 13

70172

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. Measuremen Measurements ts shall be performe performed d on two perpendicu perpendicular lar axes.

70171

Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes. Base - Februar 2009

Print P2D32N010 E

F4GE N SERIES


15

Figure 15

Sec. A-A

107399

CAMSHAFT BUSH AND HOUSING MAIN DATA * Value to be obtained after driving the bushes.

Print P2D32N010 E

Base - Februar 2009

16


Bush replacement

F4GE N SERIES

Fitting tappets — camshaft Figure 18

Figure 16

70176 70174

To replace front and rear bushes (1), remove and refit them using the beater 99360362 (2) and the handgrip 99370006 (3).

Lubrica Lubricate te the tappe tappets ts (1) and fit them them into into the relevant relevant housings on the engine block.

Figure 19

NOTE When refitting the bushes (1), direct them to make the lubricating holes (2) coincide with the holes on the block housings.

70164

Lubric Lubricate ate the camsha camshaft ft suppor supportt beari bearing ng and install install the camshaft (1) being careful to ensure that the bearing or the shaft support seats are not damaged during the operation.

Tappets Figure 20

Figure 17

70238 84053

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK Base - Februar 2009

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.

Print P2D32N010 E

F4GE N SERIES


17

OUTPUT SHAFT Measuring Measuring journals journals and crankpins crankpins

Figure 21

Figure 23

70179

Check camshaft end float (1). It shall be 0.23 ± 0.13 mm.

70182

Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with wi th a micrometer (1) to decide the final diameter to which the pins are to be ground.

Figure 22

NOTE It is recom recomme mende nded d to insert insert the found found values values in the proper table. See Figure 24. Undersize classes are: 0.250 - 0.500 mm.

70180

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

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

Figure 24

108487

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value Print P2D32N010 E

Base - Februar 2009

18


F4GE N SERIES

Figure 25

measured measured on > 45.5 mm radius radius between adjacent journals

70183

OUTPUT SHAFT MAIN TOLERANCES

TOLERANCES

DIRECTION

TOLERANCE CHARACTERISTIC

POSIT SITION

GRAPHIC SYMBOL

Roundness

○

Cilindricity

/○ / //

Parallelism Verticality Straightness Concen centricit city or coaxialit lity Circular oscillation Total oscillation

LEVE LEVELS LS OF IMP IMPORT ORTANC ANCE FOR PROD PRODU UCT CHARAC ARACTE TER RISTI ISTIC CS

GRAP RAPHIC SYMB SYMBOL OL

CRITICAL

©

IMPORTANT

⊕

SECONDARY

⊝

MAIN BEARING ON TIMING SYSTEM CONTROL SIDE

INTERMEDIATE MAIN BEARINGS

FIRST MAIN BEARING ON FRONT SIDE

70237

Base - Februar 2009

Print P2D32N010 E

F4GE N SERIES


19

Finding journal clearance

Replacing oil pump control gear

Figure 28

Figure 26

70161

Refit the output shaft (2). 70184

Check Check that that gear gear toothi toothing ng (1) is not damaged damaged or worn, worn, otherwise remove it using the proper puller (3). When fitting the new gear, heat it to 180 °C for 10 minutes in an oven and then key it to the output shaft.

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

Figure 29

Fitting main bearings bearings Figure 27

128169

- clean accurately accurately the parts and remove remove any trace of oil; 70185

- fit fit caps caps (1), (1), includi including ng the half half bearin bearings gs (2) on the releva relevant nt supports.

NOTE Refi Refitt the the main main bear bearin ings gs that that have have not not been 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 Clean accurat accurately ely the main main half half beari bearings ngs (1) having having the lubricating lubricating hole and fit them into their housings.

NOTE Before using the fixing screws again, measure measure them twice as indicated in the picture, checking checki ng D1 and D2 diameters: if D1- D2< 0,1 0,1 mmthe mmthe scre screw w can can beutili beutilise sed d agai again; n; if D1 - D2 > 0,1 mm the screw must be replace replaced. d.

D2

D1

75703

The second last main half bearing (1) is fitted fitted with shoulder shoulder half rings. Print P2D32N010 E

Base - Februar 2009

20


F4GE N SERIES

Checking output shaft shoulder clearance

Figure 30

Figure 32

70187

Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, stage, with dynamometric dynamometric wrench to 50 ± 6 Nm. - 2nd stage, with dynamometric wrench to 80 ± 6 Nm.

70190

This This check check is perfo performe rmed d by settin settingg a magnet magnetic-b ic-base ase dial dial gauge gauge (2) on the output shaft (3) as shown in the figure, standard value is 0.068 to 0.41. If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between between output output shaft pins and main half bearings.

Figure 31 α

CONNECTING ROD — PISTON ASSEMBLY 70188

-

Figure 33

3rd

stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90 ° ± 5° angle.

70191

CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.

NOTE The pistons are supplied spare with the following following sizes: sta standar ndard d; 0.4 0.4 mm over oversiz size. e. Base - Februar 2009

Print P2D32N010 E

F4GE N SERIES


Figure 34

21

Figure 35

126311

Remove split rings (2) from piston piston using pliers 99360183 (1).

126312

The circlips (2) retaining the gudgeon pin are removed using round-nose pliers (1).

Figure 36

87730

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS Print P2D32N010 E

Base - Februar 2009

22


Piston Piston pins

F4GE N SERIES

Figure 40

Figure 37

18857

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

128140

Check the clearance between the sealing rings (3) of the 2 nd and3rd slot and the releva relevant nt housing housingss on the the piston piston (2), (2), using using a feeler gauge (1).

Conditions Conditions for proper pin-piston coupling Figure 41

Figure 38

32619 41104

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.

DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since Since the first first sealin sealingg ring sectio section n is trapez trapezoid oidal, al, the cleara clearance nce 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).

Split rings Figure 39

In this position, position, use a feeler feeler gauge gauge to check the clearance clearance (X) between ring and slot: found value shall be the specified one.

16552

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

Base - Februar 2009

Print P2D32N010 E

F4GE N SERIES


Figure 42

23

Figure 44

70194

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

Connecting rods Figure 43

80339

NOTE Every connecting rod is marked as follows: - On body body and and cap with with a numbe numberr showingtheir showingtheir coupling and the corresponding cylinder. In case of replac replaceme ement nt it is theref therefore ore necess necessary ary to mark the new connecting rod with the same numbers of the replaced one. - On body with a letter showing the weight weight of the connecting rod assembled at production:

S

V, 1820 to to 1860 (yellow (yellow markin marking); g);

S

W, 1861 1861 to 1900 (green (green marking); marking);

S

X, 1901 to 1940 (blue (blue marking marking); );

Spare connecting rods are of the W class with green marking *. Material removal is not allowed.

88607

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

Print P2D32N010 E

Base - Februar 2009

24


Bushes

F4GE N SERIES

Figure 47

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 coi ncide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.

Fitting connecting rod-piston assembly Connecting rod-piston coupling 126312

Figure 45

Position the piston on the connecting rod according to the diagram diagram shown shown in the figure, figure, fit the pin and and stop it by the split rings (2).

Fitting split rings Figure 48

70198

The piston crown is marked as follows: 1. Part number number and design design modificati modification on number; number; 2. Arrow Arrow showing showing piston piston assemb assembling ling direct direction ion into into cylinde cylinder r barrel, this arrow shall face the front key of the engine block; 3. Marking Marking showin showingg 1st slot insert testing; 4. Manufac Manufactur turing ing date. date. 126311

Use Use plie pliers rs 9936 9936018 0183 3 (1) (1) to fit fit the the spli splitt ring ringss (2) (2) on the the pist piston on.. Split Split rings rings shall shall be fitted fitted with the marking marking “TOP” “TOP” facing facing upwards and their openings shall be displaced with each other by 120 °.

Figure 46

NOTE Split rings are supplied spare with the following sizes: -

stan stand dard ard;

-

0.4 0.4 mm over oversi size ze..

70199

Conne Connect ct piston piston (2) to connect connecting ing rod (4) with with pin (3) so that that the reference arrow (1) for fitting the piston (2) into the cyli cylind nder er barr barrel el and and the the numb number erss (5) (5) mark marked ed on the the connecting rod (5) are read as shown in the figure. Base - Februar 2009

Print P2D32N010 E

F4GE N SERIES


Figure 49

25

Figure 51

70202

DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL 70200

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

NOTE Refi Refitt the the main main bear bearin ings gs that that have have not not been been replaced, in the same position found at removal. Do not try to adapt the half bearings.

- Split ring openings shall be displaced with each each other by 120°; - connecting rod-piston assemblies shall have the same weight; - the the arro arrow w mark markedon edon the the pisto piston n crown crown shall shall befacing befacing the the fron frontt side side of the the engi engine ne block block or the the slot slot obta obtain ined ed on the the piston piston skirt shall shall be correspon correspondin dingg to the oil nozzle nozzle position.

Finding crankpin clearance Figure 52

Fitting Fitting connect connecting ing rod-pist rod-piston on assemb assembly ly into cylinder barrels Figure 50 128170

To measure the clearance proceed as follows: - clean the parts accurately accurately and remove remove any trace of oil; - fit the connecting rod caps (1) with the relevant half bearings (2).

70201

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 99360605 (2) to fit the connecting rod-piston assemb assembly ly (1) into into the cylinde cylinderr barrel barrelss and check check thefollowin thefollowing: g: - the number of each connecting rod shall correspond to the cap coupling number. Print P2D32N010 E

NOTE Before using the fixing screws again, measure measure them twice as indicated in the picture, checking checki ng D1 and D2 diameters: if D1- D2< 0,1 0,1 mmthe mmthe scre screw w can can beutili beutilise sed d agai again; n; if D1 - D2 > 0,1 mm the screw must be replace replaced. d.

D2

D1 75703

Base - Februar 2009

26


Figure 53

F4GE N SERIES

Figure 55

α

70204

- Lubrica Lubricate te the screws screws (1) with with engin engine e oil and then then tighte tighten n them to the specified torque using the dynamometric wrench (2).

70207

If a differ different ent cleara clearance nce value value is found, found, replacethe replacethe half half bearin bearings gs and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.

Figure 54

α

Check Check manual manually ly that that the connect connecting ing rods rods (1) are sliding sliding axiall axiallyy on the output output shaft shaft pins pins and that their end float, measured with feeler gauge (2) is 0.250 to 0.275 mm.

70205

- Apply Apply tool tool 9939521 99395216 6 (1) to the socket socket wrench wrench and tighten screws (2) of 60° ± 5°.

Checking piston protrusion Figure 56

70208

Once connecting rod-piston assemblies refitting is over, use dial gauge 39395603 (1) fitted with base 99370415 (2) to check piston piston (3) protrusion protrusion at T.D.C. T.D.C. with respect respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm. Base - Februar 2009

Print P2D32N010 E

F4GE N SERIES

27


CYLINDER HEAD Removing the valves

Figure 58

1

2 3

Figure 57

4

1 2

6

5 A

75751

75750

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

Valve removal shall be performed using tool 99360268 (1) and pressin pressingg the cap (3) so that that when when compre compressin ssingg the spring springss (4) the cotters cotters (2) can be remove removed. d. Then Then rem remove ove the cap (3) and the springs (4). Repeat Repeat this operation operation for all the valves. Overturn Overturn the cylinder cylinder head and withdraw the valves valves (5).

Figure 59 NOTE

Shou Should ld cylin cylinde derr head head valv valves es be not not repl replac aced ed,, number them before removing in order to refit them in the same position.

2

A = intake side — S = exhaust side

1

75752

NOTE Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.

Print P2D32N010 E

Base - Februar 2009

28


Checking cylinder head wet seal

F4GE N SERIES

Figure 61

Figure 60

D 0,4 C 0,025 0,025 / ¯ 25,4

1

A

B

0,4 TOTAL 0,01 / ¯ 50

C

75756 75753

This check shall be performe performed d using the proper tools.

The rated thickness A for the cylinder head is 95 ± 0.25 mm, max. max. metal metal remova removall shall shall not exceed exceed thickne thickness ss B by 0.13 0.13 mm. mm.

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 After After grindi grinding, ng, check check valve valve sinking sinking.. Regrin Regrind d the valve valve seats, seats, if requir required,to ed,to obtai obtain n the specif specifiedvalue. iedvalue.

NOTE Befor Before e refitt refitting ing,, smear smear the plug plug surface surfacess with with water-repellent sealant.

Replace the cylinder head if leaks are found.

Checking cylinder head supporting surface 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.

Base - Februar 2009

Print P2D32N010 E

F4GE N SERIES


VALVES

29

Figure 64

Figure 62 EXHAUST VALVE

INTAKE VALVE

18882

Check the valve stem (1) using a micrometer (2), it shall be 7.943 to 7.963. 116395

INTAKE AND EXHAUST VALVE MAIN DATA

Remo Removi ving ng carbo carbon n depos deposit its, s, check checkin ing g and and grinding valves Figure 63

Checking clearance between valve stem and valve guide and valve centering Figure 65

1 2

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 P2D32N010 E

75757

Use a magnetic magnetic base dial dial gauge (1) set as shown in the figure, figure, the assembling clearance c learance shall be 0.056 ± 0.096 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. Base - Februar 2009

30


VALVE GUIDE Figure 66

F4GE N SERIES

VALVE SEATS Regrinding — replacing the valve seats

Figure 67

1 2

75754

INTAKE

EXHAUST

70328

Use a bore dial gauge to measure the inside diameter of the valve valve guides guides,, the read value value shall shall comply comply with the value shown in the figure.

Chec Checkk the the valv valve e seat seatss (2). (2). If sligh slightt scori scoring ng orburnou orburnoutt is foun found, d, regrind seats using adequate tool (1) according to the angle values shown in Figure 68.

Figure 68

119982

INTAKE

EXHAUST

VALVE SEAT MAIN DATA Should valve seats be not reset just by regrinding, replace them with wi th the spare ones. Use adequate tool to remove as much material material as possible possible from from the valve seats seats (take care care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

Base - Februar 2009

Heat the cylinder head to 80 ° - 100°C and using the proper beater, fit the new valve seats, previously cooled, into the cylinder head. Use Use adeq adequa uate te tool tool to regr regrin ind d thevalve thevalve seat seatss accor accordi ding ng to the values shown in Figure 68.

Print P2D32N010 E

F4GE N SERIES

31


FITTING CYLINDER HEAD

Figure 69

Figure 71

1

3

1

2 3

1 2

75758

After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial gauge 99395603 (1).

75759

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.

VALVE SPRINGS Figure 70

Figure 72 50676

1 MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before refitting use adequate tool to check spring flexibility. Comp Compare are load load and elasti elasticc deform deformati ation on data with with those those of the new springs shown in the following table.

2 3 4

6

Height

Under a load of

mm

N

5

75751

H (free)

63.50/65.69*

0

H1

49.02

329

H2

38.20

641

*

Position on the cylinder head: the spring (4), the upper cap (3); use tool 99360268 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2).

Installe Installed d as an altern alternati ative ve

Print P2D32N010 E

Base - Februar 2009

32


F4GE N SERIES

Refitting the cylinder head NOTE Before using the fixing screws again, measure measure them twice as indicated i ndicated in i n the picture, checking D1 and D2 diameters: if D1- D2< 0,1 0,1 mmthe mmthe scre screw w can can beutili beutilise sed d agai again; n; if D1 - D2 > 0,1 mm the screw must be replaced replaced..

Figure 73

D2

D1

75703

87759

Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “TOP” (1) facing the head. The arrow shows the point where the gasket thickness is given.

Figure 74

88775

There are two types of head seals, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on Figure 74, at a dist distanc ance e of 45 mm from the centr centre e of the the pist piston on overhandings S1 and S2 in relation to the engine base upper plane then calculate the average: S cil1 = S1 + S2 2 For 4 cylinder cylinder versions: versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value. S=

Base - Februar 2009

S cil1 + S cil2 + S cil3 + S cil4 4

Print P2D32N010 E

F4GE N SERIES


33

TIGHTENING TORQUE TORQUE Cooling Nozzles (M8x1.25x10) Main bearing cap

Rear gear housing assembly (M8x1.25x40) (M8x1.25x25) (M10x1.5) Oil pump (M8x1.25x30) Front cover assembly (M8x1.25x45) (M8x1.25x30) Connec Connectin tingg rod bolts bolts (M11x1 (M11x1.25 .25))

1st stage 2nd stage 3rd stage

kgm 1.5 ± 0.3 5.0 ± 0.6 8.0 ± 0.6 90º ± 5º

24 ± 4 24 ± 4 49 ± 5 8±1 24 ± 4 24 ± 4 1st stage stage 2nd stage 3rd stage

Ladder frame assembly (M10x1.25x25) Oil rifle plugs (M10x1) (M14x1.5) Assemble oil suction tube (M8x1.25x20) Oil pan assembly (M8x1.25x25) (M18x1.50) Set timing pin Fuel pump assembly M8 screw M6 screw M6 nut M10x1.5 flange head nuts pre-torque final torque Fuel uel pump ump gear ear (drive rive gear ear nut) nut) snug snug torq torque ue final torque Timing pin cap of fuel pump Rocker assys (M8) Cylinder head bolts (M12x70) (M12x140) (M12x180) Assy rocker covers (M8x1.25x25) Intake manifold (M8x1.25) Assy air intake connection (M8x1.25) Oil bypass valve into lube filter head (M22x1.5x10) Plug (M12x1.5x12) Exhaust manifold (M10x1.5x65) Water pump (M8x1.25x25) Water outlet connection (M8x1.25x35) (M8x1.25x70) Fan support (M10x1.5x20) Fan pulley (M6) (M10)

Print P2D32N010 E

Nm 15 ± 3 50 ± 6 80 ± 6

30 ± 3 60 ± 5

2.4 ± 2.4 ± 4.9 ± 0.8 ±

0.4 0.4 0.5 0.1

2.4 ± 2.4 ± 3.0 ± 6.0 ±

0.4 0.4 0.3 0.5

60º ± 5º 43 ± 5

4.3 ± 0.5

6±1 11 ± 2

0.6 ± 0.1 1.1 ± 0.2 2.4 ± 0.4

24 ± 4 24 ± 4 60 ± 9 5±1 24 ± 4 10 ± 1 10 ± 1 10 ±15 50 ± 55 15 ±20 85 ± 90 30 ± 35 24 ± 4 50 + 90º 40 + 180º 70 + 180º 24 ± 4 24 ± 4 24 ± 4 80 ± 8 10 ± 1 43 ± 6 24 ± 4 24 ± 4 24 ± 4

2.4 ± 0.4 6.0 ± 0.9 0.5 ± 0.1 2.4 ± 0.4 1.0 ± 0.1 1.0 ± 0.1 1.0 ±1.5 5.0 ± 5.5 1.5 ± 2.0 8.5 ± 9.0 3.0 ± 3.5 2.4 ± 0.4 5.0 + 90º 4.0 + 180º 7.0 + 180º 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 8.0 ± 0.8 1.0 ± 0.1 4.3 ± 0.6 2.4 ± 0.4

33 ± 5

2.4 ± 0.4 2.4 ± 0.4 3.3 ± 0.5

10 ± 2 43 ± 6

1.0 ± 0.2 4.3 ± 0.6

Base - Februar 2009

34


F4GE N SERIES

TORQUE Rear lifting bracket (M12x1.75x30) Crankshaft pulley (M12x1.75x10.9) Flywheel housing (M12x120) (M12x80) (M10x80) (M10x40)

Nm 77 ± 1 2 110 ± 5

kgm 7.7 ± 1.2 11.0 ± 0.5

85 ± 10 85 ± 10 49 ± 5 49 ± 5

8.5 ± 8.5 ± 4.9 ± 4.9 ±

Flywheel housing (M12x1.25)

30 ± 4

3.0 ± 0.4

1st stage 2nd stage Assy rear cover plate to flywheel housing (M8x1.25x16) Fuel injectors Fuel lift pump Turbocharger to exhaust manifold (M10) Oil feed to oil filter head Oil feed to turbocharger (M12x1.5) Oil drain (M8x1.25x16) Alternator to alternator support (M8x1.25x30) Alternator to water inlet conn. assy (M8x1.25x30) Lower alternator mounting (M10x1.25x25) Alternator upper pivot to support (M10) Alternator mounting hardware (M12x1.75x120) Alternator wiring (M6x1.0 nut) Automatic belt tensioner mount (M10) Starter motor to gear case (M10) Screw M8 for fastening cylinder barrel lubricating nozzles Screw M12 for fastening output shaft caps

60º ± 5º

1 st stage 2nd stage 3rd stage

Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Scr Screw M10 for faste stenin ning connect nectiing rod cap caps

Base - Februar 2009

1.0 1.0 0.5 0.5

1 st stage 2nd stage

24 ± 4 60 ± 5 24 ± 4 43 ± 6 24 ± 4 35 ± 5 24 ± 4 24 ± 4 24 ± 4 24 ± 4 49 ± 5 43 ± 6 10 ± 2 45 ± 5 49 ± 5 15 ± 3 50 ± 6 80 ± 6

2.4 ± 0.4 6.0 ± 0.5 2.4 ± 0.4 4.3 ± 0.6 2.4 ± 0.4 3.5 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5 4.3 ± 0.6 1.0 ± 0.2 4.5 ± 0.5 4.9 ± 0.5 1.5 ± 0.3 5 ± 0.6 8 ± 0.6 90º ± 5º

24 ± 4 36 ± 4 60 ± 5

2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60º ± 5º

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F4GE N SERIES

SECTION 5 - TOOLS

1

SECTION 5 Tools Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION 5 - TOOLS

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SECTION 5 - TOOLS

3

TOOLS TOOL NO.

99322205

DESCRIPTION

Revol Revolvin vingg stand stand for overha overhauli uling ng units units (1000 (1000 daN capaci capacity, ty, 120 daN/m daN/m torque)

99340035

Injection pump gear extractor

99340055

Tool to remove remove output output shaft front gasket

99340056

Tool to remove remove output output shaft rear gasket

99340205

Injector pull-our tool

99346252

Tool for fitting fitting output output shaft rear gasket

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SECTION 5 - TOOLS

F4GE N SERIES

v

TOOL NO.

DESCRIPTION

99346253

Tool for fitting fitting output shaft rear gasket

99360076

Tool to remove oil filter (engine) (engine)

99360183

Pliers for removing/refitting piston rings (65 — 110 mm)

99360268

Tool for removing/refitting engine valves

99360330

Flywheel crank handle

99360344

Adapter, cylinder compression test (use with 99395682)

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F4GE N SERIES

SECTION 5 - TOOLS

TOOL NO.

DESCRIPTION

99360351

Tool for stopping stopping the engine flywheel flywheel

99360362

Beater Beater for removi removing/ ng/ref refitti itting ng camsha camshaft ft bushes bushes (to be used used with 99370006)

99360500

Tool for lifting lifting the output shaft

99360595

Lifting rig for engine removal/refitting

99360605

Band for fitting fitting piston piston into cylinder cylinder barrel barrel (60 — 125 mm)

99360616

Engine TDC positioning tool

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SECTION 5 - TOOLS

F4GE N SERIES

TOOL NO.

DESCRIPTION

99361037

Brackets for fastening engine to revolving stand 99322205

99363204

Tool to remove gaskets gaskets

99370006

Interchangeable willow handgrip

99370415

Gauge base for different measurements (to be used with 99395603)

99395097

Tool to check top dead centre (use with 99395604) 99395604)

99395100

Dial Dial gauge gauge hold holder er for for rota rotary ry injec injecti tion on pump pump timi timing ng (use (use with with 99395603)

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F4GE N SERIES

SECTION 5 - TOOLS

TOOL NO.

DESCRIPTION

99395216

Pair of gauges with ½” and ¾” square head for angle tightening

99395603

Dial gauge (0 — 5 mm)

99395604

Dial gauge (0 — 10 mm)

99395682

Diesel fuel engine cylinder compression control device

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SECTION 5 - TOOLS

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F4GE N SERIES

APPENDIX

1

Appendix Page SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . .

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APPENDIX

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F4GE N SERIES

SAFETY PRESCRIPTIONS Standard safety prescriptions prescriptions Particular attention shall be drawn on some precautions that must be followed absolutely 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. personnel as well of the laws in - Be informed and inform personnel force regulating regulating safety, safety, providing providing informatio information n docudocumentation available for consultation.

APPENDIX

3

intervention n if not provided provided with - Do not execute any interventio necessary instructions. - Do not use any tool or equipment for any different operation operation from the ones they’ve been designed and provided for: serious injury may occur. - In case of test or calibration operations operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.

- Keep Keep work workin ingg area areass as clean clean as possi possibl ble, e, ensur ensuring ing adequate aeration.

During maintenance

provided with emergency - Ensure that working areas are provided boxes, boxes, that must be clearly visible and always provided provided with adequate sanitary equipment.

- Never open filler cap of cooling circuit when the engine is hot. hot. Oper Operat atin ingg pres pressu sure re woul would d prov provok oke e high high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC.

- Provide for adequate adequate fire extinguishing means, properly 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.

- Never top up an overheated engine with cooler and utilize only appropriate liquids.

- Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines.

- Always operate when the engine is turned off: whether part partic icul ular ar circ circum umst stan ance cess requ requir ire e maint ainten enan ance ce intervention on running engine, be aware of all risks involved with such operation.

- Smoking in working areas subject to fire danger must be strictly prohibited.

- Be equipp equipped ed with with adequa adequate te and safe contai container nerss for drainage operation of engine liquids and exhaust oil.

Provide Warnings Warnings throughout throughout adequate adequate boards boards signaling signaling - Provide danger danger,, prohi prohibit bition ionss and indica indication tionss to ensure ensure easy easy compre comprehen hensio sion n of the instructio instructions ns even even in case of emergency.

- Keep the engine clean from oil oil tangles, diesel fuel and or chemical solvents.

Prevention of injury - Do not wear unsuitable cloths for work, with fluttering fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion.

- Use of solvents or detergents during maintenance may origin originate ate toxic toxic vapors vapors.. Always Always keep keep working working areas areas aerated. Whenever necessary wear safety mask. - Do not not leav leave e rags rags impr impreg egna nate ted d with with flam flamma mabl ble e substances substances close to the engine. engine.

- Wear safety gloves and goggles when performing the following operations: - filling inhibitors inhibitors or anti-fr anti-frost ost - lubrication lubrication oil oil topping topping or or replacem replacement ent - utiliz utilizati ation on of compre compresse ssed d air or liquid liquidss under under pressur pressure e (pressure allowed: ≤ 2 bar)

- Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate.

Wear safety safety helme helmett when when workin workingg close close to hanging hanging - Wear loads or equipment working at head height level.

- Disconnect batteries batteries before before any interventio intervention n on the electrical system.

- Always wear safety safety shoes when and cloths adhering adhering to the body, better if provided with elastics at the ends.

them - Disconnect batteries from system aboard to load them with the battery loader.

- Use protection cream for hands.

- After After every every interv intervent ention, ion, verify verify that that batter batteryy clamp clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

- Change Change wet cloths as soon as possible possible - In presence of current tension exceeding exceeding 48-60 V verify efficie efficiency ncy of earth earth and mass mass electr electrical ical connect connection ions. s. Ensure that hands and feet are dry and execute working operations utilizing isolating foot-boards. Do not carry out working operations operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material. - Put the dirty rags with oil, diesel diesel fuel fuel or solven solvents ts in anti-fire specially provided containers.

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- Do not utilize fast screw-tightening tools. tools. - Never disconnect batteries batteries when the engine is running.

- Do not disconnect and connect electrical connections connections in presence of electrical feed.

Before re proc procee eedi ding ng with with pipe pipeliline ness disa disass ssem embl bly y - Befo (pneumat (pneumatic, ic, hydraulic, hydraulic, fuel pipes) pipes) verify verify presence presence of liquid liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning.

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APPENDIX

- Avoid incorrect tightening or out of couple. Danger: incorre incorrect ct tighte tightenin ningg may may seriou seriously sly damage damage engine engine’s ’s components, affecting engine’s duration.

priming from from fuel fuel tanks tanks made out of copper copper alloys - Avoid priming and/or and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed.

not conne connect ct any any user user to the the engi engine ne elec electr trica icall - Do not equipment unless specifically approved by FPT. - Do not modify fuel systems or hydraulic hydraulic system unless FPT FPT spec specif ific ic appr approv oval al has has been been rele releas ased ed.. Any Any unauthorize unauthorized d modificati modification on will compromi compromise se warranty warranty assistance and furthermore may affect engine correct working and duration.

For engines equipped with electronic gearbox: - Do not execute execute electric electric arc welding welding withou withoutt having having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80ºC temperature.

F4GE N SERIES

Respect of the Environment - Res Respe pect ct of the the Envi Enviro ronm nmen entt shal shalll be of prim primar ary y impo import rtan ance ce:: all all neces necessa sary ry prec precau auti tion onss to ensur ensure e personnel’s safety and health shall be adopted. - Be informed and inform the personnel personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and orga organiz nize e speci specifi ficc trai trainin ningg cours courses es to ensur ensure e that that personnel is fully aware of such law prescriptions and of basic preventive safety measures.

Collect exhaus exhaustt oils oils in adequa adequate te special specially ly provi provided ded - Collect 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 environme environment nt and within anti-acid anti-acid containers. containers. Warning: batt batter eryy exha exhala lati tion on repr repres esen entt seri seriou ouss dang danger er of intoxication and environment contamination.

- Do not not pain paintt the the compo compone nent ntss and and the the elec electr tron onic ic connections. - Do not vary or alter any data filed in the electronic gear gearbo box x driv drivin ingg the the engi engine ne.. Any Any mani manipu pula lati tion on or alte altera rati tion on of elec electr tron onic ic compo compone nent ntss shall shall tota totally lly com comprom romise ise engin ngine e assi assist stan ance ce warr warran anty ty and and furthe furtherm rmore ore may may affect affect engine engine correc correctt workin workingg and duration.

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manual de reparacion motores iveco F4GE

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