580 M Series 3 F4C Engine Service Training Manual 0407 87630273

REPAIR MANUAL F4GE9454H F4GE9454J F4GE9484D F4HE9484A

Issued 04-2007 - Service Training Edits Book/Form Number 87630273 NA Copyright © 2007. CNH America LLC. All Rights Reserved. Printed in U.S.A. • Bur Source Code No. unknown

ENGINE REPAIR MANUAL

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

Issue Date

Applicable Machine

Remarks

04-2007

F4GE9454H, F4GE9454J, F4GE9484D, F4HE9484A

87630273 NA


ENGINE REPAIR MANUAL TABLE OF CONTENTS CHAPTER 1

DIAGNOSTICS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 CHAPTER 2

445TA ENGINE OVERHAUL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . 2-54 KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION FOR F4GE ENGINES . . . . . . . . . . 2-56 HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . 2-59 EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . 2-97 CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131 MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137 87519803 NA

Issued 04-07

Bur

I

SECTION 1 - ENGINE REPAIR MANUAL

INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-138 2-138 2-141 2-144 2-145 2-147 2-149 2-150 2-153 2-153 2-154 2-157 2-158 2-158 2-159

CHAPTER 3

ELECTRICAL, CHARGING AND START-UP TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-3 LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-6 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

II

Issued 04-07

Bur

87519803 NA


CHAPTER 1

445TA TIER III

DIAGNOSTICS

Issued 04-2007 Book/Form Number 87630273 NA Copyright © 2007. CNH America LLC. All Rights Reserved. Printed in U.S.A. • Bur Source Code No. unknown


CHAPTER 1 - DIAGNOSTICS


1-II

Issue Date

Applicable Machines

Remarks

04-2007

F4GE9454H, F4GE9454J, F4GE9484D, F4HE9484A

87630273 NA

Issued 04-07

Bur

87630273 NA


CHAPTER 1

DIAGNOSTICS TABLE OF CONTENTS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Engine Won’t Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Engine Lacks Power and Runs Erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Engine lacks power and runs erratically (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Engine Exhaust Smoke Black or Dark Grey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Engine exhaust smoke black or dark grey (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine Exhaust Smoke Grey (Verging On White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine Exhaust Smoke Light Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Engine Knocks Irregularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Engine Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Engine Exceeds Max. Revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Engine Won’t Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

87630273 NA

Issued 04-07

Bur

1-1



NOTES

1-2

Issued 04-07

Bur

87630273 NA



TROUBLESHOOTING ENGINE WON’T START No

Batteries fully charged.

Perform the checks described in the electrical section of the shop manual.

Yes Connections to battery terminals are tight and clean.

No

Inspect, clean, tighten nuts or replace terminals if excessively corroded.

No

Perform the checks described in the electrical section of the repair manual.

No

Check using multi meter replace or repair. Refer to Chapter 3 pages 3-5 and 3-14.

No

Refuel tank.

Yes

Replace.

No

Verify timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. Common rail pump bring to certified pump shop.

No

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

Yes

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

Yes

Check and clean the fuel system including the fuel tank.

No

Check fuel pump and replace if necessary.

No

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

No

Check cylinders for proper compression, overhaul engine or make repairs on defective parts,.

Yes Starter motor working properly.

Yes Grid heater system working properly.

Yes Fuel in tank.

Yes Fuel filters plugged.

No Injection pump timed properly.

Yes Injectors working properly.

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

No The fuel system shows traces of water.

No Fuel pump working properly.

Yes Cold start advance solenoid and shut off solenoid both in working order.

Yes Compression good on all cylinders.

87630273 NA

Issued 04-07

Bur

1-3


CHAPTER 1 - DIAGNOSTICS ENGINE OVERHEATS Coolant level correct.

No

Check for leaks, repair leaks and refill to proper level.

Yes Fan working properly.

No

Replace.

No

Replace.

No

Check for leaks, bad bearing, overhaul or replace.

No

Replace.

Yes

Wash down, repair leaks and flush out radiator. If necessary replace radiator.

Yes

Clean or replace faulty parts.

Yes

Clean thoroughly.

No

Check and adjust for correct valve clearance.

No

Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. Common rail pump bring to certified pump shop.

Yes

Replace.

Yes Drive belts serviceable. Yes Water Pump working properly. Yes Thermostat working properly. Yes Radiator plugged or leaking. No Air to Air Cooler and hoses leaking. No Openings for coolant flow within the cylinder head and engine block plugged. No Valve clearance correct. Yes

Injection pump timed correctly.

Yes Cylinder head gasket leaking.

1-4

Issued 04-07

Bur

87630273 NA


CHAPTER 1 - DIAGNOSTICS ENGINE LACKS POWER AND RUNS ERRATICALLY Correct tie rod length between hand throttle and accelerator pedal.

No

Adjust rod length.

Yes

Replace.

Yes

Clean or replace filter.

Yes

Check and clean the fuel system including the fuel tank.

No

Replace.

No

Verify correct timing described in Chapter 2 page 2-120 and 2-141 for mechanical injection. High pressure pump bring to certified pump shop.

No

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

No

Power to KKSB solenoid repair or replace if defective.

No

Replace.

No

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

No

Bring to a certified pump shop for repair.

Yes Fuel filters plugged. No Air filter plugged. No The fuel system shows impurities and or traces of water. No Thermostat working properly. Yes

Injection pump timed correctly

Yes Cold start solenoid (in injection pump) KKSB working properly. Yes Timing plunger (in injection pump) working properly. Yes Fuel pump working properly. Yes Injectors working properly Yes Injection pump rate correct. Yes Speed governor (in injection pump) in working order at all speeds.

No


Yes

87630273 NA

Issued 04-07

Bur

1-5


CHAPTER 1 - DIAGNOSTICS Engine lacks power and runs erratically (continued) Circuit and L.D.A.device both in working order.

No


Yes Injection pump peak adjusted.

No


No

Adjust clearance for proper value.

No

Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.)

No

Repair or replace unit.

Yes Correct valve clearance. Yes Compression good on all cylinders. Yes Turbocharger working properly.

1-6

Issued 04-07

Bur

87630273 NA


CHAPTER 1 - DIAGNOSTICS ENGINE EXHAUST SMOKE BLACK OR DARK GREY Fresh clean diesel fuel in tank.

No

Clean the tank and replace the fuel filter.

Yes

Clean replace if necessary.

No


No

Cold start solenoid (KKSB) working properly. Remove connector measure solenoid 4.8 ± 0.2 ohms. See Chapter 2 page 2-55

No


No


No


No


Yes Air filter plugged. No Grid heater system working properly. Yes KKSB solenoid working properly. Yes Injectors working properly. Yes


Yes Circuit and L.D.A.device both in working order. Yes Injection pump adjusted properly. Yes

87630273 NA

Issued 04-07

Bur

1-7


CHAPTER 1 - DIAGNOSTICS Engine exhaust smoke black or dark grey (continued) Injection pipes intact.

No

Check the condition of pipes and replace them if necessary.

No

Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.).

Yes Compression good on all cylinders.

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE) Grid heater working properly.

No


Yes Coolant level correct.

No

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

No


No


Yes Injectors working properly. Yes


Yes Fresh clean diesel fuel in tank.

No

Clean the tank and replace the fuel filter.

ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption.

1-8

Yes

Check: oil vapor breather, cylinder compression. Leaks into or out of turbocharger. Leaks from valve guides. Overhaul cylinder head or engine if necessary.

Issued 04-07

Bur

87630273 NA


CHAPTER 1 - DIAGNOSTICS ENGINE KNOCKS IRREGULARLY

Knock detected in the crankshaft.

Yes

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

No

Knock detected in the connecting rods.

Yes

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

Yes

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

Yes

Check the following items: Play between the rocker arms and the valves, injection pump timing, valve timing. Adjust to proper specification.

Yes

Check and replace if necessary the gears. Inspect for broken springs, excessive play between the stems and guides, and the tappets and seats. Adjust the clearance.

Yes


Yes

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

Yes


No

Knock detected in pistons.

No

Knock detected in the cylinder head.

No

Knock detected in valve gear.

No Knock detected in injectors. No Knock detected in the engine flywheel. No

Knock detected in the injection pump.

87630273 NA

Issued 04-07

Bur

1-9


CHAPTER 1 - DIAGNOSTICS ENGINE STOPS Fuel in tank.

No

Refuel and drain if necessary.

Yes

Replace.

No

Check the solenoid replace if defective.

No

Check and if defective bring to a certified pump shop for repair.For common rail refer to Chapter 2 page 2-77. For mechanical injection refer to Chapter 2 page 2-53

No

Check and if defective bring to a certified pump shop for repair.

No

Adjust.

No

Adjust play to proper specifications.

No

Replace broken valves.

Yes Fuel filters plugged. No Fuel Shut Off (FSO) solenoid working properly. Yes

Regular injection pump rate.

Yes Injection pump controls working properly. Yes Regular idle speed. Yes Correct play between the valves and rocker arms. Yes Valves intact. EXCESSIVE OR INSUFFICIENT OIL PRESSURE Oil pressure control valve working properly.

No

Check and replace if necessary.

Yes Oil level correct and proper engine oil SAE viscosity.

No

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

No

Check and replace if necessary.

No

Replace the bearings and reface if necessary the crankshaft.

Yes Oil pump and delivery lines in working properly Yes Main bearings and connecting rod bearings in acceptable condition. Yes

1-10

Issued 04-07

Bur

87630273 NA


CHAPTER 1 - DIAGNOSTICS Excessive or Insufficient Oil Pressure continued Low oil pressure caused by fuel dilution.

Yes

Check for leaking shaft seal or leaking injection pump.

No

Replace the bearings and reface if necessary the crankshaft.

Yes

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

Yes

Replace.

No

Check and if defective bring to a certified pump shop for repair.For common rail refer to Chapter 2 page 2-77. For mechanical injection refer to Chapter 2 page 2-53

No

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

No

Check and if wrong adjust to proper value.

No

Check each cylinder for proper compression, overhaul the engine or make repairs on defective parts (valves, piston rings, etc.).

No

Replace.

No

Check and if defective bring to a certified pump shop for repair.

No Main bearings and connecting rod bearings working properly. EXCESSIVE FUEL CONSUMPTION Fuel tank and lines leaking. No Air filter plugged. No

Injection pump operating properly.

Yes Electronic fuel injection system operating properly. Yes Valve adjustment correct. Yes Compression good on all cylinders.

ENGINE WON’T STOP Fuel Shut Off solenoid working properly. Yes Speed governor working properly.

87630273 NA

Issued 04-07

Bur

1-11



NOTES

1-12

Issued 04-07

Bur

87630273 NA


CHAPTER 2

445TA TIER III

445TA ENGINE OVERHAUL

Issued 04-2007 Book/Form Number 87630273 NA Copyright © 2007. CNH America LLC. All Rights Reserved. Printed in U.S.A. • Bur Source Code No. unknown


CHAPTER 2 - 445TA ENGINE OVERHAUL


2-II

Issue Date

Applicable Machines

Remarks

04-2007

F4GE9454H, F4GE9454J, F4GE9484D F4HE9484A

87630273 NA

Issued 04-07

Bur

87630273 NA



CHAPTER 2

445TA ENGINE OVERHAUL TABLE OF CONTENTS F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 F4GE9454H and F4GE9454J Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 F4GE9484D Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 F4HE9484A Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EGR Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Control for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Control for F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head for F4GE9454h and f4GE9454J Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head for F4GE9484D Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head for F4HE9484A Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves and Valve Seats for F4GE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valves and Valve Seats for- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-24 2-24 2-25 2-25 2-26 2-27 2-28 2-28 2-29 2-30 2-31 2-32 2-33 2-34 2-36 2-37

ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan (Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Vapor Recirculation for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Vapor Recirculation for- F4HE Engines with Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blow-By Recirulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Vapor Recirculation for- F4HE Engines without Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-41 2-42 2-42 2-42 2-43 2-43 2-44 2-45 2-45 2-46

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 87630273 NA

Issued 04-07

Bur

2-1



Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48 AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Boosting Version Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49 Inter-Cooled Engine Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50 MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51 Mechanical Fuel lift Pump- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52 Mechanical Injection Working Principles- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53 ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . . . . . 2-54 KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 MECHANICAL INJECTION FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION . . . . . . . . . 2-56 Parts needed for pressure/ vacuum testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57 Normal system operating observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58 HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . 2-59 EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 Engine Preheating Element Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Phase Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Injection Pressure Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Pilot and Main Injection Advance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Idle Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Maximum Engine Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Smoke Control Under Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 After Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Control Of Working Speed In Normal Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60 Recover Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61 FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 Fuel Supply System Diagram- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64 Mechanical Feed Pump- Normal Operating Condition- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 Mechanical Feed Pump- Outlet Overpressure Condition In Exhaust Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65 Fuel System Bleeding Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66 High Pressure Pump Type CP3.3- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67 High Pressure Pump Inside Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69 Operating Principal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71 COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72 COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 Injection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74 Electro-Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75 Pressure Limiter for Fuel Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76 CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77 Low Pressure Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77 Low - Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78 Test On Pressure Relief Valve On Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79 Test On Fuel Backflow From the Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80 SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82 Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82 Crank Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84 2-2

Issued 04-07

Bur

87630273 NA



Removing Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 Removing Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88 SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97 CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 Checking Crankcase Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 Checking Eccentric Lift and Bearing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Cam Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Tappets and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-102 2-102 2-103 2-103 2-103

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

2-105 2-105 2-107 2-107 2-109

PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditions for Correct Pin/Piston Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Twisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Flexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling Piston To Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing Connecting Rod-Piston Assemblies In Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuring Crank Pin Assembly Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Piston Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-109 2-111 2-111 2-112 2-113 2-113 2-114 2-114 2-114 2-115 2-116 2-116 2-118

VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121 Counter Balancer Timing- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124 MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Descaling, Check and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Valve Guide Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Seats Regrinding- Replacing Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-131 2-131 2-131 2-132 2-132 2-133 2-134

MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 Installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 87630273 NA

Issued 04-07

Bur

2-3



Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135 Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135 Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136 Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137 INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137 INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138 INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138 INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141 REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144 Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145 ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145 Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146 CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147 Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147 Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148 Checking Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149 Valve Cleaning, Checks and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149 Checking Valve guide wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150 VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150 Valve Seats- Regrinding, Replacing, Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150 VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153 INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153 Fitting Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154 Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154 INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154 Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156 Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156 LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157 ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158 INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158 INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159 Injector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160 Installing Tappet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160 Exhaust Manifold/Turbo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-161 Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162 Fuel Filter Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162 Wiring Harness Connections to the Engine- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-163

2-4

Issued 04-07

Bur

87630273 NA



F4GE- ENGINES

Figure 2-1

BS06N188

F4GE9454H & F4GE9454J ENGINE

Figure 2-2

BS06N189

F4GE9484D ENGINE

The NEF F4GE engines are characterized by a four stroke atmospheric or turbocharged two valves per cylinder. Fuel feed is provided by rotary mechanical injection pump. 87630273 NA

Issued 04-07

Bur

It differs from other applications because of the provision of different power, power take-off, for different collector configurations, boost turbine and after cooler.

2-5



F4HE- ENGINES

Figure 2-3

BS07D071

F4HE9484A ENGINE

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

1

BS07D072

Figure 2-4

F4HE9484A ENGINE SHOWING THE EDC7UC31 CONTROL BOX (1).

2-6

Issued 04-07

Bur

87630273 NA



CODING OF SOURCE ENGINES ENGINE MODEL BREAKDOWN DISCRIPTION

F

4

G

E

9

4

8

4

D

*

J

6

1= Common Rail 4 valve 2= Common Rail 2 valve 3= In Line 4 valve 4= In Line 2 valve 5= Rotary 4 valve 6= Rotary 2 valve Emissions Level: J= Tier 3 Approved power rating Application: 4= Agricultural. machinery - Earth moving Fuel / Injection / Induction 0= Diesel injection - naturally aspirated 5= Diesel injection - Turbocharged 8= Diesel injection - Turbo - after cooler Number of Cylinders 4= 4 cylinders 6= 6 cylinders 9= Internal EGR E= Engine Type of crankcase: A= Non-structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter B= Non-structural crankcase 102 mm - 2valves - 3.9 or 5.9 liter C= Structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter D= Structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter E= Structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter F= Structural crankcase 104 mm - 2 valves - 3.9 or 5.9 liter G= Non-structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter H= Non-structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter Engine Family: Includes 4 cylinder and 6 cylinder in both 2 valves and 4 valves per cylinder mechanical and common rail fuel systems

87630273 NA

Issued 04-07

Bur

2-7



ENGINE PROPERTIES A F4GE9454H F4GE9454H F4GE9454J F4GE9454J F4GE9484D F4GE9484D B

*J601

*J602

*J600

*J601

*J601

C

4 Cylinders

D

4485 cm³ (273.7 cubic inches)

E

74 kW (100 h.p.) 2000 rpm

74 kW (100 h.p.) 2000 rpm

66 kW (90 h.p.) 2000 rpm

F G H

66 kW (90 h.p.) 2000 rpm

93 kW (126 h.p.) 2200 rpm

F4HE9484A

*J602

* J101

93 kW (126 h.p.) 2200 rpm

104 kW (141 h.p.) 2200 rpm

Direct Injection High pressure Common rail EDC7UC31

Rotary Injection pump T.C. (Boosted)

T.A.A.- (Boosted by Intercooler)

A. Type of engine B. Engine model C. Number of cylinders D. Total displacement E. Maximum power currently available F. Type of Injection G. Injection system H. Air supply system

2-8

Issued 04-07

Bur

87630273 NA



GENERAL ENGINE FEATURES

1

2

6

3

7

4

5

8

9

10

11 Figure 2-5

BS06K013

REF. NO.

ENGINE TYPE

F4GE9454H J601

J602

F4GE9484D

J600

J601

J601

Boosted

Air

Direct

2

Number of cylinders

3

Bore

104 mm (4.1 in.)

4

Stroke

132 mm (5.2 in)

5

Total displacement

6

Compression ratio

Maximum Torque

9

No-load idle

10

No-load peak rpm

11

4 in-line

4485cm³ (273.7 cubic inches) 17.5: 1

Maximum power rating (net power at flywheel ISO 14396)

8

Issued 04-07

Bur

16.5: 1

74 kW

66 kW

93 kW

104 kW

2000 rpm

2000 rpm

2200 rpm

2200 rpm

100 hp

90 hp

126 hp

141 hp

2000 rpm

2000 rpm

2200 rpm

2200 rpm

400 Nm

375 Nm

510 Nm

608 Nm

1250 rpm

1250 rpm

1250 rpm

1600 rpm

295 lb.-ft.

277 lb.-ft.

376 lb.- ft.

448 lb.-ft.

1250 rpm

1250 rpm

1250 rpm

1600 rpm

without intercooler HOLSET HX25

Boosting (type of turbocharger)

87630273 NA

J101

Boosted by intercooler

Injection

7

J602

F4HE9484A

4- Stroke diesel engine

Cycle 1

F4GE9454J

with with intercooler intercooler HOLSET HX25 HOLSET HX27W

2-9



12

13

14

15

16

17

18

19

Figure 2-6

BS06K014

REF. NO.

ENGINE TYPE

Lubrication. 12

Cooling.

F4GE9454J J600

F4GE9484D

J601

J601

J602

F4HE9484A J101

Forced by means of gear pump, pressure relief valve, oil filter. 0.70 bar (10 psi) 3.50 bar (50 psi)

4.0 bar (58 psi)

By centrifugal pump, regulated by thermostat, heat exchanger, intercooler By means of Belt

Water pump drive. Thermostat start of opening temperature.

14

J602

Oil pressure with hot engine: at idle rpm. Oil pressure with hot engine: at peak rpm.

13

F4GE9454H J601

79 to 83° C (174 to 181° F)

Oil capacity engine sump.

Refer to Owners Manual

Oil capacity engine sump + filter.

Refer to Owners Manual

15

Fuel feed type

Rotary Bosch - VE4 / 12 F

High Pressure Common Rail, EDC7UC31

16

Pump setting

0° ± 0.5°

N.A.

17

Start of delivery

0.95 to 1.05 mm (0.0374 to 0.0413 in.)

N.A.

Type of injector

N.A.

CRIU 2

18

Injection sequence

19

Injection pressure

2-10

1 -3 -4 -2 250 to 1600 bar

N.A.

3626 to 23206 psi

Issued 04-07

Bur

87630273 NA



CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY

1

2

44

6

5

8

3

7

9

10 Figure 2-7

BS06K015

REF. NO. 1

ENGINE TYPE

Cylinder bore.

F4GE9454H

F4GE9454J

F4GE9484D

J601

J600

J601

J602

J601

F4HE9484A

J602

J101

104.000 to 104.024 mm. (4.0945 to 4.0954 in.)

Pistons: 2

Measurement dimension.

X=

55.90 mm. (2.20 in.)

Outer diameter.

Ø1=

103.714 to 103.732 mm. (4.0832 to 4.0839 in.) 38.010 to 38.016 mm. (1.4965 to 1.4967 in.)

Pin seat.

Ø2=

3

Piston - cylinder liners.

0.252 to 0.294 mm. (0.0099 to 0.0116 in.)

4

Piston diameter.

Ø=

5

Protrusion of pistons from crankcase.

6

Piston pin.

Ø3=

7

Piston pin-Pin seat.

0.01 to 0.022 mm. (0.0004 to 0.0009 in.)

Piston ring grooves (measured on Ø of 99.0mm 3.898 in.) 8 Piston rings (measured 1.5 mm 0.05905 in. away from external Ø).

9 10

Piston rings - Slots. Piston rings.

87630273 NA

0.4 mm. (0.0157 in.) 0.28 to 0.52 mm (0.01102 to 0.02047 in.) 37.994 to 38.000 mm. (1.4958 to 1.4961 in.)

X1=

2.705 to 2.735 mm. (0.1065 to 0.1077 in.)

X2=

2.44 to 2.46 mm. (0.0961 to 0.0969 in.)

X3=

4.03 to 4.05 mm. (0.1587 to 0.1594 in.)

S1=

2.560 to 2.605 mm. (0.1008 to 0.1026 in.)

S2=

2.350 to 2.380 mm. (0.0925 to 0.0937 in.)

S3=

3.970 to 3.990 mm. (0.1563 to 0.1571 in.)

1=

0.100 to 0.175 mm. (0.0039 to 0.0069 in.)

2=

0.060 to 0.110 mm. (0.0024 to 0.0043 in.)

3=

0.040 to 0.080 mm. (0.0016 to 0.0031 in.)

0.40 mm. (0.0157 in.)

Issued 04-07

Bur

2-11



11

12

14

13

15

17 16 Figure 2-8

BS06K016

REF. NO.

ENGINE TYPE

F4GE9454H J601

J602

F4GE9454J J600

J601

F4GE9484D J601

J602

X1=

0.30 to 0.40 mm. (0.0118 to 0.0157 in.)

X2=

0.60 to 0.80 mm. (0.0236 to 0.0315 in.)

X3=

0.30 to 0.55 mm. (0.0118 to 0.0217 in.)

Connecting rod small-end bearing seat.

Ø1=

40.987 to 41.013 mm. (1.6137 to 1.6147 in.)

Connecting rod large-bearing seat.

Ø2=

72.987 to 73.013 mm. (2.8735 to 2.8745 in.)

Inner

Ø3=

38.019 to 38.033 mm. (1.4968 to 1.4974 in.)

Big end half bearings

S=

14

Connecting rod small-end bearing seat.

0.250 to 0.500 mm. (0.0098 to 0.01968 in.)

15

Piston pin - bearing.

0.019 to 0.039 mm. (0.0007 to 0.0015 in.)

11

12

Piston ring gaps in cylinder liner.

F4HE9484A J101

Connecting rod small-end bearing diameter. 13

16

17

2-12

1.955 to 1.968 mm. (0.0770 to 0.0775 in.)

Measurement dimension.

No Information Available

Maximum error on connecting rod axis parallelism.


Bearing journals

Ø1=

82.990 to 83.010 mm. (3.2673 to 3.2681 in.)

Crank pins

Ø2=

68.987 to 69.013 mm. (2.7160 to 2.7170 in.)

Main half bearings (supplied as spares).

S1=

2.456 to 2.464 mm. (0.0967 to 0.0970 in.)

Connecting rod half bearings.

S2=

1.955 to 1.968 mm. (0.0770 to 0.0775 in.)

Numbers 1, 5

Ø3

87.982 to 88.008 mm. (3.4638 to 3.4649 in.)

Numbers 2, 3, 4

Ø3=

87.977 to 88.013 mm. (3.4637 to 3.4651 in.)

Main bearing- journals

Issued 04-07

Bur

87630273 NA



18

19

20

22

21

23 Figure 2-9

BS06K017

REF. NO.

F4GE9454H

ENGINE TYPE

J601

J602

F4GE9454J J600

J601

F4GE9484D J601

J602

F4HE9484A J101

Half bearing- journals. Numbers 1, 5 18 Numbers 2, 3, 4 Half bearing - crank pins.

0.064 to 0.095 mm. (0.0025 to 0.0037 in.)

0.041 to 0.119 mm. (0.0016 to 0.0047 in.)

0.059 to 0.100 mm. (0.0023 to 0.0039 in.)

0.041 to 0.103 mm. (0.0016 to 0.0041 in.)

0.064 to 0.090 mm. (0.0025 to 0.0035 in.)

0.033 to 0.041 mm. (0.0013 to 0.0016 in.)

19

+0.250 mm. (0.0098 in.) Main half bearings Big end connecting rod half bearings. +0.500 mm. (0.0197 in.)

20

Main journal of thrust bearing.

X1= 37.475 to 37.550 mm. (1.4754 to 1.4783 in.)

21

Main bearing housing of thrust bearing.

X2= 32.180 to 32.280 mm. (1.2669 to 1.2709 in.)

22

Shoulder half ring.

X3= 37.280 to 37.380 mm. (1.4677 to 1.4716 in.)

23

Crankshaft shoulder.

0.095 to 0.270 mm. (0.0037 to 0.0106 in.)

87630273 NA

Issued 04-07

Bur

2-13



VALVE GEAR - CYLINDER ASSEMBLY

1

3

2

7

6

5

4

8 Figure 2-10

BS06K018

REF. NO. 1

ENGINE TYPE

Valve guide seats on cylinder head.

Valves - Intake.

F4GE9454H

F4GE9454J F4GE9484D

F4HE9484A

J601

J600 J601 J601 J602

J101

J602

Ø1= 8.019 to 8.039 mm. (0.316 to 0.317 in.)

7.042 to 7.062 mm. (0.277 to 0.278 in.)

Ø4= 7.960 to 7.980 mm. (0.313 to 0.314 in.)

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

angle=

60° ± 0.25°

60° ± 0.25°

2 Ø4= 7.960 to 7.980 mm. (0.313 to 0.314 in.)

Valves - Exhaust.

Angle= 3

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

45° ± 0.25°

45° ± 0.25°

Valve stem and respective guide.

0.059 to 0.086 mm (0.002 to 0.003 in.) 0.052 to 0.092 mm (0.002 to 0.003 in.)

Seat on head for valve seat. -

Intake.

46.987 to 47.013 mm (1.850 to 1.851 in.)

34.837 to 34.863 mm (1.371 to 1.373 in.)

Seat on head for valve seat. -

Exhaust.

43.637 to 43.663 mm. (1.718 to 1.719 in.)

34.837 to 34.863 mm (1.371 to 1.373 in.)

Ø2= 47.063 to 47.089 mm. (1.853 to 1.8534 in.)

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

4

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

5

Intake.

angle=

angle=

7 8

2-14

angle= 60° 34.917 to 34.931 mm. (1.374 to 1.375 in.)

Ø2= 43.713 to 43.739 mm. (1.7210 to 1.7220 in.)

Exhaust.

6

60°

45°

angle= 45°

Recessing.

Intake valve

1.00 to 1.52 mm. (0.039 to 0.060 in.)

0.59 to 1.11 mm. (0.023 to 0.044 in.)

Recessing.

Exhaust valve

1.00 to 1.52 mm. (0.039 to 0.060 in.)

0.59 to 1.11 mm. (0.023 to 0.044 in.)

0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)

Between valve seat and head-

Intake

Between valve seat and head-

Exhaust 0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)

Valve seats


Issued 04-07

Bur

87630273 NA



9

11

10

15 18 22

17

16

14

13

12

21

20

19

Figure 2-11

BS06K019

REF. NO.

9

F4GE9454H

ENGINE TYPE

J601

F4GE9454J

J602

J600

J601

F4GE9484D J601

J602

F4HE9484A J101

Valve spring height: Free spring.

H=

63.5 mm. (2.500 in.)

47.75 mm (1.880 in.)

Under load of: 329 N (74 lbf).

H1=

49.02 mm. (1.930 in.)

35.33 mm (1.391 in.)

Under load of: 641 N (144 lbf).

H2=

38.20 mm. (1.504 in.)

25.2 mm (0.992 in.)

X=

Injector protrusion.

Not Adjustable

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

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

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

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

11

Camshaft main bearing journals: 1 through 5

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

12

Camshaft bushing outside diameter

Ø= N.A.

13

Camshaft bearing inner diameter.

Ø=54.083 to 54.147 mm. (2.129 to 2.132 in.)

14

Bearing and seats in crankcase.

N.A.

15

Bearing and main journals.

0.038 to 0.162 mm. (0.002 to 0.006 in.)

Useful cam lift- Intake.

10.74 mm. (0.423 in.)

7.5282 mm (0.296 in.)

Useful cam lift- Exhaust.

11.02 mm. (0.434 in.)

6.045 mm (0.238 in.)

Tappet plate seat in crankcase.

Ø1= 16.000 to 16.030 mm. (0.630 to 0.631 in.)

10

16

Ø2= 15.924 to 15.954 mm. (0.627 to 0.628 in.)

17 Tappet plate outside diameter. 18

Ø3= 15.965 to 15.980 mm.(0.629 to 0.629 in.)

15.960 to 15.975 mm (0.628 to 0.629 in.)

Between tappets and seat.


19

Tappets.


20

Rocker arm shaft.

Ø1= 18.963 to 18.975 mm. (0.747 to 0.747 in.)

21.965 to 21.977 mm (0.8647 to 0.8652 in.)

21

Rocker arms

Ø2=

22.001 to 22.027 mm (0.866 to 0.867 in.)

22

Between rocker arm and spindle

87630273 NA

Issued 04-07

Bur

19.000 to 19.026 mm. (0.748 to 0.749 in.) 0.025 to 0.063 mm. (0.001 to 0.003 in.)

0.024 to 0.162 mm (0.00094 to 0.0064 in.)

2-15



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

1st phase. (pre lubricated with oil) Bolts M12x1.75x70 .................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet) Bolts M12x1.75x140 ...............................................................................35 to 45 Nm (25.8 to 33.2 pound-feet) Bolts M12x1.75x180 ...............................................................................65 to 75 Nm (47.9 to 55.3 pound-feet) 2nd phase (additional rotation)..........................................................................................90 degrees ± 5 degrees 3rd phase (only for bolts 140 and 180 mm long additional rotation) .................................90 degrees ± 5 degrees Crankshaft main bearings. 1st phase (pre lubricate with oil). ................................................................44 to 56 Nm (32.5 to 41.3 pound-feet) 2nd phase ...................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet) 3rd phase. (additional rotation). ......................................................................................................90 ± 5 degrees Bolts fastening the pulley on the crankshaft ................................................105 to 115 Nm (77.4 to 84.8 pound-feet) Connecting rod cap bolts. 1st phase. (pre lubricate with oil). ...............................................................27 to 33 Nm (19.9 to 24.3 pound-feet) 2nd phase ...................................................................................................55 to 65 Nm (40.5 to 47.9 pound-feet) 3rd phase. additional rotation ..........................................................................................................60 ± 5 degrees Engine flywheel fastening bolts. M12x1.5 1st phase. (pre lubricate with oil) ................................................................26 to 34 Nm (19.2 to 25.1 pound-feet) 2nd phase. (additional rotation).......................................................................................................60 ± 5 degrees Flywheel housing M12x120 .....................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet) M12x80 .......................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet) M10x80 .......................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) M10x40 .......................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) Assembly rear cover plate to flywheel housing (M8x1.25x16).........................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel injectors. ..................................................................................................55 to 65 Nm (40.6 to 47.9 pound-feet) Sump (oil pan) M8x1.25. .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Sump (oil pan) M18x1.5 ..................................................................................51 to 69 Nm (37.6 to 50.9 pound-feet) Oil pan drain plug ............................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Oil filter............................................................................................................................................ Contact + 3/4 turn Oil bypass valve to lube filter head ..................................................................72 to 88 Nm (53.1 to 64.9 pound-feet) Fuel filter. ........................................................................................................................................ Contact + 3/4 turn Injection pump fastening bolts. ........................................................................20 to 30 Nm (14.8 to 22.1 pound-feet) Injection pump gear (drive gear nut) 1st stage......................................................................................................15 to 20 Nm (11.0 to 14.8 pound-feet) 2nd stage ....................................................................................................85 to 90 Nm (62.7 to 66.4 pound-feet) Valve gear cover and case fastening bolts (front cover). .................................20 to 30 Nm (14.8 to 22.1 pound-feet) Intake manifold fastening bolts. .......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Assembly air intake connection M8x1.25 ........................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel pump fastening bolts M8 bolt...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel pump fastening bolts M6 bolt.........................................................................9 to 11 Nm (6.6 to 8.1 pound-feet) Fuel pump M6 nut..................................................................................................9 to 11 Nm (6.6 to 8.1 pound-feet) Exhaust manifold fastening bolts. .....................................................................37 to 49Nm (27.3 to 36.1 pound-feet) Valve cover fastening nuts. ..............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Rocker arm support fastening bolts.................................................................40 to 56 Nm (29.5 to 41.3 pound-feet) Rocker arm adjusting nut.................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft shoulder plate fastening bolts..........................................................20 to 30 Nm (14.8 to 22.1 pound-feet) Camshaft retaining plate bolts M8 ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet.) Fan support fastening bolts M10x1.5x20.........................................................28 to 38 Nm (20.7 to 28.0 pound-feet) Fan pulley fastening bolts M6 ....................................................................................................................8 to 12 Nm (5.9 to 8.8 pound-feet) M10 .............................................................................................................37 to 49 Nm (27.3 to 36.1 pound-feet) Turbocharger fastening bolts. ..........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet) Starter motor fastening bolts. ..........................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) 2-16

Issued 04-07

Bur

87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL Alternator fastening bolts. Alternator to alternator support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Alternator to water inlet M8 bolt ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Alternator lower mount M10 ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Alternator upper pivot M10 bolt ...................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) Alternator mounting hardware M12x1.75x120 .............................................37 to 49Nm (27.3 to 36.1 pound-feet) Alternator wiring M6 nut ....................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Water pump fastening bolts. ............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Water outlet connection M8x1.25x35.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) M8x1.25x70.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Heat exchanger fastening bolts .......................................................................20 to 30 Nm (14.8 to 22.1 pound-feet) Camshaft gear bolt M8 ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet) Rear gear housing assembly M8 ...............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) M10 .............................................................................................................42 to 52 Nm (30.9 to 38.4 pound-feet) M12 .............................................................................................................65 to 89 Nm (47.9 to 65.6 pound-feet) Cylinder lubricating nozzles M8x1.25x10 ..........................................................12 to 18 Nm (8.9 to 13.3 pound-feet) Engine counter balancer................................................................................. 40 to 56 Nm (29.5 to 41.3 pound-feet) Engine coolant temperature sensor fastening bolt ......................................... 17 to 23 Nm (12.5 to 17.0 pound-feet)

87630273 NA

Issued 04-07

Bur

2-17



TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES PART .............................................................................................................................TORQUE - Nm (pound-feet) Camshaft sensor M6 studs....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Feed pump M8 studs .......................................................................................... 10 to 14 Nm (7.4 to 10.3 pound-feet Rear gear case M12 bolts ...............................................................................65 to 89 Nm (47.9 to 65.6 pound-feet) Rear gear case M10 bolts ...............................................................................42 to 52 Nm (31.0 to 38.4 pound-feet) Rear gear case M8 bolts .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft sensor M6 nut .......................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Oil pump M8 bolts 1st stage ..................................................................................................................7 to 9 Nm (5.2 to 6.6 pound-feet) 2nd stage.........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Front cover M8 bolts ........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft gear M8 bolts ..................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet) Crankcase plate M10 bolt................................................................................38 to 48 Nm (28.0 to 35.4 pound-feet) High pressure pump gear M18 nut ..............................................................100 to 110 Nm (73.6 to 81.1 pound-feet) Fuel pump M8 nuts..........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) 1/2 inch plug on cylinder head.........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) 1/4 inch plug on cylinder head.........................................................................31 to 41 Nm (22.9 to 30.2 pound-feet) 3/4 inch plug on cylinder head...........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet) Injector fastening M6 bolts 1st stage ........................................................................................................8.15 to 8.85 Nm (6.0 to 6.5 pound-feet) 2nd stage (additional rotation) ....................................................................................................................... 75 ° ± 5° Injector feed connector fastening nut................................................................ 45 to 55 Nm 33.2 to 40.6 pound-feet) Grid heater grill on intake manifold M6 nut ............................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Intake manifold M8 bolts..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fastening brackets (rear) for engine lifting M12 bolts ......................................65 to 89 Nm (47.9 to 65.6 pound-feet) Fastening brackets (front) for engine lifting M8 bolts .......................................20 to 28 Nm (14.8 to 20.7 pound-feet) Common rail M8 bolts......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) High pressure fuel line connectors M14 ..........................................................18 to 22 Nm (13.3 to 16.2 pound-feet) High pressure fuel line connectors M8 ............................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Cylinder head M12x1.75x130 and 150 1st stage ..........................................................................................................30 to 40 Nm (22.1 to 29.5 pound-feet) 2nd stage (additional rotation) ........................................................................................................................ 90° ± 5° 3rd stage (additional rotation)......................................................................................................................... 90° ± 5° Rocker arm bracket .........................................................................................31 to 41 Nm (22.9 to 30.2 pound-feet) Valve clearance adjusting nuts ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel line from high pressure pump to Common Rail, M14 nut ........................18 to 22 Nm (13.2 to 16.2 pound-feet) Wiring bulkhead M6 bolt ........................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Electrical wiring support for injector feed.........................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Wiring on each injector -nuts ................................................................ 1.25 to 1.75 Nm (11.1 to 15.5 pound-inches) Fuel filter bracket M12 bolts .........................................................................................................69 to 85 Nm (50.9 to 62.7 pound-feet) M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel filter......................................................................................................................................... Contact + 3/4 turn Oil pressure relief valve on oil filter support M22 bolt......................................72 to 88 Nm (53.1 to 64.9 pound-feet) Radiator seal and oil filter support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Oil filter ........................................................................................................................................... Contact + 3/4 turn Connection on oil filter support for turbine lubrication .....................................20 to 28 Nm (14.8 to 20.7 pound-feet) Turbine lubrication pipe M12 nut............................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Engine coolant inlet connection M10 bolt ........................................................37 to 49 Nm (27.3 to 36.1 pound-feet) 90° elbow (if required) to engine coolant inlet connection ...............................20 to 28 Nm (14.8 to 20.7 pound-feet) Line on cylinder head for compressor cooling .................................................20 to 24 Nm (14.8 to 17.7 pound-feet) Engine coolant drain connector M6 bolt ................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Engine block exhaust manifold pin ........................................................................8 to 12 Nm (5.9 to 8.9 pound-feet) Exhaust manifold to cylinder head M10 bolt ....................................................48 to 58 Nm (35.4 to 42.8 pound-feet) 2-18

Issued 04-07

Bur

87630273 NA



Damper adapter and damper on crankshaft M12 bolt 1st stage ..........................................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet) 2nd stage (additional rotation) ........................................................................................................................90° ± 5° Crankshaft pulley M10 bolts ............................................................................61 to 75 Nm (45.0 to 55.4 pound-feet) Water pump M8 bolts.......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Auxiliary component control belt tensioner M10 bolt .......................................37 to 49 Nm (27.3 to 36.1 pound-feet) Fixed pulleys for auxiliary component control belt M10 bolts ..........................37 to 49 Nm (27.3 to 36.1 pound-feet) Flywheel housing M10 bolts .........................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet) M12 bolts .........................................................................................................44 to 54 Nm (32.5 to 39.8 pound-feet) Heat exchanger for EDC7UC31 control unit M6 bolts ....................................................................................................................... 8 to 12 (5.9 to 8.9 pound-feet) M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Fuel inlet-outlet on heat exchanger ...................................................................10 to 14 Nm (7.4 to 10.3 pound-feet) Valve cover fastening nut M8 nut .....................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft sensor M6 bolt.......................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Crankshaft sensor M6 bolt.....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet) Coolant temperature sensor M14 bolt .............................................................17 to 23 Nm (12.5 to 17.0 pound-feet) Oil pressure/temperature sensor M5 bolt ................................................................5 to 7 Nm (3.7 to 5.2 pound-feet) Fuel pressure sensor fastening bolt......................................... 30 to 40 Nm (22.1 29.5 Nm (22.1 to 29.5 pound-feet) Fuel temperature sensor M14 bolt...................................................................17 to 23 Nm (12.5 to 17.0 pound-feet) Air temperature/pressure sensor on intake manifold ...............................................5 to 7 Nm (3.7 to 5.2 pound-feet) Engine oil level sensor M12 bolt ........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet) Turbine to exhaust manifold M8 pins ....................................................................................................................6 to 8 Nm (4.4 to 5.9 pound-feet) M8 nuts............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Adapter on turbine for lubricant oil lines (inlet) M12 adapter ...........................30 to 40 Nm (22.1 to 29.5 pound-feet) Adapter on line on turbine for lubrication M10 adapter....................................30 to 40 Nm (22.1 to 29.5 pound-feet) Adapter on oil line for turbine lubrication to block M10 adapter.......................37 to 49 Nm (27.3 to 36.1 pound-feet) Oil drain pipe on turbine M8 bolt......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Connector attaching oil return from cylinder head to flywheel housing .................8 to 12 Nm (5.9 to 8.9 pound-feet) Flywheel fastening bolts M12 bolts 1st stage ........................................................................................................... 26 to 34 Nm 19.2 to 25.1 pound-feet) 2nd stage (additional rotation) ........................................................................................................................60° ± 5° Oil pan (sump) M8 bolts ..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Cylinder bore lubricating nozzles M8 bolts ........................................................12 to 18 Nm (8.9 to 13.3 pound-feet) Crankshaft output bearings M12 bolts 1st stage ..........................................................................................................44 to 56 Nm (32.5 to 41.3 pound-feet) 2nd stage.........................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet) 3rd stage (additional rotation).........................................................................................................................90° ± 5° Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet) Camshaft gear M8 bolt ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet) Connecting rod caps M11 bolts 1st stage ........................................................................................................... 55 to 65 Nm 40.6 to 47.9 pound-feet) 2nd stage (additional rotation) .......................................................................................................................60 ° ± 5° Alternator bracket attaching to water feed pipe fitting M10 bolts .....................37 to 49 Nm (27.3 to 36.1 pound-feet) Alternator fastening M10 bolts.........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet) Starter fastening bolts M10 bolts .....................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)

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2-19



SPECIAL TOOLS 380000665............................................................................................... Tool for removing the crankshaft front seal. 380000663................................................................................................ Tool for removing the crankshaft rear seal. 380000671..................................................................................................... Tool for removing mechanical injectors. 380000666..........................................................................................Coupler for installing the crankshaft front seal. 380000664...........................................................................................Coupler for installing the crankshaft rear seal. 380000228........................................................................................................................... Dial indicator (0 - 5 mm). 380001601...........................Dial indicator holder tool for rotary injection pump timing (to be used with 380001004). 380002729..................................................................................................................... Engine TDC positioning tool. 380000979................................................................................................................ Injection pump drive gear puller. 380000158............................................................................................................................. 1 to 6 Nm torque driver. 380001099......................................................................................................... Tool for removing electrical injectors.

2-20

Issued 04-07

Bur

87630273 NA



F4GE - ENGINES F4GE9454H AND F4GE9454J ENGINE

2

1

3

9 8 7 4 5

6

Figure 2-12

BS06N188 -

1. TURBOCHARGER 2. BLOW-BY 3. ROTARY INJECTION PUMP

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Issued 04-07

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4. FUEL FILTER 5. PRIMING PUMP 6. CRANKSHAFT PULLEY

7. FIXED GUIDE PULLEY 8. WATER PUMP 9. FAN PULLEY

2-21


CHAPTER 2 - 445TA ENGINE OVERHAUL F4GE9484D ENGINE

2

1

3

9 8 7 4 5

6

Figure 2-13

BS06N189

1. TURBOCHARGER 2. BLOW-BY 3. ROTARY INJECTION PUMP

2-22

4. FUEL FILTER 5. PRIMING PUMP 6. CRANKSHAFT PULLEY

7. FIXED GUIDE PULLEY 8. WATER PUMP 9. FAN PULLEY

Issued 04-07

Bur

87630273 NA



F4HE- ENGINES F4HE9484A ENGINE

2

1

3

4

5 6

Figure 2-14

BS07D071

1. 2. 3. 4. 5. 6.

7

TURBOCHARGER COMMON RAIL FAN PULLEY FIXED GUIDE PULLEY DAMPING FLYWHEEL WATER PUMP

7. 8. 9. 10. 11.

EDC7UC31 CONTROL UNIT REAR OF CRANKSHAFT FLYWHEEL HIGH PRESSURE PUMP FUEL FILTER

8 11 10 9 Figure 2-15

BS07D072

87630273 NA

Issued 04-07

Bur

2-23



DESCRIPTION OF MAIN ENGINE COMPONENTS ENGINE BLOCK

1

5

4 2

3

Figure 2-16

BS06N190

1. CYLINDER BORE 2. SEATS FOR CAMSHAFT BEARINGS AND TAPPETS

3. MAIN BEARING HOUSINGS 4. OIL PUMP

5. WATER PUMP

The engine block consists of a cast iron structure containing the cylinder bores (1), the main bearing housings (3), and the following seats: for camshaft bearings (2), water pump (5), and oil pump (4). The block also incorporates the water jackets for cooling and the oil galleys for lubrication.

2-24

Issued 04-07

Bur

87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL CRANKSHAFT

4 3

2 1

Figure 2-17

BS06K022

1. FLYWHEEL ATTACHMENT HUB

2. TIMING DRIVE GEAR

The crankshaft is made of steel and rests on five induction hardened bearing journals. Drilled inside the crankshaft are a series of lubricating oil ducts. The following items are pressed onto the front of the crankshaft: oil pump drive gear (4), phonic wheel, the vibration damper, and auxiliary equipment drive pulley.

3. CRANKSHAFT

4. OIL PUMP DRIVE GEAR

CRANKSHAFT OIL SEALS The front and rear seals are box type with radial seal. R e m o ve w i t h s p e c i a l t o o l s 3 8 0 0 0 0 6 6 5 a n d 380000663. Install with special tools 380000666 and 380000664.

The following items are pressed onto the rear of the crankshaft: timing gear (2), and the flywheel mounting hub (1). The main bearing shells are made of steel with a antifriction alloy plating. One of the main bearing shells is equipped with shoulders to limit crankshaft endplay. The timing drive gear (2) and the flywheel attachment hub (1) are installed on the rear of the crankshaft with a force-fit and cannot be replaced.

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Issued 04-07

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2-25


CHAPTER 2 - 445TA ENGINE OVERHAUL CONNECTING RODS

Figure 2-18

BS06K023

T h e c o n n e c t i n g r o d s a r e fo r g e d s t e e l , T h e connecting rod crankshaft ends are made with an oblique angle, with separation of rod and cap obtained by means of the innovative fracture splitting system rather than the conventional machining process. The connecting rod crankshaft bearing shells are made of steel plated with an antifriction alloy.

2-26

Each connecting rod is marked: • By a number on the connecting rod body and on the cap indicating the match and the cylinder in which they are assembled. • By a letter on the connecting rod body indicating the weight class of the connecting rod installed in production.

Issued 04-07

Bur

87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL PISTONS

1 2 3 4

Figure 2-19

BS06K024

The piston crown features a high turbulence combustion chamber. The underside of the piston crown is cooled by engine oil delivered by a spray nozzle installed in the crankcase.

The following reference data is engraved into the piston crown:

There are three piston ring grooves with different functions and different geometry.

2. Stamping (facing the crankcase front side) indicating the mounting direction of the piston in the cylinder bore.

1st piston ring with trapezoidal (keystone) section, ceramic chrome plating. 2nd piston ring with torsional conical rectangular section.

1. Spare part number and design modification number.

3. Date of manufacture. 4. Stamping indicating 1st recess insert testing.

3rd piston ring with double oil ring wiper with internal spring.

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2-27


CHAPTER 2 - 445TA ENGINE OVERHAUL CAMSHAFT

NOTE: The camshaft below is a 6 cylinder camshaft. BS06K025

A D B C D Figure 2-20

BS06K026

A. CRANKSHAFT OUTPUT GEAR

B. JOURNAL

The camshaft is installed on five bearing journals (B) in the engine block. The front and rear bearing housings are equipped with steel bearings plated with antifriction material assembled by means of a force-fit. The camshaft is controlled directly by the crankshaft by means of gear (A). EGR EXHAUST GAS RECIRCULATION SYSTEM In the TIER 3 version, the profile of the exhaust lobe has been modified in order to allow the par tial opening of the exhaust valve during the intake cycle. The exhaust gases can be partially returned back into the cylinders to lower the maximum combustion temperature which is responsible for the production of nitrogen oxides (NOx).

2-28

C. INTAKE VALVE LOBE

D. EXHAUST VALVE LOBE

The exhaust gas recirculation system (EGR), lowers the combustion temperature by decreasing the concentration of oxygen in the combustion chamber. Creating an effective system to control the emission of NOx. The internal EGR system exhaust lobe design is not equipped with any electronically controlled elements, the system is always active. Its configuration does not need additional elements such as check valves, piping or heat exchangers. The exhaust lobe (D) has an additional lobe apart from the major lobe see cross sectional view of exhaust valve (D), as compared to the configuration of a cam without EGR. With the additional lobe during the intake stroke of a cylinder, this lobe permits a brief opening of the exhaust valve. Recirculation is generated in the cylinder during the intake stroke due to the greater pressure of exhaust compared to the intake gases. Issued 04-07

Bur

87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL VALVE CONTROL FOR F4GE ENGINES

2

1

9 3 8 7 4

5

6

Figure 2-21

BS06N193

1. ROCKER ARM 2. ROCKER ARM SUPPORT 3. ADJUSTING SCREW

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Issued 04-07

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4. PUSH ROD 5. TAPPET 6. CAM SHAFT

7. SPRING 8. SPRING SEAT 9. VALVE SPRING RETAINER (KEEPERS)

2-29


CHAPTER 2 - 445TA ENGINE OVERHAUL VALVE CONTROL FOR F4HE ENGINES

2 1

3

10 9 8 7

4

6

5

Figure 2-22

BS06K027

1. 2. 3. 4. 5.

2-30

ROCKER ARM ROCKER SPINDLE VALVE BRIDGE TAPPET CAMSHAFT

6. 7. 8. 9. 10.

SPRING SPRING SEAT VALVE SPRING RETAINER (KEEPERS) PUSH ROD VALVE LASH ADJUSTER SCREW

Issued 04-07

Bur

87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL CYLINDER HEAD FOR F4GE9454H AND F4GE9454J ENGINES

1

2

6 3

4

5

Figure 2-23

BS06N194

DETAIL OF CYLINDER HEAD FOR F4GE9454H/J ENGINE WITH INSERTED VALVE SEATS 1. EXHAUST MANIFOLD 2. INTAKE MANIFOLD

3. GRID HEATER 4. VALVE SEAT

The cast iron cylinder head is machined to accommodate the following parts: • Valve seats (4). • Injectors (6). • Thermostat (5).

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5. THERMOSTAT 6. INJECTOR

The cylinder head is also fitted for the following components to be installed on to the cylinder head. • Exhaust manifold (1). • Intake manifold (2) with seat for grid heater (3).

2-31


CHAPTER 2 - 445TA ENGINE OVERHAUL CYLINDER HEAD FOR F4GE9484D ENGINES

1

2

3

6

4 5

Figure 2-24

BS06N195

DETAIL OF CYLINDER HEAD FOR F4GE9484D ENGINE WITH INSERTED VALVE SEATS 1. EXHAUST MANIFOLD 2. INTAKE MANIFOLD


The cast iron cylinder head is machined to accommodate the following parts: • valve seats (4). • injectors (6). • thermostat (5).

2-32

5. THERMOSTAT 6. INJECTOR

The cylinder head is also fitted for the following components to be inserted on to the head. • exhaust manifold (1). • intake manifold (2) with seat for grid heater (3).

Issued 04-07

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87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL CYLINDER HEAD FOR F4HE9484A ENGINES

2

1 3

5

4 6

Figure 2-25

BS07D063

DETAIL OF CYLINDER HEAD FOR F4HE9484A ENGINE WITH INSERTED VALVE SEATS 1. EXHAUST MANIFOLD 2. INTAKE MANIFOLD


5. INJECTOR 6. THERMOSTAT

The cast iron cylinder head is machined to accommodate the following parts: • Valve seats (4).

The cylinder head is also fitted for the following components to be installed on the cylinder head. • Exhaust manifold (1).

• Injectors (2). • Thermostat (6).

• Intake manifold (2) with seat for grid heater (3).

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Issued 04-07

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2-33


CHAPTER 2 - 445TA ENGINE OVERHAUL VALVES AND VALVE SEATS FOR F4GE ENGINES

2 3 1

4

A

Figure 2-26

BS06N196

1. EXHAUST SIDE 2. EXHAUST VALVE

3. INTAKE VALVE 4. INTAKE SIDE

Valve seats inserted in the head have the following angles: 45° - Exhaust valves. 60° - Intake valves. NOTE: The exhaust valves (2) differ from the intake valves (3) in that they have only one notch at the stem end. (A) Shows the oil seals mounted on valve stems.

2-34

Issued 04-07

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87630273 NA



Figure 2-27

BS06N197

DETAIL OF VALVE GUIDES AND SEATS F4GE ENGINES

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Issued 04-07

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2-35


CHAPTER 2 - 445TA ENGINE OVERHAUL VALVES AND VALVE SEATS FOR- F4HE ENGINES

1

4

2

3 Figure 2-28

BS06K030

1. INTAKE VALVES 2. INTAKE SIDE

1

3. EXHAUST SIDE 4. EXHAUST VALVES

2

Valve seats have the following angles:

3 Figure 2-30

BS06K032

Exhaust valves- 45° Intake valves- 60° NOTE: Exhaust valves (4) have a distinctive identification at the center of the head of the valve.

1. 7.042 TO 7.062 MM (0.277 TO 0.278 INCHES) 2. INTAKE VALVE 3. EXHAUST VALVE

The cylinder head does not have guide inserts. The valve guide is machined directly into the head casting.

1 1

2 BS06K031

Figure 2-29

Oil seals (1) installed on valve stems. Figure 2-31

BS06K033

1. JUMPER 2. PUSH RODS

NOTE: When installing the cylinder head, the orientation of valve bridges must be positioned with marks (1) towards exhaust manifold.

2-36

Issued 04-07

Bur

87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL ENGINE FLYWHEEL The flywheel (2) is not timed to the crankshaft and does not have any stamping, notch or reference hole for sensors or timing.

Equal distance of fastening bolt holes (1) allows it to be installed in any position.

1

2

Figure 2-32

BS06N198

FLYWHEEL FOR- F4GE ENGINES

Figure 2-33

BS07D076

FLYWHEEL FOR- F4HE ENGINES

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Issued 04-07

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2-37



ACCESSORY EQUIPMENT DRIVE 2

3

1

6

5

4

Figure 2-34

BS06K038

1. ALTERNATOR 2. AUTOMATIC BELT TENSIONER

3. FAN PULLEY 4. CRANKSHAFT

5. WATER PUMP 6. POLY-V-BELT

A Poly-V-belt (6) transmits the rotation of the crankshaft (4) to water pump (5), fan pulley, and to the alternator (1). The tension of the belt is controlled by the automatic belt tensioner (2).

2-38

Issued 04-07

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87630273 NA



COUNTER BALANCER- F4GE ENGINES

A

1

B

2

10

3

9

4

5

7

8

6 Figure 2-35

BS06N200

COUNTER BALANCER FOR F4GE ENGINES 1. 2. 3. 4. 5.

FASTENING BOLTS SUPPORT FASTENING BOLTS GEAR BALANCING MASS

Inside the oil pan (sump), secured to the cylinder block is the counter balancer. The counter balancer is timed as shown above.

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6. 7. 8. 9. 10.

HALF BEARINGS COUNTER-ROTATING SHAFT GEAR RING O-RING

Match alignment marks (A) engraved on the gears for timing, insert pin in hole (B) on the balancing mass to stop rotation temporarily.

2-39



ENGINE LUBRICATION FOR- F4GE ENGINES

A B C Figure 2-36

BS06N236

LUBRICATION SYSTEM LAYOUT FOR F4GE ENGINES A. GRAVITY OIL RETURN PATH

B. PRESSURIZED OIL PATH

C. OIL SUPPLY

Pressurized lubrication is performed by the following components:

By-pass valve to cut out clogged oil filter, built into the cooler unit.

Gerotor oil pump housed in the front of the engine block, driven by the spur tooth gear force fitted on the crankshaft.

Cartridge- type oil filter.

Water / oil cooler, housed in the engine block.

2-40

Issued 04-07

Bur

87630273 NA



ENGINE LUBRICATION FOR- F4HE ENGINES

1 2 3

4 5

A B 6

Figure 2-37

BS07D132

LUBRICATION SYSTEM LAYOUT FOR- F4HE ENGINES (NOTE: THE ILLUSTRATION IS A 6 CYLINDER) 1. TURBO OIL PRESSURE CONTROL VALVE 2. BY-PASS VALVE 3. CARTRIDGE- TYPE OIL FILTER

4. HEAT EXCHANGER 5. OIL PUMP 6. OIL PAN (SUMP)

A. PRESSURIZED OIL PATH B. GRAVITY OIL RETURN PATH

Pressurized lubrication is done with the following components: • Gerotor oil pump (5) housed in the front of the engine block, driven by the spur tooth gear force fitted on the crankshaft.

• Heat exchanger (4) housed in the engine block, under the oil filter support.

• By-pass valve (2) for clogged oil filter cut off. • Cartridge type oil filter (3) • Oil pan (sump) (6) 87630273 NA

Issued 04-07

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2-41


CHAPTER 2 - 445TA ENGINE OVERHAUL HEAT EXCHANGER

1 2

3

4

Figure 2-38

BS06N237

1. HEAT EXCHANGER BODY 3. WATER / OIL COOLER 2. INNER GASKET 4. GASKET (BETWEEN COOLER AND ENGINE BLOCK)

BY-PASS VALVE

OIL PRESSURE CONTROL VALVE

1 2

3 A Figure 2-40

BS06K042 BS06K041

Figure 2-39

1. 66 MM (2.59 INCHES) 2. 41.25 MM (1.62 INCHES) 3. 136.9 ± 10.5 N (30.8 ± 2.36 LBF)

Calibration at 100° C (212° F) oil temperature.

A. DIRECTION OF FLOW

Blow-by max: 20 cm³/min (.68 oz/min) with 0.83 bar (12 psi) pressure at 26.7° C (80° F) oil temperature.

Minimum pressure 1.2 bar (17.4 psi) Maximum pressure 3.8 bar (55.1 psi) 2-42

Issued 04-07

Bur

87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL OIL PAN (SUMP)

OIL PUMP

1

2

Figure 2-41

BS06K043

OIL PUMP

Figure 2-43

BS06N238

OIL PAN (SUMP) FOR F4GE ENGINES

1

1

2

2 Figure 2-42

BS06K044

1. Crankshaft with oil pump drive gear.

Figure 2-44

BS06K045

OIL PAN (SUMP) FOR F4HE ENGINES

2. Oil pump.

The oil pan (sump) (2) is bolted to the cylinder block. The gasket (1), fitted on the oil pan reduces noise and in addition to improve tightness.

87630273 NA

Issued 04-07

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2-43


CHAPTER 2 - 445TA ENGINE OVERHAUL OIL VAPOR RECIRCULATION FOR F4GE ENGINES

1 2

3

Figure 2-45

BS06N238

Oil vapor recirculation takes place by means of valve (1) placed above the tappet cover (3) on F4GE engines.

2-44

The vapor condensed within the valve falls into the tappet cover (3) due to gravity. The remaining vapor is recovered by vent (2) and recirculated to the engine intake.

Issued 04-07

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87630273 NA


CHAPTER 2 - 445TA ENGINE OVERHAUL OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITH BLOW-BY FILTER

1

2

3

4

A B Figure 2-46

BS06K048

1. PRE-SEPARATOR 2. RECIRCULATION TO INTAKE

3. BLOW-BY FILTER 4. RETURN TO ENGINE

BLOW-BY RECIRULATION: The rocker cover has a blow-by pre-separator (1), designed to increase the outlet velocity of blow-by oil vapor while condensing them partially. Condensed oil returns to the oil pan (sump) while residual vapors are collected and routed through the blow-by filter (3). 87630273 NA

Issued 04-07

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A. OIL CONDENSATE B. OIL VAPORS

In blow-by filter (3) a portion of the vapors partially condense and return to the oil pan (sump) through line (4), while the remaining is recirculated to the engine intake by line (2).

2-45


CHAPTER 2 - 445TA ENGINE OVERHAUL OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITHOUT BLOW-BY FILTER

1

2

A B Figure 2-47

BS07D070

The tappet cover houses the pre-separator (1), whose shape and position increases the outlet velocity of the blow-by vapors and condenses part of the vapors at the same time. The condensed oil returns to the oil pan (sump), where the residual vapor is collected and discharged into the open air through the bleeder on the side (2).

2-46

Issued 04-07

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87630273 NA



COOLING SYSTEM

1

2

3

A

C

B Figure 2-48

BS06N240

1. THERMOSTAT 2. HEAT EXCHANGER

3. WATER PUMP A. WATER FLOWING OUT OF THERMOSTAT

The engine cooling system is a closed circuit, forced c i r c u l a t i o n t y p e i n c o r p o r a t i n g t h e fo l l ow i n g components: • Radiator- Dissipates the heat from the engine by circulating coolant through a long row of tubes and air flowing across them decreasing the temperature.

• Expansion tank- Collects the overflow of coolant as it expands and contracts. 87630273 NA

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B. WATER RECIRCULATING IN THE ENGINE C. WATER FLOWING INTO WATER PUMP

• Fan- Increases heat dissipating power of the radiator by flowing more air across the radiator.

• Heat exchanger- Cools the lubricating oil. • Centrifugal water pump- placed on the front of the engine block. Circulates the coolant through the engine and radiator and is driven by a Poly-V belt.

• Thermostat- Regulates the circulation of the coolant. 2-47


CHAPTER 2 - 445TA ENGINE OVERHAUL WATER PUMP

1

Figure 2-51

BS06K052

Figure 2-49

BS06K050

THERMOSTAT

Engine temperature is controlled by a thermostat.

WATER PUMP

Thermostat opening 79 to 83° C (174 to 181° F). (1)- Goes towards engine block.

BS06K051

Figure 2-50 CROSS SECTIONAL VIEW OF WATER PUMP

The water pump is housed in a cavity in the front of the engine block. and is driven by a Poly-V belt. The water pump is sealed to the block by a rubber ring.

2-48

Issued 04-07

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87630273 NA



AIR INDUCTION BOOST DIAGRAM BOOSTING VERSION ENGINES

1

2

3

4

Figure 2-52

BS07C435

4 CYLINDER BOOSTED VERSION 1. AIR FILTER

2. TURBOCHARGER

The turbocharger is composed of the following parts: turbine, transforming valve to regulate the boost pressure, main body, and compressor. When engine is running, the exhaust emission flow through the body of the turbine makes the turbine disk rotate.

3. EXHAUST

4. PISTONS

T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure of the compressor, reaches the prescribed pressure value. The cooling process and lubrication of the turbocharger and bearings is done by the engine oil.

The compressor rotor connected by a shaft to the turbine disk rotates, compressing the air drawn through the air filter. The air coming out of the compressor is sent via the intake manifold directly to the pistons. The turbocharger is equipped with a transforming valve to regulate the pressure, located on the exhaust collector before the turbine and connected by piping to the induction collector.

87630273 NA

Issued 04-07

Bur

2-49


CHAPTER 2 - 445TA ENGINE OVERHAUL INTER-COOLED ENGINE VERSION

2

1

3

4 5

Figure 2-53

BS07C436

4 CYLINDER BOOSTED / INTERCOOLED VERSION 1. AIR FILTER

2. TURBOCHARGER

3. EXHAUST

The turbocharger is composed of the following parts: turbine, transforming valve to regulate the boost pressure, main body, and compressor. When engine is running, the exhaust emission flow through the body of the turbine makes the turbine disk rotate.

4. CHARGE AIR COOLER

5. PISTONS

T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure of the compressor, reaches the prescribed pressure value. The cooling process and lubrication of the turbocharger and bearings is done by the engine oil.

The compressor rotor connected by a shaft to the turbine disk rotates, compressing the air drawn through the air filter. The air is then cooled by the charge air cooler and sent via the intake manifold to the pistons. The turbocharger is equipped with a transforming valve to regulate the pressure, located on the exhaust collector before the turbine and connected by piping to the induction collector.

2-50

Issued 04-07

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87630273 NA



MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES FUEL FILTER

1

2 6 3

4

5

Figure 2-54

BS06N241

FUEL FILTER 1. FUEL FILTER BRACKET 2. AIR BLEEDING SCREW

3. FUEL HEATING RESISTOR 4. WATER DRAIN

5. FUEL FILTER 6. FUEL TEMPERATURE SENSOR

The fuel filter is located close to the feed and priming pump. The fuel filter provides a barrier trap for impurities and to separate water from the fuel. On the filter bracket base there is a water drain screw, equipment used in cold climate areas there can be a heater assembled into the bracket (to prevent the fuel from jelling), and a fuel temperature sensor. On some versions there is a water presence sensor located on the filter cartridge base.

87630273 NA

Issued 04-07

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2-51


CHAPTER 2 - 445TA ENGINE OVERHAUL MECHANICAL FUEL LIFT PUMP- F4GE ENGINES

1

2

3

4

5

6

Figure 2-55

BS06N242

MECHANICAL FUEL PUMP 1. FUEL OUTLET TO FILTER 2. CONTROL LEVER

3. FUEL INLET FROM TANK 4. FUEL PUMP

The fuel pump is mounted on the left side of the engine. It draws fuel from the fuel tank and feeds it to the rotary injection pump. It is driven by the camshaft.

2-52

5. CONTROL LEVER 6. CAMSHAFT

Specifications for fuel lift pump: Static pressure at 1800 r/min. (rpm). 0.47 to 0.61 bar (6.8 to 8.8 psi).

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CHAPTER 2 - 445TA ENGINE OVERHAUL MECHANICAL INJECTION WORKING PRINCIPLES- F4GE ENGINES

1

3

2

4

5

Figure 2-56

BS07D011

1. Fuel filter

3. Feed pipeline from priming pump to filter

2. Feed pipe line from fuel pump to fuel filter

4. Rotary injection pump

5. Fuel pump

Fuel is drawn from the fuel tank by the fuel pump (5) and is driven by the camshaft.

To check fuel pressure for engines with mechanical fuel system.

Fuel flows through pipeline (2) to the fuel filter (1) and is piped to the vacuum chamber of the injection pump via pipeline (3), (for applications to be operated in cold climates the fuel filter is provided with a heater).

The fuel supply pressure specification is 0.27 bar (4 psi) minimum and 0.34 to 0.48 bar (5 to 7 psi) at full load rated rpm. To check fuel pressure, purchase a fuel supply line for the four cylinder engine. Cut the fuel line and install a tee fitting to measure the fuel pressure.

Transfer pump is placed inside the injection pump (4), and is a rotary type. It increases fuel pressure with the increase in the number of engine revolutions. The fuel arrives to the valve gauging the pressure inside injection pump. The distribution plunger increases the pressure and delivers fuel throughout the delivery pipe to the injectors. The fuel drawn from the injectors is recovered and delivered to the fuel tank again.

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ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES

4

3

5

2 1

6

10

7 8 9 Figure 2-57

BS06N243

INJECTION ASSEMBLY 1. INJECTOR 1 FUEL PIPE 2. INJECTOR 2 FUEL PIPE 3. INJECTOR 3 FUEL PIPE

4. INJECTOR 4 FUEL PIPE 5. PIPE FOR FUEL DISCHARGE FROM INJECTORS 6. CONNECTOR FOR MEASURING PRESSURE INSIDE THE L.D.A. INTAKE MANIFOLD

Fuel feed system is composed of:

• Fuel tank (placed on the machine). • Fuel delivery and back-flow to tank. • Fuel pre-filter (if available, it is usually placed

7. THERMAL BULB FOR KSB

10. INJECTOR

8. INJECTION PUMP 9. SOLENOID VALVE

• Fuel feed rotary injection pump. • Injector feed pipeline (from injection pump to injectors).

• Injectors

close to the engine on the machine frame).

• Priming pump, assembled to the engine driven by the camshaft.

• Fuel filter

2-54

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KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES

1

3

4

2

Figure 2-58

BS07F331

1. TEMPERATURE SWITCH

2. ADVANCE SOLENOID

Theory of operation: When the engine is cold (coolant temperature below 50° C (122° F) the injection pump is in timing advance state. When engine gets to between 60 and 66° C (140 to 151°F), the thermo switch in the cylinder head opens and system voltage is no longer sent to the solenoid on the injection pump. This allows the timing to retard to "normal" operating position. Units equipped with the Bosh VE rotary injection pump do not require a relay for the pull in circuit. The pump uses a simple shut off solenoid built into the pump.

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3. FUEL SHUT OFF SOLENOID

4. WIRE HARNESS

There is one wire connected to the main harness that goes to the ignition terminal of the key switch. This wire feeds power to the injection pump shut off s o l e n o i d . A s e c o n d w i r e fe e d s p o w e r t o a temperature switch in the head. A third wire routes from the temperature switch to an additional solenoid on the injection pump. An additional solenoid ensures that the pump will go to full advance timing during cranking and upon initial cold start up. Once the engine warms to 71° C (160° F), the temperature switch opens and power to the solenoid on the side of the injection pump is removed. This allows the injection pump to retard the timing according to engine rpm.

2-55


CHAPTER 2 - 445TA ENGINE OVERHAUL To troubleshoot the system: 1. With the engine temperature below 50° C (122° F), the key switch on, battery voltage should be present at both solenoids on the injection pump. If battery voltage is not present, troubleshoot the temperature switch circuit. 2. To check the temperature switch, when engine temperature is below 50° C (122° F), battery voltage should be present at both terminals. Warm the engine to 60 to 66° C (140 to 151° F). Battery voltage should be present at only one terminal of the temperature switch when engine is warmed to 71° C (160° F) or higher. 3. Disconnect the connector at the temperature switch. Short across the two terminals of the connector with a jumper wire and start engine. After a short time, remove the jumper wire the engine should change sound and run smoother as the injection pump time is retarded. This signifies that the cold starting advance system is operating properly.

FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION FOR F4GE ENGINES NOTE: If possible, test the fuel system as described before removing the Bosch VE fuel injection pump for repair. If leakage is too severe, complete the test procedure following the pump repair or replacement. Failure to test the system may result in continued pump leakage. To determine if the low pressure fuel supply is restricted, or if air is entering the system, follow these steps.: STEP 1 Install a clear poly-vinyl tube between the outlet of the fuel filter and the inlet of the Bosch VE fuel injection pump. Tee connector into the test line a pressure gauge which can read both 0 to 762 mm (0 to 30 inches) of Hg vacuum and 0 to 2.07 bar (0 to 30 psi) positive pressure. See figure 2-59 on page 2-57 NOTE: For more information, see further procedures in this section which describe how to build test lines, and describe normal system operating observations. STEP 2 Run the engine to purge all possible air from the system which was caused by test line installation. STEP 3 When air is no longer visible in the clear test line, measure and record the operating pressures, while continually observing for air in the fuel, under the following conditions:

• Low idle- apply no load to the engine. • High idle- apply no load to the engine. • High idle- apply load to the engine using hydraulics over relief, hydrostatic stall or converter stall, depending upon the unit being tested. Load the engine to its rated engine operating rpm.

• Run multiple tests while observing fuel pressure and looking for air in the fuel. STEP 4 If the fuel pressure is below 0.276 bar (4.0 psi) at any time during the previous Step 3, check the following, and replace as needed:

• The fuel pre-filter (replace). NOTE: some applications do not use a fuel pre-filter.

• The primary fuel filter.

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• The lines and connections from the fuel supply

Parts needed for pressure/ vacuum testing

pump inlet back to the fuel tank, checking for damaged lines (kinks and rub marks) and leakage at the Voss o-ring fittings.

2

1

• Debris in the tank, clean as required. • The fuel pick-up tube in the fuel tank, checking for

1 3

cracks, plugging, or contact with the bottom or side walls of the tank.

• The fuel tank cap, assuring that a vacuum is not being formed in the fuel tank, which would reduce the fuel supply pressure to the injection pump inlet.

4

5

NOTE: Vacuum in the fuel tank might not be observed during short-term running.

• These instructions apply only to engines with external electrical fuel shutoff valve assemblies. Ensure that fuel supplied to and from the valve assembly is properly plumbed. Fuel supplied from the fuel filter enters the shutoff valve at port number 1. Port number 2 supplies fuel to the inlet of the Bosch VE injection pump. STEP 5 If the checks in Step 4 were made and all necessary corrective actions were taken, Retest. If the pressure is still low, preform the following tests:

• From the gauges previously used to measure pressure, remove one section of test line and a barbed fitting from the tee. Install in there place a gasket and a connector. This will allow installation of the gauges between the supply pump inlet and the fuel supply line from the tank. After installation of the gauges, run the engine and observe the clear tube remaining on the gauges to ensure that air is not entering. The vacuum here should not exceed 50.8 mm (2.0 inches) of Hg under full load. If the vacuum is greater than that, look for a plugged fuel supply line or debris in the fuel tank.

• An alternative vacuum test method would be to supply fuel from an alternate fuel source, such as a five gallon container, with a known good supply line. Fit it directly to the supply pump inlet fitting, then rerun the test. If the pressures return to normal, check the fuel supply line and tank of the vehicle for leaks or restrictions.

Figure 2-59

BS07F316

SETUP FOR MEASURING PRESSURE

To build a fuel system test set for pressure testing, obtain the following : NOTE: Voss o-ring type connectors can be obtained either by purchasing the connectors, or by purchasing a fuel line for the application being worked on, then carefully removing the plastic Voss type connectors (1), from the plastic tube for re-use with poly-vinyl tubing. Quan.

Description

ID #

2

Voss type brass barbed hose connectors

1

1

6.35 mm (1/4 inch)- NPT tee fitting

3

2

6.35 mm (1/4 inch)- NPT to 7.54 mm (5/16 inch) barb connectors

5

1

Five feet of 7.54 mm (5/16 inch) O.D. poly-vinyl tubing

4

1

Dampened compound gauge which will measure 0 to 762 mm (0 to 30 inches) of Hg and 0 to 2.07 bar (0 to 30 psi).

2

• Upon completion of the diagnostic procedures, remove the test line and the gauge, and reinstall the standard fuel line.

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2-57


CHAPTER 2 - 445TA ENGINE OVERHAUL Normal system operating observations 1. Fuel supply pressures between the fuel filter and the inlet to the injection pump should be 0.276 to 0.414 bar (4 to 6 psi) with the engine loaded or unloaded.

1

2. Perform a "wiggle test" on each fuel line. A steady stream of bubbles or foam Should Not be seen moving through the fuel system. Very small random bubbles are allowable. 3. A small, high intensity flashlight can aid in observing air in the fuel lines.

2 Figure 2-60

BS07F317

SETUP FOR MEASURING VACUUM

4. The suction pressure between the inlet of the fuel supply and the tank should not exceed 50.8 mm (2 inches) of Hg vacuum.

To build a fuel system test set for vacuum testing, obtain the following : Quan.

Description

ID #

1

Connector Voss type M12 x 1.5

1

1

Sealing washer between connector (1) and tee fitting

2

NOTE: If the gauges are not equipped with a dampening device, install a small needle valve between the gauge and the test line. the needle valve can be adjusted to control gauge reading fluctuations.

2-58

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HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES 1 2 3

11 10 9 4 8

7 6 5

Figure 2-61

BS06K053

1. 2. 3. 4.

HARNESS TO INJECTORS ELECTRO- INJECTOR COOLANT TEMP. SENSOR ENGINE OIL AND PRESSURE SENSOR

5. 6. 7. 8.

CRANKSHAFT SENSOR 9. CAMSHAFT SENSOR EDC7UC31 CONTROL UNIT 10. FUEL PRESSURE SENSOR PRESSURE REGULATOR 11. BOOST TEMP. PRESSURE SENSOR FUEL HEATER AND TEMP. SENSOR

Extremely high injection pressures are necessary in order to reduce PARTICULAR emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21030 23206 psi), while the injection precision obtained by EDC7UC31 electronic control of the system serves to optimize operation of the engine while limiting emissions and fuel consumption.

NOTE: 6 cylinder version is shown in figure above, operation is the same.

For engines more powerful than 152 kW (203 hp.), the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar (23206 psi), while engines less powerful than 152 kW (203 hp.) are fitted with DSLA nozzles which work with pressures up to 1450 bar (21030 psi.).

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EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION ENGINE PREHEATING ELEMENT CONTROL Pre-post heating is activated when even just one of the water, air or fuel temperature sensors detects a temperature of less than 5° C (41° F).

MAXIMUM ENGINE SPEED LIMITING Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine speed surpasses these limits, the control unit activates power reduction by controlling tur n on time of the electro-injectors. In some applications, the maximum limiting response consists in stopping the engine.

PHASE RECOGNITION Signals transmitted by the camshaft and crankshaft sensors determine the cylinder which fuel must be injected. INJECTION CONTROL Information transmitted by the sensors, the control unit determines and regulates pressure and modifies the pre-injection and main injection mode. INJECTION PRESSURE CLOSED LOOP CONTROL

CUT OFF Fuel cut-off release is managed by the control unit with the following logical interventions:

• deactivation of the electro-injectors. • reactivation of electro-injectors immediately prior to arrival at idle speed.

• control of fuel pressure regulator. SMOKE CONTROL UNDER ACCELERATION

Engine load, determined by processing of data transmitted by the various sensors, and the control unit. Governs the regulator to maintain injection pressure at constant optimal values.

With intense load demands, signals received from the boost temperature pressure sensor and the crankshaft sensor, the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent the emission of smoke from the exhaust.

PILOT AND MAIN INJECTION ADVANCE CONTROL

AFTER ENGINE SHUT DOWN

Signals transmitted by various sensors to the control unit, determines the optimum injection point on the basis of internal mapping.

Afte r the engine is stopped, the contro l un it microprocessor saves various parameters to the EEPROM memory, including the fault log so that they will be available the next time the engine is started.

IDLE SPEED CONTROL The control unit processes signals transmitted by the various sensors and adjusts the quantity of fuel injected. It also controls the pressure regulator and modulates injection duration of the electro-injectors. Within specific limits, the control unit also monitors battery voltage.

CONTROL OF WORKING SPEED IN NORMAL OPERATING CONDITIONS Each time work load varies, the control unit adjusts torque to maintain the engine in maximum power conditions. If the load causes a reduction in power, the control unit increases torque i.e. it increases the amount of fuel injected in order to restore the engine to maximum power.

OVERHEATING PROTECTION If the water temperature reaches 110° C (230° F) the control unit reduces engine performance. When the temperature returns below 100° C (212° F) the engine resumes normal operation. In some applications, the intake manifold temperature is the reference temperature.

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CHAPTER 2 - 445TA ENGINE OVERHAUL RECOVER STRATEGIES

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

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

• Synchronism problems In the case of synchronism problems, faulty rev s e n s o r s, t h e s y s t e m c o n t r o l s t h e e n g i n e by increasing the number of revs in order to improve interpretation of the signals.

When the temperature of the supercharging air rises above 88° C (190° F), power reduction is started, when a temperature of 120° C (248° F) is reached, performance is further reduced and is comparable to that of the same engine if it were aspirated.

• Reduction of power as reference temperature varies In normal operating conditions, the system knows the supercharging air, oil and water temperatures. If the temperature of the engine water is not available, the system takes the temperature of the oil as reference and when this reaches the threshold of 103° C (217° F), it star ts to reduce the power available. On reaching 113° C (235° F), power is reduced to 50%.

• Power restrictions as operating temperature increases.

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2-61



FUEL SUPPLY SYSTEM- F4HE ENGINES

2 1

3

4 6 D

8 5 7

A B

D

C Figure 2-62

BS06K054

1. ELECTRO-INJECTOR 2. BACK PRESSURE REGULATOR FOR FUEL RETURN 3. COMMON RAIL PRESSURE RELIEF VALVE

4. PRE-FILTER

7. LOW PRESSURE GEAR TYPE B. LOW PRESSURE CHARGE PUMP

5. FUEL FILTER

8. HIGH PRESSURE PUMP

C. FUEL RETURN

6. COMMON RAIL

A. HIGH PRESSURE

D. HIGH PRESSURE FROM PUMP TERMINAL

The common rail system has a high pressure pump that constantly keeps the fuel supply at a very high pressure, not dependent on the phase of the cylinder that must receive the injection. The high pressure fuel is stored in a pipeline (the common rail) that is shared by all electro- injectors. This means that there is always a supply of fuel available at the electro- injector inlet at the injection pressure determined by the EDC7UC31 electronic control unit. When the solenoid valve of an electro- injector is energized by the EDC7UC31 electronic control unit, fuel taken directly from the common rail is injected into the corresponding cylinder. The fuel system is composed of a low pressure circuit and a high pressure circuit. 2-62

The high pressure circuit consists of the following lines:

• Line connecting the high pressure pump outlet to the common rail.

• Lines supplying the electro-injectors from the common rail. The low pressure circuit is composed of the following lines:

• Fuel line from fuel tank to prefilter. • Lines supplying the mechanical supply pump through the heat exchanger of the control unit, the manual priming pump and the pre filter. The fuel system is completed by the fuel return from the common rail, injectors and high pressure pump cooling circuit. Issued 04-07

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CHAPTER 2 - 445TA ENGINE OVERHAUL FUEL SUPPLY SYSTEM DIAGRAM- F4HE ENGINES

5

6

7

A B

4

C D

3 18 17

2

8 9

1

10

16 15

13

11

14

12 Figure 2-63

BS06K055

1. HIGH PRESSURE PUMP 2. LOW PRESSURE REGULATOR VALVE ON HIGH PRESSURE PUMP 3. COMMON RAIL SAFETY RELIEF VALVE 4. BACK PRESSURE VALVE IN FUEL RETURN LINE FROM INJECTOR 5. COMMON RAIL 6. RAIL PRESSURE SENSOR 7. ELECTRO-INJECTOR 8. ROTOR PUMP PRESSURE SAFETY BY-PASS

9. MECHANICAL ROTOR PUMP BY-PASS CHECK VALVE 10. HIGH PRESSURE PUMP AND INJECTOR RETURN LINE 11. EDC7UC31 CONTROL UNIT HEAT EXCHANGER

17. HIGH PRESSURE PUMP BYPASS CHECK VALVE 18. RETURN LINE FROM HIGH PRESSURE PUMP A. DRAIN

12. MANUAL PRIMING PUMP

B. SUCTION

13. PRE-FILTER 14. FUEL TANK 15. FUEL FILTER

C. LOW PRESSURE D. HIGH PRESSURE

16. GEAR CHARGE FEED PUMP

The supply pressure regulator controls the flow of fuel needed in the low pressure system. The high pressure pump supplies the common rail. This pressurization of fuel, improves energy efficiency and limits the heating of the fuel in the system. The low pressure regulator valve (2) installed on the high pressure pump maintains the pressure at a constant level of 5 bars (72 psi.). Low pressure regulator valve (2) operates to increase fuel flow in the high pressure pump cooling circuit through line (18) carrying fluid into and out of line (10).

In parallel with the mechanical supply pump there are two by-pass valves. Rotor pump pressure safety by-pass valve (8) makes it possible to have the fuel flow back from the mechanical pump outlet to its inlet, when the p r e s s u r e a t t h e f u e l f i l t e r i n l e t ex c e e d s t h e permissible limit. The rotor pump by-pass valve (9) makes it possible to fill the supply system via the manual priming pump (12).

The common rail safety relief valve (3) installed in the cylinder head. Controls the flow of fuel returning from the electro-injectors at a pressure of 1.3 to 2 bars (19 to 29 psi.). 87630273 NA

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2-63


CHAPTER 2 - 445TA ENGINE OVERHAUL FUEL FILTER

B

1

D

C

5 4

2

2

D

A A

B

3

C 5 E

Figure 2-64

BS06K056

1. 2. 3. 4. 5.

FUEL FILTER BRACKET FUEL TEMPERATURE SENSOR FUEL FILTER ELECTRIC FUEL HEATER FUEL TEMPERATURE SENSOR

A. B. C. D. E.

OUTLET CONNECTION TO HIGH PRESSURE PUMP COMMON RAIL, CYLINDER HEAD INJECTORS DISCHARGE LINE INLET CONNECTION CONNECTION TO HIGH PRESSURE PUMP DISCHARGE LINE INLET CONNECTION FROM FEED PUMP OUTLET CONNECTION TO FUEL TANK

The fuel filter is installed on the engine cylinder block in the circuit between supply pump and high pressure pump (CP3).

2-64

The heater is activated if the fuel temperature is less than 0° C (32° F) and is heated until the fuel reaches 5° C (41° F). Fuel temperature is monitored by the EDC7UC31 control unit.

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CHAPTER 2 - 445TA ENGINE OVERHAUL MECHANICAL FEED PUMP- NORMAL OPERATING CONDITION- F4HE ENGINES

1 A

2 B

Figure 2-65

BS06K057

1. PRESSURE SAFETY VALVE 2. PRIMING BY-PASS VALVE IN CLOSED POSITION

The charge gear pump, installed on the rear of the high pressure pump, draws fuel from the tank through the pre-filter and sends it through the main fuel filter to the high pressure pump.

A. FUEL INLET FROM TANK B. FUEL OUTLET TO FILTER

The feed pump is driven by the high pressure pump shaft. In normal operating conditions the flow in the feed pump enters port (A), flows around the outside of the gears and out through port (B).

MECHANICAL FEED PUMP- OUTLET OVERPRESSURE CONDITION IN EXHAUST UNIT

2

1

A

B

Figure 2-66

BS06K058

1. PRESSURE SAFETY VALVE 2. BY-PASS PORT

Pressure safety valve (1) opens when pump outlet pressure (B), is excessive due to filter restriction or charge pressure regulator malfunction. The pressure of the fuel would then overcome the force exerted by 87630273 NA

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spring (1) allowing fuel to flow to the pump inlet through passage (2).

2-65


CHAPTER 2 - 445TA ENGINE OVERHAUL FUEL SYSTEM BLEEDING CONDITION

1 A

2 B

Figure 2-67

BS06K059

1. PRESSURE SAFETY VALVE 2. PRIMING BY-PASS VALVE IN CLOSED POSITION

The by-pass valve (2) opens when, the engine is turned off. The supply system has to be filled with the manual priming pump.

2-66


When activating the hand pump the by-pass valve (2) is opened due to inlet pressure, this allows the fuel flow to outlet (B).

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CHAPTER 2 - 445TA ENGINE OVERHAUL HIGH PRESSURE PUMP TYPE CP3.3- F4HE ENGINES

1 2 8

3

7

6 4

5

Figure 2-68

BS06K060

HIGH PRESSURE PUMP 1. 2. 3. 4. 5. 6. 7. 8.

MECHANICAL GEAR CHARGE PUMP FUEL OUTLET CONNECTION FROM MECHANICAL PUMP TO FILTER FUEL INLET CONNECTION FROM CONTROL UNIT HEAT EXCHANGER FUEL DRAIN RETURN CONNECTION TO FILTER BRACKET FUEL INLET CONNECTION FROM FILTER HIGH PRESSURE REGULATOR HIGH PRESSURE PUMP FUEL OUTLET CONNECTION TO COMMON RAIL

The high pressure pump has 3 radial plungers driven by the cam gear. The pump does not need to be timed.

On the rear of the high pressure pump is the mechanical gear feed pump which is driven by the high pressure pump shaft.

IMPORTANT: The high pressure pump unit can not be overhauled, there are no adjustments.

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2-67



1 9

2

8

3

7

4

6 5

Figure 2-69

BS06K061

EXPLODED VIEW OF HIGH PRESSURE PUMP 1. BY-PASS VALVES ON FEED PUMP 2. PUMP SHAFT 3. HIGH PRESSURE PUMP FUEL INLET FROM FILTER

2-68

4. 5 BAR (72 PSI) LOW PRESSURE FUEL REGULATOR VALVE 5. HIGH PRESSURE REGULATOR SOLENOID VALVE

7. HIGH PRESSURE FUEL DELIVERY VALVE TO COMMON RAIL

6. INDIVIDUAL HIGH PRESSURE PUMP PLUNGER (1 OF 3)

9. MECHANICAL GEAR CHARGE FEED PUMP

8. GEAR SET

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CHAPTER 2 - 445TA ENGINE OVERHAUL HIGH PRESSURE PUMP INSIDE STRUCTURE

3 1 6

4

5

Figure 2-72

BS06K161

Figure 2-70

BS06K160

8

BS06K159

7

Figure 2-73

2 Figure 2-71

BS06K158

1. LOW PRESSURE FUEL INLET 2. PUMPING ELEMENTS SUPPLYING FUEL DUCTS 3. CYLINDER 4. THREE LOBE ELEMENT

5. PUMP SHAFT 6. PISTON 7. BALL DELIVERY VALVE 8. CAP INTAKE VALVE

Pumping unit is composed of: • Three pistons (6) which are actuated by a three lobe element (4) on the pump shaft (5) When the shaft (5) rotates the three lobe element (4) actuates the piston (6) pumping high pressure fuel past the ball delivery valve (7) to the common rail.

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2-69


CHAPTER 2 - 445TA ENGINE OVERHAUL OPERATING PRINCIPAL

1

7

2

6 5 4

3

Figure 2-74

BS06K063

Figure 2-75

BS06K160

1. OUTLET FOR RAIL DELIVERY LINE 2. HIGH PRESSURE REGULATOR

3. PRESSURE REGULATOR SUPPLY PASSAGE 4. PLUNGER SUPPLY PASSAGE

High pressure plunger (3) rides on the cam installed on the pump shaft (4). In the intake phase the plunger is supplied with fuel through the supply passage (5). The quantity of fuel to supply to the plunger is determined by pressure regulator (7). The pressure regulator controls high pressure pump outlet flow based on PWM (pulse width modulated) command received from the EDC7UC31 control unit. 2-70

5. PUMP SHAFT

7. RAIL DELIVERY VALVE

6. HIGH PRESSURE PLUNGER

During the plunger compression phase the fuel reaches sufficient pressure to open the common rail delivery valve (2) and is forced through outlet (1) to the common rail.

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2 1 1 2

9

3 8 4 7 5

6

Figure 2-76

BS06K064

1. 2. 3. 4. 5. 6. 7. 8. 9.

INLET TO HIGH PRESSURE PLUNGERS INLET TO HIGH PRESSURE PLUNGERS CHARGE PRESSURE REGULATOR DRAIN PASSAGE CHARGE PRESSURE 5 BAR (72 PSI) REGULATOR VALVE FUEL DISCHARGE FROM HIGH PRESSURE REGULATOR VALVE INLET HIGH PRESSURE REGULATOR VALVE MAIN PLUNGER SUPPLY PASSAGE INLET TO HIGH PRESSURE PLUNGERS PUMP LUBRICATION PASSAGES

3 BS06K065

Figure 2-77

1. FUEL EXHAUST FLUE 2. FUEL EXHAUST GALLERY 3. FUEL EXHAUST FLOWING FROM PUMP WITH CONNECTOR TO HIGH PRESSURE LINE FOR COMMON RAIL

The figure above shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements. THEORY OF OPERATION

The figure above shows the low pressure fuel passages inside the pump. The figure shows the main plungers supply passage (7), the individual plunger supply passages (1, 8, 2), the passages utilized for lubrication of the pump (9), the high pressure regulator (6), the 5 bar (72 psi) pressure regulator valve (4) and the fuel discharge passage (3). The high pressure regulator (6) determines the quantity of fuel which the high pressure plungers deliver to the common rail. Excess fuel flows out through passage (5). The regulator valve (4), is designed to maintain a constant pressure of 5 bar (72 psi.) at the high pressure regulator inlet.

The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements about 2 bars (29 psi.). The amount of fuel supplying the high pressure pump is metered by the high pressure regulator. The high pressure regulator is controlled by the EDC7UC31 control unit through a PWM (pulse width modulated) signal. When fuel is sent to a pumping element, the corresponding piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the fuel in the pumping element chamber, is compressed into the rail. The generated pressure makes the exhaust valve open and the compressed fuel reaches the high pressure circuit. The pumping element compresses the fuel till the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed. The pumping element piston goes back towards the bottom dead center and the remaining fuel is decompressed.

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2-71


CHAPTER 2 - 445TA ENGINE OVERHAUL When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated. The rail delivery pressure is modulated between 250 and 1600 bars (3625 to 23206 psi.) by the EDC7UC31 control unit, through the pressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel. The pump replacement time on the engine is highly reduced in comparison with traditional injection pumps, because it does not require timing. IMPORTANT: If the line between the fuel filter and high pressure pump is to be removed or replaced, be sure that components are absolutely clean.

COMMON RAIL

1

Figure 2-78

BS06K066

COMMON RAIL

The common rail volume is a high pressure fuel storage device. It has a small volume to allow a rapid pressurization at startup, at slow idle and in case of high flow rates.

A fuel rail pressure sensor (1) is screwed into the common rail. The signal sent by this sensor to the EDC7UC31 control unit, and is then feed back to the common rail pressure sensor and corrected if necessary.

It has enough volume to minimize system spikes caused by injector opening and closings and by the high pressure pump operation. This function is further enhanced by a calibrated orifice between the high pressure pump and the common rail.

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COMMON RAIL PRESSURE RELIEF VALVE

B

A

1

2

3

4

5

6

1

2

3

4

5

6 Figure 2-79

BS06K067

COMMON RAIL PRESSURE RELIEF VALVE 1. DIRECT TANK DISCHARGE 3. BODY 5. SMALL PISTON 2. STOP 4. SPRING 6. SEAT ON RAIL A. NORMALLY, THE TAPERED PISTON (5) END STAYS CLOSED THE DISCHARGE IS DIVERTED TO THE FUEL TANK. B. IF 1750 BAR FUEL PRESSURE IS EXCEEDED IN THE RAIL, THE SMALL PISTON MOVES AND THE EXCESS PRESSURE IS DISCHARGED INTO THE FUEL TANK.

The common rail pressure relief valve is installed at one end of the common rail, it is designed to protect the systems components in case of excessive increase of pressure buildup. The valve can be single stage (as the ones shown above) or two stage with two working limits for pressure relief 1750 bar and 800 bar (25381 psi. and 11603 psi.).

The relief valve enables engine operation at limited p e r fo r m a n c e, avo i d i n g f u e l ove r h e a t i n g a n d safeguarding the system If the dual stage relief valve opening pressure is reached, the EDC7UC31 control unit stops operation of the pressure regulator. The high pressure pump will then operate at maximum delivery to the common rail, and a failure code will be stored.

In the second case, when the pressure within the high pressure system reaches 1750 bar (25381 psi.), the valve is activated as a single stage one to exhaust the fuel and consequently reduce the pressure until reaching the proper pressure. Then it reduces the pressure into the common rail to approximately 800 bar (11603 psi.).

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ELECTRO-INJECTOR 1

1

14 13

13

3

12

3

4

4 11 11

15

2

15

2 12

14

5

5

6

6 10

10

7

7 9

9

8

8

Figure 2-81

BS06K069

Figure 2-80

BS06K068

INJECTOR IN REST POSITION 1. ELECTRICAL CONNECTION 2. PILOT VALVE 3. CONTROL AREA 4. CONTROL DUCT 5. PRESSURE ROD 6. SUPPLY DUCT 7. PLUNGER 8. NOZZLE

9. PRESSURE CHAMBER 10. 11. 12. 13. 14. 15.

SPRING CONTROL FUEL OUTLET HIGH PRESSURE FUEL INLET COIL BALL SHUTTER CONTROL VOLUME

The injector is similar to the conventional injectors, except for the absence of plunger return springs. The injector can be considered in terms of two basic parts: • Actuator- spray nozzle composed of pressure rod (5), plunger (7) and nozzle (8).

INJECTION START

When coil (13) is energized, it makes ball shutter (14) move upwards. The control volume (15) fuel flows towards control fuel outlet (11) making a pressure drop occur in control volume (15). Simultaneously the fuel pressure into pressure chamber (9) makes plunger (7) lift, causing injection of fuel into the cylinder. INJECTION END When coil (13) is de-energized, shutter ball (14) goes back to its closed position to restore a balance of forces to make plunger (7) go back to its closed position and end the injection cycle. IMPORTANT: The injector has no serviceable parts inside, so it is not repairable.

• Control solenoid valve composed of coil (13) and pilot valve (2). The solenoid valve controls spray nozzle plunger lift.

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CHAPTER 2 - 445TA ENGINE OVERHAUL ELECTRO-INJECTOR The NEF Tier III engines use Bosch CRIN 2 electroinjectors. The injection jet used are according to power developed by the engine.

1

Figure 2-82

BS06K070

1. JET

Pressures

Injectors

Jet

Power developed

CRIN 2

DLLA

Above 152kW (204 h.p.)

250 bar (3626 psi.)

1600 bar (23206 psi.)

CRIN 2

DSLA

Below 152kW (204 h.p.)

250 bar (3626 psi.)

1450 bar (21030 psi.)

kW / H.P.

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Minimal operating pressure

Nominal operating pressure

2-75


CHAPTER 2 - 445TA ENGINE OVERHAUL PRESSURE LIMITER FOR FUEL RETURN

A

BS06K071

B

Figure 2-83

A. TO FUEL TANK B. FROM INJECTORS

The pressure limiter for the fuel return is housed on the rear of the cylinder head, and adjusts the pressure of the fuel returning from injectors at a pressure of 1.3 to 2.0 bars (18.9 to 29 psi.). By maintaining this pressure to the return fuel, the fuel vapor formation inside the injectors is avoided, optimizing fuel spraying and combustion.

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CHECKING THE FUEL SYSTEM LOW PRESSURE SUPPLY TEST

10

9

8

7

4

4

9

9 11

3

2 4

6

12

4

4 5

1 13

Figure 2-84

BS06K214

DIAGRAM OF SET UP OF COMPONENTS FOR SPECIFIC TEST 1. FUEL TANK 2. PREFILTER

6. HIGH PRESSURE PUMP 7. HIGH PRESSURE CIRCUIT

3. LOW-PRESSURE PUMP

8. COMMON RAIL

4. FUEL DELIVERY CIRCUIT 5. FUEL FILTER

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11. M1 PRESSURE GAUGE 0-15 BAR FUEL FILTER INLET 12. M2 PRESSURE GAUGE FUEL FILTER OUTLET 13. EXTERNAL CONTAINER PLACED 1M (39 IN.) BELOW ENGINE

9. FUEL RECIRCULATION 10. INJECTORS

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6 12

11

5

13 Figure 2-85

BS06K215

LOW - PRESSURE PUMP

Figure 2-86

BS06K216

The function of the gear pump is to supply the high pressure pump. It is driven by the shaft of the high pressure pump and is installed on the rear portion of the high pressure pump. Under normal operating conditions, the flow of fuel inside the pump is as shown in the figure above.

2-78

With the fuel system pressurized, a fully charged battery and an external fuel supply placed 1m (39 in.) below the engine. The engine must start within 20 seconds of activation of the starter motor. If the pump is not able to draw fuel to the engine and start the engine the low pressure pump is probably defective.

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CHAPTER 2 - 445TA ENGINE OVERHAUL After starting the engine, check the pressure at 1500 rpm. On pressure gauge M1- (11) it must be between 6 and 9 bar (87 and 130 psi.) • If lower than 6 bar (87 psi.) replace pump • If higher than 9 bar (130 psi.) replace the fuel filter. On pressure gauge M2- (12) it must be greater than 5 bar (72.5 psi.) • If lower, replace the fuel filter • If the trouble persists, check the seals on the couplings of the fuel filter bracket and the high pressure pump inlet.

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CHAPTER 2 - 445TA ENGINE OVERHAUL TEST ON PRESSURE RELIEF VALVE ON COMMON RAIL

1

Figure 2-87

BS06K217

The pressure relief valve is installed on the end of the common rail, its function is to protect the systems components if any malfunction causes and excessive increase in the pressure of the high pressure system. Disconnect recirculation line (1) from the pressure relief valve and plug with the VOSS fitting from the test set.

If the valve seeps diesel without a fault code, then replace the valve. With the common rail pressure sensor disconnected and a fault code is generated, with the rail pressure is at 71 0 bar (1 029 8 psi.) m ea sura ble with the diagnostic instrument, the trouble is in the wiring and not the component.

No diesel must come out of the valve at any engine speed. If the diagnostic system signals a fault code “Engine - backfill valve control”, it means that the EDC7UC31 control unit has recognized that the value has opened after a significant change in the pressure of the rail greater than 1700 bar (24656 psi.). Since its opening is to be considered a consequence of abnormal increase in pressure, the valve is NOT defective even though a great amount of diesel flows out. IMPORTANT: Information acquired to date shows that the sensor is rarely defective.

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CHAPTER 2 - 445TA ENGINE OVERHAUL TEST ON FUEL BACKFLOW FROM THE RETURN

1

BS06K219

Figure 2-88

BS06K218

Tests on fuel backflow from the return establishes the operating status of the injectors. The engine s p ee d a nd powe r a re c on tr ol l e d th ro ug h t he injectors. The power required by the user, through the accelerator, is converted into the quantity of fuel injected per cycle. This in turn is converted into microseconds of injector opening according to the rail pressure.

Figure 2-89

1. INJECTOR DUCT LOCKING NUT

When the EDC7UC31 control unit warning light comes on during acceleration and/or cold star t trouble, make sure the following check is done. • Check torque of the nut (1) locking the injector duct on the cylinder head. The torque setting is 45 - 55 Nm (33.2 - 40.6 lb.- ft.).

NOTE: The injectors may have problems of both a mechanical and a electrical nature. Therefore before proceeding with the following analysis, it is wise to rule out the presence of water in the tank and the fuel prefilter.

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2

1

3

4

Figure 2-90

BS06K220

Proceed with the injector fuel backflow tests as follows: • Remove the duct (4) from the cylinder head.

• Plug it (3) • Install a transparent line (2) Make sure that the engine idling speed is correct. Check the quantity of fuel recirculation from the cylinder head. The process for measuring the quantity of injector return fuel is: • Engine idling and without air compressor or air conditioner on. • engine temperature greater than 50°C (122°F). The quantity of fuel that flows out must be no greater than 80ml. (2.7 oz.) of diesel per minute. Excessive recirculation more than 80ml. (2.7 oz.) of diesel per minute could be caused by: • Incorrect coupling between one or more injectors and the related needles. • Problem of internal leakage of the injector.

2-82

To identify the defective injector, follow the method as described below: Measure the quantity of fuel flowing out in one minute from the coupling on the cylinder head. If recirculation exceeds 80 ml. (2.7 oz.) per minute, plug the rail outlet of one injector (1) at a time using the rail plugs in the test set. The defective injector is the one when plugged causes a significant reduction in recirculated fuel. NOTE: When changing an injector it is necessary to change the duct. After identifying the injectors / ducts with high fuel recirculation, check the torque of the ducts, 45 - 55 Nm (33.2 - 40.6 pound-feet), if they are loose tighten. Then check the recirculation values again. If the torque is correct, remove the line and check the spherical end towards the injector is not out of round, replace if necessary. Recheck recirculation value. If the duct is not out of shape, replace the injector

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SPECIAL DISASSEMBLY FOR F4GE ENGINES STEP 3

DISASSEMBLING ENGINE

1

STEP 1

2

13

3 4

12

5

11

6 7

10

8

9 1 Figure 2-93

BS06N246

Version F4GE9484D Figure 2-91

BS06N244

Drain the engine oil by taking the plug off the oil pan and the oil filling cap of the valve cover. Remove the fan unit from the fan pulley. In order to apply the brackets to the engine block to fix it on the stand for overhaul it is necessary to remove electrical wiring (1). STEP 2

2

1

5

Remove the following:

• • • • • • • • • • •

Grid heater (1). Intake manifold (2). Oil recovery pipe from blow-by (3). Pipe for LDA intake manifold (4). Piping for LDA system (5). Quick-couplings pipes (6), (7), (10) see step 4. Fuel filter (8). Electrical wiring (9). Fuel filter support (11). Grid heater control unit (12). Tappet covers (13).

STEP 4

4

3

A

B

1 Figure 2-92

BS06N245


• • • •

Fastening bracket (5) from electrical wiring (1). Starter (4) turbine lubrication delivery pipe (2).

1

Oil filter (3). BS06K388

Figure 2-94

IMPORTANT: Push clamp (1), as shown in figure B to disconnect the low pressure fuel lines 6, 7, 10 from the corresponding connections. After disconnecting the line, reset the clamp (1) to position in figure A to prevent distortion to the clamp.

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CHAPTER 2 - 445TA ENGINE OVERHAUL STEP 7

STEP 5

1

2 1

6 5 4 BS06N247

3 Figure 2-95

2 Figure 2-97

BS06N248

• Remove the bolts fastening the turbine, and then


• Injector feed pipes (3) from injection pump (2). • Brackets fastening feed pipes (1), (5), (6) on the cylinder head.

remove the turbine (1).

• Remove the exhaust manifold (3). STEP 8

• Fuel pump (4).

1

STEP 6

9

2 1

8

3 4 5 6

3 2

7

BS06N249

Remove the following: Figure 2-96


• Fuel feed pipes from the injectors (1). • Remove fuel drain pipe (2) from the injectors by removing the bolt (4) and the seal (3).

Figure 2-98

BS06N250

4

• • • •

Belt tightener (2). Poly-V belt (4). Alternator fastening bracket (1). Alternator (3), water pump (6), fan pulley (5), and guide pulleys (7).

• pulley support (8). • Thermostat housing and thermostat (9) from the engine block.

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STEP 9

1 2 1

3 2

4

Figure 2-99

BS06N251

Lock the flywheel properly to prevent rotation, remove bolts (2) from pulley (1). CRANK SEAL REPLACEMENT STEP 10

Figure 2-101

BS06K244

Using the pry bar (3) of Special Tool 380000996 and the lever (4), remove the external seal ring (2) from the front cover STEP 12

A

B 1

1 2 2 3

3 4

4 Figure 2-100

BS06K243

Place Special Tool 380000665 (4) to the front of the crankshaft (2). Working through the guide holes of Special Tool 380000665 (4), drill into the internal seal ring (1) with a 3.5 mm (9/64 inches) drill bit (A) to a depth of 5 mm (3/16 inch) (B). Secure Special Tool 380000665 (4) to the ring (1) by screwing down the six bolts supplied with tool to the crankshaft front cover.

BS07C437

Figure 2-102


• Water pump (1) • Bolts (2) and (4) • Crankcase front cover (3) NOTE: Take note of bolts (2) and (4) position when removing them because they are different lengths.

Now extract seal ring (1) by tightening bolt (3).

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STEP 13

2 1

1

Figure 2-103

BS06K246

Figure 2-105

BS06N254

Remove bolts and take off oil pump (1).

LOCKING INJECTION PUMP IN PRESET CONDITION

IMPORTANT: Oil pump (1) cannot be repaired. REMOVING INJECTION PUMP

To correctly preset the injection pump prior to removing it, loosen bolt (2) and remove the L-shaped spacer (1). Tighten bolt (2) to 27 to 33 Nm (20 to 24.3 poundfeet) to block rotation of the pump shaft.

STEP 14

IMPORTANT: Keep the L-shaped spacer with the pump so it does not get misplaced (it is needed for installation). STEP 16

1

A

2

B

2 4

3

Figure 2-104

BS06N253

LOCKING FLYWHEEL

Rotate the crankshaft until the number 1 cylinder reaches top dead center (TDC). When TDC is obtained lock the flywheel by pushing pin (1) of special tool 380002729 as shown by the arrow.

1 Figure 2-106

BS06N255

Remove cover (1) from gear case (2). Loosen nut (3) securing the injection pump drive gear (4).

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STEP 17

1

1

2 Figure 2-107

BD04A025-01

Attach Special Tool 380000979 (1) to the injection pump drive gear and remove the gear.

BS06N257

Figure 2-109

Remove bolts (1) securing engine flywheel (2) to the crankshaft

STEP 18 STEP 20

1

2

5

3

1 2

4 3 Figure 2-108

BS06N256

Loosen the three nuts (1), (3) and (4) securing the injection pump (2) to the bell housing (5), then take the pump out of its housing. NOTE: Hold the pump drive gear shaft to prevent it from moving, when removing pump from the engine block.

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BS06N258

Figure 2-110

Screw two pins (2) of adequate length into crankshaft holes (3). Remove engine flywheel (1) so that it can be harnessed with a hoist and moved out of the way.

2-87



STEP 21

A 1 1 2 2

3 4

5

BS06N252

Figure 2-111

REMOVING INNER REAR CRANKSHAFT SEAL

Apply Special Tool 380000663 (3) on crankshaft rear shank (5). Dr ill inner seal ring (1), through Special Tool 380000663 (3) guide holes, with a 3.5 mm (9/64 inches) drill bit (A). Drill down to a depth of 5 mm (3/16 inches). Secure Special Tool 380000663 (3) to ring (1) by fastening the 6 bolts (4) provided.

Figure 2-113

BS06N259

Remove bolts (2) and then remove the flywheel housing. IMPORTANT: Note the installation position of the bolts (2) because they are different lengths. STEP 24

1

Extract seal ring (1) by tightening bolt (2). STEP 22

1

2

2 3 Figure 2-114

BS06N260

Turn the engine upside down, remove bolts (2), remove oil pan (1). STEP 25

4 1 BS06K244

Figure 2-112

REMOVING OUTER REAR CRANKSHAFT SEAL

Using the pry bar (3) and lever (4) remove the outer seal ring (2) as shown in figure above. Then take the same tool and remove the seal ring from the flywheel cover case in the same manner.

2 3 4 Figure 2-115

BS06N261

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

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STEP 26

1

2 1

3

2 Figure 2-116

BS06N262

REMOVING COUNTER BALANCE

Use pin (1) to lock the counter balance (3) at TDC (top dead center). Remove bolts (2) and remove the counter balance (3).

Figure 2-118

BS06N264

Remove injectors (2) with Special Tool 380000671 (1).

STEP 29 REMOVING ROCKER ARM ASSEMBLY STEP 27

1 2 3 4

1

Figure 2-119

BS06N265

Figure 2-117

BS06N263

For each cylinder, loosen adjusting nuts (3) and unscrew the adjusters (2).

Remove bolts (1) securing the cylinder head to the engine block STEP 30

Remove the bolts (4), remove rocker assembly (1) and the push rods.

1

BS06N266

Figure 2-120

Attach harness to brackets (1), and remove cylinder head from block using a hoist.

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580 M Series 3 F4C Engine Service Training Manual 0407 87630273

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