SM Engine Fage y F4he

ENGINE REPAIR MANUAL
BACKHOE LOADER
F4GE9454H
F4GE9454J
F4GE9484D
F4HE9484A
F4HE9484C
READ, UNDERSTAND, AND FOLLOW ALL SAFETY

PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS
MANUAL BEFORE OPERATING THE MACHINE.
Bur • Issued 01Aug07

Printed in U.S.A. • Book/Form Number 87630273 NA
Copyright © 2007. CNH America, LLC. All Rights Reserved.
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
This unit first became available 08-2007

REVISION HISTORY
Issue Issue Date Applicable Machines Remarks
First Edition 01Aug07 F4GE9454H, F4GE9454J, F4GE9484D, F4HE9484A, F4HE9484C 87630273 NA
Any use of editorial or pictorial content is strictly prohibited without express written permission from
CNH America, LLC. Racine, WI 53403 U.S.A..

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 (F4GE) - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TORQUE SPECIFICATIONS (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 - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
ENGINE LUBRICATION - 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 - 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 - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
SPECIAL DISASSEMBLY - 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 - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
ASSEMBLING COUNTER BALANCER - 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 08-07 Bur I

SECTION 1 - ENGINE REPAIR MANUAL
INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138

INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144
ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145
CYLINDER HEAD ASSEMBLY - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154
LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157
ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159
CHAPTER 3
ELECTRICAL, CHARGING AND START-UP
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
LOCATION OF MAIN ELECTRICAL COMPONENTS - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
LOCATION OF MAIN ELECTRICAL COMPONENTS - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
II Issued 08-07 Bur 87519803 NA

CHAPTER 1
445TA
TIER III
DIAGNOSTICS
Issued 08-2007
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
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
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
F4GE9454H, F4GE9454J,
First Edition 08-2007 F4GE9484D, F4HE9484A, 87630273 NA
F4HE9484C
1-II 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 08-07 Bur 1-1

NOTES
1-2 Issued 08-07 Bur 87630273 NA

TROUBLESHOOTING
ENGINE WON’T START
Perform the checks described in the electrical

Batteries fully charged. No
section of the shop manual.
Yes
Inspect, clean, tighten nuts or replace terminals if
Connections to battery terminals are tight and clean. No
excessively corroded.
Yes
Perform the checks described in the electrical
Starter motor working properly. No
section of the repair manual.
Yes
Fuel filters plugged. Yes Replace.
No
Fuel in tank. No Refuel tank.
Yes
Check using multi meter replace or repair. Refer to
Grid heater system working properly. No
Chapter 3 pages 3-5 and 3-14.
Yes
Verify timing described in Chapter 2 page 2-120 and
Injection pump timed properly. No 2-141 for mechanical injection. Common rail pump
bring to certified pump shop.
Yes
On common rail engines check using Electronic
Injectors working properly. No Service Tool (EST). Mechanical injection loosen
(crack) injection lines.
Yes
The fuel system or injection pump shows signs of air Check and repair air leaks. For mechanical injection
Yes
in system. see Chapter 2 page 2-56
No
Check and clean the fuel system including the fuel
The fuel system shows traces of water. Yes
tank.
No
Fuel pump working properly. No Check fuel pump and replace if necessary.
Yes
Cold start advance solenoid and shut off solenoid Check and replace defective parts. See Chapter 2
No
both in working order. page 2-55
Yes
Check cylinders for proper compression, overhaul
Compression good on all cylinders. No
engine or make repairs on defective parts,.
87630273 NA Issued 08-07 Bur 1-3

ENGINE OVERHEATS
No Check for leaks, repair leaks and refill to

Coolant level correct.
proper level.
Yes
Fan working properly. No Replace.
Yes
Drive belts serviceable. No Replace.
Yes
Check for leaks, bad bearing, overhaul or

Water Pump working properly. No
replace.
Yes
Thermostat working properly. No Replace.
Yes
Wash down, repair leaks and flush out

Radiator plugged or leaking. Yes
radiator. If necessary replace radiator.
No
Air to Air Cooler and hoses leaking. Yes Clean or replace faulty parts.
No
Openings for coolant flow within the cylinder

Yes Clean thoroughly.
head and engine block plugged.
No
No Check and adjust for correct valve

Valve clearance correct.
clearance.
Yes
Verify correct timing described in Chapter 2

page 2-120 and 2-141 for mechanical
Injection pump timed correctly. No
injection. Common rail pump bring to
certified pump shop.
Yes
Cylinder head gasket leaking. Yes Replace.
1-4 Issued 08-07 Bur 87630273 NA

ENGINE LACKS POWER AND RUNS ERRATICALLY
Correct tie rod length between hand throttle No Adjust rod length.
and accelerator pedal.
Yes
No
Air filter plugged. Yes Clean or replace filter.
No
The fuel system shows impurities and or Check and clean the fuel system including
Yes
traces of water. the fuel tank.
No
Thermostat working properly. No Replace.
Yes

Injection pump timed correctly No
injection. High pressure pump bring to
Yes
Cold start solenoid (in injection pump) KKSB No Check and if defective repair or replace.
working properly. Refer to Chapter 2 page 2-55
Yes
Timing plunger (in injection pump) working Power to KKSB solenoid repair or replace if
No
properly. defective.
Yes
Fuel pump working properly. No Replace.
Yes
On common rail engines check using

Injectors working properly No Electronic Service Tool (EST) .Mechanical
injection loosen (crack) injection lines.
Yes
Injection pump rate correct. No Bring to a certified pump shop for repair.
Yes
Speed governor (in injection pump) in

No Bring to a certified pump shop for repair.
working order at all speeds.
Yes
87630273 NA Issued 08-07 Bur 1-5

Engine lacks power and runs erratically (continued)
Circuit and L.D.A.device both in working

order.
Yes
Injection pump peak adjusted. No Bring to a certified pump shop for repair.
Yes
Correct valve clearance. No Adjust clearance for proper value.
Yes
Check each cylinder for proper compression,

Compression good on all cylinders. No overhaul the engine or make repairs on
defective parts (valves, piston rings, etc.)
Yes
Turbocharger working properly. No Repair or replace unit.
1-6 Issued 08-07 Bur 87630273 NA

ENGINE EXHAUST SMOKE BLACK OR DARK GREY
Fresh clean diesel fuel in tank. No Clean the tank and replace the fuel filter.
Yes
Air filter pluggedand charge air cooler hoses Clean replace if necessary, repair leaking
Yes
leaking. hoses.
No
Check using multi meter replace or repair.

Grid heater system working properly. No
Refer to Chapter 3 pages 3-5 and 3-14.
Yes
Cold start solenoid (KKSB) working properly.

KKSB solenoid working properly. No Remove connector measure solenoid 4.8 ±
0.2 ohms. See Chapter 2 page 2-55
Yes

Injectors working properly. No Electronic Service Tool (EST) .Mechanical
Yes

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

order.
Yes
Injection pump adjusted properly. No Bring to a certified pump shop for repair.
Yes
87630273 NA Issued 08-07 Bur 1-7

Engine exhaust smoke black or dark grey (continued)
No Check the condition of pipes and replace

Injection pipes intact.
them if necessary.
Yes
Check each cylinder for proper compression,

Compression good on all cylinders. No overhaul the engine or make repairs on
defective parts (valves, piston rings, etc.).
ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)
Check using multi meter replace or repair.

Grid heater working properly. No
Refer to Chapter 3 pages 3-5 and 3-14.
Yes
Possible flow of coolant into the combustion

Coolant level correct. No chamber. Replace the cylinder head gasket
or overhaul the engine.
Yes

Injectors working properly. No Electronic Service Tool (EST) .Mechanical
Yes

Yes
Clean the tank and replace the fuel filter.

Fresh clean diesel fuel in tank. No
ENGINE EXHAUST SMOKE LIGHT BLUE
Check: Cylinder compression, leaks into or

out of turbocharger, leaks from valve guides.
Excessive oil consumption. Yes Overhaul cylinder head or engine if
necessary. Oil vapor breather check valve
installed see Step 43 on page 2-161.
1-8 Issued 08-07 Bur 87630273 NA

ENGINE KNOCKS IRREGULARLY
Check the following items: Journal play and

out-of -roundness, bolt torque for main
Knock detected in the crankshaft. Yes journal caps and engine flywheel, oil
pressure. Replace the defective parts or
overhaul the engine.
No
Check the following items: Rod journal end

play and out-of -roundness, bolt torque for
Knock detected in the connecting rods. Yes connecting rod caps, connecting rod torsion,
straightness. Replace defective parts or
No
Check the following items: Play between the

pistons and the cylinder liners, integrity of
Knock detected in pistons. Yes piston rings, play between the pins and the
piston hubs. Replace the defective parts or
No
Check the following items: Play between the

rocker arms and the valves, injection pump
Knock detected in the cylinder head. Yes
timing and valve timing. Adjust to proper
specification.
No
Check and replace if necessary the gears.

Inspect for broken springs, excessive play
Knock detected in valve gear. Yes
between the stems and guides, and the
tappets and seats. Adjust the clearance.
No

Knock detected in injectors. Yes Electronic Service Tool (EST) .Mechanical
No
Replace loose bolts and tighten all bolts to

Knock detected in the engine flywheel. Yes
the specified torque and angles.
No

Knock detected in the injection pump. Yes
87630273 NA Issued 08-07 Bur 1-9

ENGINE STOPS
Fuel in tank. No Refuel and drain if necessary.
Yes
No
Fuel Shut Off (FSO) solenoid working

No Check the solenoid replace if defective.
properly.
Yes
Check and if defective bring to a certified

pump shop for repair. For common rail refer
Regular injection pump rate. No
to Chapter 2 page 2-77. For mechanical
injection refer to Chapter 2 page 2-53
Yes

Injection pump controls working properly. No
pump shop for repair.
Yes
Regular idle speed. No Adjust.
Yes
Correct play between the valves and rocker

No Adjust play to proper specifications.
arms.
Yes
Valves intact. No Replace broken valves.
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 Check to see if contaminated or proper
No
viscosity. viscosity and fill to proper level if low.
Yes
Oil pump and delivery lines in working No Check and replace if necessary.
properly
Yes
Main bearings and connecting rod bearings Replace the bearings and reface if
No
in acceptable condition. necessary the crankshaft.
Yes
1-10 Issued 08-07 Bur 87630273 NA

Excessive or Insufficient Oil Pressure continued
Check for leaking shaft seal or leaking

Low oil pressure caused by fuel dilution. Yes
injection pump.
No
Main bearings and connecting rod bearings Replace the bearings and reface, if
No
working properly. necessary, the crankshaft.
EXCESSIVE FUEL CONSUMPTION
Repair leaks (if any) and replace the worn

Fuel tank and lines leaking. Yes
parts.
No
Air filter plugged. Yes Replace.
No

pump shop for repair. For common rail refer
Injection pump operating properly. No
to Chapter 2 page 2-77. For mechanical
injection refer to Chapter 2 page 2-53
Yes

Electronic fuel injection system operating
No Electronic Service Tool (EST) . Mechanical
properly.
injection loosen injection lines.
Yes
Valve adjustment correct. No Check and if wrong, adjust to proper value.
Yes
Check each cylinder for proper compression

Compression good on all cylinders. No and overhaul the engine or make repairs on
defective parts (valves, piston rings, etc.).
ENGINE WON’T STOP
Fuel Shut Off solenoid working properly. No Replace.
Yes
Check and if defective, bring to a certified

Speed governor working properly. No
pump shop for repair.
87630273 NA Issued 08-07 Bur 1-11

NOTES
1-12 Issued 08-07 Bur 87630273 NA

CHAPTER 2
445TA
TIER III
Issued 08-2007
CHAPTER 2 - 445TA ENGINE OVERHAUL
Revision History
F4GE9454H, F4GE9454J, F4GE9484D
First Edition 08-2007 87630273 NA
F4HE9484A, F4HE9484C
2-II Issued 04-07 Bur 87630273 NA

CHAPTER 2
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 (F4GE) - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TORQUE SPECIFICATIONS (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Crankshaft Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
EGR Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Valve Control for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Valve Control for F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Cylinder Head for F4GE9454h and f4GE9454J Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Cylinder Head for F4GE9484D Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Cylinder Head for F4HE9484A Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Valves and Valve Seats for F4GE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Valves and Valve Seats for- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
COUNTER BALANCER - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
ENGINE LUBRICATION - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
ENGINE LUBRICATION - F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Oil Pan (Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Oil Vapor Recirculation for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Oil Vapor Recirculation for- F4HE Engines with Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Blow-By Recirulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Oil Vapor Recirculation for- F4HE Engines without Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
87630273 NA Issued 08-07 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
FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION - F4GE ENGINES . . . . . . . . . . . . . . . . . 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 - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82
Crank Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84
2-2 Issued 08-07 Bur 87630273 NA

Removing Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85

Removing Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
SPECIAL DISASSEMBLY - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Replacing Cam Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Installing Tappets and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Measuring Bearing Journals and Connecting Rods Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Replacing Oil Pump Drive Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Mounting Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Checking Crankshaft Shoulder Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Conditions for Correct Pin/Piston Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Checking Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Checking Twisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
Checking Flexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
Assembling Piston To Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
Installing Connecting Rod-Piston Assemblies In Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
Measuring Crank Pin Assembly Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
Checking Piston Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
INJECTION PUMP TIMING FIRST PHASE - F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
ASSEMBLING COUNTER BALANCER - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
Valve Descaling, Check and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
Checking Valve Guide Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Valve Seats Regrinding- Replacing Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
Installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
87630273 NA Issued 08-07 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 - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-161
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 08-07 Bur 87630273 NA

F4GE - ENGINES
BS06N188 Figure 2-1

F4GE9454H & F4GE9454J ENGINE
BS06N189 Figure 2-2

F4GE9484D ENGINE
The NEF F4GE engines are character ized as It differs from other applications due to the provision
naturally aspirated or turbocharged two valves per of different power, power take-off, for different
cylinder engines. collector configurations, boost turbine and after
Fuel feed is provided by rotary mechanical injection cooler.
pump.
87630273 NA Issued 08-07 Bur 2-5

F4HE - ENGINES
BS07D071 Figure 2-3

F4HE9484A / F4HE9484C 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.
this also limits emissions as much as possible.
1
BS07D072 Figure 2-4

F4HE9484A / F4HE9484C ENGINE SHOWING THE EDC7UC31
CONTROL BOX (1).
2-6 Issued 08-07 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 08-07 Bur 2-7

ENGINE PROPERTIES
A F4GE9454H F4GE9454H F4GE9454J F4GE9454J F4GE9484D F4GE9484D F4HE9484A F4HE9484C

B *J601 *J602 *J600 *J601 *J601 *J602 * J101 *J101/*J102
C 4 Cylinders
D 4485 cm³ (273.7 cubic inches)
74 kW 74 kW 66 kW 66 kW 93 kW 93 kW 104 kW 82 kW
E (100 h.p.) (100 h.p.) (90 h.p.) (90 h.p.) (126 h.p.) (126 h.p.) (141 h.p.) (110 h.p.)
2000 rpm 2000 rpm 2000 rpm 2000 rpm 2200 rpm 2200 rpm 2200 rpm 2200 rpm
F Direct Injection
High pressure Common rail
G Rotary Injection pump
EDC7UC31
H 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 08-07 Bur 87630273 NA

GENERAL ENGINE FEATURES
1 2 3 4 5
6 7 8 9 10 11
BS06K013 Figure 2-5
REF. F4GE9454H F4GE9454J F4GE9484D F4HE9484A F4HE9484C

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101 J101 / J102
Cycle 4- Stroke diesel engine
1 Air Boosted Boosted by intercooler
Injection Direct
2 Number of cylinders 4 in-line
3 Bore 104 mm (4.1 in.)
4 Stroke 132 mm (5.2 in)
5 Total displacement 4485cm³ (273.7 cubic inches)
6 Compression ratio 17.5: 1 16.5: 1 17.5: 1
74 kW 66 kW 93 kW 104 kW 82 kw
Maximum power rating (net power at flywheel 2000 rpm 2000 rpm 2200 rpm 2200 rpm 2200 rpm
7
ISO 14396) 100 hp 90 hp 126 hp 141 hp 110 hp
2000 rpm 2000 rpm 2200 rpm 2200 rpm 2200 rpm
400 Nm 375 Nm 510 Nm 608 Nm 516 Nm
8 Maximum Torque
295 lb.-ft. 277 lb.-ft. 376 lb.- ft. 448 lb.-ft. 381 lb. - ft.
9 No-load idle 950 rpm
10 No-load peak rpm 2430 rpm
with
without intercooler with intercooler intercooler
11 Boosting (type of turbocharger) ???
HOLSET HX25 HOLSET HX25 HOLSET
HX27W
87630273 NA Issued 08-07 Bur 2-9

12 13 14 15
16 17 18 19
BS06K014 Figure 2-6

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101 J101 / J102
Lubrication. Forced by means of gear pump, pressure relief valve, oil filter.
Oil pressure with hot engine: at idle rpm. 0.70 bar (10 psi)
12
4.0 bar
Oil pressure with hot engine: at peak rpm. 3.50 bar (50 psi)
(58 psi)
Cooling. By centrifugal pump, regulated by thermostat, heat exchanger, intercooler
13 Water pump drive. By means of Belt
Thermostat start of opening temperature. 79 to 83° C (174 to 181° F)
Oil capacity engine sump. Refer to Owners Manual
14
Oil capacity engine sump + filter. Refer to Owners Manual
High Pressure Common
15 Fuel feed type Rotary Bosch - VE4 / 12 F
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 No information available CRIU 2
18 Injection sequence 1 -3 -4 -2
250 to 1600
bar
19 Injection pressure N.A.
3626 to
23206 psi
2-10 Issued 08-07 Bur 87630273 NA

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY
1 2 44 5 6
8 3 7 9 10
BS06K015 Figure 2-7

ENGINE TYPE
NO.
J601 J602 J600 J601 J601 J602 J101 J101 / J102
1 Cylinder bore. 104.000 to 104.024 mm. (4.0945 to 4.0954 in.)
Pistons:
Measurement dimension. X= 55.90 mm. (2.20 in.)
2
Outer diameter. Ø1= 103.714 to 103.732 mm. (4.0832 to 4.0839 in.)
Pin seat. Ø2= 38.010 to 38.016 mm. (1.4965 to 1.4967 in.)
3 Piston - cylinder liners. 0.252 to 0.294 mm. (0.0099 to 0.0116 in.)
4 Piston diameter. Ø= 0.4 mm. (0.0157 in.)
5 Protrusion of pistons from crankcase. 0.28 to 0.52 mm (0.01102 to 0.02047 in.)
6 Piston pin. Ø3= 37.994 to 38.000 mm. (1.4958 to 1.4961 in.)
7 Piston pin-Pin seat. 0.01 to 0.022 mm. (0.0004 to 0.0009 in.)
X1= 2.705 to 2.735 mm. (0.1065 to 0.1077 in.)
Piston ring grooves
X2= 2.44 to 2.46 mm. (0.0961 to 0.0969 in.)
(measured on Ø of 99.0mm 3.898 in.)
X3= 4.03 to 4.05 mm. (0.1587 to 0.1594 in.)
8
Piston rings S1= 2.560 to 2.605 mm. (0.1008 to 0.1026 in.)
(measured 1.5 mm 0.05905 in. away from S2= 2.350 to 2.380 mm. (0.0925 to 0.0937 in.)
external Ø). 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.)
9 Piston rings - Slots. 2= 0.060 to 0.110 mm. (0.0024 to 0.0043 in.)
3= 0.040 to 0.080 mm. (0.0016 to 0.0031 in.)
10 Piston rings. 0.40 mm. (0.0157 in.)
87630273 NA Issued 08-07 Bur 2-11

11 12 14
13
15 17
16
BS06K016 Figure 2-8

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101 J101 / J102
X1= 0.30 to 0.40 mm. (0.0118 to 0.0157 in.)
11 Piston ring gaps in cylinder liner. 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.)
12
Connecting rod large-bearing seat. Ø2= 72.987 to 73.013 mm. (2.8735 to 2.8745 in.)
Connecting rod small-end bearing diameter.
13 Inner Ø3= 38.019 to 38.033 mm. (1.4968 to 1.4974 in.)
Big end half bearings S= 1.955 to 1.968 mm. (0.0770 to 0.0775 in.)
14 Connecting rod small-end bearing seat. 0.250 to 0.500 mm. (0.0098 to 0.01968 in.)
15 Piston pin - bearing. 0.019 to 0.039 mm. (0.0007 to 0.0015 in.)
Measurement dimension. No Information Available
Maximum error on connecting rod axis No Information Available
parallelism.
16 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.)
17 Main bearing- journals
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.)
2-12 Issued 08-07 Bur 87630273 NA

18 19 20
21 22 23
BS06K017 Figure 2-9
REF F4GE9454H F4GE9454J F4GE9484D F4HE9484A F4HE9484C

. ENGINE TYPE
J601 J602 J600 J601 J601 J602 J101 J101 / J102
NO.
Half bearing- journals.
0.064 to 0.095 mm. 0.041 to 0.119 mm.
Numbers 1, 5
(0.0025 to 0.0037 in.) (0.0016 to 0.0047 in.)
18 0.059 to 0.100 mm. 0.041 to 0.103 mm.
Numbers 2, 3, 4
(0.0023 to 0.0039 in.) (0.0016 to 0.0041 in.)
0.064 to 0.090 mm. (0.0025 to 0.0035 in.) 0.033 to 0.041 mm.
Half bearing - crank pins.
(0.0025 to 0.0035 in.) (0.0013 to 0.0016 in.)
+0.250 mm. (0.0098 in.)
19 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 X2= 32.180 to 32.280 mm. (1.2669 to 1.2709 in.)
bearing.
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 08-07 Bur 2-13

VALVE GEAR - CYLINDER ASSEMBLY
1 2 3 4
5 6 7 8
BS06K018 Figure 2-10

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101 J101 / J102
Ø1= 8.019 to 8.039 mm. Ø1= 7.042 to 7.062 mm.
1 Valve guide seats on cylinder head.
(0.316 to 0.317 in.) (0.277 to 0.278 in.)
Ø4= 7.960 to 7.980 mm. Ø4= 6.970 to 6.990 mm.
Valves - Intake. (0.313 to 0.314 in.) (0.274 to 0.275 in.)
Angle= 60° ± 0.25°
2 Ø4= 6.970 to 6.990 mm.
Ø4= 7.960 to 7.980 mm. (0.274 to 0.275 in.)
Valves - Exhaust. (0.313 to 0.314 in.)
Angle= 45° ± 0.25°

3 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. - 46.987 to 47.013 mm 34.837 to 34.863 mm
Intake. (1.850 to 1.851 in.) (1.371 to 1.373 in.)
4
Seat on head for valve seat. - 43.637 to 43.663 mm. 34.837 to 34.863 mm
Exhaust. (1.718 to 1.719 in.) (1.371 to 1.373 in.)
Valve seat outer diameter; angle of
valve seats on cylinder head.
Ø2= 47.063 to 47.089 mm. Ø2= 34.917 to 34.931 mm.
Intake. (1.853 to 1.8534 in.) (1.374 to 1.375 in.)
5
angle= 60°
Ø2= 43.713 to 43.739 mm. Ø2= 34.917 to 34.931 mm.
Exhaust. (1.7210 to 1.7220 in.) (1.374 to 1.375 in.)
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.)
6
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.)
Between valve seat and head-
0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)
Intake
7
Between valve seat and head-
0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)
Exhaust
8 Valve seats No Information Available
2-14 Issued 08-07 Bur 87630273 NA

9 10 11 12 13 14
15 18 22 16 17 19 20 21

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101 J101 / J102
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.)
9
Under load of: 641 N (144 lbf). H2= 38.20 mm. (1.504 in.) 25.2 mm (0.992 in.)
Injector protrusion. X= Not Adjustable
Seats camshaft bearing.- number - 1 Ø 7= 59.222 to 59.248 mm.
(flywheel side) (2.332 to 2.333 in.)
10
Seats camshaft bearings.- Ø 1-6= 54.089 to 54.139 mm.
numbers - 2, 3, 4, 5 (2.130 to 2.132 in.)
Camshaft main bearing journals: Ø 1, 2, 3, 4, 5 = 53.995 to 54.045 mm.
11
1 through 5 (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.)
16
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.)
Ø2= 15.924 to 15.954 mm. (0.627 to 0.628 in.)
17
Tappet plate outside diameter. 15.960 to 15.975 mm
Ø3= 15.965 to 15.980 mm.(0.629 to 0.629 in.) (0.628 to 0.629 in.)
18 Between tappets and seat. No Information Available
19 Tappets. No Information Available
Ø1= 18.963 to 18.975 mm. Ø1= 21.965 to 21.977 mm
20 Rocker arm shaft.
(0.747 to 0.747 in.) (0.8647 to 0.8652 in.)
Ø2= 22.001 to 22.027 mm
21 Rocker arms Ø2= 19.000 to 19.026 mm. (0.748 to 0.749 in.) (0.866 to 0.867 in.)
0.025 to 0.063 mm. 0.024 to 0.162 mm
22 Between rocker arm and spindle (0.001 to 0.003 in.) (0.00094 to 0.0064 in.)
87630273 NA Issued 08-07 Bur 2-15

TORQUE SPECIFICATIONS (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)
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 08-07 Bur 87630273 NA

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)
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 08-07 Bur 2-17

TORQUE SPECIFICATIONS (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 08-07 Bur 87630273 NA

Damper adapter and damper on crankshaft M12 bolt

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
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
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)
87630273 NA Issued 08-07 Bur 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 08-07 Bur 87630273 NA

F4GE - ENGINES
F4GE9454H AND F4GE9454J ENGINE
1 2
5
6
BS06N188 Figure 2-12

-
1. TURBOCHARGER 4. FUEL FILTER 7. FIXED GUIDE PULLEY

2. OIL VAPOR RECIRCULATION VALVE 5. PRIMING PUMP 8. WATER PUMP
3. ROTARY INJECTION PUMP 6. CRANKSHAFT PULLEY 9. FAN PULLEY
87630273 NA Issued 08-07 Bur 2-21

F4GE9484D ENGINE
1 2
5
6
1. TURBOCHARGER 4. FUEL FILTER 7. FIXED GUIDE PULLEY

2. BLOW-BY 5. PRIMING PUMP 8. WATER PUMP
3. ROTARY INJECTION PUMP 6. CRANKSHAFT PULLEY 9. FAN PULLEY
2-22 Issued 08-07 Bur 87630273 NA

F4HE - ENGINES
F4HE9484A ENGINE
1 2
5
6
BS07D071 Figure 2-14
1. TURBOCHARGER 7. EDC7UC31 CONTROL UNIT

2. COMMON RAIL 8. REAR OF CRANKSHAFT
3. FAN PULLEY 9. FLYWHEEL
4. FIXED GUIDE PULLEY 10. HIGH PRESSURE PUMP
5. DAMPING FLYWHEEL 11. FUEL FILTER
7 6. WATER PUMP
8
11
10
9
87630273 NA Issued 08-07 Bur 2-23

DESCRIPTION OF MAIN ENGINE COMPONENTS

ENGINE BLOCK
1. CYLINDER BORE 3. MAIN BEARING HOUSINGS 5. WATER PUMP

2. SEATS FOR CAMSHAFT BEARINGS AND TAPPETS 4. OIL 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 08-07 Bur 87630273 NA

CRANKSHAFT
2
1
1. FLYWHEEL ATTACHMENT HUB 2. TIMING DRIVE GEAR 3. CRANKSHAFT 4. OIL PUMP DRIVE GEAR
The crankshaft is made of steel and rests on five CRANKSHAFT OIL SEALS
induction hardened bearing journals. Drilled inside The front and rear seals are box type with radial seal.
the crankshaft are a series of lubricating oil ducts. 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
The following items are pressed onto the front of the 380000663. Install with special tools 380000666 and
crankshaft: oil pump drive gear (4), phonic wheel, the 380000664.
vibration damper, and auxiliary equipment drive
pulley.
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.
87630273 NA Issued 08-07 Bur 2-25

CONNECTING RODS

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 Each connecting rod is marked:
connecting rod crankshaft ends are made with an • By a number on the connecting rod body and
oblique angle, with separation of rod and cap on the cap indicating the match and the cylinder
obtained by means of the innovative fracture splitting in which they are assembled.
system rather than the conventional machining • By a letter on the connecting rod body
process. indicating the weight class of the connecting rod
The connecting rod crankshaft bearing shells are installed in production.
made of steel plated with an antifriction alloy.
2-26 Issued 08-07 Bur 87630273 NA

PISTONS
2
3
4

The piston crown features a high turbulence The following reference data is engraved into the
combustion chamber. The underside of the piston piston crown:
crown is cooled by engine oil delivered by a spray 1. Spare part number and design modification
nozzle installed in the crankcase. number.
There are three piston ring grooves with different 2. Stamping (facing the crankcase front side)
functions and different geometry. indicating the mounting direction of the piston in
1st piston ring with trapezoidal (keystone) the cylinder bore.
section, ceramic chrome plating. 3. Date of manufacture.
2nd piston ring with torsional conical rectangular 4. Stamping indicating 1st recess insert testing.
section.
3rd piston ring with double oil ring wiper with
internal spring.
87630273 NA Issued 08-07 Bur 2-27

CAMSHAFT
NOTE: The camshaft below is a 6 cylinder camshaft.
BS06K025
C
D
A. CRANKSHAFT OUTPUT GEAR B. JOURNAL C. INTAKE VALVE LOBE D. EXHAUST VALVE LOBE
The camshaft is installed on five bearing journals (B) The exhaust gas recirculation system (EGR), lowers
in the engine block. the combustion temperature by decreasing the
The front and rear bearing housings are equipped concentration of oxygen in the combustion chamber.
with steel bearings plated with antifriction material Creating an effective system to control the emission
assembled by means of a force-fit. of NOx.
The camshaft is controlled directly by the crankshaft The internal EGR system exhaust lobe design is not
by means of gear (A). equipped with any electronically controlled elements,
the system is always active. Its configuration does
EGR EXHAUST GAS RECIRCULATION SYSTEM not need additional elements such as check valves,
piping or heat exchangers.
In the TIER 3 version, the profile of the exhaust lobe
has been modified in order to allow the par tial The exhaust lobe (D) has an additional lobe apart
opening of the exhaust valve during the intake cycle. from the major lobe see cross sectional view of
The exhaust gases can be partially returned back exhaust valve (D), as compared to the configuration
into the cylinders to lower the maximum combustion of a cam without EGR.
temperature which is responsible for the production With the additional lobe during the intake stroke of a
of nitrogen oxides (NOx). 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.
2-28 Issued 08-07 Bur 87630273 NA

VALVE CONTROL FOR F4GE ENGINES
1 2
9
3
8
1. ROCKER ARM 4. PUSH ROD 7. SPRING

2. ROCKER ARM SUPPORT 5. TAPPET 8. SPRING SEAT
3. ADJUSTING SCREW 6. CAM SHAFT 9. VALVE SPRING RETAINER (KEEPERS)
87630273 NA Issued 08-07 Bur 2-29

VALVE CONTROL FOR F4HE ENGINES
2
1
3
10
7
4
6
1. ROCKER ARM 6. SPRING

2. ROCKER SPINDLE 7. SPRING SEAT
3. VALVE BRIDGE 8. VALVE SPRING RETAINER (KEEPERS)
4. TAPPET 9. PUSH ROD
5. CAMSHAFT 10. VALVE LASH ADJUSTER SCREW
2-30 Issued 08-07 Bur 87630273 NA

CYLINDER HEAD FOR F4GE9454H AND F4GE9454J ENGINES
1 2
6
3
5 4

DETAIL OF CYLINDER HEAD FOR F4GE9454H/J ENGINE WITH INSERTED VALVE SEATS
1. EXHAUST MANIFOLD 3. GRID HEATER 5. THERMOSTAT

2. INTAKE MANIFOLD 4. VALVE SEAT 6. INJECTOR
The cast iron cylinder head is machined to The cylinder head is also fitted for the following
accommodate the following parts: components to be installed on to the cylinder head.
• Valve seats (4). • Exhaust manifold (1).
• Injectors (6). • Intake manifold (2) with seat for grid heater (3).
• Thermostat (5).
87630273 NA Issued 08-07 Bur 2-31

CYLINDER HEAD FOR F4GE9484D ENGINES
1 2
4
5

DETAIL OF CYLINDER HEAD FOR F4GE9484D ENGINE WITH INSERTED VALVE SEATS
1. EXHAUST MANIFOLD 3. GRID HEATER 5. THERMOSTAT

2. INTAKE MANIFOLD 4. VALVE SEAT 6. INJECTOR
accommodate the following parts: components to be inserted on to the head.
• valve seats (4). • exhaust manifold (1).
• injectors (6). • intake manifold (2) with seat for grid heater (3).
• thermostat (5).
2-32 Issued 08-07 Bur 87630273 NA

CYLINDER HEAD FOR F4HE9484A ENGINES
4
6

DETAIL OF CYLINDER HEAD FOR F4HE9484A ENGINE WITH INSERTED VALVE SEATS
1. EXHAUST MANIFOLD 3. GRID HEATER 5. INJECTOR

2. INTAKE MANIFOLD 4. VALVE SEAT 6. THERMOSTAT
accommodate the following parts: components to be installed on the cylinder head.
• Valve seats (4). • Exhaust manifold (1).
• Injectors (2). • Intake manifold (2) with seat for grid heater (3).
• Thermostat (6).
87630273 NA Issued 08-07 Bur 2-33

VALVES AND VALVE SEATS FOR F4GE ENGINES
2
3
1
1. EXHAUST SIDE 3. INTAKE VALVE

2. EXHAUST 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 08-07 Bur 87630273 NA


DETAIL OF VALVE GUIDES AND SEATS F4GE ENGINES
87630273 NA Issued 08-07 Bur 2-35

VALVES AND VALVE SEATS FOR- F4HE ENGINES
1 2 1
4 3
1. INTAKE VALVES 3. EXHAUST SIDE

2. INTAKE SIDE 4. EXHAUST VALVES
2 3
Valve seats have the following angles:
Exhaust valves- 45°
1. 7.042 TO 7.062 MM (0.277 TO 0.278 INCHES)
Intake valves- 60° 2. INTAKE VALVE
3. EXHAUST VALVE
NOTE: Exhaust valves (4) have a distinctive
identification at the center of the head of the valve. The cylinder head does not have guide inserts. The
valve guide is machined directly into the head
casting.
1

Oil seals (1) installed on valve stems.
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 08-07 Bur 87630273 NA

ENGINE FLYWHEEL Equal distance of fastening bolt holes (1) allows it to

The flywheel (2) is not timed to the crankshaft and be installed in any position.
does not have any stamping, notch or reference hole
for sensors or timing.

FLYWHEEL FOR- F4GE ENGINES

FLYWHEEL FOR- F4HE ENGINES
87630273 NA Issued 08-07 Bur 2-37

ACCESSORY EQUIPMENT DRIVE
2 3
1. ALTERNATOR 3. FAN PULLEY 5. WATER PUMP

2. AUTOMATIC BELT TENSIONER 4. CRANKSHAFT 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 08-07 Bur 87630273 NA

COUNTER BALANCER - F4GE ENGINES
A 1 2 3 4 5
B 10 9 8 7 6

COUNTER BALANCER FOR F4GE ENGINES
1. FASTENING BOLTS 6. HALF BEARINGS

2. SUPPORT 7. COUNTER-ROTATING SHAFT
3. FASTENING BOLTS 8. GEAR
4. GEAR 9. RING
5. BALANCING MASS 10. O-RING
Inside the oil pan (sump), secured to the cylinder Match alignment marks (A) engraved on the gears for
block is the counter balancer. timing, insert pin in hole (B) on the balancing mass to
The counter balancer is timed as shown above. stop rotation temporarily.
87630273 NA Issued 08-07 Bur 2-39

ENGINE LUBRICATION - F4GE ENGINES
A
B
C
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 A by-pass valve in case the oil filter becomes
components: clogged. To cut out oil filter, is built into the cooler
Gerotor oil pump housed in the front of the engine unit.
block, is driven by the spur tooth gear force fitted on The filter is a cartridge- type oil filter.
the crankshaft.
Water / oil cooler, is housed in the engine block.
2-40 Issued 08-07 Bur 87630273 NA

ENGINE LUBRICATION - F4HE ENGINES
A
B

LUBRICATION SYSTEM LAYOUT FOR- F4HE ENGINES
(NOTE: THE ILLUSTRATION IS A 6 CYLINDER)
1. TURBO OIL PRESSURE CONTROL VALVE 4. HEAT EXCHANGER A. PRESSURIZED OIL PATH
2. BY-PASS VALVE 5. OIL PUMP B. GRAVITY OIL RETURN PATH
3. CARTRIDGE- TYPE OIL FILTER 6. OIL PAN (SUMP)
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 08-07 Bur 2-41

HEAT EXCHANGER
1. HEAT EXCHANGER BODY 3. WATER / OIL COOLER

2. INNER GASKET 4. GASKET (BETWEEN COOLER AND ENGINE BLOCK)
OIL PRESSURE CONTROL VALVE BY-PASS VALVE
2 3
A
BS06K041 Figure 2-39 A. DIRECTION OF FLOW
1. 66 MM (2.59 INCHES) Blow-by max:
2. 41.25 MM (1.62 INCHES)
3. 136.9 ± 10.5 N (30.8 ± 2.36 LBF)
20 cm³/min (.68 oz/min) with 0.83 bar (12 psi)
pressure at 26.7° C (80° F) oil temperature.
Calibration at 100° C (212° F) oil temperature.
Minimum pressure 1.2 bar (17.4 psi)
Maximum pressure 3.8 bar (55.1 psi)
2-42 Issued 08-07 Bur 87630273 NA

OIL PUMP OIL PAN (SUMP)

OIL PUMP

OIL PAN (SUMP) FOR F4GE ENGINES
2
2
1. Crankshaft with oil pump drive gear. BS06K045 Figure 2-44
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 08-07 Bur 2-43

OIL VAPOR RECIRCULATION FOR F4GE ENGINES

Oil vapor recirculation takes place by means of valve The vapor condensed within the valve falls into the
(1) placed above the tappet cover (3) on F4GE tappet cover (3) due to gravity. The remaining vapor
engines. is recovered by vent (2) and recirculated to the
engine intake.
2-44 Issued 08-07 Bur 87630273 NA

OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITH BLOW-BY FILTER
A
B
1. PRE-SEPARATOR 3. BLOW-BY FILTER A. OIL CONDENSATE

2. RECIRCULATION TO INTAKE 4. RETURN TO ENGINE B. OIL VAPORS
BLOW-BY RECIRULATION: In blow-by filter (3) a portion of the vapors partially

The rocker cover has a blow-by pre-separator (1), condense and return to the oil pan (sump) through
designed to increase the outlet velocity of blow-by oil line (4), while the remaining is recirculated to the
vapor while condensing them partially. Condensed oil engine intake by line (2).
returns to the oil pan (sump) while residual vapors
are collected and routed through the blow-by filter
(3).
87630273 NA Issued 08-07 Bur 2-45

OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITHOUT BLOW-BY FILTER
A
B
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 08-07 Bur 87630273 NA

COOLING SYSTEM
A C
B
1. THERMOSTAT 3. WATER PUMP B. WATER RECIRCULATING IN THE ENGINE

2. HEAT EXCHANGER A. WATER FLOWING OUT OF THERMOSTAT C. WATER FLOWING INTO WATER PUMP
The engine cooling system is a closed circuit, forced • Fan- Increases heat dissipating power of the
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 radiator by flowing more air across the radiator.
components: • Heat exchanger- Cools the lubricating oil.
• Radiator- Dissipates the heat from the engine by
circulating coolant through a long row of tubes that • Centrifugal water pump- placed on the front of the
has air flowing across them thus decreasing the engine block. Circulates the coolant through the
temperature. engine and radiator and is driven by a Poly-V belt.
• Expansion tank- Collects the overflow of coolant • Thermostat- Regulates the circulation of the
as it expands and contracts. coolant.
87630273 NA Issued 08-07 Bur 2-47
WATER PUMP

BS06K050 Figure 2-49 THERMOSTAT
WATER PUMP Engine temperature is controlled by a thermostat.
Thermostat opening 79 to 83° C (174 to 181° F).
(1)- This side goes towards engine block.

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 08-07 Bur 87630273 NA

AIR INDUCTION BOOST DIAGRAM

BOOSTING VERSION ENGINES
1 2
BS07C435 Figure 2-52

4 CYLINDER BOOSTED VERSION
1. AIR FILTER 2. TURBOCHARGER 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
The turbocharger is composed of the following parts: emissions, releasing part of them directly to the
turbine, wastegate valve to regulate the boost exhaust tube when the boost feeding pressure of the
pressure, main body, and compressor. compressor, reaches the prescribed pressure value.
When the engine is running, the exhaust emission The cooling process and lubrication of the
flow through the body of the turbine makes the turbocharger and bearings is done by the engine oil.
turbine disk rotate.
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 wastegate valve
to regulate the pressure, located on the exhaust
collector before the turbine and connected by piping
to the induction collector.
87630273 NA Issued 08-07 Bur 2-49

INTER-COOLED ENGINE VERSION
1 2
4
5

4 CYLINDER BOOSTED / INTERCOOLED VERSION
1. AIR FILTER 2. TURBOCHARGER 3. EXHAUST 4. CHARGE AIR COOLER 5. PISTONS
The turbocharger is composed of the following parts: 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

turbine, wastgate valve to regulate the boost emissions, releasing part of them directly to the
pressure, main body, and compressor. exhaust tube when the boost feeding pressure of the
compressor, reaches the prescribed pressure value.
When the engine is running, the exhaust emission
flow through the body of the turbine makes the The cooling process and lubrication of the
turbine disk rotate. 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 wastegate valve
to regulate the pressure, located on the exhaust
collector before the turbine and connected by piping
to the induction collector.
2-50 Issued 08-07 Bur 87630273 NA

MECHANICAL INJECTION FEEDING SYSTEM - F4GE ENGINES

FUEL FILTER
6
3

FUEL FILTER
1. FUEL FILTER BRACKET 3. FUEL HEATING RESISTOR 5. FUEL FILTER

2. AIR BLEEDING SCREW 4. WATER DRAIN 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 have 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 08-07 Bur 2-51

MECHANICAL FUEL LIFT PUMP- F4GE ENGINES
1 2
5 6

MECHANICAL FUEL PUMP
1. FUEL OUTLET TO FILTER 3. FUEL INLET FROM TANK 5. CONTROL LEVER

2. CONTROL LEVER 4. FUEL PUMP 6. CAMSHAFT
The fuel pump is mounted on the left side of the Specifications for fuel lift pump:
engine. It draws fuel from the fuel tank and feeds it to Static pressure at 1800 r/min. (rpm).
the rotary injection pump. It is driven by the camshaft.
0.47 to 0.61 bar (6.8 to 8.8 psi).
2-52 Issued 08-07 Bur 87630273 NA

MECHANICAL INJECTION WORKING PRINCIPLES- F4GE ENGINES
1 2 3
1. Fuel filter 3. Feed pipeline from priming pump to filter 5. Fuel pump
2. Feed pipe line from fuel pump to fuel filter 4. Rotary injection pump
Fuel is drawn from the fuel tank by the fuel pump (5) To check fuel pressure for engines with mechanical
and is driven by the camshaft. fuel system.
Fuel flows through pipeline (2) to the fuel filter (1) and The fuel supply pressure specification is 0.27 bar
is piped to the vacuum chamber of the injection pump (4 psi) minimum and 0.34 to 0.48 bar (5 to 7 psi) at
via pipeline (3), (for applications to be operated in full load rated rpm. To check fuel pressure, purchase
cold climates the fuel filter is provided with a heater). a fuel supply line for the four cylinder engine. Cut the
Transfer pump is placed inside the injection pump (4), fuel line and install a tee fitting to measure the fuel
and is a rotary type. It increases fuel pressure with pressure.
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.
87630273 NA Issued 08-07 Bur 2-53

ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES
3 4
5
2
1 6
10
7
8
9

INJECTION ASSEMBLY
1. INJECTOR 1 FUEL PIPE 4. INJECTOR 4 FUEL PIPE 7. THERMAL BULB FOR KSB 10. INJECTOR
5. PIPE FOR FUEL DISCHARGE FROM
2. INJECTOR 2 FUEL PIPE 8. INJECTION PUMP
INJECTORS
6. CONNECTOR FOR MEASURING PRESSURE
3. INJECTOR 3 FUEL PIPE 9. SOLENOID VALVE
INSIDE THE L.D.A. INTAKE MANIFOLD
Fuel feed system is composed of: • Fuel feed rotary injection pump.
• Fuel tank (placed on the machine). • Injector feed pipeline (from injection pump to
injectors).
• Fuel delivery and back-flow to tank.
• Injectors
• Fuel pre-filter (if available, it is usually placed
close to the engine on the machine frame).
• Priming pump, assembled to the engine driven by
the camshaft.
• Fuel filter
2-54 Issued 08-07 Bur 87630273 NA

KKSB COLD START ADVANCE SYSTEM - F4GE ENGINES
4 3
BS07F331 Figure 2-58
1. TEMPERATURE SWITCH 2. ADVANCE SOLENOID 3. FUEL SHUT OFF SOLENOID 4. WIRE HARNESS
Theory of operation: There is one wire connected to the main harness that
When the engine is cold (coolant temperature below goes to the ignition terminal of the key switch. This
50° C (122° F), the injection pump is in timing wire feeds power to the injection pump shut off
advance state. When engine gets to between 60 and 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
66° C (140 to 151°F), the thermo switch in the temperature switch in the head. A third wire routes
cylinder head opens and system voltage is no longer from the temperature switch to an additional solenoid
sent to the solenoid on the injection pump. This on the injection pump.
allows the timing to retard to "normal" operating An additional solenoid ensures that the pump will go
position. to full advance timing during cranking and upon initial
Units equipped with the Bosh VE rotary injection cold start up. Once the engine warms to 71° C
pump do not require a relay for the pull in circuit. The (160° F), the temperature switch opens and power to
pump uses a simple shut off solenoid built into the the solenoid on the side of the injection pump is
pump. removed. This allows the injection pump to retard the
timing according to engine rpm.
87630273 NA Issued 08-07 Bur 2-55

To troubleshoot the system: FUEL SYSTEM TEST FOR RESTRICTION

1. With the engine temperature below 50° C OR AIR INFILTRATION - F4GE ENGINES
(122° F), and the key switch on, battery voltage NOTE: If possible, test the fuel system as described
should be present at both solenoids on the before removing the Bosch VE fuel injection pump for
injection pump. If battery voltage is not present, repair. If leakage is too severe, complete the test
troubleshoot the temperature switch circuit. procedure following the pump repair or replacement.
To check the temperature switch: Failure to test the system may result in continued
2. With the engine temperature is below 50° C pump leakage.
(122° F), battery voltage should be present at To determine if the low pressure fuel supply is
both terminals. Warm the engine to 60 to 66° C restricted, or if air is entering the system, follow these
(140 to 151° F). Batter y voltage should be steps.:
present at only one terminal of the temperature
switch when engine is warmed to 71° C (160° F) STEP 1
or higher. Install a clear poly-vinyl tube between the outlet of
the fuel filter and the inlet of the Bosch VE fuel
3. Disconnect the connector at the temperature
injection pump. Tee the connector into the test line a
switch. Short across the two terminals of the
pressure gauge which can read both 0 to 762 mm
connector with a jumper wire and start engine.
(0 to 30 inches) of Hg vacuum and 0 to 2.07 bar (0 to
After a short time, remove the jumper wire the
30 psi) positive pressure. See figure 2-59 on
engine should change sound and run smoother
page 2-57
as the injection pump time is retarded. This
signifies that the cold starting advance system is NOTE: For more information, see further procedures
operating properly. 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.
• The lines and connections from the fuel supply
pump inlet back to the fuel tank, checking for
damaged lines (kinks and rub marks) and leakage
at the Voss o-ring fittings.
2-56 Issued 08-07 Bur 87630273 NA
• Debris in the tank, clean as required. Parts needed for pressure/ vacuum testing
• The fuel pick-up tube in the fuel tank, checking for
cracks, plugging, or contact with the bottom or side 2
walls of the tank. 1
• The fuel tank cap, assuring that a vacuum is not 1
being formed in the fuel tank, which would reduce
the fuel supply pressure to the injection pump inlet. 3
NOTE: Vacuum in the fuel tank might not be
observed during short-term running.
• These instructions apply only to engines with 4
external electrical fuel shutoff valve assemblies. 5
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. BS07F316 Figure 2-59
SETUP FOR MEASURING PRESSURE
STEP 5
To build a fuel system test set for pressure testing,
If the checks in Step 4 were made and all necessary
obtain the following :
corrective actions were taken, Retest. If the pressure
is still low, preform the following tests: NOTE: Voss o-ring type connectors can be obtained
• From the gauges previously used to measure either by purchasing the connectors, or by
pressure, remove one section of test line and a purchasing a fuel line for the application being
barbed fitting from the tee. Install in there place a worked on, then carefully removing the plastic Voss
gasket and a connector. This will allow installation type connectors (1), from the plastic tube for re-use
of the gauges between the supply pump inlet and with poly-vinyl tubing.
the fuel supply line from the tank. After installation Quan. Description ID #
of the gauges, run the engine and observe the
clear tube remaining on the gauges to ensure that Voss type brass barbed hose
2 1
connectors
air is not entering. The vacuum here should not
exceed 50.8 mm (2.0 inches) of Hg under full load. 1 6.35 mm (1/4 inch)- NPT tee fitting 3
If the vacuum is greater than that, look for a 6.35 mm (1/4 inch)- NPT to 7.54
plugged fuel supply line or debris in the fuel tank. 2 5
mm (5/16 inch) barb connectors
• An alternative vacuum test method would be to Five feet of 7.54 mm (5/16 inch)
supply fuel from an alternate fuel source, such as 1 4
O.D. poly-vinyl tubing
a five gallon container, with a known good supply
Dampened compound gauge
line. Fit it directly to the supply pump inlet fitting, which will measure 0 to 762 mm (0
then rerun the test. If the pressures return to 1 to 30 inches) of Hg and 0 to 2.07 2
normal, check the fuel supply line and tank of the bar (0 to 30 psi).
vehicle for leaks or restrictions.
• Upon completion of the diagnostic procedures,
remove the test line and the gauge, and reinstall
the standard fuel line.
87630273 NA Issued 08-07 Bur 2-57

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 4. The suction pressure between the inlet of the
BS07F317 Figure 2-60 fuel supply and the tank should not exceed
SETUP FOR MEASURING VACUUM 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
Sealing washer between connector
1 2
(1) and tee fitting
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 Issued 08-07 Bur 87630273 NA

HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL) - F4HE ENGINES
11
10
4
8
1. HARNESS TO INJECTORS 5. CRANKSHAFT SENSOR 9. CAMSHAFT SENSOR

2. ELECTRO- INJECTOR 6. EDC7UC31 CONTROL UNIT 10. FUEL PRESSURE SENSOR
3. COOLANT TEMP. SENSOR 7. PRESSURE REGULATOR 11. BOOST TEMP. PRESSURE SENSOR
4. ENGINE OIL AND PRESSURE SENSOR 8. FUEL HEATER AND TEMP. SENSOR
Extremely high injection pressures are necessary in

order to reduce PARTICULAR emissions.
NOTE: 6 cylinder version is shown in figure above,
The common rail system makes it possible to inject operation is the same.
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.
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.).
87630273 NA Issued 08-07 Bur 2-59

EDC7UC31- ELECTRONIC CONTROL MAXIMUM ENGINE SPEED LIMITING

UNIT OPERATION Depending on the application, the control unit
memory can contain appropriate engine speed limits.
ENGINE PREHEATING ELEMENT CONTROL When the engine speed surpasses these limits, the
Pre-post heating is activated when even just one of control unit activates power reduction by controlling
the water, air or fuel temperature sensors detects a the "on time" of the electro-injectors. In some
temperature of less than 5° C (41° F). applications, the maximum limiting response consists
in stopping the engine.
PHASE RECOGNITION
CUT OFF
Signals transmitted by the camshaft and crankshaft
sensors determine the cylinder which fuel must be Fuel cut-off release is managed by the control unit
injected. with the following logical interventions:
• deactivation of the electro-injectors.
INJECTION CONTROL
• reactivation of electro-injectors immediately prior
Information transmitted by the sensors, the control to arrival at idle speed.
unit determines and regulates pressure and modifies
the pre-injection and main injection mode.
• control of fuel pressure regulator.
SMOKE CONTROL UNDER ACCELERATION
INJECTION PRESSURE CLOSED LOOP
CONTROL With intense load demands, signals received from
Engine load, determined by processing of data the boost temperature pressure sensor and the
transmitted by the various sensors, and the control crankshaft sensor, the control unit manages the
unit. Governs the regulator to maintain injection pressure regulator and modulates the activation time
pressure at constant optimal values. 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 Afte r the engine is stopped, the contro l un it
unit, determines the optimum injection point on the microprocessor saves various parameters to the
basis of internal mapping. EEPROM memory, including the fault log so that they
will be available the next time the engine is started.
IDLE SPEED CONTROL
CONTROL OF WORKING SPEED IN NORMAL
The control unit processes signals transmitted by the OPERATING CONDITIONS
various sensors and adjusts the quantity of fuel
injected. Each time work load varies, the control unit adjusts
torque to maintain the engine in maximum power
It also controls the pressure regulator and modulates conditions. If the load causes a reduction in power,
injection duration of the electro-injectors. Within the control unit increases torque i.e. it increases the
specific limits, the control unit also monitors battery amount of fuel injected in order to restore the engine
voltage. 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.
2-60 Issued 08-07 Bur 87630273 NA

RECOVER STRATEGIES When the temperature of the supercharging air rises

• Control of fuel leaks. above 88° C (190° F), power reduction is started,
when a temperature of 120° C (248° F) is reached,
In the case of fuel supply problems, the system performance is further reduced and is comparable to
controls the engine with suitable constant power that of the same engine if it were aspirated.
values obtained with a low number of rev and high
torque values in order to inject the maximum quantity • Reduction of power as reference temperature
of fuel. varies
• Control of pressure in the rail. In normal operating conditions, the system knows the
supercharging air, oil and water temperatures.
When the pressure in the rail exceeds safety values,
the engine reduces power. If the temperature of the engine water is not
available, the system takes the temperature of the oil
• Synchronism problems as reference and when this reaches the threshold of
In the case of synchronism problems, faulty rev 103° C (217° F), it star ts to reduce the power
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 available. On reaching 113° C (235° F), power is
increasing the number of revs in order to improve reduced to 50%.
interpretation of the signals.
• Power restrictions as operating temperature
increases.
87630273 NA Issued 08-07 Bur 2-61

FUEL SUPPLY SYSTEM - F4HE ENGINES
2
1
3
4
6
7
A
B D
C
7. LOW PRESSURE GEAR TYPE

1. ELECTRO-INJECTOR 4. PRE-FILTER B. LOW PRESSURE
CHARGE PUMP
2. PRESSURE RELIEF VALVE FOR
5. FUEL FILTER 8. HIGH PRESSURE PUMP C. FUEL RETURN
FUEL RETURN
3. COMMON RAIL PRESSURE D. HIGH PRESSURE FROM
6. COMMON RAIL A. HIGH PRESSURE
RELIEF VALVE PUMP TERMINAL
The common rail system has a high pressure pump The high pressure circuit consists of the following
that constantly keeps the fuel supply at a very high lines:
pressure, not dependent on the phase of the cylinder • Line connecting the high pressure pump outlet to
that must receive the injection. The high pressure the common rail.
fuel is stored in a pipeline (the common rail) that is
shared by all electro- injectors. • Lines supplying the electro-injectors from the
common rail.
This means that there is always a supply of fuel
available at the electro- injector inlet at the injection The low pressure circuit is composed of the following
pressure determined by the EDC7UC31 electronic lines:
control unit. • Fuel line from fuel tank to prefilter.
When the solenoid valve of an electro- injector is • Lines supplying the mechanical supply pump
energized by the EDC7UC31 electronic control unit, through the heat exchanger of the control unit, the
fuel taken directly from the common rail is injected manual priming pump and the pre filter.
into the corresponding cylinder. The fuel system is completed by the fuel return from
The fuel system is composed of a low pressure the common rail, injectors and high pressure pump
circuit and a high pressure circuit. cooling circuit.
2-62 Issued 08-07 Bur 87630273 NA
FUEL SUPPLY SYSTEM DIAGRAM- F4HE ENGINES
5 6 7 A
B
4
C
3 D
18
2 17
9
1
16 10
15
13 11
14
12
9. EDC7UC31 CONTROL UNIT HEAT 17. HIGH PRESSURE PUMP BY-

1. HIGH PRESSURE PUMP
EXCHANGER PASS CHECK VALVE
2. PRESSURE RELIEF VALVE ON HIGH 18. ROTOR PUMP PRESSURE
10. MANUAL PRIMING PUMP
PRESSURE PUMP SAFETY BY-PASS
3. PRESSURE RELIEF VALVE ON FUEL
11. PRE-FILTER A. DRAIN
RETURN LINE FROM INJECTORS
4. COMMON RAIL SAFETY RELIEF
12. FUEL TANK B. SUCTION
VALVE
5. COMMON RAIL 13. MECHANICAL SUPPLY PUMP C. LOW PRESSURE
6. RAIL PRESSURE SENSOR 14. FUEL FILTER D. HIGH PRESSURE
7. ELECTRO-INJECTOR 15. PRESSURE REGULATOR
8. RETURN LINE FROM HIGH PRESSURE
16. HIGH PRESSURE PUMP COOLING PIPING
PUMP
The fuel system is a Common Rail with a CP3 high The pressure relief valve (3) installed on the cylinder
pressure pump. head. Controls the flow of fuel returning from the
The supply pressure regulator controls the flow of electro-injectors at a pressure of 1.3 to 2 bars (19 to
fuel needed in the low pressure system. The high 29 psi.).
pressure pump supplies the common rail. This In parallel with the mechanical supply pump there are
pressurization of fuel, improves energy efficiency and two by-pass valves.
limits the heating of the fuel in the system. The by-pass valve (18) allows fuel to flow from
Function of low pressure regulator valve (2), installed mechanical pump outlet to its inlet, when the fuel
on the high pressure pump maintains the pressure at filter inlet pressure exceeds the allowed limit.
a constant level of 5 bars (72 psi.). The by-pass valve (17) allows filling the supply
Low pressure relief valve (2), operates to increase system through the manual priming pump (10).
fuel flow in the high pressure pump cooling circuit
through inlet and drain piping (16), from piping (8).
87630273 NA Issued 08-07 Bur 2-63

FUEL FILTER
B
1
D C
5
4 2 2 D
A
A
B
3 C
5
E
1. FUEL FILTER BRACKET A. OUTLET CONNECTION TO HIGH PRESSURE PUMP

2. FUEL TEMPERATURE SENSOR B. COMMON RAIL, CYLINDER HEAD INJECTORS DISCHARGE LINE INLET CONNECTION
3. FUEL FILTER C. CONNECTION TO HIGH PRESSURE PUMP DISCHARGE LINE
4. ELECTRIC FUEL HEATER D. INLET CONNECTION FROM FEED PUMP
5. FUEL TEMPERATURE SENSOR E. OUTLET CONNECTION TO FUEL TANK
The fuel filter is installed on the engine cylinder block The heater is activated if the fuel temperature is less
in the circuit between supply pump and high pressure than 0° C (32° F) and is heated until the fuel reaches
pump (CP3). 5° C (41° F). Fuel temperature is monitored by the
EDC7UC31 control unit.
2-64 Issued 08-07 Bur 87630273 NA

MECHANICAL FEED PUMP- NORMAL OPERATING CONDITION- F4HE ENGINES
1. PRESSURE SAFETY VALVE A. FUEL INLET FROM TANK

2. PRIMING BY-PASS VALVE IN CLOSED POSITION B. FUEL OUTLET TO FILTER
The charge gear pump, installed on the rear of the The feed pump is driven by the high pressure pump
high pressure pump, draws fuel from the tank shaft.
through the pre-filter and sends it through the main In normal operating conditions the flow in the feed
fuel filter to the high pressure pump. 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
1 2

2. BY-PASS PORT B. FUEL OUTLET TO FILTER
Pressure safety valve (1) opens when pump outlet spring (1) allowing fuel to flow to the pump inlet
pressure (B), is excessive due to filter restriction or through passage (2).
charge pressure regulator malfunction. The pressure
of the fuel would then overcome the force exerted by
87630273 NA Issued 08-07 Bur 2-65
FUEL SYSTEM BLEEDING CONDITION

2. PRIMING BY-PASS VALVE IN CLOSED POSITION B. FUEL OUTLET TO FILTER
The by-pass valve (2) opens when, the engine is When activating the hand pump the by-pass valve (2)
turned off. The supply system has to be filled with the is opened due to inlet pressure, this allows the fuel
manual priming pump. flow to outlet (B).
2-66 Issued 08-07 Bur 87630273 NA

HIGH PRESSURE PUMP TYPE CP3.3- F4HE ENGINES
2
8 3
6
4

HIGH PRESSURE PUMP
1. MECHANICAL GEAR CHARGE PUMP

2. FUEL OUTLET CONNECTION FROM MECHANICAL PUMP TO FILTER
3. FUEL INLET CONNECTION FROM CONTROL UNIT HEAT EXCHANGER
4. FUEL DRAIN RETURN CONNECTION TO FILTER BRACKET
5. FUEL INLET CONNECTION FROM FILTER
6. HIGH PRESSURE REGULATOR
8. FUEL OUTLET CONNECTION TO COMMON RAIL
The high pressure pump has 3 radial plungers driven On the rear of the high pressure pump is the
by the cam gear. The pump does not need to be mechanical gear feed pump which is driven by the
timed. high pressure pump shaft.
IMPORTANT: The high pressure pump unit can not be overhauled, there are no adjustments.
87630273 NA Issued 08-07 Bur 2-67

1
9 2
8 3
7 4
6
5

EXPLODED VIEW OF HIGH PRESSURE PUMP
1. BY-PASS VALVES ON 4. 5 BAR (72 PSI) LOW PRESSURE 7. HIGH PRESSURE FUEL DELIVERY
FEED PUMP FUEL REGULATOR VALVE VALVE TO COMMON RAIL
5. HIGH PRESSURE REGULATOR
2. PUMP SHAFT 8. GEAR SET
SOLENOID VALVE
6. INDIVIDUAL HIGH PRESSURE 9. MECHANICAL GEAR CHARGE FEED
FUEL INLET FROM
PUMP PLUNGER (1 OF 3) PUMP
FILTER
2-68 Issued 08-07 Bur 87630273 NA

HIGH PRESSURE PUMP INSIDE STRUCTURE

3
5 4
8 7
2
1. LOW PRESSURE FUEL INLET 5. PUMP SHAFT

2. PUMPING ELEMENTS SUPPLYING
6. PISTON
FUEL DUCTS
3. CYLINDER 7. BALL DELIVERY VALVE
4. THREE LOBE ELEMENT 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.
87630273 NA Issued 08-07 Bur 2-69

OPERATING PRINCIPAL
7
2
4 3
1. OUTLET FOR RAIL 3. PRESSURE REGULATOR 7. RAIL DELIVERY

5. PUMP SHAFT
DELIVERY LINE SUPPLY PASSAGE VALVE
2. HIGH PRESSURE 4. PLUNGER SUPPLY 6. HIGH PRESSURE
REGULATOR PASSAGE PLUNGER
High pressure plunger (3) rides on the cam installed During the plunger compression phase the fuel
on the pump shaft (4). In the intake phase the reaches sufficient pressure to open the common rail
plunger is supplied with fuel through the supply delivery valve (2) and is forced through outlet (1) to
passage (5). The quantity of fuel supplied to the the common rail.
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 Issued 08-07 Bur 87630273 NA
2
1
1
9 2
3
8
4
7
3
5
6
BS06K064 Figure 2-76 BS06K065 Figure 2-77
1. INLET TO HIGH PRESSURE PLUNGERS 1. FUEL EXHAUST FLUE

2. INLET TO HIGH PRESSURE PLUNGERS 2. FUEL EXHAUST GALLERY
3. CHARGE PRESSURE REGULATOR DRAIN PASSAGE 3. FUEL EXHAUST FLOWING FROM PUMP WITH
4. CHARGE PRESSURE 5 BAR (72 PSI) REGULATOR VALVE CONNECTOR TO HIGH PRESSURE LINE FOR
5. FUEL DISCHARGE FROM HIGH PRESSURE REGULATOR COMMON RAIL
VALVE INLET
6. HIGH PRESSURE REGULATOR VALVE The figure above shows the fuel flow under high
7. MAIN PLUNGER SUPPLY PASSAGE pressure running through the exhaust galleries of the
8. INLET TO HIGH PRESSURE PLUNGERS pumping elements.
9. PUMP LUBRICATION PASSAGES
THEORY OF OPERATION
The figure above shows the low pressure fuel
The cylinder is filled through the cap intake valve only
passages inside the pump. The figure shows the
if the supply pressure is suitable to open the delivery
main plungers supply passage (7), the individual
valves set on the pumping elements about
plunger supply passages (1, 8, 2), the passages
2 bars (29 psi.).
utilized for lubrication of the pump (9), the high
pressure regulator (6), the 5 bar (72 psi) pressure The amount of fuel supplying the high pressure pump
regulator valve (4) and the fuel discharge passage is metered by the high pressure regulator. The high
(3). pressure regulator is controlled by the EDC7UC31
control unit through a PWM (pulse width modulated)
The high pressure regulator (6) determines the
signal.
quantity of fuel which the high pressure plungers
deliver to the common rail. Excess fuel flows out When fuel is sent to a pumping element, the
through passage (5). corresponding piston is moving downwards (suction
stroke). When the piston stroke is reversed, the
The regulator valve (4), is designed to maintain a
intake valve closes and the fuel in the pumping
constant pressure of 5 bar (72 psi.) at the high
element chamber, is compressed into the rail.
pressure regulator inlet.
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.
87630273 NA Issued 08-07 Bur 2-71

When the pumping element chamber pressure The pump is lubricated and cooled by the fuel.
becomes less than the supply pressure, the intake The pump replacement time on the engine is highly
valve is again opened and the cycle is repeated. reduced in comparison with traditional injection
The rail delivery pressure is modulated between 250 pumps, because it does not require timing.
and 1600 bars (3625 to 23206 psi.) by the
IMPORTANT: If the line between the fuel filter and
EDC7UC31 control unit, through the pressure
high pressure pump is to be removed or replaced, be
regulator solenoid valve.
sure that components are absolutely clean.
COMMON RAIL

COMMON RAIL
A fuel rail pressure sensor (1) is screwed into the
The common rail volume is a high pressure fuel common rail. The sensor has a feedback signal to
storage device. It has a small volume to allow a rapid the EDC7UC31 control unit in order for the control
pressurization at startup, at slow idle and in case of unit to verify correct rail pressure.
high flow rates.
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.
2-72 Issued 08-07 Bur 87630273 NA

COMMON RAIL PRESSURE RELIEF VALVE
A B
1 2 3 4 5 6 1 2 3 4 5 6

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 The relief valve enables engine operation at limited
one end of the common rail, it is designed to protect 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
the systems components in case of excessive safeguarding the system
increase of pressure buildup. If the dual stage relief valve opening pressure is
The valve can be single stage (as the ones shown reached, the EDC7UC31 control unit stops operation
above) or two stage with two working limits for of the pressure regulator. The high pressure pump
pressure relief 1750 bar and 800 bar (25381 psi. and will then operate at maximum delivery to the common
11603 psi.). 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.).
87630273 NA Issued 08-07 Bur 2-73

ELECTRO-INJECTOR
1 1
14
14
13 13
15
2 15 2
3
3 12
12
4 4
11
11 5 5
6 6
10 10
7
7
9
9
8 8
INJECTION START
INJECTOR IN REST POSITION
When coil (13) is energized, it makes ball shutter (14)
1. ELECTRICAL
9. PRESSURE CHAMBER
move upwards. The control volume (15) fuel flows
CONNECTION towards control fuel outlet (11) making a pressure
2. PILOT VALVE 10. SPRING drop occur in control volume (15). Simultaneously the
3. CONTROL AREA 11. CONTROL FUEL OUTLET
fuel pressure into pressure chamber (9) makes
4. CONTROL DUCT 12. HIGH PRESSURE FUEL INLET
plunger (7) lift, causing injection of fuel into the
5. PRESSURE ROD 13. COIL
6. SUPPLY DUCT 14. BALL SHUTTER
cylinder.
7. PLUNGER 15. CONTROL VOLUME
8. NOZZLE INJECTION END
When coil (13) is de-energized, shutter ball (14) goes
The injector is similar to the conventional injectors, back to its closed position to restore a balance of
except for the absence of plunger return springs. forces to make plunger (7) go back to its closed
The injector can be considered in terms of two basic position and end the injection cycle.
parts:
IMPORTANT: The injector has no serviceable parts
• Actuator- spray nozzle composed of pressure rod
inside, so it is not repairable.
(5), plunger (7) and nozzle (8).
• Control solenoid valve composed of coil (13) and
pilot valve (2).
The solenoid valve controls spray nozzle plunger lift.
2-74 Issued 08-07 Bur 87630273 NA

ELECTRO-INJECTOR
The NEF Tier III engines use Bosch CRIN 2 electro-
injectors. The injection jet used are according to
power developed by the engine.

1. JET
Pressures
Injectors Jet Power developed
kW / H.P. Minimal operating pressure Nominal operating pressure
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.)
87630273 NA Issued 08-07 Bur 2-75

PRESSURE LIMITER FOR FUEL RETURN
A B

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.
2-76 Issued 08-07 Bur 87630273 NA

CHECKING THE FUEL SYSTEM

LOW PRESSURE SUPPLY TEST
10
9
8
7
4 4 9
9 11
3
2 12 6
4
4
4
1 5
13
DIAGRAM OF SET UP OF COMPONENTS FOR SPECIFIC TEST
1. FUEL TANK 6. HIGH PRESSURE PUMP 11. M1 PRESSURE GAUGE 0-15 BAR FUEL FILTER INLET
2. PREFILTER 7. HIGH PRESSURE CIRCUIT 12. M2 PRESSURE GAUGE FUEL FILTER OUTLET
3. LOW-PRESSURE PUMP 8. COMMON RAIL 13. EXTERNAL CONTAINER PLACED 1M (39 IN.) BELOW ENGINE
4. FUEL DELIVERY CIRCUIT 9. FUEL RECIRCULATION
5. FUEL FILTER 10. INJECTORS
12
11
13
87630273 NA Issued 08-07 Bur 2-77

LOW - PRESSURE PUMP

The function of the gear pump is to supply the high After starting the engine, check the pressure at 1500
pressure pump. It is driven by the shaft of the high rpm.
pressure pump and is installed on the rear portion of On pressure gauge M1- (11) it must be between 6
the high pressure pump. and 9 bar (87 and 130 psi.)
Under normal operating conditions, the flow of fuel • If lower than 6 bar (87 psi.) replace pump
inside the pump is as shown in the figure above. • If higher than 9 bar (130 psi.) replace the fuel
With the fuel system pressurized, a fully charged filter.
battery and an external fuel supply placed 1m (39 in.) On pressure gauge M2- (12) it must be greater than
below the engine. The engine must start within 20 5 bar (72.5 psi.)
seconds of activation of the starter motor. If the pump • If lower, replace the fuel filter
is not able to draw fuel to the engine and start the • If the trouble persists, check the seals on the
engine the low pressure pump is probably defective. couplings of the fuel filter bracket and the high
pressure pump inlet.
2-78 Issued 08-07 Bur 87630273 NA

TEST ON PRESSURE RELIEF VALVE ON COMMON RAIL

The pressure relief valve is installed on the end of the If the valve seeps diesel without a fault code, then
common rail, its function is to protect the systems replace the valve.
components if any malfunction causes and excessive With the common rail pressure sensor disconnected
increase in the pressure of the high pressure system. and a fault code is generated, with the rail pressure is
Disconnect recirculation line (1) from the pressure at 71 0 bar (1 029 8 psi.) m ea sura ble with th e
relief valve and plug with the VOSS fitting from the diagnostic instrument, the trouble is in the wiring and
test set. 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.
87630273 NA Issued 08-07 Bur 2-79

TEST ON FUEL BACKFLOW FROM THE RETURN

1. INJECTOR DUCT LOCKING NUT
Tests on fuel backflow from the return establishes the
operating status of the injectors. The engine speed When the EDC7UC31 control unit warning light
and power are controlled through the injectors. The comes on during acceleration and/or cold star t
power required by the user, through the accelerator, trouble, make sure the following check is done.
is converted into the quantity of fuel injected per • Check torque of the nut (1) locking the injector
cycle. This in turn is converted into microseconds of duct on the cylinder head. The torque setting is
injector opening according to the rail pressure. 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.
2-80 Issued 08-07 Bur 87630273 NA

2
1

Proceed with the injector fuel backflow tests as To identify the defective injector, follow the method as
follows: described below:
• Remove the duct (4) from the cylinder head. Measure the quantity of fuel flowing out in one minute
• Plug it (3) from the coupling on the cylinder head. If
• Install a transparent line (2) recirculation exceeds 80 ml. (2.7 oz.) per minute,
plug the rail outlet of one injector (1) at a time using
Make sure that the engine idling speed is correct. the rail plugs in the test set.
Check the quantity of fuel recirculation from the
cylinder head. The defective injector is the one when plugged
causes a significant reduction in recirculated fuel.
The process for measuring the quantity of injector
return fuel is: NOTE: When changing an injector it is necessary to
• Engine idling and without air compressor or air change the duct.
conditioner on. After identifying the injectors / ducts with high fuel
• engine temperature greater than 50°C (122°F). recirculation, check the torque of the ducts, 45 - 55
The quantity of fuel that flows out must be no greater Nm (33.2 - 40.6 pound-feet), if they are loose tighten.
than 80ml. (2.7 oz.) of diesel per minute. Excessive Then check the recirculation values again.
recirculation more than 80ml. (2.7 oz.) of diesel per If the torque is correct, remove the line and check the
minute could be caused by: spherical end towards the injector is not out of round,
• Incorrect coupling between one or more replace if necessary. Recheck recirculation value.
injectors and the related needles.
If the duct is not out of shape, replace the injector.
• Problem of internal leakage of the injector.
87630273 NA Issued 08-07 Bur 2-81

SPECIAL DISASSEMBLY - F4GE ENGINES

DISASSEMBLING ENGINE STEP 3
STEP 1 1 2 3
13
4
12 5
11 6
7
10
8
9
1
Version F4GE9484D
BS06N244 Figure 2-91 Remove the following:
Drain the engine oil by taking the plug off the oil pan • Grid heater (1).
and the oil filling cap of the valve cover.
• Intake manifold (2).
Remove the fan unit from the fan pulley.
• Oil recovery pipe from blow-by (3).
In order to apply the brackets to the engine block to
fix it on the stand for overhaul it is necessary to • Pipe for LDA intake manifold (4).
remove electrical wiring (1). • Piping for LDA system (5).
STEP 2
• Quick-couplings pipes (6), (7), (10) see step 4.
• Fuel filter (8).
• Electrical wiring (9).
2
1 • Fuel filter support (11).
• Grid heater control unit (12).
• Tappet covers (13).
5
STEP 4
4
3 A B
1
Remove the following:
• Fastening bracket (5) from electrical wiring (1).
• Starter (4)
• turbine lubrication delivery pipe (2).
• Oil filter (3). 1
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.
2-82 Issued 08-07 Bur 87630273 NA

STEP 5 STEP 7
1 2
1
4 3 2
BS06N247 Figure 2-95 BS06N248 Figure 2-97

Remove the following: • Remove the bolts fastening the turbine, and then
• Injector feed pipes (3) from injection pump (2). remove the turbine (1).
• Brackets fastening feed pipes (1), (5), (6) on the • Remove the exhaust manifold (3).
cylinder head.
STEP 8
• Fuel pump (4).
1 9
STEP 6
2
1 8
3
4
5
6
3
2
7
4 Remove the following:
BS06N249 Figure 2-96 • Belt tightener (2).
Remove the following: • Poly-V belt (4).
• Fuel feed pipes from the injectors (1). • Alternator fastening bracket (1).
• Remove fuel drain pipe (2) from the injectors by • Alternator (3), water pump (6), fan pulley (5), and
removing the bolt (4) and the seal (3). guide pulleys (7).
• pulley support (8).
• Thermostat housing and thermostat (9) from the
engine block.
87630273 NA Issued 08-07 Bur 2-83

STEP 9 STEP 11
1
2
1
3
2
4

Lock the flywheel properly to prevent rotation, BS06K244 Figure 2-101
remove bolts (2) from pulley (1). Using the pry bar (3) of Special Tool 380000996 and
the lever (4), remove the external seal ring (2) from
CRANK SEAL REPLACEMENT the front cover
STEP 10
STEP 12
A B
1
1
2
2
3 3
4
4
BS06K243 Figure 2-100 BS07C437 Figure 2-102
Place Special Tool 380000665 (4) to the front of the Remove the following:
crankshaft (2). • Water pump (1)
Working through the guide holes of Special Tool • Bolts (2) and (4)
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 • Crankcase front cover (3)
(3/16 inch) (B). NOTE: Take note of bolts (2) and (4) position when
Secure Special Tool 380000665 (4) to the ring (1) by removing them because they are different lengths.
screwing down the six bolts supplied with tool to the
crankshaft front cover.
Now extract seal ring (1) by tightening bolt (3).
2-84 Issued 08-07 Bur 87630273 NA

STEP 13 STEP 15
2
1
1
BS06K246 Figure 2-103 BS06N254 Figure 2-105

Remove bolts and take off oil pump (1). LOCKING INJECTION PUMP IN PRESET CONDITION
IMPORTANT: Oil pump (1) cannot be repaired. To correctly preset the injection pump prior to
removing it, loosen bolt (2) and remove the
REMOVING INJECTION PUMP L-shaped spacer (1).
Tighten bolt (2) to 27 to 33 Nm (20 to 24.3 pound-
STEP 14
feet) to block rotation of the pump shaft.
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

LOCKING FLYWHEEL
Rotate the crankshaft until the number 1 cylinder
reaches top dead center (TDC).
1
When TDC is obtained lock the flywheel by pushing
pin (1) of special tool 380002729 as shown by the
arrow.
Remove cover (1) from gear case (2).
Loosen nut (3) securing the injection pump drive gear
(4).
87630273 NA Issued 08-07 Bur 2-85

STEP 17 STEP 19
1 1
BD04A025-01 Figure 2-107

Attach Special Tool 380000979 (1) to the injection BS06N257 Figure 2-109
pump drive gear and remove the gear. Remove bolts (1) securing engine flywheel (2) to the
crankshaft
STEP 18
STEP 20
1 2
3 1
5
2
4

Loosen the three nuts (1), (3) and (4) securing the
injection pump (2) to the bell housing (5), then take BS06N258 Figure 2-110
the pump out of its housing. Screw two pins (2) of adequate length into crankshaft
NOTE: Hold the pump drive gear shaft to prevent it holes (3).
from moving, when removing pump from the engine Remove engine flywheel (1) so that it can be
block. harnessed with a hoist and moved out of the way.
2-86 Issued 08-07 Bur 87630273 NA

STEP 21 STEP 23
A
1
1
2
2
3
4 5
REMOVING INNER REAR CRANKSHAFT SEAL
Remove bolts (2) and then remove the flywheel
Apply Special Tool 380000663 (3) on crankshaft rear housing.
shank (5).
IMPORTANT: Note the installation position of the
Dr ill inner seal ring (1), through Special Tool bolts (2) because they are different lengths.
380000663 (3) guide holes, with a 3.5 mm
(9/64 inches) drill bit (A). Drill down to a depth of STEP 24
5 mm (3/16 inches).
Secure Special Tool 380000663 (3) to ring (1) by 1
fastening the 6 bolts (4) provided.
Extract seal ring (1) by tightening bolt (2).
STEP 22
1 2
2
3
Turn the engine upside down, remove bolts (2),
remove oil pan (1).
STEP 25
4
1
REMOVING OUTER REAR CRANKSHAFT SEAL 2
Using the pry bar (3) and lever (4) remove the outer
seal ring (2) as shown in figure above.
3
Then take the same tool and remove the seal ring
from the flywheel cover case in the same manner.
4

Remove bolts (1) and disassemble gears (3) and (4)
from camshaft (2).
87630273 NA Issued 08-07 Bur 2-87

STEP 26 STEP 28
1 2
3 1
2
REMOVING COUNTER BALANCE Remove injectors (2) with Special Tool 380000671
Use pin (1) to lock the counter balance (3) at TDC (1).
(top dead center). Remove bolts (2) and remove the
counter balance (3).
STEP 29
REMOVING ROCKER ARM ASSEMBLY
STEP 27
1
2
3
4
1

Remove bolts (1) securing the cylinder head to the
BS06N263 Figure 2-117 engine block
For each cylinder, loosen adjusting nuts (3) and
unscrew the adjusters (2). STEP 30
Remove the bolts (4), remove rocker assembly (1)
and the push rods. 1

Attach harness to brackets (1), and remove cylinder
head from block using a hoist.
2-88 Issued 08-07 Bur 87630273 NA

SPECIAL DISASSEMBLY - F4HE ENGINES

DISASSEMBLING ENGINE STEP 4
STEP 1
Drain the engine oil by removing the plug from the oil 1
pan (sump). 2
STEP 2
1
5
3
2 4
3 Disconnect fuel line (1) from common rail and from
4 high pressure pump (2) and remove it by taking out
securing bolts (5).
5 IMPORTANT: When loosing fitting (4) of fuel line (1),
BS06K221 Figure 2-121 it is necessary to use a suitable wrench to prevent
Apply the brackets for fastening the engine to the fitting (3) of high pressure pump (2) from rotating.
engine stand as follows (working from the left side of
the engine. STEP 5
• Use a suitable tool to remove fuel filter (5) from the From the Right Side:
fuel filter bracket (1).
• Disconnect the low pressure lines (2, 3, 4) from 1
the fuel filter bracket (1).
• Remove fuel filter bracket (1) from engine block.
STEP 3
2
A B
1

Remove the mounting bolts and remove the oil line
(2) from the Turbo-charger (1) from the engine block.
1 Remove the starter from the flywheel housing
BS06K222 Figure 2-122 Secure the engine to a engine stand.
Push clamp (1), as shown in figure B to disconnect
the low pressure fuel lines (2, 3, 4) from the
corresponding connections. After disconnecting the
line, reset the clamp (1) to locking position figure (A)
to prevent distortion to the clamp.
87630273 NA Issued 08-07 Bur 2-89

STEP 6
1 2
11
3
10 4
9
7
8
9. OIL TEMPERATURE-PRESSURE
1. INJECTOR CONNECTIONS 5. FUEL HEATER TEMPERATURE SENSOR
SENSOR
10. COMMON RAIL FUEL PRESSURE
2. INJECTOR 6. HIGH PRESSURE REGULATOR
SENSOR
3. BOOST TEMPERATURE-PRESSURE 11. ENGINE COOLANT
7. EDC7UC31 CONTROL UNIT
SENSOR TEMPERATURE SENSOR
4. CAMSHAFT SENSOR 8. CRANKSHAFT SPEED SENSOR
Disconnect the following connectors from the engine: STEP 7

• Connectors (1) from injector wiring (2)
2 3
• Engine coolant temperature sensor on the
thermostat (11)
• Common rail fuel pressure sensor (10) 1
• Crankshaft speed sensor (8)
• Boost pressure / temperature sensor (3)
• Camshaft sensor (4) 5
• High pressure regulator (6)
4
• EDC7UC31 control unit (7)

Disconnect from the common rail (2):
• Fuel line (4) according to procedure on page 2-89
• Fuel lines (3)
• Injector manifolds (5)
• Remove the bolts (1) and disconnect the common
rail (2)
2-90 Issued 08-07 Bur 87630273 NA

STEP 8 STEP 10
1 1
2
5
3
2 4
5
6
3 7
4
8
Loosen tappet adjusting nuts (1) and unscrew the
Disconnect line (5) from fuel return pressure limiter adjusters.
(1) as shown in step 3 page 2-89.
Remove bolts (2), remove the rocker assembly (3),
Remove the nut, loosen the retainer collar and consisting of bracket (6), rockers (4), shafts (5) and
disconnect the oil vapor line (2). Remove bolts (4) remove jumpers (7) from valves. Remove rods (8).
and take off the blow-by filter (3).
STEP 11
STEP 9
1
1
6
2
3 2
5 4
Remove nuts and remove the tappet cover including
the gasket.
Remove bolts (1) and disconnect the injector wiring
Remove injector fastening bolts. Use Special Tool
housing (6) complete with gasket.
380001099 (1) to remove injectors (2) from the
Remove bolts (3) and detach the boost temperature/ cylinder head.
pressure sensor (2).
R e m o ve n u t s ( 5 ) a n d r e m o ve t h e f u e l i n l e t
connectors (4).
IMPORTANT: Disassembled fuel inlet connectors (4)
must not be used again. They must be replaced with
new ones.
87630273 NA Issued 08-07 Bur 2-91

STEP 12 STEP 14
1 2 3 4
1

Remove the bolts and take off the ther mostat
housing (1) and the thermostat under the housing.
Disconnect oil line (4) from heat exchanger oil filter
bracket and from the line fitting (2) to the turbine. Remove fastening bolts (2) and remove cylinder
head (3).
Remove nuts and detach turbocharger (3) from
exhaust manifold (1). STEP 15
Remove bolts and disconnect the exhaust manifold
(1), from the cylinder head. 1
STEP 13
2 BS06K234 Figure 2-134

Attach brackets (1) to cylinder head and remove
cylinder head from block using a hoist.
STEP 16

1
On the opposite side, remove the bolts from the
intake manifold (1) and remove grid heater (2).

Remove cylinder head gasket (1).
2-92 Issued 08-07 Bur 87630273 NA

STEP 17 STEP 19
1
1
3
Remove the bolts and disconnect the EDC7UC31
Remove bolts (2) and disconnect the alternator
control unit (1), including the heat exchanger.
support (3).
Remove oil filter (1) STEP 20
STEP 18
1 3
1 2
4
2
3 4
Take out bolts and remove the oil temperature- Remove bolts (3) and remove the cap (1). Keep the
pressure sensor (2). gasket (2), the power take-off (4) and the second
gasket (4).
Take out bolts and then remove heat exchanger/ oil
filter bracket (1) and intermediate plate (4) and
relevant gaskets.
Remove the oil level sensor (3).
87630273 NA Issued 08-07 Bur 2-93

STEP 21 STEP 24
1
1 2

Remove the nut and disconnect the timing sensor BS06K242 Figure 2-143
(1). Remove the nuts and disconnect the high Remove the bolts and disconnect the water pump
pressure pump (2) including the feed pump (3). (1). Remove the bolt and disconnect the engine
speed sensor (2).
STEP 22
STEP 25
A B
1
2
1
3
4
Install tool to flywheel housing, loosen bolts on BS06K243 Figure 2-144
flywheel (1) but do not remove the flywheel. Place Special Tool 380000665 (4) to the front of the
NOTE: The special tool 380000988 is not shown in crankshaft (2).
figure, see page 2-95 Working through the guide holes of Special Tool
380000665 (4), drill into the internal seal ring (1) with
STEP 23 a 3.5mm
(9/64 inch.) drill bit (A) to a depth of 5mm (3/16 inch.)
(B).
1
Secure Special Tool 3800000665 (4) to the ring (1)
2 by screwing down the six bolts supplied with tool to
the crankshaft front cover.
Now extract seal ring (1) by tightening bolt (3).
3
Remove the bolts (3) and take off the damping
flywheel (2) and the pulley (1).
2-94 Issued 08-07 Bur 87630273 NA
STEP 26 STEP 29
1
2
2
3
1
4
3

BS06K244 Figure 2-145 Remove Special tool 380000988 (1), remove bolts
Using the pry bar (3) and the lever (4), remove the securing flywheel (2) to crankshaft (3).
external seal ring (2) from the front cover (1).
STEP 30
\
STEP 27
1
1
3

Screw two pins (2) of adequate length into the
Remove the bolts and take off the front cover (1).
crankshaft holes (3) slide flywheel out on them.
IMPORTANT: Note the installation position of the Attach a harness to flywheel.
bolts because they are different lengths. Remove the flywheel (1) with a hoist.
STEP 28

Remove bolts and take off gear oil pump (1).
IMPORTANT: Oil pump (1) can not be repaired.
87630273 NA Issued 08-07 Bur 2-95

STEP 31 STEP 33
2
1 1
5
4
Remove bolts and take off rear cover (1). Remove the bolts (1 and 3) and remove the oil
suction tube (2). Remove the bolts (5) and remove
IMPORTANT: Note the installation position of the the stiffening plate (4).
bolts because they are different lengths.
Remove bolts (1 and 4) and remove oil suction tube
STEP 32 (5). Remove bolts (2) and remove stiffening plate (3).
Turn engine upside down STEP 34
2
2

Remove the bolts, plate (2) and oil pan (sump) (1). Remove bolts and take gear (2) off of camshaft (1).
2-96 Issued 08-07 Bur 87630273 NA

CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES

STEP 36
1 1
2
2
BS06N267 Figure 2-154 BS06K257 Figure 2-156

Remove bolts (2) and take off timing gear case (1). Remove bolts (1), and take off main bearing journals
IMPORTANT: Note the installation position of the (2)
bolts because they are different lengths.
STEP 37
STEP 35
1
1
2

BS06K256 Figure 2-155 The main bearing journal cap (1) and its respective
Remove connecting rod cap fastening bolts (1) then thr ust bear ing (2) have a shoulder to control
take off rod caps (2). crankshaft endplay.
Remove the pistons (complete with connecting rods) IMPORTANT: Take note of the mounting position of
from the crankcase by pushing them up thorough the the main bearings and thrust bearings. If they have to
top of the block. be reused again, they must be installed in the same
position they had prior to being removed.
IMPORTANT: Half bearings must be kept in there
respective housings. If they are going to be used
again, they must be mounted in the same position
they had prior to being removed.
87630273 NA Issued 08-07 Bur 2-97

STEP 38 STEP 41
2 1

Remove crankshaft (2) from engine crankcase by Carefully remove the camshaft (1) from the engine
means of a suitable tool (1) and a hoist. crankcase.
STEP 39 STEP 42
1
1 2
3
BS06K260 Figure 2-159 Remove tappets (1) from the engine crankcase.
Take off main half bearings (1).
Remove bolts (2) and take off oil nozzles (3).
STEP 40

Remove bolts (1) and take off camshaft retainer plate
(2).
IMPORTANT: Note plate (1) mounting position.
2-98 Issued 08-07 Bur 87630273 NA

CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE

INSPECTION STEP 44
After the engine has been dismantled, clean the
crankcase thoroughly.
Check the crankcase carefully for cracks. Check the
condition of freeze plugs. They must be replaced if 1
they are rusty or sealing properties are in doubt.
Inspect the cylinder bore surfaces, they must not
B
show traces of seizing, scoring, out-of-roundness, 2 A
taper or excessive wear.
STEP 43
3
1 1 BS06K265 Figure 2-164

Measurements must be taken for each cylinder, at
three different heights (1, 2, 3) of the bore and two
planes perpendicular to each other. One parallel to
2 the engine longitudinal axis (A), the other
perpendicular (B).
2 NOTE: the greatest amount of wear is usually found
on the (B) axis and during measurement (1) of the
vertical plane.
When detecting out-of-roundness, taper or wear, the
BS06K264 Figure 2-163 cylinder bores must be bored and resurfaced.
Cylinder bore reconditioning must be done in
CHECKING CYLINDER BORE OUT-OF-ROUNDNESS AND
TAPER standard increments of 0.5mm (0.020 inches) of over
Check the cylinder bore inner diameter (in order to sized pistons and rings, and to prescribed assembly
measure the amount of out-of-roundness, taper and play.
wear) with a bore gauge (1) equipped with a dial
indicator. Set ring gage to zero and check the
cylinder bore diameter (2).
IMPORTANT: If a bore gage is not available, use a
micrometer to perform test.
87630273 NA Issued 08-07 Bur 2-99

STEP 45 CHECKING CRANKCASE CYLINDER HEAD

MATING SURFACE
STEP 46
1 2

Verify that the crankcase cylinder head mating
surface does not show any warping.
This check can be carried out by taking out dowels
(2). With a straight edge (1) and a thickness gauge
(4). Measure for warpage. Warpage must not be
greater than 0.075 mm (0.0030 inches). If there are
any deformed areas greater than the specified value,
BS06K269 Figure 2-165 resurface the block.
CYLINDER BORE DIMENSIONS AND SPECIFICATIONS
IMPORTANT: When the repair work has been
IMPORTANT: In the case of reconditioning, all the completed, check that the protrusion of the piston
bores must be machined to the same increment of from the bore is not greater than the specified value.
0.5 mm (0.02 inches). As shown on page 2-118.
Check the main bearing seats as follows: After flattening, restore the bore countersink as
• Mount the bed caps on the supports without shown on page 2-100.
bearings.
• Tighten the fastening bolts to the specified torque.
• Check, with an internal comparator, that the seat
diameter is the same as the specified value.
NOTE: If a greater value is found, replace the
crankcase.
2-100 Issued 08-07 Bur 87630273 NA

CAMSHAFT

MAIN FEATURES OF CAMSHAFT
The camshaft support journals and lobe surfaces For F4HE engines:
must be perfectly smooth. If they show signs of 6.045 mm (0.238 inches) for Exhaust.
seizing and scoring, replace the camshaft and
respective bearings. 7.528 mm (0.296 inches) for Intake .
If different values are found than specifications,
CHECKING ECCENTRIC LIFT AND BEARING replace the camshaft.
SURFACE
STEP 47

Check the camshaft with a micrometer (1). The
journal surface (2) must not have greater than 0.04
mm (0.0016 inches) of wear otherwise replace
camshaft. Check the diameter of the camshaft
bearing journals with a micrometer (1) on two axis
perpendicular to each other.
Also check the eccentric (lobe) lift (3) which must be
equal to.
For F4GE engines:
11.02 mm (0.434 inches) for Exhaust.
10.74 mm (0.423 inches) for Intake.
87630273 NA Issued 08-07 Bur 2-101

REASSEMBLY
BEARINGS

MAIN FEATURES OF CAMSHAFT BEARINGS AND RELATED SEATS
* DIMENSION TO BE OBTAINED AFTER DRIVING THE BEARING
STEP 48

The camshaft bearings (2) must be pressed into their
respective seats.
The inner surface must show no traces of internal
wear.
Use bore gauge (3) to measure the diameter of rear
bearing (2) and camshaft intermediate seats (1).
Measurements must be take on two axis
perpendicular to each other.
2-102 Issued 08-07 Bur 87630273 NA

REPLACING CAM BEARINGS INSTALLING TAPPETS AND CAMSHAFT
STEP 49 STEP 51
2
1
3

To replace front and rear bearings (1), remove and BS06K274 Figure 2-173
refit them using an acceptable driver (2) and striker Lubricate tappets (1) and fit them to there respective
(3). seats on the crankcase.
IMPORTANT: When installing bearings (1) it must be
aligned so that the lubrication holes are aligned with STEP 52
the holes on the crankcase seat.
TAPPETS
STEP 50

Lubricate the camshaft support bearings and mount
the camshaft (1) taking care not to damage the
bearings or support seats.

MAIN FEATURES OF TAPPETS AND THEIR RESPECTIVE
SEATS ON THE CRANKCASE
87630273 NA Issued 08-07 Bur 2-103

STEP 53 STEP 55
1
1

Place camshaft retaining plate (1) with the slotted BS06K278 Figure 2-177
hole facing the crankcase upper side and the Mount nozzles (2) and tighten fastening bolts to 12 to
stamping facing the operator, then torque bolts to 18 Nm (8.9 to 13.3 pound-feet).
20 to 28 Nm (14.8 to 20.7 pound-feet).
STEP 54

Check the camshaft end play (1). It must be between
0.13 to 0.23 mm (0.005 to 0.009 inches).
2-104 Issued 08-07 Bur 87630273 NA

CRANKSHAFT
MEASURING BEARING JOURNALS AND If any traces of seizing, scoring, or out-of-roundness
CONNECTING RODS JOURNALS are found on the bearing journals and connecting rod
journals, it is necessary to resurface the bearing
STEP 56
journals by machining. Prior to resurfacing the
bearing journals (2), measure the bearing journals
with a micrometer (1) to determine the amount
(diameter) by which the bearing journals will have to
be reduced.
Reduction in classes are 0.25 and 0.50 mm (0.010
and 0.020 inches)
IMPORTANT: It is advisable to write down the
measured values on the table on page 2-105
IMPORTANT: Bearing journals and connecting rod
journals must always be ground to the same
reduction class.
BS06K279 Figure 2-178 The reduction done on the bearing journals and
connecting rod journals must be marked with a
special stamping made on the side of the crank arm.
For reduced connecting rod journals, use letter M.
For reduced bearing journals, use letter B.
For reduced connecting rod journals and bearing
journals use letters MB

DATA ON WHICH CRANKSHAFT BEARING JOURNAL AND CONNECTING ROD JOURNAL MEASURING VALUES ARE TO BE
WRITTEN DOWN
* - RATED VALUE
87630273 NA Issued 08-07 Bur 2-105

1 2 3 4 5 6 7 8 9
MAIN TOLERANCES OF DRIVE SHAFT
Tolerance Concerning Tolerance-Related-Feature Graphic Symbol
Roundness 1
SHAPE
Cylindrical 2
Parallelism 3
ORIENTATION Perpendicularity 4
Straightness 5
POSITION Concentricity or Coaxial 6
Circular Oscillation 7
OSCILLATION Total Oscillation 8
Taper 9
2-106 Issued 08-07 Bur 87630273 NA

1 2 3

1. MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
2. INTERMEDIATE MAIN BEARINGS
3. FIRST MAIN BEARING ON FRONT SIDE
REPLACING OIL PUMP DRIVE GEARS MOUNTING MAIN BEARINGS
STEP 57 STEP 58
2
3
IMPORTANT: If main bearings do not need
Verify that the teeth of gear (1) force-fitted on
replacing, they must be fitted in the same order and
crankshaft (2) are not damaged or worn; otherwise,
positions they were removed.
proceed with removal by means of a suitable
extractor (3). Main bearings (1) are supplied as spares with
incrementally reduced inner diameters by
When fitting the new gear, the gear must be heated
0.250 - 0.500 mm (0.010 - 0.020 inches).
for 10 minutes at a temperature of 180° C ± 10%
(356° F ± 10%). IMPORTANT: No matching operation must be
carried out on bearings.
Thoroughly clean the main half bearings (1) provided
WARNING: Always wear heat protective with lubrication holes, then fit them into their seats.
gloves to prevent burning your hands when han- The main half bear ings (1) are provided with
dling heated parts. shoulder half rings.
SM121A
87630273 NA Issued 08-07 Bur 2-107

STEP 59 STEP 61
2
1 3

Install the crankshaft (2) in the engine crankcase on Fasten pre-lubricated bolts (1) by tightening them in
which gears (1) and (3) are force fitted. three phases.
• 1st phase with a torque wrench to 44 to 56 Nm
STEP 60 (32.5 to 41.3 pound-feet).
• 2nd phase with a torque wrench to 74 to 86 Nm
(54.6 to 63.4 pound-feet).
1
STEP 62
2
1
3
2
4

Check the play between the crankshaft bearing
journals and their respective bearings by following
the procedure below:
• Thoroughly clean the parts to eliminate any BS06K288 Figure 2-187
foreign material and oil. • 3rd phase with a acceptable tool (1) placed as
• Place a piece of gauged wire (3) parallel to the shown, tighten bolts (2) further to an angle of
axis of the crankshaft pins (4) 90° ± 5°.
• Install the mount caps (1), with half bearings (2),
on their respective supports.
2-108 Issued 08-07 Bur 87630273 NA

STEP 63 CHECKING CRANKSHAFT SHOULDER PLAY
STEP 64
1
2 1 2
BS06K289 Figure 2-188 3
Take the caps off the supports.
The play between the main bearings and their The shoulder play is checked by placing a magnetic
respective pins can be measured by comparing the
width taken on by the gauged wire (2) at the base indicator (2) on crankshaft (3) as shown in
narrowest point with the scale graduation shown on o figure.
the gauge (1) containing the calibrated wire. Normal assembly play is 0.068 to 0.410 mm
The numbers shown on the scale indicate the (.0027 to 0.0161 inches)
backlash play in (mm). If play falls out of the window, replace the main thrust
If the measured play is different than specifications, half bearings of the second last rear support (1) and
replace half bearings and repeat the check. Once the repeat the clearance check between crankshaft and
specified backlash play has been obtained, lubricate main half bearings.
main bearings and mount the supports and torque as
described in step 61 and 62.
PISTONS
1 2
4
7 3
6
5
PARTS MAKING UP THE CONNECTING ROD PISTON ASSEMBLY
1. PISTON 3. ROD CAP BOLTS 5. HALF BEARINGS 7. WRIST PIN

2. PISTON RINGS 4. CONNECTING ROD 6. BEARING 8. RETAINING RINGS
87630273 NA Issued 08-07 Bur 2-109


MAIN DATA ABOUT PISTON
STEP 65 STEP 67
1 1
2 3

Taking piston rings (1) off piston (2) by using an Measure the piston diameter (1) by means of a
acceptable tool. micrometer (2) to determine the assembly play.
STEP 66 NOTE: The diameter of piston must be measured

8mm (0.315 inches) from the piston skirt base.
2
3

The retaining rings (1) retaining the piston pin (2) are
removed by means of a scribe (3).
2-110 Issued 08-07 Bur 87630273 NA

STEP 68 CONDITIONS FOR CORRECT PIN/PISTON

MATCHING
STEP 70
1

The play between the piston and the cylinder bore
can also be measured by means of a thickness BS06K298 Figure 2-197
gauge (1) as shown in figure.
Lubricate piston pin (1) and its respective seat on
piston hubs with engine oil, the pin must be inserted
PISTON PINS
into the piston by pressing with your fingers slightly
STEP 69 and must not slide out due to gravity.
STEP 71
2
1
2
1

Measure the piston pin diameter (1) by means of a
micrometer (2).
Check the thickness of piston rings (2) by means of a
micrometer (1).
87630273 NA Issued 08-07 Bur 2-111

STEP 72 STEP 74
1 1
2
3

Use a thickness gauge (1) to check the play between Measure the piston ring gap (2) inserted into cylinder
the piston rings (3) of the 3rd slot and the respective bore (3), by means of a thickness gauge (1).
seats on piston (2).
CONNECTING RODS
STEP 73
STEP 75
1
3
2

DIAGRAM FOR MEASURING PLAY X FOR THE TRAPEZOIDAL
RING
Due to the peculiar shape of the first trapezoidal
cross-sectional seal ring, the play between the slot
and the ring itself must be measured as follows.
• Allow piston (1) to protrude from the crankcase so
that ring (2) comes out of the cylinder bore (3)
about half way. BS06K303 Figure 2-202
• In this position, check by means of a thickness MAIN DATA OF CONNECTING ROD, PISTON PIN BUSHING
AND HALF BEARINGS
gauge, the play (X) between the ring and the slot, it
must correspond to the specified value. * Dimension of inner diameter to be obtained after
driving into the connecting rod small-end and
refacing by means of a reamer.
** This dimension cannot be measured in released
condition.
IMPORTANT: The connecting rod, connecting rod
cap matching surfaces are knurled to ensure better
match.
Therefore, it is recommended not to remove knurls.
2-112 Issued 08-07 Bur 87630273 NA

STEP 76 BEARINGS
STEP 77
Verify that the bearings in the connecting rod small-
end is not loosened and does not show traces of
scoring or seizing. If it does replace them.
Removing and reassembling are carried out with the
same suitable driver.
When driving the bearings, make sure that the holes
allowing oil to flow onto the bear ing and the
connecting rod small- end correspond to each other.
Use a reamer to reface the bearing to obtain the
required diameter.
CHECKING CONNECTING RODS
STEP 78
BS06K304 Figure 2-203 3

▲ -Production year
● -Production day 4
■ -Weight class
IMPORTANT: Each connecting rod is marked as
follows: Check the centerlines of the connecting rods (1) are
parallel using proper device (5) as follows.
• By a number (on the body and cap) which • Install connecting rod (1) on tool (5) spindle, then
indicates the connecting rod match and the
secure it by means of bolt (4).
cylinder on which it is mounted. In case of
replacement, it is necessary to number the new • Place spindle (3) on V-blocks by putting
connecting rod with the same number as the connecting rod (1) on stop bar (2).
replaced one.
• By letter (on the connecting rod body) which
indicates the weight class of the factory-
assembled connecting rod.
V- 1820 to 1860 grams (marked in yellow)
W- 1861 to 1900 grams (marked in green)
X- 1901 to 1940 grams (marked in blue)
Replacement rods are supplied class W and marked
in green.
Material removal is not permitted.
87630273 NA Issued 08-07 Bur 2-113

CHECKING TWISTING CHECKING FLEXING
STEP 79 STEP 80
1
B
1 2 D
C
2 A
3
3 5
5
4
4

Check connecting rod torsion (5) by comparing two Check connecting rod flexing (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of points (C) and (D) of pin (3) on the vertical plane of
the connecting rod axis. the connecting rod axis.
Place comparator (2) suppor t (1) so that the Place comparator (2) vertical support (1) so that the
comparator is preloaded by approximately 0.5mm comparator rests on pin (3) at point (C).
(.02 inches) on pin (3) at point A, then set comparator Swing the connecting rod back and forth, looking for
(2) to zero. Move spindle (4) with connecting rod (5), the highest position of the pin. Under such condition,
then compare the deviation (if any) on opposite side set comparator (2) to zero.
(B) of pin (3). The difference between A and B must Move the spindle with connecting rod (5) and repeat
not be greater than 0.08mm (0.003 inches). the highest point check on opposite side (D) of pin
(3). The difference between points (C) and (D) must
not be greater than 0.08 mm (0.003 inches).
ASSEMBLING PISTON TO CONNECTING ROD
3
4
The following reference data is engraved on the
piston crown.
1. Part number and design modification number
2. Arrow showing piston assembly direction into
cylinder bore, this arrow shall face the front key
of the engine block.
3. Manufacture date
4. Marking showing 1st slot insert testing.
2-114 Issued 08-07 Bur 87630273 NA

STEP 81 INSTALLING PISTON RINGS
1 STEP 83
3 1
2 3
4

Connect piston (2) to connecting rod (4) by means of
pin (3) so reference inscription (1) for installing piston
(2) in the cylinder bore and the numbers stamped on BS06K311 Figure 2-210
connecting rod (4) can be seen as shown in the Use a suitable tool (3) to install piston rings (1) on
figure above. piston (2).
IMPORTANT: The rings must be installed with the
STEP 82
writing "TOP" facing upwards and they should be
inserted so that the ring gaps are turned so that they
are offset to each other by 120°.
2 NOTE: Spare piston rings are supplied in the
following dimensions:
1 • Standard, marked with yellow paint.
• Oversized by 0.4mm (0.016 inches), marked with
yellow/green paint.
STEP 84

Insert pin (1) fastening split rings (2)
1

Install the half bearings (1) both on the connecting
rod and the cap.
IMPORTANT: If connecting rod bearings do not need
replacing, they must be installed in the same order
and position they had prior to being taken off.
No matching operation must be carried out on half
bearings.
87630273 NA Issued 08-07 Bur 2-115

INSTALLING CONNECTING ROD-PISTON MEASURING CRANK PIN ASSEMBLY PLAY

ASSEMBLIES IN CYLINDER BORES
STEP 87
STEP 85
1
3
2
4
BS06K313 Figure 2-212 T h e p l ay c a n b e m e a s u r e d by fo l l ow i n g t h e
Lubricate the pistons, including the piston rings and procedure below.
the cylinder bore inside. • Thoroughly clean the parts and eliminate any
traces of oil.
Use acceptable tool (2) to install the connecting rod-
piston assemblies (1) into the cylinder bores verify • Place a piece of gauged wire (2) on crankshaft
that: pins (1).
• The number of each connecting rod corresponds • Install the connecting rod caps (3) with their
to the cap matching number. respective half bearings (4).
STEP 86 STEP 88
1
2

SCHEME FOR INSTALLING THE CONNECTING ROD-PISTON Tighten bolts (1) previously lubricated with engine oil
ASSEMBLY INTO THE CYLINDER BORE
to the specified torque by means of a torque wrench
• The piston ring gaps are offset to each other by (2) in three phases.
120°.
1st phase- 27 to 33 Nm (19.9 to 24.3 pound-feet)
• All the connecting rod-piston assemblies weigh
2nd phase- 55 to 65 Nm (40.5 to 47.9 pound-feet)
the same.
• The writing stamped on the piston crown (1) faces
the engine block front side, the notch on the piston
skirt corresponds to the position of oil nozzles.
2-116 Issued 08-07 Bur 87630273 NA

STEP 89 STEP 91
2 1
Use an acceptable tool (1) on the socket wrench,
If the measured play is different from the specified,
then tighten bolts (2) fur ther in a cr isscross
replace half bearings and repeat the check.
sequence.
Once the specified play has been obtained, lubricate
3rd phase additional rotation- 60° ± 5°.
the connecting rod half bearings and install them by
STEP 90 tightening the connecting rod cap fastening bolts to
specified torque
2 1st phase- 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°
IMPORTANT: Prior to installing the connecting rod
cap fastening bolts, verify that the diameter
measured at the middle of the thread length is not
smaller than 0.1mm (0.004 inches) of the diameter
measured at about 10mm (0.39 inches) from the bolt
1 end.
Manually check that connecting rods (1) slide axially
on the crankshaft pins, and that the end play
measured by means of a thickness gauge (2) is 0.10
Take off the cap and calculate the existing play by to 0.33mm (0.004 to 0.013 inches)
comparing the width of gauged wire (1) with the scale
(2) graduation shown on the wire envelope.
87630273 NA Issued 08-07 Bur 2-117

CHECKING PISTON PROTRUSION STEP 94
STEP 92
2 3
1

After the connecting rod-piston assemblies have
been installed, check with a dial indicator (1)
equipped with base (2), the protrusion of pistons (3) Install gear box case to the crankcase.
at the top dead center relative to the engine block Install the bolts in the same positions they had prior
upper plane. Protrusion shall be 0.28 - 0.52 mm to being taken off, then torque the bolts to:
(0.011 - 0.0205 inches)
M8- 20 to 28 Nm (14.8 to 20.7 pound-feet)
M10- 42 to 52 Nm (30.9 to 38.4 pound-feet)
VALVE GEAR DISTRIBUTION GEARBOX
CASE ASSEMBLY M12- 65 to 89 Nm (47.9 to 65.6 pound-feet)
STEP 93 STEP 95
1 1

BS07D078 Figure 2-220 Mark, with a felt tip pen, the tooth of drive gear (1)
SEALANT APPLICATION AREA mounted on crankshaft (2) having the mark (→) on the
side surface.
Thoroughly clean timing gear box case and the
engine block. To obtain a good seal the surface must
be clean. Apply a bead of LOCTITE 5205 to the case
a few millimeters in diameter (1). It should be uniform
in size without air bubbles, thin areas or voids. Any
imperfection should be corrected as soon as
possible. Avoid the use of excessive sealant to seal
the joint. Excessive sealant could come out from the
joint sides and cause lubrication passage clogging.
After applying the sealant, the joint should be
assembled within (10 - 20 minutes).
2-118 Issued 08-07 Bur 87630273 NA

STEP 96 STEP 97
1 3 2
2 4 3

Turn crankshaft (4) and camshaft (2) so drive gear BS06K325 Figure 2-224
(1) on the camshaft and the stamped marks on gears Tighten gear (2) fastening bolts (1) to camshaft (3),
(1 and 3) align with each other. tighten them to 32 to 40 Nm (23.6 to 29.5 pound-
feet).
87630273 NA Issued 08-07 Bur 2-119

INJECTION PUMP TIMING FIRST PHASE STEP 100

- F4GE ENGINES
STEP 98
1
2
Force-fit the injection pump drive gear (1), then
tighten nut (2) by hand.
Bring cylinder 1 to top-dead-center (TDC). When this NOTE: Be sure not to move the shaft for the injection
occurs push pin (1) it is housed in the seat in the pump when installing the pump.
camshaft drive gear (shown by arrow) to lock the
camshaft in the TDC position.
STEP 99

Mount the injection pump body (1) in the gearbox
seat (2), then secure it by means of bolts (3). Tighten
to 20 to 30 Nm (14.8 to 20.7 pound-feet).
2-120 Issued 08-07 Bur 87630273 NA

ASSEMBLING COUNTER BALANCER -

F4GE ENGINES
STEP 101
1
3
2

Turn engine over and install the counter balancer (2)
and tighten the bolts (3) to 40 to 56 Nm
(29.5 to 41.3 pound-feet)
Remove the counter balancer locking pin (1).
87630273 NA Issued 08-07 Bur 2-121

COUNTER BALANCER TIMING- F4GE ENGINES
1 2

COUNTER BALANCER GEAR ALIGNMENT
1. INJECTION PUMP GEAR 3. INJECTION PUMP CONTROL GEAR

2. CAMSHAFT CONTROL GEAR 4. COUNTER BALANCER UNIT
Make the marks (A) on the timing gears align, insert

counter balancer locking pin into hole (B) on the
counter balancer.
2-122 Issued 08-07 Bur 87630273 NA

FLYWHEEL STEP 103
STEP 102
1
1

FLYWHEEL BELL HOUSING BOLT TORQUE SPECIFICATION
Install bell housing (1) on to the crankcase, install
SEALANT APPLICATION AREA TO FLYWHEEL BELL bolts (2) in the positions they had prior to being
HOUSING
removed. Then tighten to the specified torque.
Thoroughly clean bell housing (1) and the engine
block. To obtain a good seal the surface must be M12 x 120- 75 to 95 Nm (55.3 to 70.1 pound-feet)
clean. Apply a bead of LOCTITE 5205 to the case a M12 x 80- 75 to 95 Nm (55.3 to 70.1 pound-feet)
few millimeters in diameter. It should be uniform in M10 x 80- 44 to 54 Nm (32.5 to 39.8 pound-feet)
size without air bubbles, thin areas or voids. Any
imperfection should be corrected as soon as M10 x 40- 75 to 95 Nm (32.5 to 39.8 pound-feet)
possible. Avoid the use of excessive sealant to seal Rear cover plate to bell housing
the joint. Excessive sealant could come out from the M8x1.25x16 - 20 to 28 Nm (14.8 to 20.7 pound-feet)
joint sides and cause lubrication passage clogging.
After applying the sealant, the joint should be NOTE: Tighten the bolts in the bell housing in a
assembled within (10 - 20 minutes). crisscross cross pattern.
STEP 104
2
1
6
5
4 3

Apply p ar t (4 ) o f Special tool 3 8000 0664 o n
crankshaft rear shank (3), secure it with bolts (5) and
force-fit the new seal ring (6) on to the rear shank.
Position part (1) on part (4), then screw nut (7) to fully
mount seal ring (6) in flywheel bell housing case (2).
87630273 NA Issued 08-07 Bur 2-123

ENGINE FLYWHEEL STEP 106
STEP 105
1
2
2
1

FLYWHEEL FOR F4GE ENGINES Screw two pins (2) of adequate length into the shaft
holes (3), then install the engine flywheel (1) by
means of suitable harness and a hoist into the
2 flywheel bell housing.
1
STEP 107

Remove the two pins and install the flywheel bolts (1)
FLYWHEEL FOR F4HE ENGINES
to the drive shaft.
Check contact surface of the flywheel and turn it if
scoring is detected.
Check the condition of ring gear (2) teeth. If breaks or
excessive tooth wear is found, remove the ring gear
from the flywheel (1) by using a suitable tool. then
mount the new ring gear after previously heating it to
150° C (302° F) for 15 to 20 minutes. Chamfering on
the ring gear inside diameter must face the engine
flywheel.
WARNING: Always wear heat protective

gloves to prevent burning your hands when han-
dling heated parts.
SM121A
2-124 Issued 08-07 Bur 87630273 NA

STEP 108 STEP 110
1 2

Tighten flywheel bolts in two separate phases: Apply a new seal ring (2) onto the water pump (1).
1st phase- 26 to 34 Nm (19.2 to 25.1 pound-feet)
STEP 111
2nd phase- 60° ± 5°
NOTE: Before assembly check the threads of the
ports and of the bolts to make sure there is no
evidence of wear or dirt.
MOUNTING THE OIL AND WATER PUMP

STEP 109 1

Mount water pump (1).
1 Install bolts (2) and torque them to
2 M8 bolts-20 to 28 Nm (14.8 to 20.7 pound-feet)
STEP 112

Install oil pump (1).
Install bolts (2) and tighten them to specified torque:
1st stage- 7 to 9 Nm (5.2 to 6.6 pound-feet). 1
2nd stage- 20 to 28 Nm (14.8 to 20.7 pound-feet).
2

Take seal ring (2) off front cover (1), clean sealing
surface thoroughly and apply Loctite 5205 sealant to
the surface.
87630273 NA Issued 08-07 Bur 2-125
STEP 113 STEP 115
1 2

BS06K337 Figure 2-242 FOR F4HE ENGINES
Thoroughly clean the mating surface of the front Install stiffner plate (3), oil pick up tube (1) and
cover and install the front cover (2). tighten fastening bolts (2). Torque to:
Fasten bolts (1) and torque them to Stiffner plate M10- 38 to 48 Nm (28 to 35 pound-feet)
M8 bolts- 20 to 30 Nm (14.8 to 22.1 pound-feet). Pick up tube- M8- 20 to 28 Nm (14.8 to 20.7 pound-
feet).
STEP 114
STEP 116
1
1
2
3 1
4
2
5
OIL PAN (SUMP) FOR F4GE ENGINES
Apply part (5) of tool 380000666 on crankshaft front
shank (6), secure it by means of bolts (4) and force-fit
the new seal ring (3) on the front shank.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in front cover (7).
2-126 Issued 08-07 Bur 87630273 NA

1
4
1
2 5
2
3
6
OIL PAN (SUMP) FOR F4HE ENGINES FOR F4HE ENGINES
Install phonic wheel (1) and hub (2) on the
Install a new oil pan gasket.
crankshaft.
Mount the oil pan (1).
Torque bolts to:
Fasten bolts (2) and torque them to
1st stage- 45 to 55 Nm (33.2 to 40.6 pound-feet).
M8x1.25- 20 to 28 Nm (14.8 to 20.7 pound-feet).
2nd stage- 90° ± 5°
STEP 117
1 3
2
3
4

FOR F4GE ENGINES
Force-fit pulley (1) complete with spacer (2) onto the
crankshaft, then torque the bolts to
105 to 115 Nm (77.4 to 84.8 pound-feet)
Install guide pulleys (4) to the front cover by means of
bolts (3) and tighten to:
87630273 NA Issued 08-07 Bur 2-127

STEP 118 STEP 120
1
1 2
2
3
4

FOR F4HE ENGINES BS06N323 Figure 2-251
Install a new seal ring on RPM sensor (2). Install alternator support (1) in such a way that pins
Install RPM sensor (2) on front cover (1) (2) and (3) are placed against the crankcase. Fasten
bolts (4) and tighten them to specified torque.
Torque bolt to 6 to 10 Nm (4.4 to 7.4 pound-feet).
Alternator Torque Specifications:
STEP 119
Support M8 - 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
1 Lower mount M10- 20 to 28 Nm (14.8 to 20.7 lb.-ft.)
2 Upper pivot M10- 44 to 54 Nm (32.5 to 39.8 lb.-ft.)
Alternator wiring M6 nut- 8 to 12 Nm (5.9 to 8.9 lb.-ft.)
3
Mounting hardware M12- 37 to 49 Nm
4 (27.3 to 36.1 lb.-ft.)
Alternator to water inlet M8- 20 to 28 Nm
5 (14.8 to 20.7 lb.-ft.)
STEP 121

INSTALLING WATER/OIL HEAT EXCHANGER
Install the following items on the crankcase:
A new gasket between the exchanger unit and
2
crankcase (1), heat exchanger (2), new inner gasket 1
(3), heat exchanger body (4). Fasten bolts (5) and
tighten to specified torque of.

Install alternator (1) on support (2) and connect
associated hardware. Tighten to specified torque
information listed above in step 120.
2-128 Issued 08-07 Bur 87630273 NA

CYLINDER HEAD FOR F4GE ENGINES

REMOVING THE VALVES STEP 124
STEP 122
1
2
1 3

In addition to the head dimensions, the exhaust
valves differ from the intake valves in that they are
Valves can be removed by means of acceptable tools equipped with a additional notch (1) located on the
(1), by pressing slightly spring seat (3) so that stem of the intake valves.
keepers (2) can be removed by compressing spring
(4). Then remove spring seat (3) and spring (4).
Repeat the above procedure on all the valves.
STEP 123

Take off seals (1) fitted to the valve stems.
To remove the valves, turn the head upside down.
IMPORTANT: Mark the exhaust and intake valves
prior to removing them.
87630273 NA Issued 08-07 Bur 2-129

STEP 125 STEP 127
1
2

MAIN FEATURES OF CYLINDER HEAD
Remove the thermostat housing (1) and thermostat
(2) from the cylinder head. Nominal thickness (A) of the cylinder head is 95 ±
0.25 mm (3.740 ± 0.0099 inches) max. Material
STEP 126 removal shall not exceed thickness (B) 0.13 mm
(0.005 inches)
1 IMPORTANT: After resurfacing, check valve sinking
and regrind valve seats if required, to obtain the
required value.
CHECKING CYLINDER HEAD WATER SEAL
STEP 128
C h e ck t h e wa t e r s e a l by m e a n s o f s u i t a bl e
3 equipment. Use a pump to feed water heated to
2 approximately 90° C (194° F) at a pressure of 2 to 3
bar (29 to 43.5 psi).
BS06N328 Figure 2-257 If leaks are detected from the freeze plugs, they must
The plane of the supporting surface of the cylinder be replaced by using a suitable beater for removal
head (1) is checked by means of a straight edge (2) and reassembling operations.
and a thickness gauge (3). IMPORTANT: Prior to mounting the freeze plugs,
The warpage found on the entire length of the apply water repellent sealant to the freeze plugs.
cylinder head must not be greater than 0.20 mm If leaks are found from the cylinder head the cylinder
(0.008 inches). head must be replaced.
If greater values are found, resurface the cylinder
head according to the values in figure on page 2-130.
2-130 Issued 08-07 Bur 87630273 NA

VALVES STEP 130

Use a micrometer (2) to measure valve stem (1),
which must be equal to 7.943 to 7.963 mm (0.313 to
0.314 inches)
MAIN DATA OF INTAKE AND EXHAUST VALVES CHECKING VALVE GUIDE WEAR
VALVE DESCALING, CHECK AND GRINDING STEP 131
STEP 129

Check can be made by means of a magnetic dial
BS06K359 Figure 2-260 indicator (1) placed as shown. Assembly play must
Remove the carbon deposits from the valves by be equal to 0.056 to 0.096 mm (0.002 to 0.004
means of the special metal brush. inches).
Verify that the valves do not show traces of seizing, Check, by turning valve (2) and making sure that the
scoring or burns. centering error does not exceed 0.03 mm
Adjust if required, the valve seats with the proper (0.001 inches).
grinder, removing the least amount of material
possible.
87630273 NA Issued 08-07 Bur 2-131

VALVE GUIDE VALVE SEATS REGRINDING- REPLACING

VALVE SEATS
STEP 132
STEP 133

Use a bore gauge to measure the valve guide inner BS06N333 Figure 2-264
diameter, which must be equal to the value shown in Check valve seats (2). If slight scoring or burrs are
the figure above. found, regrind seats with tool (1) according to the
angle values shown in figure on page 2-133.
2-132 Issued 08-07 Bur 87630273 NA

VALVE SEATS
BS07E175 Figure 2-265

VALVE SEAT DIMENSIONS
If the valve seats cannot be restored by simply STEP 134

reconditioning them, they can be replaced with spare
parts. By using the same tool (1) in (figure 2-262)
and taking care not to indent the cylinder head. 1
Remove as much material as possible from the valve
seats until the seat can be taken off the cylinder head 2
by using a punch.
Heat the cylinder head to 80 to 100° C 3
(176 to 212° F), then mount the new valve seats
(previously cooled) into the heated cylinder head by
means of a suitable beater.
Recondition the valve seats with tool (1) in
(figure 2-262), according to values shown in (figure
2-263). BS06N336 Figure 2-266
After regrinding, check that valve (3) recess value is
as specified by using the base and dial indicator.
WARNING: Always wear heat protective
gloves to prevent burning your hands when han-
dling heated parts.
SM121A
87630273 NA Issued 08-07 Bur 2-133

VALVE SPRINGS MOUNTING CYLINDER HEAD

STEP 135 STEP 136
1
2
3
MAIN DATA FOR INTAKE / EXHAUST VALVE SPRING CHECK Lubr icate the va lve stem and inser t into the
Prior to installing, check the valve spring flexibility by respective valve guide according to the position
means of the proper tool. Compare the elastic strain marked when disassembling.
and load data with the existing springs to the new Fit the sealing rings (2 and 3) on the valve guide.
springs shown in the table below.
NOTE: Sealing rings (3) for intake valves are yellow
Height in mm / inches Under a load of N / lbf and sealing rings (2) for exhaust valves are green.
H (Free) 63.50 (2.50) No Load
INSTALLING VALVES
H1 49.02 (1.93) P1 329 (73.96)
H2 38.20 (1.50) P2 641 (144.10) STEP 137
2
1 3

Position spring (4) and spring seat (3) on the cylinder
head. Use acceptable tool (1) to compress spring (4)
and lock the par ts to the valve by means of the
keepers (2).
2-134 Issued 08-07 Bur 87630273 NA

STEP 138 RODS AND TAPPETS
STEP 140
A B

Verify that the cylinder head and the crankcase
mating surfaces are both clean. BS06K378 Figure 2-272
Take care not to damage the cylinder head gasket. A. BAD PUSH ROD
B. GOOD PUSH ROD
The gasket thickness to be used, will have to take in
consideration of the cylinder protrusion measured Prior to inserting the pushrods, verify their conditions:
with respect to the crankcase upper surface • The push rods should not be distorted
Set the head gasket with writing "TOP" facing the • The ball seats in contact with the rocker arm
head. adjusting screw and tappet (arrows) must not show
The arrow shows the point where the gasket traces of seizing or wear, otherwise they must be
thickness is given. replaced
IMPORTANT: Prior to reusing the cylinder head

• Intake and exhaust pushrods are identical and
therefore interchangeable.
bolts, verify that they do not show traces of wear,
corrosion or deformation. If they do
ROCKER ARM ASSEMBLY
STEP 139
STEP 141
2
1
3

Lubricate cylinder head bolts prior to installing them.
PARTS MAKING UP THE ROCKER ARM ASSEMBLY
Mount the cylinder head on the crankcase by
fastening bolts (1), WITHOUT tightening them. 1. SUPPORT 2. ROCKER ARM
3. ARBOR 4. BOLTS
87630273 NA Issued 08-07 Bur 2-135

STEP 142 TORQUING CYLINDER HEAD
STEP 144

MAIN DATA OF ARBOR-ROCKER ARM
Install lubricated bolts into the cylinder head.
Verify that the arbor/rocker arm matching surfaces do
not show excessive wear or damage. NOTE: install in the same position that they came
out. There are three different length bolts used.
STEP 143
2
1

TIGHTENING SEQUENCE FOR CYLINDER HEAD BOLTS
Verify that the tappet adjusters are unscrewed to F4GE ENGINES
prevent the tappet from crawling on the rods when Pre lubricated bolts
the rocker arm assembly (1) is mounted.
M12x1.75x70 mm- 3, 6, 11, 14.
Mount the rocker arm assembly made up of the
arbors and rocker arm support, then secure them to M12x1.75x140 mm- 1, 2, 7, 8, 9, 10, 15, 16, 17, 18.
the head WITHOUT tightening the bolts (2). M12x1.75x180 mm - 4, 5, 12, 13.
1st phase:
70 mm bolts- 45 to 55 Nm (33.2 to 40.6 pound-feet).
2nd phase:
90° ± 5°.
3rd phase:
Only for 140 and 180 mm long bolts.
An additional 90° ± 5°.
2-136 Issued 08-07 Bur 87630273 NA

ADJUSTING TAPPETS INSTALLING THE INJECTORS

STEP 145 STEP 146
2
1
1
2
3

Adjust the play between rocker arms and valves Mount a new seal ring (2) lubricated with clean
using allen wrench (1), box end wrench (3) and feeler engine oil and a new seal washer (3) on injector (1).
gauge (2). Mount the injectors on their seats on the cylinder
Correct play is: head, then tighten them to the following torque.
Intake valves- 0.2 to 0.3 mm 55 to 65 Nm (40.6 to 47.9 pound-feet).

(0.008 to 0.012 inches).
STEP 147
Exhaust valves-0.2 to 0.3 mm
(0.008 to 0.012 inches). 1
NOTE: On tier 3 engines, due to the additional lobe
for the Internal E.G.R., it is not possible to use the
valve clearance adjustment procedure that requires 4
adjusting the clearance of all the valves by
positioning the crankshaft 2 times only.
Each cylinder must be checked by taking it to the Top
Dead Center (TDC) at the end of compression stroke
and adjusting the clearance of both valves on the
cylinder. See procedure on page 2-157.
3 2
Mount the injector feeding pipe assembly (1). Mount
the pipes for fuel discharge (2) from injectors, by
using gaskets (4) and by tightening bolts (3).
87630273 NA Issued 08-07 Bur 2-137

STEP 148 INSTALLING EXHAUST MANIFOLD,

TURBOCHARGER
1
2 STEP 149
6
1
4 2
3

Mount the injection pump (2), injector feeding pipes BS06N371 Figure 2-282
(3), then secure brackets (1), (5), (6) fastening the
pipe assembly onto the cylinder head. • Install exhaust manifold (2).
Mount priming pump(4). Tighten to specified torque of:
M10 bolts- 37 to 49 Nm (27.3 to 36.1 pound-feet).
Torque spec for fuel pump:
• Install turbine (1).
Tighten to specified torque of:
M6 bolts- 9 to 11 Nm (6.6 to 8.1 pound-feet). M10 bolts- 37 to 49 Nm (27.3 to 36.1 pound-feet).
M6 nut- 9 to 11 Nm (6.6 to 8.1 pound-feet).
NOTE: Be sure and not turn the injector pump drive INSTALLING INTAKE MANIFOLD
shaft when installing injector pump. do not torque
STEP 150
injector pump bolts yet.
Injector pump drive shaft to be connected later.
1
6
2
3
4
5

APPLICATION FOR F4GE9454H AND F4GE9454J ENGINES
2-138 Issued 08-07 Bur 87630273 NA

STEP 152
1 A B
2
6
3 1
BS06N373 Figure 2-284 1

APPLICATION FOR F4GE9484D ENGINES
The intake manifold is made up of manifold (5) on the
Press the clamp (1) in direction of arrow (figure B)
cylinder head, cover (6), seal gaskets (2) and (4),
and connect the pipe.
grid heater (3) and elbow (1).
Reset the clamp to the initial locking position (A).
Apply Loctite 5205 sealant between cover (6) and
intake manifold (5), then tighten the bolts to the STEP 153
specified torque.
M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet)
STEP 151
12 1 2 3
4
1
11 5
10 6
9 7
Assemble the wire harness (1).
8

• Install valve covers (12).
• Install the grid heater (2).
• Install intake manifold elbow (1).
• Install grid heater control unit (11).
• Install fuel filter bracket (10).
• Install fuel filter (7).
• Attach quick coupling pipes (5,6,9) by following
installation in figure 2-199.
• Install electric wiring (8)
• Install L.D.A. system piping (4)
• Install engine oil vapor recovery pipe to blow-by
(3).
87630273 NA Issued 08-07 Bur 2-139

STEP 154 STEP 156
1
1 2
2
4
3

• Install turbine lubricating oil return piping (1) and Figure 2-290
BS06N380
fastening bracket (4). Install fan pulley (2) on support (1) tighten bolts (3) to
specified torque.
• Install turbine lubricating oil delivery pipe and
engine oil pipes to water/oil cooler (2). M6 bolts- 8 to 12 Nm (5.9 to 8.8 pound-feet)
• Install the starter motor tighten bolts to specified M10 bolts- 37 to 49 Nm (27.3 to 36.1 pound-feet)
torque.
STEP 157
STEP 155 1
2
1 2
3
3
4
6 4
5
6
5
Install Polly-V belt (3) on pulley (4) crankshaft pulley,
guide pulley (6), water pump (5) and on the alternator
• Install the thermostat housing (1) to the cylinder (2). Then loosen the automatic belt tensioner (2) and
head (5) and tighten bolts (6) to specified torque. release onto the belt.
M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet)
• Install water temperature sensor (2) and tighten to
specified torque.
• Install the fan pulley support (3) on the head (5) by
means of bolt (4), and tighten to specified torque.
2-140 Issued 08-07 Bur 87630273 NA

INJECTION PUMP TIMING STEP 160

The following two steps (step 158, 159) are two ways
of finding Top Dead Center (TDC)
STEP 158
1
1
2 Tighten the already installed lock washer and nut (1)

on the back side of the injector pump drive shaft.
Tighten to specified torque.
BS06N305 Figure 2-292 1st phase- 15 to 20 Nm (11 to 14.8 pound-feet)
SEARCHING FOR TDC WITH GEAR BLOCKING PIN 2nd phase- 90 to 95 Nm (66 to 70 pound-feet)
Turn the flywheel until, the pin (1) can be inserted
NOTE: Make sure that the injector pump drive shaft
into the gear (2). This will put the engine at Top Dead
does not move when tightening the nut.
Center (TDC) of the number 1 cylinder.
WARNING: Be careful not to drop the nut and
washer inside engine.
STEP 159
STEP 161
A B
1
2
1

BS07C720 Figure 2-293 Apply Loctite 5205 sealant (1) as shown in figure (A).
FINDING TDC WITH FALSE INJECTOR Then install the cover (2) and tighten bolts to
specified torque.
Remove the rocker cover from the number one
cylinder, remove the number one injector and place M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet).
dial indicator (1) to set the number one cylinder to
TDC (end of compression stroke). Pre-load the dial
indicator.
Rotate engine until you find the maximum value on
the dial indicator, and then check that both the intake
and exhaust valves are closed (both exhaust and
intake pushrods should be loose).
Once TDC has been obtained lock the flywheel with
acceptable tool to prevent engine from turning.
87630273 NA Issued 08-07 Bur 2-141

STEP 162 STEP 163
1 2

Loosen bolt (2) that prevents pump shaft rotation and BS07C721 Figure 2-297
insert spacer (1). Tighten bolt (2) so it locks spacer • Locate the timing plug at the center of the four
(1), now the injection pump drive shaft will be able to injection lines and remove it with a 12mm socket.
rotate freely. Disengage flywheel locking pin see, • Install adapter (1) CAS2458 and insert dial
step 158 on page 2-141. indicator (2) into the timing hole.
• Preload the gauge approximately 2.5 mm.
• Turn the engine counterclockwise from TDC until
dial indicator needle stops moving.
• Turn the engine clockwise until the TDC is
reached again.
• Note the timing prelift shown on the gauge.
The timing prelift specification is:
0.95 to 1.10 mm (0.037 to 0.043 inches)
STEP 164
If the pre-lift timing meets specification then tighten
the nuts to the following torque specification:
NOTE: Use a 38 mm (15 inches) socket extension
minimum to tighten the back bolt so that the gauge
reading will not be altered.
STEP 165
Remove dial indicator and adaptor, install timing plug
cap.
STEP 166
If timing prelift is out of specification, do the following
procedures.
2-142 Issued 08-07 Bur 87630273 NA

STEP 167 STEP 174

With engine at TDC and dial indicator installed. Make
sure the three nuts that secure pump to housing are
still loose.
STEP 168
Rotate the pump in a counter clockwise direction if
the stroke is shorter or in a clockwise direction if the
stroke is longer. 1
STEP 169
When proper prelift is obtained, tighten the mounting
nuts to the following torque specification:
20 to 30 Nm (14.8 to 22.1 pound-feet) BD04A025-01 Figure 2-299
Attach Special Tool 380000979 (1) to the injection
NOTE: Use a 38 cm (15 inches) socket extension
pump drive gear and loosen the nut and lock washer.
minimum to tighten the back bolt so that the gauge
reading will not be altered. STEP 175
STEP 170 Turn the engine back to TDC (Top Dead Center).
NOTE: If the timing prelift can not be achieved by STEP 176

rotating the pump do the following procedures.
STEP 171
Make sure the pump housing nuts are tight.
STEP 172
1
Turn the engine over until the prelift reads,
1.00 to 1.10 mm (0.039 to 0.043 inches)
STEP 173

Tighten the lock washer and nut (1) to the back side
of the injector pump drive shaft, to specified torque.
1 2 1st phase- 15 to 20 Nm (11 to 14.8 pound-feet)
2nd phase- 90 to 95 Nm (66 to 70 pound-feet)
NOTE: Make sure that the injector pump drive shaft
does not move when tightening the nut.
WARNING: Be careful not to drop the nut and
washer inside engine.
Lock the injection pump by removing the slotted plate
(1) and tightening the bolt (2).
87630273 NA Issued 08-07 Bur 2-143

STEP 177 REPLACING THE INJECTORS

A B REMOVAL
2 STEP 1
1
2 3
1
BS06N317 Figure 2-301 4

Apply Loctite 5205 sealant (1) as shown in figure (A).
Then install the cover (2) and tighten bolts to
specified torque.
Lift engine compar tment cover, disconnect the
STEP 178 battery cables and proceed as follows:
Verify that the pump prelift is within specifications:

• Disconnect engine oil vapor recovery pipe (1) from
blow-by.
0.95 to 1.10 mm (0.037 to 0.043 inches).
• Take off tappet cover (3) by removing nut (2).
STEP 179 • Disconnect the fuel manifold pipes from injectors
Remove dial indicator and adaptor. Install timing plug (4).
cap back on injection pump.
NOTE: Always replace tappet cover gaskets during
assembly
STEP 2
2
Remove injectors (2) with Special Tool 380000671
(1) and take out of the cylinder head.
2-144 Issued 08-07 Bur 87630273 NA

REASSEMBLING ROCKER ARM REMOVAL / ASSEMBLY

STEP 3
REMOVAL
STEP 1
1
2
1 3

Install a new seal ring (2) lubricated with clean
engine oil on the injector. BS06N345 Figure 2-306
Install injector, verify that the locator pin (1) is Loosen tappet adjuster fastening nuts (3), then
correctly positioned in the cylinder head. unscrew adjusters (2).
Tighten the injectors to the specified torque: Remove bolts (4) and remove rocker arm assembly
55 to 65 Nm (40.6 to 47.9 pound-feet). (1) made up of the rocker arm support and arbors,
then remove valves.
STEP 4
ASSEMBLY
1 Verify that the tappet adjusters are unscrewed to
2
prevent tappets from crawling on the push rods when
the rocker arm assembly is installed.
Mount the rocker arm assemblies made up of rocker
arm support and arbors, then secure them to the
cylinder head by tightening bolts to the specified
torque.
Rocker arm fastening bolts:
M8 bolts- 36 Nm (26.5 pound-feet).

• Mount new seal rings (2) on fuel manifolds (1).
• Connect the manifolds to the injectors, by
tightening the tightening nuts to specified torque
of:
50 Nm (37 pound-feet).
• Re-connect the engine oil vapor recovery pipe to
the blow-by.
87630273 NA Issued 08-07 Bur 2-145

ADJUSTING TAPPETS
STEP 2
3
1

Adjust the play between rocker arms and valves
using allen wrench (1), box end wrench (2) and feeler
gauge (3).
Correct play is:
Intake valves- 0.2 to 0.3 mm
(0.008 to 0.012 inches).
Exhaust valves-0.2 to 0.3 mm
(0.008 to 0.012 inches).

valve clearance adjustment procedure that requires
cylinder. See procedure on page 2-157.
2-146 Issued 08-07 Bur 87630273 NA

CYLINDER HEAD ASSEMBLY - F4HE ENGINES

STEP 1 STEP 3
1 3
1 3
2
2
4
5

BS06K350 Figure 2-308 Insert the power take-off (4) equipped with the gasket
Install the high pressure pump (4) including the feed (2) the cover (1) and its gasket (2).
pump (5) and tighten the nuts to the specified torque. Tighten the bolts (3) to the general bolt torque
M8 nuts- 20 to 28 Nm (14.8 to 20.7 pound-feet) specifications.
Install the support (3) with a new sealing ring, the
timing sensor (2) with a new sealing ring and tighten REMOVING THE VALVES
the fastening nut (1), to specified torque. STEP 4
M6 nut- 6 to 10 Nm (4.4 to 7.4 pound-feet)
A
STEP 2 1
2
1
3
B
Intake (1) and exhaust (2) valves have heads with the
same diameter.
BS06K351 Figure 2-309 The central notch (→) of the exhaust valve (2) head
Install the EDC7UC31 electronic control unit (3) distinguishes it from the intake valve.
including the heat exchanger to the engine block and
tighten the bolts (2), to: IMPORTANT: Should cylinder head valves not be
replaced, number them before removing in order to
M6 bolts- 8 to 12 Nm (5.9 to 8.9 pound-feet). install them in the same position.
M8 bolts- 20 to 28 Nm (14.8 to 20.7 pound-feet). A = Intake side B = Exhaust side
IMPORTANT: Replace the vibration damper
elements (1) if they are cracked or excessively
deformed.
87630273 NA Issued 08-07 Bur 2-147

STEP 5 CHECKING CYLINDER HEAD WATER SEAL
STEP 7
2
1
3
1
Va l ve s c a n b e r e m o ve d w i t h a va l ve s p r i n g C h e ck t h e wa t e r s e a l by m e a n s o f s u i t a bl e
compressor tool (1) by pressing slightly on collar (3) equipment.
so that lock cones (2) can be removed by
compressing springs (4). Use pump to feed water heated to 90° C (194° F) at a
pressure of 2 to 3 bar (29 to 43 psi.)
Then remove collar (3) and springs (4).
If leaks are detected from the freeze plugs, they must
Repeat the operation on all valves. be replaced by using a suitable tool for removal and
Turn the head upside down and remove the valves reassembling operations.
(5).
IMPORTANT: Prior to installing the freeze plugs,
STEP 6 apply water repellent sealant to them.
If leaks are detected from the cylinder head, the
cylinder head must be replaced.
2
CHECKING CYLINDER HEAD MATING SURFACE
STEP 8
1 2
3
Remove the sealing rings (1 and 2) from the valve
guides.
IMPORTANT: Sealing rings (1) for intake valves are 1
yellow.
Sealing rings (2) for exhaust valves are green. BS06K356 Figure 2-315
The plane of the supporting surface of the head (1) to
cylinder cluster is checked by means of a straight
edge (2) and a thickness gauge (3).
The warping found on the entire length of the cylinder
head must not be greater than 0.20mm (0.008
inches).
If greater values are found, reface the cylinder head
according to values given in the next step.
2-148 Issued 08-07 Bur 87630273 NA

STEP 9 VALVE CLEANING, CHECKS AND GRINDING
STEP 10

The rated thickness "A" of the cylinder head is 105 ±
0.25mm (4.134 ± 0.0099 inches). Maximum allowed
metal removal must not exceed thickness "B" by Remove the carbon deposits from the valves by
0.13 mm (0.005 inches). means of a special metal brush.
Verify that the valves do not show traces of seizing,
IMPORTANT: After grinding, check valve sinking.
scoring or cracking.
Regrind the valve seats if necessary, to obtain the
specified value Reface if necessary the valve seats by grinding,
removing as little material as necessary.
VALVES STEP 11

INTAKE AND EXHAUST VALVE MAIN DATA

Use a micrometer (2) to measure valve stem (1),
which must be equal to 6.97 to 6.99 mm
(0.2744 to 0.2751 inches)
87630273 NA Issued 08-07 Bur 2-149

CHECKING VALVE GUIDE WEAR VALVE SEATS- REGRINDING, REPLACING
STEP 12 STEP 14
1
2

Use a magnetic dial indicator (1) placed as shown. BS06K363 Figure 2-322
Assembly play must be equal to 0.052 to 0.092 mm Check valve seats (2). If slight scoring or burrs are
(0.0020 to 0.0036 inches) found, regrind seats with tool (1) according to the
Turn valve (2) and check that the centering error is angle values shown on page 2-151 figure 2-321.
not exceeding 0.03 mm (0.0011 inches)
VALVE GUIDES
STEP 13

Use a bore gauge to measure the valve guide inner
diameter, which must be equal to 7.042 to 7.062 mm
(0.2772 to 0.2780 inches).
2-150 Issued 08-07 Bur 87630273 NA


MAIN DATA ON VALVE SEATS ON CYLINDER HEAD F4HE ENGINES

MAIN DATA ON VALVE SEATS
If the valve seats cannot be reseated, just by Recondition the valve seats with tool (1 in step 14)
grinding, replace them with replacement parts. By according to the values shown on page 2-151 figure
using tool (1, in step 14) to remove as much material 2-321 .
as possible from the valve seats (taking care not to
damage the cylinder head) until they can be WARNING: Always wear heat protective
extracted from the cylinder head using a punch. gloves to prevent burning your hands when handling
Heat the cylinder head to 80° to 100° C heated parts.
(176° to 212° F) and using the proper beater, install
the new valve seats (previously cooled) into the SM121A
heated cylinder head.
87630273 NA Issued 08-07 Bur 2-151

STEP 15
2
3

After the reconditioning operations, verify by means
of a base (2) and dial indicator (1), that the valve
recess (3) corresponds to the specified value.
2-152 Issued 08-07 Bur 87630273 NA

VALVE SPRINGS
STEP 16

MAIN DATA FOR INTAKE AND EXHAUST VALVE SPRING CHECK
Height Under a force of

mm/ inches N/ pound-force (lbf)
H 47.75 (1.88 inches) Free
H1 35.33 (1.39 inches) P 339.8 ± 19 N (76.2 ± 4.27 lbf.)
H2 25.20 (0.992 inches) P2 741 ± 39 N (166.6 ± 8.77 lbf.)
INSTALLING CYLINDER HEAD STEP 18
STEP 17
1 2
3 3
1
2
4

Position spring (4) and upper collar (3) on the
cylinder head. Use tool (1) to compress spring (4)
Figure 2-327
and lock the parts to the valve by means of lock
Lubricate the valve stem (1) and insert into the cones (2).
respective valve guide according to the position
marked when disassembling.
Install seal rings (2 and 3) into the valve guide.
IMPORTANT: Seal rings (2) for intake valves are
yellow. Seal rings (3) for exhaust valves are green.
87630273 NA Issued 08-07 Bur 2-153

FITTING CYLINDER HEAD STEP 21
STEP 19

Cylinder head fastening bolt tightening sequence:
BS06K370 Figure 2-329 Pre lubricated bolts
Verify that the cylinder head and the engine block 1st phase:
mating surfaces are both clean.
130mm bolts- 30 to 40 Nm (22.1 to 29.5 pound-feet)
Take care not to damage the cylinder head gasket.
150 mm bolts- 50 to 60 Nm (36.9 to 44.3 pound-feet)
Set the cylinder head gasket (1) with the writing
2nd phase:
"TOP" (1) facing the head.
Angle tighten- 90° ±5°
The arrow shows the point where the gasket
thickness is given. 3rd phase:
IMPORTANT: Prior to reusing the cylinder head Angle tighten an additional- 90° ± 5°
fastening bolts, verify that they do not show traces of
wear, deformations or corrosion. If they do replace INSTALLING INJECTORS
them.
STEP 22
TORQUING CYLINDER HEAD
STEP 20
1
3
2
3 1 2
Install a new sealing ring (2) lubricated with vaseline
and a new sealing washer (3) on injector (1).
Install cylinder head (1), attach bolts (2) and tighten
them in three successive steps according to the
procedure in (step 21) on page 2-154.
2-154 Issued 08-07 Bur 87630273 NA

STEP 23 STEP 25
1 1
2
5 3
3 4
Install injectors (1) on the cylinder head seats, Install a new sealing ring (4) lubricated with vaseline
directed so that the fuel inlet hole (2) is facing the fuel on the fuel manifold (5) and install it into the cylinder
manifold seat (3) side head seat so that the positioning ball (3) is lined up
with the notch in the housing (2).
STEP 24
IMPORTANT: Disassembled fuel manifolds (5) must
not be reused, they need to be replaced with new
ones.
1 IMPORTANT: During this operation, the injector (1)
shall be moved so that the manifold (5) is properly
inserted into the fuel inlet hole.
STEP 26
2
1

Use Special Tool 380001099 (1) to install the injector
(2) into its seat.
Screw injector fastening bolts without tightening
them.
2 3
Use a torque wrench to tighten gradually and
alternating the injector fastening bolts (1) to:
1st stage- 7.7 - 9.3 Nm (5.7 - 6.9 lbf ft.).
2nd stage- 75° ± 5°
Screw the fastening nuts (2) on the fuel manifold (3)
without locking them.
Tighten the fuel manifold (3) fastening nuts (2) to
45 to 55 Nm (33.2 to 40.6 lbf ft.) of torque.
87630273 NA Issued 08-07 Bur 2-155

RODS AND TAPPETS STEP 28
STEP 27
A B

MAIN DATA OF ARBOR-ROCKER ARM
BS06K378 Figure 2-337 Check that shaft/rocker coupling surfaces are not
A. BAD PUSH ROD showing excessive wear or any damage.
B. GOOD PUSH ROD
Prior to inserting the pushrods, verify their conditions: STEP 29
• The push rods should not be distorted
• The ball seats in contact with the rocker arm 1
adjusting screw and tappet (arrows) must not show
traces of seizing or wear, otherwise they must be
replaced
• Intake and exhaust pushrods are identical and
therefore interchangeable.
ROCKER ARM ASSEMBLY
1 BS06K381 Figure 2-340

2 Install the push rods (2).
Position jumpers (1) on valves with marks (→) facing
3 the exhaust manifold.
4 4

PARTS MAKING UP THE ROCKER ARM ASSEMBLY
1. BOLTS
2. SUPPORT
3. ROCKER ARM
4. ARBOR
2-156 Issued 08-07 Bur 87630273 NA

STEP 30 LOCATING TOP DEAD CENTER (TDC)

1 IMPORTANT: Due to the additional lobe for the
Internal EGR, each cylinder must cylinder must be
adjusted by taking it to the TDC. (top dead center)
2 and adjusting the clearance of both valves on every
cylinder.
3 STEP 31

Check tappet adjusters (1) that they are loose to
prevent their balking on the rods (2) when installing
the rocker assembly. 1
Then install the rocker assembly consisting of:
2
bracket (5), rockers (3), shafts (4), and secure them
to the cylinder head by tightening the fastening bolts BS06K345 Figure 2-342
(2) to the specified torque.
1. ENGINE BLOCK 2. TONE WHEEL
M8 bolts- 36 Nm (26.5 lbf ft.)
• Remove the injector from the number one
cylinder.
• Rotate engine over using Special Tool 380000988
to bring the number one cylinder to the highest
point using a dial indicator. Check to see if push
rods are loose, if they are not rotate the engine
360° now they should be loose.
• Put a reference mark on tone wheel (1) and the
engine block (2) this is (Cylinder 1).
STEP 32
Measure the circumference of the tone wheel and
divide by 2. Starting from the reference mark on tone
wheel put on in step 31. Put the other mark of the
calculated length on the tone wheel. Once these
marks are installed, adjust the corresponding
cylinder valves (Cylinder 1).
Rotate engine to the next mark, and adjust valves for
corresponding cylinder in firing order (Cylinder 3).
Next rotate engine to the next mark and adjust the
valves for the next cylinder in the firing order
(Cylinder 4). Repeat sequence for next cylinder
(Cylinder 2)
NOTE: Firing order is (1, 3, 4, 2)
NOTE: You will need to rotate the crankshaft two
complete rotations in order to adjust all the valves.
NOTE: Before adjusting make sure the valves on
each cylinder are loose. If they are not, you are on
the wrong cylinder
87630273 NA Issued 08-07 Bur 2-157

INSTALLING INTAKE MANIFOLD

STEP 34
ADJUSTING VALVE PLAY
STEP 33
3
1 1
2

Adjust the play between rocker arms and valves Apply Loctite 5999 to the contact surfaces of intake
using allen wrench (1), box end wrench (2) and feeler manifold (1) and install the intake manifold and grid
gauge (3). heater (3) to the cylinder head. Install air intake (2)
with a new gasket and tighten to general bolt torque
Correct play is: specifications.
Intake valves- 0.2 to 0.3 mm Tighten intake manifold bolts to:
(0.008 to 0.012 inches).
Exhaust valves- 0.45 to 0.55 mm
(0.018 to 0.022 inches). Tighten grid heater cover plate nuts to:
M6 nuts- 6 to 10 Nm (4.4 to 7.4 pound-feet).
valve clearance adjustment procedure that requires
cylinder.See page 2-157.
2-158 Issued 08-07 Bur 87630273 NA

INSTALLING FUEL SYSTEM STEP 37
STEP 35 3
1
4
2 1
3 2
4
5
Connect the fuel line (4) to rail (2) following the
BS06K385 Figure 2-345 procedure shown in the following figure (step 38).
Install the rail (2) and tighten the bolts (1) to the
IMPORTANT: Fuel line (4) connections shall be
general bolt torque specifications in the repair
tighten to 20 Nm (14.8 lb.-ft.) of torque, using the
manual. Connect the ground cable (3) to the intake
proper box wrench and the torque wrench
manifold (4) and tighten the fastening nut (5) to
380000158 (3).
20 to 30 Nm (14.8 to 22.1 lb.- ft.) of torque.
STEP 38
STEP 36
A B
1
2 1
1
Press the clamp (1) in arrow direction (Figure B) and
Connect new fuel lines (1) to rail (3) and injector connect the line to the rail, reset the clamp to the
manifolds (2). initial locking position (Figure A).
IMPORTANT: When fuel lines (1) are removed they IMPORTANT: Check for proper fuel line connection.
should always be replaced with new ones
87630273 NA Issued 08-07 Bur 2-159

INJECTOR WIRING STEP 41
STEP 39
1 4
1 2
2
5 4 3 BS06K391 Figure 2-351

BS06K389 Figure 2-349 Connect the electrical cables (1) to the injectors (3)
and use Special Tool 380000158 torque wrench (4)
Check wir ing cable (2) condition, replace it if
to tighten the fastening nuts (2) to the general bolt
damaged, by cutting the support (5) clamps and
torque specifications in the repair manual.
removing the bolts (3) that secure it to connectors
(4). Install a new gasket (1) on the support (5).
STEP 40

Install the wiring support (2) and tighten the bolts (1)
to the general bolt torque specifications in the repair
manual.
2-160 Issued 08-07 Bur 87630273 NA

INSTALLING TAPPET COVER STEP 44
STEP 42
1 2
2
Install the tappet cover (1) and tighten the nuts (2) to
20 to 30 Nm (14.8 to 22.1 lb.-ft.) the specified torque.
Install a new gasket (2) on the tappet cover (1).
EXHAUST MANIFOLD / TURBO INSTALLATION
STEP 43
STEP 45
2
1
1 4
BS07G387 Figure 2-353 3

1. BLOW-BY FILTER

Re-attach exhaust manifold (3) with new gaskets.
Install bolts and tighten them to:
2 Re-attach turbo-charger (1) to exhaust collector, with
a new gasket and tighten nuts to:
M8 nuts- 20 to 30 Nm (14.8 to 22.1 pound-feet).
Connect the oil pipeline (4) to the support of the heat
exchanger. Attach the oil line to the line fitting on the
turbocharger (2) tighten nut to:
BS07G388 Figure 2-354
M12 nut- 8 to 12 Nm (5.9 to 8.9 pound-feet).
2. CHECK VALVE INSTALLED IN THE BLOW-BY FILTER
Make sure the check valve (2) is installed in the blow-
by filter (1) located in the tappet cover. If not replace
the filter.
87630273 NA Issued 08-07 Bur 2-161

STEP 46 STARTER INSTALLATION
1 STEP 48
2
6 1
3
2
4
5 3
4
5
If present, insert the blow-by filter (4) tightening the
bolts to the general bolt torque specifications.
Connect the line (2) and attach the oil vapor recovery BS06K399 Figure 2-359
line with clamp (3). Install the starter (5) to the flywheel housing (4) and
Connect the line (6) to the pressure-limiter device (1) tighten the bolts to:
by the figure below (step 46). 37 to 49 Nm (27.3 to 36.1 pound-feet).
Install the oil line (3) with a new sealing ring into the
STEP 47
engine block and secure it to the turbo charger (1) by
the bolts (2) and tighten to
A B
1 FUEL FILTER BRACKET INSTALLATION
STEP 49
1
1 2
Press the clamp (1) in arrow direction (Figure B) and
connect the line. Reset the clamp to the initial locking
position (Figure A). 3
IMPORTANT: Check for proper fuel line connection.

Install the bracket (2) including the fuel filter bracket
(1) to the engine block, tighten bolts (3) to:
2-162 Issued 08-07 Bur 87630273 NA

WIRING HARNESS CONNECTIONS TO THE ENGINE- F4HE ENGINES
STEP 50
1
6
2
3
8
4
9
10
11
5
9. FUEL HEATER AND TEMP

1. CONNECTIONS FOR ELECTRO-INJECTORS 5. CRANKSHAFT SENSOR
SENSOR
2. ENGINE COOLANT TEMPERATURE
6. ELECTRO-INJECTOR 10. HIGH PRESSURE REGULATOR
SENSOR
7. BOOST TEMPERATURE AND
3. COMMON RAIL FUEL PRESSURE SENSOR 11. EDC7UC31 CONTROL UNIT
PRESSURE SENSOR
4. OIL TEMPERATURE-PRESSURE SENSOR 8. CAMSHAFT SENSOR
Re-attach engine cable by connecting electro- Apply rocker lever to engine lifting hooks, hook the
injectors (6) wiring connectors (1), boost pressure/ rocker lever to a hoist and detach the engine from
temperature sensor (7), common rail pressure rotating stand. Remove brackets.
sensor (3), EDC7UC31 electronic control unit (11),
high pressure pump sensor (10), camshaft sensor
(8), engine coolant temperature sensor on
thermostat (2), crankshaft sensor (5).
87630273 NA Issued 08-07 Bur 2-163

STEP 51 STEP 52
2 A B
1
1
5
1
4 BS06K388 Figure 2-363
3 Press the clamp (1) in arrow direction (Figure B) and
BS06K401 Figure 2-362 connect the line. Reset the clamp to the initial locking
position (Figure A).
By hand screw on the fuel filter (3) to the bracket (1).
Tighten the fuel filter 3/4 of a turn after the gasket NOTE: When installation is complete, fill engine with
makes contact with the bracket. Connect the fuel the proper lubricating oil.
lines (2, 4, 5) to the relevant support connections (1)
as shown in step 51.
2-164 Issued 08-07 Bur 87630273 NA

CHAPTER 3
445TA
TIER III
ELECTRICAL, CHARGING AND

START-UP
Issued 08-2007
CHAPTER 3 - ELECTRICAL, CHARGING AND START-UP
Revision History
F4GE9454H, F4GE9454J, F4GE9484D
First Edition 08-2007 87630273 NA
F4HE9484A, F4HE9484C
3-II Issued 04-07 Bur 87630273 NA

CHAPTER 3
ELECTRICAL, CHARGING AND START-UP
TABLE OF CONTENTS
LOCATION OF THE MAIN ELECTRICAL COMPONENTS FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . 3-3

Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Rotary Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
KSB Water Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Grid Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
EDC7UC31 Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cabling Connector Pinout On Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Connector (A) Injectors Pinout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connector (C) Sensors Pinout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Crankshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Camshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Boost Temperature - Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Engine Oil Temperature - Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Common Rail Fuel Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Intake Air Pre-post Resistance Heater And Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
High Pressure Pump - Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Quick Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Quick Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
87630273 NA Issued 08-07 Bur 3-1

NOTES
3-2 Issued 08-07 Bur 87630273 NA

LOCATION OF MAIN ELECTRICAL COMPONENTS - F4GE ENGINES
1 2 3
7 B
4
BS07C722 Figure 3-1
Below are listed the electrical components which are present on F4GE9454H, F4GE9454J, F4GE9484D engines.
1. STARTER 4. OIL PRESSURE SENSOR
2. KKSB- WATER TEMPERATURE SENSOR 5. GRID HEATER- (FOR COLD START UP)
3. ELECTROMAGNETS ASSEMBLED TO INJECTION PUMP 6. ALTERNATOR
(A)- ON HYDRAULIC HEAD UNIT 7. COOLANT TEMPERATURE SENSOR
(B)- ON KSB
87630273 NA Issued 08-07 Bur 3-3

COOLANT TEMPERATURE SENSOR ROTARY INJECTION PUMP
2
BS07C726 Figure 3-3
1. Hydraulic head Electro-magnet.
2. KKSB Electro-magnet.
C
Cold start advance system (KKSB)
A B When engine is cold (coolant temp. is below 50° C
122° F), the injection pump is in timing advanced
B C state. When engine reaches 60 to 66° C (140 to
A
151°F), the thermo switch in the cylinder head opens
BS07C723 Figure 3-2 and the system voltage is no longer sent to the
Coolant temperature sensor is installed on the solenoid on the injection pump. This allows the timing
engine cylinder head close to the thermostat unit, it to retard to "normal" operating position.
detects engine coolant temperature.
Specifications: KKSB WATER TEMPERATURE SENSOR
Range of working temperatures:

Connection side: -40 to +150 °C for < 10 minutes.
-40 to +302 °F for < 10 minutes.
Bulb side on engine: -40 to +140 °C
-40 to + 284 °F
Working voltages: 6 to 28 volts
Resistance readings at temperatures:
80 °C (176 °F)- 304 to 342 Ohms.
20 °C (68 °F)- 2262 to 2760 Ohms.
-10 °C (14 °F)- 8244 to 10661 Ohms.
BS07C725 Figure 3-4

KKSB water temperature sensor is installed on the
cylinder head on the left hand side of the engine.
Specifications:
Working voltage 12 to 24 volts
Electrical power load:
3-4 Issued 08-07 Bur 87630273 NA

OIL PRESSURE SENSOR GRID HEATER
BS07C729 Figure 3-6

BS07C727 Figure 3-5 Grid heater is a resistor installed in the intake
Oil pressure sensor is installed to the engine manifold. It is used to heat the intake air during cold
crankcase on the engines left hand side. weather starting.
The grid heater is controlled by the grid heater
Specifications: control unit located very close to the engine. Which is
activated when temperature is below 5° C (41° F)
Working voltage: 12 to 24 volts
Contact closure
Specifications:
Upon lower pressure: 0.2 bar (2.9 psi)
Working voltage: depending on equipment
Contact opening 12 volt or 24 volt.
Upon higher pressure: 0.9 bar (13 psi)
Maximum air flow: 2cc / min
Pressure: 138 kPa (20 psi)
Impedance : Approximately 0.5 Ohm.
87630273 NA Issued 08-07 Bur 3-5

LOCATION OF MAIN ELECTRICAL COMPONENTS - F4HE ENGINES
3
1 2 4
12
11
9 8 7
10
BS06K072 Figure 3-7
Below are listed the electrical components which are present on F4HE9484A / F4HE9484C engines.
1. COOLANT TEMPERATURE SENSOR 7. SOLENOID VALVE FOR PRESSURE REGULATOR
2. ELECTRO-INJECTOR 8. FUEL TEMPERATURE SENSOR
3. FUEL RAIL PRESSURE SENSOR 9. EDC7UC31 ELECTRONIC CONTROL UNIT
4. BOOST TEMPERATURE/PRESSURE SENSOR 10. CRANKSHAFT SENSOR
5. STARTER MOTOR 11. ENGINE OIL PRESSURE/TEMPERATURE SENSOR
6. CAMSHAFT SENSOR 12. HEATING ELEMENT FOR PRE-POST HEATING
T h e e n g i n e i s c o n t r o l l e d by t h e E D C 7 U C 3 1 Through the engine control module, it is possible to

electronic control module. The control module is verify the correct operations of the engine and also
installed on flexible mounts to reduce vibration help troubleshoot problems with error codes
transmitted by the engine. The fuel heat exchanger generated from the EDC7UC31 control module.
removes heat from the controller due to the high
voltages needed for firing the injectors. It removes
the heat from the controller and loses it in the fuel
cooler. It also picks up some engine heat when it is
returned from the cylinder head. The unit is supplied
with a 20 amp fuse. The main relay used to supply
the power to the system is located inside the control
unit.
3-6 Issued 08-07 Bur 87630273 NA

EDC7UC31 ELECTRONIC CONTROL UNIT
C A
BS06K073 Figure 3-8

EDC7UC31 ELECTRONIC CONTROL UNIT
A. CONNECTOR TO INJECTORS
B. CONNECTOR FOR POWER INPUT AND FUNCTIONS PROVIDED FOR IN THE APPLICATION
C. CONNECTOR TO SENSORS
NOTE: Ensure you replace the electronic control unit

(EDC7UC31) with the correct model. The previous
controller model EDC7 has similar connectors but
with different wiring.
87630273 NA Issued 08-07 Bur 3-7

CABLING CONNECTOR PINOUT ON ENGINE
C A
10 1
9 2
7
3
6
BS07D157 Figure 3-9

CONNECTOR / CABLING DIAGRAM
A. CONNECTOR A (INJECTORS) EDC7UC31 ECU (POWER) 5. OIL PRESSURE AND TEMPERATURE SENSOR
B. CONNECTOR B NOT SHOWN (SEE NOTE BELOW) 6. FUEL TEMPERATURE
C. CONNECTOR C (SENSORS) EDC7UC31 ECU (SIGNAL) 7. COOLANT TEMPERATURE SENSOR
1. INJECTORS FOR CYLINDERS 1-2 8. BOOST AIR TEMPERATURE AND PRESSURE SENSOR
2. INJECTORS FOR CYLINDERS 3-4 9. COMMON RAIL PRESSURE SENSOR
3. CRANKSHAFT SENSOR 10. FUEL HIGH PRESSURE REGULATOR SENSOR
4. CAMSHAFT SENSOR
NOTE: Connector B is not shown because it is specific to the machine application see the particular machine
schematic.
3-8 Issued 08-07 Bur 87630273 NA

CONNECTOR (A) INJECTORS PINOUT DIAGRAM CONNECTOR (C) SENSORS PINOUT DIAGRAM
EDC7UC31 EDC7UC31
FUNCTION FUNCTION
ECU PIN ECU PIN
1. Not Used 1. Not Used
3. Cylinder 4 injector 3. Not Used
9. High pressure regulator with fuel metering 9. Camshaft speed sensor - Signal
10. High pressure regulator with fuel metering 10. Camshaft speed sensor - Ground
12. Cylinder 3 injector 12. Common rail temperature and pressure
13. Cylinder 1 injector sensor - Ground
14. Cylinder 4 injector 13. Common rail temperature and pressure

sensor - Positive
15. Not Used
14. Common rail temperature and pressure
16. Not Used sensor - Signal
15. Coolant temperature sensor - Signal
16. Not Used
NOTE: Connector B is not shown because it is 17. Not Used
specific to the machine application see the particular 18. Fuel temperature sensor - Signal
machine schematic. 19. Crankshaft speed sensor - Ground
20. Not Used
21. Not Used
22. Not Used
23. Crankshaft speed sensor - Signal
24. Engine oil pressure and temperature sensor -
Ground
25. Boost intake pressure sensor - Ground
26. Coolant temperature sensor - Ground
27. Oil pressure sensor - Signal
28. Oil temperature sensor- Signal
29. Not Used
30. Not Used
31. Not Used
32. Engine oil pressure and temperature sensor -
Positive
33. Boost intake pressure sensor - Positive
34. Boost intake pressure sensor - Signal
35. Fuel temperature sensor - Signal
36. Boost intake temperature sensor - Signal
87630273 NA Issued 08-07 Bur 3-9

CRANKSHAFT SENSOR

CRANKSHAFT SENSOR
The crankshaft sensor is an inductive sensor located The crankshaft sensor is connected to the
at the front left hand side of the engine. The EDC -7 control unit on pins 19C - 23C. The sensor
crankshaft sensor produces signals obtained from impedance is approximately 900 Ohms.
magnetic flux field through the openings in a phonic
wheel fitted on the crankshaft.
CAMSHAFT SENSOR
3 2 1
1
B C 2
A. CAMSHAFT SENSOR B. CONNECTOR C. WIRING DIAGRAM
EDC7UC31 ECU
Reference Description
Crankshaft sensor Camshaft sensor
1 Signal 19C 10C
2 Signal 23C 9C
3 Shield
3-10 Issued 08-07 Bur 87630273 NA

BOOST TEMPERATURE - PRESSURE SENSOR

This component incorporates a temperature sensor
and a pressure sensor all in one unit.
I n s t a l l e d o n t h e i n t a ke m a n i fo l d , t h e s e n s o r
measures the temperature and boost pressure,
which serves to make an accurate calculation of the
quantity of fuel to be injected in each cycle.
The sensor is connected to the EDC7UC31
electronic control unit on pins 25C - 36C - 33C - 34C.
The sensor is supplied with 5 volts.
Voltage at the sensor output is proportional to the
detected pressure or temperature.
• Pin 25C - 36C Temperature
• Pin 33C - 34C Pressure
ENGINE OIL TEMPERATURE - PRESSURE
SENSOR PRESSURE - TEMPERATURE SENSOR
This component incorporates a temperature sensor
and a pressure sensor all in one unit. 1 2 3 4
The engine oil temperature-pressure sensor is
installed on the engine oil filter bracket in a vertical
position. This sensor measures the engine oil
temperature and pressure.
The sensor is connected to the EDC7UC31
electronic control unit on pins 24C - 28C - 32C - 27C.
The sensor is supplied with 5 volts. The pressure
signal is transmitted to the EDC7UC31 electronic
control unit which in turn, sends a signal to the
instrument panel gauge and low pressure warning
light.
The oil temperature is not displayed on any gauges
this value is used exclusively by the control unit. BS06K078 Figure 3-13
Pin 24C - 28C Temperature
Pin 32C - 27C Pressure
EDC7UC31 Control unit pin number

Oil Air
1 Ground 24C 25C
EDC7UC31 control unit- Signal
2 28C 36C
(temperature)
3 +5 volt power supplied to sensor 32C 33C
4 Signal (pressure) 27C 34C
87630273 NA Issued 08-07 Bur 3-11

COMMON RAIL FUEL PRESSURE SENSOR
2
1 3

COMMON RAIL FUEL PRESSURE SENSOR CONNECTOR
Reference Description EDC7UC31 control unit pin

1 Ground 12C
2 Signal 14C
3 Power supply 13C
The fuel rail pressure sensor is installed on one end This sensor is connected to the EDC7UC31 control
of the common rail, this sensor measures the internal unit on pins 12C - 14C - 13C.
fuel pressure and feeds back this information to the The power supplied to sensor is 5 volts.
EDC7UC31 control unit.
The injection pressure value is used as a pressure
control feedback signal and to determine the duration
of the electrical pulse for the injection command.
3-12 Issued 08-07 Bur 87630273 NA

ELECTRO-INJECTORS

INJECTOR WIRE HARNESS LAYOUT

INJECTOR WIRE HARNESS (NOTE 6 CYLINDER HARNESS SHOWN)
The electro-injectors are a normally Closed (N.C.) The impedance of the coil of each injector is 0.56 -
solenoid valve. 0.57 Ohms.
Each injector is connected to the EDC7UC31 control
unit on connector A.
EDC7UC31 control
unit pin
1 Cylinder 2 injector 11A
CONNECTOR 1
CONNECTOR 2
3 Cylinder 3injector 12A
87630273 NA Issued 08-07 Bur 3-13

GRID HEATER AND CONTROL RELAY

A

GRID PLATE HEATER CONTROL RELAY
The control relay is connected to the EDC7UC31
control unit B connector.
GRID PLATE HEATER T h e r e l ay i s t r i p p e d w h e n wa t e r a n d o r f u e l
The pre-post grid plate heater is located on the temperature below 5° C (41° F).
intake manifold. The relay impedance is approximately 15 Ohms.
The purpose of the grid plate heater is to heat the air
in pre-post heating operations. The grid plate heater
is powered by a relay on the chassis.
The impedance of the grid plate heater is
approximately 0.5 Ohm.
WARNING: Starting fluids or aids, such as

ether, must not be used to help start this
engine. The use of these starting fluids or
aids will cause severe internal damage to the
engine and can also cause personal injury.
50-41
3-14 Issued 08-07 Bur 87630273 NA

COOLANT TEMPERATURE SENSOR

COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is a variable
resistance sensor able to read the coolant
temperature in order to provide the EDC7UC31
control unit with an indication of the temperature
status of the engine.
The same signal is utilized by the control unit to drive
an instrument panel gauge, if present.
This sensor is connected to the EDC7UC31 control
unit on pins 15C - 26C.
Resistance readings at various temperatures for
sensor:
80 °C (176 °F)- 304 to 342 Ohms.
20 °C (68 °F)- 2262 to 2760 Ohms.
-10 °C (14 °F)- 8244 to 10661 Ohms.
87630273 NA Issued 08-07 Bur 3-15

FUEL TEMPERATURE SENSOR This sensor detects the fuel temperature so the
EDC7UC31 control unit can precisely inject the fuel
required.
The fuel temperature sensor is connected to the
EDC7UC31 control unit on pins 35C - 18C.
Resistance readings at various temperatures for
sensor:
80 °C (176 °F)- 304 to 342 Ohms.
20 °C (68 °F)- 2262 to 2760 Ohms.
-10 °C (14 °F)- 8244 to 10661 Ohms.
1

1. FUEL TEMPERATURE SENSOR
2. FILTER HEATER RELAY
1 2
FILTER HEATER RELAY
The EDC7UC31 control unit activates the filter heater relay when fuel temp drops below 5° C (41° F)
EDC7UC31 Control unit Pin

Coolant Fuel
1 Ground 15C 35C
2 Temperature Signal 26C 18C
3-16 Issued 08-07 Bur 87630273 NA

HIGH PRESSURE PUMP - PRESSURE REGULATOR

A. PRESSURE REGULATOR Delivery pressure to the common rail is modulated
The quantity of fuel supplied to the high pressure between 250 and 1600 bar (3626 and 23206 psi) by
pump is controlled by the supply pressure regulator the EDC7UC31 control unit by controlling the high
solenoid valve. The high pressure regulator is pressure regulator solenoid valve.
controlled by the EDC7UC31 control unit. • This component is a Normally Open solenoid
valve.
• The solenoid is connected to the EDC7UC31
control unit on pins 9A - 10A.
• The solenoid valve impedance is approximately
3.2 ohms.
87630273 NA Issued 08-07 Bur 3-17

STARTER MOTOR Starter is usually controlled by a switch on the vehicle

dashboard, which in turn energizes the solenoid
assembled to the starter.
Depending on equipment:
Manufacture- BOSCH - 24 Volt - 4kW
Manufacture- BOSCH - 12 Volt - 3kW
QUICK DIAGNOSIS
Fault Possible Causes Remedy

1. - Batteries run down Recharge or Replace
2. - Circuit connections oxidized or loose Clean or replace the component
3. - Brushes damaged or worn Replace defective component
Cranking power insufficient
4. - Short-circuit in field windings Replace defective component
5. -Open or short circuit in armature Replace defective component
6. - Out of round bushings Replace defective component
Cranking power sufficient, but
Starter bendix or solenoid
the engine won’t start Replace defective component
Bevelled ring gear or flywheel
Pinion won’t engage
3-18 Issued 08-07 Bur 87630273 NA

ALTERNATOR Alternator is installed on the front right side of the

engine and is driven by a belt.
Specifications:
Working voltage: Depending on equipment
12 volt or 24 volt.
Current delivered: 90 amps at 6000 rpm
Direction of rotation: Clockwise
QUICK DIAGNOSIS
Fault Possible causes Remedy

Check the recharge circuit connections. Clean and
1. Open in recharge circuit (warning light,
tighten the cable terminals on the alternator and
fuse, connector, etc.)
battery.
No charge 2. Voltage regulator not working Replace the component
3. Open rotor winding Replace the component
4. Worn brushes Replace the component
1. Loose belt Check automatic belt tensioner
2. Faulty voltage regulator Replace the component
Low charge 3. Excessive wear of rotor rings or brushes Replace the component
4. Short-circuited diodes Replace the component
5. Short-circuited rotor windings Replace the component
Check the connections to terminals and cable
1. Loose circuit connections
terminals of batteries, starter motor and alternator
Excessive charging
2. Voltage regulator not working Replace component
3. Faulty ground Check ground connections
87630273 NA Issued 08-07 Bur 3-19

NOTES
3-20 Issued 08-07 Bur 87630273 NA

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ENGINE REPAIR MANUAL

READ, UNDERSTAND, AND FOLLOW ALL SAFETY

Bur • Issued 01Aug07

This unit first became available 08-2007

ENGINE REPAIR MANUAL

87519803 NA Issued 08-07 Bur I

INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138

II Issued 08-07 Bur 87519803 NA

1-II Issued 04-07 Bur 87630273 NA

87630273 NA Issued 08-07 Bur 1-1

1-2 Issued 08-07 Bur 87630273 NA

Perform the checks described in the electrical

87630273 NA Issued 08-07 Bur 1-3

No Check for leaks, repair leaks and refill to

Fan working properly. No Replace.

Drive belts serviceable. No Replace.

Check for leaks, bad bearing, overhaul or

Thermostat working properly. No Replace.

Wash down, repair leaks and flush out

Openings for coolant flow within the cylinder

No Check and adjust for correct valve

Verify correct timing described in Chapter 2

Cylinder head gasket leaking. Yes Replace.

1-4 Issued 08-07 Bur 87630273 NA

ENGINE LACKS POWER AND RUNS ERRATICALLY

Fuel filters plugged. Yes Replace.

Air filter plugged. Yes Clean or replace filter.

Thermostat working properly. No Replace.

Verify correct timing described in Chapter 2

Fuel pump working properly. No Replace.

On common rail engines check using

Speed governor (in injection pump) in

87630273 NA Issued 08-07 Bur 1-5

Engine lacks power and runs erratically (continued)

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

Correct valve clearance. No Adjust clearance for proper value.

Check each cylinder for proper compression,

Turbocharger working properly. No Repair or replace unit.

1-6 Issued 08-07 Bur 87630273 NA

ENGINE EXHAUST SMOKE BLACK OR DARK GREY

Check using multi meter replace or repair.

Cold start solenoid (KKSB) working properly.

On common rail engines check using

Verify correct timing described in Chapter 2

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

87630273 NA Issued 08-07 Bur 1-7

Engine exhaust smoke black or dark grey (continued)

No Check the condition of pipes and replace

Check each cylinder for proper compression,

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

Check using multi meter replace or repair.

Possible flow of coolant into the combustion

On common rail engines check using

Verify correct timing described in Chapter 2

Clean the tank and replace the fuel filter.

ENGINE EXHAUST SMOKE LIGHT BLUE

Check: Cylinder compression, leaks into or

1-8 Issued 08-07 Bur 87630273 NA

ENGINE KNOCKS IRREGULARLY

Check the following items: Journal play and

Check the following items: Rod journal end

Check the following items: Play between the

Check the following items: Play between the