Beruflich Dokumente
Kultur Dokumente
3 SERIES
Industrial application
N45
N45 ENT.X - N45 MSS.X - N45 MNS.X
N45 MRT.X - N45 MST.X - N45 MNT.X
N67
N67 ENT.X - N67 ERT.X
N67 MST.X - N67 MRT.X - N67 MNT.X
Publication edited by
FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
N TIER 3 ENGINES
Introduction
Page
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . . . 7
SYMBOLS - Warnings
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
Example
Removal
Disconnection Intake
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly Compression ratio
Tolerance
Tighten to torque
Weight difference
Regulation Angle
Adjustment Angular value
Warning
! Preload
Note
Visual inspection
Number of revolutions
Fitting position check
Measurement
Value to find Temperature
Check
Equipment Pressure
bar
Oversized
Surface for machining
Higher than.
Machine finish
Maximum, peak
Undersized
Interference
Less than.
Strained assembly
Minimum
Selection
Thickness
Classes
Clearance
Oversizing
Lubrication Temperature < 0 C
Damp Cold
Grease Winter
Temperature > 0 C
Sealant
Hot
Adhesive
Summer
Air bleeding
GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to
! contact immediate superiors where a danger situation occurs which is not described.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and
on the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the co-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on
harmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes,
free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting
fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to
store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable
substances into suitable containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil
spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis
bonding) and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other
materials flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
! always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections,
which would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or
special truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of
cable side.
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding serial or chain connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
Figure 2
88039
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1
1 kg/cm2 = 1 bar.
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F
Part 1
F4HE N SERIES
Section
General specifications 1
Fuel 2
Industrial application 3
Tools 5
UPDATING
SECTION 1
General specifications
Page
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
To the
exchanger
and to the
turbo--
blower
6-cylinder engine version Also in this case, the components such as the oil exchanger,
Even for the 6 cylinders version lubrication is obtained by the turbo-blower and the eventual compressor are specifically
forced circulation and achieved through an oil rotary expan- studied and made out to suit the equipment or the duty for
sion pump similar to the 4 cylinders one. which the engine has been developed.
Figure 2 (Demonstration)
To the
exchanger
and to the
turbo--
blower
Introduction of oil
70484
Oil condensate
Oil vapours
Oil condensate
COOLING SYSTEM - Heat exchanger to cool the lubrication oil: even this
The engine cooling system, closed circuit forced circulation component is part of the engines specific equipment.
type, generally incorporates the following components: - Centrifugal water pump, placed in the front part of the
- Expansion tank; placement, shape and dimensions are engine block.
subject to change according to the engines equipment. - Thermostat regulating the circulation of the cooling liquid.
- Radiator, which has the duty to dissipate the heat - The circuit may eventually be extended to the
subtracted to the engine by the cooling liquid. Also this compressor, if this is included in the equipment.
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
- Viscous pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engines
development.
Expansion tank
Heater
(optional)
Radiator
Radiator
Figure 6 (Demonstration)
Expansion tank
Expansion
tank
Heater
(optional)
Radiator
Radiator
108513
Figure 7
4 Cylinders version
EXHAUST
RADIATOR
6 Cylinders version
EXHAUST
RADIATOR
74195
EXHAUST GAS RE-CIRCULATION SYSTEM The internal EGR system is not equipped with any
(EGR) electronically controlled elements: the system is always active.
In the TIER 3 version, the profile of the exhaust cam has been Its configuration does not need additional elements
modified in order to allow the partial opening of the relative i.e.checking valves, piping or heat exchangers.
valve during the aspiration phase (re-circulation of EGR The exhaust cam (B) has another lobe apart from the major
exhaust gas) with the subsequent re-introduction of part of lobe (see Section. A-A fig.) with respects to the configuration
the exhaust gas into the engine cylinders. without EGR.
The exhaust gases can partially be re-directed into the The additional lobe, during the aspiration phase in the cylinder
cylinders so as to reduce the maximum combustion in question, allows a brief opening of the exhaust valve
temperature values responsible for the production of nitric generating re-circulation due to the intake of the exhaust gases
acid (NOx). caused by depression which is created in the aspiration phase
The exhaust gas re-circulation system (EGR), reducing the inside the cylinder.
combustion temperature by means of the diminishing of the
concentration of oxygen in the combustion chamber,
represents therefore an efficient control system of the
emission of NOx .
Figure 8
114789
SECTION 2
Fuel
Page
- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Description of system . . . . . . . . . . . . . . . . . 3
- Electrical system . . . . . . . . . . . . . . . . . . . . . . 3
EDC 7 OPERATION . . . . . . . . . . . . . . . . . . . . . 5
WORKING PROCESS . . . . . . . . . . . . . . . . . . . . 6
- Jettison condition . . . . . . . . . . . . . . . . . . . . . 10
- Working principle . . . . . . . . . . . . . . . . . . . . 13
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . 16
- Injection start . . . . . . . . . . . . . . . . . . . . . . . . 16
- Injection end . . . . . . . . . . . . . . . . . . . . . . . . 16
HIGH PRESSURE ELECTRONIC INJECTION For engines more powerful than 152 kW, the CRIN2 injec-
SYSTEM (COMMON RAIL) tors have DLLA nozzles that work up to a pressure of 1600
Introduction bar, whilst for engines less powerful than 152 kW, DSLA
Extremely high injection pressures are necessary in order to nozzles are fitted which work a pressures up to 1450 bar.
reduce PARTICULATE emissions.
Description of system
The common rail system makes it possible to inject fuel at
pressures of up to 1450 - 1600 bar, while the injection preci- The injection system is composed of an electrical part and a
sion obtained by electronic control of the system serves to hydraulic part.
optimise operation of the engine while limiting emissions and
fuel consumption. Electrical system
The electronic control unit monitors engine control para-
meters by means of the various sensors on the engine.
4 cylinders version
Figure 1
108501
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engines cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engines oil temperature and pressure - 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and
air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor - 10. Pressure gauge cabling -
11. EDC 7 gearbox.
6 cylinders version
Figure 2
107851
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engines cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engines oil temperature and pressure - 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and
air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor - 10. Pressure gauge cabling -
11. EDC 7 gearbox.
WORKING PROCESS
4 Cylinders version
Figure 3
High Pressure
Low Pressure
Fuel outlet
158007
6 cylinders version
Figure 4
High Pressure
Low Pressure
Fuel outlet
158008
FUEL SYSTEM LAYOUT The pressure relief valve (2) intervention brings about a fuel
This fuel system is a Common Rail injection with CP3 high flow increase in the high-pressure pump cooling circuit,
pressure pump and this layout is for 4 cylinder version. through inlet and drain piping (16) from piping (8).
The pressure regulator, placed upstream of the high-pressure The pressure relief valve housed on the cylinder head, as-
pump, adjusts the fuel flow that is necessary on the low-pres- sembled on injector return (3), limits the fuel return flow
sure system. Afterwards, the high-pressure pump takes care from injectors at a pressure of 1.3 to 2 bars.
of supplying the rail properly. This arrangement, by pressuris- Two by-pass valves are placed in parallel with the mechanical
ing the necessary fuel only, improves the energetic efficiency supply pump.
and limits fuel heating in the system.
The by-pass valve (18) allows fuel to flow from mechanical
Function of the pressure relief valve (2), assembled on the pump outlet to its inlet, when the fuel filter inlet pressure ex-
high-pressure pump, is keeping the pressure, at the pressure ceeds the allowed threshold value.
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream. The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).
4 cylinders version
Figure 5
EXHAUST
HIGH PRESSURE
114545
1. High-pressure pump. 2. Pressure relief valve on high-pressure pump, 5 bars. 3. Pressure relief valve assembled on fuel
return from injectors, 1.3 to 2 bars. 4. Rail overpressure valve. 5. Common Rail. 6. Pressure sensor. 7. Injector.
8. Return piping. 9. Control unit heat exchanger. 10. Mechanical priming pump. 11. Prefilter assembled on chassis.
12. Fuel tank. 13. Mechanical supply pump. 14. Fuel filter. 15. Pressure regulator. 16. High-pressure pump cooling
piping. 17. By-pass valve. 18. By-pass valve.
6 Cylinders version
Figure 6
EXHAUST
114545
1. High-pressure pump. 2. Pressure relief valve on high-pressure pump, 5 bars. 3. Pressure relief valve assembled on fuel
return from injectors, 1.3 to 2 bars. 4. Rail overpressure valve. 5. Common Rail. 6. Pressure sensor. 7. Injector.
8. Return piping. 9. Control unit heat exchanger. 10. Mechanical priming pump. 11. Prefilter assembled on chassis.
12. Fuel tank. 13. Mechanical supply pump. 14. Fuel filter. 15. Pressure regulator. 16. High-pressure pump cooling
piping. 17. By-pass valve. 18. By-pass valve.
72594
72593
NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
Figure 10
72595
1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear -
5. Connector to fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry
flowing from engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter -
9. Mechanical feeding pump.
Sec. B-B
Sec. C-C
70498
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft.
7. Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
Working principle
Figure 12
Sec. B-B
Sec. D-D
72597
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft.
7. Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
The pumping element (3) is orientated towards the pumps During compression phase of the pumping element, the fuel
camshaft (4). During the intake phase, the pumping element achieves the level of pressure determining the opening of the
is fed through the feeding line (5). The quantity of fuel to flow by-pass valve to common rail (2), feeding it through the
to the pumping element is determined by the pressure exhaust unit (I).
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
Print P2D32N003 E Base - May 2010
14 SECTION 2 - FUEL F4HE N ENGINES
Figure 13 Figure 14
72601
72598
Sec. C - C Sec. A - A
1. Cylinder. 2. Three-lobe element. 3. Cap intake 1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft. exhaust flowing from pump with connector to high
7. Low-pressure fuel inlet. 8. Pumping elements supplying pressure pipe for common rail.
fuel ducts.
Figure 13 shows the fuel runs at low pressure inside the Figure 14 shows the fuel flow under high pressure running
pump; the following elements are clearly visible: the main through the exhaust galleries of the pumping elements.
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.
Operation RAIL
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 15
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing 108609
in the rail.
The thereby-generated pressure makes the exhaust valve 1. Rail 2. Fuel inlet from high-pressure pump
open and the compressed fuel reaches the high-pressure 3. Overpressure valve - 4. Pressure sensor.
circuit. The rail volume is comparatively small to allow a quick
The pumping element compresses the fuel till the top dead pressurisation at startup, at idle and in case of high flow-rates.
center (delivery stroke) is reached. Afterwards, the pressure It anyway has enough volume as to minimise system spikes
decreases till the exhaust valve is closed.
and the use of plenum chambers caused by injectors
The pumping element piston goes back towards the bottom openings and closings and by the high-pressure pump
dead center and the remaining fuel is decompressed. operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and A fuel pressure sensor (4) is screwed to the rail. The signal
the cycle is repeated. sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
The delivery valves must always be free in their movements, value is checked and, if necessary, corrected.
free from impurities and oxidation.
The rail delivery pressure is modulated between 250 and
1600 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
RELIEF VALVE
If the pipe between fuel filter and high-pressure pump is to Mounted on the end of the rail, it has the function of
be removed-refitted, be sure that hands and components are protecting the systems components in case the failure of the
absolutely clean. rail pressure sensor or the pressure regulator of pump CP3
causes an excessive pressure increase in the high-pressure
plant.
When the rail pressure reaches 1800 bars, the valve initially
intervenes in order to allow the fuel to flow and subsequently
to reduce the pressure within safety limits and then it
mechanically regulates the rail pressure to approx. 800 bars.
This valve allows the engine to work for long periods at a
limited efficiency and avoids the excessive overheating of the
fuel preserving the return pipes to the tank.
Powers Pressures
Jet kW bar
DLLA Up to 152 250 1600 bar
DSLA Lower to 152 250 1450 bar
15
The injector is similar as construction to the traditional ones,
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.
70506
70505
Figure 18
70507
SECTION 3
Duty-industrial application
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
PART ONE -
MECHANICAL COMPONENTS . . . . . . . . . . . 7
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PART TWO -
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . 31
- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Cable on engine . . . . . . . . . . . . . . . . . . . . . . . 35
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . 37
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 37
Page Page
GENERAL SPECIFICATIONS
Section pictures of complete engine - common rail version
Figure 1
108540
The NEF F4HE engines are characterised by four-stroke diesel The section herein described is composed or four sections:
cycles supercharged with 4 or 6 cylinders with 4 valves per
cylinder. - Section of mechanical overhaul prescribed in accordance
to the engines specific duty, illustrating all necessary
They have high pressure injection fuelling (common rail) and operation to remove and assembly the external
are entirely electronically driven in order to optimise the components of the engine, including cylinder heads,
working process in accordance to the operation, limiting as gearbox of the timing system and of the front part cover;
much as possible the pollution emissions and consumption.
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.
rpm 2200
Max. torque Nm 608
(kgm) 60.8
rpm 1600
Loadless engine
idling rpm -
Loadless engine
peak rpm -
Bore x stroke 104 x 132
Displacement cm3 4485
TURBOCHARGING with intercooler
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by FPT.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.
F4HE9684
Type P*J101 A*J100 Q*J100 W*J100
Compression ratio 17.5 : 1
Max. output kW 175 154 143 134
(HP) 238 210 195 180
Loadless engine
idling rpm
-
Loadless engine
peak rpm rpm
-
Bore x stroke 104 x 132
LUBRICATION
Forced by gear pump, relief valve single action
Oil pressure (warm engine) oil filter
bar - idling bar
0.7
- peak rpm bar 3.5
COOLING By liquid
Water pump control Through belt
Thermostat
- start of opening C 81 2
FILLING
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by FPT.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.
F4HE9684
Type B*J101 E*J101 P*J101 A*J100 X*J101
Compression ratio 17.5 : 1
Max. output kW 129 123 175 154 112
(HP) 175 170 240 210 150
LUBRICATION Forced by gear pump, relief valve single action oil filter
COOLING By liquid
FILLING
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by FPT.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.
PART ONE -
MECHANICAL COMPONENTS
ENGINE OVERHAUL - disconnect the high pressure fuel pipeline from the rail
Preface diffuser and from the high pressure pump and
disassemble it from the engine block removing the fixing
Part of the operations illustrated within this section can be
clamps.
partially executed while the engine is assembled on the
vehicle, depending on the room available for access to the - disconnect the pipeline feeding the mechanic pump that
engine and on the equipment application as well. is combined to the high pressure pump through the
exchanger of the engine control module;
- disassemble the oil introduction tube (if present) by
NOTE With regard to the engine disassembly operations undoing and removing the fixing screws. Remove the
from the machine, please apply for Information O-ring from the tube.
consulting the specific manual.
All operations of Engine disassembly operations as NOTE Because of the high pressure in the pipelines
well as overhaul operations must be executed by running from the high pressure pump to the rail and
qualified technicians provided with the specific from this last one to the electro-injectors, it is
tooling and equipment required. absolutely required NOT to:
- disconnect the pipelines when the engine is
The following information relates to the engine overhaul working;
operations only for what concerns the different components - re-use the disassembled pipelines.
customising the engine, according to its specific duties.
In section General overhaul, all the operations of engine
block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the Figure 3
part hereby described.
116237
2
74166
107246
1. Connections for Electro-injectors - 2. Engine cooling liquid temperatures sensor - 2. Cable of the fuel pressure sensor -
4. Sensor of engines oil temperature and pressure - 5. Driving shaft sensor - 6. EDC 7 gearbox - 7. Temperature - air
pressure sensor - 8. Timing system sensor - 9. Cable of fuel heater and fuel temperatures sensor - 10. Cable of pressure
regulating gauge - 11. Electro-injector.
Base - May 2010 Print P2D32N003 E
F4HE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 11
74170
108543
Disconnect from the rail (2): the fuel pipe (7) according to Figure 9
procedures described in Figure 3. Disconnect fuel pipes (5)
from rail (2) and injector manifolds (6).
74744
Figure 10 Figure 12
70132 108545
Loosen tappet adjustment fastening nuts (1) and unscrew the Release on the drive belt tensioner (1) and extract the belt
adjusters. (2) from the belt pulleys from the water pump ones and from
Remove the screws (2), remove the rocker assembly (3),
the belt rebound pulleys;
consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves. Disassemble the belt tensioner (1).
Remove rods (8).
Loosen the screws fixing the alternator to the support and
Figure 11 disassemble it.
Figure 13
70133
108546
Disconnect the oil pipeline (3) from the supports of the heat
exchanger / oil filter and from the pipe fitting (4) to the
turbine.
Remove the fixing nuts and disassemble the turbocharger (1)
from the exhaust collector (2).
Loosen the screws and disassemble the exhaust collector (2)
from the cylinder head.
Figure 14 Figure 17
108547
108580
74779 74174
Hook brackets (1) with suitable lifting chains and remove Remove the screws (1) and disconnect the ECU (2) including
cylinder head (2) from block using hoist. the heat exchanger.
Figure 19
Figure 16
1 4 3
74176
108549
Remove the screws (2) and disconnect the alternator Unloose the screws (3) and remove the cap (1). Keep the
support (3). gasket (4), the power take-off (2) and the second gasket (4).
Use tool 99360076 to remove the oil filter (1).
Print P2D32N003 E Base - May 2010
14 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE N ENGINES
Figure 20 Figure 23
70145 116241
Remove the nut (1) and disconnect the timing sensor (2). Remove the screws (1) and disconnect the water pump (2).
Remove the nuts (3) and disconnect the high pressure pump Remove the screw (3) and the roller (4).
(4) including the feed pump (5). Remove the screw (5) and disconnect the engine speed
sensor (6).
Figure 24
Figure 21
00900t
Remove the ring sealing the engines driving shaft from the
front cover. Use the tool 99340055 (4) to operate on the
front bar hold of the driving shaft. Through the steering holes
70146
of the tool, perforate the inside holding ring (1) with a straight
Fit tool 99360339 (2) to the flywheel housing (1) to stop way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool
flywheel (3) rotation. to the ring tightening the 6 screws provided with the
equipment. Then proceed removing the ring (2) by tightening
Loosen the screws (4). the screw (3).
Figure 22
Figure 25
108548
Figure 26 Figure 29
70152
116242
Remove the screws (1 and 3) and take out the front cover Tighten two screws of medium length into the holes (4) to
(2). sling the flywheel with the hoist.
Throughout the two guide pins (2) previously screw into the
NOTE Take note of screw (1) assembling positions since driving shaft holes (3) withdraw the engine flywheel (1) after
they have different lengths. slinging it with the hoist.
Figure 30
Figure 27
Remove the screws (1) and disconnect the oil pump (2).
00903t
Figure 28 Remove the holding ring of the flywheel cover box using the
tool 99340056 (3) to operate on the driving shafts back bar
hold (5).
Through the steering holes of the tool, perforate the inside
holding ring with a straight way drill (diam. 3,5mm) for the
depth of 5mm.
Fix the tool 99340056 (3) to the ring tightening the 6 screws
provided with the equipment.(4)
Then proceed removing the ring (1) by tightening the screw
(2).
Using a specific tie rod of the tool 99363204 and an ancillary
lever, remove the external holding ring (2) from the front
cover.
70151
Remove two opposite screws (1) from the area where the
withdrawal pins will be introduced (2, Figure 29).
Loosen the remaining flywheel fixing screws (3) from the
driving shaft (4).
Remove the flywheel locking tool 99360351.
Print P2D32N003 E Base - May 2010
16 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE N ENGINES
Figure 31 Figure 33
70153
Remove the screws (2) and take out the rear cover (1). 86516
Figure 34
74775
70157
Remove the screws (2) and disconnect the timing gear case
(1).
Figure 36
70210
70209
LOCTITE 5205 SEALANT APPLICATION AREAS DIAGRAM FOR TIGHTENING THE REAR TIMING
Clean accurately the timing gear case (1) and the engine GEAR CASE FASTENING SCREWS
block. Refit the case (1) to the engine block.
Screw the fastening screws in the same position found at
removal and tighten them to the following torque values in
the sequence shown in the figure:
Screws M12 65 to 89 Nm
NOTE Perfect seal is only obtained by cleaning accurately Screws M8 20 to 28 Nm
the surface to seal. Screws M10 42 to 52 Nm
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
NOTE Before any assembly operation always verify that
It shall be uniform (no clots), without air bubbles, the hole and screw threads have no evidence of
thin areas or discontinuities. wear or dirt.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint. Figure 38
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 20 minutes).
70211
Figure 39
NOTE Perfect seal is only obtained by cleaning accurately
the surface to seal.
Smear the case with LOCTITE 5205 to obtain a
bead of few mm diameter.
It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities.
Any imperfection shall be corrected as soon as
possible.
Avoid to use excess material to seal the joint.
Excessive sealant could come out from joint sides
and cause lubricant passage clogging.
After applying the sealant, the joint shall be
assembled immediately (10 20 minutes).
114791
Turn the engine shaft (3) and the distribution shaft (4) so that
by mounting the bevel gear on the latter (1) the stencilled
Figure 42
mark on the gear (1) coincides with the groove on the gear
tooth (2).
Figure 40
70215
70214
Figure 43 Figure 45
70152
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
0901t
hoister.
Apply tool 99346253 part (6) to the rear output shaft tang Figure 46
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
Figure 44
Figure 47
70217
70219
Figure 48 Figure 51
106549
70220
Remove the sealing ring (2) from the front cover (1), clean
Fit the oil pump (1).
accurately the coupling surfaces and smear them with
Tighten the fastening screws (2) to the specified torque. LOCTITE 5205.
Figure 52
Figure 49
106550
Clean accurately the front cover (2) surface and refit it.
70221
Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
Figure 53
Figure 50
00902t
70222
Apply tool 99346252 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Fit the water pump (1). Position part (2) on part (4), screw nut (3) until completing
Tighten the screws (2) to the specified torque. sealing ring (7) fitting into front cover (1).
Figure 54 Figure 57
108548
Assemble the pulley (1) and the damping flywheel (2) to the
108553 driving shaft.
Fit the plate (1), the oil pick up tube (2) and tighten the
fastening screws (3) to the specified torque. Tighten the fixing screws (3) and clamp them to the couple
68 7 Nm.
Figure 55 Figure 58
116245
Set the gasket (1) on the oil sump (2). Fit a new sealing ring on the speed sensor (3).
NOTE The pictures of the instructions relating to the oil pan Fit the speed sensor (3) on the front cover (1) and tighten
and to thesuction rose may not reflect the actual the screw (2) to the specified torque.
shape and dimensions of your engine equipment.
However the procedures described are still appli- Figure 59
cable.
Figure 56
108576
Fit on the engine block: a new gasket (1), the heat exchanger
74775
Fit the oil sump (1) and apply the plate (3) to it. (2) a new gasket (3) and the oil filter support (4).
Tighten the screws (2) to the specified torque. Tighten the screws (5) to the specified torque.
NOTE Before any assembly operation always verify that NOTE Before any assembly operation always verify that
the hole and screw threads have no evidence of the hole and screw threads have no evidence of
wear or dirt. wear or dirt.
Figure 60 Figure 62
108578 114792
Refit the alternator (1).
Lubricate the sealing ring (2) with engine oil and set it on the Tighten the screw (2) to the specified torque.
oil filter (3).
Screw manually to seat the oil filter (3) on the support Figure 63
connection (1) and then screw again the oil filter (3) by
turn.
Apply a new sealing ring on the oil temperature/pressure
sensor (4) and fit it on the support (1).
Tighten the screws (5) to the specified torque.
Fit a new sealing ring (6) in the engine block seat.
Figure 61
114793
Refit the automatic belt tensioner (2).
Tighten the screw (3) to the specified torque using a wrench,
turn the automatic belt tensioner (2) to fit the belt (1) on
pulleys and guide rollers.
Figure 64
70234
70145
Refit the high pressure pump (6) including the feed pump (5)
and tighten the nuts (3) to the specified torque. Fit the
NOTE Before any assembly operation always verify that support (4) with a new sealing ring, the timing sensor (2) with
the hole and screw threads have no evidence of a new sealing ring and tighten the relevant fastening nut (1)
wear or dirt. to the specified torque.
2
74176
76152
Insert the power take-off (2) equipped with the gasket (4),
the cover (I) and its gasket (4). - Disassemble cylinder head;
Tighten the screws (3) to the prescribed matching couple. loosen the screws (1) and (2) fixing the cylinder head (3);
hook the brackets with metal ropes and, throughout a
Figure 66 hoist withdraw cylinder head from the block.
1 Figure 69
74174
Assemble the electronic gearbox (2) equipped with the
exchanger to the engine, fixing it with the screws (1). 70336
In case the rubber buffers are cracked or excessively
deformed, provide replacing them. Assemble cylinder head (1), tighten the screws (2) in three
following steps, following order and mode shown in the
figure below.
For 4 cylinder engines
NOTE The angle tightening is carried out through tool
Figure 67 99395216 (3).
1
NOTE Before any assembly operation always verify that
2 the hole and screw threads have no evidence of
wear or dirt.
Figure 70 Figure 73
6-cylinder engine A
70476
NOTE Between the phases, wait a few minutes for settling Figure 74
Figure 71
4-cylinder engine A
70337
Figure 72
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
a new sealing washer (3) on injector (1).
Base - May 2010 Print P2D32N003 E
F4HE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 25
Figure 75 Figure 77
91572 70343
Screw the fastening nuts (2, Figure 76) without locking them.
Figure 79
32655
70342
Rocker control rods shall not be distorted; the ball seats in
Use the torque wrench to tighten gradually and alternately touch with the rocker adjusting screw and with tappets
the injector fastening screws (1) to 8.5 0.8 Nm torque. (arrows) shall not show seizing or wear; otherwise replace
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm them. Intake and exhaust valve control rods are identical and
torque. are therefore interchangeable.
Carry out the assembly of the equalisers unit , after previous
check of the components.
IGNITION SEQUENCE: 1 3 4 - 2
6 cylinder engines
IGNITION SEQUENCE: 1 - 5 - 3 - 6 - 2 - 4
70346
Check that tappet adjusters (1) are loose to prevent their Adjust intake and
balking on the rods (2, Figure 80) when refitting the rocker Engine shaft Bilance exhaust valves
assembly. starting and valves
clearance cylinder
Then refit the rocker assembly consisting of: bracket (5), rotation cylinder n
n
rockers (3), shafts (4) and secure them to the cylinder head
by tightening the fastening screws (2) to 36 Nm torque. 1 al PMS 1 1
120 5 5
Figure 82 120 3 3
120 6 6
120 2 2
120 4 4
70520
Figure 83 Figure 86
108547
Connect the fuel pipe (3) to the rail (2) following the
procedure shown in the following figure.
Figure 87
108567
Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut to the specified torque.
Figure 85
116237
108568
Connect new fuel pipes (1) to rail (3) and injector manifolds
(2).
Print P2D32N003 E Base - May 2010
28 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4HE N ENGINES
Figure 88 Connect the electrical cables (1) to the injectors (3) and use
the torque wrench 99389834 (4) to tighten the fastening
nuts (2) to the specified torque.
Figure 91
70352
Figure 92
108570
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.
Figure 90
108572
Figure 93 Figure 95
6
2 5
4
3
74170
If present, insert blow-by filter (4) and tighten the screws (3).
Connect the pipeline (6) and fix the oil vapour recover pipe 108541
through the clamp (5); lock up the nut fixing it to the upper
edge. Assemble the bracket and the support of the fuel filter.
Proceed connecting the pipelines (9,3,4 and 5) of the support
Connect the pipeline (2) to the pressure- limiter (1). to the high pressure pump.
Connect the pipeline from the high pressure pump to the
engine control module heat exchanger.
Connect the pipeline from the high pressure pump to the rail
Completion of the engine diffuser.
Properly handle the engine holding it by a lifter, remove it
from the rotating shaft, remove the brackets 99341009 and Figure 96
place it on proper suitable support to carry out the
completion.
Proceed assembling the oil filter.
Figure 94
116237
All the low-pressure fuel pipes are fastened with clips shown
in the picture.
In order to connect the low-pressure fuel pipes to the
2 connection joint, insert the rapid fitting joint into the latter,
(2) and press until the clip fastens securely (3).
PART TWO -
ELECTRICAL EQUIPMENT
108641
The NEF F4HE engines are fully driven by the electronic The electrical and electronic components of the engine are
engine control module, which is assembled directly to the listed here following:
engine by means of a heat exchanger enabling its cooling,
1. Coolant temperature sensor.
utilising rubber buffers to reduce vibration originated by the
engine. 2. Electro-injector.
Through the engine control module it is possible to verify the 3. RAIL pressure sensor.
correct working of the engine. (See part three of the hereby
4. Air temperature/pressure sensor.
users guide specifically dedicated to diagnostic).
6. Timing sensor.
7. Solenoid valve for pressure regulator.
8. Fuel temperature sensor.
9. EDC electronic control unit.
10. Crankshaft sensor.
11. Engine oil pressure/temperature sensor.
12. Heating element for pre-post heating.
EDC7 ECU
Figure 98
01525t
A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled);
C - Connector to sensors.
Cable on engine
All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary
version, in other words at the approval stage.
Figure 99
0051064t
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor -
5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor -
8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Rail temperature and pressure sensor -
11. Pressure regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).
Crankshaft sensor
This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from
a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is 900 .
Figure 100
50319
Crankshaft sensor
Timing sensor
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a
magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by
the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance
is 900 .
Figure 101
50320
Timing sensor
3 2 1
50342 50288
Figure 102
50324 50344
Wiring diagram
ECU Pin
Ref. Description
Oil Air
1 Ground 24C 25C
2 NTC signal (temperature) 28C 36C
3 +5 V power input 32C 34C
4 Signal (pressure) 27C 34C
Figure 103
0051065t
Electro-injectors
The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The impedance of the coil of each injector is 0.56 - 0.57 .
Figure 104
50343
Figure 105
50349
Figure 106
B
108909
A. - B. Connection terminals
Figure 107
002371t
A. Control contactor
Figure 108
107471
Figure 109
0051140t
107799 107798
Connector
ECU Pin
Ref. Description
Coolant Fuel
1 Ground 15C 35C
2 Temperature signal 26C 18C
Figure 110
000912t
A. Pressure regulator.
The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the
pressure regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 and 1450 bar by the electronic control unit by controlling the pressure
regulator solenoid valve.
- This component is a N.O. solenoid valve.
- The solenoid is connected to the control unit on pins 9A - 10A.
- The solenoid valve impedance is approximately 3.2 .
PART THREE -
TROUBLESHOOTING
PT - BOX
PT - BOX is a test tool to be connected to a Laptop.
Figure 111
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator - 5. Serial port indicator -
6. Error indicator - 7. CAN line indicator - 8. Line K indicator for automatic management
PT-BOX functions:
- ECU ID reading;
- Failure memory reading;
- Flight recorder reading;
- Parameters reading;
- Failure memory cleaning;
- Active diagnosis: actuators activation/testing;
- Programming of repalced components and parameters/second level;
- Acquisition/Saving of parameters
FAULT CODES
Failure code Failure description
Vehicle 1 ((Sensors / Consistency tests)
1.1.2 ACCELERATOR PEDAL
1.1.9 PLAUSIBILITY +15
1.1.A PLAUSIBILITY +50
Vehicle 2 (Indicator lamps / Relais / Actuators)
1.2.3 EDC LAMP
1.2.5 MAIN RELAY DEFECT
1.2.6 BATTERY VOLTAGE
1.2.8 MAIN RELAY - SHORT CIRCUIT TO BATTERY
1.2.9 AIR-CONDITIONER COMPRESSOR RELAY
1.2.B THERMOSTARTER RELAY 1 (HEATER)
1.2.E MANAGEMENT SYSTEM PRE/POST-HEATING (ACTIVE)
2.2.5 INTERRUPTED AFTER-RUN
2.2.8 MAIN RELAY - SHORT CIRCUIT TO GROUND
Engine 1 (Temperature and pressure sensors)
1.3.1 COOLANT TEMPERATURE SENSOR
1.3.2 COOLANT TEMPERATURE SENSOR (TEST)
1.3.3 AIR TEMPERATURE SENSOR BOOST AIR
1.3.4 BOOST PRESSURE SENSOR
1.3.5 FUEL TEMPERATURE SENSOR
1.3.6 RAIL PRESSURE SENSOR OR SIGNAL ERROR
1.3.7 DBV VALVE MANAGEMENT (BOOST PRESSURE)
1.3.8 OIL PRESSURE SENSOR
1.3.A OIL TEMPERATURE SENSOR
2.3.2 COOLANT TEMPERATURE SENSOR ABSOLUTE TEST
2.3.6 RAIL PRESSURE SENSOR OFFSET
2.3.8 OIL LOW PRESSURE
2.3.A OIL TEMPERATURE ABOVE NORMAL
Engine 2 (Speed sensors/actuators)
1.4.1 CRANKSHAFT SPEED
1.4.2 ENGINE WORKING ONLY WITH CAMSHAFT SENSOR
1.4.3 CAMSHAFT SENSOR
1.4.4 FAULT BETWEEN FLYWHEEL SENSOR AND CAMSHAFT
Damage information
1.4.D ENGINE OVERSPEED
1.5.B HIGH PRESSURE TEST (DEACTIVATES RAIL PRESS.MONITORING)
1.9.D INDICATES TORQUE LIMITATION DUE TO PERFORMANCE LIMITER
4.9.E INDICATES THE TORQUE LIMITATION DUE TO ENGINE PROTECTION
6.9.E INDICATES TORQUE LIMITATION DUE TO FUEL QUANTITY LIMITATION
F4HE N ENGINES
POSSIBLE CAUSE RECOMMENDED TESTS OR
ANOMALY (*) = if available in the equipment INTERVENTION REMARKS
Low performance at load request. Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact
that, in case of insufficient fuel feeding, the
Possible exessive smoke. engine control module tries to compen-
sate prolonging the injectors working
Possible blink-code 8.1 time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of over- is working correctly.
heating.
If the pump plunger is permanently de-
pressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter. Replace the air filter. Solve the cause of the filters obstruction.
Excessive fuel blow-by from rail boost Check the O Rings and the correct con- Unless the leakage is significant, no per-
valve. nection of the pipe fittings under the formance failures will be detected.
feeding pump (the lockers must stay out- To verify O-rings integrity, extract from
side and the fittings must be well locked). the tank the fuel recycling pipeline, seal
Visually check the low pressure pipeline the end and activate the priming pump
integrity. driving the low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve. there are any significant blow-by from the
boost gauge valve; in such case replace
the valve.
53
Base - May 2010
54
POSSIBLE CAUSE RECOMMENDED TESTS OR
ANOMALY (*) = if available in the equipment INTERVENTION REMARKS
F4HE N ENGINES
Print P2D32N003 E
F4HE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 55
PART FOUR -
MAINTENANCE PLANNING
MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES
Checks and inspections
Figure 113
Engine oil level check
The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided flexible
rod (1) placed on the right hand side of the EDC.
Figure 112
108540
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.
1 2
74188
Figure 115
70520
Oil motor and filter replacement Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in differ-
Warning: We recommend to wear proper protec- ent positions: the following procedure is a valid guide for all ap-
tions because of high motor service temperature. plications.
The motor oil reaches very high temperature: you - The filter is composed by a support and a filtering car-
must always wear protection gloves. tridge. For the cartridge replacement use the
9936076-tool.
We recommend to carry out the oil drainage when the motor Warning: avoid the contact of skin with the motor oil:
is hot. in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the The motor oil is very pollutant: it must be disposed
pan connected with the drain plug. of according to the rules.
- Unscrew the plug and then take out the control dipsick
and the inserting plug to ease the downflow of the lubrica-
tion oil.
- After the complete drainage, screw the plug and carry out
the clean oil filling.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dip-
sick.
108545
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 16
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 18
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Page Page
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 28
- Regrinding replacing the valve seats . . . . . . . 34
- Fitting connecting rod-piston assembly into
cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . 28
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Finding crankpin clearance . . . . . . . . . . . . . . . . 29 FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . 36
GENERAL SPECIFICATIONS
Number of cylinders 4 6
Bore mm 104
Stroke mm 132
TIMING
Checking timing
mm 0.20 to 0.30
X
X mm 0.45 to 0.55
FUEL FEED
Injector CRIU 2
bar
CLEARANCE DATA
1 0.4
Pistons
1
X Size X 55.9 / 49.5 ()
Outside diameter 1 103.714 to 103.732 / 103.759 to 103.777 ()
2 Pin housing 2 38.010 to 38.016
X
Piston protrusion X 0.28 to 0.52
S 1 S1 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110 / 0.040 to 0.090 ()
3 0.040 to 0.080
Split rings 0.4
X1
Split ring end opening
X2 X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82.99 to 83.01
Crankpins 2 68.987 to 69.013
Main bearings
3 No. 1 5 / 1- 7 3 87.982 to 88.008
No. 2 3 4 3 87.977 to 88.013
X 1
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
4 Valves:
4 6.970 to 6.990
60o 0.25o
4 6.970 to 6.990
45o 0.25o
1 34.837 to 34.863
1 1 34.837 to 34.863
2 34.917 to 34.931
45o
X 0.59 to 1.11
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -
Injector protrusion X -
X
Bush inside
diameter 54.083 to 54.147
H
H 6.045
H 7.582
2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.960 to 15.975
2
Between tappets and housings 0.025 to 0.070
Tappets -
1
Rocker shaft 1 21.965 to 21.977
2
Between rockers and shaft 0.024 to 0.162
Figure 1
70160
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
70158
Figure 4
Loosen the fixing screws (1) and remove the rod caps (2).
Withdraw the pistons including the connecting rods from the
top of the engine block.
70161
Use tool 99360500 (1) and hoist to remove the crankshaft (2)
from the block.
Figure 2
Figure 5
70159
70162
Remove the screws (1) and the main bearing caps (2). Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).
70163
Figure 10
Withdraw carefully the camshaft (1) from the engine block.
Figure 8
70167
107804
TIMING SYSTEM
Camshaft
Figure 12
70169
Figure 13
84089
Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bush.
if they show any traces of seizing or scoring replace the
Base - May 2010 Print P2D32N003 E
F4HE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 15
Figure 14
70172
Figure 16
Sec. A-A
107399
Figure 17
sec. A-A
107268
70174
112890
Figure 20
70238
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
70176
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Figure 23
70179
Figure 24
70164
70180
Lubricate the camshaft bush and fit the camshaft (1) taking
care not to damage the bush or the housings.
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Print P2D32N003 E Base - May 2010
18 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE N ENGINES
OUTPUT SHAFT
Measuring journals and crankpins NOTE It is recommended to insert the found values in the
proper table.
Figure 25 See Figure 26.
Figure 26
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)
*Rated value
Figure 27
70237
Figure 28
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Figure 29
Figure 30
70237
70161
Figure 32
70186
Figure 38
70187
70191
Figure 40 Pistons
Measuring piston diameter
Figure 43
32613
32615
Remove split rings (1) from piston (2) using pliers 99360183
(3). Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
Figure 41
Figure 44
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 42
1.5
2.705 2.420
2.560 2.735 2.440
* 2.605
220
2.350
2.380
3.970
3.990 38.010 37.994
38.016 38.000
114797
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter
Figure 45
114798
MAIN DATA OF THE PISTON WITHOUT PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter
Piston pins
Figure 46
Figure 48
18857
32619
Lubricate the pin (1) and its seat on piston hubs with engine 32620
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity. Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Print P2D32N003 E Base - May 2010
26 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4HE N ENGINES
41104
70194
Figure 53 Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
CONNECTING ROD BODY
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
CONNECT- CONNECT-
ING ROD ING ROD *
BODY BODY
70196
70198
NOTE Every connecting rod is marked as follows:
The piston crown is marked as follows:
- On body and cap with a number showing their 1. Part number and design modification number;
coupling and the corresponding cylinder. 2. Arrow showing piston assembling direction into cylinder
In case of replacement it is therefore necessary barrel, this arrow shall face the front key of the engine
to mark the new connecting rod with the same block;
numbers of the replaced one. 3. Manufacturing date.
- On body with a letter showing the weight of 4. Marking showing 1st slot insert testing;
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
Figure 55
S X, 1901 to 1940 (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
108597
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Figure 56 Figure 58
72705
70200
Position the piston (1) on the connecting rod according to
the diagram shown in the figure, fit the pin (3) and stop it by Fit half bearings (1) on connecting rod and cap.
the split rings (2).
Fitting split rings
NOTE Refit the main bearings that have not been
Figure 57 replaced, in the same position found at removal.
Do not try to adapt the half bearings.
Use pliers 99360183 (3) to fit the split rings (1) on the piston Figure 59
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
70201
Figure 60 Figure 62
108596
70204
DIAGRAM FOR CONNECTING ROD-PISTON - Lubricate the screws (1) with engine oil and then tighten
ASSEMBLY FITTING INTO BARREL them to the specified torque using the torque wrench
(2).
- Split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same Figure 63
weight;
- the arrow marked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
Figure 61
70205
Figure 64
70203
Figure 66
70207
70208
If a different clearance value is found, replace the half bearings
and repeat the check. Once connecting rod-piston assemblies refitting is over, use
dial gauge 99395603 (1) fitted with base 99370415 (2) to
Once the specified clearance has been obtained, lubricate check piston (3) protrusion at T.D.C. with respect to the top
the main half bearings and fit them by tightening the of the engine block.
connecting rod cap fastening screws to the specified torque.
Protrusion shall be 0.28 to 0.52 mm.
70321
70322
Figure 70
70323 70325
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90C and 2 The rated thickness A for the cylinder head is 105 0.25 mm,
to 3 bar pressure. max. metal removal shall not exceed thickness B by 1 mm.
Replace the core plugs (1) if leaks are found, use the proper
punch for their removal/refitting.
NOTE After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with
water-repellent sealant.
VALVES Figure 74
Figure 72
EXHAUST INTAKE
VALVE VALVE
18882
18625
Check that the valves show no signs of seizing, scoring or Use a magnetic base dial gauge (1) set as shown in the figure,
cracking. the assembling clearance shall be 0.052 0.092 mm.
If necessary, rectify the valve seats, taking away the least Turn the valve (2) and check that the centering error is not
amount of material possible. exceeding 0.03 mm.
Figure 77
70330
INTAKE EXHAUST Should slight scratches or burns be found, go over with the
79457
adequate tool (1) according to the inclination values
Use a bore dial gauge to measure the inside diameter of the indicated in the Figure 78.
valve guides, the read value shall comply with the value
shown in the figure.
Figure 78
INTAKE EXHAUST
70331
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 - 100C and using the proper
them with the spare ones. Using a suitable tool, remove as punch, fit the new valve seats, previously cooled, into the
much material as possible from the valve seats (take care not cylinder head.
to damage the cylinder head) until they can be extracted
Therefore, with an adequate tool, go over the valve seats
from the cylinder head using a punch.
according to the values stated in the Figure 78.
Figure 79
EXHAUST INTAKE
70332
Figure 80 After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).
70333
50676
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
Height Under a load of
mm N
H 47.75 Free
H1 35.33 P 339.8 19 N
H2 25.2 P1 741 39 N
Figure 83
770321
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
Refitting the cylinder head There are two types of head seals, for the thickness (1.25 mm
Type A and 1.15 mm Type B) take the following measures:
Figure 84
- for each piston detect, as indicated on Figure 85, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:
S cil1 = S1 + S2
For 4 cylinder versions: 2
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
75703
88775
TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Studs M6 for camshaft sensors 82 0.8 0.2
Studs M8 for feed pump 12 2 1.2 0.2
Screw M12 for fastening rear gear case 77 12 7.7 1.2
Screw M10 for fastening rear gear case 47 5 4.7 0.5
Screw M8 for fastening rear gear case 24 4 2.4 0.4
Nut M6 for fastening camshaft sensor 10 2 1 0.2
1st stage 81 0.8 0.1
Screw M8 for fastening oil pump 2nd stage 24 4 2.4 0.4
Screw M8 for fastening front cover 24 4 2.4 0.4
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening crankcase plate 43 5 4.3 0.4
Nut M18 for fastening high pressure pump gear 105 5 10.5 0.5
Nuts M8 for fastening fuel pump 24 4 2.4 0.4
inch plug on cylinder head 24 4 2.4 0.4
inch plug on cylinder head 36 5 3.6 0.5
inch plug on cylinder head 12 2 1.2 0.2
1st stage 8.5 0.35 0.85 0.035
Screw M6 for fastening injectors
2nd stage 75 5
Nut fastening for injector feed connector 50 5 5 0.5
Nut M6 for flame start grille on intake manifold 82 0.8 0.2
Screw M8 for fastening intake manifold 24 4 2.4 0.4
Screw M12 for fastening rear brackets for engine lifting 77 12 7.7 1.2
Screws M8 for fastening Common Rail 24 4 2.4 0.4
Connectors M14 for high pressure fuel pipes 20 2 2 0.2
Screw M12 (12 x 1.75 x 130) for fastening cylinder head 35 5 3.5 0.5
Screw M12 (12 x 1.75 x 150) for fastening cylinder head
}1 st stage
55 5 5.5 0.5
2nd stage 90 5
3rd stage 90 5
Screw for fastening rocker bracket 36 5 3.6 0.5
Valve clearance adjusting nuts 24 4 2.4 0.4
Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 2 2 0.2
Screw M8 for fastening high pressure pipe connector 24 4 2.4 0.4
Screw M6 for fastening wiring bulkhead 10 2 1 0.2
Screw M8 for fastening electric wiring support for injector feed 24 4 2.4 0.4
Nuts for fastening wiring on each injector 1.5 0.25 0.15 0.025
Screw M12 for fastening fuel filter bracket 77 8 7.7 0.8
Screw M8 for fastening fuel filter holder 24 4 2.4 0.4
Fuel filter contact + turn
Screw M22 for fastening oil pressure relief valve on oil filter support 80 8 8 0.8
Screw M8 for radiator seal and oil filter support 24 4 2.4 0.4
Oil filter contact + turn
11/8 inch connection on filter support for turbine lubrication 24 4 2.4 0.4
Nut M12 for fastening turbine lubrication pipe 10 2 1 0.2
Screw M10 for fastening engine coolant inlet connection 43 6 4.3 0.6
90 elbow fastening (if required) to engine coolant inlet connection 24 4 2.4 0.4
Pipe on cylinder head for compressor cooling 22 2 2.2 0.2
TORQUE
COMPONENT
Nm kgm
Screw M6 for fastening engine coolant drain connector 10 2 1 0.2
Pin fastening on engine block for exhaust manifold 10 2 1 0.2
Screw M10 for fastening exhaust manifold on cylinder head 53 5 5.3 0.5
Screw M12 for fastening damper adapter 1st stage 50 5 5 0.5
and damper on output shaft 2nd stage 90
Screw M10 for fastening pulley on output shaft 68 7 6.8 0.7
Screw M8 for fastening water pump 24 4 2.4 0.4
Screw M10 for fastening auxiliary component control belt tensioners 43 6 4.3 0.6
Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 6 4.3 0.6
Screw M10 for fastening flywheel housing 85 10 8.5 1
Screw M12 for fastening flywheel housing 49 5 4.9 0.5
Screw M6 for fastening heat exchanger for control unit 10 2 1 0.2
Screw M8 for fastening heat exchanger for control unit 24 4 2.4 0.4
Connection M12 for fuel inlet-outlet on heat exchanger 12 2 1.2 0.2
Nut M8 for fastening valve cover 24 4 2.4 0.4
Screw M6 for fastening camshaft sensor 82 0.8 0.2
Screw M6 for fastening output shaft sensor 82 0.8 0.2
Screw M14 for fastening coolant temperature sensor 20 3 2 0.3
Screw M5 for fastening oil pressure/temperature sensor 61 0.6 0.1
Screw for fastening fuel pressure sensor 35 5 3.5 0.5
Screw M14 for fastening fuel temperature sensor 20 3 2 0.3
Screw for fastening air temperature/pressure sensor on intake manifold 61 0.6 0.1
Screw M12 for fastening engine oil level sensor 12 2 1.2 0.2
71 0.7 0.1
6-cyl. { pins
nuts
M8
M8 43 6 4.3 0.6
Turbine fixing to exhaust manifold
4-cyl. { pins
nuts
M8
M8
71
24 4
0.7 0.1
2.4 0.4
Adapter M12 on turbine for lubricant oil pipes (inlet) 35 5 3.5 0.5
Pipe fixing on adapter M10 for turbine lubrication 35 5 3.5 0.5
Oil pipe fixing on adapter M10 for turbine lubrication to block 43 6 4.3 0.6
Oil drain pipe fixing M8 on turbine 24 4 2.4 0.4
Connector fixing M6 for oil return from cylinder head to flywheel housing 10 2 1 0.2
Screw M12 for fastening engine flywheel 1st stage 30 4 3 0.4
2nd stage 60 5
Screw M8 for fastening front bracket for engine lifting 24 4 2.4 0.4
Screw for fastening engine oil sump 24 4 2.4 0.4
Screw M8 for fastening cylinder barrel lubricating nozzles 15 3 1.5 0.3
Screw M12 for fastening output shaft caps 1st stage 50 6 5 0.6
2nd stage 80 6 8 0.6
3rd stage 90 5
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening connecting rod caps 1st stage 60 5 6 0.5
2nd stage 60 5
Alternator
M10 Screw, Bracket fixing on water feed pipefitting 43 6 4.3 0.6
M10 Screw, alternator locking 43 6 4.3 0.6
Starter
Starter fixing screw 43 6 4.3 0.6
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99341015 Press
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
99370415 Gauge base for different measurements (to be used with 99395603)
TOOLS
TOOL NO. DESCRIPTION
99395216 Pair of gauges with and square head for angle tightening
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections
efficiency of earth and mass electrical connections. in presence of electrical feed.
Ensure that hands and feet are dry and execute working - Before proceeding with pipelines disassembly
operations utilizing isolating foot-boards. Do not carry (pneumatic, hydraulic, fuel pipes) verify presence of liquid
out working operations if not trained for. or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
Non fulfillment of these prescriptions may cause serious
- Put the dirty rags with oil, diesel fuel or solvents in injury and poisoning.
anti-fire specially provided containers.
Part 2
F4CE N SERIES
Section
General specifications 1
Fuel 2
Industrial application 3
Tools 5
UPDATING
SECTION 1
General specifications
Page
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 7
- Description . . . . . . . . . . . . . . . . . . . . . . . . . 9
6- cylinder engine version Also in this case, the components such as the oil exchanger,
Even for the 6 cylinders version lubrication is obtained by the turbo-blower and the eventual compressor are specifically
forced circulation and achieved through an oil rotary expan- studied and made out to suit the equipment or the duty for
sion pump similar to the 4 cylinders one. which the engine has been developed.
Figure 2
Introduction of oil
Figure 3
3240t
COOLING SYSTEM - Visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
The engine cooling system, closed circuit forced circulation type, will be specifically equipped based on the engines
generally incorporates the following components: development.
- Expansion tank; placement, shape and dimensions are - Heat exchanger to cool the lubrication oil: even this
subject to change according to the engines equipment. component is part of the engines specific equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this - Centrifugal water pump, placed in the front part of the
component will have specific peculiarities based on the engine block.
equipment developed, both for what concerns the - Thermostat regulating the circulation of the cooling liquid.
placement and the dimensions.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.
TO RADIATOR
FROM
RADIATOR
117592
Figure 5 (Demonstration)
117592
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
Figure 6
4 Cylinders version
EXHAUST
RADIATOR
6 Cylinders version
EXHAUST
RADIATOR
74195
EXHAUST GAS RE-CIRCULATION SYSTEM The internal EGR system is not equipped with any
(EGR) electronically controlled elements: the system is always active.
In the TIER 3 version, the profile of the exhaust cam has been Its configuration does not need additional elements
modified in order to allow the partial opening of the relative i.e.checking valves, piping or heat exchangers.
valve during the aspiration phase (re-circulation of EGR The exhaust cam (B) has another lobe apart from the major
exhaust gas) with the subsequent re-introduction of part of lobe (see Section. A-A fig.) with respects to the configuration
the exhaust gas into the engine cylinders. without EGR.
The exhaust gases can partially be re-directed into the The additional lobe, during the aspiration phase in the cylinder
cylinders so as to reduce the maximum combustion in question, allows a brief opening of the exhaust valve
temperature values responsible for the production of nitric generating re-circulation due to the intake of the exhaust gases
acid (NOx). caused by depression which is created in the aspiration phase
The exhaust gas re-circulation system (EGR), reducing the inside the cylinder.
combustion temperature by means of the diminishing of the
concentration of oxygen in the combustion chamber,
represents therefore an efficient control system of the
emission of NOx .
Figure 7
114789
SECTION 2
Fuel
Page
- General information . . . . . . . . . . . . . . . . . . . . 3
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Example of identification . . . . . . . . . . . . . . . . . 5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- General information . . . . . . . . . . . . . . . . . . . . 8
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 1
2
1
4
74168
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure
gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.
Figure 2
116385
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Fuel is sucked from the fuel tank by the priming pump. This The fuel arrives therefore to the valve gauging the pressure
last one is placed on the engine basement and is driven by inside feed pump.
the camshaft.
The distribution plunger further increases this pressure and
Throughout the filter, the fuel is piped to the union fitting delivers fuel throughout the delivery pipe fitting to the
vacuum chamber of the transfer pump. (For applications to injectors.
be equipped in cold climate areas, the fuel filter is provided
The fuel drawing from the injectors is recovered and
with heater).
delivered to the tank again.
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
FEED PUMP
The rotary type pump is driven by a gear mating the camshafts one.
Example of identification
V = Distribution rotary plunger
E = Pump dimensions
4 = 4 cylinders engine
12 = Distribution plunger in mm.
1150 = N. of pump revolutions per minute
LV = Left direction of rotation
Figure 3
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
Injection pump longitudinal section
1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk -
9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate -
14. Gauge pin - 15. Counteracting spring.
PRIMING PUMP
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to
the engine basement and driven by the camshaft.
Figure 4
88209
FUEL FILTER
The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and
separation of water from fuel.
On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the
bearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperature
sensor. On some versions, a water presence sensor is present at filtering cartridge base.
Figure 5
88210
Figure 6
86495
1. Injector fuel pipe 1 - 2. Injector fuel pipe 2 - 3. Injector fuel pipe 3 - 4. Injector fuel pipe 4 - 5. Injector fuel pipe -
6. Injector fuel pipe 5 - 7. Injector fuel pipe 6 - 7. Injector fuel pipe 6 - 8. Injection pump - 9. Injector.
Figure 7
114799
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Fuel is sucked from the fuel tank by the priming pump. This
Fuel is delivered to the pressure gauge valve within feed
last one is placed on the engine basement and is driven by
pump.
the camshaft.
Timing plungers further increase the pressure and deliver fuel
Throughout the filter/s, the fuel is piped to the union fitting
to the injectors throughout the delivery pipe fittings.
vacuum chamber of the transfer pump. (For applications to
be equipped in cold climate areas, the fuel filter is provided Fuel bleeding from the injectors is recovered and piped back
with heater). to the pump.
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
PRIMING PUMP
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to
the engine basement and driven by the camshaft.
Figure 8
88209
FUEL FILTER
The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and
separation of water from fuel.
On the filter cartridge base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the
bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a
temperature sensor (5).
Figure 9
88210
SECTION 3
Industrial application
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . 4
- 6-cylinder engines . . . . . . . . . . . . . . . . . . . . . . 5
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Power takeoff . . . . . . . . . . . . . . . . . . . . . . . . . 32
PART TWO -
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . 33
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Page
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
MAINTENANCE PLANNING . . . . . . . . . . . . . . . . 51
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . 52
GENERAL INFORMATION
Version equipped with mechanical feed pump
Figure 1
114800
F4CE9484F*J600
Type
rpm 2200
Max. torque Nm 430
(kgm) (44)
rpm 1250
Loadless engine
idling rpm -
Loadless engine
peak rpm -
Bore x stroke mm 104 x 132
Displacement cm3 4485
SUPERCHARGING with intercooler
bar
Oil pressure
(warm engine)
- idling bar 0.8
- peak rpm bar 3.5
COOLING Liquid
Water pump control
Thermostat Through belt
- start of opening C 81 2
FILLING
engine sump*
liters 16
15W40 ACEA E3 engine sump + filter*
liters 17
* First filling
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
6-cylinder engines
F4CE9684
Type L*J602 N*J600
Compression ratio 17,5 : 1 17,5 : 1
Max. output kW 86 126
(HP) (117) (170)
bar
Oil pressure
(warm engine)
- idling bar 0.8
- peak rpm bar 3.5
COOLING Liquid
Water pump control
Thermostat Through belt
- start of opening C 81 2
FILLING
engine sump*
liters 16
15W40 ACEA E3 engine sump + filter*
liters 17
* First filling
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
PART ONE -
MECHANICAL COMPONENTS
88216
In order to apply the brackets 99361037 to the engine block - assemble the second bracket 99361037 throughout the
to fix it on to the stand 99322205 for the overhaul, it is screw-threaded ports (1).
necessary to perform the following operations: - Lift the engine using the rocker arm 99360595 and put
On the right hand side: it on the turning stand 99322205.
- disassemble lubrication oil exhaust pipe (2) from the - Drain the oil through the cap underneath the plug.
turbo-blower:
Underneath the turbo-blower loosen the screws (1);;
finally loosen and remove the union (5) from the block;
plug the pipe ends and the exhaust of the turbo-blower.
- oil level rod (4);
- oil filter (3). Warning: avoid contact of engine oil with the skin:
in case of skin contamination, rinse in running water.
Provide for oil recovery and disposal in compliance Engine oil is highly pollutant: provide for disposal in
with the law and regulations in force. compliance with the law and regulations in force.
75675
- loosen the fixing nut (1) and remove the lubrication pipe
from the supercharger. Analogously carry out the same NOTE To disconnect fuel pipelines (2 and 3, Figure 6), in
operation on the other end of the pipe and remove it low pressure from the relating pipe fittings, it is
from the upper part of the heat exchanger. Necessary to press the locking fastener (1) as
- Loosen the fixing screw (3) and remove the exaust shown in picture B.
lubrication pipe from the supercharger.
After having disconnected the pipeline, reset the
- Hold up the supercharger and after lifting it remove the locking fastener (1) in lock position as shown in.
gasket. picture A, to avoid any possible deformation of the
fastener itself.
Figure 6
4
3
2
Figure 8
1
87404
Figure 9
88311
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Bracket fixing screw to injection pump side- -
6. Bracket fixing screw to injection pump side- - 7. Front bracket fixing screw (on suction collector plate) - 8. Injector.
Figure 10 Figure 11
88218 88102
- Disconnect the pipelines (1) and (2) that provide feed - Loosen the two fixing screws (2) and disassemble
and fuel recovery between pump and injectors; screw priming pump (1).
out the nuts fixing the pipes to the pumping elements;
loosen the fuel recovery pipe collar on the injection
pump; operate on the nuts assembled to the injectors
and loosen the screws fixing the fuel recovery pipeline;
loosen the screws holding the fixing brackets of such
pipelines (1, 5, 6, and 7, Figure 9); pipe the pipeline ends.
- Disassemble the injectors and remove them from their
slot: remove the gaskets.
Figure 12 Figure 14
2
1
76149 75683
- Disassemble rocker arm bearings; loosen the two fixing
- Remove tappet caps: screws (2) and remove the complete rocker arm bearing;
Loosen the fixing screws (1) and lift the caps (2); withdraw tappet rods. Repeat the operation for all the
remove the gaskets. remaining rocker arm bearings.
- Disassemble water temperature transmitter (1).
NOTE On the central cap there is a blow-by valve for the
lubrication oil vapours. Figure 15 (Demonstration)
All the gaskets shall always be replaced during
assembly.
Figure 13
88305
- Using the square wrench with suitable dimensions, work
on the A point shown in the picture, release the pressure
and withdraw the Poli-V belt (3) from the transmission
and drive pulleys.
- Proceed disconnecting the automatic tightening device
(1) and the relevant support (2).
Figure 16
87409
87413
- Duly hold the alternator (2) removing it from its support
by loosening the screw (3) and from the bracket by
loosening the screw (1); recover nuts and washers.
Base - May 2010 Print P2D32N003 E
F4CE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 13
Figure 17 Figure 19
88219
117593
- Disassemble thermostat unit; loosen the three fixing - Loosen the fastening screws (4) and remove the oil filter
screws (1), disassemble the thermostat unit (2). support (5), together with the sheaths (1) and (3) and
Remove the gasket (3) and the thermostat (4). the heat exchanger (2).
- Disassemble the ignition pump (see the specific
procedure) and the power takeoff underneath (if
available).
Figure 18 Figure 20
88231 88306
- Loosen the screws (1) and withdraw the alternator - Loosen the fastening screws (3) and remove the pulley
bearing (2). controlling the fan (2).
- Proceed detaching the support (1).
- Remove the transmission pulley (4).
4 75688
4 3
75689
76152
Figure 25
- Proceed disconnecting the cylinder head;
loosen the screws (1) and (2) fixing the cylinder head (3);
hook the brackets with metal ropes and, throughout a
hoist withdraw cylinder head from the block.
- Remove the gasket (4).
Figure 23
00900t
- Remove the engine drive shaft fixing ring from the front
cover. Use the tool 99340055 (4) to operate on the
87747
front tang (2) of the engine drive shaft. Throughout the
tool guide ports, drill the internal holding ring (1) using
- Use the tool 99360339 to operate on the flywheel cover 3,5 mm drill for a 5mm depth. Fix the tool to the ring
box (1) in order to block flywheel rotation (2).
tightening the screws specially provided.
(Utilise starter holding down studs and fixing screw nuts).
Proceed withdrawing the ring (1) tightening the screw
- Loosen the flywheel fixing screws (3) to engine drive (3).
shaft.
Base - May 2010 Print P2D32N003 E
F4CE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 15
Figure 26 Figure 28
88214 87420
- Using the specially provided tie rod (3) for the tool - Screw out the opposite screws (1) from the ports and
99363204 and the lever (4), withdraw the external introduce the withdrawal pins (see picture following).
holding ring (1) from the front cover (2).
- Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (2).
- Remove the flywheel block tool (2).
Figure 27 Figure 29
87419
- Loosen the screws (2) and remove the front cover (1).
87421
- Remove the gasket.
- Screw up two medium length screws in the ports (4) to
sling the flywheel with a hoist.
NOTE Take note of the screw (2) assembly position, since
the screws have different length. Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine
flywheel withdrawal by means of a hoist.
Figure 30 Figure 32
88307
00903t
- Turn the engine upside-down.
- Remove the flywheel cover box fixing ring using the tool - Loosen the screws (2), remove the oil pan(1) recovering
99340056 (3) to operate on the back tang (5) of the the gasket.
engine drive shaft. Throughout the tool guide ports, drill
the internal holding ring using 3,5 mm drill for a 5mm
depth. Figure 33
- Fix the tool 99340056 (3) to the ring (1) tightening the
screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
Figure 31
87655
Figure 34
87422
87424
NOTE Take note of the screw (1) assembly position, since
the screws have different length.
- Remove the screws (1) and disassemble the gears (3)
and (4) from the camshaft (2).
Base - May 2010 Print P2D32N003 E
F4CE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 17
87653
- Place the dial gauge (1) on the timing gear (2) and check
that the slack between the gears (2) and (3) is included
in the range between 0,076 0,280 mm.
70211
Figure 36
87654
- Fit the screws (1) fastening the gears (2) to the camshaft
(3) and tighten them to the prescribed pair.
Figure 39
116355
- Turn the engine shaft (3) and the distribution shaft (4)
so that by mounting the bevel gear on the latter (1) the
stencilled mark on the gear (1) coincides with the groove
on the gear tooth (2).
87655
Figure 40 Figure 42
87656 87658
- Fit the power take-off gear (2) (if available) into the - Re-assemble the box (1) to the engine basement.
specially provided housing and fasten the screws (1),
- Tighten the fastening screws (2) to the same position
detected before disassembly.
Figure 41
NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt.
Figure 43
87657
Figure 44 Figure 47
87663
87660
Tighten the engine flywheel (1) fixing screws (2) in two
- Check the laying surface (1) of the clutch disk: if it is phases:
scratched proceed with facing. - 1st phase; tightening by means of dynamometric wrench
- Check the tooth conditions of the toothed rim (2), to couple 30 4 Nm;
replace it in case of broken tooth or excessive wear. Fit - 2nd phase, 60 5 angle dwell.
the new one, previously heated at the temperature of
150 C for 1520. NOTE Angle dwell shall always be performed using
99395216 tool.
Figure 45 Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt.
Figure 48
87661
87662 88307
- Fit the new sheath on the basement.
- Spline the flywheel (1) on the engine drive shaft by - Assemble the oil pan (1).
tightening the screws (2) manually. - Fit the screws (2) and tighten them to the prescribed
- Duly lock the flywheel before proceeding with tightening pair.
the relevant screws to the prescribed pair. - Tighten the exhaust caps to the prescribed pair.
Print P2D32N003 E Base - May 2010
20 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4CE N ENGINES
Figure 50 Figure 53
87666
87668
- Assemble the water pump (1).
- Fit part (4) of the tool 99346252 on the front tang (3)
of the engine drive shaft; fasten it with the screws (5) and - Tighten the screws (2) and lock them to the prescribed
spline the new tight ring on it (6). couple.
- Fit part (1) on part (4), screw-tighten the nut (7) until Figure 54
the assembly of the tight ring (6) into the front cover (2)
is completed.
Figure 51
88219
88225
NOTE Before assembly, always check that the threads of
- Spline the pulley (2) on the engine drive shaft and tighten the ports and of the screws have no evidence of
the screws to the prescribed pair and angle (1). tear and wear nor dirt.
Figure 55
Figure 52
70221
88231
- Apply to the water pump (1) a new fixing ring (2). - Fit the alternator support (1) and tighten the screws (2)
fastening them to the prescribed pair.
Base - May 2010 Print P2D32N003 E
F4CE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 21
87676
4 75688
- Fit the bracket (1) back to fix the alternator (2) to the - Place the head (3) over the block and insert screws (1)
engine basement. Tighten the screws (3) fastening the and (2).
alternator to the support.
Figure 57 NOTE If the valves have been removed from the head, it
is necessary to assemble them before assembling
the head itself on the engine block.
75703
87670
Figure 59
- Place the gasket (1) over the block.
10 4 1 5 11
NOTE Verify that the engine block stand is clean.
Do not grease the gasket. It is recommended to 13 7 2 8 14
keep the gasket inside packaging until assembly to 9 3 6 12
the cylinder head.
Gasket assembly shall be made following the 76115
direction of wording printed on the gasket itself so - Lubricate cylinder head bolts and install to head.
that this will be readable as indicated in the picture. - Bolts must be torqued using stitching pattern starting
with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque, then
90 degrees rotation for all bolts.
- 1st phase of pre-tightening.
Screws 70 mm: 60 5 N.
Screws 140 mm: 40 5 N.
Screws 180 mm: 70 5 N.
- 2nd phase of angle tightening for all screws: 90 5
- 3rd phase of angle tightening solo per le viti da 140 e da
180 mm: 90 5
1
3
2
2
1 3
75705
76152
- Place the head (3) over the block and insert screws (1) ROCKER ARM UNIT COMPONENTS:
and (2). 1. Elastic ring - 2. Spacer- 3. Rocker arms-
4. Support.
NOTE If the valves have been removed from the head, it - Carry out the assembly of the rocker arms after previous
is necessary to assemble them before assembling check of the components.
the head itself on the engine block.
Figure 63
NOTE Before using the fixing screws again, measure them 18.975
twice as indicated in the picture, checking D1 and 18.963
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced.
D2 D1
75703
19.000 19.000
19.026 19.026
Figure 61 75704
Figure 65 Figure 68
2 1
75806
32655
Adjust the slack between rocker arms and valves using socket
Before executing assembly, check the Rocker Arm driving wrench (1), point wrench (3) and feeler gauge (2).
rods: these shall not be deformed; the spherical ends in Correct slack is:
contact with the Rocker Arm adjustment screw and with the
- suction valves 0.25 0.05 mm
tappet (arrows) shall not present evidence of seizure or wear:
in case of detection proceed replacing them. - exhaust valves 0.50 0.05 mm.
The rods driving the suction and exhaust valves are identical
and therefore interchangeable.
Figure 66 NOTE In TIER 3 engines, due to the presence of a
supplementary lobe, as regards the INTERNAL
E.G.R. the procedure of the regulation of the valve
clearance, which foresees the enforcement of the
D2 D1 clearance regulation of all valves by using only 2
movements of the engine shaft, cannot be used.
Each cylinder must be checked by bringing it up to
the U.D.C. (upper dead centre) at the end of
compression and by regulating the clearance of
both valves exclusively on the cylinder in question.
75703
- Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure them twice
as indicated in the picture, checking D1 and D2
diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced;
Figure 67
75683
Figure 69 Figure 71
1
75707
117588
- Assemble injectors after having replaced the sealing
gasket (1). - Assemble thermostat unit (2) including thermostat (5)
and gasket (4).
NOTE During assembly of injectors, verify that the injector - Tighten the screws to the prescribed couple.
sphere is correctly positioned on the head housing.
NOTE The screws (1) have been have been utilised to fix
the bracket (3) (if available).
Figure 70 The gasket (4) must be new.
Figure 72
87409
Figure 73 Figure 76
87677
88309
- Assemble the ignition pump unit (1) into the gearbox - Assemble the support (3) of the automatic tightening
housing (2) and fix it, without tightening, throughout the device by fastening the relevant screws.
screws (3). - Tighten the fastening screw (1) and assemble the
automatic tightening device (2).
Figure 74 Figure 77
88308
Figure 75 88310
88306
Figure 78 Figure 80
88102 88218
- Assemble priming pump (1) providing new gasket and - Assemble the fastening brackets of the fuel pipes.
tighten the screws (2) to the prescribed couple.
- Assemble the pipes (1) and (2) providing fuel feed and
recovery between pump and injectors;
Screw up the locking nuts and tighten the screws fixing
the fuel recovery manifold; fix the pipes to the injectors
throughout the brackets previously assembled.
Figure 79
88311
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Bracket fixing screw to injection pump side- -
6. Bracket fixing screw to injection pump side- - 7. Front bracket fixing screw (on suction collector plate) - 8. Injector.
Figure 81 Figure 83
70126
4 Figure 84
3 1
87404 75675
Figure 85
88215 87712
Rotary feed pump disassembly and assembly Search for top dead center throughout tool 99360339
procedure
Figure 88
NOTE This procedure prescribes that:
- The fuel pipelines (from pumping elements to
injectors, bleeding recovery pipes from
injectors to pump, LDA pipeline and feed
provided by priming pump) shall all be
disassembled.
- Electrical connection to feed pump shall be
disconnected.
- Accelerator cable shall be disconnected.
On the other hand, in case the pump shall be disassembled - Fit the racket of the tool 99360339 (1) holding the
and reassembled later on without being repaired it will be flywheel provided with the rotation coil (2).
necessary to pr-set it while it is still assembled to the engine - Carefully rotate the flywheel in its rotation director to
and disassemble it only afterwards. annul the gear slacks.
The following procedure analyses this second hypothesis - Rotate the flywheel until the pin (4) provided with the
since it is the more complex. tool 99360339 engages in the notch of the flywheel (3).
87712
88101
Remove the first injector, fit the tool 99395097 (2) and the
relevant dial gauge 99395604 (1) and remove the tappet
cover.
Apply tool 99360339 (see Figure 88) in order to make the
engine shaft rotate.
The condition of 1st cylinder to TDC at end of compression
phase is obtained when the dial gauge pointer reaches
maximum value and suction and exhaust valves are both
closed and not balancing.
Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 88).
Print P2D32N003 E Base - May 2010
30 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4CE N ENGINES
Figure 90 Figure 93
88102
Figure 94
87715
Figure 92
87718
Figure 95 Figure 97
2 1
88148 88102
- Loosen screw (1) that prevents pump shaft rotation and - Assemble the priming pump (1) to the basement (3) and
insert spacer (2). Tighten screw (1)so that it locks spacer tighten the fastening screws (2) to the prescribed pair.
(2): in this way the suppl pump shaft will be able to rotate
- Connect all pipelines (from pumping elements to
freely.
injectors, bleeding recovery pipes from injectors to
- Unlock the engine flywheel. pump, LDA pipeline and feed provided by priming
pump).
- Remove the flywheel rotation locking tool 99360339;
place the starter into its housing. - Connect electrical connections to electro-magnets on
the hydraulic head and on KSB.
88312
- With the ignition pump fitting into its housing and with
loosened fastening screws, remove the closure cap
placed over the pump cover.
- Fit the dial gauge 99395603 (2) and the relevant tool
99395100 (1), pre-loading the rod by 2,5 mm.
- Rotate the engine derive shaft to shift from the condition
of the first cylinder to TDC end of compression phase.
Reset the dial gauges and rotate the engine drive shaft
into the opposite direction until recovering the
condition of the 1st cylinder to TDC in phase of
compression (see Figure 84 or 85).
From this position on the comparator applied on the
pump it must be possible to read the value listed on the
pumping element pre-lift table. Section 4.
- Rotate the pump in anti-clockwise direction if the stroke
is shorter or in clockwise direction if the stroke is longer,
until obtaining the stroke prescribed.
- Checking these conditions, lock the pump by tightening
the relevant nuts to the prescribed pair.
Print P2D32N003 E Base - May 2010
32 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4CE N ENGINES
88230
PART TWO -
ELECTRICAL EQUIPMENT
88320
88314
A C
B
75718
Pre-post heating resistor
Figure 103
It is a component integrating a temperature sensor.
It is assembled to the engine head close to the thermostat unit
and its duty is to detect engine cooling liquid temperature.
Specifications:
Range of working temperatures:
Connection side -40 130 C/(+150 C for
< 10 min.)
Bulb side on engine: -40 140 C
Working tensions: 6 28 V
Settings:
80 C 0.304 0.342 k
20 C 2.262 2.760 k 75723
-10 C 8.244 10.661 k It is a resistor assembled to the suction collector and is utilised
to heat the air during pre-post heating operations.
It is fed by a tele-switch usually placed very close to the engine.
Specifications:
Working tensions: 12 V
Maximum possible
Air flow: 2 cc / min
(pressure 138 kPa)
+0 30
F 15 7
4
6 GH F
30 50 5
NTC 10 GHC T
31 8
N31
1 3 FB
1.2W R
75719
88153 It is assembled to the cylinder head on the engine left hand si-
de.
Legend
Specifications:
F= Fuse
R= Pre-post heating resistance Working tensions: 12 24 V
T= Remote control switch
GHC = Pre-post heating unit Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 633C Contact opening
Electrical diagram pin out upon increasing temperatu-
re
533 C Contact closure
upon decreasing tempera-
PIN Description ture
1 Output for cold start warning light
2 Not connected
3 Feedback signal input from pre-post heating
resistance (FB)
4 Started engine signal input (D)
5 Start-up signal input (50)
6 Pre-post heating resistance supply remote
control switch output (GH)
7 Supply positive (15)
8 Supply negative (31)
9 Not connected
10 Temperature analogue signal input (NTC)
88321
Figure 108
75722
Figure 109
88315
75725
Figure 110
It is place front view on the right hand side of the engine, and
is driven by tooth belt.
Specifications:
Working tension: 12 V
Current delivered: 90A (at 6000 rpm)
Absorption in stand-by: 1mA
Sense of rotation: clockwices
88316
Pin out
PIN Description
1 Signal
2 Signal
3 Screening
PART THREE -
TROUBLESHOOTING
F4CE N ENGINES
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine does not start Battery flat or faulty. Check and recharge battery. Replace bat-
tery if necessary.
Connections to battery terminals cor- Clean, examine and tighten the nuts on
roded or loose. the battery terminals. Replace the cable
terminals and the nuts if excessively cor-
roded.
Incorrect timing of injection pump. Check and correctly time the injection See your Iveco dealer.
pump.
Deposits or water in the fuel tank. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air.
Dismantle and clean the injection pump.
Remove water from tank and refuel.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or transfer
pump.
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in
pump. fact present and also check the fuel pump.
Eliminate the air from the injection pump
by unscrewing the cap and working the
fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.
43
Base - May 2010
44
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use
The engine cuts out. Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection pump. Adjust flow. See your Iveco dealer.
Impurities or water in the fuel lines. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air. Dismantle
and clean the injection pump. Remove
water from fuel tank and refuel.
Clogged fuel filter. Dismantle and replace if necessary.
Presence of air in the fuel and injection Check that the hoses are not cracked or
system. the unions loose. Replace worn parts, re-
move the air from the hoses and deaerate
the injection pump and fuel filter by un-
screwing the caps and working the primer
pump by hand.
Broken injection pump controls. Replace the faulty parts.
Abnormal clearance between camshaft Adjust clearance by replacing shims.
cams and tappets.
Burnt, corroded or chalky valves. Replace the valves, rectify or replace the
cylinder head seatings.
F4CE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4CE N ENGINES
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine overheats Faulty water pump. Check the unit and replace if necessary.
Replace the gasket.
Malfunctioning thermostat. Replace the thermostat.
Fouling in coolant openings in the cylinder Wash following the standards specified
head and cylinder groups. for the type of descaling product used.
Water pump drive belt slack. Check and adjust the tightness of the belt. On applications provided with automatic
tensioner, check corret worching of such
device.
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injection pump. Correct the delivery rate of the pump on See your Iveco dealer.
a bench so that the injection is at the
specified rate.
Dry air cleaner blocked. Clean the air filter or replace if necessary.
Engine operation is irregular and lacks Incorrect timing of injection pump. Check timing and correctly set pump.
power
K.S.B. automatic cold advance device mal- Check or replace injection pump.
functioning.
Excessive piston wear. Check or replace injection pump.
Incorrect calibration of speed regulator. Check and correctly calibrate the regula- See your Iveco dealer.
tor.
45
Base - May 2010
46
ANOMALY POSSIBLE CAUSE REMEDY NOTE
Engine operation is irregular and lacks Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using
F4CE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4CE N ENGINES
ANOMALY POSSIBLE CAUSE REMEDY NOTE
Engine running with abnormal knocking Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and in-
play on one or more main or rod bearings stall smaller bearings. Replace the thrust
or excessive play on shoulders. half-rings.
Crankshaft unbalanced. Check alignment of crankshaft.
Loosening of screws securing flywheel. Replace the loosened screws and tighten
all the screws to the specified torque.
Misalignment of rods. Replace the rods.
Noise from piston journals due to excess- Replace the piston journal and/or the pis-
ive play of piston hubs and in the rod ton and rod bushing.
bushing.
Loose bushings in the rod seatings. Replace with new bushings.
Noisy timing. Adjust the play between camshaft cams
and tappets and check that there are no
broken springs, that there is no excessive
play between the valve stems and the
valve guides, tappets and seatings.
The engine smokes abnormally. Black or Excessive maximum pump output. Disconnect the pump and adjust delivery See your Iveco dealer.
dark grey smoke. in accordance with the data given in the
calibration table.
K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust
tioning. correctly as described in the manual.
There is an excessive delay on the injec- Correct the set-up.
tion pump.
47
Base - May 2010
48
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up.
F4CE N ENGINES
Print P2D32N003 E
F4CE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 49
PART FOUR -
MAINTENANCE PLANNING
MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
Figure 112
87757
Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level. The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
Whether it should be difficult to make the evaluation, proceed and detergent.
cleaning the rod using a clean cloth with no rag grinding and Adequately protect the skin and the eyes, operate
put it back in its slot. Draw it off again and check the level. in full compliance with safety regulations.
In case the level results being close to the tag showing Disposal must be carried out properly, and in full
minimum level, provide filling lubrication of the engines compliance with the law and regulations in force.
components.
87673
Oil motor and filter replacement Whereas you replace the lubrication oil, it is necessary to re-
place the filter.
According to the application the filter can be located in different
Warning: We recommend to wear proper protec- positions: the following procedure is a valid guide for all applica-
tions because of high motor service temperature. tions.
The motor oil reaches very high temperature: you - The filter is composed by a support and a filtering cartridge.
must always wear protection gloves. For the cartridge replacement use the 9936076-tool.
Due to the several applications, the pan shape and the oil
quantity can change slightly. However, the following oper- Warning: the oil filter contains inside a quantity of oil
ations are valid for all applications. of about 1 kg.
We recommend to carry out the oil drainage when the motor Place properly a container for the liquid.
is hot. Warning: avoid the contact of skin with the motor oil:
- Place a proper container for the oil collecting under the in case of contact wash the skin with running water.
pan connected with the drain plug. The motor oil is very pollutant: it must be disposed of
- Unscrew the plug and then take out the control dipsick according to the rules.
and the inserting plug to ease the downflow of the
lubrication oil.
- Replace the filtering cartidge with a new one and screw
manually until when the gasket is in contact with the
support.
The oil motor is very pollutant and harmful.
- Tigthen by means of the 99360076-tool of three fourth
In case of contact with the skin, wash with much turn.
water and detergent.
- Operate the motor for some minutes and check the level
Protect properly skin and eyes: operate according to through the dipsick again. If it is necessary, carry out a
safety rules. topping up to compensate the quantity of oil used for the
Dispose of the residual properly following the rules. filling of the filtering cartridge.
- After the complete drainage, screw the plug and carry out
the clean oil filling.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the
dipsick.
SECTION 4
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Page Page
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Measuring piston diameter . . . . . . . . . . . . . . . . 21
- Removing the valves . . . . . . . . . . . . . . . . . . . . 28
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Checking cylinder head wet seal . . . . . . . . . . . 29
- Conditions for proper pin-piston
coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 - Checking cylinder head supporting surface . . . 29
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Removing carbon deposits, checking and
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 23 grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . 30
GENERAL SPECIFICATIONS
Number of cylinders 4 6
Bore mm 104
Stroke mm 132
TIMING
Checking timing
mm 0.25 0.05
X X
mm 0.50 0.05
FUEL FEED
Injection
Type: Bosch VE 6/12F
bar
CLEARANCE DATA
1 0.4
Pistons
1
X Size X 55.9
Outside diameter 1 103.714 to 103.732
2 Pin housing 2 38.010 to 38.016
X
Piston protrusion X 0.28 to 0.52
X1 X 1* 2.705 to 2.735*
Split ring slots X2 2.440 to 2.460
X2
X3 4.030 to 4.050
X3
* measured on 101 mm
S 1 S1 2.560 to 2.605
S2 Split rings S2 2.350 to 2.380
S3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110
3 0.040 to 0.080
Split rings 0.4
X1 Split ring end opening
X2 in cylinder barrel:
X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3
Small end bush diameter
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82,990 to 83,010
Crankpins 2 68,987 to 69,013
Main bearings
3 No. 1 - 7 / 1 - 5 3 87.982 to 88.008
No. 2-3-4-5-6 / 2-3-4 3 87.977 to 88.013
X1
X2
X3
Shoulder half-rings X3 37.28 to 37.38
4 Valves:
4 7.960 to 7.980
60
4 7.960 to 7.980
45
1 46.987 to 47.013
1 1 43.637 to 43.663
2 43.713 to 43.739
45o
X 1 to 1.52
Sinking
X X 1.05 to 1.52
0.050 to 0.102
Between valve seat
and head 0.050 to 0.102
Valve seats -
Camshaft bush
housings No. 1-5 59.222 to 59.248
Camshaft housings
No. 2-3-4-5 / 2-3-4-5-6-7 54.089 to 54.139
1 23 4 5
2
Camshaft journals:
15 53.995 to 54.045
17
1 3
Bush inside
diameter 54.083 to 54.147
H H 11.02
H 10.74
2
3 Tappet cap outside
diameter: 2 15.929 to 15.959
3 15.965 to 15.980
2
Between tappets and housings 0.020 to 0.065
Tappets -
1
Rocker shaft 1 18.963 to 18.975
2
Between rockers and shaft 0.025 to 0.063
70160
The second last main bearing cap (1) and the relevant
Figure 1 support are fitted with shoulder half-bearing (2).
Figure 4
70158
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdraw the pistons including the connecting rods from the
top of the engine block.
Figure 5
Figure 2
87754
70163
70164
Figure 10
Withdraw carefully the camshaft (1) from the engine block.
Figure 8
70167
107804
TIMING SYSTEM
Camshaft
Figure 12
70512
Figure 13
70172
Figure 15
sec. A-A
107268
70176
Lubricate the tappets (1) and fit them into the relevant
70174
housings on the engine block.
To replace front and rear bushes (1), remove and refit them Figure 19
using the beater 99360362 (2) and the handgrip 99370006
(3).
Tappets
Figure 17 70164
Lubricate the camshaft bush and fit the camshaft (1) taking
care not to damage the bush or its housing.
Figure 20
84053
70238
MAIN DATA CONCERNING THE TAPPETS AND THE
RELEVANT HOUSINGS ON THE ENGINE BLOCK
(dimensions in mm). Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
70179
70182
Check camshaft end float (1).
It shall be 0.23 0.13 mm. Grind journals and crankpins if seizing, scoring or excessive
ovalisation are found. Before grinding the pins (2) measure
Figure 22 them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value (dimensions in mm)
Figure 25
Figure 26
70237
74774
70186
D2 D1
Main bearings (1) are supplied spare with 0.250 0.500 mm
undersize on the internal diameter.
75703
NOTE Do not try to adapt the bearings.
- At final assembly, before re-using the bench support
fastening screws, measure them twice as indicated in the
picture, checking D1 and D2
diameters:
Clean accurately the main half bearings (1) having the if D1 - D2 < 0,1 mm the screw can be utilised again;
lubricating hole and fit them into their housings. if D1 - D2 > 0,1 mm the screw must be replaced;
The second last main half bearing (1) is fitted with shoulder
half rings.
Figure 35
70187
70191
70189
CONNECTING ROD PISTON ASSEMBLY
- Remove caps from supports. COMPONENTS
The backlash between the main bearings and the pins is 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
found by comparing the width of the calibrated wire (2) at 6. Half bearings - 7. Connecting rod - 8. Bush.
the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
The numbers on the scale indicate the backlash in mm. NOTE The pistons are supplied spare with the following
Replace the half bearings and repeat the check if a different sizes:
backlash value is found. Once the specified backlash is - standard;
obtained, lubricate the main bearings and fit the supports by - 0.4 mm oversize.
tightening the fastening screws as previously described.
Base - May 2010 Print P2D32N003 E
F4CE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 21
Figure 37 Pistons
Measuring piston diameter
Figure 39
32613
32615
Figure 40
Figure 38
70192
32614
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Piston pin (1) split rings (2) are removed using a scriber (3).
Figure 41
87730
18857
32619 32620
Lubricate the pin (1) and its seat on piston hubs with engine Check the clearance between the sealing rings (3) of the 1st
oil; the pin shall be fitted into the piston with a slight finger slot (only for pistons of supercharged engines), of the 2nd and
pressure and shall not be withdrawn by gravity. 3rd slot and the relevant housings on the piston (2), using a
feeler gauge (1).
Base - May 2010 Print P2D32N003 E
F4CE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 23
41104
70194
Figure 49
YEAR DAY
CONN.
WEIGHT
ROD No.
87742
Bushes
NOTE Every connecting rod is marked as follows: Check that the bush in the connecting rod small end is free
- On body and cap with a number showing their from scoring or seizing and that it is not loosen. Otherwise
coupling and the corresponding cylinder. replace.
In case of replacement it is therefore necessary Removal and refitting shall be performed using the proper
to mark the new connecting rod with the same beater.
numbers of the replaced one.
When refitting take care to make coincide the oil holes set
- On the body and on the top by numbers on the bush with those set on the connecting rod small end.
indicating number of connecting rod and date Grind the bush to obtain the specified diameter.
of production and by a coloured identification
mark.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1600 to 1640 g (yellow marking);
S W, 1641 to 1680 g (green marking);
S X, 1681 to 1720 g (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
72705
Figure 51
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
Figure 54 Figure 56
87733
Fit half bearings (1) on connecting rod and cap. - connecting rod-piston assemblies shall have the same
weight;
- the arrow marked on the piston crown shall be facing the
NOTE Refit the main bearings that have not been front side of the engine block or the slot obtained on the
replaced, in the same position found at removal. piston skirt shall be corresponding to the oil nozzle
Do not try to adapt the half bearings. position.
Figure 55
70203
Figure 58 Figure 61
70204
- Lubricate the screws (1) with engine oil and then tighten 70207
70205
Figure 60
70208
2 6
A 75751
Figure 65
NOTE Should cylinder head valves be not replaced,
number them before removing in order to refit
them in the same position.
2
A = intake side
75752
A
B
87735
VALVES Figure 70
Figure 68
EXHAUST INTAKE
VALVE VALVE
18882
Removing carbon deposits, checking and Checking clearance between valve stem and
grinding valves valve guide and valve centering
Figure 69 Figure 71
18625
Remove carbon deposits from valves using the proper metal 87738
brush.
Check that the valves show no signs of seizing, scoring or Use a magnetic base dial gauge (1) set as shown in the figure,
cracking. the assembling clearance shall be 0.052 0.092 mm.
Regrind the valve seat, if required, removing as less material Turn the valve (2) and check that the centering error is not
as possible. exceeding 0.03 mm.
75754
Figure 74
88368
Figure 75
116356
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 - 100C and using the proper
them with the spare ones. Use adequate tool to remove as beater, fit the new valve seats, previously cooled, into the
much material as possible from the valve seats (take care not cylinder head.
to damage the cylinder head) until they can be extracted
Use adequate tool to regrind the valve seats according to the
from the cylinder head using a punch.
values shown in Figure 74.
VALVE SPRINGS
Figure 77
Figure 76
50676
3 1
1
70335
2
Check cleanness of cylinder head and engine block coupling
surface.
75759 Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking TOP (1)
Lubricate the valve stems (1) and fit them into the relevant facing the head.
valve guides according to the position marked at removal. The arrow shows the point where the gasket thickness is
Fit the sealing rings (2 and 3) on the valve guide. given.
Figure 81
Figure 79
1 2
3
4
88775
6
There are two types of head seals for F4AE04.., F4AE06.. and
F4HE06.. engines, for the thickness (1.25 mm Type A and
1.15 mm Type B) take the following measures:
5 - for each piston detect, as indicated on Figure 81, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
75751 upper plane then calculate the average:
Position on the cylinder head: the protection cap (5), the S cil1 = S1 + S2
spring (4), the upper cap (3); use tool 99360268 (1) to 2
compress the spring (4) and lock the parts to the valve (6) Repeat the operation for pistons 2, 3, 4, 5 and 6 and
by the cotters (2). calculate the average value.
S + S cil2 + S cil3 + S cil4 + S cil5 + S cil6
S = cil1
6
If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.
75703
TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15 3 1.5 0.3
Main bearing cap 1st stage 50 6 5.0 0.6
2nd stage 80 6 8.0 0.6
3rd stage 90 5
Rear gear housing assembly
(M8x1.25x40) 24 4 2.4 0.4
(M8x1.25x25) 24 4 2.4 0.4
(M10x1.5) 49 5 4.9 0.5
Front cover assembly - Oil pump
(M8x1.25x45) 24 4 2.4 0.4
(M8x1.25x30) 24 4 2.4 0.4
Connecting rod bolts(M11x1.25) 1st stage 30 3 3.0 0.3
2nd stage 60 5 6.0 0.5
3rd stage 60 5
Ladder frame assembly (M10x1.25x25) 43 5 4.3 0.5
Oil rifle plugs
(M10x1) 61 0.6 0.1
(M14x1.5) 11 2 1.1 0.2
Assemble oil suction tube (M8x1.25x20) 24 4 2.4 0.4
Oil pan assembly
(M8x1.25x25) 24 4 2.4 0.4
(M18x1.50) 60 9 6.0 0.9
Set timing pin 51 0.5 0.1
Fuel pump assembly
M8 screw 24 4 2.4 0.4
M6 screw 10 1 1.0 0.1
M6 nut 10 1 1.0 0.1
M10x1.5 flange head nuts pre-torque 10 - 15 1.0 - 1.5
Final torque 50 - 55 5.0 - 5.5
Fuel pump gear (drive gear nut) Snug torque 15 - 20 1.5 - 2.0
Final torque 85 - 90 8.5 - 9.0
Timing pin cap of fuel pump 30 - 35 3.0 - 3.5
Equalizer fastening to cylinder head (M8) 24 4 2.4 0.4
Cylinder head bolts
(M12x70) 50 + 90 5.0 + 90
(M12x140) 40 + 180 4.0 + 180
(M12x180) 70 + 180 7.0 + 180
Assy rocker covers (M8x1.25x25) 24 4 2.4 0.4
Intake manifold (M8x1.25) 24 4 2.4 0.4
Assy air intake connection (M8x1.25) 24 4 2.4 0.4
Oil bypass valve into lube filter head (M22x1.5x10) 80 8 8.0 0.8
Plug (M12x1.5x12) 10 1 2.4 0.4
Exhaust manifold (M10x1.5x65) 43 6 4.3 0.6
Water pump (M8x1.25x25) 24 4 2.4 0.4
Water outlet connection
(M8x1.25x35) 24 4 2.4 0.4
(M8x1.25x70) 24 4 2.4 0.4
Fan support (M10x1.5x20) 33 5 3.3 0.5
Fan pulley
(M6) 10 2 1.0 0.2
(M10) 43 6 4.3 0.6
TORQUE
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 12 7.7 1.2
Crankshaft pulley (M12x1.75x10.9) 110 5 11 0.5
Flywheel housing
(M12x120) 85 10 8.5 1.0
(M12x80) 85 10 8.5 1.0
(M10x80) 49 5 4.9 0.5
(M10x40) 49 5 4.9 0.5
Flywheel housing (M12x1.25) 1st stage 30 4 3.0 0.4
2nd stage 60 5
Assy rear cover plate to flywheel housing (M8x1.25x16) 24 4 2.4 0.4
Fuel injectors 60 5 60 0.5
Fuel lift pump 24 4 24 0.4
Turbocharger to exhaust manifold (M10) 43 6 4.3 0.6
Oil feed to oil filter head 24 4 2.4 0.4
Oil feed to turbocharger (M12x1.5) 35 5 3.5 0.5
Oil drain (M8x1.25x16) 24 4 2.4 0.4
Alternator to alternator support (M8x1.25x30) 24 4 2.4 0.4
Alternator to water inlet conn. assy (M8x1.25x30) 24 4 2.4 0.4
Lower alternator mounting (M10x1.25x25) 24 4 2.4 0.4
Alternator upper pivot to support (M10) 49 5 4.9 0.5
Alternator mounting hardware (M12x1.75x120) 43 6 4.3 0.6
Alternator wiring (M6x1.0 nut) 10 2 1.0 0.2
Starter motor to gear case (M10) 49 5 4.9 0.5
Screw M12 for fastening output shaft caps 1st stage 50 6 5 0.6
2nd stage 80 6 8 0.6
3rd stage 90 5
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening connecting rod caps 1st stage 60 5 6 0.5
2nd stage 60 5
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
TOOLS
TOOL NO. DESCRIPTION
99370415 Gauge base for different measurements (to be used with 99395603)
Dial gauge holding tool for rotating ignition pump timing (use with
99395100 99395603)
99395216 Pair of gauges with and square head for angle tightening
TOOLS
TOOL NO. DESCRIPTION
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
GENERALMANUTENZIONE
Part 3
F4DE N SERIES
Section
General specifications 1
Fuel 2
G-DRIVE applications 3
Tools 5
UPDATING
SECTION 1
General specifications
Page
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 1
COOLING SYSTEM - Viscous pusher fan, having the duty to increase the heat
The engine cooling system, closed circuit forced circulation dissipating power of the radiator. This component as
type, generally incorporates the following components: well will be specifically equipped based on the engines
development.
- Expansion tank; placement, shape and dimensions are
subject to change according to the engines equipment. - Heat exchanger to cool the lubrication oil: even this
component is part of the engines specific equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this - Centrifugal water pump, placed in the front part of the
component will have specific peculiarities based on the engine block.
equipment developed, both for what concerns the - Thermostat regulating the circulation of the cooling
placement and the dimensions. liquid.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.
Figure 2
116359
A = TO RADIATOR
B = FROM RADIATOR
6 Cylinders version
EXHAUST
RADIATOR
74195
Description
The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust
feeding pressure , one main body and one compressor. collector before the turbine and connected by piping to the
induction collector.
During engine working process, the exhaust emissions flow
through the body of the turbine, causing the turbine disk Its funchon is to restrict the exhaust of the emissions ,
wheels rotation. releasing part of them directly to the exhaust tube when the
boost feeding pressure, over the compressor, reaches the
The compressor rotor, being connected by shaft to the
prescribed bar value.
turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air through the air filter. The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
Base - May 2010 Print P2D32N003 E
F4DE N ENGINES SECTION 1 - GENERAL SPECIFICATIONS 7
EXHAUST GAS RE-CIRCULATION SYSTEM The internal EGR system is not equipped with any
(EGR) electronically controlled elements: the system is always
In the TIER 3 version, the profile of the exhaust cam has been active.
modified in order to allow the partial opening of the relative Its configuration does not need additional elements
valve during the aspiration phase (re-circulation of EGR i.e.checking valves, piping or heat exchangers.
exhaust gas) with the subsequent re-introduction of part of The exhaust cam (B) has another lobe apart from the major
the exhaust gas into the engine cylinders. lobe (see Section. A-A fig.) with respects to the configuration
The exhaust gases can partially be re-directed into the without EGR.
cylinders so as to reduce the maximum combustion The additional lobe, during the aspiration phase in the
temperature values responsible for the production of nitric cylinder in question, allows a brief opening of the exhaust
acid (NOx). valve generating re-circulation due to the intake of the
The exhaust gas re-circulation system (EGR), reducing the exhaust gases caused by depression which is created in the
combustion temperature by means of the diminishing of the aspiration phase inside the cylinder.
concentration of oxygen in the combustion chamber,
represents therefore an efficient control system of the
emission of NOx .
Figure 4
114789
SECTION 2
Fuel
Page
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . 3
WORKING PROCESS . . . . . . . . . . . . . . . . . . . . 5
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . 13
COMMON RAIL
General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 1
116360
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engines cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engines oil temperature and pressure - 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and
air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor - 10. Pressure gauge cabling -
11. EDC 7 gearbox.
Through the sensors, present on the engine, the ECU con- The outlet voltage is proportional to the pressure or tem-
trols the engine operation. perature obtained by the sensor.
Air pressure/temperature sensor Engine oil temperature and pressure sensor
It is a component integrating a temperature sensor and a Same as air pressure/temperature sensor, it is fitted on the
pressure sensor. engine oil filter, in a horizontal position.
Fitted on the intake manifold, it measures the max. inlet air It measures engine oil temperature and pressure.
capacity to calculate precisely the fuel quantity to inject at
every cycle.
WORKING PROCESS
Figure 2
High Pressure
Low Pressure
116361
1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on
chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
FUEL SYSTEM DIAGRAM The pressure relief valve housed on the cylinder head, fitted
The following figure outlines the common rail injection on the return of the electro-injectors (3), limits the fuel
system with pump CP3. return flow from the electro-injectors to a pressure of 1.3 2
bar.
The pressure regulator, located upstream from the
high-pressure pump, governs the necessary flow of fuel on In parallel with the mechanical supply pump there are two
the low-pressure system. Then the high-pressure pump by-pass valves.
supplies the rail correctly. This solution, pressurizing only the The by-pass valve (18) is used to run off the fuel from the
necessary amount of fuel, improves energy efficiency and outlet of the mechanical pump at its inlet when the pressure
limits fuel heating in the system. at the inlet of the fuel filter exceeds the allowed limit.
The pressure relief valve (2), fitted on the high-pressure The by-pass valve (17) is used to fill the fuel system through
pump, has the function of keeping the regulator inlet pressure the manual priming pump (10).
constant at 5 bar, irrespective of the efficiency of the fuel filter
and of the system upstream.
The action of the pressure relief valve (2) causes an increase
in the flow of fuel in the cooling circuit of the high-pressure
pump through the pipe (16) for the intake and exhaust from
the pipe (8).
Figure 3
EXHAUST
HIGH PRESSURE
74786
1. High-pressure pump - 2. Pressure relief valve on the high-pressure pump, 5 bar. - 3. Pressure relief valve fitted on the fuel
return from the electro-injectors, from 1.3 to 2 bar. - 4. Rail pressure relief valve. - 5. Common Rail.- 6. Pressure sensor. -
7. Electro-injector. - 8. Return feed line. - 9. Heat exchanger of the control unit. - 10. Mechanical priming pump. -
11. Prefilter fitted on the chassis (if applicable)- 12. Fuel tank - 13. Mechanical fuel pump. - 14. Fuel filter. - 15. Pressure
regulator. - 16. Pipe for cooling high-pressure pump. - 17. By-pass valve. - 18. By-pass valve.
Figure 4
72594
72592 The dump by-pass valve (2) is activated in case, when the
engine is off, it is necessary to fill the feeding system through
the priming pump. In this condition the by pass valve (I) keeps
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, closed while the dump by-pass valve (2) opens up due to the
I - 2 By-pass valves in close position. pressure effect on the entry unit so the fuel flows to the
exhaust unit B.
72593
NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
the fixing screws must be tampered.
The only allowed interventions concern control gear and pressure regulator replacement.
Figure 7
72595
1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear - 5. Connector to
fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry flowing from
engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter - 9. Mechanical
feeding pump.
Sec. B-B
Sec. C-C
70498
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft.
7. Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
Working principle
Figure 9
Sec. B - B
Sec. D - D 72597
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft.
7. Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
The pumping element (3) is orientated towards the pumps During compression phase of the pumping element, the fuel
camshaft (4). During the intake phase, the pumping element achieves the level of pressure determining the opening of the
is fed through the feeding line (5). The quantity of fuel to flow by-pass valve to common rail (2), feeding it through the
to the pumping element is determined by the pressure exhaust unit (I).
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
Base - May 2010 Print P2D32N003 E
F4DE N ENGINES SECTION 2 - FUEL 11
Figure 10 Figure 11
72601
72598
Sec. C - C Sec. A - A
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
4. Ball delivery valve. 5. Piston. 6- Pump shaft. exhaust flowing from pump with connector to high
7. Low-pressure fuel inlet. 8. Pumping elements supplying pressure pipe for common rail.
fuel ducts.
Picture 10 shows the fuel runs at low pressure inside the Picture 11 shows the fuel flow under high pressure running
pump; the following elements are clearly visible: the main through the exhaust galleries of the pumping elements.
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.
Operation RAIL
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on Figure 12
the pumping elements (about 2 bars).
The amount of fuel supplying the high-pressure pump is
metered by the pressure regulator, placed on the
low-pressure system; the pressure regulator is controlled by
the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston
is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining
fuel in the pumping element chamber, not being able to come
out, is compressed above the supply pressure value existing 108609
in the rail.
The thereby-generated pressure makes the exhaust valve 1. Rail 2. Fuel inlet from high-pressure pump
open and the compressed fuel reaches the high-pressure 3. Overpressure valve - 4. Pressure sensor.
circuit. The rail volume is comparatively small to allow a quick
The pumping element compresses the fuel till the top dead pressurisation at startup, at idle and in case of high flow-rates.
center (delivery stroke) is reached. Afterwards, the pressure It anyway has enough volume as to minimise system spikes
decreases till the exhaust valve is closed.
and the use of plenum chambers caused by injectors
The pumping element piston goes back towards the bottom openings and closings and by the high-pressure pump
dead center and the remaining fuel is decompressed. operation. This function is further enabled by a calibrated
hole being set downstream of the high-pressure pump.
When the pumping element chamber pressure becomes less
than the supply pressure, the intake valve is again opened and A fuel pressure sensor (4) is screwed to the rail. The signal
the cycle is repeated. sent by this sensor to the electronic control unit is a
feed-back information, depending on which the rail pressure
The delivery valves must always be free in their movements, value is checked and, if necessary, corrected.
free from impurities and oxidation.
The rail delivery pressure is modulated between 250 and
1600 bars by the electronic control unit, through the
pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
RELIEF VALVE
If the pipe between fuel filter and high-pressure pump is to Mounted on the end of the rail, it has the function of
be removed-refitted, be sure that hands and components are protecting the systems components in case the failure of the
absolutely clean. rail pressure sensor or the pressure regulator of pump CP3
causes an excessive pressure increase in the high-pressure
plant.
When the rail pressure reaches 1800 bars, the valve initially
intervenes in order to allow the fuel to flow and subsequently
to reduce the pressure within safety limits and then it
mechanically regulates the rail pressure to approx. 800 bars.
This valve allows the engine to work for long periods at a
limited efficiency and avoids the excessive overheating of the
fuel preserving the return pipes to the tank.
Powers Pressures
Jet kW bar
DLLA Up to 152 250 1600 bar
DSLA Lower to 152 250 1400 bar
15
The injector is similar as construction to the traditional ones,
apart from the absence of plunger return springs.
The injector can be deemed as composed of two parts:
- actuator spray nozzle composed of pressure rod (1),
plunger (2) and nozzle (3);
- control solenoid valve composed of coil (4) and pilot
valve (5).
The solenoid valve controls spray nozzle plunger lift.
70506
70505
Figure 15
70507
SECTION 3
Industrial application
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 7
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Page Page
GENERAL SPECIFICATIONS
Section pictures of complete engine - common rail version
Figure 1
116362
The and F4DE9684 engines are turbocharged a 4-stroke The section herein described is composed or four sections:
diesel engines with 6 cylinders, with 4 valves per cylinder.
- Section of mechanical overhaul prescribed in accordance
They have high pressure injection fuelling (common rail) and to the engines specific duty, illustrating all necessary
are entirely electronically driven in order to optimise the operation to remove and assembly the external
working process in accordance to the operation, limiting as components of the engine, including cylinder heads,
much as possible the pollution emissions and consumption. gearbox of the timing system and of the front part cover;
- Electrical section, describing the connections to the
different components of the engine control module and
of the sensors assembled to the engine;
- Diagnosis section;
- Section of preventive maintenance operations, providing
instructions for the execution of the main operations.
F4DE9684
Type A*J100 Q*J100 W*J100 E*J103 X*J102 B*J100
Displacement 4485
TURBOCHARGING with intercooler
COOLING By liquid
Water pump control Through belt
Thermostat
- start of opening C 81 2
FILLING
min 12
15W40
engine sump* liters { max 15
engine sump + filter* liters 15 + 1
* first filling
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements
provided by FPT.
Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for
which the engine has been designed.
116366
Disconnect the lubricating pipe (2) from the upper side of the
heat exchanger on the turbo blower (1).
Undo the fastening screws (4) and remove the support (3).
Disassemble the thermostat body including the seal.
116365
Figure 6
Disconnect the oil filling pipe (1).
Unscrew the fixing screws and disconnect the starting motor
(2) from its seat.
116367
Make holes (1) and (2) on both sides of the engine base,
brackets 99361037 and then fix by means of the later, the en-
gine to revolving stand 99322205.
Empty the engine oil by removing the cap of the sump.
116360
1. Connections for Electro-injectors - 2. Engine cooling liquid temperatures sensor - 2. Cable of the fuel pressure sensor -
4. Sensor of engines oil temperature and pressure - 5. Driving shaft sensor -
6. Electro-injector - 7. Temperature - air pressure sensor - 8. Timing system sensor - 9. Cable of fuel heater and fuel
temperatures sensor - 10. Cable of pressure regulating gauge - 11. EDC 7 electronic module.
Disconnect the engines cable from the connectors (1, Disassemble the engine from the engine block removing the
Figure 7) wiring harness to fixing clamps.
Electro-injectors (6); (7) air pressure/temperature sensor; (3)
fuel pressure sensor;
(11) engine control module; (10) high pressure pump sensor;
(8) timing system sensor; (2) Thermostat sensor of engine
cooling liquids temperature; (5) sensor of engines
revolutions.
Print P2D32N003 E Base - May 2010
10 SECTION 3 - INDUSTRIAL APPLICATION F4DE N ENGINES
Figure 8 Figure 10
116370
116368
Figure 11
Figure 9
116371
116369 On the opposite side, loosen the fixing screws (2) of the inlet
manifold (1) and disassemble the joint to the air heater for
Disconnect the fuel return pressure limiter (1), the pipeline the cold start.
by acting on the connections as described on Figure 3. Remove the pressure-air temperature sensor from the
induction manifold (1).
Remove the external vent pipe (2).
Loosen the nuts (3) and disconnect the tappet cap (4).
Figure 12 Figure 14
116372
Undo the fastening screws and remove the belt tightener (2).
Undo the fastening screws and remove the drawback pulley
(3 and 5).
Undo the fastening screws and remove the belt tightener (7). NOTE Disassembled fuel manifolds (4) must not be used
Undo the fastening screws on the cylinder head and remove again, but however replaced with other new ones.
the support (6).
Undo the fastening screws and remove the ventilator
support (1).
Figure 13
Figure 15
70132
70133 Loosen tappet adjustment fastening nuts (1) and unscrew the
adjusters.
Remove injector fastening screws. Use tool 99342101 (1) to Remove the screws (2), remove the rocker assembly (3),
remove injectors (2) from the cylinder head. consisting of: bracket (6), rockers (4), shafts (5) and remove
jumpers (7) from valves.
Remove rods (8).
Figure 16 Figure 18
116377
116373
Remove the fastening screws (1) from the cylinder head (2).
Figure 19
Figure 17
88555
116374
Figure 20 Figure 22
88558
Apply the tool (1) to stop flywheel rotation (2) through the
88556 hole (3) made on the base. Tool (1) positioned in hole (3)
is to be inserted in the groove made on the flywheel blocking
Disconnect connector (1) from the oil temperature pressure its rotation.
sensor. Loosen the engine shaft flywheel fixing screws.
Unscrew screws (2) and disconnect oil temperature pressure
sensor (3).
Unscrew screws(4) and disconnect oil filter support (5) from
the base, and remove the relevant seals.
Remove the heat exchanger from its seat.
Figure 23
Figure 21
116376
Undo the screws (1), disassemble the silencer (2) and the
pulley (3).
The blocking tool of the engine flywheel can facilitate disas-
88557 sembly of dampening flywheel (2) assembled on pulley (3).
Remove nuts (1) and disconnect high pressure pump (2)
along with the fuel pump (3).
Figure 24 Figure 26
88560
00900t
Remove the screws (1) and take out the front cover (2).
Remove the ring sealing the engines driving shaft from the
front cover. Use the tool 99340055 (4) to operate on the
front bar hold of the driving shaft. Through the steering holes
of the tool, perforate the inside holding ring (1) with a straight NOTE Take note of screw (1) assembling positions since
way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool they have different lengths.
to the ring tightening the 6 screws provided with the
equipment. Then proceed removing the ring (2) by tightening
the screw (3).
Figure 27
Figure 25
88561
00904t
Using the specific tie rod (3) of the tool 99363204 and the Remove two opposite screws (1) from the area where the
ancillary lever (4), remove the external holding ring (2) from withdrawal pins will be introduced (2, Figure 28).
the front cover (1). Loosen the remaining flywheel fixing screws (3) from the
driving shaft (2).
Remove the flywheel locking tool (4).
Figure 28 Figure 30
88307
88562
Tighten two screws of medium length into the holes (4) to Turn the engine upside down.
sling the flywheel with the hoist. Remove screws (2) and disconnect oil sump (1).
Throughout the two guide pins (2) previously screw into the Disconnect the high pressure pump stroke sensor.
driving shaft holes (3) withdraw the engine flywheel (1) after
Unscrew the screws(3) and remove timing gear distribution
slinging it with the hoist.
box (4) from the base.
Figure 29
Figure 31
00903t
Remove the holding ring of the flywheel cover box using the
tool 99340056 (3) to operate on the driving shafts back bar
hold (5).
Through the steering holes of the tool, perforate the inside
holding ring with a straight way drill (diam. 3,5mm) for the
depth of 5mm.
Fix the tool 99340056 (3) to the ring (1) tightening the 6
screws provided with the equipment (4). 88564
Figure 32
88567
With a felt-tip pen, highlight the conducting gear tooth (1) Figure 35
mounted on the engine shaft (2) on the upright surface
where a groove has been created for the ignition timing.
Figure 33 70214
Figure 36 Figure 38
88569
88571
GEARCASE FIXING SCREW TIGHTENING DIAGRAM Put a new seal ring on the water pump.
Reassemble box (1) on the engine. Assemble water pump (1); tighten the screws (2) up to the
prescribed torque.
Tighten fixing screws (2) on the same position from where
they had been removed up to the tightening torque indicated
Figure 39
below.
Screws M8 20 28 Nm
Screws M10 42 52 Nm
Reconnect stroke sensor (3) of the high pressure pump.
Figure 37
88572
Disassemble seal ring (2) from the front cap (1), clean the
coupling surface accurately.
Figure 40
88570
Apply tool 99346253 part (6) to the rear output shaft tang
(5), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into housing. 88573
Figure 41 Figure 44
88574
88307
Assemble oil pump (1) on the block and tighten the screws
up to the prescribed torque. Fit the new sheath on the basement.
Assemble the oil pan (1).
Figure 42 Fit the screws (2) and tighten them to the prescribed pair.
Tighten the exhaust caps to the prescribed pair.
88575
Apply tool 99346252 part (4) to the front output shaft tang
(6), secure it by screws (5) and fit the new sealing ring (7).
Position part (2) on part (4), screw nut (3) until completing Figure 45
sealing ring (7) fitting into front cover (1).
Figure 43
88581
Figure 46 Figure 49
88582
80359
Screw two manoeuvring hooks or lunettes on flywheel (1)
using holes (4). Fit on the engine block: a new gasket (1), the heat exchanger
With the help of a hoist bring the flywheel closer to its seat (2) a new gasket (3) and the oil filter support (4).
inside the flywheel housing box. Tighten the screws (5) to the specified torque.
Screw two pins (2) with proper length for shaft holes (3) and
use them as guides, assemble engine flywheel (1) by arrang-
ing it properly in the flywheel housing box. NOTE Before any assembly operation always verify that
Figure 47 the hole and screw threads have no evidence of
wear or dirt.
Figure 50
88583
Figure 48
88586
Lubricate the sealing ring (2) with engine oil and set it on the
oil filter (3).
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3) by
88584
turn.
Tighten engine flywheel (1) fastening screws (2). Apply a new sealing ring on the oil temperature/pressure
sensor (4) and fit it on the support (1).
Tighten the screws (5) to the specified torque.
NOTE Tightening to angle is performed using tool
99395216. Before any assembly operation always Fit a new sealing ring (6) in the engine block seat.
verify that the hole and screw threads have no
evidence of wear or dirt.
Figure 51 Figure 53
88590
88587
Refit the high pressure pump (2) including the feed pump (3)
and tighten the nuts (1) to the specified torque.
Assemble pipeline union (1) and tighten screws (2) up to the
prescribed torque.
Figure 54
Figure 52
116378
Figure 55 Figure 57
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and
70336 a new sealing washer (3) on injector (1).
75703
A
6-cylinder engine
70476
Figure 60 Figure 62
70343
Screw the fastening nuts (2, Figure 61) without locking them.
70342
32655
Use the torque wrench to tighten gradually and alternately Rocker control rods shall not be distorted; the ball seats in
the injector fastening screws (1) to 8.5 0.8 Nm torque. touch with the rocker adjusting screw and with tappets
Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm (arrows) shall not show seizing or wear; otherwise replace
torque. them. Intake and exhaust valve control rods are identical and
are therefore interchangeable.
Carry out the assembly of the equalisers unit , after previous
check of the components.
Figure 65 Figure 67
70520
70345
Adjust clearance between rockers and valves using setscrew
Fit the rods (2). wrench (1), box wrench (3) and feeler gauge (2).
Position jumpers (1) on valves with marks () facing the Clearance shall be as follows:
exhaust manifold. - intake valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.
Figure 66
70346
Figure 68 Figure 70
116371
116379
Figure 69 Figure 71
70352
70355
Check electrical cable (5) conditions, replace if damaged by Fit a new gasket (2) on the tappet cover (1).
cutting the support (2) clamps and removing the screws (5)
Place the tappet cover on, install the bolts in the correct
that secure it to connections (3).
position and tighten.
Fit a new gasket (1) on the support (2).
Figure 72 Figure 74
116370
116380
Reconnect the exhaust manifold (2) with new gaskets.
Tighten the fastening screws (1) to the specified torque.
Assemble the rail (2) and fasten the fixing screws (1) to the
prescribed torque. Sling the turbocharger (4) and place it over the manifold after
Connect new fuel pipes (6) to the rail (2) and to the manifold having first inserted a new gasket, tighten the fastening screws
for electro-injectors (5). (3) to the specified torque.
Connect the fuel pipe (4) to the rail based on the procedure
described in the following illustration.
Figure 73 Figure 75
70126
NOTE Check proper fuel pipe connection. Connect the oil discharge pipe (2) to the turbo-compressor
junction (1) and to the support of the oil filter heat
exchanger.
Assemble the support (3) and fasten with the screws (4).
Figure 76 Figure 78
116381
Connect the piping (2) to the fuel return pressure limiting 116364
device (1).
Connect the external vent pipe (3) to the head cover and to Assemble the bracket and the support (1) of the fuel filter (6).
the crankcase. Proceed connecting in sequence the pipelines (9,3,4 and 5)
of the support (1) to the high pressure pump (8).
Completion of the engine
Connect the pipeline (7) from the high pressure pump to the
Properly handle the engine holding it by a lifter, remove it rail diffuser.
from the rotating shaft, remove the brackets 99361037 and
place it on proper suitable support to carry out the
completion.
Figure 77
Figure 79
70126
All the fuel pipelines are fixed using the clamps shown in the
picture.
For the connection of the pipes, press the clamp (I) following
the arrows direction (Figure B) and connect the pipe to the
clamp on the high pressure pump or on the support of the
fuel filter.
Reset the clamp in the initial locking A position.
116365 NOTE In case the pipes are re-employed, they must keep
the sealing tops at the edges.
Make sure that the fuel pipeline is correctly
connected.
Assemble oil filling pipe (1).
Screw fixing screws and assemble starting motor (2) in place. Reconnect the engine harness to all the sensors, the engine
control module and the rail diffuser.
116382
The and F4DE9684 engines are fully driven by the electronic The electrical and electronic components of the engine are
engine control module. listed here following:
Through the engine control module it is possible to verify the 1. Temperature sensor of cooling liquid;
correct working of the engine. (See part three of the hereby
2. Electro-injector;
users guide specifically dedicated to diagnostic).
3. Starter;
4. Pressure sensor assembled to rail diffuser;
5. Temperature and air pressure sensor;
6. Timing system sensor;
7. Fuel temperature sensor;
8. EDC7 electronic module (not positioned on engine);
9. Driving shaft sensor;
10. Sensor of engines oil temperature and pressure;
11. Pre-post heating resistor.
EDC7 ECU
Figure 81
01525t
A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled);
C - Connector to sensors.
12 16
6 11
50350
1 5
1 - -
2 - -
3 MN Injector cylinder 2 (**)
4 MV Injector cylinder 3 (**) / Injector cylinder 4 (*)
5 VB Injector cylinder 4 (**)
6 HR Injector cylinder 2 (**)
7 - Earth
8 - Injector cylinder
9 MB Injector cylinder 1 (*) / (**)
10 VN Injector cylinder 6 (**) / Injector cylinder 2 (*)
11 VG Injector cylinder 5 (**) / Injector cylinder 3 (*)
12 HN Injector cylinder 3 (**) / Injector cylinder 4 (*)
13 HG Injector cylinder 1 (*) / (**)
14 CN Injector cylinder 4 (**)
15 CB Injector cylinder 6 (**) / Injector cylinder 2 (*)
16 CL Injector cylinder 5 (**) / Injector cylinder 3 (*)
71 11
53 7
35 18 36 17 12 03210t
6 8 16 9 15 C ORANGE
A SKY BLUE
B WHITE
L BLUE
5 22 G YELLOW
4 H GREY
29 M BROWN
N BLACK
1 W LIGHT BROWN
3 23 30 36 03211t S PINK
R RED
V GREEN
Z PURPLE
50319
3 2 1
50342
3 2 1
116384
116383
88440
Starter Figure 91
The starter is usually driven by the starting block assembled to
the vehicles dashboard and provides positive voltage to pin
B20 of the EDC.
Electro-injectors
This is a N.A. type solenoid valves
They are individually connected to the EDC gearcase on con-
88314
nector A.
The resistance of each injector coil is 0.56 0.57 .
1. Feeding relay of the starter
6 cylinder engines
REFERENCE DESCRIPTION PIN EDC
1 Injector cylinder 2 3A
2 Injector cylinder 2 6A
CONNECTOR 1
3 Injector cylinder 1 13 A
4 Injector cylinder 1 9A
1 Injector cylinder 4 5A
2 Injector cylinder 4 14 A
CONNECTOR 2 3 Injector cylinder 3 12 A
4 Injector cylinder 3 4A
1 Injector cylinder 6 10 A
2 Injector cylinder 6 15 A
CONNECTOR 3
3 Injector cylinder 5 16 A
4 Injector cylinder 5 11 A
Figure 92
50343
50349
PT - BOX
PT - BOX is a test tool to be connected to a Laptop.
Figure 93
120995
PT-BOX functions:
- ECU ID reading;
- Failure memory reading;
- Flight recorder reading;
- Parameters reading;
- Failure memory cleaning;
- Active diagnosis: actuators activation/testing;
- Programming of repalced components and parameters/second level;
- Acquisition/Saving of parameters
FAULT CODES
Failure code Failure description
Vehicle 1 ((Sensors / Consistency tests)
1.1.2 ACCELERATOR PEDAL
1.1.9 PLAUSIBILITY +15
1.1.A PLAUSIBILITY +50
Vehicle 2 (Indicator lamps / Relais / Actuators)
1.2.3 EDC LAMP
1.2.5 MAIN RELAY DEFECT
1.2.6 BATTERY VOLTAGE
1.2.8 MAIN RELAY - SHORT CIRCUIT TO BATTERY
1.2.9 AIR-CONDITIONER COMPRESSOR RELAY
1.2.B THERMOSTARTER RELAY 1 (HEATER)
1.2.E MANAGEMENT SYSTEM PRE/POST-HEATING (ACTIVE)
2.2.5 INTERRUPTED AFTER-RUN
2.2.8 MAIN RELAY - SHORT CIRCUIT TO GROUND
Engine 1 (Temperature and pressure sensors)
1.3.1 COOLANT TEMPERATURE SENSOR
1.3.2 COOLANT TEMPERATURE SENSOR (TEST)
1.3.3 AIR TEMPERATURE SENSOR BOOST AIR
1.3.4 BOOST PRESSURE SENSOR
1.3.5 FUEL TEMPERATURE SENSOR
1.3.6 RAIL PRESSURE SENSOR OR SIGNAL ERROR
1.3.7 DBV VALVE MANAGEMENT (BOOST PRESSURE)
1.3.8 OIL PRESSURE SENSOR
1.3.A OIL TEMPERATURE SENSOR
2.3.2 COOLANT TEMPERATURE SENSOR ABSOLUTE TEST
2.3.6 RAIL PRESSURE SENSOR OFFSET
2.3.8 OIL LOW PRESSURE
2.3.A OIL TEMPERATURE ABOVE NORMAL
Engine 2 (Speed sensors/actuators)
1.4.1 CRANKSHAFT SPEED
1.4.2 ENGINE WORKING ONLY WITH CAMSHAFT SENSOR
1.4.3 CAMSHAFT SENSOR
1.4.4 FAULT BETWEEN FLYWHEEL SENSOR AND CAMSHAFT
Damage information
1.4.D ENGINE OVERSPEED
1.5.B HIGH PRESSURE TEST (DEACTIVATES RAIL PRESS.MONITORING)
1.9.D INDICATES TORQUE LIMITATION DUE TO PERFORMANCE LIMITER
4.9.E INDICATES THE TORQUE LIMITATION DUE TO ENGINE PROTECTION
6.9.E INDICATES TORQUE LIMITATION DUE TO FUEL QUANTITY LIMITATION
F4DE N ENGINES
POSSIBLE CAUSE RECOMMENDED TESTS OR
ANOMALY (*) = if available in the equipment INTERVENTION REMARKS
Low performance at load request. Insufficient fuel level in the tank. Check fuel level. The excessive smoke is due to the fact
that, in case of insufficient fuel feeding, the
Possible exessive smoke. engine control module tries to compen-
sate prolonging the injectors working
Possible blink-code 8.1 time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter
impurities or deformed because of over- is working correctly.
heating.
If the pump plunger is permanently de-
pressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.
Obstructed air filter. Replace the air filter. Solve the cause of the filters obstruction.
Excessive fuel blow-by from rail boost Check the O Rings and the correct con- Unless the leakage is significant, no per-
valve. nection of the pipe fittings under the formance failures will be detected.
feeding pump (the lockers must stay out- To verify O-rings integrity, extract from
side and the fittings must be well locked). the tank the fuel recycling pipeline, seal
Visually check the low pressure pipeline the end and activate the priming pump
integrity. driving the low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if
valve. there are any significant blow-by from the
boost gauge valve; in such case replace
the valve.
The engine suddenly stops(with no previ- Obstructed fuel filter. Replace the fuel filter. Solve the cause of the filters obstruction
ous problems) and does not start again. (empty and clean the tank and the part of
47
Base - May 2010
48
POSSIBLE CAUSE RECOMMENDED TESTS OR
ANOMALY (*) = if available in the equipment INTERVENTION REMARKS
F4DE N ENGINES
Print P2D32N003 E
F4DE N ENGINES SECTION 3 - INDUSTRIAL APPLICATION 49
MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
MAINTENANCE PROCEDURES
Checks and inspections
Figure 95
Engine oil level check
The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided rod (1).
Figure 94
88543
Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level. The engine oil is highly polluting and harmful.
Whether it should be difficult to make the evaluation, proceed In case of contact with the skin, rinse well with water
cleaning the rod using a clean cloth with no rag grinding and and detergent.
put it back in its slot. Draw it off again and check the level.
In case the level results being close to the tag showing mini- Adequately protect the skin and the eyes, operate in
mum level, provide filling lubrication of the engines compo- full compliance with safety regulations.
nents. Disposal must be carried out properly, and in full com-
pliance with the law and regulations in force.
Verify that the radiator is clean, the correct working of the fan Inspection of drive belt tensioning
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit. The drive belt tensioning control is made using an automatic
tensioning device therefore no intervention is required apart
from checking the wear status of the belt itself.
Inspection and setting of tappet clearance Oil motor and filter replacement
Figure 96
Warning: We recommend to wear proper protec-
tions because of high motor service temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves.
Due to the several applications, the pan shape and the oil
quantity can change slightly. However, the following oper-
ations are valid for all applications.
We recommend to carry out the oil drainage when the motor
is hot.
- Place a proper container for the oil collecting under the
70520 pan connected with the drain plug.
Adjust clearance between rockers and valves using setscrew - Unscrew the plug and then take out the control dipsick
wrench (1), box wrench (3) and feeler gauge (2). and the inserting plug to ease the downflow of the lubrica-
Clearance shall be as follows: tion oil.
- intake valves 0.25 0.05 mm
- exhaust valves 0.50 0.05 mm.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dip-
sick.
Whereas you replace the lubrication oil, it is necessary to re- Alternator belt replacement
place the filter. Due to several applications the belt run can change very much.
According to the application the filter can be located in differ-
ent positions: the following procedure is a valid guide for all ap-
plications.
Warning: with switched off motor (but still hot) the
- The filter is composed by a support and a filtering car- belt can operate without advance notice.
tridge. For the cartridge replacement use the
9936076-tool. Wait for the motor temperature lowering to avoid
very serious accidents.
Warning: the oil filter contains inside a quantity of oil
of about 1 kg.
Place properly a container for the liquid.
Warning: avoid the contact of skin with the motor oil:
in case of contact wash the skin with running water. For applications with automatic belt stretcher, the procedure
is the following:
The motor oil is very pollutant: it must be disposed of
according to the rules. Figure 97 (Demonstration)
During this operation dont smoke and dont use free - By means of a square wrench of proper size act on point
flames. A, indicated on the figure, of the automatic belt tightener
Avoid to breathe the vapors coming from filter. (1) and release the pressure.
- Remove the control belt (2) from the driven and inter-
mediate pulleys.
- Replace the worn belt with a new one.
According to the applications the filters position and the quan-
tity can change. - Place the belt on the pulleys and the guide rollers.
However the following operations are valid for all applications. - Place the automatic tightener in order to key the belt in
the functioning position.
- Drain the fuel inside the filter by operating the water re-
lease screw. Collect the fuel in a container without impu- - Check proper position in the races of the pulleys.
rities.
- Unscrew the cartridge by using the 99360076-tool.
- Collect the eventual fuel inside the filtering cartridge.
- Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.
- Screw manually the new filtering cartdrige until when the
gasket is completely on its seat.
- Tigthen through the 99360076-tool at 10-15 Nm torque.
SECTION 4
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 16
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Page Page
GENERAL SPECIFICATIONS
Type 6 CYLINDERS
Number of cylinders 6
Bore mm 104
Stroke mm 132
TIMING
Checking timing
mm 0.20 to 0.30
X X
mm 0.45 to 0.55
FUEL FEED
ba
r Injection pressure bar 250 - 1600
CLEARANCE DATA
Type 6 CYLINDERS
1 0.4
Pistons
1
X Size X 55.9 / 49.5 ()
Outside diameter 1 103.714 to 103.732 / 103.759 to 103.777 ()
2 Pin housing 2 38.010 to 38.016
X
Piston protrusion X 0.28 to 0.42
Type 6 CYLINDER
S 1 S1 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0,.060 to 0,110 / 0.040 to 0.090 ()
3 0.040 to 0.080
Split rings 0.4
X1 Split ring end opening
X2 in cylinder barrel:
X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3
Small end bush diameter
Type 6 CYLINDERS
Max. tolerance
on connecting rod
axis alignment -
1 2
Journals 1 82.990 to 83.010
Crankpins 2 68.987 to 69.013
Main bearings
3 No. 1 - 7 3 87.982 to 88.008
No. 2-3-4-5-6 3 87.977 to 88.013
X 1
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
Type 6 CYLINDERS
4 6.970 to 6.990
60 0.25
4 6.970 to 6.990
45 0.25
1 34.837 to 34.863
1 1 34.837 to 34.863
2 34.917 to 34.931
45
X 0.59 to 1.11
Sinking
X X 0.96 to 1.48
0.054 to 0.094
Between valve seat
and head 0.054 to 0.094
Valve seats -
Type 6 CYLINDERS
Injector protrusion X -
X
Camshaft bush
housings No. 1 59.222 to 59.248
(flywheel side)
Camshaft housings 54.089 to 54.139
No. 2-3-4-5-6-7
1 23 4 5
2
Camshaft journals:
17 53.995 to 54.045
1 3
Bush inside
diameter 54.083 to 54.147
H H 6.045
H 7.582
Type 6 CYLINDERS
2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.960 to 15.975
2
Between tappets and housings 0.025 to 0.070
Tappets -
1
Rocker shaft 1 21.965 to 21.977
2
Between rockers and shaft 0.024 to 0.162
Figure 1 70160
The second last main bearing cap (1) and the relevant support
are fitted with shoulder half-bearing (2).
Figure 4
70158
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdraw the pistons including the connecting rods from the
top of the engine block.
Use tool 99360500 (1) and hoist to remove the crankshaft (2)
from the block.
Figure 2
Figure 5
70159
Remove the screws (1) and the main bearing caps (2). 70162
Figure 9
70163 s
Figure 10
Withdraw carefully the camshaft (1) from the engine block.
Figure 8
70167
107804
TIMING SYSTEM
Camshaft
Figure 12
88595
Camshaft pin and cam surfaces shall be absolutely smooth; if camshaft and the bushes.
they show any traces of seizing or scoring replace the
Figure 13
88596
Figure 15
116363
88600
88599
Lubricate the tappets (1) and fit them into the relevant
To replace bush (1), remove and refit it using the beater housings on the engine block.
99360362 (2) and the handgrip 99370006 (3).
Figure 19
88601
Tappets Lubricate the camshaft bush and fit the camshaft (1) taking
care not to damage the bush or the housing.
Figure 17
Figure 20
88602
88612
Set camshaft (3) retaining plate (1) with the slot facing the top
MAIN DATA CONCERNING THE TAPPETS AND THE of the engine block and the marking facing the operator, then
RELEVANT HOUSINGS ON THE ENGINE BLOCK tighten the screws (2) to the specified torque.
88605
70182
Check camshaft end float (1).
It shall be 0.23 0.13 mm.
Grind journals and crankpins if seizing, scoring or excessive
ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Figure 24
88604
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Figure 25
Figure 26
70237
74774
Figure 28
70186
NOTE Refit the main bearings that have not been - fit caps (1), including the half bearings (2) on the relevant
replaced, in the same position found at removal. supports.
Clean accurately the main half bearings (1) having the 75703
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
Figure 34
70187
- 2nd stage, with dynamometric wrench to 80 6 Nm. This check is performed by setting a magnetic-base dial gauge
(2) on the output shaft (3) as shown in the figure, standard
Figure 32 value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.
70188
Figure 35
- 3rd stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90 5 angle.
Figure 33
70191
Figure 36 Pistons
Measuring piston diameter
Figure 39
32613
Remove split rings (1) from piston (2) using pliers 99360183
32615
(3).
Figure 40
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 38
1.5
2.705 2.420
2.560 2.735 2.440
* 2.605
220
2.350
2.380
3.970
3.990 38.010 37.994
38.016 38.000
114797
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS
* Value measured on 101 mm diameter
Print P2D32N003 E Base - May 2010
22 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4DE N ENGINES
Figure 41
114798
MAIN DATA CONCERNING MONDIAL MAHLE PISTON, PINS AND SPLIT RINGS
* Value measured on 101 mm diameter
Piston pins
Figure 42
Figure 44
18857
32619
Lubricate the pin (1) and its seat on piston hubs with engine 32620
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity. Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Base - May 2010 Print P2D32N003 E
F4DE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 23
41104
70194
Figure 49 Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
80339
88609
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (4) are read as shown in the figure.
Figure 52 Figure 54
72705
Figure 55
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
70201
NOTE Split rings are supplied spare with the following
sizes: Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
- standard; Use band 99360605 (2) to fit the connecting rod-piston
- 0.4 mm oversize. assembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to
the cap coupling number.
Figure 56
NOTE Before using the fixing screws again, measure them
twice as indicated in the picture, checking D1 and
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced.
D2 D1
75703
88610
Figure 58
DIAGRAM FOR CONNECTING ROD-PISTON
ASSEMBLY FITTING INTO BARREL
- Split ring openings shall be displaced with each other by
120;
- connecting rod-piston assemblies shall have the same
weight;
- the arrow marked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
piston skirt shall be corresponding to the oil nozzle
position.
70204
Finding crankpin clearance
- Lubricate the screws (1) with engine oil and then tighten
Figure 57 them to the specified torque using the dynamometric
wrench (2).
Figure 59
70203
70205
Figure 62
70206
70208
- Remove the cap and find the existing clearance by
comparing the calibrated wire width (1) with the scale Once connecting rod-piston assemblies refitting is over, use
on the wire envelope (2). dial gauge 39395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 to 0.52 mm.
Figure 61
70207
If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
70321
70322
Figure 66
70323 70325
This check shall be performed using the proper tools.
Use a pump to fill with water heated to approx. 90C and 2 The rated thickness A for the cylinder head is 105 0.25 mm,
to 3 bar pressure. max. metal removal shall not exceed thickness B by 1 mm.
Replace the cup plugs (1) if leaks are found, use the proper
beater for their removal/refitting.
NOTE After grinding, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with
water-repellent sealant.
Use a rule (2) and a feeler gauge (3) to check the cylinder
head (1) supporting surface.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.
VALVES Figure 70
Figure 68
EXHAUST INTAKE
VALVE VALVE
18882
107280
Removing carbon deposits, checking and Checking clearance between valve stem and
grinding valves valve guide and valve centering
Figure 69 Figure 71
18625
Figure 73
70328 Check the valve seats (2). If slight scoring or burnout is found,
regrind seats using adequate tool (1) according to the angle
Use a bore dial gauge to measure the inside diameter of the values shown in Figure 74.
valve guides, the read value shall comply with the value
shown in the figure.
Figure 74
INTAKE EXHAUST
70331
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 - 100C and using the proper
them with the spare ones. Use adequate tool to remove as beater, fit the new valve seats, previously cooled, into the
much material as possible from the valve seats (take care not cylinder head.
to damage the cylinder head) until they can be extracted
Use adequate tool to regrind the valve seats according to the
from the cylinder head using a punch.
values shown in Figure 74.
Figure 75
EXHAUST INTAKE
70332
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD (6-CYL.)
Figure 76 After regrinding, check that valve (3) sinking value is the
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1).
70333
50676
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
Height Under a load of
mm kg
H 47,75 Free
H1 35,33 P 339,8 19 N
H2 25,2 P1 741 39 N
Figure 79
770321
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
88775
There are two types of head seals, for the thickness (1.25 mm
70335
Type A and 1.15 mm Type B) take the following measures:
- for each piston detect, as indicated on Figure 81, at a
Check cleanness of cylinder head and engine block coupling distance of 45 mm from the centre of the piston
surface. overhandings S1 and S2 in relation to the engine base
Take care not to foul the cylinder head gasket. upper plane then calculate the average:
Set the cylinder head gasket (1) with the marking TOP (1)
facing the head.
The arrow shows the point where the gasket thickness is
given. S cil1 = S1 + S2
2
For 6 cylinder versions:
Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate
NOTE Before using the fixing screws again, measure them the average value.
twice as indicated in the picture, checking D1 and
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again; S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6
S=
if D1 - D2 > 0,1 mm the screw must be replaced. 6
D2 D1 If S is > 0,40 mm use seal type A.
If S is < 0,40 mm use seal type B.
75703
TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Bench fixing screws: 1st step 50 6 5 0.6
2nd step 80 6 8 0.6
3rd step 90_ 5_
Connecting rod cap: 1st step 30 3 3 0.3
2nd step 60 5 6 0.5
3rd step 60_ 5_
Engine cover fixing nuts (M8x125) 25 5 2.5 0.5
Engine flywheel fixing screws: 1st step 30 4 3 0.4
2nd step 60_ 5_
Pulleys and dampener fixing screws 110 5 11 0.5
Screws used to fix the injectors on the cylinder heads 110 5 11 0.5
P.A.P. gear fixing nut: 105 7 10.5 0.7
Compressor gear fixing nut: 125 19 12.5 1.9
Distribution gear fixing screws: 36 4 3.6 0.4
Piston lubricating nozzle fixing unions: 15 3 1.5 0.3
Distribution box fixing screws
M8 1.25x40 24 4 2.4 0.4
M10 1.5x30 47 5 4.7 0.5
Front cover fixing screws
M10 1.5x30 24 4 2.4 0.4
Bench cap fixing screws M12x1.50 1st step 50 6 5.0 0.6
2nd step 80 6 8.0 0.6
3rd step + 90_ 5_
Ladder Frame fixing screws M10 1.5x25 43 5 4.3 0.5
Hoisting bracket fixing screws:
M12 1.75x25 70 12 7 1.2
M10 43 5 4.3 0.5
Heat exchanger fixing screws
M8 1.25x35 25 5 2.5 0.5
M8 1.25x100 25 5 2.5 0.5
M12 Connector 25 5 2.5 0.5
TORQUE
COMPONENT
Nm kgm
Screws used to fix the exhaust manifold on the head:
M8x1.25x25 mm 25 5 2.5 0.5
M8x1.25x14 mm 25 5 2.5 0.5
M11x1.25 connection rod cap fixing screws 1st step 30 3 3.0 0.3
2nd step 60 5 6.0 0.5
3rd step + 90_ 5_
Flywheel fixing screws
M12 85 10 8.5 1.0
M10 49 5 4.9 0.5
M8x1.25x25 distribution shaft should plate fixing screws 24 4 2.4 0.4
M8x1.25x20 distribution shaft gear fixing screws 36 4 3.6 0.4
Rocker arm fixing screws 36 5 3.6 0.5
3/8 rocker arm register fixing screws 24 4 2.4 0.4
Rocker arm box fixing screws 24 4 2.4 0.4
M12x1.25 phonic wheel fixing screws 110 5 11.0 0.5
Head side fuel connector fixing 50 5 5.0 0.5
Common Rail side fuel connector fixing 20 2 2.0 0.2
Common Rail fixing M8 1.25x10
M8 1.25x50 24 4 2.4 0.4
M8 1.25x90
Fixing of high pressure pipe between Common Rail and M14x1.5 cylinder head 20 2 2.0 0.2
Fixing of fuel combustion filter support on M12x1.75x25 base 77 8 7.7 0.8
Fixing of turbine on the M8x1.25 exhaust manifold 25 5 2.5 0.5
M12x1.5 oil delivery and return pipeline fixing 35 5 3.5 0.5
Oil level rod fixing 24 4 2.4 0.4
81 0.8 0.1
M8x1.25x30 oil pump fixing screws 24 4 2.4 0.4
Principal oil delivery screws (caps)
M10 1 61 0.6 0.1
M14 1.5 11 2 1.1 0.2
Fixing between oil cooler with oil filter assembly 24 4 2.4 0.4
Fixing of the water pump on the base: 24 4 2.4 0.4
M8x1.25x25 43 6 4.3 0.6
Belt tightener fixing
M10x1.5x60
M10 fan support fixing 33 5 3.3 0.5
Fan pulley fixing
Fan spacer or accessory pulley fixing (on request)
M6 10 2 1.0 0.2
M10 43 6 4.3 0.6
M12 77 12 7.7 1.2
TORQUE
COMPONENT
Nm kgm
Stud fixing for M8 fuel pump assembly 12 2 1.2 0.2
M8x1.5 injection pump fixing screws 24 4 2.4 0.4
M18x1.5 injection pump gear fixing nut closure 105 5 10.5 0.5
Fixing of the unions between the injection pump and the M12x15 Common Rail 20 2 2.0 0.2
Injector fixing screws 3.5 0.35 0.35 0..35
Injector connector fixing screws 1.5 0.25 0.15 0..25
Oil pressure regulator sensor fixing 82 0.8 0.2
Fixing of distribution shaft sensor in the M6 gear box 82 0.8 0.2
Fixing of engine shaft speed sensor on the M6 front cap 82 0.8 0.2
Fixing of the temperature sensor on the M14x1.5x12 cylinder heads 20 3 2.0 0.3
Fixing of the air temperature sensor on the M6x1x20 intake manifold 31 0.3 0.1
Fixing of the air pressure and temperature sensor on the intake manifold M5 31 0.3 0.1
Fuel pressure sensor fixing 35 5 3.5 0.5
M14x1.5x12 fuel temperature sensor fixing 20 3 2.0 0.3
Fixing of gear on the 5/8 air compressor 125 19 12.5 1.9
Air compressor fixing on the M12 base 81 12 8.1 1.2
Screw M12 for fastening output shaft caps 1st stage 50 6 5 0.6
2nd stage 80 6 8 0.6
3rd stage 90 5
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening connecting rod caps 1st stage 60 5 6 0.5
2nd stage 60 5
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99341015 Press
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
99370415 Gauge base for different measurements (to be used with 99395603)
TOOLS
TOOL NO. DESCRIPTION
99395216 Pair of gauges with and square head for angle tightening
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
Part 4
F4GE N ENGINES
Sezione
General specifications 1
Fuel 2
Tools 5
SPECIAL REMARKS
Where possible, the same sequence of procedures has been followed for easy reference.
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.
Example
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly
Compression ratio
Tolerance
Tighten to torque
Weight difference
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Oversized
Interference
Higher than.
Strained assembly
Maximum, peak
Undersized
Thickness
Less than.
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer
UPDATING
SECTION 1
General specifications
Page
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 7
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 1
Routing of oil
under pressure
Routing of oil return
by gravity to sump
Introduction of oil
116396
Figure 2
112886
Figure 3
003240t
COOLING SYSTEM - Heat exchanger to cool the lubrication oil: even this
The engine cooling system, closed circuit forced circulation component is part of the engines specific equipment.
type, generally incorporates the following components: - Centrifugal water pump, placed in the front part of the
- Expansion tank; placement, shape and dimensions are engine block.
subject to change according to the engines equipment. - Thermostat regulating the circulation of the cooling liquid.
- Radiator, which has the duty to dissipate the heat - The circuit may eventually be extended to the
subtracted to the engine by the cooling liquid. Also this compressor, if this is included in the equipment.
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
- Visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engines
development.
6 cylinders version
Figure 4
TO RADIATOR
FROM RADIATOR
117586
Water coming out from thermostat
6 cylinders version
Figure 5
TO RADIATOR
FROM RADIATOR
117587
EXHAUST
4 cylinders version
EXHAUST
6 cylinders version
88208
Description
The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust collector
feeding pressure , one main body and one compressor. before the turbine and connected by piping to the induction
During engine working process, the exhaust emission flow collector.
through the body of the turbine, provoking the turbine disk Its duty is to choke the exhaust of the emissions , releasing part
wheels rotation. of them directly to the exhaust tube when the boost feeding
The compressor rotor, being connected by shaft to the pressure, over the compressor, reaches the prescribed bar
turbine disk wheel, rotates as long as this last one rotates, value.
compressing the sucked air through the air filter. The cooling process and the lubrication of the turbocharger
The air coming out of the compressor is sent via the intake and of the bearings is made by the oil of the engine.
manifold directly to the pistons.
EXHAUST
RADIATOR
74195
4 cylinders version
EXHAUST
RADIATOR
74195
6 cylinders version
Description
The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust collector
feeding pressure , one main body and one compressor. before the turbine and connected by piping to the induction
collector.
During engine working process, the exhaust emission flow
through the body of the turbine, provoking the turbine disk Its duty is to choke the exhaust of the emissions , releasing part
wheels rotation. of them directly to the exhaust tube when the boost feeding
pressure, over the compressor, reaches the prescribed bar
The compressor rotor, being connected by shaft to the
value.
turbine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter. The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 1 - GENERAL SPECIFICATIONS 11
EXHAUST GAS RE-CIRCULATION SYSTEM The internal EGR system is not equipped with any
(EGR) electronically controlled elements: the system is always active.
In the TIER 3 version, the profile of the exhaust cam has been Its configuration does not need additional elements
modified in order to allow the partial opening of the relative i.e.checking valves, piping or heat exchangers.
valve during the aspiration phase (re-circulation of EGR The exhaust cam (B) has another lobe apart from the major
exhaust gas) with the subsequent re-introduction of part of lobe (see Section. A-A fig.) with respects to the configuration
the exhaust gas into the engine cylinders. without EGR.
The exhaust gases can partially be re-directed into the The additional lobe, during the aspiration phase in the cylinder
cylinders so as to reduce the maximum combustion in question, allows a brief opening of the exhaust valve
temperature values responsible for the production of nitric generating re-circulation due to the intake of the exhaust gases
acid (NOx). caused by depression which is created in the aspiration phase
The exhaust gas re-circulation system (EGR), reducing the inside the cylinder.
combustion temperature by means of the diminishing of the
concentration of oxygen in the combustion chamber,
represents therefore an efficient control system of the
emission of NOx .
Figure 8
114789
SECTION 2
Fuel
Page
- General information . . . . . . . . . . . . . . . . . . . . 3
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Example of identification . . . . . . . . . . . . . . . . . 5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- General information . . . . . . . . . . . . . . . . . . . . 8
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- General information . . . . . . . . . . . . . . . . . . . . 12
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 14
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 1
2
1
4
74168
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure
gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.
Figure 2
116385
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Fuel is sucked from the fuel tank by the priming pump. This The fuel arrives therefore to the valve gauging the pressure
last one is placed on the engine basement and is driven by inside feed pump.
the camshaft.
The distribution plunger further increases this pressure and
Throughout the filter, the fuel is piped to the union fitting delivers fuel throughout the delivery pipe fitting to the
vacuum chamber of the transfer pump. (For applications to injectors.
be equipped in cold climate areas, the fuel filter is provided
The fuel drawing from the injectors is recovered and
with heater).
delivered to the tank again.
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
FEED PUMP
The rotary type pump is driven by a gear mating the camshafts one.
Example of identification
V = Distribution rotary plunger
E = Pump dimensions
4 = 4 cylinders engine
12 = Distribution plunger in mm.
1150 = N. of pump revolutions per minute
LV = Left direction of rotation
Figure 3
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
Injection pump longitudinal section
1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk -
9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate -
14. Gauge pin - 15. Counteracting spring.
PRIMING PUMP
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to
the engine basement and driven by the camshaft.
Figure 4
88209
FUEL FILTER
The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and
separation of water from fuel.
On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the
bearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperature
sensor. On some versions, a water presence sensor is present at filtering cartridge base.
Figure 5
88210
Figure 6
86495
1. Injector fuel pipe 1 - 2. Injector fuel pipe 2 - 3. Injector fuel pipe 3 - 4. Injector fuel pipe 4 - 5. Injector fuel pipe -
6. Injector fuel pipe 5 - 7. Injector fuel pipe 6 - 7. Injector fuel pipe 6 - 8. Injection pump - 9. Injector.
Figure 7
114799
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Fuel is sucked from the fuel tank by the priming pump. This
Fuel is delivered to the pressure gauge valve within feed
last one is placed on the engine basement and is driven by
pump.
the camshaft.
Timing plungers further increase the pressure and deliver fuel
Throughout the filter/s, the fuel is piped to the union fitting
to the injectors throughout the delivery pipe fittings.
vacuum chamber of the transfer pump. (For applications to
be equipped in cold climate areas, the fuel filter is provided Fuel bleeding from the injectors is recovered and piped back
with heater). to the pump.
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
PRIMING PUMP
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to
the engine basement and driven by the camshaft.
Figure 8
88209
FUEL FILTER
The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and
separation of water from fuel.
On the filter cartridge base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the
bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a
temperature sensor (5).
Figure 9
88210
Figure 10
127132
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Connector for LDA pressure gauge pipe within suction
collector - 4. Fuel feed rotary pump - 5. Electro-valve - 6. KSB thermal bulb - 7. KSB Sensor - 8. Injector.
Figure 11
127134
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Fuel is sucked from the fuel tank by the priming pump. This The fuel arrives therefore to the valve gauging the pressure
last one is placed on the engine basement and is driven by inside feed pump.
the camshaft.
The distribution plunger further increases this pressure and
Throughout the filter, the fuel is piped to the union fitting delivers fuel throughout the delivery pipe fitting to the
vacuum chamber of the transfer pump. (For applications to injectors.
be equipped in cold climate areas, the fuel filter is provided
The fuel drawing from the injectors is recovered and delivered
with heater).
to the tank again.
Transfer pump is placed inside the feed pump, and is bladed
type; its duty is to increase fuel pressure in correspondence
with the increase of the number of revolutions.
PRIMING PUMP
This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to
the engine basement and driven by the camshaft.
Figure 12
88209
FUEL FILTER
The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and
separation of water from fuel.
On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage.
Figure 13
127131
1. Bleed screw - 2. Fuel filter bearing- - 3. Filter cartridge - 4. Water dump screw.
SECTION 3
Industrial application
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 5
F4GE ENGINE CHARACTERISTICS . . . . . . . . . . . . 6
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE ENGINE CHARACTERISTICS . . . . . . . . . . . . 7
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . 7
- 6-cylinder engines . . . . . . . . . . . . . . . . . . . . . . . 9
PART ONE - MECHANICAL COMPONENTS . . . 11
OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED
WITH MECHANICAL ROTARY PUMP . . . . . . 13
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Engine setting operations for the assembly on turning
stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Disassembly of application components . . . . . . 14
- Installation of rear components . . . . . . . . . . . . 23
- Installation of rear components with reduced
distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Flywheel installation . . . . . . . . . . . . . . . . . . . . . 28
- Installation of front components . . . . . . . . . . . . 28
- Timing of additional masses . . . . . . . . . . . . . . . 30
- Assembly of additional masses . . . . . . . . . . . . . 30
- Completion of engine re-assembly . . . . . . . . . . 39
- Rotary feed pump disassembly and assembly
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
- Power take-off disassembly and assembly
procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Feed system bleed procedure . . . . . . . . . . . . . . 43
- Checks and controls . . . . . . . . . . . . . . . . . . . . . 44
OVERHAUL OF THE 6 CYLINDER ENGINE PROVIDED
WITH MECHANICAL ROTARY PUMP . . . . . . 45
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Engine setting operations for the assembly on turning
stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Page Page
Page
GENERAL INFORMATION
Figure 1
116390
They are characteristed by diesel cycle 4 stroke atmospheric Furthermore, the expanders assembled by the
or supercharged 4 and 6 cylinders each with 2 valves. Setter must always comply with couple, power and
number of revolutions based on which the engine
Feed is provided by rotary mechanical pump or on line has been designed.
according to the equipment application.
It differs from other applications because of the provision of
The section herein described is composed or four directories:
different power, power take-off for the different collector
configuration, priming pump, oil pan and boost turbine. - directory of mechanical overhaul prescribed in
accordance to the engines specific duty, illustrating all
necessary operations to remove and assembly the
external components of the engine, including cylinder
heads, gearbox of the timing system and of the front part
cover;
NOTE The picture shows application designed for 6 - electrical directory, describing the connections of the
cylinders version, 2 valves per cylinder, having fuel different components, of the pre-post heating gearbox
feed mechanical pump. (only for some versions) and of the sensors assembled to
the engine;
- troubleshooting directory;
- directory of preventive and regular maintenance
operations, providing instructions for the execution of the
main operations.
Print P2D32N003 E Base - May 2010
6 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4GE N ENGINES
F4GE9454H*
Type
J601 J602 J600 J603 J605
Compression ratio 17.5:1
Max. output kW 74
(HP) (100)
rpm 2000
Loadless engine
idling rpm - -
Loadless engine
peak rpm rpm - -
Bore x stroke mm 104 X 132
Displacement cm3 6728
FILLING
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
Type F4GE9454J*J6
Max. output kW 66
(HP) (90)
rpm 2000
Loadless engine
idling rpm - -
Loadless engine
peak rpm rpm - -
Bore x stroke mm 104 X 132
Displacement cm3 6728
FILLING
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
Type F4GE9484
J*J602 D*J6
Compression ratio 17.5:1
Max. output kW 88 93
(HP) (120) (126)
rpm 2200 2200
Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -
Bore x stroke mm 104 X 132
Displacement cm3 4485
SUPERCHARGING
with intercooler
FILLING
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
6-cylinder engines
F4GE9684
Type
A*J6
Compression ratio 17.5:1
Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -
Bore x stroke mm 104 X 132
Displacement cm3 6728
FILLING
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
F4GE9684P*
Type
J601 J602
Compression ratio 17.5:1
Max. output kW 98
(HP) (133)
rpm 2200
Loadless engine
idling rpm -
Loadless engine
peak rpm rpm -
Bore x stroke mm 104 X 132
Displacement cm3 6728
FILLING
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
turning stand
Figure 2 - disassemble lubrication oil exhaust pipe from the
turbo-blower:
Underneath the turbo-blower loosen the two screws
(1), loosen the screw (2) fixing the pipe throughout the
stop collar (3) fixing the block; finally loosen and remove
the union (5) from the block; plug the pipe ends and the
exhaust of the turbo-blower.
Figure 4
164007
Warning: the oil filter contains inside aprx. 1 kg. of - Disassemble the starter;
engine oil. Provide for oil recovery and disposal in Properly hold the starter (1) and loosen the fixing screws
compliance with the law and regulations in force. (2);
- assemble the bracket bearing 99361037 using the four
screw threaded ports (3).
Print P2D32N003 E Base - May 2010
14 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4GE N ENGINES
Figure 5 Figure 7
75674
75675
70126
- Hold up the supercharger and after lifting it remove the After having disconnected the pipeline, reset the
gasket. locking fastener (1) in lock position as shown in.
picture A, to avoid any possible deformation of the
fastener itself.
75679
75677
- Disconnect the pipelines (1) and (2) that provide feed
- Disconnect the LDA pipe (1) from the head and from and fuel recovery between pump and injectors; screw
the feed pump. Pipe the ends of the pipelines as well as out the nuts fixing the pipes to the pumping elements;
the feed pump and the engine head. loosen the fuel recovery pipe collar on the injection
pump; operate on the nuts assembled to the injectors
and loosen the screws fixing the fuel recovery pipeline;
loosen the screws holding the fixing brackets of such
pipelines (1,6, and 7, Figure 11); pipe the pipeline ends.
- Disassemble the injectors and remove them from their
slot: remove the gaskets.
Figure 11
3
7
4
6 5
75680
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing
screw (on suction collector plate).
Figure 12 Figure 14
87409
88102
Figure 13
Figure 15
87406
Figure 16 Figure 18
1 2
117588
75686
- Disassemble thermostat unit; loosen the three fixing
screws (1) and disassemble the thermostat unit (2)
together with the bracket (3); remove the gasket (4) and - Properly hold the alternator (1) separating it from its
the thermostat (5). bearing by loosening the screw (2); remove screw nut
and washer.
- Assemble the bracket in the original position fixing it with
the screws of the thermostat unit.
Figure 19
Figure 17
88091
88089
- Loosen the screws (1) and withdraw the alternator
- Loosen screw (1) and relevant nut on belt stretcher bearing (2).
bracket (3).
- Loosen screw (2, Figure 18) in order to slide out
POLY-V belt (2). NOTE The shape and the dimensions of the support of
the alternator vary according to the use of the
- Remove the belt stretcher bracket (3). engine. The relevant pictures provide a general
- Disassemble the driven pulleys and the guide rollers. trace of the intervention that is to be carried out.
The procedures described are always applicable.
Figure 20 Figure 22
4 75692
75810
- Loosen the screws (4) and disassemble the oil - Use the tool 99360339 (2) to operate on the flywheel
pressure/temperature sensor (3) (if fitted). cover box (1) in order to block flywheel rotation (3).
- Loosen the screws (1) and disassemble the oil filter/heat (Utilise starter holding down studs and fixing screw nuts).
exchanger bearing (2), interlayer plate (6) and relating - Loosen the flywheel fixing screws (4) to engine drive
gaskets. shaft.
- Disassemble oil level sensor (5) (whether provided).
- Disassemble injection pump (see specific procedure)
and the power take-off underneath. NOTE In some versions there is provided 99360351 tool
checking the flywheel.
Figure 21
3
Figure 23
4
75688
90504
Figure 24 Figure 26
116242
75811
Figure 25 - Loosen the screws (1) and remove oil pump (2).
Figure 28
1 2
3
75691
- Screw out the opposite screws (1) from the ports where
00904t
the withdrawal pins shall be introduced (see picture
following).
- Loosen remaining flywheel fixing screws (3) to the
- Using the specially provided tie rod (3) for the tool
engine drive shaft (4).
99363204 and the lever (4), withdraw the external
holding ring (2) from the front cover (1). - Remove the flywheel block tool (2).
Print P2D32N003 E Base - May 2010
20 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4GE N ENGINES
Figure 29 Figure 31
1 4
70153
75690
- Loosen the screws (2) and remove the flywheel cover
- Screw up two medium length screws in the ports (4) to box (1).
sling the flywheel with a hoist.
Throughout two guide pins (2) previously screwed up NOTE Take note of the screw (1) assembly position, since
into the engine drive shaft ports (3) control the engine the screws have different length.
flywheel withdrawal by means of a hoist.
Figure 32
Figure 30
00903t
99222
90505
- Loosen the screws (1) and disassemble the gear from the
camshaft (2).
86601
Figure 37
- Remove the screws (1) and (4) and disassembled the
suction rose (5).
- Remove the screws (2) and disassemble the stiffening
plate (3)
Version with additional masses
Figure 35
70157
86578 NOTE Take note of the screw (2) assembly position, since
By means of pin (1) lock the additional masses (2) in the the screws have different length.
P.M.S. Loosen the fixing screws (3) and remove the additional
masses (2).
Print P2D32N003 E Base - May 2010
22 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4GE N ENGINES
Figure 38
87424
87422
Figure 39
87655
6 8
4 3
2
1
7 5
1 75711
75712 DIAGRAM SHOWING SCREW
TIGHTENING TO FIX REAR GEARBOX
DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION WITHIN GEARBOX AREAS - Reassemble to box (1) to the engine block.
- Accurately clean the timing gearbox (1) and the engine - Tighten the fixing screws in the same position as found
block. out during disassembly and fix the screws to the locking
couples listed here below, following the order as shown
in the picture.
It is necessary and essential to clean the surface to Screws M12 65 89 Nm
! be sealed in order to achieve excellent tight seal. Screws M8 20 28 Nm
Screws M10 42 52 Nm
Apply sealing LOCTITE 5205 on the box in order to
form a kerbstone of a few mm. Diameter.
NOTE Before assembly, always check that the threads of
It must be uniform (no crumbs), with no air blisters, the ports and of the screws have no evidence of
thinner or irregular zones. tear and wear nor dirt.
Any eventual imperfection shall be correct as soon
as possible.
Figure 43
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both sides
of the joint and obstruct lubricant passages.
Couplings must be assembled within 10 minutes
after completing the sealing operation.
70211
Figure 44 Figure 46
90508
90506
- Tighten the screws (1) fixing the gear to the camshaft (3)
- Turn the engine shaft (3) and the distribution shaft (4) and lock them to the prescribed couple.
so that by mounting the bevel gear on the latter (1) the
stencilled mark on the gear (1) coincides with the groove
on the gear tooth (2).
Figure 47
Figure 45
90507 1
75708
- Position comparator (1) on timing system gear (2) and
check that the clearance between gears (2) and (3) is
within 0.076 0.280 mm range. DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION.
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 25
Figure 49
NOTE It is necessary and essential to clean the surface to
be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order
to form a kerbstone of a few mm. Diameter. It must
be uniform (no crumbs), with no air blisters, thinner
or irregular zones.
Any eventual imperfection shall be correct as soon
as possible.
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both
sides of the joint and obstruct lubricant passages.
Couplings must be assembled within 10 minutes
after completing the sealing operation.
0901t
- Apply to engine drive shaft rear tang (6), the detail (5)
of the tool 99346253, fix it tightening the screws (4) and
key the new holding ring on it (3).
- Place detail (1) on detail (5), tighten the screw nut (2)
until complete assembly of the fixing ring (3) into the
flywheel cover box (7).
Figure 48
1
16 15 Figure 50
8 14 7
17
6 1 2
18 13
5
19 12
11
20 1
2
21
4 9 10 3
75709 75696
87653
- Place the dial gauge (1) on the timing gear (2) and check
that the slack between the gears (2) and (3) is included
in the range between 0,076 0,280 mm.
70211
Figure 52
87654
- Fit the screws (1) fastening the gears (2) to the camshaft
(3) and tighten them to the prescribed pair.
Figure 55
116375
- Turn the engine shaft (3) and the distribution shaft (4)
so that by mounting the bevel gear on the latter (1) the
stencilled mark on the gear (1) coincides with the groove
on the gear tooth (2).
87655
Figure 56 Figure 58
87656 87658
- Fit the power take-off gear (2) (if available) into the - Re-assemble the box (1) to the engine basement.
specially provided housing and fasten the screws (1),
- Tighten the fastening screws (2) to the same position
detected before disassembly.
Figure 57
NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt.
Figure 59
87657
75690
4 75692
75695
NOTE Before assembly, always check that the threads of - Assemble the water pump (1).
the ports and of the screws have no evidence of
tear and wear nor dirt. - Tighten the screws (2) and lock them to the prescribed
couple.
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 29
Figure 66 Figure 69
106549
- Remove the fixing ring (2) from the front cover (1), 00902t
accurately clean the plug surface.
- Apply on engine drive shaft front tang (6) the detail (4)
Figure 67 of the tool 99346252, fix it with the screws (5) and key
the new holding ring on it (7).
- Place the detail (2) on the detail (4), screw-up the
threaded nut until carrying out the complete assembly
of the holding ring (7) to the front cover.
Figure 70
87260
- Assemble the plate (1), the rose pipe (2), tighten the
75710
fixing screws (3) and fix them to the prescribed couple.
- Accurately clean the contact surface of engine block and
apply sealing LOCTITE 5205 on it in order to form a Figure 71
uniform and continuous kerbstone with no crumbs.
Figure 68
86601
106550
- Assemble the front cover (2) to the block and tighten - Assemble the plate (3), the suction rose (5) and tighten
the screws (1) fixing them to the prescribed couple. the fixing screws (1, 2 and 4) to the prescribed torque.
Assembly of additional masses Fit the additional masses (2) and tighten the screws (3) on
the engine block.
Figure 72
Remove the lock pin (1) of the additional masses.
86578
86614
1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) -
4. Additional masses.
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 31
zs
Figure 74 Figure 76
- Provide for new gasket replacement (1) of the oil pan (2).
3
NOTE The pictures illustrating the pan and of the rose
pipe may not correspond to the ones of your
model. However the procedures described are
applicable anyway.
Figure 75 1 2
75697
Figure 77
75814
NOTE Before assembly, always check that the threads of NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of the ports and of the screws have no evidence of
tear and wear nor dirt. tear and wear nor dirt.
Figure 78 Figure 80
1 2
76113
- Lubricate the fixing ring (2) using engine oil and place it 75686
on the oil filter (3).
- Manually start the oil filter (3) on the bearing union (1) - Connect the alternator (1) to the support.
until counter-boring, further screw up the oil filter (3) by - Tighten the screw without locking it (2).
3/4 turn.
- Place a new fixing ring on the block housing (6).
- Apply, (if needed) new fixing ring on the oil
temperature/pressure sensor (4) and assemble it to the
bearing (1) tightening the fixing screws to the prescribed
couple.
Figure 79
Figure 81
76114
Figure 82 Figure 84
1 4
2 1
3
3 2
2
1 3
75705
4
75688
- Place the head (3) over the block and insert screws (1) - Carry out the assembly of the rocker arms after previous
and (2). check of the components.
NOTE If the valves have been removed from the head, it ROCKER ARM UNIT COMPONENTS:
is necessary to assemble them before assembling 1. Elastic ring - 2. Spacer- 3. Rocker arms-
the head itself on the engine block. 4. Support.
Figure 85
NOTE Before using the fixing screws again, measure them
twice as indicated in the picture, checking D1 and
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again; 18.975
if D1 - D2 > 0,1 mm the screw must be replaced. 18.963
D2 D1
75703
19.000 19.000
Figure 83
19.026 19.026
75704
1
76115
Figure 87 Figure 89
2
1
32655
75683
Before executing assembly, check the Rocker Arm driving
rods: these shall not be deformed; the spherical ends in - Tighten the screws (2) to the prescribed couple and
contact with the Rocker Arm adjustment screw and with the assemble water temperature sensor (1).
tappet (arrows) shall not present evidence of seizure or wear: Figure 90
in case of detection proceed replacing them.
The rods driving the suction and exhaust valves are identical
and therefore interchangeable. 2 1
3
Figure 88
D2 D1
75703 75806
Adjust the slack between rocker arms and valves using socket
- Insert the tappet driving rods and the Rocker Arm unit. wrench (1), point wrench (3) and feeler gauge (2).
Before using the fixing screws again, measure them twice Correct slack is:
as indicated in the picture, checking D1 and D2 - suction valves 0.25 0.05 mm
diameters: - exhaust valves 0.50 0.05 mm.
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced;
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 adjusting the clearance of all the valves by
positioning the crankshaft 2 times only.
Each cylinder must be checked by taking it to the
T.D.C. (top dead centre) at the end of compression
and adjusting the clearance of both valves on the
cylinder in question.
Figure 91 Figure 93
2
1
75808
75707
Figure 92
Figure 94
117588
87406
- Assemble cylinder covers (2) with the respective gaskets; - Assemble thermostat unit (2) including thermostat (5)
and gasket (4).
- Fit the seal nods and tighten the screws fixing them to
the prescribed couple. - Tighten the screws to the prescribed couple.
NOTE The screws (1) have been have been utilised to fix
NOTE Always replace the gaskets using new ones. the bracket (3).
Check the threads of the fixing screws: there shall Disassemble the bracket and reassemble
be no evidence of wear or dirt deposit. components from 1 to 5 as shown in the picture.
Seal nods shall have no visible deformation. In such The gasket must be new.
case provide for replacement with new nods.
Figure 95 Figure 96
88090
1
- Tighten the control belt turning the alternator as
illustrated.
- Tighten the screws (1) and the alternator fixing bolt to
the support.
75687
Figure 97
- Fit the new belt onto the pulleys and guide rollers.
4
3
NOTE If the old belt is to be reassembled examine it
carefully in order to see if there may be incisions or 75701
Figure 98 Figure 99
1 88102
3
7
4
6 5
75680
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing
screw (on suction collector plate).
1 1
75679 116387
Figure 104
Figure 102
70126
75677
NOTE To connect fuel pipelines (3 and 4, Figure 103) in
low pressure from the relating connection unions
it is necessary to press the locking fastener (1) as
shown in picture B.
- Fix the LDA pipeline (1) to the engine head and to the
feed pump. After having connected the pipeline, reset the
fastener (1) into block position as shown in picture
A.
1 Figure 106
75675
Figure 107
1
75717
Rotary feed pump disassembly and assembly In case feed pump replacement is necessary, this shall be
procedure supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
NOTE This procedure prescribes that: and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the engine
- the fuel pipes (from the pumping elements to and disassemble it only afterwards.
the injectors, recovering blow-by from the
injectors to the pump and the supply from the The following procedure analyses this second hypothesis
priming pump) have all been removed; since it is the more complex.
- the electrical connections have been Find the top dead centre with the tool (99395097) - False
disconnected. injector
- Accelerator cable shall be disconnected. Figure 110
88141
Remove the rocker covers of the 1st cylinder; remove the 1st
injector and place the tool (1) to set the 1st cylinder top dead
1 centre position (end-of-compression phase). Pre-load the
gauge.
The searched condition is obtained by rotating the engine
88140
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
Disassemble the starter from the flywheel box and use tool valves are both closed.
99360330 to rotate the flywheel. Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 109).
Engine versions with tool (99360339)
Searching for the top dead centre with timing gear blocking
Figure 109 pin
Figure 111
75714
84071
Disassemble the starter from the flywheel box (1) and use Turn the flywheel until, when pushing the pin 99360616 (1),
tool 99360339 (2) to rotate the flywheel. it blocks the gear (2) obtaining the TDC of the 1 cylinder.
2 1
75694
75721
- From the pump side, loosen the fixing nuts (1) without
- Unscrew the side screw that locks the pump shaft removing them in order to enable moving the pump
partially (1) and remove spacer (2). This must be kept on backwards using 99340035 extractor.
a side (we recommend to fix it on the pump with a wire - Assemble the 99340035 extractor throughout the two
or a clip). threaded ports (4, Figure 113) and withdraw the gear
- Tighten the lateral screw (1) blocking rotation of the from the pump shaft.
pump shaft. - Properly hold the feed pump and loosen completely the
fixing nuts.
Figure 113
- Withdraw the pump from the studs, together with the
gasket.
1 4
When the supply pump is to be assembled on the engine the
P.M.S. conditions at compression end stage cylinder No. 1
must be carried out.
2 3
75693
1 2
75721
1 4
2 3 87720
75715
- With the injection pump inserted in relating seat and
securing screws loosened, mount comparator
99395603 (2) and 99395100 gauge tool (1), preloading
- On the timing side, throughout the specially appointed the rod by 2.5 mm.
- Rotate the engine derive shaft to shift from the condition
port, fit the washer and screw up the fixing nut (3) to the of the first cylinder to TDC end of compression phase.
pump shaft. Lock the nut to the 90-95 Nm couple. Reset the dial gauges and rotate the engine drive shaft
into the opposite direction until recovering the
condition of the 1st cylinder to TDC in phase of
compression (see Figure 111).
From this position on the comparator applied on the
pump it must be possible to read the value listed on the
pumping element pre-lift table. Section 4.
- Rotate the pump in anti-clockwise direction if the stroke
is shorter or in clockwise direction if the stroke is longer,
until obtaining the stroke prescribed.
- Checking these conditions, lock the pump by tightening
the relevant nuts to the prescribed pair.
1 4 3
2 75720
87751
Where designed, there is a power take-off able to transmit
motion to different auxiliary parts.
- Disconnect the fuel pipe (1) of the filter and repeat Disassembly of such mechanism shall be executed as
working on the drain lever (2) of the priming pump. following:
- Continue the operation until when fuel outflows. - Loosen the two screws (3) and after having removed the
- Connect the (1) to the filter. cover (1) with a specially provided extractor, withdraw
the power take-off (2).
- The two gaskets (4) shall be replaced in phase of
reassemble.
- Vary out the assembly fitting the power take-off in its
housing, providing new gasket and checking the sprocket
gear meshing.
- Assemble cover and gasket and tighten the screws to the
prescribed couple.
Figure 123
Within General overhaul section, all the operations of
engine block overhaul have been contemplated. Therefore
the above mentioned section is to be considered as following
the part hereby described.
76145
116389
116387
Warning: the oil filter contains inside aprx. 1 kg. of - Place a container under the fuel filter and screw out the
engine oil. condense drain faucet underneath said filter. Carry out
Provide tank with sufficient capacity to contain the complete drainage of the fuel contained therein.
liquid.
- Screw out completely the faucet and, using equipment
Warning: avoid contact of engine oil with the skin: 99360076 disassemble oil filter (2).
in case of skin contamination rinse in running water.
- Disconnect fuel pipelines (4 and 3) respectively from
Engine oil is highly pollutant: provide for disposal in priming pump to filter bearing and from this last one to
compliance with the law and regulations in force. the feed pump.
- Remove the fuel filter bearing (1) from the bracket fixed
to the engine head.
70126
88143
76148
Figure 131
88142
- Disconnect the LDA pipe (1) from the head and from
the feed pump. Pipe the ends of the pipelines as well as
the feed pump and the engine head.
- Disassemble the pipes (2) that constitute the fuel
recovery and supply between the pump and the
injectors. 76150
76149
76151
- Remove tappet caps:
Loosen the fixing screws (1) and lift the caps (2);
remove the gaskets. - Disassemble suction and exhaust manifolds: loosen the
screws (1) fixing the suction manifold plate to the
cylinder head (some of them have already been
NOTE On the tappet cap there is a blow-by valve for the screwed-out since fixing the pipe brackets to the
lubrication oil vapours. injectors); from the exhaust manifold side loosen the (2)
All the gaskets shall always be replaced during fixing screws; remove the gaskets.
assembly.
Figure 135
2
Figure 133
75683
1 2
75686
88089
Figure 139
Figure 137
117588
88091
70141 4 75692
- Loosen the screws (4) and disassemble the oil - Apply the suitable tool (2) on the flywheel covering box
pressure/temperature sensor (3) (if fitted). (1) in order to lock flywheel (3) rotation. (use the starting
motor fixing nuts and studs).
- Loosen the screws (1) and disassemble the oil filter/heat
exchanger bearing (2), interlayer plate (6) and relating - Loosen the flywheel fixing screws (4) to engine drive
gaskets. shaft.
- Disassemble oil level sensor (5) (whether provided).
- Disassemble injection pump (see specific procedure).
Figure 143
Figure 141
3 74175
76152
70148
- Remove the screws (1) and disconnect the water pump 00904t
(2).
- Using the specially provided tie rod (3) for the tool
- Remove the screw (3) and the roller (4). 99363204 and the lever (4), withdraw the external
- Remove the screw (5) and disconnect the engine speed holding ring (2) from the front cover (1).
sensor (6).
116242
00900t - Loosen the screws (1 and 3) and remove the front cover
(2).
- Remove the engine drive shaft fixing ring from the front
cover. Use the tool 99340055 (4) to operate on the
front tang (2) of the engine drive shaft. Throughout the NOTE Take note of the screw (1 and 3) assembly position,
tool guide ports, drill the internal holding ring (1) using since the screws have different length.
3,5 mm drill for a 5mm depth. Fix the tool to the ring
tightening the 6 screws specially provided.
Proceed withdrawing the ring (1) tightening the screw
(3).
1 4
3
75811
75690
1 2
Figure 151
75691
- Screw out the opposite screws (1) from the ports where
the withdrawal pins shall be introduced (see picture
following).
- Loosen remaining flywheel fixing screws (3) to the
engine drive shaft (4).
- Remove the flywheel block tool (2). 00903t
- Remove the flywheel cover box fixing ring using the tool
99340056 (3) to operate on the back tang (5) of the
engine drive shaft. Throughout the tool guide ports, drill
the internal holding ring using 3,5 mm drill for a 5mm
depth.
- Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
6 8
4 3
2
1
7 5
75711
DIAGRAM SHOWING SCREW
TIGHTENING TO FIX REAR GEARBOX
- Reassemble to box (1) to the engine block.
- Tighten the fixing screws in the same position as found
out during disassembly and fix the screws to the locking
couples listed here below, following the order as shown
in the picture.
Screws M12 65 89 Nm
Screws M8 20 28 Nm
Screws M10 42 52 Nm
- Orient engine drive shaft (3) and camshaft (4) taking care
that in phase of assembly of the driving gear (2) to the
Figure 153 camshaft, the notches marked on the gears (1 and 2)
shall match.
Figure 155
70211
Figure 156
NOTE It is necessary and essential to clean the surface to
be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order
to form a kerbstone of a few mm. Diameter. It must
be uniform (no crumbs), with no air blisters,
thinner or irregular zones.
Any eventual imperfection shall be correct as soon
as possible.
Avoid using material in excess to seal the joint. Too
much sealing material would drop out on both
sides of the joint and obstruct lubricant passages.
Couplings must be assembled within 10 minutes
after completing the sealing operation.
Figure 158
90508
1
16 15
8 14 7
- Tighten the screws (1) fixing the gear to the camshaft (3) 17
and lock them to the prescribed couple.
6
18 13
5
19 12
11
Figure 157 20 1
2
21
4 9 10 3
75709
1 4
75690
0901t
- Screw up two hooks or trail rings in the flywheel (1)
- Apply to engine drive shaft rear tang (6), the detail (5) threaded ports (4) for handling .
of the tool 99346253, fix it tightening the screws (4) and
- Using a hoist, handle the flywheel to place it in its housing
key the new holding ring on it (3).
inside the flywheel cover box.
- Place detail (1) on detail (5), tighten the screw nut (2)
- Screw up to pins (2) having appropriate length, in the
until complete assembly of the fixing ring (3) into the
shaft ports (3) and using them as guide, assemble the
flywheel cover box (7).
engine flywheel (1) properly placing it inside the flywheel
cover box.
Figure 160
1 2
Figure 162
75696 1
75695
70221
76112
Installation of front components
- Assemble the water pump (1).
Figure 164 - Tighten the screws (2) and lock them to the prescribed
couple.
Figure 167
70220
106549
00902t
- Apply on engine drive shaft front tang (6) the detail (4)
of the tool 99346252, fix it with the screws (5) and key
the new holding ring on it (7).
- Place the detail (2) on the detail (4), screw-up the
threaded nut until carrying out the complete assembly
of the holding ring (7) to the front cover.
75710
Figure 171
Figure 169
106550
86516
- Assemble the front cover (2) to the block and tighten - Assemble the plate (3), the rose pipe (5), tighten the
the screws (1) fixing them to the prescribed couple. fixing screws (1, 2 and 4) and fix them to the prescribed
couple.
Print P2D32N003 E Base - May 2010
58 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4GE N ENGINES
3 74175
70230
- Fit a new sealing ring on the speed sensor (3) (if fitted).
- Fit the speed sensor (3) on the front cover (1) and
Figure 173 tighten the screw (2) to the specified torque (if fitted).
Figure 176
70231
88076
- Assemble the following elements to the block: new
gasket (1), heat exchanger (2), new gasket (3), oil filter
- Assemble oil pan (1), apply the plate over it (2). Tighten bearing (4).
the screws (2) and lock them to the prescribed couple. Tighten the screws (5) and lock them to the prescribed
couple.
NOTE Before assembly, always check that the threads of NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of the ports and of the screws have no evidence of
tear and wear nor dirt. tear and wear nor dirt.
1 2
76113 75686
- Lubricate the fixing ring (2) using engine oil and place it
on the oil filter (3).
- Connect the alternator (1) to the support.
- Manually start the oil filter (3) on the bearing union (1)
until counter-boring, further screw up the oil filter (3) by - Tighten without locking the screw (2).
3/4 turn.
- Apply, (if needed) new fixing ring on the oil
temperature/pressure sensor (4) and assemble it to the
bearing (1) tightening the fixing screws to the prescribed
couple.
- Place a new fixing ring on the block housing (6).
- Tighten the screw (5) and lock it to the prescribed
couple.
Figure 180
Figure 178
70234 88090
- Assemble the alternator bearing (1) ensuring that the - Fit the new belt onto pulleys and guide rollers.
pins (3 and 4) are against the engine block.
- Tighten the control belt by turning the alternator as
- Tighten the screws (2) and lock them to the prescribed illustrated.
couple.
- Fix the screw (1) and the alternator fixing bolt (2,
Figure 179) to the support.
NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt. NOTE In case the same belt priory removed is assembled
again, proceed examining it carefully to check there
Figure 181
NOTE Before using the fixing screws again, measure them
twice as indicated in the picture, checking D1 and
1
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced.
D2 D1
75703
M12 x 70 50 Nm + 90 degs
Figure 182 M12 x 140 40 Nm + 180 degs
M12 x 180 70 Nm + 180 degs
Figure 184
1
3
2
76152 2
- Place the head (3) over the block and insert screws (1)
and (2). 1 3
75705
NOTE If the valves have been removed from the head, it
is necessary to assemble them before assembling
the head itself on the engine block.
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms-
4. Support.
- Carry out the assembly of the rocker arms after previous
check of the components.
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 61
18.975
18.963
D2 D1
75703
19.000 - Insert the tappet driving rods and the Rocker Arm unit.
19.000 Before using the fixing screws again, measure them twice
19.026 19.026 as indicated in the picture, checking D1 and D2
75704 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
SHAFT AND ROCKER ARM BASIC DATA if D1 - D2 > 0,1 mm the screw must be replaced;
Check the coupling surfaces of bearing and shaft: no evidence
of excessive wear shall be detected or damages.
Replace if necessary.
Figure 186
Figure 189
13.00
11.00
2
116391
Figure 187
75683
32655
2 1
75806
1
Adjust the slack between rocker arms and valves using socket
wrench (1), point wrench (3) and feeler gauge (2). 75707
76149
76207
76206
- Apply on the surface joining the suction manifold plate
- Assemble exhaust manifold (1) providing new gaskets (1) the gasket (3) and provide. Fixing the screws (2) to
(2). the prescribed couple.
- If the pipe (7) of the suction manifold plate (1) has been
removed, reassemble it after having fit a new gasket (6).
NOTE The illustration of exhaust manifold may be not
matching your model. Anyhow, described - Tighten the screws (8) to the prescribed couple.
procedure is applicable.
Figure 196
117588
76208
- Assemble thermostat unit (2) including thermostat (5)
and gasket (4). - Also assemble the brackets (1) fixing the fuel pipelines
to the injectors: use the same screws (2) fixing the
- Tighten the screws to the prescribed couple. manifold plate as shown in the picture.
- Also assemble feed pump (see specific procedure).
NOTE The screws (1) have been have been utilised to fix
the bracket (3).
Disassemble the bracket (3) and reassemble
components from 1 to 5 as shown in the picture. NOTE Pump mounting requires specific procedure
The gasket (4) must be new. contained in this section.
Figure 197
88144
Figure 201
Figure 198
76148
88145
Figure 199
- Fix the LDA pipeline (1) to the engine head and to the
feed pump.
76150
116389
116387 - Hold the turbocharger and place it on the exhaust
- Assemble the fuel filter bearing (1) to the bracket fixed manifold after having interposed the gasket.
to the engine head. - Screw up the fixing nuts (2) of the turbocharger to the
- Connect the fuel pipelines (4 and 3) respectively from exhaust manifold tightening them to the prescribed
priming pump to filter bearing and from this last one to couple.
feed pump. - Tighten the lubrication pipe fixing ring (1). Operate in the
- Using 99360076 equipment assemble fuel filter (2). same way on the other end of the pipe. Connect it to
the upper part of the heat exchanger.
Figure 205
NOTE The filter shall be priory filled with fuel to facilitate
feed system bleed operations.
Figure 203
70126
164006
Rotary feed pump disassembly and assembly In case feed pump replacement is necessary, this shall be
procedure supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
NOTE This procedure prescribes that: and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the engine
- the fuel pipes (from the pumping elements to and disassemble it only afterwards.
the injectors, recovering blow-by from the
injectors to the pump and the supply from the The following procedure analyses this second hypothesis
priming pump) have all been removed; since it is the more complex.
- the electrical connections have been Find the top dead centre with the tool (99395097) - False
disconnected. injector
- Accelerator cable shall be disconnected. Figure 209
88141
Remove the rocker covers of the 1st cylinder; remove the 1st
injector and place the tool (1) to set the 1st cylinder top dead
1 centre position (end-of-compression phase). Pre-load the
gauge.
The searched condition is obtained by rotating the engine
88140
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
Disassemble the starter from the flywheel box and use tool valves are both closed.
99360330 to rotate the flywheel. Once PMS has been obtained, lock the flywheel by means of
tool 99360339 (Figure 208).
Engine versions with tool (99360339)
Searching for the top dead centre with timing gear blocking
Figure 208 pin
Figure 210
75714
84071
Disassemble the starter from the flywheel box (1) and use Turn the flywheel until, when pushing the pin 99360616 (1),
tool 99360339 (2) to rotate the flywheel. it blocks the gear (2) obtaining the TDC of the 1 cylinder.
2 1
88149
- From the pump side, loosen the fixing nuts (1) without
removing them in order to enable moving the pump
88148 backwards using 99340035 extractor.
- Assemble the 99340035 extractor throughout the two
- Unscrew the side screw that locks the pump shaft threaded ports (4, Figure 212) and withdraw the gear
partially (1) and remove spacer (2). This must be kept on from the pump shaft.
a side (we recommend to fix it on the pump with a wire
or a clip). - Properly hold the feed pump and loosen completely the
fixing nuts.
- Tighten the lateral screw (1) blocking rotation of the
pump shaft. - Withdraw the pump from the studs, together with the
gasket.
When the supply pump is to be assembled on the engine the
P.M.S. conditions at compression end stage cylinder No. 1
Figure 212 must be carried out.
2 3
75693
2 1
88148
1 4
2 3 87720
75715
- With the injection pump inserted in relating seat and
securing screws loosened, mount comparator
99395605 (2) and 99395100 gauge tool (1), preloading
- On the timing side, throughout the specially appointed the rod by 2.5 mm.
port, fit the washer and screw up the fixing nut (3) to the - Rotate the engine derive shaft to shift from the condition
of the first cylinder to TDC end of compression phase.
pump shaft. Lock the nut to the 90-95 Nm couple. Reset the dial gauges and rotate the engine drive shaft
into the opposite direction until recovering the
condition of the 1st cylinder to TDC in phase of
compression (see Figure 209).
From this position on the comparator applied on the
pump it must be possible to read the value listed on the
pumping element pre-lift table. Section 4.
- Rotate the pump in anti-clockwise direction if the stroke
is shorter or in clockwise direction if the stroke is longer,
until obtaining the stroke prescribed.
- Checking these conditions, lock the pump by tightening
the relevant nuts to the prescribed pair.
Print P2D32N003 E Base - May 2010
70 SECTION 3 - DUTY-INDUSTRIAL APPLICATION F4GE N ENGINES
87751 76137
- Disconnect the fuel pipe (1) of the filter and repeat Where designed, there is a power take-off able to transmit
working on the drain lever (2) of the priming pump. motion to different auxiliary parts.
- Continue the operation until when fuel outflows. Disassembly of such mechanism shall be executed as
following:
- Connect the (1) to the filter.
- Loosen the two screws (3) and after having removed the
cover (1) with a specially provided extractor, withdraw
the power take-off (2).
- The two gaskets (4) shall be replaced in phase of
reassemble.
- Vary out the assembly fitting the power take-off in its
housing, providing new gasket and checking the sprocket
gear meshing.
- Assemble cover and gasket and tighten the screws to the
prescribed couple.
Figure 222
164007
Warning: the oil filter contains inside aprx. 1 kg. of - Disassemble the starter;
engine oil. Provide for oil recovery and disposal in Properly hold the starter (1) and loosen the fixing screws
compliance with the law and regulations in force. (2);
- assemble the supporting bracket 99361037 using the
threaded ports on the basement.
1 Figure 225
75674
- Lift the engine using the rocker arm 99360595 and put
it on the turning stand 99322205. Proceed disassembling the supercharger:
- Drain the oil through the cap underneath the plug. - loosen the fixing nut (1) and remove the lubrication pipe
from the supercharger. Analogously carry out the same
operation on the other end of the pipe and remove it
from the upper part of the heat exchanger.
Warning: avoid contact of engine oil with the skin:
in case of skin contamination, rinse in running water. - Loosen the screw nuts fixing (2) the supercharger on the
exhaust manifold.
Engine oil is highly pollutant: provide for disposal in
compliance with the law and regulations in force. - Hold up the supercharger and after lifting it remove the
gasket.
Figure 226
Figure 224
116387
Figure 229
70126
After having disconnected the pipeline, reset the - Disconnect the LDA pipe (1) from the head and from
locking fastener (1) in lock position as shown in. the feed pump. Pipe the ends of the pipelines as well as
picture A, to avoid any possible deformation of the the feed pump and the engine head.
fastener itself.
Figure 230
Figure 228
127133
87406
125114
88102
- Disassemble rocker arm bearings; loosen the two fixing
- Loosen the two fixing screws (2) and disassemble screws (2) and remove the complete rocker arm bearing;
priming pump (1). withdraw tappet rods. Repeat the operation for all the
remaining rocker arm bearings.
- Disassemble water temperature transmitter (1).
87409
88555
88089
4
90504
75688
- Disassemble cylinder head;
loosen the screws (1) and (2) fixing the cylinder head (3); - Loosen the screws (1) and disassemble the pulley (2).
hook the brackets with metal ropes and, throughout a
hoist withdraw cylinder head from the block.
Figure 240
Figure 243
88140
- Remove the engine drive shaft fixing ring from the front
cover. Use the tool 99340055 (4) to operate on the
front tang (2) of the engine drive shaft. Throughout the
tool guide ports, drill the internal holding ring (1) using
3,5 mm drill for a 5mm depth. Fix the tool to the ring
tightening the 6 screws specially provided.
Proceed withdrawing the ring (1) tightening the screw
(3).
84071
Turn the flywheel until, when pushing the pin 99360616 (1),
it blocks the gear (2).
75811
00904t
- Loosen the screws (1 and 3) and remove the front cover
(2).
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring (2) from the front cover (1).
75695
116242 - Screw out the opposite screws from the ports where the
withdrawal pins shall be introduced (see picture
following).
- Loosen the screws (1 and 3) and remove the front cover
(2). - Loosen remaining (2) flywheel fixing screws (1) to the
engine drive shaft.
- Remove the flywheel block tool (2).
NOTE Take note of the screw (1 and 3) assembly position,
since the screws have different length.
1 4
75690
127124
00903t
- Turn the engine upside-down.
- Remove the flywheel cover box fixing ring using the
tool 99340056 (3) to operate on the back tang (5) of - Loosen the screws (2) and remove the oil pan (1).
the engine drive shaft. Throughout the tool guide ports,
drill the internal holding ring using 3,5 mm drill for
a 5mm depth.
- Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using the specially provided tie rod (3) for the tool
99363204 and the lever (4), withdraw the external
holding ring of the flywheel cover box.
127125 87656
88221
87655
87424
70210
70157
NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of
- Loosen the screws (2) and disassemble the timing
gearbox (1). tear and wear nor dirt.
87653
70211
- Place the dial gauge (1) on the timing gear (2) and check
that the slack between the gears (2) and (3) is included
- With a felt-tip pen, highlight the conducting gear tooth in the range between 0,076 0,280 mm.
(1) mounted on the engine shaft (2) upon the upright
surface on which a groove (3) has been created for the Figure 262
ignition timing.
Figure 260
87654
- Fit the screws (1) fastening the gears (2) to the camshaft
(3) and tighten them to the prescribed pair.
Figure 263
116355
- Turn the engine shaft (3) and the distribution shaft (4)
so that by mounting the bevel gear on the latter (1) the
stencilled mark on the gear (1) coincides with the groove
on the gear tooth (2).
87655
87656
84077
- Fit the power take-off gear (2) (if available) into the - Re-assemble the box (1) to the engine basement.
specially provided housing and fasten the screws (1),
- Tighten the fastening screws (2) to the same position
detected before disassembly.
Figure 265
NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of
tear and wear nor dirt.
Figure 267
122588
1 4
75690
Figure 271
Figure 269
75695
76112
70221 106549
- Apply to the water pump (1) a new fixing ring (2). - Remove the fixing ring (2) from the front cover (1),
Apply a new sealing ring (2) to the water pump (1). accurately clean the plug surface.
00902t
- Apply on engine drive shaft front tang (6) the detail (4)
of the tool 99346252, fix it with the screws (5) and key
the new holding ring on it (7).
- Place the detail (2) on the detail (4), screw-up the
threaded nut until carrying out the complete assembly
75710 of the holding ring (7) to the front cover.
- Accurately clean the contact surface of engine block and
apply sealing LOCTITE 5205 on it in order to form a
uniform and continuous kerbstone with no crumbs.
Figure 277
88221
Fit the additional masses (2) and tighten the screws (3) on
the engine block.
Remove the lock pin (1) of the additional masses.
106550
Figure 280
86614
1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) -
4. Additional masses.
Figure 281 - Assemble, the suction rose (2) and tighten the fixing
screws (1 and 3) to the prescribed torque.
127125
119123
3
- Provide for new gasket replacement (1) of the oil pan (2).
1 2
75697
Figure 283
- Assemble the pulley (1) to the engine drive shaft , and
the distance ring (3).
- Tighten the fixing screws (2) and lock them to the 68
7 Nm couple.
Figure 285
127124
- Assemble oil pan (1). Tighten the screws (2) and lock
them to the prescribed couple.
1 2
122589 75686
- Lubricate the fixing ring (4) using engine oil and place it
- Connect the alternator (1) to the support.
on the oil filter (2).
- Tighten the screw without locking it (2).
- Manually start the oil filter (2) on the bearing union (1)
until counter-boring, further screw up the oil filter (2) by
3/4 turn.
- Place a new fixing ring on the block housing (3).
Figure 289
Figure 287
87759
NOTE Before any assembly operation always verify that NOTE Verify that the engine block stand is clean.
the hole and screw threads have no evidence of Do not grease the gasket. It is recommended to
wear or dirt. keep the gasket inside packaging until assembly to
the cylinder head.
Gasket assembly shall be made following the
direction of wording printed on the gasket itself so
that this will be readable as indicated in the picture.
1 3
4 75705
75688
- Place the head (3) over the block and insert screws (1) - Carry out the assembly of the rocker arms after previous
and (2). check of the components.
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms-
NOTE If the valves have been removed from the head, it 4. Support.
is necessary to assemble them before assembling
the head itself on the engine block.
Figure 293
18.975
NOTE Before using the fixing screws again, measure them 18.963
twice as indicated in the picture, checking D1 and
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced.
D2 D1
19.000 19.000
19.026 19.026
75703
75704
Figure 294
13 7 2 8 14
9 3 6 12
76115
- Lubricate cylinder head bolts and install to head. 13.00
- Bolts must be torqued using stitching pattern starting 11.00
with the centre bolts and moving out. Bolts to be
torqued in stages: all bolts torqued to snug torque, then
90 degrees rotation for all bolts. Then a further 90
116391
degrees for the M12 x 140 and M12 x 180.
ROCKER ARM ADJUSTMENT SCREW
M12 x 70 50 Nm + 90 degs
M12 x 140 40 Nm + 180 degs If unscrewed, check adjustment quota.
M12 x 180 70 Nm + 180 degs Tighten the screw-threaded nut (1) to the i 4 6 Nm couple.
122587
75703
Adjust the slack between rocker arms and valves using socket
wrench (1), point wrench (3) and feeler gauge (2).
Correct slack is:
- Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure them twice - suction valves 0.25 0.05 mm
as indicated in the picture, checking D1 and D2 - exhaust valves 0.50 0.05 mm.
diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
if D1 - D2 > 0,1 mm the screw must be replaced;
IGNITION SEQUENCE: 1 3 4 - 2
125114
1
75707
127122
Figure 300
123025
127123
127127
127120
- Assemble the pipes (1) and (2) providing fuel feed and
recovery between pump and injectors;
Screw up the locking nuts and tighten the screws fixing
75700
the fuel recovery manifold; fix the pipes to the injectors
- Assemble the brackets (1) fixing the fuel pipelines to the throughout the brackets previously assembled.
injectors: use the same screws (2) fixing the manifold
plate as shown in the picture.
Figure 306
Figure 308
88102
87406
- Assemble priming pump (1) providing new gasket and - Assemble cylinder covers (2) with the respective gaskets;
tighten the screws (2) to the prescribed couple.
- Fit the seal nods and tighten the screws fixing them to
- Also assemble feed pump (see specific procedure) and the prescribed couple.
the power take-off underneath.
116387
- Fix the LDA pipeline (1) to the engine head and to the
feed pump. NOTE Pump mounting requires specific procedure
contained in this section.
Figure 312
Figure 310
70126
116389
- Using rocker arm 99360595 hold the engine and loosen From the right-hand side:
the screws fixing the brackets to the turning stand
99322205. - Re-assemble the lubrifying oil discharge pipe (6) from the
turbo-blower by inserting the joint (5) into the engine
- Disassemble the brackets 99361037 from the engine crankcase and tightening the two fastening (1) screws
after having properly put it on a wooden bearing. underneath the turbo blower;
- Tighten the screw (2) which holds the piping to the (6)
monoblock by means of the cylinder bracket (3);
- Re-assemble the oil filter (4) onto the heat exchanger
with tool 99360076;
Figure 315
87712
Rotary feed pump disassembly and assembly Find the top dead centre with the tool (99395097) - False
procedure injector
Figure 317
NOTE This procedure prescribes that:
- the fuel pipes (from the pumping elements to
the injectors, recovering blow-by from the
injectors to the pump and the supply from the
priming pump) have all been removed;
- the electrical connections have been
disconnected.
- Accelerator cable shall be disconnected.
1
Figure 316
88141
Remove the rocker covers of the 1st cylinder; remove the 1st
injector and place the tool (1) to set the 1st cylinder top dead
centre position (end-of-compression phase). Pre-load the
gauge.
The searched condition is obtained by rotating the engine
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
valves are both closed.
1 Figure 318
88140
Disassemble the starter from the flywheel box and use tool
99360330 to rotate the flywheel.
In case feed pump replacement is necessary, this shall be
supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the engine
and disassemble it only afterwards.
The following procedure analyses this second hypothesis
since it is the more complex.
84071
Turn the flywheel until, when pushing the pin 99360616 (1),
it blocks the gear (2) obtaining the TDC of the 1 cylinder.
75694
- From the pump side, loosen the fixing nuts (1) without
127693 removing them in order to enable moving the pump
backwards using 99340035 extractor.
- Unscrew the side screw that locks the pump shaft
partially (1) and move spacer (2) from position (A) to - Assemble the 99340035 extractor throughout the two
position (B) threaded ports (4, Figure 320) and withdraw the gear
from the pump shaft.
- Tighten the lateral screw (1) blocking rotation of the
pump shaft. - Properly hold the feed pump and loosen completely the
fixing nuts.
- Withdraw the pump from the studs, together with the
gasket.
When the supply pump is to be assembled on the engine the
P.M.S. conditions at compression end stage cylinder No. 1
must be carried out.
Figure 320
2 3
75693
75694
Figure 323
1 4
NOTE If the pump has been removed with the engine
mounted, connect the accelerator cable, if present
in the application.
2 3
75693
1 4 3
2 75720
127694
Where designed, there is a power take-off able to transmit
motion to different auxiliary parts.
- Disconnect the fuel pipe (1) of the filter and repeat
working on the drain lever (2) of the priming pump. Disassembly of such mechanism shall be executed as
following:
- Continue the operation until when fuel outflows.
- Loosen the two screws (3) and after having removed the
- Connect the (1) to the filter.
cover (1) with a specially provided extractor, withdraw
the power take-off (2).
- The two gaskets (4) shall be replaced in phase of
reassemble.
- Vary out the assembly fitting the power take-off in its
housing, providing new gasket and checking the sprocket
gear meshing.
- Assemble cover and gasket and tighten the screws to the
prescribed couple.
PART TWO -
ELECTRICAL EQUIPMENT
116392
1
75717
Figure 330
It is a component integrating a temperature sensor.
It is assembled to the engine head close to the thermostat unit
and its duty is to detect engine cooling liquid temperature.
Specifications:
Range of working temperatures:
Connection side -40 +150 C for < 10 min.
Bulb side on engine: -40 +140 C
Working tensions: 6 28 V
Settings:
80 C 0.304 0.342 k
20 C 2.262 2.760 k
-10 C 8.244 10.661 k
75719
2
75724a
75725
75722
Working tensions: 12 24 V
Contact closure
upon lower pressure: 0.2 bar
Contact opening It is a resistor assembled to the suction collector and is utilised
upon higher pressure: 0.9 bar to heat the air during pre-post heating operations.
It is fed by a tele-switch usually placed very close to the engine.
Specifications:
Working tension: 12 V
Maximum possible
air flow: 2 cc / min
(pressure 138 kPa)
B 116393
1
75717
Figure 338
It is a component integrating a temperature sensor.
It is assembled to the engine head close to the thermostat unit
and its duty is to detect engine cooling liquid temperature.
Specifications:
Range of working temperatures:
Connection side -40 +150 C for < 10 min.
Bulb side on engine: -40 +140 C
Working tensions:6 28 V
Settings:
80 C 0.304 0.342 k
20 C 2.262 2.760 k
-10 C 8.244 10.661 k
75719
75723
75722
Alternator
Figure 340
75725
It is place front view on the right hand side of the engine, and
is driven by tooth belt.
Specifications:
Rated tensions: 24 V
Current delivered: 90A (at 6000 rpm)
Absorption in stand-by: 1mA
Sense of rotation: clockwices
127135
1
75717
A Specifications:
B
BOSCH 3 kW - 12V
A C
B
Cooling liquid temperature sensor
75718
Figure 345
75725
4 3
It is place front view on the right hand side of the engine, and
is driven by tooth belt.
127136
Specifications:
1. KSB Water temperature sensor - 2. KSB Working tension: 12 V
Electro-magnet - 3. Pump stop connection - Current delivered: 90A (at 6000 rpm)
4. 1D. Engine stop solenoid;
Absorption in stand-by: 1mA
Sense of rotation: clockwices
Figure 347
75722
F4GE N ENGINES
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine does not start Battery flat or faulty. Check and recharge battery. Replace bat-
tery if necessary.
Connections to battery terminals cor- Clean, examine and tighten the nuts on
roded or loose. the battery terminals. Replace the cable
terminals and the nuts if excessively cor-
roded.
Incorrect timing of injection pump. Check and correctly time the injection See your Iveco dealer.
pump.
Deposits or water in the fuel tank. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air.
Dismantle and clean the injection pump.
Remove water from tank and refuel.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or transfer
pump.
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in
pump. fact present and also check the fuel pump.
Eliminate the air from the injection pump
by unscrewing the cap and working the
fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.
117
Base - May 2010
118
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use
The engine cuts out. Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection pump. Adjust flow. See your Iveco dealer.
Impurities or water in the fuel lines. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air. Dismantle
and clean the injection pump. Remove
water from fuel tank and refuel.
Clogged fuel filter. Dismantle and replace if necessary.
Presence of air in the fuel and injection Check that the hoses are not cracked or
system. the unions loose. Replace worn parts, re-
move the air from the hoses and deaerate
the injection pump and fuel filter by un-
screwing the caps and working the primer
pump by hand.
Broken injection pump controls. Replace the faulty parts.
Abnormal clearance between camshaft Adjust clearance by replacing shims.
cams and tappets.
Burnt, corroded or chalky valves. Replace the valves, rectify or replace the
cylinder head seatings.
F4GE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4GE N ENGINES
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine overheats Faulty water pump. Check the unit and replace if necessary.
Replace the gasket.
Malfunctioning thermostat. Replace the thermostat.
Fouling in coolant openings in the cylinder Wash following the standards specified
head and cylinder groups. for the type of descaling product used.
Water pump drive belt slack. Check and adjust the tightness of the belt. On applications provided with automatic
tensioner, check corret worching of such
device.
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injection pump. Correct the delivery rate of the pump on See your Iveco dealer.
a bench so that the injection is at the
specified rate.
Dry air cleaner blocked. Clean the air filter or replace if necessary.
Engine operation is irregular and lacks Incorrect timing of injection pump. Check timing and correctly set pump.
power
K.S.B. automatic cold advance device mal- Check or replace injection pump.
functioning.
Excessive piston wear. Check or replace injection pump.
Incorrect calibration of speed regulator. Check and correctly calibrate the regula- See your Iveco dealer.
tor.
119
Base - May 2010
120
ANOMALY POSSIBLE CAUSE REMEDY NOTE
Engine operation is irregular and lacks Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using
F4GE N ENGINES
Print P2D32N003 E
Print P2D32N003 E
F4GE N ENGINES
ANOMALY POSSIBLE CAUSE REMEDY NOTE
Engine running with abnormal knocking Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and in-
play on one or more main or rod bearings stall smaller bearings. Replace the thrust
or excessive play on shoulders. half-rings.
Crankshaft unbalanced. Check alignment of crankshaft.
Loosening of screws securing flywheel. Replace the loosened screws and tighten
all the screws to the specified torque.
Misalignment of rods. Replace the rods.
Noise from piston journals due to excess- Replace the piston journal and/or the pis-
ive play of piston hubs and in the rod ton and rod bushing.
bushing.
Loose bushings in the rod seatings. Replace with new bushings.
Noisy timing. Adjust the play between camshaft cams
and tappets and check that there are no
broken springs, that there is no excessive
play between the valve stems and the
valve guides, tappets and seatings.
The engine smokes abnormally. Black or Excessive maximum pump output. Disconnect the pump and adjust delivery See your Iveco dealer.
dark grey smoke. in accordance with the data given in the
calibration table.
K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust
tioning. correctly as described in the manual.
There is an excessive delay on the injec- Correct the set-up.
tion pump.
121
Base - May 2010
122
ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up.
F4GE N ENGINES
Print P2D32N003 E
F4GE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 123
MAINTENANCE PLANNING
Recovery
To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.
The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.
The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.
MAX
2
75749
MIN
To provide filling, operate through the upper top (1) or
through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
1 flow easier.
Some applications are equipped with a level transmitter
alerting dashboard instruments in case of insufficient
lubrication oil within the pan.
75748
The engine oil is highly polluting and harmful.
Draw off the rod from its slot and check that the level is within In case of contact with the skin, rinse well with water
the etched tags of minimum and maximum level. and detergent.
Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and Adequately protect the skin and the eyes, operate in
put it back in its slot. Draw it off again and check the level. full compliance with safety regulations.
In case the level results being close to the tag showing Disposal must be carried out properly, and in full
minimum level, provide filling lubrication of the engines compliance with the law and regulations in force.
components.
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 3 - DUTY-INDUSTRIAL APPLICATION 127
- After the complete drainage, screw the plug and carry out
the clean oil filling.
75806
Adjust clearance between rockers and valves using setscrew Use only the recommended oil or oil having the re-
wrench (1), box wrench (3) and feeler gauge (2). ! quested features for the corrrect motor functioning.
Clearance shall be as follows: In case of topping up, dont mix oils having different
- intake valves 0.25 0.05 mm features.
- exhaust valves 0.50 0.05 mm. If you dont comply with theses rules, the service war-
ranty is no more valid.
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 - Check the level through the dipsick until when the filling
adjusting the clearance of all the valves by is next to the maximum level notch indicated on the dip-
positioning the crankshaft 2 times only. sick.
Each cylinder must be checked by taking it to the
T.D.C. (top dead centre) at the end of compression
and adjusting the clearance of both valves on the
cylinder in question.
Whereas you replace the lubrication oil, it is necessary to re- Fuel filter replacement
place the filter.
According to the application the filter can be located in different
positions: the following procedure is a valid guide for all applica- During this operation dont smoke and dont use free
tions. flames.
- The filter is composed by a support and a filtering cartridge. Avoid to breathe the vapors coming from filter.
For the cartridge replacement use the 9936076-tool.
Due to several applications the belt run can change very much.
We describe the replacement of a belt mounted on a 4-cylin-
ders motor with traditional belt tension.
88089
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 12
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 17
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 18
Page Page
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 30
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Removing the valves . . . . . . . . . . . . . . . . . . . . 30
- Measuring piston diameter . . . . . . . . . . . . . . . . 24
- Checking cylinder head wet seal . . . . . . . . . . . 31
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Checking cylinder head supporting surface . . . 31
- Conditions for proper pin-piston coupling . . . . 25
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - Removing carbon deposits, checking and grinding val-
ves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 26
- Checking clearance between valve stem and valve
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 guide and valve centering . . . . . . . . . . . . . . . . . 32
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Connecting rod-piston coupling . . . . . . . . . . . . 27
- Regrinding replacing the valve seats . . . . . . . 33
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 27
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Fitting connecting rod-piston assembly into cylinder
barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . 34
GENERAL SPECIFICATIONS
Bore mm 104
Stroke mm 132
TIMING
Checking timing
mm 0.25 0.05
X X
mm 0.50 0.05
FUEL FEED
Bosch* Bosch
Type: rotary VE 4/12 F VE 6/12 F
Nozzle type -
bar
Injection pressure bar
-
CLEARANCE DATA
1 0.4
Pistons
1
X Size X 55.9
Outside diameter 1 103.714 to 103.732
2 Pin housing 2 38.010 to 38.016
X
Piston protrusion X 0.28 to 0.52
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110
3 0.040 to 0.080
Split rings 0.4
X1 Split ring end opening
X2 in cylinder barrel:
X1 0.30 to 0.40
X3 X2 0.60 to 0.80
X3 0.30 to 0.55
1
Small end bush
housing 1 40.987 to 41.013
Big end bearing
2 housing 2 72.987 to 73.013
3
Small end bush diameter
Max. tolerance
on connecting rod
axis alignment -
S 1 S 2
Main bearings
3 No. 1 5 3 87.982 to 88.008
No. 2 3 4 3 87.977 to 88.013
X 1
X 2
X 3
Shoulder half-rings X3 37.28 to 37.38
4 Valves:
4 7.960 to 7.980
60
4 7.960 to 7.980
45
1 46.987 to 47.013
1 1 43.637 to 43.663
2 43.713 to 43.739
45
X 1 to 1.52
X Sinking X 1 to 1.52
0.050 to 0.102
Between valve seat
and head 0.050 to 0.102
Valve seats -
Injector protrusion X -
X
Camshaft bush
housings No. 1 59.222 to 59.248
(flywheel side)
Camshaft housings 54.089 to 54.139
No. 2-3-4-5 / 2-3-4-5-6-7
1 23 4 5
2
Camshaft journals:
15
53.995 to 54.045
17
1 3
Bush inside
diameter 54.083 to 54.147
H H -
H -
2
3 Tappet cap outside
diameter: 2 15.924 to 15.954
3 15.965 to 15.980
2
Between tappets and housings -
Tappets -
1
Rocker shaft 1 18.963 to 18.975
2
Between rockers and shaft 0.025 to 0.063
The second last main bearing cap (1) and the relevant
Figure 1 support are fitted with shoulder half-bearing (2).
Figure 4
70158
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdraw the pistons including the connecting rods from the
top of the engine block.
Use tool 99360500 (1) and hoist to remove the output shaft
(2) from the block.
Figure 2
Figure 5
70159
Remove the screws (1) and the main bearing caps (2). 70162
Figure 9
70163 s
Figure 10
Withdraw carefully the camshaft (1) from the engine block.
Figure 8
70167
107804
TIMING SYSTEM
Camshaft
Figure 12
70169
Figure 13
70512
Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bushes.
if they show any traces of seizing or scoring replace the
Figure 14
70172
Figure 16
sec. A-A
107399
MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (4-cylinder engines)
* Dimension to be measured after inserting the bearing bush.
Figure 17
sec. A-A
107268
MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (6-cylinder engines)
* Dimension to be measured after inserting the bearing bush.
70176
70174
Lubricate the tappets (1) and fit them into the relevant
To replace the bearing (1) use tool 99360362 (2) and handle housings on the engine block.
99370006 (3) to remove and install it.
Figure 21
70164
70238
84053
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
MAIN DATA CONCERNING THE TAPPETS AND THE then tighten the screws (2) to the specified torque.
RELEVANT HOUSINGS ON THE ENGINE BLOCK
Print P2D32N003 E Base - May 2010
18 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N ENGINES
70179
Figure 26
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 19
Figure 27
70237
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value
Figure 29
Figure 30
70237
70161
Refit the output shaft (2).
Check the backlash between output shaft main journals and
the relevant bearings as follows:
70184
Figure 32
70186
Figure 38
70187
Tighten the pre-lubricated screws (1) in the following three
successive stages:
- 1st stage, with dynamometric wrench to 50 6 Nm. 70190
- 2nd stage, with dynamometric wrench to 80 6 Nm. This check is performed by setting a magnetic-base dial gauge
Figure 36 (2) on the output shaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
If higher value is found, replace main thrust half bearings of
the second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.
- 3rd stage, with tool 99395216 (1) set as shown in the Figure 39
figure, tighten the screws (2) with 90 5 angle.
Figure 37
70191
70189
CONNECTING ROD PISTON ASSEMBLY
- Remove caps from supports. COMPONENTS
The backlash between the main bearings and the pins is 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
found by comparing the width of the calibrated wire (2) at 6. Half bearings - 7. Connecting rod - 8. Bush.
the narrowest point with the scale on the envelope (1)
containing the calibrated wire.
The numbers on the scale indicate the backlash in mm. NOTE The pistons are supplied spare with the following
Replace the half bearings and repeat the check if a different sizes:
backlash value is found. Once the specified backlash is - standard;
obtained, lubricate the main bearings and fit the supports by - 0.4 mm oversize.
tightening the fastening screws as previously described.
Print P2D32N003 E Base - May 2010
24 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N ENGINES
Figure 40 Pistons
Measuring piston diameter
Figure 43
32613
Remove split rings (1) from piston (2) using pliers 99360183 32615
(3). Using a micrometer (2), measure the diameter of the piston
(1) to determine the assembly clearance.
Figure 44
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 42
87760
18857 32620
To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2nd
(2). and 3rd slot and the relevant housings on the piston (2), using
Conditions for proper pin-piston coupling a feeler gauge (1).
Figure 46 Figure 49
32619 41104
Lubricate the pin (1) and its seat on piston hubs with engine DIAGRAM FOR MEASURING THE CLEARANCE X
oil; the pin shall be fitted into the piston with a slight finger BETWEEN THE FIRST PISTON SLOT AND THE
pressure and shall not be withdrawn by gravity. TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
Split rings between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
Figure 47 the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
16552
Figure 50 Figure 52
70194
Connecting rods
Figure 51 80339
Bushes Figure 55
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
70198
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston
Figure 54 (2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
70199
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Print P2D32N003 E Base - May 2010
28 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N ENGINES
Figure 57 Figure 59
70202
Figure 58
70203
Figure 61 Figure 64
70204
70207
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2). If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
Figure 62
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
Check manually that the connecting rods (1) are sliding
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.250 to 0.275 mm.
70205
Figure 63
70208
2 6
A 75751
75752
A B
0,4 TOTAL C
0,01 / 50
75753 75756
This check shall be performed using the proper tools. The rated thickness A for the cylinder head is 95 0.25 mm,
max. metal removal shall not exceed thickness B by 1 mm.
Use a pump to fill with water heated to approx. 90C and 2
to 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the proper NOTE After grinding, check valve sinking. Regrind the
beater for their removal/refitting. valve seats, if required, to obtain the specified value.
VALVES Figure 73
Figure 71
EXHAUST INTAKE
VALVE VALVE
18882
116395
Removing carbon deposits, checking and Checking clearance between valve stem and
grinding valves valve guide and valve centering
Figure 72
Figure 74
18625
Remove carbon deposits from valves using the proper metal 75757
brush.
Use a magnetic base dial gauge (1) set as shown in the figure,
Check that the valves show no signs of seizing, scoring or the assembling clearance shall be 0.056 0.096 mm.
cracking.
Turn the valve (2) and check that the centering error is not
Regrind the valve seats, if required, removing as less material
exceeding 0.03 mm.
as possible.
Base - May 2010 Print P2D32N003 E
F4GE N ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 33
75754
Figure 77
116356
INTAKE EXHAUST
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80 - 100C and using the proper
them with the spare ones. Use adequate tool to remove as beater, fit the new valve seats, previously cooled, into the
much material as possible from the valve seats (take care not cylinder head.
to damage the cylinder head) until they can be extracted
Use adequate tool to regrind the valve seats according to the
from the cylinder head using a punch.
values shown in Figure 77.
Figure 80
1
3 1
2
2
75758
75759
NOTE Sealing rings (2) for intake valves are yellow and
VALVE SPRINGS sealing rings (3) for exhaust valves are green.
Figure 79
50676 Figure 81
1 2
MAIN DATA TO CHECK INTAKE AND EXHAUST
VALVE SPRINGS 3
Before refitting use adequate tool to check spring flexibility. 4
Compare load and elastic deformation data with those of the
new springs shown in the following table.
6
Height Under a load of
mm N
H (free) 63.50 0 5
H1 49.02 329
H2 38.20 641 75751
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
88775
There are two types of head seals, for the thickness (1.25 mm
Type A and 1.15 mm Type B) take the following measures:
- for each piston detect, as indicated on Figure 83, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:
S cil1 = S1 + S2
2
For 4 cylinder versions:
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
S cil1 + S cil2 + S cil3 + S cil4
S=
4
TORQUE
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 12 7.7 1.2
Crankshaft pulley (M12x1.75x10.9) 110 5 11.0 0.5
Flywheel housing
(M12x120) 85 10 8.5 1.0
(M12x80) 85 10 8.5 1.0
(M10x80) 49 5 4.9 0.5
(M10x40) 49 5 4.9 0.5
Flywheel housing (M12x1.25) 1st stage 30 4 3.0 0.4
2nd stage 60 5
Assy rear cover plate to flywheel housing (M8x1.25x16) 24 4 2.4 0.4
Fuel injectors 60 5 6.0 0.5
Fuel lift pump 24 4 2.4 0.4
Turbocharger to exhaust manifold (M10) 43 6 4.3 0.6
Oil feed to oil filter head 24 4 2.4 0.4
Oil feed to turbocharger (M12x1.5) 35 5 3.5 0.5
Oil drain (M8x1.25x16) 24 4 2.4 0.4
Alternator to alternator support (M8x1.25x30) 24 4 2.4 0.4
Alternator to water inlet conn. assy (M8x1.25x30) 24 4 2.4 0.4
Lower alternator mounting (M10x1.25x25) 24 4 2.4 0.4
Alternator upper pivot to support (M10) 49 5 4.9 0.5
Alternator mounting hardware (M12x1.75x120) 43 6 4.3 0.6
Alternator wiring (M6x1.0 nut) 10 2 1.0 0.2
Starter motor to gear case (M10) 49 5 4.9 0.5
Screw M8 for fastening cylinder barrel lubricating nozzles 15 3 1.5 0.3
Screw M12 for fastening output shaft caps 1st stage 50 6 5 0.6
2nd stage 80 6 8 0.6
3rd stage 90 5
Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2.4 0.4
Screw M8 for fastening camshaft gear 36 4 3.6 0.4
Screw M10 for fastening connecting rod caps 1st stage 60 5 6 0.5
2nd stage 60 5
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
TOOLS
TOOL NO. DESCRIPTION
99360605 Band for fitting piston into cylinder barrel (60 125 mm)
TOOLS
TOOL NO. DESCRIPTION
99370415 Gauge base for different measurements (to be used with 99395603)
TOOLS
TOOL NO. DESCRIPTION
Dial gauge holder for rotary injection pump timing (use with
99395100 99395603)
99395216 Pair of gauges with and square head for angle tightening
Part 5
PT-BOX ISTRUCTIONS
Section
PT-BOX istructions 1
PT-BOX INSTRUCTIONS Select your user configuration type and then follow the
relevant information.
Hardware installation
1. PT-PLUS configuration
- PC Panasonic user
This Sw may cause engine start-up. Be extremely - PT-BOX module
! careful. - PT-DIAGNOSIS sw
The user is responsible for the correct use of the 2. PT-DIAGNOSIS configuration
PT-DIAGNOSIS software so as not to any cause
injury to people or damage to items. - user with own PC
- PT-BOX module
The user is also responsible for complying with all - PT-DIAGNOSIS sw
the rules relating to security for activities on the
industrial applications (engine, pump, generating The PT-BOX module (Electronic Communication Interface)
set) carried out in the workshop.
Carefully read the user manual before using the PT-BOX is an interface module allowing the communication
diagnostic tool and follow the instructions displayed between the engine ecus and the PC.
on the screen. - Weight: 500 g;
- Dimension: 175x75x30mm;
General rules for use - Flash memory: 4Mb - RAM 1Mb;
The following instructions should always be strictly followed: - Thermal tolerance: 0-50C;
- all instruments ensuring the security must be applied as - Power supply: 6-32V;
indicated in the application; - Connection interfaces: USB and RS232 standard
- ensure that the PT-BOX module is connected to the Bluetooth optional;
diagnostic socket of the engine on which work is to be - Interface for engine electronic systems: 9 KL ISO 9141
carried out; lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O
- in case of emergency, disconnect the PT-BOX module PWM.
from the engine or disconnect the USB cable; The led indicators on the front view allow to check the
- ensure that while using the software, there is nobody communication lines activity with the engine and with the PC
near the engine/vehicle you are working on; to which the instrument is connected.
- if it is necessary for more than one person to be working
on or near the engine/vehicle, they are all responsible for Figure 1
complying with security regulations of the workshop;
- we strongly suggest that the PT-BOX modules be visibly
and uniquely identified (for example by using coloured
adhesive tape, labels with names, etc).
156138
156135
1. serial port - 2. USB port NOTE The module is power-supplied by the diagnostic
cable; for this reason to work correctly it must be
Figure 3 connected to the engine.
System requirements
Minimum
- Processor: 300 MHz Pentium-II CPU;
- Hard disk space: 3 GB available;
- Ram: 256 MB;
156136
- Display: 800 x 600 video adapter and monitor;
Connector for the connection of the engine communication
cable. - Internet connection only needed for rss and pt-diagnosis
software update (eaus): modem;
- External ports: USB connector;
Pt-box - pc connection
- External reader: DVD-ROM reader;
Figure 4
- Os: Microsoft WindowsTM XP Professional Service Pack
2 - Microsoft Windows 2000 Service Pack 4 plus -
Windows 2000-KB835732-x86-ENU.EXE (login with
administrator privileges);
- Browser: Internet Explorer 5.5.
Recommended
- Processor: 1 GHz Pentium IV - Centrino CPU;
- Hard disk space: 5 GB available;
- Ram: 512 MB;
- Display: 1024 x 768 high colour video adapter and
156137 monitor;
- Internet connection only needed for rss and pt-diagnosis
software update (eaus): high-speed e.g. ADSL;
- connect the USB cable (PT-BOX side marked) to the - External ports: 2 USB 2.0 connectors, Bluetooth;
PT-BOX module (remove the holding screws from the
PT-BOX module, where present); - External reader: DVD-ROM reader;
- connect the USB cable to the PC; - Os: Microsoft WindowsTM XP Professional - Service Pack
3 (login with administrator privileges);
- turn the PC on.
- Browser: Internet Explorer 6.0.
Software installation
Registration
Before using the PT-Diagnosis system you have to carry out
the registration of the system being used. This procedure
allows you to obtain the activation code.
The registration procedure is carried out on-line and it is
different according to the user type:
- OEM users
- Dealer users
- Select www.eltrac.it/ivecomotors/default.asp.
- From the starting page, select the language.
- Select pt users registration.
In the registration form:
1. Enter the Customer PIN:
it is the customer authentication code; it is an
alphanumeric code sent by e-mail to the user after having
bought the PT-DIAGNOSIS system.
2. Select the send key:
the identification data and the Network characteristics
areautomatically entered.
3. Enter the serial number of the PT-BOX instrument.
Figure 6
NOTE Before carrying out the registration we suggest to
install the PT-Diagnosis SW.
156139
1. Connect to
http://www.fptpowertrain.com/index_main.htm.
The following information for each one of the available
2. Select the language.
applications for downloading is displayed: ECU, license, file
name, Release Date, Release Type and short description.
Each option can be used to sort the list: to sort the list in
ascending/descending order according to a given key, select
the title of the corresponding column.
1. Select the application to be downloaded; the selected line
is highlighted in red.
2. Select the download the selected application key and follow
the system instructions.
3. Identify the path where the packets have been
downloaded.
4. At the end of the download install the packets (double
click) one by one.
3. Fill in the yellow field by entering the alpha code supplied 6. Select the send key (only once!) wait
with the Registration Card (scrap the area on the card).
After sending a summary window is displayed waiting for the
4. Enter the serial number of the pt-box instrument. end of the registration procedure.
Wait for the following window:
- the activation code;
- the link to download the EAUS application (EAsy Update
Software).
7. Print the activation codes (print key) and keep them
together.
8. Select the link to download the EAUS application.
156139
Connection
Figure 8
156138
NOTE Before carrying out the registration we suggest to The PT-BOX module is supplied by the diagnosis
install the PT-Diagnosis SW. ! cable; therefore it must be connected to the
engine/vehicle to be able to work.
Figure 9
156140
10. The system informs that the new hardware has been
correctly installed; select the cross button to continue.
11. Re-start the PC.
Software Interface
The PT-DIAGNOSIS software interface is designed to facilitate access to tools, view functions and make diagnostic procedures clear
and adaptable to various needs.
All windows follow the same design with additional features which depend on the specific working environments.
Each window presents three main areas to which specific functions are univocally associated:
- Keys Area
- Title Area
- Operative Area
The Title area shows the selected function under test and previous choices by which you arrived.
3. Select the Class and the System under test to which the
engine/ vehicle belongs; then press the navigation key (is
active - green) to continue.
1. The Start Window shows the family.
Start Window
- It is possible to select a new family or to choose a family
from the database;
- green identifies a pull-down menu.
Database key
Browse key
communication panel
It indicates that the communication with the ECU is active or
that the ECU is not present (no ecu).
The lower leds indicate the communication state of the
electronic system as shown below:
Square LEDs: two states (green/red); green indicates that
communication with the electronic system has been initialised;
if red indicates the communication has been interrupted.
Rectangular LEDs: blinking indicate that data exchange
between electronic system and diagnostic system is in
progress.
Utilities key
stop key
To quit PT-DIAGNOSIS application at any time.
engine/vehicle key
It allows you to return to the Family Choice Window.
utilities key
When selected the Key background will be yellow and allows
you to access a menu.
Teleservices key
It allows you to access the remote connections services. Electronic control units key
Activations key
It allows you to access the Electronic Ecus environment.
It allows you to access the management function of the The key appears on a yellow background (default status,
activation codes. environment Electronic Control Units enabled) or on a grey
Select the measure unit key background (environment Electronic Control Units disabled).
If you want to work at the same time with more Ecus, select
It allows you to choose the measure unit system. the key environment electronic ecus>add ecu.
On/Off-line key
It can be on-line or off-line.
The on-line key indicates that the PT-Diagnosis SW uses the
In the Start Window select the fami ly; by pressing the PT-BOX/PC module connection.
navigation key forward it is possible to access the next The off-line key indicates the PT-Diagnosis SW is working in
window. New icons appear in the Keys area for accessing simulated mode. To change the status select the key.
specific functions:
Acceptance
Environment DataBase key search
From the PT-DIAGNOSIS start window it is possible to select It allows you to search an engine by applying a filter (DATE,
a new engine or to select one from the database. engine mode l, CUSTOMER or NUMBER PLATE).
key order
It orders the list according to the selected ordering criterion.
key report
It gives access to the summary environment; enabled after
selecting an engine.
key delete
1. Select the database button: you access the DataBase
environment (it contains the list of accepted engines). It deletes the selected engine from the database; it is active
only after selecting an engine.
How to order the engines list 3. If required, enter the word or the code to be searched
and confirm by selecting the tick icon.
To cancel the search and display all elements from the archive
select the cancel search key.
Environment Report
How to search for an engine from the database
When the engine sheet of the engine under test has been
saved in the Report Environment, the engine has been
accepted.
You access the Report environment in the following ways:
Environment Report
Acceptance When you read or cancel the faults memory or carry out a
programming it is not possible to return directly to the window
The acceptance (sheet saving) is mandatory when important Family Choice; by selecting the engine button the following
operations are performed on the engine (read or cancel faults windows are displayed:
memory, programming).
1. Read or cancel the faults memory or carry out a 1. Before continuing it is necessary to save the data of the
programming and then select from the corresponding performed activity; select the tick icon; the Report
environment the report button; you enter the Report environment appears.
environment.
2. Enter data.
2. Enter data.
3. Save the sheet by selecting the save button.
Automatic acceptance
From the Report environment it is also possible to accept the
engine automatically.
1. Sselect the Family, the Class and then the System of engine
under diagnosis.
2. Press the navigation button forward (enabled - green) to
continue.
4. By means of the automatic acceptance the system tries to
communicate with the engine ECU: confirm the displayed
message by pressing the tick icon; wait until the ECU is
ready.
3. The window Choose Activity appears; it is here possible 2. PT-DIAGNOSIS system presents a pop-up window
to choose from four lists: where to select the automatic or the manual activation of
Window Choose Activity the ignition key; select the required mode; the key button
is disabled.
- diagnosis
Under the automatic mode all activation of the ignition key are
- test controlled by the diagnosis instrument (key button working).
- programming Under the manual mode all activation of the ignition key are
- specific functions controlled by the operator on the engine.
Multitasking option
report key
PT-DIAGNOSIS introduces a very important news: it is
Shows the Diagnosis Report List (and allows you to print each
possible to associate more ECUs to the family of engine under
report).
test.
Add an ecu
print key
It is possible to interrupt the diagnosis with an ECU and to start
Prints the summary page of Identification Parameters. the procedure with another one.
Cancel an ecu
5. To access the other activities from the environment It is possible to stop the activity on one of the connected
Identification Code Reading, select the choose activities ECUs.
buttons: choose an activity; the system automatically access
the selected activity.
The choose activities buttons are shown in yellow when
selected.
6. To exit the diagnosis of the engine under test select the 1. Slect the button ecus area>required ecu>cancel.
button ecus area>ecu under test>cancel.
2. Select the required ECU.
faults key
It allows you to access the Faults environment; it can be yellow
(the faults list is displayed) or gray (environment Faults
disabled).
4. Wait until the ECU is ready; the list and faults type
occurred during the working are displayed.
There are two types of failures:
- failures present during the reading procedure (red);
- intermittent failures not present during the reading
operation but which occurred at least once before
(black).
On line Mode
Faults Memory Reading Icons
off key
The communication with the ECU has been interrupted. print key
Select the button to start again the electronic system reading. It allows you to print the displayed window.
measures key
- the fault
- the signal type
- the repetition type
The button faults appears on yellow background because it
is selected.
Parameters reading 3. The read parameters are shown and the values assumed
4. Select the groups key.
The groups key allows you to access the groups management
functions (see group Management).
on key
The communication between the system and the ECU is
active: select the button to interrupt the reading.
off key
The communication with the ECU has been interrupted; select
the button to start again the electronic system reading.
groups key
2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation It opens the GROUPS window showing the list of created
of the ignition key; select the required mode; the key group (A) and the keys to create/modify the groups (B).
button is disabled.
Pay close attention to the displayed messages and wait until
the ECU is ready.
report key
It allows you to save the report of carried out operations.
print key
It allows you to print the displayed window.
Groups Management 9. From the drop down menu (above on the left), select one
of the available parameter groups, excluding the
parameter you are changing.
10. On the left-hand list the parameters of the selected group
are shown; on the right-hand list the parameter of the
group you are changing are shown.
The parameters with a gray background on the left-hand list
are parameters that have already been added and can not be
selected.
Archive window
- To display tables (horizontal or vertical).
- To colour display the area indicated by the diagram.
- Print.
- To go back
Programming
The consultation can be started
To access the programming area of the ECU under test
proceed as follows:
4. Select the programming option from the Programming 7. Read the displayed messages and select the green tick
list; select the forward navigation key (enabled - green). icon to continue.
5. If required, enter the required data, by following the 8. At the end the system permits access to the
indicated procedure. Programming environment; the components list is
displayed, on which tests can be carried out.
It is possible to carry out a programming only in During the programming do not disconnect the
! online mode. In case of error check the connections ! USB cable. Before carrying out the ECU
ECU/PT-BOX/PT-DIAGNOSIS. programming verify the charge left in the
computers battery.
It is recommended to plug the PC in (connect it to
the engine/vehicle or to the mains supply).
Programming environment
It is possible to use specific functions, by selecting the
corresponding key:
- The ignition key ON is automatically activated. - PTO (only for the PT-DIAGNOSIS full version SW)
The available function types are determined according to the Data Reading
type of ECU under test. The Keys area contains the buttons
for accessing the functions specific for the Programming This is used to view the data concerning the ECU and the
environment. respective programming state; tampering attempts are shown.
cancel key
navigation keys
cross key
scroll keys
If enabled, select to scroll the list step by step.
Active diagnosis
It is possible to carry out an active diagnosis only in
To start the Active Diagnosis online mode. In case of error check the following
!
connections ECU/PT-BOX/PT-DIAGNOSIS.
3. Select the Class and the System under test to which the
engine belongs; select the forward navigation key (enabled
- green) to continue.
Forward navigation
key
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
GENERALMANUTENZIONE