580 M Series 3 F4C Engine Service Training Manual 0407 87630273 PDF

REPAIR MANUAL
F4GE9454H
F4GE9454J
F4GE9484D
F4HE9484A
Issued 04-2007 - Service Training Edits

Book/Form Number 87630273 NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. unknown
ENGINE REPAIR MANUAL
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer
Revision History
Issue Issue Date Applicable Machine Remarks
F4GE9454H, F4GE9454J, F4GE9484D,
First Edition 04-2007 87630273 NA
F4HE9484A

TABLE OF CONTENTS
CHAPTER 1
DIAGNOSTICS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHAPTER 2
445TA ENGINE OVERHAUL
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . 2-54
KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION FOR F4GE ENGINES . . . . . . . . . . 2-56
HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . 2-59
EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . 2-97
CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123
MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137
87519803 NA Issued 04-07 Bur I

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

INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144
ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145
CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154
LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157
ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159
CHAPTER 3
ELECTRICAL, CHARGING AND START-UP
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-3
LOCATION OF MAIN ELECTRICAL COMPONENTS FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . 3-6
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
II Issued 04-07 Bur 87519803 NA

CHAPTER 1
445TA
TIER III
DIAGNOSTICS
Issued 04-2007
CHAPTER 1 - DIAGNOSTICS
Revision History
Issue Issue Date Applicable Machines Remarks
F4GE9454H, F4GE9454J,
F4GE9484D, F4HE9484A
1-II Issued 04-07 Bur 87630273 NA

CHAPTER 1
DIAGNOSTICS
TABLE OF CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine Won’t Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine Overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Engine Lacks Power and Runs Erratically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Engine lacks power and runs erratically (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine Exhaust Smoke Black or Dark Grey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine exhaust smoke black or dark grey (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Engine Exhaust Smoke Grey (Verging On White) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Engine Exhaust Smoke Light Blue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Engine Knocks Irregularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Engine Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Engine Exceeds Max. Revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Excessive or Insufficient Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Excessive Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Engine Won’t Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
87630273 NA Issued 04-07 Bur 1-1

NOTES
1-2 Issued 04-07 Bur 87630273 NA

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

Batteries fully charged. No
section of the shop manual.
Yes
Inspect, clean, tighten nuts or replace terminals if
Connections to battery terminals are tight and clean. No
excessively corroded.
Yes
Perform the checks described in the electrical
Starter motor working properly. No
section of the repair manual.
Yes
Check using multi meter replace or repair. Refer to
Grid heater system working properly. No
Chapter 3 pages 3-5 and 3-14.
Yes
Fuel in tank. No Refuel tank.
Yes
Fuel filters plugged. Yes Replace.
No
Verify timing described in Chapter 2 page 2-120 and
Injection pump timed properly. No 2-141 for mechanical injection. Common rail pump
bring to certified pump shop.
Yes
On common rail engines check using Electronic
Injectors working properly. No Service Tool (EST). Mechanical injection loosen
(crack) injection lines.
Yes
The fuel system or injection pump shows signs of air Check and repair air leaks. For mechanical injection
Yes
in system. see Chapter 2 page 2-56
No
Check and clean the fuel system including the fuel
The fuel system shows traces of water. Yes
tank.
No
Fuel pump working properly. No Check fuel pump and replace if necessary.
Yes
Cold start advance solenoid and shut off solenoid Check and replace defective parts. See Chapter 2
No
both in working order. page 2-55
Yes
Check cylinders for proper compression, overhaul
Compression good on all cylinders. No
engine or make repairs on defective parts,.
87630273 NA Issued 04-07 Bur 1-3

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

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

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

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

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

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

page 2-120 and 2-141 for mechanical
Injection pump timed correctly. No
injection. Common rail pump bring to
certified pump shop.
Yes
Cylinder head gasket leaking. Yes Replace.
1-4 Issued 04-07 Bur 87630273 NA

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

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

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

No Bring to a certified pump shop for repair.
working order at all speeds.
Yes
87630273 NA Issued 04-07 Bur 1-5

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

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

Compression good on all cylinders. No overhaul the engine or make repairs on
defective parts (valves, piston rings, etc.)
Yes
Turbocharger working properly. No Repair or replace unit.
1-6 Issued 04-07 Bur 87630273 NA

ENGINE EXHAUST SMOKE BLACK OR DARK GREY
Fresh clean diesel fuel in tank. No Clean the tank and replace the fuel filter.
Yes
Air filter plugged. Yes Clean replace if necessary.
No
Check using multi meter replace or repair.

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

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

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

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

order.
Yes
Injection pump adjusted properly. No Bring to a certified pump shop for repair.
Yes
87630273 NA Issued 04-07 Bur 1-7

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

Injection pipes intact.
them if necessary.
Yes

defective parts (valves, piston rings, etc.).
ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)
Check using multi meter replace or repair.

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

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

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

Yes
Clean the tank and replace the fuel filter.

Fresh clean diesel fuel in tank. No
ENGINE EXHAUST SMOKE LIGHT BLUE
Check: oil vapor breather, cylinder

compression. Leaks into or out of
Excessive oil consumption. Yes turbocharger. Leaks from valve guides.
Overhaul cylinder head or engine if
necessary.
1-8 Issued 04-07 Bur 87630273 NA

ENGINE KNOCKS IRREGULARLY
Check the following items: Journal play and

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

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

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

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

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

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

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

Knock detected in the injection pump. Yes
87630273 NA Issued 04-07 Bur 1-9

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

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

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

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

No Adjust play to proper specifications.
arms.
Yes
Valves intact. No Replace broken valves.
EXCESSIVE OR INSUFFICIENT OIL PRESSURE
Oil pressure control valve working properly. No Check and replace if necessary.
Yes
Oil level correct and proper engine oil SAE Check to see if contaminated or proper
No
viscosity. viscosity and fill to proper level if low.
Yes
Oil pump and delivery lines in working No Check and replace if necessary.
properly
Yes
Main bearings and connecting rod bearings Replace the bearings and reface if
No
in acceptable condition. necessary the crankshaft.
Yes
1-10 Issued 04-07 Bur 87630273 NA

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

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

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

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

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

defective parts (valves, piston rings, etc.).
ENGINE WON’T STOP
Fuel Shut Off solenoid working properly. No Replace.
Yes

Speed governor working properly. No
pump shop for repair.
87630273 NA Issued 04-07 Bur 1-11

NOTES
1-12 Issued 04-07 Bur 87630273 NA

CHAPTER 2
445TA
TIER III
Issued 04-2007
CHAPTER 2 - 445TA ENGINE OVERHAUL
Revision History
Issue Issue Date Applicable Machines Remarks
F4GE9454H, F4GE9454J, F4GE9484D
F4HE9484A
2-II Issued 04-07 Bur 87630273 NA

CHAPTER 2
TABLE OF CONTENTS
F4GE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CODING OF SOURCE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ENGINE PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
GENERAL ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
VALVE GEAR - CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
F4GE - ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
F4GE9454H and F4GE9454J Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
F4GE9484D Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
F4HE- ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
F4HE9484A Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
DESCRIPTION OF MAIN ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Crankshaft Oil Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
EGR Exhaust Gas Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Valve Control for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Valve Control for F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Cylinder Head for F4GE9454h and f4GE9454J Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Cylinder Head for F4GE9484D Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Cylinder Head for F4HE9484A Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Valves and Valve Seats for F4GE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Valves and Valve Seats for- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
ACCESSORY EQUIPMENT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
COUNTER BALANCER- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
ENGINE LUBRICATION FOR- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
ENGINE LUBRICATION FOR- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Oil Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
By-Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Oil Pan (Sump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Oil Vapor Recirculation for F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Oil Vapor Recirculation for- F4HE Engines with Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Blow-By Recirulation: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Oil Vapor Recirculation for- F4HE Engines without Blow-by Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
87630273 NA Issued 04-07 Bur 2-1

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Boosting Version Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Inter-Cooled Engine Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Mechanical Fuel lift Pump- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Mechanical Injection Working Principles- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
ENGINES WITH BOSCH (VE 4/12 F) ROTARY INJECTION PUMP- F4GE ENGINES . . . . . . . . . . . . . . . . . . 2-54
KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
MECHANICAL INJECTION FUEL SYSTEM TEST FOR RESTRICTION OR AIR INFILTRATION . . . . . . . . . 2-56
Parts needed for pressure/ vacuum testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57
Normal system operating observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
HIGH PRESSURE ELECTRONIC INJECTION (COMMON RAIL)- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . 2-59
EDC7UC31- ELECTRONIC CONTROL UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
Engine Preheating Element Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Phase Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Injection Pressure Closed Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Pilot and Main Injection Advance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Idle Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Overheating Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Maximum Engine Speed Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Cut Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Smoke Control Under Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
After Engine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Control Of Working Speed In Normal Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Recover Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61
FUEL SUPPLY SYSTEM- F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Fuel Supply System Diagram- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64
Mechanical Feed Pump- Normal Operating Condition- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65
Mechanical Feed Pump- Outlet Overpressure Condition In Exhaust Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65
Fuel System Bleeding Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
High Pressure Pump Type CP3.3- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
High Pressure Pump Inside Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69
Operating Principal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
COMMON RAIL PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
Injection End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74
Electro-Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75
Pressure Limiter for Fuel Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76
CHECKING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Low Pressure Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77
Low - Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78
Test On Pressure Relief Valve On Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79
Test On Fuel Backflow From the Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80
SPECIAL DISASSEMBLY FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82
Crank Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84
2-2 Issued 04-07 Bur 87630273 NA

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

Removing Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
SPECIAL DISASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Disassembling Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
CONTINUATION OF ENGINE DISASSEMBLY STEPS FOR ALL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
CHECKS AND MEASUREMENTS ON ENGINE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Checking Crankcase Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
Checking Eccentric Lift and Bearing Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
Replacing Cam Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Installing Tappets and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Measuring Bearing Journals and Connecting Rods Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Replacing Oil Pump Drive Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Mounting Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
Checking Crankshaft Shoulder Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Conditions for Correct Pin/Piston Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Checking Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Checking Twisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
Checking Flexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
Assembling Piston To Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
Installing Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
Installing Connecting Rod-Piston Assemblies In Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
Measuring Crank Pin Assembly Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
Checking Piston Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
VALVE GEAR DISTRIBUTION GEARBOX CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118
INJECTION PUMP TIMING FIRST PHASE FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
ASSEMBLING COUNTER BALANCER FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
Counter Balancer Timing- F4GE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123
Engine Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-124
MOUNTING THE OIL AND WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
CYLINDER HEAD FOR F4GE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-130
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
Valve Descaling, Check and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
Checking Valve Guide Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Valve Seats Regrinding- Replacing Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
MOUNTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
Installing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
87630273 NA Issued 04-07 Bur 2-3
Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135

Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135
Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-136
Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-137
INSTALLING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137
INSTALLING EXHAUST MANIFOLD, TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138
INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141
REPLACING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-144
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-144
Reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
ROCKER ARM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-145
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-145
Adjusting Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146
CYLINDER HEAD ASSEMBLY FOR F4HE ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-147
Removing the Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147
Checking Cylinder Head Water Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
Checking Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-149
Valve Cleaning, Checks and Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149
Checking Valve guide wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-150
Valve Seats- Regrinding, Replacing, Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-150
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
INSTALLING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-153
Fitting Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154
Torquing Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-154
INSTALLING INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-154
Rods and Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156
Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-156
LOCATING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-157
ADJUSTING VALVE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-158
INSTALLING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-159
Injector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160
Installing Tappet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-160
Exhaust Manifold/Turbo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-161
Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162
Fuel Filter Bracket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-162
Wiring Harness Connections to the Engine- F4HE Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-163
2-4 Issued 04-07 Bur 87630273 NA

F4GE- ENGINES
BS06N188 Figure 2-1

F4GE9454H & F4GE9454J ENGINE
BS06N189 Figure 2-2

F4GE9484D ENGINE
The NEF F4GE engines are characterized by a four It differs from other applications because of the
stroke atmospheric or turbocharged two valves per provision of different power, power take-off, for
cylinder. different collector configurations, boost turbine and
Fuel feed is provided by rotary mechanical injection after cooler.
pump.
87630273 NA Issued 04-07 Bur 2-5

F4HE- ENGINES
BS07D071 Figure 2-3

F4HE9484A ENGINE
The NEF F4HE engines are characterized by a four
stroke diesel, turbocharged, four valves per cylinder.
They have high pressure injection fueling
(common rail) and are entirely electronically driven in
order to optimize the fuel efficiency and performance.
Also limiting emissions as much as possible.
1
BS07D072 Figure 2-4

F4HE9484A ENGINE SHOWING THE EDC7UC31
CONTROL BOX (1).
2-6 Issued 04-07 Bur 87630273 NA

CODING OF SOURCE ENGINES

ENGINE MODEL BREAKDOWN DISCRIPTION
F 4 G E 9 4 8 4 D J * 6
1= Common Rail 4 valve
2= Common Rail 2 valve
3= In Line 4 valve
4= In Line 2 valve
5= Rotary 4 valve
6= Rotary 2 valve
Emissions Level: J= Tier 3
Approved power rating
Application:
4= Agricultural. machinery - Earth moving
Fuel / Injection / Induction
0= Diesel injection - naturally aspirated
5= Diesel injection - Turbocharged
8= Diesel injection - Turbo - after cooler
Number of Cylinders
4= 4 cylinders
6= 6 cylinders
9= Internal EGR
E= Engine
Type of crankcase:
A= Non-structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter
B= Non-structural crankcase 102 mm - 2valves - 3.9 or 5.9 liter
C= Structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter
D= Structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter
E= Structural crankcase 102 mm - 4 valves - 3.9 or 5.9 liter
F= Structural crankcase 104 mm - 2 valves - 3.9 or 5.9 liter
G= Non-structural crankcase 104 mm - 2 valves - 4.5 or 6.8 liter
H= Non-structural crankcase 104 mm - 4 valves - 4.5 or 6.8 liter
Engine Family: Includes 4 cylinder and 6 cylinder in both 2 valves and 4 valves per cylinder
mechanical and common rail fuel systems
87630273 NA Issued 04-07 Bur 2-7

ENGINE PROPERTIES
A F4GE9454H F4GE9454H F4GE9454J F4GE9454J F4GE9484D F4GE9484D F4HE9484A

B *J601 *J602 *J600 *J601 *J601 *J602 * J101
C 4 Cylinders
D 4485 cm³ (273.7 cubic inches)
74 kW 74 kW 66 kW 66 kW 93 kW 93 kW 104 kW
E (100 h.p.) (100 h.p.) (90 h.p.) (90 h.p.) (126 h.p.) (126 h.p.) (141 h.p.)
2000 rpm 2000 rpm 2000 rpm 2000 rpm 2200 rpm 2200 rpm 2200 rpm
F Direct Injection
High pressure
G Rotary Injection pump Common rail
EDC7UC31
H T.C. (Boosted) T.A.A.- (Boosted by Intercooler)
A. Type of engine
B. Engine model
C. Number of cylinders
D. Total displacement
E. Maximum power currently available
F. Type of Injection
G. Injection system
H. Air supply system
2-8 Issued 04-07 Bur 87630273 NA

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

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101
Cycle 4- Stroke diesel engine
1 Air Boosted Boosted by intercooler
Injection Direct
2 Number of cylinders 4 in-line
3 Bore 104 mm (4.1 in.)
4 Stroke 132 mm (5.2 in)
5 Total displacement 4485cm³ (273.7 cubic inches)
6 Compression ratio 17.5: 1 16.5: 1
74 kW 66 kW 93 kW 104 kW
2000 rpm 2000 rpm 2200 rpm 2200 rpm
7 Maximum power rating (net power at flywheel ISO 14396)
100 hp 90 hp 126 hp 141 hp
2000 rpm 2000 rpm 2200 rpm 2200 rpm
400 Nm 375 Nm 510 Nm 608 Nm
1250 rpm 1250 rpm 1250 rpm 1600 rpm
8 Maximum Torque
295 lb.-ft. 277 lb.-ft. 376 lb.- ft. 448 lb.-ft.
1250 rpm 1250 rpm 1250 rpm 1600 rpm
9 No-load idle
10 No-load peak rpm
with
without intercooler with intercooler intercooler
11 Boosting (type of turbocharger) HOLSET HX25 HOLSET HX25 HOLSET
HX27W
87630273 NA Issued 04-07 Bur 2-9

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

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101
Lubrication. Forced by means of gear pump, pressure relief valve, oil filter.
12 Oil pressure with hot engine: at idle rpm. 0.70 bar (10 psi)
Oil pressure with hot engine: at peak rpm. 3.50 bar (50 psi) 4.0 bar (58 psi)
By centrifugal pump, regulated by thermostat, heat exchanger,
Cooling. intercooler
13
Water pump drive. By means of Belt
Thermostat start of opening temperature. 79 to 83° C (174 to 181° F)
Oil capacity engine sump. Refer to Owners Manual
14
Oil capacity engine sump + filter. Refer to Owners Manual
High Pressure
15 Fuel feed type Rotary Bosch - VE4 / 12 F Common Rail,
EDC7UC31
16 Pump setting 0° ± 0.5° N.A.
17 Start of delivery 0.95 to 1.05 mm (0.0374 to 0.0413 in.) N.A.
Type of injector N.A. CRIU 2
18 Injection sequence 1 -3 -4 -2
250 to 1600 bar
19 Injection pressure N.A.
3626 to 23206 psi
2-10 Issued 04-07 Bur 87630273 NA

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

ENGINE TYPE
NO.
J601 J602 J600 J601 J601 J602 J101
1 Cylinder bore. 104.000 to 104.024 mm. (4.0945 to 4.0954 in.)
Pistons:
Measurement dimension. X= 55.90 mm. (2.20 in.)
2
Outer diameter. Ø1= 103.714 to 103.732 mm. (4.0832 to 4.0839 in.)
Pin seat. Ø2= 38.010 to 38.016 mm. (1.4965 to 1.4967 in.)
3 Piston - cylinder liners. 0.252 to 0.294 mm. (0.0099 to 0.0116 in.)
4 Piston diameter. Ø= 0.4 mm. (0.0157 in.)
5 Protrusion of pistons from crankcase. 0.28 to 0.52 mm (0.01102 to 0.02047 in.)
6 Piston pin. Ø3= 37.994 to 38.000 mm. (1.4958 to 1.4961 in.)
7 Piston pin-Pin seat. 0.01 to 0.022 mm. (0.0004 to 0.0009 in.)
X1= 2.705 to 2.735 mm. (0.1065 to 0.1077 in.)
Piston ring grooves
X2= 2.44 to 2.46 mm. (0.0961 to 0.0969 in.)
(measured on Ø of 99.0mm 3.898 in.)
X3= 4.03 to 4.05 mm. (0.1587 to 0.1594 in.)
8
S1= 2.560 to 2.605 mm. (0.1008 to 0.1026 in.)
Piston rings
S2= 2.350 to 2.380 mm. (0.0925 to 0.0937 in.)
(measured 1.5 mm 0.05905 in. away from external Ø).
S3= 3.970 to 3.990 mm. (0.1563 to 0.1571 in.)
1= 0.100 to 0.175 mm. (0.0039 to 0.0069 in.)
9 Piston rings - Slots. 2= 0.060 to 0.110 mm. (0.0024 to 0.0043 in.)
3= 0.040 to 0.080 mm. (0.0016 to 0.0031 in.)
10 Piston rings. 0.40 mm. (0.0157 in.)
87630273 NA Issued 04-07 Bur 2-11

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

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101
X1= 0.30 to 0.40 mm. (0.0118 to 0.0157 in.)
11 Piston ring gaps in cylinder liner. X2= 0.60 to 0.80 mm. (0.0236 to 0.0315 in.)
X3= 0.30 to 0.55 mm. (0.0118 to 0.0217 in.)
Connecting rod small-end bearing seat. Ø1= 40.987 to 41.013 mm. (1.6137 to 1.6147 in.)
12
Connecting rod large-bearing seat. Ø2= 72.987 to 73.013 mm. (2.8735 to 2.8745 in.)
Connecting rod small-end bearing diameter.
13 Inner Ø3= 38.019 to 38.033 mm. (1.4968 to 1.4974 in.)
Big end half bearings S= 1.955 to 1.968 mm. (0.0770 to 0.0775 in.)
14 Connecting rod small-end bearing seat. 0.250 to 0.500 mm. (0.0098 to 0.01968 in.)
15 Piston pin - bearing. 0.019 to 0.039 mm. (0.0007 to 0.0015 in.)
Measurement dimension. No Information Available
Maximum error on connecting rod axis parallelism. No Information Available
Bearing journals Ø1= 82.990 to 83.010 mm. (3.2673 to 3.2681 in.)
16
Crank pins Ø2= 68.987 to 69.013 mm. (2.7160 to 2.7170 in.)
Main half bearings (supplied as spares). S1= 2.456 to 2.464 mm. (0.0967 to 0.0970 in.)
Connecting rod half bearings. S2= 1.955 to 1.968 mm. (0.0770 to 0.0775 in.)
17 Main bearing- journals
Numbers 1, 5 Ø3 87.982 to 88.008 mm. (3.4638 to 3.4649 in.)
Numbers 2, 3, 4 Ø3= 87.977 to 88.013 mm. (3.4637 to 3.4651 in.)
2-12 Issued 04-07 Bur 87630273 NA

18 19 20
21 22 23
BS06K017 Figure 2-9

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101
Half bearing- journals.
0.064 to 0.095 mm. (0.0025 to 0.0037 in.) 0.041 to 0.119 mm. (0.0016
Numbers 1, 5 to 0.0047 in.)
18 0.059 to 0.100 mm. (0.0023 to 0.0039 in.) 0.041 to 0.103 mm. (0.0016
Numbers 2, 3, 4 to 0.0041 in.)
0.064 to 0.090 mm. (0.0025 to 0.0035 in.) 0.033 to 0.041 mm. (0.0013
Half bearing - crank pins. to 0.0016 in.)
Main half bearings +0.250 mm. (0.0098 in.)

19
Big end connecting rod half bearings. +0.500 mm. (0.0197 in.)
20 Main journal of thrust bearing. X1= 37.475 to 37.550 mm. (1.4754 to 1.4783 in.)
Main bearing housing of thrust
21 X2= 32.180 to 32.280 mm. (1.2669 to 1.2709 in.)
bearing.
22 Shoulder half ring. X3= 37.280 to 37.380 mm. (1.4677 to 1.4716 in.)
23 Crankshaft shoulder. 0.095 to 0.270 mm. (0.0037 to 0.0106 in.)
87630273 NA Issued 04-07 Bur 2-13

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

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

3 Valve stem and respective guide. 0.059 to 0.086 mm (0.002 to 0.003 in.) 0.052 to 0.092 mm (0.002 to 0.003 in.)
46.987 to 47.013 mm 34.837 to 34.863 mm
Seat on head for valve seat. - Intake.
(1.850 to 1.851 in.) (1.371 to 1.373 in.)
4
43.637 to 43.663 mm. 34.837 to 34.863 mm
Seat on head for valve seat. - Exhaust.
(1.718 to 1.719 in.) (1.371 to 1.373 in.)
Valve seat outer diameter; angle of valve
seats on cylinder head.
Ø2= 47.063 to 47.089 mm. 34.917 to 34.931 mm.
Intake. (1.853 to 1.8534 in.) (1.374 to 1.375 in.)
5
angle= 60° angle= 60°
Ø2= 43.713 to 43.739 mm. 34.917 to 34.931 mm.
Exhaust. (1.7210 to 1.7220 in.) (1.374 to 1.375 in.)
angle= 45° angle= 45°
Recessing. Intake valve 1.00 to 1.52 mm. (0.039 to 0.060 in.) 0.59 to 1.11 mm. (0.023 to 0.044 in.)
6
Recessing. Exhaust valve 1.00 to 1.52 mm. (0.039 to 0.060 in.) 0.59 to 1.11 mm. (0.023 to 0.044 in.)
Between valve seat and head- Intake 0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)
7
Between valve seat and head- Exhaust 0.050 to 0.102 mm.(0.002 to 0.004 in.) 0.054 to 0.094 mm (0.002 to 0.004 in.)
8 Valve seats No Information Available
2-14 Issued 04-07 Bur 87630273 NA

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

ENGINE TYPE
NO. J601 J602 J600 J601 J601 J602 J101
Valve spring height: Free spring. H= 63.5 mm. (2.500 in.) 47.75 mm (1.880 in.)
Under load of: 329 N (74 lbf). H1= 49.02 mm. (1.930 in.) 35.33 mm (1.391 in.)
9
Under load of: 641 N (144 lbf). H2= 38.20 mm. (1.504 in.) 25.2 mm (0.992 in.)
Injector protrusion. X= Not Adjustable
Seats camshaft bearing.- number - 1 Ø 7= 59.222 to 59.248 mm.
(flywheel side) (2.332 to 2.333 in.)
10
Seats camshaft bearings.- Ø 1-6= 54.089 to 54.139 mm.
numbers - 2, 3, 4, 5 (2.130 to 2.132 in.)
Camshaft main bearing journals: Ø 1, 2, 3, 4, 5 = 53.995 to 54.045 mm.
11
1 through 5 (2.126 to 2.128 in.)
12 Camshaft bushing outside diameter Ø= N.A.
13 Camshaft bearing inner diameter. Ø=54.083 to 54.147 mm. (2.129 to 2.132 in.)
14 Bearing and seats in crankcase. N.A.
15 Bearing and main journals. 0.038 to 0.162 mm. (0.002 to 0.006 in.)
Useful cam lift- Intake. 10.74 mm. (0.423 in.) 7.5282 mm (0.296 in.)
16
Useful cam lift- Exhaust. 11.02 mm. (0.434 in.) 6.045 mm (0.238 in.)
Tappet plate seat in crankcase. Ø1= 16.000 to 16.030 mm. (0.630 to 0.631 in.)
Ø2= 15.924 to 15.954 mm. (0.627 to 0.628 in.)
17
Tappet plate outside diameter. 15.960 to 15.975 mm
Ø3= 15.965 to 15.980 mm.(0.629 to 0.629 in.) (0.628 to 0.629 in.)
18 Between tappets and seat. No Information Available
19 Tappets. No Information Available
Ø1= 18.963 to 18.975 mm. 21.965 to 21.977 mm
20 Rocker arm shaft.
(0.747 to 0.747 in.) (0.8647 to 0.8652 in.)
22.001 to 22.027 mm
21 Rocker arms Ø2= 19.000 to 19.026 mm. (0.748 to 0.749 in.) (0.866 to 0.867 in.)
0.025 to 0.063 mm. 0.024 to 0.162 mm
22 Between rocker arm and spindle (0.001 to 0.003 in.) (0.00094 to 0.0064 in.)
87630273 NA Issued 04-07 Bur 2-15

TORQUE SPECIFICATIONS FOR (F4GE)- ENGINES

PART ...................................................................................................................................... TORQUE - Nm (lb.-ft.)
Cylinder head fastening bolts.
1st phase. (pre lubricated with oil)
Bolts M12x1.75x70 .................................................................................45 to 55 Nm (33.2 to 40.6 pound-feet)
Bolts M12x1.75x140 ...............................................................................35 to 45 Nm (25.8 to 33.2 pound-feet)
Bolts M12x1.75x180 ...............................................................................65 to 75 Nm (47.9 to 55.3 pound-feet)
2nd phase (additional rotation)..........................................................................................90 degrees ± 5 degrees
3rd phase (only for bolts 140 and 180 mm long additional rotation) .................................90 degrees ± 5 degrees
Crankshaft main bearings.
1st phase (pre lubricate with oil). ................................................................44 to 56 Nm (32.5 to 41.3 pound-feet)
2nd phase ...................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet)
3rd phase. (additional rotation). ......................................................................................................90 ± 5 degrees
Bolts fastening the pulley on the crankshaft ................................................105 to 115 Nm (77.4 to 84.8 pound-feet)
Connecting rod cap bolts.
1st phase. (pre lubricate with oil). ...............................................................27 to 33 Nm (19.9 to 24.3 pound-feet)
2nd phase ...................................................................................................55 to 65 Nm (40.5 to 47.9 pound-feet)
3rd phase. additional rotation ..........................................................................................................60 ± 5 degrees
Engine flywheel fastening bolts. M12x1.5
1st phase. (pre lubricate with oil) ................................................................26 to 34 Nm (19.2 to 25.1 pound-feet)
2nd phase. (additional rotation).......................................................................................................60 ± 5 degrees
Flywheel housing
M12x120 .....................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet)
M12x80 .......................................................................................................75 to 95 Nm (55.3 to 70.1 pound-feet)
Assembly rear cover plate to flywheel housing (M8x1.25x16).........................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel injectors. ..................................................................................................55 to 65 Nm (40.6 to 47.9 pound-feet)
Sump (oil pan) M8x1.25. .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Sump (oil pan) M18x1.5 ..................................................................................51 to 69 Nm (37.6 to 50.9 pound-feet)
Oil pan drain plug ............................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Oil filter............................................................................................................................................ Contact + 3/4 turn
Oil bypass valve to lube filter head ..................................................................72 to 88 Nm (53.1 to 64.9 pound-feet)
Fuel filter. ........................................................................................................................................ Contact + 3/4 turn
Injection pump fastening bolts. ........................................................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Injection pump gear (drive gear nut)
1st stage......................................................................................................15 to 20 Nm (11.0 to 14.8 pound-feet)
2nd stage ....................................................................................................85 to 90 Nm (62.7 to 66.4 pound-feet)
Valve gear cover and case fastening bolts (front cover). .................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Intake manifold fastening bolts. .......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Assembly air intake connection M8x1.25 ........................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel pump fastening bolts M8 bolt...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel pump fastening bolts M6 bolt.........................................................................9 to 11 Nm (6.6 to 8.1 pound-feet)
Fuel pump M6 nut..................................................................................................9 to 11 Nm (6.6 to 8.1 pound-feet)
Exhaust manifold fastening bolts. .....................................................................37 to 49Nm (27.3 to 36.1 pound-feet)
Valve cover fastening nuts. ..............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Rocker arm support fastening bolts.................................................................40 to 56 Nm (29.5 to 41.3 pound-feet)
Rocker arm adjusting nut.................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft shoulder plate fastening bolts..........................................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Camshaft retaining plate bolts M8 ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet.)
Fan support fastening bolts M10x1.5x20.........................................................28 to 38 Nm (20.7 to 28.0 pound-feet)
Fan pulley fastening bolts
M6 ....................................................................................................................8 to 12 Nm (5.9 to 8.8 pound-feet)
M10 .............................................................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Turbocharger fastening bolts. ..........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Starter motor fastening bolts. ..........................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)
2-16 Issued 04-07 Bur 87630273 NA

Alternator fastening bolts.

Alternator to alternator support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Alternator to water inlet M8 bolt ..................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Alternator lower mount M10 ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Alternator upper pivot M10 bolt ...................................................................44 to 54 Nm (32.5 to 39.8 pound-feet)
Alternator mounting hardware M12x1.75x120 .............................................37 to 49Nm (27.3 to 36.1 pound-feet)
Alternator wiring M6 nut ....................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Water pump fastening bolts. ............................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Water outlet connection
M8x1.25x35.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
M8x1.25x70.................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Heat exchanger fastening bolts .......................................................................20 to 30 Nm (14.8 to 22.1 pound-feet)
Camshaft gear bolt M8 ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)
Rear gear housing assembly
M8 ...............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Cylinder lubricating nozzles M8x1.25x10 ..........................................................12 to 18 Nm (8.9 to 13.3 pound-feet)
Engine counter balancer................................................................................. 40 to 56 Nm (29.5 to 41.3 pound-feet)
Engine coolant temperature sensor fastening bolt ......................................... 17 to 23 Nm (12.5 to 17.0 pound-feet)
87630273 NA Issued 04-07 Bur 2-17

TORQUE SPECIFICATIONS FOR (F4HE)- ENGINES

PART .............................................................................................................................TORQUE - Nm (pound-feet)
Camshaft sensor M6 studs....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Feed pump M8 studs .......................................................................................... 10 to 14 Nm (7.4 to 10.3 pound-feet
Rear gear case M12 bolts ...............................................................................65 to 89 Nm (47.9 to 65.6 pound-feet)
Rear gear case M10 bolts ...............................................................................42 to 52 Nm (31.0 to 38.4 pound-feet)
Rear gear case M8 bolts .................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft sensor M6 nut .......................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Oil pump M8 bolts
1st stage ..................................................................................................................7 to 9 Nm (5.2 to 6.6 pound-feet)
2nd stage.........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Front cover M8 bolts ........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft gear M8 bolts ..................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)
Crankcase plate M10 bolt................................................................................38 to 48 Nm (28.0 to 35.4 pound-feet)
High pressure pump gear M18 nut ..............................................................100 to 110 Nm (73.6 to 81.1 pound-feet)
Fuel pump M8 nuts..........................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
1/2 inch plug on cylinder head.........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
1/4 inch plug on cylinder head.........................................................................31 to 41 Nm (22.9 to 30.2 pound-feet)
3/4 inch plug on cylinder head...........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)
Injector fastening M6 bolts
1st stage ........................................................................................................8.15 to 8.85 Nm (6.0 to 6.5 pound-feet)
2nd stage (additional rotation) ....................................................................................................................... 75 ° ± 5°
Injector feed connector fastening nut................................................................ 45 to 55 Nm 33.2 to 40.6 pound-feet)
Grid heater grill on intake manifold M6 nut ............................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Intake manifold M8 bolts..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fastening brackets (rear) for engine lifting M12 bolts ......................................65 to 89 Nm (47.9 to 65.6 pound-feet)
Fastening brackets (front) for engine lifting M8 bolts .......................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Common rail M8 bolts......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
High pressure fuel line connectors M14 ..........................................................18 to 22 Nm (13.3 to 16.2 pound-feet)
High pressure fuel line connectors M8 ............................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Cylinder head M12x1.75x130 and 150
1st stage ..........................................................................................................30 to 40 Nm (22.1 to 29.5 pound-feet)
2nd stage (additional rotation) ........................................................................................................................ 90° ± 5°
3rd stage (additional rotation)......................................................................................................................... 90° ± 5°
Rocker arm bracket .........................................................................................31 to 41 Nm (22.9 to 30.2 pound-feet)
Valve clearance adjusting nuts ........................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel line from high pressure pump to Common Rail, M14 nut ........................18 to 22 Nm (13.2 to 16.2 pound-feet)
Wiring bulkhead M6 bolt ........................................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Electrical wiring support for injector feed.........................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Wiring on each injector -nuts ................................................................ 1.25 to 1.75 Nm (11.1 to 15.5 pound-inches)
Fuel filter bracket
M12 bolts .........................................................................................................69 to 85 Nm (50.9 to 62.7 pound-feet)
M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel filter......................................................................................................................................... Contact + 3/4 turn
Oil pressure relief valve on oil filter support M22 bolt......................................72 to 88 Nm (53.1 to 64.9 pound-feet)
Radiator seal and oil filter support M8 bolt ......................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Oil filter ........................................................................................................................................... Contact + 3/4 turn
Connection on oil filter support for turbine lubrication .....................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Turbine lubrication pipe M12 nut............................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Engine coolant inlet connection M10 bolt ........................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
90° elbow (if required) to engine coolant inlet connection ...............................20 to 28 Nm (14.8 to 20.7 pound-feet)
Line on cylinder head for compressor cooling .................................................20 to 24 Nm (14.8 to 17.7 pound-feet)
Engine coolant drain connector M6 bolt ................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Engine block exhaust manifold pin ........................................................................8 to 12 Nm (5.9 to 8.9 pound-feet)
Exhaust manifold to cylinder head M10 bolt ....................................................48 to 58 Nm (35.4 to 42.8 pound-feet)
2-18 Issued 04-07 Bur 87630273 NA

Damper adapter and damper on crankshaft M12 bolt

2nd stage (additional rotation) ........................................................................................................................90° ± 5°
Crankshaft pulley M10 bolts ............................................................................61 to 75 Nm (45.0 to 55.4 pound-feet)
Water pump M8 bolts.......................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Auxiliary component control belt tensioner M10 bolt .......................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Fixed pulleys for auxiliary component control belt M10 bolts ..........................37 to 49 Nm (27.3 to 36.1 pound-feet)
Flywheel housing
Heat exchanger for EDC7UC31 control unit
M6 bolts ....................................................................................................................... 8 to 12 (5.9 to 8.9 pound-feet)
M8 bolts ...........................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Fuel inlet-outlet on heat exchanger ...................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)
Valve cover fastening nut M8 nut .....................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft sensor M6 bolt.......................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Crankshaft sensor M6 bolt.....................................................................................6 to 10 Nm (4.4 to 7.4 pound-feet)
Coolant temperature sensor M14 bolt .............................................................17 to 23 Nm (12.5 to 17.0 pound-feet)
Oil pressure/temperature sensor M5 bolt ................................................................5 to 7 Nm (3.7 to 5.2 pound-feet)
Fuel pressure sensor fastening bolt......................................... 30 to 40 Nm (22.1 29.5 Nm (22.1 to 29.5 pound-feet)
Fuel temperature sensor M14 bolt...................................................................17 to 23 Nm (12.5 to 17.0 pound-feet)
Air temperature/pressure sensor on intake manifold ...............................................5 to 7 Nm (3.7 to 5.2 pound-feet)
Engine oil level sensor M12 bolt ........................................................................10 to 14 Nm (7.4 to 10.3 pound-feet)
Turbine to exhaust manifold
M8 pins ....................................................................................................................6 to 8 Nm (4.4 to 5.9 pound-feet)
M8 nuts............................................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Adapter on turbine for lubricant oil lines (inlet) M12 adapter ...........................30 to 40 Nm (22.1 to 29.5 pound-feet)
Adapter on line on turbine for lubrication M10 adapter....................................30 to 40 Nm (22.1 to 29.5 pound-feet)
Adapter on oil line for turbine lubrication to block M10 adapter.......................37 to 49 Nm (27.3 to 36.1 pound-feet)
Oil drain pipe on turbine M8 bolt......................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Connector attaching oil return from cylinder head to flywheel housing .................8 to 12 Nm (5.9 to 8.9 pound-feet)
Flywheel fastening bolts M12 bolts
1st stage ........................................................................................................... 26 to 34 Nm 19.2 to 25.1 pound-feet)
2nd stage (additional rotation) ........................................................................................................................60° ± 5°
Oil pan (sump) M8 bolts ..................................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Cylinder bore lubricating nozzles M8 bolts ........................................................12 to 18 Nm (8.9 to 13.3 pound-feet)
Crankshaft output bearings M12 bolts
2nd stage.........................................................................................................74 to 86 Nm (54.6 to 63.4 pound-feet)
3rd stage (additional rotation).........................................................................................................................90° ± 5°
Camshaft retaining plate M8 bolts ...................................................................20 to 28 Nm (14.8 to 20.7 pound-feet)
Camshaft gear M8 bolt ....................................................................................32 to 40 Nm (23.6 to 29.5 pound-feet)
Connecting rod caps M11 bolts
1st stage ........................................................................................................... 55 to 65 Nm 40.6 to 47.9 pound-feet)
2nd stage (additional rotation) .......................................................................................................................60 ° ± 5°
Alternator bracket attaching to water feed pipe fitting M10 bolts .....................37 to 49 Nm (27.3 to 36.1 pound-feet)
Alternator fastening M10 bolts.........................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
Starter fastening bolts M10 bolts .....................................................................37 to 49 Nm (27.3 to 36.1 pound-feet)
87630273 NA Issued 04-07 Bur 2-19

SPECIAL TOOLS
380000665............................................................................................... Tool for removing the crankshaft front seal.

380000663................................................................................................ Tool for removing the crankshaft rear seal.
380000671..................................................................................................... Tool for removing mechanical injectors.
380000666..........................................................................................Coupler for installing the crankshaft front seal.
380000664...........................................................................................Coupler for installing the crankshaft rear seal.
380000228........................................................................................................................... Dial indicator (0 - 5 mm).
380001601...........................Dial indicator holder tool for rotary injection pump timing (to be used with 380001004).
380002729..................................................................................................................... Engine TDC positioning tool.
380000979................................................................................................................ Injection pump drive gear puller.
380000158............................................................................................................................. 1 to 6 Nm torque driver.
380001099......................................................................................................... Tool for removing electrical injectors.
2-20 Issued 04-07 Bur 87630273 NA

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

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

2. BLOW-BY 5. PRIMING PUMP 8. WATER PUMP
3. ROTARY INJECTION PUMP 6. CRANKSHAFT PULLEY 9. FAN PULLEY
87630273 NA Issued 04-07 Bur 2-21

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

2. BLOW-BY 5. PRIMING PUMP 8. WATER PUMP
3. ROTARY INJECTION PUMP 6. CRANKSHAFT PULLEY 9. FAN PULLEY
2-22 Issued 04-07 Bur 87630273 NA

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

2. COMMON RAIL 8. REAR OF CRANKSHAFT
3. FAN PULLEY 9. FLYWHEEL
4. FIXED GUIDE PULLEY 10. HIGH PRESSURE PUMP
5. DAMPING FLYWHEEL 11. FUEL FILTER
7 6. WATER PUMP
8
11
10
9
87630273 NA Issued 04-07 Bur 2-23

DESCRIPTION OF MAIN ENGINE COMPONENTS

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

2. SEATS FOR CAMSHAFT BEARINGS AND TAPPETS 4. OIL PUMP
The engine block consists of a cast iron structure

containing the cylinder bores (1), the main bearing
housings (3), and the following seats: for camshaft
bearings (2), water pump (5), and oil pump (4). The
block also incorporates the water jackets for cooling
and the oil galleys for lubrication.
2-24 Issued 04-07 Bur 87630273 NA

CRANKSHAFT
2
1
1. FLYWHEEL ATTACHMENT HUB 2. TIMING DRIVE GEAR 3. CRANKSHAFT 4. OIL PUMP DRIVE GEAR
The crankshaft is made of steel and rests on five CRANKSHAFT OIL SEALS
induction hardened bearing journals. Drilled inside The front and rear seals are box type with radial seal.
the crankshaft are a series of lubricating oil ducts. R e m o ve w i t h s p e c i a l t o o l s 3 8 0 0 0 0 6 6 5 a n d
The following items are pressed onto the front of the 380000663. Install with special tools 380000666 and
crankshaft: oil pump drive gear (4), phonic wheel, the 380000664.
vibration damper, and auxiliary equipment drive
pulley.
The following items are pressed onto the rear of the
crankshaft: timing gear (2), and the flywheel
mounting hub (1).
The main bearing shells are made of steel with a
antifriction alloy plating.
One of the main bearing shells is equipped with
shoulders to limit crankshaft endplay.
The timing drive gear (2) and the flywheel attachment
hub (1) are installed on the rear of the crankshaft with
a force-fit and cannot be replaced.
87630273 NA Issued 04-07 Bur 2-25

CONNECTING RODS

T h e c o n n e c t i n g r o d s a r e fo r g e d s t e e l , T h e Each connecting rod is marked:
connecting rod crankshaft ends are made with an • By a number on the connecting rod body and
oblique angle, with separation of rod and cap on the cap indicating the match and the cylinder
obtained by means of the innovative fracture splitting in which they are assembled.
system rather than the conventional machining • By a letter on the connecting rod body
process. indicating the weight class of the connecting rod
The connecting rod crankshaft bearing shells are installed in production.
made of steel plated with an antifriction alloy.
2-26 Issued 04-07 Bur 87630273 NA

PISTONS
2
3
4

The piston crown features a high turbulence The following reference data is engraved into the
combustion chamber. The underside of the piston piston crown:
crown is cooled by engine oil delivered by a spray 1. Spare part number and design modification
nozzle installed in the crankcase. number.
There are three piston ring grooves with different 2. Stamping (facing the crankcase front side)
functions and different geometry. indicating the mounting direction of the piston in
1st piston ring with trapezoidal (keystone) the cylinder bore.
section, ceramic chrome plating. 3. Date of manufacture.
2nd piston ring with torsional conical rectangular 4. Stamping indicating 1st recess insert testing.
section.
3rd piston ring with double oil ring wiper with
internal spring.
87630273 NA Issued 04-07 Bur 2-27

CAMSHAFT
NOTE: The camshaft below is a 6 cylinder camshaft.
BS06K025
C
D
A. CRANKSHAFT OUTPUT GEAR B. JOURNAL C. INTAKE VALVE LOBE D. EXHAUST VALVE LOBE
The camshaft is installed on five bearing journals (B) The exhaust gas recirculation system (EGR), lowers
in the engine block. the combustion temperature by decreasing the
The front and rear bearing housings are equipped concentration of oxygen in the combustion chamber.
with steel bearings plated with antifriction material Creating an effective system to control the emission
assembled by means of a force-fit. of NOx.
The camshaft is controlled directly by the crankshaft The internal EGR system exhaust lobe design is not
by means of gear (A). equipped with any electronically controlled elements,
the system is always active. Its configuration does
EGR EXHAUST GAS RECIRCULATION SYSTEM not need additional elements such as check valves,
piping or heat exchangers.
In the TIER 3 version, the profile of the exhaust lobe
has been modified in order to allow the par tial The exhaust lobe (D) has an additional lobe apart
opening of the exhaust valve during the intake cycle. from the major lobe see cross sectional view of
The exhaust gases can be partially returned back exhaust valve (D), as compared to the configuration
into the cylinders to lower the maximum combustion of a cam without EGR.
temperature which is responsible for the production With the additional lobe during the intake stroke of a
of nitrogen oxides (NOx). cylinder, this lobe permits a brief opening of the
exhaust valve. Recirculation is generated in the
cylinder during the intake stroke due to the greater
pressure of exhaust compared to the intake gases.
2-28 Issued 04-07 Bur 87630273 NA

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

2. ROCKER ARM SUPPORT 5. TAPPET 8. SPRING SEAT
3. ADJUSTING SCREW 6. CAM SHAFT 9. VALVE SPRING RETAINER (KEEPERS)
87630273 NA Issued 04-07 Bur 2-29

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

2. ROCKER SPINDLE 7. SPRING SEAT
3. VALVE BRIDGE 8. VALVE SPRING RETAINER (KEEPERS)
4. TAPPET 9. PUSH ROD
5. CAMSHAFT 10. VALVE LASH ADJUSTER SCREW
2-30 Issued 04-07 Bur 87630273 NA

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

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

2. INTAKE MANIFOLD 4. VALVE SEAT 6. INJECTOR
The cast iron cylinder head is machined to The cylinder head is also fitted for the following
accommodate the following parts: components to be installed on to the cylinder head.
• Valve seats (4). • Exhaust manifold (1).
• Injectors (6). • Intake manifold (2) with seat for grid heater (3).
• Thermostat (5).
87630273 NA Issued 04-07 Bur 2-31

CYLINDER HEAD FOR F4GE9484D ENGINES
1 2
4
5

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

2. INTAKE MANIFOLD 4. VALVE SEAT 6. INJECTOR
accommodate the following parts: components to be inserted on to the head.
• valve seats (4). • exhaust manifold (1).
• injectors (6). • intake manifold (2) with seat for grid heater (3).
• thermostat (5).
2-32 Issued 04-07 Bur 87630273 NA

CYLINDER HEAD FOR F4HE9484A ENGINES
4
6

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

2. INTAKE MANIFOLD 4. VALVE SEAT 6. THERMOSTAT
accommodate the following parts: components to be installed on the cylinder head.
• Valve seats (4). • Exhaust manifold (1).
• Injectors (2). • Intake manifold (2) with seat for grid heater (3).
• Thermostat (6).
87630273 NA Issued 04-07 Bur 2-33

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

2. EXHAUST VALVE 4. INTAKE SIDE
Valve seats inserted in the head have the following

angles:
45° - Exhaust valves.
60° - Intake valves.
NOTE: The exhaust valves (2) differ from the intake
valves (3) in that they have only one notch at the
stem end.
(A) Shows the oil seals mounted on valve stems.
2-34 Issued 04-07 Bur 87630273 NA


DETAIL OF VALVE GUIDES AND SEATS F4GE ENGINES
87630273 NA Issued 04-07 Bur 2-35

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

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

Oil seals (1) installed on valve stems.
1. JUMPER
2. PUSH RODS
NOTE: When installing the cylinder head, the

orientation of valve bridges must be positioned with
marks (1) towards exhaust manifold.
2-36 Issued 04-07 Bur 87630273 NA

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

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

FLYWHEEL FOR- F4GE ENGINES

FLYWHEEL FOR- F4HE ENGINES
87630273 NA Issued 04-07 Bur 2-37

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

2. AUTOMATIC BELT TENSIONER 4. CRANKSHAFT 6. POLY-V-BELT
A Poly-V-belt (6) transmits the rotation of the

crankshaft (4) to water pump (5), fan pulley, and to
the alternator (1). The tension of the belt is controlled
by the automatic belt tensioner (2).
2-38 Issued 04-07 Bur 87630273 NA

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

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

2. SUPPORT 7. COUNTER-ROTATING SHAFT
3. FASTENING BOLTS 8. GEAR
4. GEAR 9. RING
5. BALANCING MASS 10. O-RING
Inside the oil pan (sump), secured to the cylinder Match alignment marks (A) engraved on the gears for
block is the counter balancer. timing, insert pin in hole (B) on the balancing mass to
The counter balancer is timed as shown above. stop rotation temporarily.
87630273 NA Issued 04-07 Bur 2-39

ENGINE LUBRICATION FOR- F4GE ENGINES
A
B
C
LUBRICATION SYSTEM LAYOUT FOR F4GE ENGINES
A. GRAVITY OIL RETURN PATH B. PRESSURIZED OIL PATH C. OIL SUPPLY
Pressurized lubrication is performed by the following By-pass valve to cut out clogged oil filter, built into the
components: cooler unit.
Gerotor oil pump housed in the front of the engine Cartridge- type oil filter.
block, driven by the spur tooth gear force fitted on the
crankshaft.
Water / oil cooler, housed in the engine block.
2-40 Issued 04-07 Bur 87630273 NA

ENGINE LUBRICATION FOR- F4HE ENGINES
A
B

LUBRICATION SYSTEM LAYOUT FOR- F4HE ENGINES
(NOTE: THE ILLUSTRATION IS A 6 CYLINDER)
1. TURBO OIL PRESSURE CONTROL VALVE 4. HEAT EXCHANGER A. PRESSURIZED OIL PATH
2. BY-PASS VALVE 5. OIL PUMP B. GRAVITY OIL RETURN PATH
3. CARTRIDGE- TYPE OIL FILTER 6. OIL PAN (SUMP)
Pressurized lubrication is done with the following

components:
• Gerotor oil pump (5) housed in the front of the
engine block, driven by the spur tooth gear force
fitted on the crankshaft.
• Heat exchanger (4) housed in the engine block,
under the oil filter support.
• By-pass valve (2) for clogged oil filter cut off.
• Cartridge type oil filter (3)
• Oil pan (sump) (6)
87630273 NA Issued 04-07 Bur 2-41

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

2. INNER GASKET 4. GASKET (BETWEEN COOLER AND ENGINE BLOCK)
OIL PRESSURE CONTROL VALVE BY-PASS VALVE
2 3
A
BS06K041 Figure 2-39 A. DIRECTION OF FLOW
1. 66 MM (2.59 INCHES) Blow-by max:
2. 41.25 MM (1.62 INCHES)
3. 136.9 ± 10.5 N (30.8 ± 2.36 LBF)
20 cm³/min (.68 oz/min) with 0.83 bar (12 psi)
pressure at 26.7° C (80° F) oil temperature.
Calibration at 100° C (212° F) oil temperature.
Minimum pressure 1.2 bar (17.4 psi)
Maximum pressure 3.8 bar (55.1 psi)
2-42 Issued 04-07 Bur 87630273 NA

OIL PUMP OIL PAN (SUMP)

OIL PUMP

OIL PAN (SUMP) FOR F4GE ENGINES
2
2
1. Crankshaft with oil pump drive gear. BS06K045 Figure 2-44
OIL PAN (SUMP) FOR F4HE ENGINES
2. Oil pump.
The oil pan (sump) (2) is bolted to the cylinder block.
The gasket (1), fitted on the oil pan reduces noise
and in addition to improve tightness.
87630273 NA Issued 04-07 Bur 2-43

OIL VAPOR RECIRCULATION FOR F4GE ENGINES

Oil vapor recirculation takes place by means of valve The vapor condensed within the valve falls into the
(1) placed above the tappet cover (3) on F4GE tappet cover (3) due to gravity. The remaining vapor
engines. is recovered by vent (2) and recirculated to the
engine intake.
2-44 Issued 04-07 Bur 87630273 NA

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

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

The rocker cover has a blow-by pre-separator (1), condense and return to the oil pan (sump) through
designed to increase the outlet velocity of blow-by oil line (4), while the remaining is recirculated to the
vapor while condensing them partially. Condensed oil engine intake by line (2).
returns to the oil pan (sump) while residual vapors
are collected and routed through the blow-by filter
(3).
87630273 NA Issued 04-07 Bur 2-45

OIL VAPOR RECIRCULATION FOR- F4HE ENGINES WITHOUT BLOW-BY FILTER
A
B
The tappet cover houses the pre-separator (1),
whose shape and position increases the outlet
velocity of the blow-by vapors and condenses part of
the vapors at the same time.
The condensed oil returns to the oil pan (sump),
where the residual vapor is collected and discharged
into the open air through the bleeder on the side (2).
2-46 Issued 04-07 Bur 87630273 NA

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

2. HEAT EXCHANGER A. WATER FLOWING OUT OF THERMOSTAT C. WATER FLOWING INTO WATER PUMP
The engine cooling system is a closed circuit, forced • Fan- Increases heat dissipating power of the
c i r c u l a t i o n t y p e i n c o r p o r a t i n g t h e fo l l ow i n g radiator by flowing more air across the radiator.
components: • Heat exchanger- Cools the lubricating oil.
• Radiator- Dissipates the heat from the engine by
circulating coolant through a long row of tubes and • Centrifugal water pump- placed on the front of the
air flowing across them decreasing the engine block. Circulates the coolant through the
temperature. engine and radiator and is driven by a Poly-V belt.
• Expansion tank- Collects the overflow of coolant • Thermostat- Regulates the circulation of the
as it expands and contracts. coolant.
87630273 NA Issued 04-07 Bur 2-47
WATER PUMP

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

CROSS SECTIONAL VIEW OF WATER PUMP
The water pump is housed in a cavity in the front of
the engine block. and is driven by a Poly-V belt. The
water pump is sealed to the block by a rubber ring.
2-48 Issued 04-07 Bur 87630273 NA

AIR INDUCTION BOOST DIAGRAM

BOOSTING VERSION ENGINES
1 2
BS07C435 Figure 2-52

4 CYLINDER BOOSTED VERSION
1. AIR FILTER 2. TURBOCHARGER 3. EXHAUST 4. PISTONS
T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t
The turbocharger is composed of the following parts: emissions, releasing part of them directly to the
turbine, transforming valve to regulate the boost exhaust tube when the boost feeding pressure of the
pressure, main body, and compressor. compressor, reaches the prescribed pressure value.
When engine is running, the exhaust emission flow The cooling process and lubrication of the
through the body of the turbine makes the turbine turbocharger and bearings is done by the engine oil.
disk rotate.
The compressor rotor connected by a shaft to the
turbine disk rotates, compressing the air drawn
through the air filter.
The air coming out of the compressor is sent via the
intake manifold directly to the pistons.
The turbocharger is equipped with a transforming
valve to regulate the pressure, located on the
exhaust collector before the turbine and connected
by piping to the induction collector.
87630273 NA Issued 04-07 Bur 2-49

INTER-COOLED ENGINE VERSION
1 2
4
5
BS07C436 Figure 2-53

4 CYLINDER BOOSTED / INTERCOOLED VERSION
1. AIR FILTER 2. TURBOCHARGER 3. EXHAUST 4. CHARGE AIR COOLER 5. PISTONS
The turbocharger is composed of the following parts: T h e i n d u c t i o n c o l l e c t o r d i r e c t s t h e ex h a u s t

turbine, transforming valve to regulate the boost emissions, releasing part of them directly to the
pressure, main body, and compressor. exhaust tube when the boost feeding pressure of the
compressor, reaches the prescribed pressure value.
When engine is running, the exhaust emission flow
through the body of the turbine makes the turbine The cooling process and lubrication of the
disk rotate. turbocharger and bearings is done by the engine oil.
The compressor rotor connected by a shaft to the

turbine disk rotates, compressing the air drawn
through the air filter.
The air is then cooled by the charge air cooler and
sent via the intake manifold to the pistons.
The turbocharger is equipped with a transforming
valve to regulate the pressure, located on the
exhaust collector before the turbine and connected
by piping to the induction collector.
2-50 Issued 04-07 Bur 87630273 NA

MECHANICAL INJECTION FEEDING SYSTEM- F4GE ENGINES

FUEL FILTER
6
3

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

2. AIR BLEEDING SCREW 4. WATER DRAIN 6. FUEL TEMPERATURE SENSOR
The fuel filter is located close to the feed and priming

pump. The fuel filter provides a barrier trap for
impurities and to separate water from the fuel.
On the filter bracket base there is a water drain
screw, equipment used in cold climate areas there
can be a heater assembled into the bracket (to
prevent the fuel from jelling), and a fuel temperature
sensor. On some versions there is a water presence
sensor located on the filter cartridge base.
87630273 NA Issued 04-07 Bur 2-51

MECHANICAL FUEL LIFT PUMP- F4GE ENGINES
1 2
5 6

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

2. CONTROL LEVER 4. FUEL PUMP 6. CAMSHAFT
The fuel pump is mounted on the left side of the Specifications for fuel lift pump:
engine. It draws fuel from the fuel tank and feeds it to Static pressure at 1800 r/min. (rpm).
the rotary injection pump. It is driven by the camshaft.
0.47 to 0.61 bar (6.8 to 8.8 psi).
2-52 Issued 04-07 Bur 87630273 NA

MECHANICAL INJECTION WORKING PRINCIPLES- F4GE ENGINES
1 2 3
1. Fuel filter 3. Feed pipeline from priming pump to filter 5. Fuel pump
2. Feed pipe line from fuel pump to fuel filter 4. Rotary injection pump
Fuel is drawn from the fuel tank by the fuel pump (5) To check fuel pressure for engines with mechanical
and is driven by the camshaft. fuel system.
Fuel flows through pipeline (2) to the fuel filter (1) and The fuel supply pressure specification is 0.27 bar
is piped to the vacuum chamber of the injection pump (4 psi) minimum and 0.34 to 0.48 bar (5 to 7 psi) at
via pipeline (3), (for applications to be operated in full load rated rpm. To check fuel pressure, purchase
cold climates the fuel filter is provided with a heater). a fuel supply line for the four cylinder engine. Cut the
Transfer pump is placed inside the injection pump (4), fuel line and install a tee fitting to measure the fuel
and is a rotary type. It increases fuel pressure with pressure.
the increase in the number of engine revolutions.
The fuel arrives to the valve gauging the pressure
inside injection pump.
The distribution plunger increases the pressure and
delivers fuel throughout the delivery pipe to the
injectors.
The fuel drawn from the injectors is recovered and
delivered to the fuel tank again.
87630273 NA Issued 04-07 Bur 2-53

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

INJECTION ASSEMBLY
1. INJECTOR 1 FUEL PIPE 4. INJECTOR 4 FUEL PIPE 7. THERMAL BULB FOR KSB 10. INJECTOR
5. PIPE FOR FUEL DISCHARGE FROM
2. INJECTOR 2 FUEL PIPE 8. INJECTION PUMP
INJECTORS
6. CONNECTOR FOR MEASURING PRESSURE
3. INJECTOR 3 FUEL PIPE 9. SOLENOID VALVE
INSIDE THE L.D.A. INTAKE MANIFOLD
Fuel feed system is composed of: • Fuel feed rotary injection pump.
• Fuel tank (placed on the machine). • Injector feed pipeline (from injection pump to
injectors).
• Fuel delivery and back-flow to tank.
• Injectors
• Fuel pre-filter (if available, it is usually placed
close to the engine on the machine frame).
• Priming pump, assembled to the engine driven by
the camshaft.
• Fuel filter
2-54 Issued 04-07 Bur 87630273 NA

KKSB COLD START ADVANCE SYSTEM- F4GE ENGINES
4 3
BS07F331 Figure 2-58
1. TEMPERATURE SWITCH 2. ADVANCE SOLENOID 3. FUEL SHUT OFF SOLENOID 4. WIRE HARNESS
Theory of operation: There is one wire connected to the main harness that
When the engine is cold (coolant temperature below goes to the ignition terminal of the key switch. This
50° C (122° F) the injection pump is in timing wire feeds power to the injection pump shut off
advance state. When engine gets to between 60 and s o l e n o i d . A s e c o n d w i r e fe e d s p o w e r t o a
66° C (140 to 151°F), the thermo switch in the temperature switch in the head. A third wire routes
cylinder head opens and system voltage is no longer from the temperature switch to an additional solenoid
sent to the solenoid on the injection pump. This on the injection pump.
allows the timing to retard to "normal" operating An additional solenoid ensures that the pump will go
position. to full advance timing during cranking and upon initial
Units equipped with the Bosh VE rotary injection cold start up. Once the engine warms to 71° C
pump do not require a relay for the pull in circuit. The (160° F), the temperature switch opens and power to
pump uses a simple shut off solenoid built into the the solenoid on the side of the injection pump is
pump. removed. This allows the injection pump to retard the
timing according to engine rpm.
87630273 NA Issued 04-07 Bur 2-55

To troubleshoot the system: FUEL SYSTEM TEST FOR RESTRICTION

1. With the engine temperature below 50° C OR AIR INFILTRATION FOR F4GE
(122° F), the key switch on, battery voltage ENGINES
should be present at both solenoids on the
NOTE: If possible, test the fuel system as described
injection pump. If battery voltage is not present,
before removing the Bosch VE fuel injection pump for
troubleshoot the temperature switch circuit.
repair. If leakage is too severe, complete the test
2. To check the temperature switch, when engine procedure following the pump repair or replacement.
temperature is below 50° C (122° F), battery Failure to test the system may result in continued
voltage should be present at both terminals. pump leakage.
Warm the engine to 60 to 66° C (140 to 151° F).
To determine if the low pressure fuel supply is
Battery voltage should be present at only one
restricted, or if air is entering the system, follow these
terminal of the temperature switch when engine
steps.:
is warmed to 71° C (160° F) or higher.
3. Disconnect the connector at the temperature STEP 1
switch. Short across the two terminals of the Install a clear poly-vinyl tube between the outlet of
connector with a jumper wire and start engine. the fuel filter and the inlet of the Bosch VE fuel
After a short time, remove the jumper wire the injection pump. Tee connector into the test line a
engine should change sound and run smoother pressure gauge which can read both 0 to 762 mm
as the injection pump time is retarded. This (0 to 30 inches) of Hg vacuum and 0 to 2.07 bar (0 to
signifies that the cold starting advance system is 30 psi) positive pressure. See figure 2-59 on
operating properly. page 2-57
NOTE: For more information, see further procedures
in this section which describe how to build test lines,
and describe normal system operating observations.
STEP 2
Run the engine to purge all possible air from the
system which was caused by test line installation.
STEP 3
When air is no longer visible in the clear test line,
measure and record the operating pressures, while
continually observing for air in the fuel, under the
following conditions:
• Low idle- apply no load to the engine.
• High idle- apply no load to the engine.
• High idle- apply load to the engine using
hydraulics over relief, hydrostatic stall or converter
stall, depending upon the unit being tested. Load
the engine to its rated engine operating rpm.
• Run multiple tests while observing fuel pressure
and looking for air in the fuel.
STEP 4
If the fuel pressure is below 0.276 bar (4.0 psi) at any
time during the previous Step 3, check the following,
and replace as needed:
• The fuel pre-filter (replace).
NOTE: some applications do not use a fuel pre-filter.
• The primary fuel filter.
2-56 Issued 04-07 Bur 87630273 NA

• The lines and connections from the fuel supply Parts needed for pressure/ vacuum testing
pump inlet back to the fuel tank, checking for
damaged lines (kinks and rub marks) and leakage
at the Voss o-ring fittings.
2
1
• Debris in the tank, clean as required.
1
• The fuel pick-up tube in the fuel tank, checking for
cracks, plugging, or contact with the bottom or side 3
walls of the tank.
• The fuel tank cap, assuring that a vacuum is not
being formed in the fuel tank, which would reduce
the fuel supply pressure to the injection pump inlet. 4
5
NOTE: Vacuum in the fuel tank might not be
observed during short-term running.
• These instructions apply only to engines with
external electrical fuel shutoff valve assemblies.
Ensure that fuel supplied to and from the valve BS07F316 Figure 2-59
assembly is properly plumbed. Fuel supplied from SETUP FOR MEASURING PRESSURE
the fuel filter enters the shutoff valve at port To build a fuel system test set for pressure testing,
number 1. Port number 2 supplies fuel to the inlet obtain the following :
of the Bosch VE injection pump.
NOTE: Voss o-ring type connectors can be obtained
STEP 5 either by purchasing the connectors, or by
If the checks in Step 4 were made and all necessary purchasing a fuel line for the application being
corrective actions were taken, Retest. If the pressure worked on, then carefully removing the plastic Voss
is still low, preform the following tests: type connectors (1), from the plastic tube for re-use
with poly-vinyl tubing.
• From the gauges previously used to measure
pressure, remove one section of test line and a Quan. Description ID #
barbed fitting from the tee. Install in there place a Voss type brass barbed hose
gasket and a connector. This will allow installation 2 1
connectors
of the gauges between the supply pump inlet and
1 6.35 mm (1/4 inch)- NPT tee fitting 3
the fuel supply line from the tank. After installation
of the gauges, run the engine and observe the 6.35 mm (1/4 inch)- NPT to 7.54
5
2
clear tube remaining on the gauges to ensure that mm (5/16 inch) barb connectors
air is not entering. The vacuum here should not Five feet of 7.54 mm (5/16 inch)
exceed 50.8 mm (2.0 inches) of Hg under full load. 1 4
O.D. poly-vinyl tubing
If the vacuum is greater than that, look for a
Dampened compound gauge
plugged fuel supply line or debris in the fuel tank. which will measure 0 to 762 mm (0
• An alternative vacuum test method would be to 1 to 30 inches) of Hg and 0 to 2.07 2
supply fuel from an alternate fuel source, such as bar (0 to 30 psi).
a five gallon container, with a known good supply
line. Fit it directly to the supply pump inlet fitting,
then rerun the test. If the pressures return to
normal, check the fuel supply line and tank of the
vehicle for leaks or restrictions.
• Upon completion of the diagnostic procedures,
remove the test line and the gauge, and reinstall
the standard fuel line.
87630273 NA Issued 04-07 Bur 2-57

Normal system operating observations

1. Fuel supply pressures between the fuel filter and
the inlet to the injection pump should be 0.276 to
0.414 bar (4 to 6 psi) with the engine loaded or
unloaded.
1 2. Perform a "wiggle test" on each fuel line. A
steady stream of bubbles or foam Should Not be
seen moving through the fuel system. Very small
random bubbles are allowable.
3. A small, high intensity flashlight can aid in
observing air in the fuel lines.
2 4. The suction pressure between the inlet of the
BS07F317 Figure 2-60 fuel supply and the tank should not exceed
SETUP FOR MEASURING VACUUM 50.8 mm (2 inches) of Hg vacuum.
To build a fuel system test set for vacuum testing,
obtain the following :
Quan. Description ID #
1 Connector Voss type M12 x 1.5 1
Sealing washer between connector
1 2
(1) and tee fitting
NOTE: If the gauges are not equipped with a

dampening device, install a small needle valve
between the gauge and the test line. the needle valve
can be adjusted to control gauge reading
fluctuations.
2-58 Issued 04-07 Bur 87630273 NA

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

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

order to reduce PARTICULAR emissions.
NOTE: 6 cylinder version is shown in figure above,
The common rail system makes it possible to inject operation is the same.
fuel at pressures of up to 1450 - 1600 bar (21030 -
23206 psi), while the injection precision obtained by
EDC7UC31 electronic control of the system serves
to optimize operation of the engine while limiting
emissions and fuel consumption.
For engines more powerful than 152 kW (203 hp.),
the CRIN2 injectors have DLLA nozzles that work up
to a pressure of 1600 bar (23206 psi), while engines
less powerful than 152 kW (203 hp.) are fitted with
DSLA nozzles which work with pressures up to 1450
bar (21030 psi.).
87630273 NA Issued 04-07 Bur 2-59

EDC7UC31- ELECTRONIC CONTROL MAXIMUM ENGINE SPEED LIMITING

UNIT OPERATION Depending on the application, the control unit
memory can contain appropriate engine speed limits.
ENGINE PREHEATING ELEMENT CONTROL When the engine speed surpasses these limits, the
Pre-post heating is activated when even just one of control unit activates power reduction by controlling
the water, air or fuel temperature sensors detects a tur n on time of the electro-injectors. In some
temperature of less than 5° C (41° F). applications, the maximum limiting response consists
in stopping the engine.
PHASE RECOGNITION
CUT OFF
Signals transmitted by the camshaft and crankshaft
sensors determine the cylinder which fuel must be Fuel cut-off release is managed by the control unit
injected. with the following logical interventions:
• deactivation of the electro-injectors.
INJECTION CONTROL
• reactivation of electro-injectors immediately prior
Information transmitted by the sensors, the control to arrival at idle speed.
unit determines and regulates pressure and modifies
the pre-injection and main injection mode.
• control of fuel pressure regulator.
SMOKE CONTROL UNDER ACCELERATION
INJECTION PRESSURE CLOSED LOOP
CONTROL With intense load demands, signals received from
Engine load, determined by processing of data the boost temperature pressure sensor and the
transmitted by the various sensors, and the control crankshaft sensor, the control unit manages the
unit. Governs the regulator to maintain injection pressure regulator and modulates the activation time
pressure at constant optimal values. of the electro-injectors to prevent the emission of
smoke from the exhaust.
PILOT AND MAIN INJECTION ADVANCE
CONTROL AFTER ENGINE SHUT DOWN
Signals transmitted by various sensors to the control Afte r the engine is stopped, the contro l un it
unit, determines the optimum injection point on the microprocessor saves various parameters to the
basis of internal mapping. EEPROM memory, including the fault log so that they
will be available the next time the engine is started.
IDLE SPEED CONTROL
CONTROL OF WORKING SPEED IN NORMAL
The control unit processes signals transmitted by the OPERATING CONDITIONS
various sensors and adjusts the quantity of fuel
injected. Each time work load varies, the control unit adjusts
torque to maintain the engine in maximum power
It also controls the pressure regulator and modulates conditions. If the load causes a reduction in power,
injection duration of the electro-injectors. Within the control unit increases torque i.e. it increases the
specific limits, the control unit also monitors battery amount of fuel injected in order to restore the engine
voltage. to maximum power.
OVERHEATING PROTECTION
If the water temperature reaches 110° C (230° F) the
control unit reduces engine performance.
When the temperature returns below 100° C (212° F)
the engine resumes normal operation. In some
applications, the intake manifold temperature is the
reference temperature.
2-60 Issued 04-07 Bur 87630273 NA

RECOVER STRATEGIES When the temperature of the supercharging air rises

• Control of fuel leaks. above 88° C (190° F), power reduction is started,
when a temperature of 120° C (248° F) is reached,
In the case of fuel supply problems, the system performance is further reduced and is comparable to
controls the engine with suitable constant power that of the same engine if it were aspirated.
values obtained with a low number of rev and high
torque values in order to inject the maximum quantity • Reduction of power as reference temperature
of fuel. varies
• Control of pressure in the rail. In normal operating conditions, the system knows the
supercharging air, oil and water temperatures.
When the pressure in the rail exceeds safety values,
the engine reduces power. If the temperature of the engine water is not
available, the system takes the temperature of the oil
• Synchronism problems as reference and when this reaches the threshold of
In the case of synchronism problems, faulty rev 103° C (217° F), it star ts to reduce the power
s e n s o r s, t h e s y s t e m c o n t r o l s t h e e n g i n e by available. On reaching 113° C (235° F), power is
increasing the number of revs in order to improve reduced to 50%.
interpretation of the signals.
• Power restrictions as operating temperature
increases.
87630273 NA Issued 04-07 Bur 2-61

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

1. ELECTRO-INJECTOR 4. PRE-FILTER B. LOW PRESSURE
CHARGE PUMP
2. BACK PRESSURE REGULATOR
5. FUEL FILTER 8. HIGH PRESSURE PUMP C. FUEL RETURN
FOR FUEL RETURN
3. COMMON RAIL PRESSURE D. HIGH PRESSURE FROM
6. COMMON RAIL A. HIGH PRESSURE
RELIEF VALVE PUMP TERMINAL
The common rail system has a high pressure pump The high pressure circuit consists of the following
that constantly keeps the fuel supply at a very high lines:
pressure, not dependent on the phase of the cylinder • Line connecting the high pressure pump outlet to
that must receive the injection. The high pressure the common rail.
fuel is stored in a pipeline (the common rail) that is
shared by all electro- injectors. • Lines supplying the electro-injectors from the
common rail.
This means that there is always a supply of fuel
available at the electro- injector inlet at the injection The low pressure circuit is composed of the following
pressure determined by the EDC7UC31 electronic lines:
control unit. • Fuel line from fuel tank to prefilter.
When the solenoid valve of an electro- injector is • Lines supplying the mechanical supply pump
energized by the EDC7UC31 electronic control unit, through the heat exchanger of the control unit, the
fuel taken directly from the common rail is injected manual priming pump and the pre filter.
into the corresponding cylinder. The fuel system is completed by the fuel return from
The fuel system is composed of a low pressure the common rail, injectors and high pressure pump
circuit and a high pressure circuit. cooling circuit.
2-62 Issued 04-07 Bur 87630273 NA
FUEL SUPPLY SYSTEM DIAGRAM- F4HE ENGINES
5 6 7 A
B
4
C
3 D
18
2 17
9
1
16 10
15
13 11
14
12
9. MECHANICAL ROTOR PUMP BY-PASS 17. HIGH PRESSURE PUMP BY-

1. HIGH PRESSURE PUMP
CHECK VALVE PASS CHECK VALVE
2. LOW PRESSURE REGULATOR 10. HIGH PRESSURE PUMP AND INJECTOR 18. RETURN LINE FROM HIGH
VALVE ON HIGH PRESSURE PUMP RETURN LINE PRESSURE PUMP
3. COMMON RAIL SAFETY RELIEF 11. EDC7UC31 CONTROL UNIT HEAT
A. DRAIN
VALVE EXCHANGER
4. BACK PRESSURE VALVE IN FUEL
12. MANUAL PRIMING PUMP B. SUCTION
RETURN LINE FROM INJECTOR
5. COMMON RAIL 13. PRE-FILTER C. LOW PRESSURE
6. RAIL PRESSURE SENSOR 14. FUEL TANK D. HIGH PRESSURE
7. ELECTRO-INJECTOR 15. FUEL FILTER
8. ROTOR PUMP PRESSURE SAFETY
16. GEAR CHARGE FEED PUMP
BY-PASS
The supply pressure regulator controls the flow of In parallel with the mechanical supply pump there are
fuel needed in the low pressure system. The high two by-pass valves.
pressure pump supplies the common rail. This Rotor pump pressure safety by-pass valve (8) makes
pressurization of fuel, improves energy efficiency and it possible to have the fuel flow back from the
limits the heating of the fuel in the system. mechanical pump outlet to its inlet, when the
The low pressure regulator valve (2) installed on the p r e s s u r e a t t h e f u e l f i l t e r i n l e t ex c e e d s t h e
high pressure pump maintains the pressure at a permissible limit. The rotor pump by-pass valve (9)
constant level of 5 bars (72 psi.). makes it possible to fill the supply system via the
Low pressure regulator valve (2) operates to increase manual priming pump (12).
fuel flow in the high pressure pump cooling circuit
through line (18) carrying fluid into and out of line
(10).
The common rail safety relief valve (3) installed in the
cylinder head. Controls the flow of fuel returning from
the electro-injectors at a pressure of 1.3 to 2 bars (19
to 29 psi.).
87630273 NA Issued 04-07 Bur 2-63

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

2. FUEL TEMPERATURE SENSOR B. COMMON RAIL, CYLINDER HEAD INJECTORS DISCHARGE LINE INLET CONNECTION
3. FUEL FILTER C. CONNECTION TO HIGH PRESSURE PUMP DISCHARGE LINE
4. ELECTRIC FUEL HEATER D. INLET CONNECTION FROM FEED PUMP
5. FUEL TEMPERATURE SENSOR E. OUTLET CONNECTION TO FUEL TANK
The fuel filter is installed on the engine cylinder block The heater is activated if the fuel temperature is less
in the circuit between supply pump and high pressure than 0° C (32° F) and is heated until the fuel reaches
pump (CP3). 5° C (41° F). Fuel temperature is monitored by the
EDC7UC31 control unit.
2-64 Issued 04-07 Bur 87630273 NA

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

2. PRIMING BY-PASS VALVE IN CLOSED POSITION B. FUEL OUTLET TO FILTER
The charge gear pump, installed on the rear of the The feed pump is driven by the high pressure pump
high pressure pump, draws fuel from the tank shaft.
through the pre-filter and sends it through the main In normal operating conditions the flow in the feed
fuel filter to the high pressure pump. pump enters port (A), flows around the outside of the
gears and out through port (B).
MECHANICAL FEED PUMP- OUTLET OVERPRESSURE CONDITION IN EXHAUST UNIT
1 2

2. BY-PASS PORT B. FUEL OUTLET TO FILTER
Pressure safety valve (1) opens when pump outlet spring (1) allowing fuel to flow to the pump inlet
pressure (B), is excessive due to filter restriction or through passage (2).
charge pressure regulator malfunction. The pressure
of the fuel would then overcome the force exerted by
87630273 NA Issued 04-07 Bur 2-65
FUEL SYSTEM BLEEDING CONDITION

2. PRIMING BY-PASS VALVE IN CLOSED POSITION B. FUEL OUTLET TO FILTER
The by-pass valve (2) opens when, the engine is When activating the hand pump the by-pass valve (2)
turned off. The supply system has to be filled with the is opened due to inlet pressure, this allows the fuel
manual priming pump. flow to outlet (B).
2-66 Issued 04-07 Bur 87630273 NA

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

HIGH PRESSURE PUMP
1. MECHANICAL GEAR CHARGE PUMP

2. FUEL OUTLET CONNECTION FROM MECHANICAL PUMP TO FILTER
3. FUEL INLET CONNECTION FROM CONTROL UNIT HEAT EXCHANGER
4. FUEL DRAIN RETURN CONNECTION TO FILTER BRACKET
5. FUEL INLET CONNECTION FROM FILTER
6. HIGH PRESSURE REGULATOR
8. FUEL OUTLET CONNECTION TO COMMON RAIL
The high pressure pump has 3 radial plungers driven On the rear of the high pressure pump is the
by the cam gear. The pump does not need to be mechanical gear feed pump which is driven by the
timed. high pressure pump shaft.
IMPORTANT: The high pressure pump unit can not be overhauled, there are no adjustments.
87630273 NA Issued 04-07 Bur 2-67

1
9 2
8 3
7 4
6
5

EXPLODED VIEW OF HIGH PRESSURE PUMP
1. BY-PASS VALVES ON 4. 5 BAR (72 PSI) LOW PRESSURE 7. HIGH PRESSURE FUEL DELIVERY
FEED PUMP FUEL REGULATOR VALVE VALVE TO COMMON RAIL
5. HIGH PRESSURE REGULATOR
2. PUMP SHAFT 8. GEAR SET
SOLENOID VALVE
6. INDIVIDUAL HIGH PRESSURE 9. MECHANICAL GEAR CHARGE FEED
FUEL INLET FROM
PUMP PLUNGER (1 OF 3) PUMP
FILTER
2-68 Issued 04-07 Bur 87630273 NA

HIGH PRESSURE PUMP INSIDE STRUCTURE

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

2. PUMPING ELEMENTS SUPPLYING
6. PISTON
FUEL DUCTS
3. CYLINDER 7. BALL DELIVERY VALVE
4. THREE LOBE ELEMENT 8. CAP INTAKE VALVE
Pumping unit is composed of:

• Three pistons (6) which are actuated by a three
lobe element (4) on the pump shaft (5) When the
shaft (5) rotates the three lobe element (4)
actuates the piston (6) pumping high pressure fuel
past the ball delivery valve (7) to the common rail.
87630273 NA Issued 04-07 Bur 2-69

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

5. PUMP SHAFT
DELIVERY LINE SUPPLY PASSAGE VALVE
2. HIGH PRESSURE 4. PLUNGER SUPPLY 6. HIGH PRESSURE
REGULATOR PASSAGE PLUNGER
High pressure plunger (3) rides on the cam installed During the plunger compression phase the fuel
on the pump shaft (4). In the intake phase the reaches sufficient pressure to open the common rail
plunger is supplied with fuel through the supply delivery valve (2) and is forced through outlet (1) to
passage (5). The quantity of fuel to supply to the the common rail.
plunger is determined by pressure regulator (7). The
pressure regulator controls high pressure pump
outlet flow based on PWM (pulse width modulated)
command received from the EDC7UC31 control unit.
2-70 Issued 04-07 Bur 87630273 NA
2
1
1
9 2
3
8
4
7
3
5
6
BS06K064 Figure 2-76 BS06K065 Figure 2-77
1. INLET TO HIGH PRESSURE PLUNGERS 1. FUEL EXHAUST FLUE

2. INLET TO HIGH PRESSURE PLUNGERS 2. FUEL EXHAUST GALLERY
3. CHARGE PRESSURE REGULATOR DRAIN PASSAGE 3. FUEL EXHAUST FLOWING FROM PUMP WITH
4. CHARGE PRESSURE 5 BAR (72 PSI) REGULATOR VALVE CONNECTOR TO HIGH PRESSURE LINE FOR
5. FUEL DISCHARGE FROM HIGH PRESSURE REGULATOR COMMON RAIL
VALVE INLET
6. HIGH PRESSURE REGULATOR VALVE The figure above shows the fuel flow under high
7. MAIN PLUNGER SUPPLY PASSAGE pressure running through the exhaust galleries of the
8. INLET TO HIGH PRESSURE PLUNGERS pumping elements.
9. PUMP LUBRICATION PASSAGES
THEORY OF OPERATION
The figure above shows the low pressure fuel
The cylinder is filled through the cap intake valve only
passages inside the pump. The figure shows the
if the supply pressure is suitable to open the delivery
main plungers supply passage (7), the individual
valves set on the pumping elements about
plunger supply passages (1, 8, 2), the passages
2 bars (29 psi.).
utilized for lubrication of the pump (9), the high
pressure regulator (6), the 5 bar (72 psi) pressure The amount of fuel supplying the high pressure pump
regulator valve (4) and the fuel discharge passage is metered by the high pressure regulator. The high
(3). pressure regulator is controlled by the EDC7UC31
control unit through a PWM (pulse width modulated)
The high pressure regulator (6) determines the
signal.
quantity of fuel which the high pressure plungers
deliver to the common rail. Excess fuel flows out When fuel is sent to a pumping element, the
through passage (5). corresponding piston is moving downwards (suction
stroke). When the piston stroke is reversed, the
The regulator valve (4), is designed to maintain a
intake valve closes and the fuel in the pumping
constant pressure of 5 bar (72 psi.) at the high
element chamber, is compressed into the rail.
pressure regulator inlet.
The generated pressure makes the exhaust valve
open and the compressed fuel reaches the high
pressure circuit.
The pumping element compresses the fuel till the top
dead center (delivery stroke) is reached. Afterwards,
the pressure decreases till the exhaust valve is
closed.
The pumping element piston goes back towards the
bottom dead center and the remaining fuel is
decompressed.
87630273 NA Issued 04-07 Bur 2-71

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

COMMON RAIL
A fuel rail pressure sensor (1) is screwed into the
The common rail volume is a high pressure fuel common rail. The signal sent by this sensor to the
storage device. It has a small volume to allow a rapid EDC7UC31 control unit, and is then feed back to the
pressurization at startup, at slow idle and in case of common rail pressure sensor and corrected if
high flow rates. necessary.
It has enough volume to minimize system spikes
caused by injector opening and closings and by the
high pressure pump operation. This function is
further enhanced by a calibrated orifice between the
high pressure pump and the common rail.
2-72 Issued 04-07 Bur 87630273 NA

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

COMMON RAIL PRESSURE RELIEF VALVE
1. DIRECT TANK DISCHARGE 3. BODY 5. SMALL PISTON

2. STOP 4. SPRING 6. SEAT ON RAIL
A. NORMALLY, THE TAPERED PISTON (5) END STAYS CLOSED THE
DISCHARGE IS DIVERTED TO THE FUEL TANK.
B. IF 1750 BAR FUEL PRESSURE IS EXCEEDED IN THE RAIL, THE SMALL
PISTON MOVES AND THE EXCESS PRESSURE IS DISCHARGED INTO
THE FUEL TANK.
The common rail pressure relief valve is installed at The relief valve enables engine operation at limited
one end of the common rail, it is designed to protect p e r fo r m a n c e, avo i d i n g f u e l ove r h e a t i n g a n d
the systems components in case of excessive safeguarding the system
increase of pressure buildup. If the dual stage relief valve opening pressure is
The valve can be single stage (as the ones shown reached, the EDC7UC31 control unit stops operation
above) or two stage with two working limits for of the pressure regulator. The high pressure pump
pressure relief 1750 bar and 800 bar (25381 psi. and will then operate at maximum delivery to the common
11603 psi.). rail, and a failure code will be stored.
In the second case, when the pressure within the
high pressure system reaches 1750 bar (25381 psi.),
the valve is activated as a single stage one to
exhaust the fuel and consequently reduce the
pressure until reaching the proper pressure. Then it
reduces the pressure into the common rail to
approximately 800 bar (11603 psi.).
87630273 NA Issued 04-07 Bur 2-73

ELECTRO-INJECTOR
1 1
14
14
13 13
15
2 15 2
3
3 12
12
4 4
11
11 5 5
6 6
10 10
7
7
9
9
8 8
INJECTION START
INJECTOR IN REST POSITION
When coil (13) is energized, it makes ball shutter (14)
1. ELECTRICAL
9. PRESSURE CHAMBER
move upwards. The control volume (15) fuel flows
CONNECTION towards control fuel outlet (11) making a pressure
2. PILOT VALVE 10. SPRING drop occur in control volume (15). Simultaneously the
3. CONTROL AREA 11. CONTROL FUEL OUTLET
fuel pressure into pressure chamber (9) makes
4. CONTROL DUCT 12. HIGH PRESSURE FUEL INLET
plunger (7) lift, causing injection of fuel into the
5. PRESSURE ROD 13. COIL
6. SUPPLY DUCT 14. BALL SHUTTER
cylinder.
7. PLUNGER 15. CONTROL VOLUME
8. NOZZLE INJECTION END
When coil (13) is de-energized, shutter ball (14) goes
The injector is similar to the conventional injectors, back to its closed position to restore a balance of
except for the absence of plunger return springs. forces to make plunger (7) go back to its closed
The injector can be considered in terms of two basic position and end the injection cycle.
parts:
IMPORTANT: The injector has no serviceable parts
• Actuator- spray nozzle composed of pressure rod
inside, so it is not repairable.
(5), plunger (7) and nozzle (8).
• Control solenoid valve composed of coil (13) and
pilot valve (2).
The solenoid valve controls spray nozzle plunger lift.
2-74 Issued 04-07 Bur 87630273 NA

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

1. JET
Pressures
Injectors Jet Power developed
kW / H.P. Minimal operating pressure Nominal operating pressure
CRIN 2 DLLA Above 152kW (204 h.p.) 250 bar (3626 psi.) 1600 bar (23206 psi.)
CRIN 2 DSLA Below 152kW (204 h.p.) 250 bar (3626 psi.) 1450 bar (21030 psi.)
87630273 NA Issued 04-07 Bur 2-75

PRESSURE LIMITER FOR FUEL RETURN
A B

A. TO FUEL TANK
B. FROM INJECTORS
The pressure limiter for the fuel return is housed on
the rear of the cylinder head, and adjusts the
pressure of the fuel returning from injectors at a
pressure of 1.3 to 2.0 bars (18.9 to 29 psi.). By
maintaining this pressure to the return fuel, the fuel
vapor formation inside the injectors is avoided,
optimizing fuel spraying and combustion.
2-76 Issued 04-07 Bur 87630273 NA

CHECKING THE FUEL SYSTEM

LOW PRESSURE SUPPLY TEST
10
9
8
7
4 4 9
9 11
3
2 12 6
4
4
4
1 5
13
DIAGRAM OF SET UP OF COMPONENTS FOR SPECIFIC TEST
1. FUEL TANK 6. HIGH PRESSURE PUMP 11. M1 PRESSURE GAUGE 0-15 BAR FUEL FILTER INLET
2. PREFILTER 7. HIGH PRESSURE CIRCUIT 12. M2 PRESSURE GAUGE FUEL FILTER OUTLET
13. EXTERNAL CONTAINER PLACED 1M (39 IN.) BELOW
3. LOW-PRESSURE PUMP 8. COMMON RAIL
ENGINE
4. FUEL DELIVERY CIRCUIT 9. FUEL RECIRCULATION
5. FUEL FILTER 10. INJECTORS
87630273 NA Issued 04-07 Bur 2-77

12
11
13
LOW - PRESSURE PUMP

The function of the gear pump is to supply the high With the fuel system pressurized, a fully charged
pressure pump. It is driven by the shaft of the high battery and an external fuel supply placed 1m (39 in.)
pressure pump and is installed on the rear portion of below the engine. The engine must start within 20
the high pressure pump. seconds of activation of the starter motor. If the pump
Under normal operating conditions, the flow of fuel is not able to draw fuel to the engine and start the
inside the pump is as shown in the figure above. engine the low pressure pump is probably defective.
2-78 Issued 04-07 Bur 87630273 NA

After starting the engine, check the pressure at 1500

rpm.
On pressure gauge M1- (11) it must be between 6
and 9 bar (87 and 130 psi.)
• If lower than 6 bar (87 psi.) replace pump
• If higher than 9 bar (130 psi.) replace the fuel
filter.
On pressure gauge M2- (12) it must be greater than
5 bar (72.5 psi.)
• If lower, replace the fuel filter
• If the trouble persists, check the seals on the
couplings of the fuel filter bracket and the high
pressure pump inlet.
87630273 NA Issued 04-07 Bur 2-79

TEST ON PRESSURE RELIEF VALVE ON COMMON RAIL

The pressure relief valve is installed on the end of the If the valve seeps diesel without a fault code, then
common rail, its function is to protect the systems replace the valve.
components if any malfunction causes and excessive With the common rail pressure sensor disconnected
increase in the pressure of the high pressure system. and a fault code is generated, with the rail pressure is
Disconnect recirculation line (1) from the pressure at 71 0 bar (1 029 8 psi.) m ea sura ble with the
relief valve and plug with the VOSS fitting from the diagnostic instrument, the trouble is in the wiring and
test set. not the component.
No diesel must come out of the valve at any engine
speed. If the diagnostic system signals a fault code
“Engine - backfill valve control”, it means that the
EDC7UC31 control unit has recognized that the
value has opened after a significant change in the
pressure of the rail greater than 1700 bar (24656
psi.). Since its opening is to be considered a
consequence of abnormal increase in pressure, the
valve is NOT defective even though a great amount
of diesel flows out.
IMPORTANT: Information acquired to date shows that the sensor is rarely defective.
2-80 Issued 04-07 Bur 87630273 NA

TEST ON FUEL BACKFLOW FROM THE RETURN

1. INJECTOR DUCT LOCKING NUT
Tests on fuel backflow from the return establishes
the operating status of the injectors. The engine When the EDC7UC31 control unit warning light
s p ee d a nd powe r a re c on tr ol l e d th ro ug h t he comes on during acceleration and/or cold star t
injectors. The power required by the user, through trouble, make sure the following check is done.
the accelerator, is converted into the quantity of fuel • Check torque of the nut (1) locking the injector
injected per cycle. This in turn is converted into duct on the cylinder head. The torque setting is
microseconds of injector opening according to the 45 - 55 Nm (33.2 - 40.6 lb.- ft.).
rail pressure.
NOTE: The injectors may have problems of both a
mechanical and a electrical nature. Therefore before
proceeding with the following analysis, it is wise to
rule out the presence of water in the tank and the fuel
prefilter.
87630273 NA Issued 04-07 Bur 2-81

2
1

Proceed with the injector fuel backflow tests as To identify the defective injector, follow the method
follows: as described below:
• Remove the duct (4) from the cylinder head. Measure the quantity of fuel flowing out in one
• Plug it (3) minute from the coupling on the cylinder head. If
• Install a transparent line (2) recirculation exceeds 80 ml. (2.7 oz.) per minute,
plug the rail outlet of one injector (1) at a time using
Make sure that the engine idling speed is correct. the rail plugs in the test set.
Check the quantity of fuel recirculation from the
cylinder head. The defective injector is the one when plugged
causes a significant reduction in recirculated fuel.
The process for measuring the quantity of injector
return fuel is: NOTE: When changing an injector it is necessary to
• Engine idling and without air compressor or air change the duct.
conditioner on. After identifying the injectors / ducts with high fuel
• engine temperature greater than 50°C (122°F). recirculation, check the torque of the ducts, 45 - 55
The quantity of fuel that flows out must be no greater Nm (33.2 - 40.6 pound-feet), if they are loose tighten.
than 80ml. (2.7 oz.) of diesel per minute. Excessive Then check the recirculation values again.
recirculation more than 80ml. (2.7 oz.) of diesel per If the torque is correct, remove the line and check the
minute could be caused by: spherical end towards the injector is not out of round,
• Incorrect coupling between one or more replace if necessary. Recheck recirculation value.
injectors and the related needles.
If the duct is not out of shape, replace the injector
• Problem of internal leakage of the injector.
2-82 Issued 04-07 Bur 87630273 NA

SPECIAL DISASSEMBLY FOR F4GE ENGINES

DISASSEMBLING ENGINE STEP 3
STEP 1 1 2 3
13
4
12 5
11 6
7
10
8
9
1
Version F4GE9484D
BS06N244 Figure 2-91 Remove the following:
Drain the engine oil by taking the plug off the oil pan • Grid heater (1).
and the oil filling cap of the valve cover.
• Intake manifold (2).
Remove the fan unit from the fan pulley.
• Oil recovery pipe from blow-by (3).
In order to apply the brackets to the engine block to
fix it on the stand for overhaul it is necessary to • Pipe for LDA intake manifold (4).
remove electrical wiring (1). • Piping for LDA system (5).
STEP 2
• Quick-couplings pipes (6), (7), (10) see step 4.
• Fuel filter (8).
• Electrical wiring (9).
2
1 • Fuel filter support (11).
• Grid heater control unit (12).
• Tappet covers (13).
5
STEP 4
4
3 A B
1
Remove the following:
• Fastening bracket (5) from electrical wiring (1).
• Starter (4)
• turbine lubrication delivery pipe (2).
• Oil filter (3). 1
IMPORTANT: Push clamp (1), as shown in figure B
to disconnect the low pressure fuel lines 6, 7, 10 from
the corresponding connections. After disconnecting
the line, reset the clamp (1) to position in figure A to
prevent distortion to the clamp.
87630273 NA Issued 04-07 Bur 2-83

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

Remove the following: • Remove the bolts fastening the turbine, and then
• Injector feed pipes (3) from injection pump (2). remove the turbine (1).
• Brackets fastening feed pipes (1), (5), (6) on the • Remove the exhaust manifold (3).
cylinder head.
STEP 8
• Fuel pump (4).
1 9
STEP 6
2
1 8
3
4
5
6
3
2
7
4 Remove the following:
BS06N249 Figure 2-96 • Belt tightener (2).
Remove the following: • Poly-V belt (4).
• Fuel feed pipes from the injectors (1). • Alternator fastening bracket (1).
• Remove fuel drain pipe (2) from the injectors by • Alternator (3), water pump (6), fan pulley (5), and
removing the bolt (4) and the seal (3). guide pulleys (7).
• pulley support (8).
• Thermostat housing and thermostat (9) from the
engine block.
2-84 Issued 04-07 Bur 87630273 NA

STEP 9 STEP 11
1
2
1
3
2
4

Lock the flywheel properly to prevent rotation, BS06K244 Figure 2-101
remove bolts (2) from pulley (1). Using the pry bar (3) of Special Tool 380000996 and
the lever (4), remove the external seal ring (2) from
CRANK SEAL REPLACEMENT the front cover
STEP 10
STEP 12
A B
1
1
2
2
3 3
4
4
BS06K243 Figure 2-100 BS07C437 Figure 2-102
Place Special Tool 380000665 (4) to the front of the Remove the following:
crankshaft (2). • Water pump (1)
Working through the guide holes of Special Tool • Bolts (2) and (4)
380000665 (4), drill into the internal seal ring (1) with
a 3.5 mm (9/64 inches) drill bit (A) to a depth of 5 mm • Crankcase front cover (3)
(3/16 inch) (B). NOTE: Take note of bolts (2) and (4) position when
Secure Special Tool 380000665 (4) to the ring (1) by removing them because they are different lengths.
screwing down the six bolts supplied with tool to the
crankshaft front cover.
Now extract seal ring (1) by tightening bolt (3).
87630273 NA Issued 04-07 Bur 2-85

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

Remove bolts and take off oil pump (1). LOCKING INJECTION PUMP IN PRESET CONDITION
IMPORTANT: Oil pump (1) cannot be repaired. To correctly preset the injection pump prior to
removing it, loosen bolt (2) and remove the
REMOVING INJECTION PUMP L-shaped spacer (1).
Tighten bolt (2) to 27 to 33 Nm (20 to 24.3 pound-
STEP 14
feet) to block rotation of the pump shaft.
IMPORTANT: Keep the L-shaped spacer with the
pump so it does not get misplaced (it is needed for
installation).
STEP 16
1
A 2 B
2
4
3

LOCKING FLYWHEEL
Rotate the crankshaft until the number 1 cylinder
reaches top dead center (TDC).
1
When TDC is obtained lock the flywheel by pushing
pin (1) of special tool 380002729 as shown by the
arrow.
Remove cover (1) from gear case (2).
Loosen nut (3) securing the injection pump drive gear
(4).
2-86 Issued 04-07 Bur 87630273 NA

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

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

Loosen the three nuts (1), (3) and (4) securing the
injection pump (2) to the bell housing (5), then take BS06N258 Figure 2-110
the pump out of its housing. Screw two pins (2) of adequate length into crankshaft
NOTE: Hold the pump drive gear shaft to prevent it holes (3).
from moving, when removing pump from the engine Remove engine flywheel (1) so that it can be
block. harnessed with a hoist and moved out of the way.
87630273 NA Issued 04-07 Bur 2-87

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

Remove bolts (1) and disassemble gears (3) and (4)
from camshaft (2).
2-88 Issued 04-07 Bur 87630273 NA

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

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

Attach harness to brackets (1), and remove cylinder
head from block using a hoist.
87630273 NA Issued 04-07 Bur 2-89

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REPAIR MANUAL

Issued 04-2007 - Service Training Edits

ENGINE REPAIR MANUAL

87519803 NA Issued 04-07 Bur I

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

II Issued 04-07 Bur 87519803 NA

1-II Issued 04-07 Bur 87630273 NA

87630273 NA Issued 04-07 Bur 1-1

1-2 Issued 04-07 Bur 87630273 NA

Perform the checks described in the electrical

87630273 NA Issued 04-07 Bur 1-3

No Check for leaks, repair leaks and refill to

Fan working properly. No Replace.

Drive belts serviceable. No Replace.

Check for leaks, bad bearing, overhaul or

Thermostat working properly. No Replace.

Wash down, repair leaks and flush out

Openings for coolant flow within the cylinder

No Check and adjust for correct valve

Verify correct timing described in Chapter 2

Cylinder head gasket leaking. Yes Replace.

1-4 Issued 04-07 Bur 87630273 NA

ENGINE LACKS POWER AND RUNS ERRATICALLY

Fuel filters plugged. Yes Replace.

Air filter plugged. Yes Clean or replace filter.

Thermostat working properly. No Replace.

Verify correct timing described in Chapter 2

Fuel pump working properly. No Replace.

On common rail engines check using

Speed governor (in injection pump) in

87630273 NA Issued 04-07 Bur 1-5

Engine lacks power and runs erratically (continued)

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

Correct valve clearance. No Adjust clearance for proper value.

Check each cylinder for proper compression,

Turbocharger working properly. No Repair or replace unit.

1-6 Issued 04-07 Bur 87630273 NA

ENGINE EXHAUST SMOKE BLACK OR DARK GREY

Air filter plugged. Yes Clean replace if necessary.

Check using multi meter replace or repair.

Cold start solenoid (KKSB) working properly.

On common rail engines check using

Verify correct timing described in Chapter 2

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

87630273 NA Issued 04-07 Bur 1-7

Engine exhaust smoke black or dark grey (continued)

No Check the condition of pipes and replace

Check each cylinder for proper compression,

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

Check using multi meter replace or repair.

Possible flow of coolant into the combustion

On common rail engines check using

Verify correct timing described in Chapter 2

Clean the tank and replace the fuel filter.

ENGINE EXHAUST SMOKE LIGHT BLUE

Check: oil vapor breather, cylinder

1-8 Issued 04-07 Bur 87630273 NA

ENGINE KNOCKS IRREGULARLY

Check the following items: Journal play and

Check the following items: Rod journal end

Check the following items: Play between the

Check the following items: Play between the

Check and replace if necessary the gears.