REPAIR MANUAL FOR IVECO NEF ENGINES

F4GE0484E -- F4GE0684F -- F4HE0684J

F4GE0484E F4G0684F

F4HE0684J

Every information, illustration and specification contained in the present manual is based on the most recent informa-
tion available at the time of printing.
2 WE

MOTORI

2
 IN--1

INTRODUCTION

TO THE READER
- This manual was written for a skilled technician - For any question or comment, or should you no-
and contains all the technical information needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact an Authorised Dealer.
- Read this manual carefully for the information
concerning repairing operations.

FURTHER REFERENCES
PAGE NUMBER
- Every page carries a number on the top right corner. Every page contains the following information:

Example:: T 1 -- 2 -- 3

Progressive page number for each group

Group number (if any)

Section number

S: Safety rules
Operation principle
T: Technical section Performance tests
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing

SYMBOLS
This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.

This symbol regards safety.

! Use great care when you see this symbol because possible injuries to the personnel may occur.
Strictly observe the precautions marked with this symbol.
The safety warning symbol is used also to draw attention on the weight of a component or an element.
Make sure you are always using the right equipment and lifting techniques when handling heavy
loads, in order to prevent injuries or damages.
IN--2

INTRODUCTION

UNIT OF MEASURE
This manual adopts the units of measure based on the International System.
The MKSA system units of measure are indicated within brackets after the units of measure of the International
System.
Example: 24.5 Mpa (250 kgf/cm2).
The following table converts the International System units of measure in some of the main units belonging to
other systems.

To convert in To convert in
Quantity Multiply by Quantity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Speed
N kgf 0.10197 min --1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Capacity
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
REPAIR MANUAL
ENGINES

INDEX OF SECTIONS

Section 1 -- Diagnostics EW--1--1

Section 2 -- Engine F4GE0484E overhaul EW--2--1

Section 3 -- Engine F4GE0684F -- F4HE0684J overhaul EW--3--1

Section 4 -- Recharging and start--up EW--4--1

4 WE

MOTORI
SECTION 1

DIAGNOSTICS
(for engines F4GE0484E -- F4G0684F)

INDEX
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
INDICE
 EW--1--3

DIAGNOSTICS

Main engine operating anomalies:

1 -- Engine won’t start; 6 -- Engine exhaust smoke light blue;

2 -- Engine overheats; 7 -- Engine knocks irregularly;
3 -- Engine lacks power and works erratically; 8 -- Engine stops;
4 -- Engine exhaust smoke black or dark grey; 9 -- Engine exceeds max. revs number;
5 -- Engine exhaust smoke grey (verging on 10 -- Excessive or insufficient oil pressure;
white); 11 -- Excessive fuel consumption;
12 -- Engine won’t stop.

1 ENGINE WON’T START

Connections to battery terminals are in working Clean, check, tighten or replace clamp nuts.
order NO

YES

Batteries in working order Carry out the checks described in the “Electric
NO system” repair manual.

YES

Starter motor in working order Carry out the checks described in the “Electric
NO system” repair manual.

YES

Thermal starter in working order Replace.

NO

YES

Injection pump timed Verify correct timing as described in the relevant

NO chapter.

(to be continued)
EW--1--4

DIAGNOSTICS

Injectors in working order Check operation and adjust.

NO

YES

The feeding circuit or injection pump does not Check and blow off.
show air penetration NO

YES

The feeding circuit or pump does not show traces Check and clean the feeding circuit (including the
of water NO tank).

YES

Prescribed compression ratio Overhaul the engine or make repairs only on

NO
concerned parts (valves, piston rings, etc.).

YES

Fuel filters in working order Replace.

NO

YES

Automatic advance variator and electric STOP Check and replace the concerned parts.
device both in working order NO

YES

Fuel pump fed correctly Check and replace (if necessary) the fuel pump.
NO

YES

Fuel tank supplied correctly Refuel.

NO
 EW--1--5

DIAGNOSTICS

2 ENGINE OVERHEATS

Coolant level correct Check for leaks and restore the level.
NO

YES

Fan and water pump drive belts in working order Check for leaks and restore the level.
NO

YES

Water pump in working order Overhaul or replace the unit.

NO

YES

Thermostat in working order Replace.

NO

YES

Radiator in working order Wash down thoroughly, check for fluid leaks, re-
NO place (if necessary) the part.

YES

Air filter and circuit piping both in working order Clean or replace faulty parts.
NO

YES

Openings for coolant flow to the head in working Wash down thoroughly.
order NO
EW--1--6

DIAGNOSTICS

Valve timing correct Check and perform correct timing.

NO

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

Cylinder head gasket in working order Replace.

NO

YES

Fan in working order Replace.

NO

3 ENGINE LACKS POWER AND WORKS

ERRATICALLY

Air filter in working order Clean the unit and replace (if necessary) the filter
NO element.

YES

Fuel filters in working order Replace by following the instructions given in the
NO “Owner Handbook”.

YES

Feeding circuit in working order Check and make (if necessary) the required re-
NO pairs.

(to be continued)
 EW--1--7

DIAGNOSTICS

The feeling circuit does not show impurities and/ Take off the pipes and injection pump, clean them
or traces of water NO thoroughly, then clean (if necessary) and dry the
fuel tank.

YES

Thermostat in working order Replace.

NO

YES

Fuel pump in working order Replace.

NO

YES

Injectors in working order Check operation and adjust them.

NO

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

Automatic advance variator (in injection pump) in Check and bench--adjust the injection pump.
working order NO

YES

Distributing plunger (in injection pump) in work- Check and bench--adjust the injection pump.
ing order NO

(to be continued)
EW--1--8

DIAGNOSTICS

Injection pump rate correct Check and bench--adjust the injection pump.
NO

YES

Speed governor (in injection pump) in working Check and bench--adjust the injection pump.
order at all speeds NO

YES

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

NO

YES

Injection pump with peak adjusting--screw fine-- Fine--tune the peak adjusting--screw.
tuned NO

YES

Correct play between the valves and rocker arms Adjust the play between the valves and rocker
NO arms.

YES

Prescribed compression ratio Check and bench--adjust the injection pump.

NO

YES

Turbocharger in working order Repair or replace the unit.

NO

YES

Correct tie rod length between the accelerator Adjust the tie rod length.
and injection pump NO
 EW--1--9

DIAGNOSTICS

4 ENGINE EXHAUST SMOKE BLACK OR

DARK GREY

Air filter in working order Replace.

NO

YES

Thermal starter in working order Replace.

NO

YES

Automatic addition device comes into operation Check and replace (if necessary).
NO

YES

Injectors in working order Check operation and adjust them as described.

NO

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

L.D.A. device in working order Ad just the L.D.A. device.

NO

YES

Injection pump adjusted as prescribed Check and bench--adjust the injection pump.
NO

(to be continued)
EW--1--10

DIAGNOSTICS

Injection pipes intact Check the condition of pipes and replace them (if
NO necessary).

YES

Prescribed compression ratio Check by means of a Motometer 75301430 tool

NO and carry out the necessary operations.

YES

High--quality diesel fuel Clean the tank and replace the diesel oil filter.
NO

5 ENGINE EXHAUST SMOKE GREY (VERG-

ING ON WHITE)

The thermostat comes into operation correctly Replace.

NO

YES

Injectors in working order Check operation and adjust as described in S.I.

NO 1094.

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

Coolant level correct Possible flow of coolant into the combustion

NO
chamber; replace the cylinder head gasket or
overhaul the engine.

(to be continued)
 EW--1--11

DIAGNOSTICS

High--quality diesel oil Clean the tank and replace the diesel oil filters.
NO

6 ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption Check the oil vapour vent and cylinder compres-
YES sion. Overhaul, if necessary, the cylinder head or
engine.

7 ENGINE KNOCKS IRREGULARLY

Knock detected in the injection pump Perform correct timing of injection pump on the
YES engine.

NO

Knock detected in the drive shaft Check the following items: journal play and out--
YES of--roundness; screw fastening for bed caps and
engine flywheel; oil pressure. Replace the parts
or overhaul the engine.

NO

Knock detected in the connecting rods Check the following items: crankpin play and
YES out--of--roundness; screw fastening for connect-
ing rod caps; connecting rod squaring. Replace
the parts or overhaul the engine.

NO

Knock detected in pistons Check the following items: play between the pis-
YES tons and the cylinder liners; integrity of piston
rings; play between the pins and the piston hubs.
Replace the parts or overhaul the engine.

(to be continued)
EW--1--12

DIAGNOSTICS

Knock detected in the cylinder head Check the following items: operation play be-
YES tween the rocker arms and the valves; injection
pump timing; valve timing. Adjust.

NO

Knock detected in the valve gear Check and replace (if necessary) the gears;
moreover, check for broken springs, for excess-
YES ive play between the stems and guides, the
tappets and seats. Adjust the play between the
valves and rocker arms.

NO

Knock detected in injectors Check and adjust as described in S.I. 1094, then
YES replace.

NO

Knock detected in the engine flywheel Replace loose screws and tighten all screws to
YES the specified torque and angles.

NO

Knock detected in the fuel piping Clean the pipes and replace the pipes that show
YES evident dents; clean (if necessary) the injection
pump.

8 ENGINE STOPS

Fuel tank filled Refuel and drain (if necessary).

NO

YES

Fuel filters in working order Replace.

NO

(to be continued)
 EW--1--13

DIAGNOSTICS

Feeling circuit in working order Check the circuit and drain.

NO

YES

Regular idle speed Adjust.

NO

YES

Regular injection pump rates Bench--check the flow rates.

NO

YES

Injection pump controls in working order Replace worn parts and adjust.
NO

YES

Correct play between the valves and rocker arms Ad just the play between the valves and rocker
arms.
NO

YES

Intact valves Replace the valves.

NO

9 ENGINE EXCEEDS MAX. REVS NUMBER

Speed governor in working order Check and replace (if necessary) the worn parts.
NO
EW--1--14

DIAGNOSTICS

10 EXCESSIVE OR INSUFFICIENT OIL

PRESSURE

Pressure control valve in working order Check and replace (if necessary).
NO

YES

Oil pump and delivery pipes both in working or- Check and replace (if necessary).
der NO

YES

Main bearings and connecting rod bearings both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.

YES

Engine oil SAE viscosity conforming to stan- Replace the engine oil with equivalent of ad-
dards NO equate viscosity.

11 EXCESSIVE FUEL CONSUMPTION

Fuel tank and pipes in working order Eliminate leaks (if any) and replace the worn
NO parts.

YES

Air filter in working order Replace.

NO

(to be continued)
 EW--1--15

DIAGNOSTICS

Correct injector adjustment Check operation and adjust them.

NO

YES

Correct injection pump adjustment Check and bench--adjust.

NO

YES

L.D.A. device in working order Adjust the L.D.A. device.

NO

YES

Injection pump timed Check static force--fit of the injection pump.

NO

12 ENGINE WON’T STOP

Cut--off electromagnet in working order Replace the electromagnet.

NO

YES

Speed governor in working order at all speeds Overhaul the injection pump and bench--adjust it
NO according to the relevant adjustment table.
EW--1--16

DIAGNOSTICS

NOTES
SECTION 2 ENGINE F4GE0484E

ENGINE F4GE0484E OVERHAUL

INDEX
Engine F4GE0484E . . . . . . . . . . . . . . . EW--2--3 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--50
Coding of source engines . . . . . . . . . . EW--2--4 Replacing the bushings . . . . . . . . . . . . . . EW--2--51
Main engine features . . . . . . . . . . . . . . EW--2--5 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--51
General engine features . . . . . . . . . . . EW--2--6 Mounting the tappets – Distributing shaft EW--2--51
Assembling play -- specifications . . . EW--2--8 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW--2--52
Tightening torque . . . . . . . . . . . . . . . . . EW--2--14 Measuring the journals and crankpins . EW--2--52
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15
Replacing the oil pump drive gears . . . . EW--2--55
Graphic indications and symbols . . . EW--2--16
Mounting the main bearings . . . . . . . . . . EW--2--55
General remarks . . . . . . . . . . . . . . . . . . EW--2--17
Description of main mechanic Measuring the journal assembling play EW--2--55
engine components . . . . . . . . . . . . . . . EW--2--18 Checking the drive shaft shoulder play . EW--2--56
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--18 Connecting rod--piston assembly . . . EW--2--57
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--58
Drive shaft seal rings . . . . . . . . . . . . . . . EW--2--19 Measuring the piston diameter . . . . . . . EW--2--58
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--20 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--21 Conditions for correct pin/piston
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--22 matching . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Valve control . . . . . . . . . . . . . . . . . . . . . . . EW--2--23 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW--2--59
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--24 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--60
Valves and valve seats . . . . . . . . . . . . . . EW--2--25 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--61
Valve guides . . . . . . . . . . . . . . . . . . . . . . . EW--2--26
Checking the connecting rods . . . . . . . . EW--2--61
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--27
Checking the torsion . . . . . . . . . . . . . . . . EW--2--61
Auxiliary component drive . . . . . . . . . . . EW--2--28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . EW--2--29 Checking the flexion . . . . . . . . . . . . . . . . EW--2--61
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW--2--30 Mounting the connecting rod--piston
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--31
Connecting rod--piston match . . . . . . . . EW--2--62
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--32
Oil vapour recirculation . . . . . . . . . . . . . . EW--2--33 Mounting the piston rings . . . . . . . . . . . . EW--2--62
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34 Mounting the connecting rod/piston
assemblies in the cylinder liners . . . . . . EW--2--63
Water pump . . . . . . . . . . . . . . . . . . . . . . . EW--2--35
Mechanic injection feeding system . EW--2--36 Measuring the crankpin assembling play EW--2--63
Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . EW--2--36 Checking piston protrusion . . . . . . . . . . . EW--2--64
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--36 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--64
Mechanic fuel pump . . . . . . . . . . . . . . . . EW--2--37 Distribution gearbox case . . . . . . . . . . . . EW--2--64
Injection assembly . . . . . . . . . . . . . . . . EW--2--38 Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--2--65
Engine bench--overhaul . . . . . . . . . . . . EW--2--39 Injection pump – 1st phase . . . . . . . . . . EW--2--66
Disassembling the engine . . . . . . . . . . . EW--2--39 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--66
Replacing the seal ring . . . . . . . . . . . . . . EW--2--41 Flywheel cover case . . . . . . . . . . . . . . . . EW--2--66
Removing the injection pump . . . . . . . . . EW--2--42 Engine flywheel . . . . . . . . . . . . . . . . . . . EW--2--67
Removing the rocker arm assembly . . . EW--2--44 Replacing the engine flywheel ring gear EW--2--67
Repair work on cylinder cluster . . . . . EW--2--47
Injection pump – 2nd phase . . . . . . . . . . EW--2--68
Checks and measurements . . . . . . . . . . EW--2--47
Mounting the injection pump –
Checking the surface supporting the 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--68
head on the cylinder cluster . . . . . . . . . . EW--2--48
Checking the eccentric lift and the pin Mounting the oil and water pumps . . . . EW--2--69
alignment . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--49 Mounting the water / oil heat exchanger EW--2--71
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW--2--49 Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--71
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--49 Removing the valves . . . . . . . . . . . . . . . . EW--2--71
INDEX

Checking the cylinder head Rocker arm assembly . . . . . . . . . . . . . . . EW--2--77

supporting surface . . . . . . . . . . . . . . . . . . EW--2--72
Mounting the injectors . . . . . . . . . . . . . . . EW--2--78
Checking the cylinder head water seal . EW--2--73
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--73 Replacing the injectors . . . . . . . . . . . . EW--2--81
Valve descaling, check and grinding . . . EW--2--73 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Checking the play between the valve
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--81
stem, valve guide and valve centring . . EW--2--74
Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW--2--74 Rocker arm removal/reassembling . EW--2--82
Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW--2--74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--82
Valve seat reconditioning -- replacement EW--2--74
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--82
Valve springs . . . . . . . . . . . . . . . . . . . . . EW--2--76
Mounting the cylinder head . . . . . . . . EW--2--76 Adjusting the tappets . . . . . . . . . . . . . . EW--2--82
Reattaching the cylinder head . . . . . . . . EW--2--77 Valve timing . . . . . . . . . . . . . . . . . . . . . . EW--2--83
 EW--2--3

ENGINE F4GE0484E OVERHAUL

ENGINE F4GE0484E

Figure 1

86597
EW--2--4

ENGINE F4GE0484E OVERHAUL

CODING OF SOURCE ENGINES

F 4 G E 0 4 8 4 E * D +

Emission level

Approved rating

Use

Feeding / Injection
D = TIER 2
Cylinder no.

Cylinder pattern:
0 = 4 strokes, vertical

Engine

Type of crankcase:
G = non--structural 4 = 4--cylinder

Group
Engines

8 = Direct injection turbo

diesel with intercooler

4 = Earthmovers

X Y Y Y Y Y Y Y Y

X = 6 rotary, 2--valve injection pump Manufacturing sequence number

Y = Engine model
 EW--2--5

ENGINE F4GE0484E OVERHAUL

MAIN ENGINE FEATURES

A Applications

B F4GE0484E

C *D601

E 4485 cm3

89 kW
F 2,000 rpm

G Direct injection

H Rotary injection pump

T.A.A.
I (Boosted by intercooler)

A Wheeled loaders
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--2--6

ENGINE F4GE0484E OVERHAUL

GENERAL ENGINE FEATURES

F4GE0484
Type
*D601

Cycle 4--stroke diesel engine

Feeding Boosted by intercooler
Injection Direct

Number of cylinders In--line, 4--cylinder

Bore mm 104

Stroke mm 132

Total displacement cm3 4485

Compression ratio 17.5 : 1

Max. rating kW 89
min --1 2000

Max. torque Nm 480

min --1 1400

No--load idle rpm min --1 800

No--load peak rpm min --1 --

BOOSTING With intercooler

Type of turbocompressor: HOLSET HX25W

Forced by means of gear pump,

LUBRICATION
pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
 EW--2--7

ENGINE F4GE0484E OVERHAUL

F4GE0484E
Type
*D601
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81 ± 2
REFUELLING
Full filling capacity 1° litres --
Ambra Super Gold
15W40 kg
10W30 -- engine sump litres --
kg
-- engine sump + filter litres --
kg

FEEDING
VE4 / 12 F 1000 L 691
Bosch--type injection

Pump setting 0° ± 0°.5

Start of delivery mm 1

Type of nozzle DSLA 145 P1174

Injection sequence 1 -- 3 -- 4 -- 2

Injection pressure (bar) 245 bar

EW--2--8

ENGINE F4GE0484E OVERHAUL

ASSEMBLING PLAY -- SPECIFICATIONS

F4GE0484E
Tipo
*D601
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Cylinder liners ∅1 104

Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter ∅1 103.73 ÷ 103.748
Pin seat ∅2 38.016 ÷ 38.010
Piston -- cylinder liners --

Piston diameter ∅1 0,5

Position of pistons from crankcase X

0.28 ÷ 0.52

Gudgeon pin ∅3 37.994 ÷ 38.000

Gudgeon pin -- Pin seat 0.01 ÷ 0.022

Type of piston X1* 2.705 ÷ 2.735

Piston ring slots X2 2.35 ÷ 2.38
X3 4.03 ÷ 4.05
* measured on ∅ of 99 mm
S1* 2.560 ÷ 2.605
Piston rings S2 2.350 ÷ 2.380
S3 3.977 ÷ 3.990
* measured on ∅ of 99 mm
1 0.100 ÷ 0.175
Piston rings – Slots 2 0.06 ÷ 0.11
3 0.040 ÷ 0.083

Piston rings 0.5

 EW--2--9

ENGINE F4GE0484E OVERHAUL

F4GE0484E
Type
*D601
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.3 ÷ 0.4
X2 0.6 ÷ 0.8
X3 0.3 ÷ 0.55

Connecting rod small--end

bushing seat ∅1 41.279 ÷ 41.553
Connecting rod bearing seat ∅2 72.987 ÷ 73.013

Connecting rod small--end bushing

diameter
40.987 ÷ 41.013
Outer ∅4
38.019 ÷ 38.033
Inner ∅3

Connecting rod small--end bushing –

0.266 ÷ 0.566
seat
Gudgeon pin – Bushing 0.019 ÷ 0.039

Measurement dimension X --

Max. error on connecting rod axis

parallelism = --

Journals ∅1 82,99 ÷ 83,01

Crankpins ∅2 68,987 ÷ 69,013
Main half bearings S1* 2,456 ÷ 2,464
Connecting rod half bearings S2* 1,955 ÷ 1,968
* supplied with spares

Bed supports no.:

n. 1--5 ∅3 87.982 ÷ 88.008
n. 2--3--4 87.977 ÷ 88.013
EW--2--10

ENGINE F4GE0484E OVERHAUL

F4GE0484E
Type
*D601
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
n. 1--5 0.041 ÷ 0.119
n. 2--3--4 0.041 ÷ 0.103
Half bearings -- crankpins 0.033 ÷ 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings

Shoulder journal X1 37.475 ÷ 37.545

Shoulder bed support X2 25.98 ÷ 26.48

Shoulder half rings X3 37.28 ÷ 37.38

Drive shaft shoulder 0.068 ÷ 0.410

 EW--2--11

ENGINE F4GE0484E OVERHAUL

F4GE0484E
Type
*D601
VALVE GEAR – CYLINDER ASSEMBLY mm

Valve guide seats on

cylinder head ∅1 8.019 ÷ 8.039

Valves:
∅4 7.96 ÷ 7.98
α 60°
∅4 7.96 ÷ 7.98
α 45°

Valve stem and respective guide 0.052 ÷ 0.092

Seat on head for valve seat:

∅1 46.987 ÷ 47.013

∅1 43.637 ÷ 43.668

Valve seat outer diameter;

inclination of valve seats on cylinder
head:
∅2 47.063 ÷ 47.089
α 60°
∅2 43.713 ÷ 43.739
α 45°
Hollow X 0.356 ÷ 1.102

X 0.104 ÷ 0.840

Between the valve 0.050 ÷ 0.102

seat and the head
0.050 ÷ 0.102

Valve seats --
EW--2--12

ENGINE F4GE0484E OVERHAUL

F4GE0484E
Type
*D601
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20

Injector protrusion X not adjustable

Seats for distributing shaft bushings

no. 1--5 --
Distributing shaft seats no. 2--3--4 --

Distributing shaft support pins:

1⇒5 ∅
53.995 ÷ 54.045

Bushing outer diameter for

distributing shaft: ∅ --

Bushing inner diameter ∅ 54.083 ÷ 54.147

Bushings and seats in crankcase --

Bushings and support pins 0.038 ÷ 0.162

Eccentric working lift:
6.045

7.239
 EW--2--13

ENGINE F4GE0484E OVERHAUL

F4GE0484E
Type
*D601
VALVE GEAR – CYLINDER ASSEMBLY mm

∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 ÷ 16.030

∅2
Outer diameter of tappet collar:
∅3 ∅2 15.929 ÷ 15.959
∅2 ∅3 15.965 ÷ 15.980

Between the tappets and the seats 0.020 ÷ 0.065

Tappets --

∅1

Rocker arm shaft ∅1 18.963 ÷ 18.975

Rocker arms ∅2 19.000 ÷ 19.026

∅2
Between the rocker arm and the
0.025 ÷ 0.063
shaft
EW--2--14

ENGINE F4GE0484E OVERHAUL

TIGHTENING TORQUE

PART TORQUE
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
2nd pphase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st phase
p 50 ± 6 (5 ± 0.6)
2nd p
phase 80 ± 6 (8 ± 0.6)
rd
3 phase 90°
Connecting g rod cap
p fastening
g screws 1st p
phase 30 ± 5 (3 ± 0.5)
nd
2 p phase 50 ± 5 (5 ± 0.5)
rd
3 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)

-- Lubrication with oil

 EW--2--15

ENGINE F4GE0484E OVERHAUL

TOOLS
380000975 Box with equipment complete with tools for valve seat reconditioning
380000976 Unit for spring load check
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Adapter for compressor check in cylinders (380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000998 Manual pump for pressure and vacuum measurements
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001002 All--purpose inclinometer/Goniometer
380001003 Full square for connecting rod squaring check
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Device for checking diesel engine cylinder compression
380001084 Comparator holder tool for rotary injection pump timing (to be used with 380001005)
EW--2--16

ENGINE F4GE0484E OVERHAUL

GRAPHIC INDICATIONS AND SYMBOLS

Detachment
Intake
Disconnect

Reattachment
Exhaust
Connect

Removing
Operation
Disassembling

Mounting
Assembling
ρ Compression ratio

Tolerance
Torque--tighten
Weight difference

Torque--tighten + angular value Dragging torque

α

Replacement
Countersink
Genuine spares

Adjustment
Rotation
Setting

Warning Angle
! Note Angular value

Visual check
Preload
Mounting position check

Measurement
Dimension to be measured Revs number
Check

Equipment Temperature

Surface to be machined
Pressure
Machining finish bar

Increase
Interference
Greater than .....
Forced mounting
Maximum
Decrease
Thickness
Smaller than ....
Play
Minimum
Lubricate Selection
Moisten Classes
Grease Increases
Temperature < 0 °C
Sealant Cold
Winter
Temperature < 0 °C
Air bleed Hot
Summer
 EW--2--17

ENGINE F4GE0484E OVERHAUL

GENERAL REMARKS

Figure 2

86598

1. Turbocompressor – 2. Fixed guide pulley – 3. Alternator – 4. Water pump and alternator drive belt – 5.
Automatic belt stretcher – 6. Water pump -- 7. Fixed guide pulley – 8. Crankshaft pulley -- 9. In--line injec-
tion pump – 10. Cold start air heater – 11. Blow--by
EW--2--18

ENGINE F4GE0484E OVERHAUL

DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the fol- It also incorporates the coolant circulation chambers
lowing items are realized: cylinder liners (1); bed and the engine member lubricating circuit ducts.
supports (5) and seats for: distributing shaft bush-
ings (3), tappets, water/oil heat exchanger (7), water Plate (6) is fitted to the lower part of the crankcase
pump (2) and oil pump (4). and ensures greater resistance to forces and stress.

Figure 3

86605
 EW--2--19

ENGINE F4GE0484E OVERHAUL

Drive shaft
It is made of steel and rests on five induction--har-
dened supports.
Inside the drive shaft are the lubricating oil ducts.
The following items are force--fitted on the front
shank: oil pump drive gear, phonic wheel, damper
flywheel and auxiliary component drive pulley.
The following items are force--fitted on the rear
shank: distributing shaft drive gear and engine fly-
wheel mounting hub.
The main half bearings are made of steel with anti--
friction alloy coating.
The second main half bearing is equipped with a
shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.

Figure 4

84207

1. Valve gear drive gear -- 2. Flywheel attachment hub -- 3. Oil pump drive gear

Drive shaft seal rings

The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000980 and 380000981, and mounted by means of tools 380000983 and 380000984.
EW--2--20
ENGINE F4GE0484E OVERHAUL
Connecting rods
They are steel--stamped, of the oblique cut type,
with separation of the cap obtained by an advanced
technology (fracture split) instead of mechanic ma-
chining.
The connecting rod half bearings are made of steel,
with anti--friction alloy coating.
Figure 5
Each connecting rod is marked:
- By a number (on the connecting rod body and
cap) indicating its respective match and the cyl-
inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
ing the weight class of the factory--assembled
connecting rod.
84038

ENGINE F4GE0484E OVERHAUL
Pistons
The combustion chamber is machined in the piston
crown. The crown of the piston is cooled by the engi-
ne oil supplied by the sprayer.
There are three grooves that house the compres-
sion rings; the 1st of which is V shaped and is obtai-
ned using a cast iron insert.
Figure 6
EW--2--21
The following references are engraved on the crown
of the piston:
1. Spare part number and design change number.
2. Arrow indicating the assembly sign of the piston
in the cylindrical liner; this must be facing to-
wards the front side of the engine block.
3. Date of manufacture.
4. Stamp indicating testing of the 1st groove insert
86549
EW--2--22

ENGINE F4GE0484E OVERHAUL

Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
The supports (front and rear) are equipped with steel B. Exhaust valve control
bushings mounted in an interfering manner and
coated with anti--friction material; two control eccen- The distributing shaft is controlled directly by the
trics are provided for each cylinder. drive shaft by means of straight--tooth gears.

Figure 7

70164

84238
 EW--2--23

ENGINE F4GE0484E OVERHAUL

Valve control

Figure 8

84239

1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
EW--2--24

ENGINE F4GE0484E OVERHAUL

Cylinder head
The seats of the following parts are obtained from Moreover, the following components are inserted on
the cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injector (6); - intake manifold (2) with seat for cold start air
heater (3).
- thermostat (5);

Figure 9

84240

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

 EW--2--25

ENGINE F4GE0484E OVERHAUL

Valves and valve seats

Figure 10

S 1

84241

1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side.

The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).

Figure 11

84242

Figure 11 shows the oil seals mounted on valve

stems.
EW--2--26

ENGINE F4GE0484E OVERHAUL

Valve guides

Figure 12

INTAKE EXHAUST
84046

DETAIL OF VALVE GUIDES AND SEATS

 EW--2--27

ENGINE F4GE0484E OVERHAUL

Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-

Figure 13

86488
EW--2--28

ENGINE F4GE0484E OVERHAUL

Auxiliary component drive

A Poly--V belt (4) transmits the movement of the The belt is stretched by means of automatic belt
crankshaft (5) to the water pump (1) and to the alter- stretcher (3).
nator (2).

Figure 14

86455

1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft

 EW--2--29

ENGINE F4GE0484E OVERHAUL

LUBRICATION
Forced circulation lubrication is performed by the fol-
lowing components:
- rotor--equipped oil pump housed in the crank-
case front part, controlled by the straight--tooth
gear force--fitted on the drive shaft shank;
- water / oil heat exchanger housed in the crank-
case;
- oil pressure control valve;
- by--pass valve for clogged oil filter cut--off, built
into the oil filter adapter;
- cartridge--type oil filter.

Figure 15

86599

Oil return drop--type path Oil supply

Pressure oil path

EW--2--30

ENGINE F4GE0484E OVERHAUL

Heat exchanger

Figure 16

86458

1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block
 EW--2--31

ENGINE F4GE0484E OVERHAUL

Oil pump

Figure 17

84052

Figure 18

70150

1. Drive shaft with oil pump drive gear

EW--2--32

ENGINE F4GE0484E OVERHAUL

Oil sump
The oil sump (1) is secured elastically to the crank-
case by means of an aluminium plate (3), Figure 19.
The C--section rubber gasket (2) (fitted onto the oil
sump leading profile) enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.

Figure 19

84245

Figure 20

84246
 EW--2--33

ENGINE F4GE0484E OVERHAUL

Oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.

Figure 21

86460
EW--2--34

ENGINE F4GE0484E OVERHAUL

COOLING
The engine cooling system is of the forced, closed--
circuit circulation type and is made up of the follow-
ing components:
- heat exchanger, to cool the lubricating oil;
- centrifugal water pump, housed in the crank-
case front part;
- thermostat, to regulate coolant flow.

Figure 22

86600

Water flowing out of the thermostat Water flowing into the pump

Water recirculating in the engine

 EW--2--35

ENGINE F4GE0484E OVERHAUL

Water pump
The water pump is housed in a seat obtained from The engine temperature is controlled by a thermo-
the crankcase and is controlled by means of a stat.
poly--V belt.
The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.

Figure 23

84058

Figure 24

84059
EW--2--36

ENGINE F4GE0484E OVERHAUL

MECHANIC INJECTION FEEDING SYSTEM

Fuel prefilter

The filter support (1) incorporates manual priming

pump (4), screw (2) used to blow air off the system,
and cartridge (3).
Figure 25

84060

Fuel filter
The support (1) incorporates fuel temperature sen- Degree of filtration of cartridge: 6 micron.
sor (5), heater resistor (2), water drain screw (3), air Maximum working pressure: 5 bar.
bleeding screw (6) and filter (4). Working temperature: – 40 °C to + 90 °C.

Figure 26

84248
 EW--2--37

ENGINE F4GE0484E OVERHAUL

Mechanic fuel pump

Displacement pump mounted on the engine left
side; it is used to feed the injection pump and is con-
trolled by the distributing shaft.

Figure 27

84249

1. Fuel outflow to the filter -- 2. Control lever -- 3. Fuel inflow from the tank

Figure 28

84250

1. Pump -- 2. Control lever -- 3. Distributing shaft

EW--2--38

ENGINE F4GE0484E OVERHAUL

INJECTION ASSEMBLY

Figure 29

84251

1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake
manifold -- 7. Thermal bulb for KKSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector

ENGINE F4GE0484E OVERHAUL
ENGINE BENCH--OVERHAUL
Disassembling the engine
Figure 30
84252
Drain the engine oil by taking the cap off the sump
and the oil filling cap off the head cover.
In order to be able to fit bracket 380000995 (which
fastens the engine to the overhaul stand) to the
crankcase, it is necessary to:
- remove electric wiring (1).
from the engine left side.
Figure 31
5
86463
To fit bracket 380000995 to the engine block on the
right--hand side, remove:
- the fastening bracket (2) of the harness (1);
- the harness (1);
- the starter motor (3);
- Turbine lubrication delivery hose (5).
- Heat exchanger with oil filter (4).
Secure the engine to rotary stand 380000978.
EW--2--39
Figure 32
84254
- disconnect the engine oil vapour recovery pipe
from blow--by (1);
- take off tappet covers (4);
- disconnect electric wiring (8);
- take off fuel filter (9);
- take off intake manifold (3);
- take off container (2);
- take off container control unit (5);
- disconnect the piping from L.D.A. system (13);
- disconnect quick--coupling pipes (7), (10), (11)
and (13), by following the indications given in
Figure 33;
- take off fuel filter support (6).
Figure 33
70126
Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
bring fork (1) back to the locking position (detail B)
after the adapter has been removed.
EW--2--40

ENGINE F4GE0484E OVERHAUL

Figure 34 Figure 37

84255

- Remove injector (5) feed pipes (5) from injection

pump (6); remove the rackets fastening the pipe 86466
unit (1), (2) and (3) on the cylinder head.
- Remove the belt tightener (4).
- Remove the priming pump (4).
- Remove the auxiliary component belt (6) operat-
ing the alternator fastening bracket (1).
Figure 35
- Remove the alternator (2), the water pump (5)
and the guide pulley (7).
- Remove the engine cooling system connection
(3) from the cylinder block.

84256

- Remove the feed pipe unit from injectors (1).

- Remove fuel drain pipe (2) from injectors by re-
moving the screw (4) and the seal (3).
Figure 38

Figure 36

84257 84068

- Remove the screws (3) and then remove the tur- Apply tool 380000990 (1) to the flywheel housing to
bine (1). stop flywheel rotation.
- Remove the exhaust manifold (2).
 EW--2--41

ENGINE F4GE0484E OVERHAUL

Figure 39 Figure 41

84259 78257

Unscrew fastening screws (1) from pulley (2). Apply the proper tension rod (3) of tool 380000996 to
outer seal ring (2) as shown in the figure, then take the
same off front cover (1) by means of lever (4).
Remove the front cover.

Replacing the seal ring

Figure 40 Figure 42

78256 84237

Apply tool 380000980 (4) on drive shaft front shank Remove gear oil pump (1).
(2).
Drill inner seal ring (1), through tool 380000980 (4)
guide holes, with an inset (∅ 3.5 mm) down to a depth IMPORTANT -- Oil pump (1) cannot be recondi-
of 5 mm. tioned.
Secure tool 380000980 (4) to ring (1) by screwing the
6 screws (5) provided.
Take off ring (1) by fastening screw (3).
EW--2--42

ENGINE F4GE0484E OVERHAUL

Removing the injection pump Figure 45

Figure 43

84073

84071

Prior to removing the injection pump, take off the fly-
wheel locking tool described in Figure 38.
Rotate the drive shaft until it reaches the condition of
1° cylinder at top dead centre.
Such condition is obtained when, by pushing pin (1)
shown by the arrow, it is housed in its own seat ob-
tained on distributing shaft drive gear (2).
- Remove cover (1) from gear covering case (2).
- Lock the engine flywheel as described in
Figure 38.
- Loosen nut (3) securing the injection pump drive
gear (4).

Figure 44 Figure 46

84260 84261

To correctly preset the injection pump prior to remov-
ing it, loosen screw (2) and remove L--shaped spacer
(1).
Fasten again screw (2) to its abutting end.
Loosen the three nuts (2) (4) (5) securing the injection
pump (1) to the flywheel covering case (3), then take
the pump out of its housing by means of tool
380000979 through proper application to gear (4) in
Figure 45B.

IMPORTANT -- Carefully store the L--shaped

spacer with the pump body.
 EW--2--43

ENGINE F4GE0484E OVERHAUL

Figure 47 Figure 49

84075 78258

Remove screws (3) securing engine flywheel (4) to the
drive shaft.
Apply tool 380000981 (3) on drive shaft rear shank
(5).
Drill inner seal ring (1), through tool 380000981 (3)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by fastening the
6 screws (4) provided.
Take off ring (1) by fastening screw (2).

Figure 48 Figure 50

78257
84076
Screw two pins (2) of adequate length into drive shaft Apply the proper torsion bar (3) of tool 380000996 to
holes (3). outer seal ring (2) as shown in the figure, then take the
same off flywheel cover case (1) by means of lever
Remove tool 380000990 (2).
(4).
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.
EW--2--44

ENGINE F4GE0484E OVERHAUL

Figure 51 Figure 53

84077
86601
Remove screws (2) and take off rear cover (1). Remove screws (1) and (4) and take off oil suction
strainer (5).
Remove screws (2) and take off stiffening plate (3).
IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter.
Figure 54

70156
Remove screws (1) and take off gear (3) from distrib-
uting shaft (2).
Removing the rocker arm assembly
Figure 55
Figure 52

84081

84278 For each cylinder, remove rocker arm assembly (1),

Turn the engine upside down, remove screws (2), loosen adjusting nuts (3), unscrew registers (2) and
take off both plate (3) and oil sump (1). remove screws (4).
 EW--2--45

ENGINE F4GE0484E OVERHAUL

Figure 56 Figure 59

84082 84085

Take out injectors (2) by means of tool (1) 380000982. Remove screws (2) and take off timing gear case (1).

IMPORTANT -- Take note of the mounting position

of screws (2), due to the different size of the latter.
Figure 57

84265 Figure 60
Remove screws (1) securing the head to the crank-
case.

Figure 58

70158

Remove connecting rod cap (2) fastening screws (1),

then take off the caps.
Remove the pistons (complete with connecting rods)
from the crankcase upper part.

84266
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be used
Hook the wire ropes to brackets (1) and (2), then sep-
again, they must be mounted in the same position
arate the cylinder head from the crankcase by means
they had prior to being taken off.
of a hoist.
EW--2--46

ENGINE F4GE0484E OVERHAUL

Figure 61 Figure 64

70159

Remove screws (1) and take off bed caps (2). 70162

Take off main half bearings (1).

Figure 62
Remove screws (2) and take off oil nozzles (3).

Figure 65

70160

The penultimate bed cap (1) and its respective sup-

port have half bearing (2) provided with shoulder.
70163

Remove screws (1) and take off distributing shaft (3)

IMPORTANT -- Take note of the mounting position retaining plate (2).
of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in IMPORTANT -- Take note of plate (2) mounting
the same position they had prior to being taken off. position.

Figure 63
Figure 66

70161
70164
Remove drive shaft (2) from crankcase by means of Carefully remove the distributing shaft from the
tool 380000992(1) and a hoist. crankcase.

ENGINE F4GE0484E OVERHAUL
Figure 67
70165
Remove tappets (1) from the engine crankcase.
REPAIR WORK ON CYLINDER CLUSTER
Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.
EW--2--47
Figure 68
70166
The check of cylinder liner inner diameter (in order to
measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter.
NOTE – If no ring gauge is available, use a micro-
meter to perform reset.
Figure 69
70167
Measurements must be taken for each single cylin-
der, at three different heights of the liner and on two
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on
the latter plane and during the first measurement.
When detecting out--of--roundness, taper or wear, the
cylinder liners must be bored and refaced. Cylinder
liner reconditioning must be performed with regard to
the spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.
EW--2--48
ENGINE F4GE0484E OVERHAUL
Figure 70
80585
IMPORTANT -- In case of reconditioning, all the
liners must be machined to the same increase (0.5
mm).
Check the main bearing seats as follows:
- mount the bed caps on the supports without bear-
ings;
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com-
parator, that the seat diameter is the same as the
specified value.
If a greater value is found, replace the crankcase.
Checking the surface supporting the head on
the cylinder cluster
Figure 71
70170
Verify that the head supporting plane on the cylinder
cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
The flatness error must not be greater than 0.075 mm.
NOTE -- Crankcase flattening may be carried out
only after making sure, when the repair work has
been completed, that the protrusion of the piston
from the cylinder liner is not greater than the speci-
fied value.
Check the condition of cylinder cluster working caps
(1); they must be replaced if they are rusty or their
sealing properties are in doubt.
After flattening, restore the cylinder liner countersink,
as shown in Figure 70.
 EW--2--49

ENGINE F4GE0484E OVERHAUL

VALVE GEAR
Distributing shaft
Figure 72

86581

MAIN FEATURES OF DISTRIBUTING SHAFT

The features given below refer to the normal diameter of pins

The shaft support pin and eccentric surfaces must be Figure 73

perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.239 mm for ex-
haust eccentrics and 6.045 mm for intake eccentrics;
if different values are found, replace the shaft.

70171

Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
EW--2--50

ENGINE F4GE0484E OVERHAUL

BUSHINGS Figure 74
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.

70172

Figure 75

sec. A-A

70173

MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushings
 EW--2--51

ENGINE F4GE0484E OVERHAUL

Replacing the bushings Mounting the tappets – Distributing shaft

Figure 76 Figure 78

70174 70176

To replace front and rear bushings (1), use beater Lubricate tappets (1) and fit them to their respective
380000991 (2) and handle 380000999 (3) to remove seats of the crankcase.
and reassemble the bushings.

IMPORTANT -- Bushings (1) must, upon mount-

ing, be turned in such a way that the lubricating
holes match with the holes available on the crank-
case seats.

Tappets

Figure 77 Figure 79

84053 70164

MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushings and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage the
bushings or supporting seats during operation.
EW--2--52

ENGINE F4GE0484E OVERHAUL

Figure 80 Figure 82

70238 70180

Place distributing shaft (3) retaining plate (1) with Mount nozzles (2) and tighten fastening screws (1) to
the slotted hole facing the crankcase upper side and the specified torque.
the stamping facing the operator, then fasten
screws (2) to the specified torque.

DRIVE SHAFT
Measuring the journals and crankpins

Figure 83

Figure 81

70182

If traces of excessive seizing, scoring or out--of--

roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to
grinding pins (2), measure the journals by means of
a micrometer (1) so as to determine the amount (di-
ameter) by which the pins have to be reduced.

NOTE -- It is advisable to write down the measured

values on a table.
See Figure 84.

70179

Check the distributing shaft end play (1).

 EW--2--53

ENGINE F4GE0484E OVERHAUL

Reduction classes are 0.250 and 0.500 mm.

IMPORTANT -- Journals and crankpins must al-
ways be ground to the same reduction class.
The reduction carried out on journals and crank-
pins must be marked with a special stamping
made on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.

Figure 84

70181

DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--2--54

ENGINE F4GE0484E OVERHAUL

Figure 85

70183

MAIN TOLERANCES OF DRIVE SHAFT

TOLERANCES
TOLERANCE--RELATED FEATURE GRAPHIC SYMBOL
CONCERNING:
Roundness f
SHAPE
Cylindricality /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL

CRITICAL 
IMPORTANT
SECONDARY
 EW--2--55

ENGINE F4GE0484E OVERHAUL

Replacing the oil pump drive gears Measuring the journal assembling play
Figure 86 Figure 88

70184 70161

Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1) on which gears (2) and (3)
shaft (2) are not damaged or worn; otherwise, pro- are force--fitted.
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature
of 180 °C and force--fitted onto the drive shaft by put-
ting the key in between.
Mounting the main bearings
Figure 87 Figure 89

70185 70186

Check the play between the drive shaft journals and

IMPORTANT -- If main bearings do not need re- their respective bearings by following the procedure
placing, they must be fitted in the same order and below:
positions they had when removed. - clean thoroughly the parts and eliminate traces (if
any) of oil;
- place a piece of gauged wire (3) (parallel to the
Main bearings (1) are supplied as spares reduced on longitudinal axis) on drive shaft pins (4);
their inner diameter by 0.250 – 0.500 mm.
- mount caps (1), complete with half bearings (2),
on their respective supports.
IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided
with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided with
shoulder half rings.
EW--2--56

ENGINE F4GE0484E OVERHAUL

Figure 90 Figure 92

70187 70189

Fasten pre--lubricated screws (1) by tightening them
in three subsequent phases.
- 1st phase with a torque wrench at 50 ± 6 Nm.
- 2nd phase with a torque wrench at 80 ± 6 Nm.
- Take the caps off the supports.
The play between the main bearings and their re-
spective pins can be measured by comparing the
width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.

Checking the drive shaft shoulder play

Figure 91 Figure 93

70188 70190

- 3rd phase with tool 380001001 (1) placed as
shown in the figure: tighten screws (2) further to
an angle of 60° ± 5°.
The shoulder play is checked by placing a magnetic
comparator (2) on drive shaft (3) as shown in the fig-
ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
 EW--2--57

ENGINE F4GE0484E OVERHAUL

CONNECTING ROD--PISTON ASSEMBLY

Figure 94

70191

PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing

NOTE -- Pistons are supplied as spares increased by 0.5 mm.

Figure 95 Figure 96

84093 84094

Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
EW--2--58

ENGINE F4GE0484E OVERHAUL

Figure 97

86497

MAIN DATA OF PISTON

Pistons
Measuring the piston diameter
Figure 98 Figure 99

84096 70192

Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.

NOTE -- The diameter must be measured 61 mm far

from the piston skirt base.
 EW--2--59

ENGINE F4GE0484E OVERHAUL

Gudgeon pins Figure 103

Figure 100

84097 84100

Measuring the gudgeon pin diameter (1) by means Use a thickness gauge (1) to check the play between
of a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching

Figure 101

Figure 104

84098

Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 102

84101

SCHEME FOR MEASURING PLAY X FOR THE

TRAPEZOIDAL RING
Due to the peculiar shape of the first trapezoidal cross--
sectioned seal ring, the play between the slot and the
ring itself must be measured as follows; allow piston (1)
to protrude from the crankcase so that ring (2) at issue
comes out of about half from cylinder liner (3).
In this position, check, by means of a thickness
84099 gauge, the play (X) between the ring and the slot: it
must correspond to the specified value.
Check the thickness of seal rings (2) by means of a
micrometer (1).
EW--2--60

ENGINE F4GE0484E OVERHAUL

Figure 105 Figure 107

70194

Measuring the play between the ends of piston rings

(2) inserted into cylinder liner (3), by means of a thick-
ness gauge (1).

Connecting rods

Figure 106

80339

IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted. In case of replace-
86498 ment, it is therefore necessary to number the
MAIN DATA OF CONNECTING ROD, GUDGEON new connecting rod with the same number as
PIN BUSHING AND HALF BEARINGS the replaced one.

* Dimension of inner diameter to be obtained after
driving into the connecting rod small--end and refacing
by means of a reamer.
** This dimension cannot be measured in a free state.
IMPORTANT -- The connecting rod--connecting
rod cap matching surfaces are knurled to ensure
better match.
Therefore, it is recommended not to remove
knurls.
- By a letter (on the connecting rod body) which
indicates the weight class of the factory--as-
sembled connecting rod:
-- V, 1600 to 1640 (marked in yellow);
-- W, 1641 to 1680 (marked in green);
-- X, 1681 to 1720 (marked in blue);
Replacement rods are supplied class W and
marked in green *.
Material removal is not permitted.
 EW--2--61

ENGINE F4GE0484E OVERHAUL

Bushings Checking the torsion

Figure 109
Verify that the bushing in the connecting rod small--
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods
Figure 108

61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ∼ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.

Checking the flexion

Figure 110

61696
Check the parallelism of connecting rod axes (1) by
means of device 380001003 (5). Proceed as follows:
- mount connecting rod (1) on tool 380001003 (5)
spindle, then secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).

61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--2--62

ENGINE F4GE0484E OVERHAUL

Mounting the connecting rod--piston assembly Mounting the piston rings

Connecting rod--piston match Figure 114
Figure 111

86550

The following reference data are engraved on the pis-

84093
ton crown:
1. Spare part number and design modification Use pliers 380000986 (3) to fit piston rings (1) on pis-
number; ton (2).
The rings must be mounted with the writing “TOP”
2. Inscription (facing the crankcase front side) indi- facing upwards; moreover, the ring apertures must be
cating the mounting sign of the piston in the cylin- turned in such a way that they are offset to each other
der liner. by 120°.
3. Date of manufacture;
4. Stamp indicating testing of the 1st groove insert IMPORTANT -- Spare piston rings are supplied in
the following dimensions:
Figure 112 -- standard, marked with yellow paint;
-- increased by 0.5 mm, marked with yellow/green
paint;

Figure 115

86551
Connect piston (2) to connecting rod (4) by means of
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers
stamped on connecting rod (4) can be seen as shown
in the figure.
Figure 113

70200
Mount half bearings (1) both on the connecting rod
and the cap.

IMPORTANT -- If connecting rod bearings do not

need replacing, they must be fitted in the same
order and positions they had prior to being taken
off.
No matching operation must be carried out on half
72705 bearings.
Insert pin (1) fastening piston rings (2).
 EW--2--63

ENGINE F4GE0484E OVERHAUL

Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 118
Figure 116

70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners; of oil;
moreover, verify that: - place a piece of gauged wire (2) on drive shaft
- the number of each connecting rod corresponds pins (1);
to the cap matching number. - mount the connecting rod caps (3) with their re-
spective half bearings (4);
Figure 119

Figure 117

70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a
torque wrench (2).
Figure 120

70202

SCHEME FOR MOUNTING THE CONNECTING

ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
by 120°;
- all the connecting rod/piston assemblies weigh
the same;
- the writing stamped on the piston crown faces the 70205
crankcase front side, or the notch obtained on the - Apply tool 380001001 (1) on the compass
piston skirt corresponds to the position of oil nozz- wrench, then tighten screws (2) further in a criss--
les. cross sequence.
EW--2--64
ENGINE F4GE0484E OVERHAUL
Figure 121
70206
- Take off the cap and calculate the existing play by
comparing the width of gauged wire (1) with the
scale graduation shown on the wire envelope (2).
Figure 122
70207
If the measured play is different from the specified
one, replace half bearings and repeat the check.
Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them defi-
nitely by tightening the connecting rod cap fastening
screws as described.
IMPORTANT -- Prior to mounting the connecting
rod cap fastening screws definitely, verify that the
diameter of the same (as measured at the middle
of the thread length) is not smaller than 0.1 mm of
the diameter measured at about 10 mm from the
screw end.
Check manually that connecting rods (1) run axially
on the drive shaft pins, and that the end play of the
same (as measured by means of a thickness gauge
(2) is 0.10 to 0.33 mm.
Checking piston protrusion
Figure 123
70208
After the connecting rod--piston assemblies have
been mounted, check, by means of comparator
380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.28 to 0.52 mm.
Valve gear
Distribution gearbox case
Figure 124
86602
SCHEME FOR SEALANT LOCTITE 5999
APPLICATION AREA
Clean thoroughly distribution gearbox case (1) and
the engine crankcase.
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5999 on the case so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).
 EW--2--65

ENGINE F4GE0484E OVERHAUL

Figure 125 Figure 127

84106
SCHEME FOR REAR GEARBOX CASE FASTEN-
ING SCREW TIGHTENING SEQUENCE
Reassemble case to the crankcase.
Tighten the fastening screws in the same positions
they had prior to being taken off, then fasten the
screws to the specified torque.
84107
Turn drive shaft (4) and distributing shaft (2) in such
a direction that when mounting driven gear (1) on the
distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.

Valve timing
Figure 126 Figure 128

70211 70213

Mark, with a felt--tip pen, the tooth of drive gear (1) Tighten gear (2) fastening screws (1) to distributing
mounted on drive shaft (2), the side surface of which shaft (3), then fasten them to the specified torque.
bears a stamped notch (→) for timing.
EW--2--66

ENGINE F4GE0484E OVERHAUL

Injection pump – 1st phase Figure 131

Timing
Figure 129

84108
Force--fit gear (1) transmitting the motion to the pump,
then fasten nut (2) by hand.
84071
Flywheel cover case
Bring cylinder 1 to the top dead centre. This condition
occurs when pin (1) (shown by an arrow) is housed in Figure 132
the seat available on the distributing shaft drive gear
(2).

84109

SCHEME FOR SEALANT LOCTITE 5999 AP-

PLICATION AREA
Clean thoroughly the attaching surfaces of flywheel
case (1) and distribution gearbox.
Figure 130
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5999 on the case (1) so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).
84273
Mount the injection pump body (1) in the gearbox seat
(2), then secure it by means of screws (3).
 EW--2--67

ENGINE F4GE0484E OVERHAUL

Figure 133 ENGINE FLYWHEEL

Figure 135

84110 84111

SCHEME FOR FLYWHEEL COVER CASE Check the clutch disc supporting surface and turn it if
FASTENING SCREW TIGHTENING SEQUENCE scoring is detected.
Fit case (1) back to the crankcase, tighten the fasten-
ing screws in the positions they had prior to being
taken off, then fasten them to the specified torque. NOTE -- The rated thickness of the engine flywheel
is 45 ± 0.25 mm.
Screws:
- M12 x 1.75 x 100 80 ± 10 Nm Replacing the engine flywheel ring gear
- M16 x 1.50 x 80 200 ± 20 Nm Check the condition of ring gear (2) teeth. If breaks or
- M16 x 1.50 x 100 200 ± 20 Nm excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 135) by using a
- M12 x 1.75 x 78 80 ± 10 Nm normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter
must face the engine flywheel.

Figure 134 Figure 136

70216
Apply part (5) of tool 380000983 on drive shaft rear
shank (6), secure it by means of screws (4) and force--
fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
84076
Screw down two pins (2) of adequate length into the
shaft holes (3), then remove the engine flywheel (1)
by means of suitable harnesses and a hoist.
EW--2--68

ENGINE F4GE0484E OVERHAUL

Figure 137 Injection pump – 2nd phase

Mounting the injection pump – 2nd phase
Figure 139

84075 84115
Apply tool 380000990 (2) to the flywheel cover case Torque--tighten nut (1) by means of torque wrench (2).
(1) to stop engine flywheel (4) rotation.
Tighten screws (3) fastening engine flywheel (4) to the
Figure 140
drive shaft.

Figure 138

α 84116

Apply sealant (1) as shown in the figure, then put on

small cover (2).

Figure 141

84114

Tighten engine flywheel (2) fastening screws (1) in

two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
- 2nd phase: tighten to an angle of 60° ± 5°. 84260

Remove plug (1) from the distribution gear seat

Figure 43.
IMPORTANT -- Angle tightening is carried out by
means of tool 380001001. Remove presetting screw (2) and insert L--shaped
spacer (1). Fasten again the screw to its abutting end.
 EW--2--69

ENGINE F4GE0484E OVERHAUL

Mounting the oil and water pumps Figure 145

Figure 142

70223

Take seal ring (2) off front cover (1), clean thoroughly
the attaching surface and apply sealant LOCTITE
5999 onto the same.
70220
Figure 146
Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.

Figure 143

70224

Clean thoroughly the surface of front cover (2) attach-

ing base, then mount front cover (2).
Fasten screws (1) and tighten them to the specified
torque.
70221 Figure 147
Apply a new seal ring (2) onto water pump (1).

Figure 144

70225
Apply part (5) of tool 380000983 on drive shaft front
shank (6), secure it by means of screws (4) and force--
70222 fit the new seal ring (3) on the same.
Mount water pump (1). Position part (1) on part (5), then screw nut (2) to fully
Fasten screws (2) and tighten them to the specified
mount seal ring (3) in front cover (7).
torque.
EW--2--70

ENGINE F4GE0484E OVERHAUL

Figure 148 Figure 150

84263 84278

Mount oil sump (1) and apply plate (3) on the same.
Fasten screws (2) and tighten them to the specified
torque.
Screws:
- M10 x 1.50 x 70 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 100 70 ± 5 Nm
- M10 x 1.50 x 90 70 ± 5 Nm

NOTE -- The application relative to excavator E165

Evolution requires that the sump is mounted in a
position rotated by 180° relative to the figure.

Figure 151
Figure 149

70227 86476

Place gasket (1) on oil sump (2).
IMPORTANT -- The gasket can be used again,
provided it is not damaged.
Force--fit pulley (1) complete with spacer onto the
drive shaft, then torque--tighten and angle--tighten the
screws (2) by means of tool 380001001.
Secure guide pulleys (4) to the front cover by means
of screws (3).
 EW--2--71

ENGINE F4GE0484E OVERHAUL

Mounting the water / oil heat exchanger Figure 154

Figure 152

84175 86477
Mount the following items on the crankcase: a new Fit alternator (1) back to alternator support (3).
gasket (1), heat exchanger (2), a new gasket (3), and
Fasten screws (2) without torque--tightening them.
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Fit the oil filter cartridge.

Cylinder head
Removing the valves
Figure 155

Figure 153

84179

Valves can be removed by means of tool 380000987

(1) by pressing slightly on collar (3) so that lock cones
84177
(2) can be removed by compressing springs (4). Then
Position alternator support (1) in such a way that pins
remove collar (3) and springs (4).
(3 and 4) are placed against the engine crankcase.
Fasten screws (2) and tighten them to the specified Repeat the procedure on all valves.
torque.
EW--2--72

ENGINE F4GE0484E OVERHAUL

Figure 156 Figure 158

84282 84283

Take off oil seals (1) fitted to the valve stems. Remove the thermostat unit (2) and brackets (1) and
(3).
To remove the valves, properly turn the head upside
down.

IMPORTANT -- Mark the exhaust and intake

valves prior to removing them.

Checking the cylinder head supporting surface

Figure 157 Figure 159

INTAKE EXHAUST
84181 84183

In addition to the head dimensions, the exhaust
valves differ from intake valves in that they are
equipped with a supplementary notch (1) obtained on
the stem for intake valves.
The plane of the supporting surface of head (1) to cyl-
inder cluster is checked by means of a ruler (2) and
a thickness gauge (3).
The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
 EW--2--73

ENGINE F4GE0484E OVERHAUL

Checking the cylinder head water seal VALVES

Check the water seal by means of suitable equipment. Figure 161
Use a pump to feed water heated to ∼ 90 °C at a pres- EXHAUST INTAKE
sure of 2 to 3 bar. VALVE VALVE
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassembling/
assembling operations.

IMPORTANT -- Prior to mounting the caps, apply

water--repellent sealant on the sealing surface of
the same.

If leaks are detected from the cylinder head, the latter

must be replaced. 84185

MAIN DATA OF INTAKE AND EXHAUST VALVES

Valve descaling, check and grinding

Figure 160
Figure 162

84284

Nominal thickness A of the cylinder head is 95 ± 0.25

mm, max. admitted metal removal shall not exceed
thickness B, i.e. 0.13 mm.
IMPORTANT -- After regrinding, check valve sink-
ing and regrind valve seats if required, to obtain
the required value.
84186
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns.
Reface, if necessary, the valve seats by means of a
grinder 380000975, by removing as less material as
possible.
EW--2--74

ENGINE F4GE0484E OVERHAUL

Figure 163 VALVE GUIDE

Figure 165

84187

Use a micrometer (2) to measure valve stem (1),

which must be equal to 7.96 to 7.98. INTAKE EXHAUST
84046

Use a bore gauge to measure the valve guide inner

diameter, which must be equal to the value shown in
the figure.

Checking the play between the valve stem, VALVE SEATS

valve guide and valve centring
Valve seat reconditioning -- replacement
Figure 164 Figure 166

84188 84189

Check can be made by means of a magnetic com-
parator (1) placed as shown. Assembling play must
be equal to 0.039 to 0.079 mm.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
Check valve seats (2). If slight burns or scoring are
found, proceed with reconditioning by means of tool
380000975 (1) according to the inclination values
shown in Figure 167.
 EW--2--75

ENGINE F4GE0484E OVERHAUL

Figure 167

INTAKE EXHAUST

84190

VALVE SEAT DIMENSIONS

Figure 168

86591

VALVE SEAT HOUSING DIMENSIONS

If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool 380000975 (1, Figure 166) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of tool 380000975, according to the values shown in Figure 167.
EW--2--76

ENGINE F4GE0484E OVERHAUL

Figure 169 MOUNTING THE CYLINDER HEAD

Figure 171

84192 84282

After the reconditioning operations, verify, by means
of base 380001000 (2) and comparator 380001004
(1), that valve hollow (3) corresponds to the specified
value.
Lubricate the valve stem and insert into the respective
valve guide according to the position marked upon
disassembling.
Mount seal rings (1) onto the valve guide.

VALVE SPRINGS
Figure 170

Figure 172
84193

MAIN DATA FOR INTAKE AND EXHAUST VALVE

SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of tool 380000976. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below.

Height Under a load of

mm N 84179
H(Free) 63.50 No load Position spring (4) and upper collar (3) on the cylinder
H1 49.02 P1 329 head: use tool 380000987 (1) to compress spring (4)
H2 38.20 P2 641 and link the parts to the valve by means of lock cones
(2).

ENGINE F4GE0484E OVERHAUL
Reattaching the cylinder head
Figure 173
84113
Verify that the cylinder head attaching plane and the
crankcase attaching plane are both clean.
Do not spoil the cylinder head gasket.
IMPORTANT -- Prior to reusing the cylinder head
fastening screws, verify that they do not show
traces of wear or deformations; otherwise, replace
them.
Figure 174
84265
Mount the cylinder head on the crankcase by fastening
screws (1) without torque--tightening them.
EW--2--77
Figure 175
84209
Prior to inserting the pushrods, verify their state of
preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
take and exhaust valves are identical and, therefore,
they are interchangeable.
Rocker arm assembly
Figure 176
84195
PARTS MAKING UP THE ROCKER ARM
ASSEMBLY:
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
Figure 177
84196
MAIN DATA OF ARBOUR--ROCKER ARM
Verify that the arbour/rocker arm matching sur-
faces do not show excessive wear or damages.
EW--2--78

ENGINE F4GE0484E OVERHAUL

Figure 178 Figure 181

84197

Verify that the tappet adjusters are unscrewed to pre- 84200

vent the latter from crawling on the rods when the Ad just the play between the rocker arms and the
rocker arm assembly (1) is mounted. valves by means of an Allen wrench (2), box wrench
Mount the rocker arm assembly made up of the ar- (3) and thickness gauge (1).
bours and rocker arm support, then secure them to
the head without torque--tightening screws (2) and The operation play is:
(3). -- intake valves: 0.25 ± 0.05 mm
Figure 179 -- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
FIRING ORDER 1--3--4--2
Adjusting cylinder
1 3 4 2
valve no.
Adjusting clearance
4 2 1 3
of cylinder valve no.

Mounting the injectors

Figure 182
84198

Fasten the head screws according to the instructions

given in Figure 180.
Figure 180

84285
Scheme of cylinder head fastening screw tightening
sequence:
- 1st phase: pre--fastening by means of a torque
wrench: 84201

screw M12 x 1.75 x 70 [ ]50 Nm ± 5 Nm;

screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm;
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm;
- 2nd phase: angle tightening: 90°
- 3rd phase: angle tightening only for screws 140
and 180 mm long: 90°.
Mount a new seal ring (2) lubricated with petrolatum
and a new seal washer (3) on injector (1).
Mount the injectors on their seats on the cylinder
head, then tighten them by means of a torque wrench.
 EW--2--79

ENGINE F4GE0484E OVERHAUL

Figure 183 Figure 186

86603

Mount the injector feeding pipe assembly (1). Mount

the pipes for fuel discharge (2) from injectors, by using
gaskets (3) and by tightening screws (4).

Figure 184

86604

The intake manifold unit is made up of manifold (6) on

the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5999 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.
Figure 187

84257
- Mount exhaust manifold (3).
- Mount turbine (1) by means of screws (2).

Figure 185

84254

- Mount tappet covers (4).

84255
Mount the injection pump (6) injector feeding pipes
(5), then secure brackets (1), (2) and (3) fastening the
pipe assembly onto the cylinder head.
Mount priming pump (4).
- Mount container (2).
- Mount intake manifold elbow (3).
- Mount container control unit (5).
- Mount fuel filter support (6).
- Mount fuel filter (9).
- Attach quick coupling pipes (7), (10), (11) and (12)
by following the indications given in Figure 188.
- Mount electric wiring (8).
- Mount L.D.A. system piping (13).
- Connect the engine oil vapour recovery pipe to
blow--by (1).
EW--2--80

ENGINE F4GE0484E OVERHAUL

Figure 188 Figure 191

70126 86479

Press clip (1) in the direction of the arrow (detail B),
then connect the piping. Bring the clip back to the in-
itial locking position (detail A).
Figure 189
- Mount thermostat unit (1) to cylinder head (3) by
torque--tightening screws (2).
- Mount water temperature sensor (4) by screwing
it by means of a torque wrench.

84252
- Mount electric wiring (1).

Figure 190 Figure 192

86478 86480

- Mount the starter motor (3). Fit the Poli--V belt (5) on the pulley (6) of the crank-
- Fit the fastening bracket (2) and the harness (1). shaft, on the guide pulley (7), on the water pump (4)
and on the alternator (2); stretch the belt using the au-
tomatic take--up unit (3).
 EW--2--81

ENGINE F4GE0484E OVERHAUL

REPLACING THE INJECTORS Reassembling

Removal Figure 195
Figure 193

84289

Place the vehicle in safe conditions.

84201
Lift the engine compartment cover, disconnect the
battery cables and proceed as follows:
Mount a new seal ring (2) lubricated with petrolatum
- disconnect engine oil vapour recovery pipe (2) and a new seal washer (3) on injector (1).
from blow--by;
- take off tappet cover (1); Mount the injectors on their seats on the cylinder
head, then tighten them by means of a torque wrench.
- disconnect the fuel manifold pipes from injectors
(3).

Figure 196

Figure 194

84290

Mount new seal rings (1) on fuel manifolds (2).

84082
Remove injectors (2) by means of tool 380000982 (1)
and take them off the cylinder head.
Connect the manifolds to the injectors, by tightening
the fastening nuts to a torque of 50 Nm.
Reassemble the tappet cover.
Re--connect the engine oil vapour recovery pipe to the
blow--by.
EW--2--82

ENGINE F4GE0484E OVERHAUL

ROCKER ARM REMOVAL/REASSEMBLING ADJUSTING THE TAPPETS

Removal Figure 198

Figure 197

Ad just the play between the rocker arms and the

valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
84081
The operation play is:
-- ± 0.05 mm
Loosen tappet adjuster fastening nuts (3), then un-
screw adjusters (2). – intake valves: 0.25 ± 0.05 mm
Remove screws (4) and dismount rocker arm assem- -- exhaust valves: 0.50 ± 0.05 mm.
bly (1) made up of the rocker arm support and ar- Take the cylinder where clearance must be adjusted
bours, then take off valves. to the bursting phase; its valves are closed while bal-
Reassembling ancing the symmetric cylinder valves.
Verify that the tappet adjusters are unscrewed to pre- Symmetric cylinders are 1--4 and 3--2.
vent the latter from crawling on the rods when the
rocker arm assembly is mounted.
FIRING ORDER 1--3--4--2
Mount the rocker arm assemblies made up of rocker
arm support and arbours, then secure them to the cyl- Adjusting cylinder
inder head by tightening the fastening screws to a 1 3 4 2
valve no.
torque of 36 Nm.
Adjusting clearance
4 2 1 3
Ad just the tappets as described above. of cylinder valve no.
 EW--2--83

ENGINE F4GE0484E OVERHAUL

VALVE TIMING
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.

Figure 199

84210
EW--2--84

ENGINE F4GE0484E OVERHAUL

SECTION 3 F4GE0684F -- F4HE0684J

ENGINES
F4GE0684F -- F4HE0684J OVERHAUL

INDEX
Engine coding . . . . . . . . . . . . . . . . . . . . EW--3--4 Engine F4GE0684F cooling . . . . . . . . . EW--3--43
Main engine features . . . . . . . . . . . . . . EW--3--5 Engine F4HE0684J cooling . . . . . . . . . EW--3--44
Assembling play / specifications . . . EW--3--8 Water pump . . . . . . . . . . . . . . . . . . . . . . . EW--3--45
Tightening torque . . . . . . . . . . . . . . . . . EW--3--14 Engine F4GE0684F mechanic
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--15 injection feeding system . . . . . . . . . . . EW--3--46
Graphic indications and symbols . . . EW--3--16 Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . EW--3--46
General remarks . . . . . . . . . . . . . . . . . . EW--3--17 Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--46
Engine F4GE0684F . . . . . . . . . . . . . . . . EW--3--17 Mechanic fuel pump . . . . . . . . . . . . . . . . EW--3--47
Engine F4HE0684J . . . . . . . . . . . . . . . . EW--3--18 Engine F4GE0684F Injection
Description of main mechanic assembly . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--48
engine components . . . . . . . . . . . . . . . EW--3--19 Engine F4HE0684J fuel supply
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--19 system . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--49
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--20 Engine F4HE0684J fuel system
Drive shaft seal rings . . . . . . . . . . . . . . . EW--3--20 diagram . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--50
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--21 Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . EW--3--51
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--22 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--52
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--3--23 Mechanical feed pump . . . . . . . . . . . . . . EW--3--53
Engine F4GE0684F valve control . . . . . EW--3--24 Normal operating condition . . . . . . . . . . EW--3--53
Engine F4HE0684J valve control . . . . . EW--3--25 Outlet overpressure condition . . . . . . . . EW--3--53
Engine F4GE0684F cylinder head . . . . EW--3--26 Bleed conditions . . . . . . . . . . . . . . . . . . . . EW--3--54
Engine F4GE0684F cylinder head . . . . EW--3--27 High pressure pump . . . . . . . . . . . . . . . . EW--3--54
Engine F4GE0684F valves and valve Operating principle . . . . . . . . . . . . . . . . . EW--3--56
seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--28 Engine F4GE0684F bench--overhaul EW--3--59
Engine F4HE0684J valves and valve Disassembling the engine . . . . . . . . . . . EW--3--59
seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--29 Replacing the seal ring . . . . . . . . . . . . . . EW--3--62
Engine F4GE0684F valve guides . . . . . EW--3--30 Removing the injection pump . . . . . . . . . EW--3--62
Engine F4HE0684J valve guides . . . . . EW--3--31 Removing the rocker arm assembly . . . EW--3--65
Valve control bridges F4HE0684J Repair work on cylinder cluster . . . . . EW--3--67
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--31 Checks and measurements . . . . . . . . . . EW--3--67
Grinding of the F4HE0684J cylinder Checking the surface supporting the
head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--31 head on the cylinder cluster . . . . . . . . . . EW--3--68
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--3--32 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW--3--69
Engine F4GE0684F auxiliary component Distributing shaft . . . . . . . . . . . . . . . . . . . EW--3--69
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--33 Checking the eccentric lift and the pin
Engine F4HE0684J auxiliary component alignment . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--69
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--34 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--70
Engine F4GE0684F Lubrication . . . . . EW--3--35 Replacing the bushings . . . . . . . . . . . . . . EW--3--71
Engine F4HE0684J Lubrication . . . . . EW--3--36 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--71
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW--3--37 Mounting the tappets – Distributing shaft EW--3--71
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--38 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW--3--72
Engine F4GE0684F oil sump . . . . . . . . . EW--3--39 Measuring the journals and crankpins . EW--3--72
Engine F4HE0684J oil sump . . . . . . . . . EW--3--40 Replacing the oil pump drive gears . . . . EW--3--75
Engine F4GE0684F oil vapour Mounting the main bearings . . . . . . . . . . EW--3--75
recirculation . . . . . . . . . . . . . . . . . . . . . . . EW--3--41 Measuring the journal assembling play EW--3--75
Engine F4HE0684J oil vapour Checking the drive shaft shoulder play . EW--3--76
recirculation . . . . . . . . . . . . . . . . . . . . . . . EW--3--42 Connecting rod--piston assembly . . . EW--3--77
INDEX

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--78 Cam lift check and pin alignment check EW--3--113
Measuring the piston diameter . . . . . . . EW--3--78 Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--113
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--3--79 Head face check on the cylinder group EW--3--115
Conditions for correct pin/piston Timing system . . . . . . . . . . . . . . . . . . . . EW--3--115
matching . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--79 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--115
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW--3--79 Bush replacement . . . . . . . . . . . . . . . . . . EW--3--116
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--80 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--116
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--81 Fitting tappets – camshaft . . . . . . . . . . . EW--3--116
Checking the connecting rods . . . . . . . . EW--3--81 Output shaft . . . . . . . . . . . . . . . . . . . . . . EW--3--117
Checking the torsion . . . . . . . . . . . . . . . . EW--3--81 Measuring journals and crankpins . . . . EW--3--117
Checking the flexion . . . . . . . . . . . . . . . . EW--3--81
Mounting the connecting rod--piston Replacing oil pump control gear . . . . . . EW--3--119
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--82 Fitting main bearings . . . . . . . . . . . . . . . . EW--3--119
Connecting rod--piston match . . . . . . . . EW--3--82 Finding journal clearance . . . . . . . . . . . . EW--3--119
Mounting the piston rings . . . . . . . . . . . . EW--3--82 Checking output shaft shoulder
Mounting the connecting rod/piston clearance . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--120
assemblies in the cylinder liners . . . . . . EW--3--83 Connecting rod -- piston assembly . . EW--3--120
Measuring the crankpin assembling play EW--3--83 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--121
Checking piston protrusion . . . . . . . . . . . EW--3--84 Measuring piston diameter . . . . . . . . . . . EW--3--121
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--85 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--3--122
Distribution gearbox case . . . . . . . . . . . . EW--3--85 Conditions for proper pin--piston
Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--3--85 coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--122
Injection pump – 1st phase . . . . . . . . . . EW--3--86 Split rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--122
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--86 Connecting rods . . . . . . . . . . . . . . . . . . . . EW--3--123
Flywheel cover case . . . . . . . . . . . . . . . . EW--3--87 Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--123
Engine flywheel . . . . . . . . . . . . . . . . . . . EW--3--88 Checking torsion . . . . . . . . . . . . . . . . . . . EW--3--124
Replacing the engine flywheel ring gear EW--3--88 Checking connecting rods . . . . . . . . . . . EW--3--124
Injection pump – 2nd phase . . . . . . . . . . EW--3--89 Checking bending . . . . . . . . . . . . . . . . . . EW--3--124
Mounting the injection pump – Fitting connecting rod--piston assembly EW--3--124
2nd phase . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--89 Connecting rod--piston coupling . . . . . . EW--3--124
Mounting the oil and water pumps . . . . EW--3--89 Fitting split rings . . . . . . . . . . . . . . . . . . . . EW--3--125
Mounting the oil sump . . . . . . . . . . . . . . . EW--3--90 Fitting connecting rod--piston assembly
Mounting the water / oil heat exchanger EW--3--91
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--3--92 into cylinder barrels . . . . . . . . . . . . . . . . . EW--3--125
Removing the valves . . . . . . . . . . . . . . . . EW--3--92 Finding crankpin clearance . . . . . . . . . . EW--3--126
Checking the cylinder head supporting Checking piston protrusion . . . . . . . . . . . EW--3--127
surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--93 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--128
Checking the cylinder head water seal . EW--3--93 Flywheel housin . . . . . . . . . . . . . . . . . . . . EW--3--128
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--93 Engine flywheel . . . . . . . . . . . . . . . . . . . EW--3--129
Valve descaling, check and grinding . . . EW--3--94 Replacing engine flywheel ring gear . . . EW--3--129
Checking the play between the valve Cylinder head . . . . . . . . . . . . . . . . . . . . . EW--3--133
stem, valve guide and valve centring . . EW--3--94 Removing the valves . . . . . . . . . . . . . . . . EW--3--133
Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW--3--94 Removing carbon deposits, checking
Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW--3--94 and grinding valves . . . . . . . . . . . . . . . . . EW--3--135
Valve seat reconditioning -- replacement EW--3--94 Checking cylinder head supporting
Valve springs . . . . . . . . . . . . . . . . . . . . . EW--3--96 surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--134
Mounting the cylinder head . . . . . . . . EW--3--96 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--135
Reattaching the cylinder head . . . . . . . . EW--3--96 Removing carbon deposits, checking
Rocker arm assembly . . . . . . . . . . . . . . . EW--3--97 and grinding valves . . . . . . . . . . . . . . . . . EW--3--135
Mounting the injectors . . . . . . . . . . . . . . . EW--3--98 Checking clearance between valve
Replacing the injectors . . . . . . . . . . . . EW--3--101 stem and valve guide and valve
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--101 centering . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--135
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--3--101
Adjusting the tappets . . . . . . . . . . . . . . EW--3--103 Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW--3--135
Rocker arm removal/reassembling . EW--3--103 Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW--3--136
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--103 Regrinding – replacing the valve seats . EW--3--136
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--3--103 Valve springs . . . . . . . . . . . . . . . . . . . . . EW--3--137
Valve timing . . . . . . . . . . . . . . . . . . . . . . EW--3--103 Fitting cylinder head . . . . . . . . . . . . . . . EW--3--138
ENGINE OVERHAUL AT THE BENCH Refitting the cylinder head . . . . . . . . . . . EW--3--138
FAHE0684J . . . . . . . . . . . . . . . . . . . . . . . EW--3--104 Fitting injectors . . . . . . . . . . . . . . . . . . . . . EW--3--139
Disassembly of the engine . . . . . . . . . . . EW--3--104 Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--3--140
Repair interventions . . . . . . . . . . . . . . . EW--3--113 Rocker assembly . . . . . . . . . . . . . . . . . . . EW--3--140
Cylinder group . . . . . . . . . . . . . . . . . . . . EW--3--113 Tappet clearance adjustment . . . . . . . . . EW--3--141
Controls and measurements . . . . . . . . . EW--3--113 Harness support . . . . . . . . . . . . . . . . . . . EW--3--143
 EW--3--3

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 1

86483

ENGINE F4GE0684F

Figure 2

86484

ENGINE F4HE0684J
EW--3--4

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE CODING

F 4 G E 0 6 8 4 J * D +

Emission level

Approved rating

Use

Feeding / Injection
D = TIER 2
Cylinder no.

Cylinder pattern
0 = 4 strokes, vertical

Engine

Type of crankcase:
B = non--structural 6 = 6--cylinder

Engine
group

8 = Direct injection turbo

diesel with intercooler

4 = Earthmovers

X Y Y Y Y Y Y Y Y

X = 4 in--line, 2--valve injection pump Manufacturing sequence number

Y = Engine model
X = X= 1 4--valve Common Rail
 EW--3--5

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

MAIN ENGINE FEATURES

A Applications

B F4GE0684F F4HE0684J

C *D601 *D100

E 6728 cm3

110 kW 145 kW
F 2000 rpm 2000 rpm

G Direct injection

H In--line injection pump

T.A.A.
I (Boosted by intercooler)

A Wheeled loaders
B T
Type off engine
i
C Engine model
D Number of cylinders
E Total displacement
F Max. power currently available
G Type of injection
H Injection system
I Air supply system
EW--3--6

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

MAIN ENGINE FEATURES

F4GE6484F F4HE6484J
Type
*D601 *D100

Cycle 4--stroke diesel engine

Feeding Boosted by intercooler
Injection Direct

Number of cylinders In--line, 6--cylinder

Bore mm 11042

Stroke mm 132

Total displacement cm3 6728 cm3

Compression ratio

Max. rating kW 110 145

min --1 2000 2000

Max. torque Nm (kgm) 675 850

min --1 1400 1400

No--load idle rpm min --1 700

No--load peak rpm min --1 --

BOOSTING With intercooler

Type of turbocompressor: HOLSET HX35W

Forced by means of gear pump,

LUBRICATION
pressure relief valve, oil filter
Oil pressure with hot engine:
at idle rpm bar 1.2
at peak rpm bar 3.8
 EW--3--7

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

F4GE0684F F4HE0684J
Type
*D601 *D100
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
start of opening: °C 81 ± 2
REFUELLING
Full filling capacity 1° litres --
Ambra Super Gold
15W40 kg
10W30 -- engine sump litres --
kg
-- engine sump + filter litres
kg

FEEDING VE6/12F9000 High pressure

Bosch--type injection L968 Common Rail

Pump setting 0° ± 0°.5

Start of delivery mm 1

Type of nozzle DSLA 145 P1174 Electro--injectors

Injection sequence 1 -- 5 -- 3 --6 --2 -- 4

Injection pressure bar 245 bar 250 -- 1450 bar

EW--3--8

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ASSEMBLING PLAY -- SPECIFICATIONS

F4GE0684F F4HE0684J
Type
*D601 *D100
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Cylinder liners ∅1 104

Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter ∅1 103.730 to 10.748
Pin seat ∅2 38.016 to 38.010
Piston -- cylinder liners --

Piston diameter ∅1 0.5

Position of pistons
from crankcase X --

Gudgeon pin ∅3 37.994 to 38.000

Gudgeon pin--Pin seat 0.01 to 0.022

Type of piston X1* 2.705 to 2.735

Piston ring slots X2 2.440 to 2.460
X3 4.03 to 4.05

S1* 2.560 to 2.605

Piston rings S2 2.350 to 2.380
S3 3.977 to 3.990

1 0.100 to 0.175
Piston rings– Slots 2 0.010 to 0.11
3 0.040 to 0.083

Piston rings 0.5

 EW--3--9

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

F4GE0684F F4HE0684J
Type
*D601 *D100
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cylinder
liner:
X1 0.3 to 0.4
X2 0.6 to 0.8
X3 0.3 to 0.55

Connecting rod small--end

bushing seat ∅1 41.2797 to 41.553
Connecting rod bearing seat ∅2 72.987 to 73.013

Connecting rod small--end bushing

diameter
Outer ∅4 40.987 to 410.13
Inner ∅3 38.019 to 38.033

Connecting rod small--end bushing –

0.266 to 0.566
seat
Gudgeon pin – Bushing 0.019 to 0.039

Measurement dimension X --

Max. error on connecting rod axis

parallelism = --

Journals ∅1 82.99 to 83.01

Crankpins ∅2 68.987 to 69.013
Main half bearings S1* 2.456 to 2.464
Connecting rod half bearings S2* 1.955 to 1.968
* supplied with spares

Bed supports no.:

n. 1--5 ∅3 87.982 to 88.008
n. 2--3--4 87.977 to 88.013
EW--3--10

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

F4GE0684F F4HE0684J
Type
*D6011 *D100
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
n. 1--7 0.041 to 0.119
n. 2--3--4--5--6 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings

Shoulder journal X1 37.475 to 37.545

Shoulder bed support X2 25.98 to 26.48

Shoulder half rings X3 37.28 to 3738

Drive shaft shoulder 0.068 to 0.410

 EW--3--11

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

F4GE0684F F4HE0684J
Type
*D601 *D100
VALVE GEAR – CYLINDER ASSEMBLY mm

Valve guide seats on

cylinder head ∅1 8.019 to 8.039 70.42 to 7.062

Valves:
∅4 7.96 to 7.98 6.970 to 6.999
α 60° 60 ÷ 0.25°
∅4 7.96 to 7.98 6.970 to 6.999
α 45° 45 ÷ 0.25°

Valve stem and respective guide 0.052 to 0.092 0.043 to 0.092

Seat on head for valve seat:

∅1 46.987 to 47.013 34.837 to 34.863

∅1 43.637 to 43.668 34.837 to 34.863

Valve seat outer diameter; inclination

of valve seats on cylinder head:

∅2 47.063 to 47.089 34.917 to 34.931

α 60° 60°
∅2 43.713 to 43.739 34.917 to 34.931
α 45° 45°
Hollow X 0.356 to 1.102 0.59 to 1.11

X 0.104 to 0.840 0.96 to 1.48

Between the valve 0.050 to 0.102 0.054 to 0.094

seat and the head
0.050 to 0.102 0.054 to 0.094

Valve seats --
EW--3--12

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

F4GE0684F F4HE0684J
Type
*D601 *D100
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5 47.75
under a load of:
329 N (•) -- 3398 N (H) H1 49.02 (•) 35.33 (H)
641 N (•) -- 741 N (H) H2 38.20 (•) 25.2 (H)

Injector protrusion X not adjustable

Seats for distributing shaft bushings

no. n. 1--7
--
Distributing shaft seats no.
--
2--3--4--5--6

Distributing shaft support pins:

1⇒7 ∅ 53.995 to 54.045

Bushing inner diameter ∅ 54.083 to 54.147

Bushings and seats in crankcase --

Bushings and support pins 0.038 to 0.162

Eccentric working lift:
6.045 6.45

7.239 7.582
 EW--3--13

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

F4GE0684F F4HE0684J
Type
*D601 *D100
VALVE GEAR – CYLINDER ASSEMBLY mm

∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030

∅2
Outer diameter of
tappet collar:
∅3
∅2 15.929 to 15.959 15.924 to 15.954
∅2 ∅3 15.965 to 15.980 15.960 to 15.970

Between the tappets and the seats 0.020 to 0.065 0.025 to 0.070

Tappets --

∅1

Rocker arm shaft ∅1 18.963 to 18.975 21.965 to 21.977

Rocker arms ∅2 19.000 to 19.026 22.001 to 0027

∅2
Between the rocker arm and the
0.025 to 0.063 0.024 to 0.377
shaft
EW--3--14

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

TIGHTENING TORQUE

PART COPPIA
Nm (kgm)
Cylinder
y g screw 1st p
head fastening phase: screws M12x1.75x70 50 ± 5 (5 ± 0.5)
screws M12x1.75x140 40 ± 5 (4 ± 0.5)
screws M12x1.75x180 70 ± 5 (7 ± 0.5)
2nd pphase: 90°
3rdd phase: (only for screws 140 and 180 mm long) 90°
p fastening
Bed cap g screws 1st pphase 50 ± 6 (5 ± 0.6)
nd
2 p phase 80 ± 6 (8 ± 0.6)
rd
3 phase 90° ± 5°
Connecting g rod cap g 1st p
p fastening phase 30 ± 5 (3 ± 0.5)
nd
2 p phase 50 ± 5 (5 ± 0.5)
rd
3 phase 60° ± 5°
g
Engine y
flywheel g screws
fastening p g
pre--tighten 30 ± 5 (3 ± 0.5)
Angle 60° ± 5°
Injector fastening 60 ± 5 (6 ± 0.5)
Sump oil drain plug 60 ± 5 (6 ± 0.5)
Fuel filter contact + 3/4 turn
Injection pump gear cover fastening screw 25 ± 5 (2.5 ± 0.5)
Valve gear cover and case fastening screw 25 ± 5 (2.5 ± 0.5)
Container fastening screw 25 ± 5 (2.5 ± 0.5)
Intake manifold fastening screw 25 ± 5 (2.5 ± 0.5)
Fuel pump fastening screw 25 ± 5 (2.5 ± 0.5)
Exhaust manifold fastening screw 53 ± 5 (5.3 ± 0.5)
Tappet cover fastening nut 25 ± 5 (2.5 ± 0.5)
Rocker arm support fastening screw 48 ± 8 (4.8 ± 0.8)
Nut for rocker arm adjusting screw 25 ± 5 (2.5 ± 0.5)
Screw fastening the pulley on drive shaft pre--tighten 50 ± 5 (5 ± 0.5)
Angle 90° ± 5°
Distributing shaft shoulder plate fastening screw 25 ± 5 (2.5 ± 0.5)
Fan support fastening screw 25 ± 5 (2.5 ± 0.5)
Injection pump fastening screw 12 ± 5 (1.2 ± 0.5)
Fan pulley fastening screw 45 ± 5 (4.5 ± 0.5)
Turbocompressor fastening screw 25 ± 5 (2.5 ± 0.5)
Heat exchanger fastening screw 25 ± 5 (2.5 ± 0.5)
Oil pump and front cover fastening screw 25 ± 5 (2.5 ± 0.5)
Starter motor fastening screw 55 ± 5 (5.5 ± 0.5)
Alternator fastening screw 45 ± 5 (4.5 ± 0.5)
Water pump fastening screw 25 ± 5 (2.5 ± 0.5)
Oil filter contact + 3/4 turn
Belt stretcher fastening screw 45 ± 5 (4.5 ± 0.5)

-- Lubrication with oil

 EW--3--15

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

TOOLS
380000158 Nm torque wrench for calibration of the injector solenoid valve connector lock nut
380000216 Engine detachment and re--attachment device
380000975 Box with equipment complete with tools for valve seat reconditioning
380000976 Unit for spring load check.
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000988 Tool for rotating the engine flywheel
380000989 Adapter for compressor check in cylinders (380001006)
380000990 Engine flywheel retaining tool
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000997 Comparator holder tool for rotary injection pump timing (to be used with 380001005)
380000998 Manual pump for pressure and vacuum measurements
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001002 All--purpose inclinometer/Goniometer
380001003 Full square for connecting rod squaring check
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Device for checking diesel engine cylinder compression
380001099 Electro--injector extraction tool (Common Rail engines)
EW--3--16

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

GRAPHIC INDICATIONS AND SYMBOLS

Detachment
Intake
Disconnect

Reattachment
Exhaust
Connect

Removing
Operation
Disassembling

Mounting
Assembling
ρ Compression ratio

Tolerance
Torque--tighten
Weight difference

Torque--tighten + angular value Dragging torque

α

Replacement
Countersink
Genuine spares

Adjustment
Rotation
Setting

Warning Angle
! Note Angular value

Visual check
Preload
Mounting position check

Measurement
Dimension to be measured Revs number
Check

Equipment Temperature

Surface to be machined
Pressure
Machining finish bar

Increase
Interference
Greater than .....
Forced mounting
Maximum
Decrease
Thickness
Smaller than .....
Play
Minimum
Lubricate Selection
Moisten Classes
Grease Increases
Temperature < 0 °C
Sealant Cold
Winter
Temperature > 0 °C
Air bleed Hot
Summer
 EW--3--17

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

GENERAL REMARKS
ENGINE F4GE0684F
Figure 3

86485

1. Turbocompressor – 2. Fixed guide pulley – 3. Alternator -- 4. Automatic belt stretcher – 5. Water pump
-- 6. Poly--V water pump and alternator drive belt– 7. Fixed guide pulley – 8. Damper flywheel – 9. Sump –
10. Diesel oil filters – 11. Rotary injection pump – 12. Blow--by -- 13. Cold start air heater
EW--3--18

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4HE0684J
Figure 4

86486

1. Turboblower-- 2. Conditioner compressor -- 3. Alternator -- 4. Fixed guide pulley --

5. . Automatic take--up unit -- 6. Water pump -- 7. Fixed guide pulley
8. Damper flywheel -- 9. Electronic control unit -- 10. Oil sump -- 11. Fuel oil filter -- 12. High pressure
pump with fuel pump -- 13. Common rail
 EW--3--19

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

DESCRIPTION OF MAIN MECHANIC EN-

GINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the follow- It also incorporates the coolant circulation chambers
ing items are realized: cylinder liners (1); bed sup- and the engine member lubricating circuit ducts.
ports (5) and seats for: distributing shaft bushings
(3), tappets, water/oil heat exchanger (7), water Plate (6) is fitted to the lower part of the crankcase
pump (2) and oil pump (4). and ensures greater resistance to forces and stress.

Figure 5

86605
EW--3--20

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Drive shaft
It is made of steel and rests on seven induction--har-
dened supports.
Inside the drive shaft are the lubricating oil ducts.
The following items are force--fitted on the front
shank: oil pump drive gear, phonic wheel, damper
flywheel and auxiliary component drive pulley.
The following items are force--fitted on the rear
shank: distributing shaft drive gear and engine fly-
wheel mounting hub.
The main half bearings are made of steel with anti--
friction alloy coating.
The penultimate main half bearings are equipped
with a shoulder to restrain the drive shaft end play.
Parts (1) and (3) are mounted in an interfering
manner on the rear shank and cannot be replaced.

Figure 6

84037

1. Oil pump drive gear -- 2. Drive shaft -- 3. Valve gear drive gear --
4. Flywheel attachment hub

Drive shaft seal rings

The front and rear seal rings are of the “box” type, with radial seal. They can be removed by means of tools
380000980 and 380000981, and mounted by means of tools 380000983and 380000984.

ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Connecting rods
They are steel--stamped, of the oblique cut type,
with separation of the cap obtained by an advanced
technology (fracture split) instead of mechanic ma-
chining.
The connecting rod half bearings are made of steel,
with anti--friction alloy coating.
Figure 7
EW--3--21
Each connecting rod is marked:
- By a number (on the connecting rod body and
cap) indicating its respective match and the cyl-
inder in which it is mounted.
- By a letter (on the connecting rod body) indicat-
ing the weight class of the factory--assembled
connecting rod.
84038
EW--3--22
ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Pistons
The combustion chamber is machined in the piston
crown.The crown of the piston is cooled by the engi-
ne oil supplied by the sprayer.
There are three grooves that house the compres-
sion rings; the 1st of which is V shaped and is obtai-
ned using a cast iron insert.
Figure 8
The following references are engraved on the crown
of the piston:
1. Spare part number and design change number.
2. Arrow indicating the assembly sign of the piston
in the cylindrical liner; this must be facing to-
wards the front side of the engine block.
3. Date of manufacture.
4. Stamp indicating testing of the 1st groove insert
86549
 EW--3--23

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Distributing shaft
The distributing shaft rests on seven supports in the
crankcase.
The supports (front and rear) are equipped with steel
bushings mounted in an interfering manner and
coated with anti--friction material; two control eccen-
trics are provided for each cylinder.
A. Intake valve control
B. Exhaust valve control
The distributing shaft is controlled directly by the
drive shaft by means of straight--tooth gears.

Figure 9

70164

84041
EW--3--24

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F valve control

Figure 10

84042

1. Rocker arm – 2. Arbour support – 3. Adjusting screw – 4. Rod – 5. Lock cones – 6. Cup – 7. Spring –
8. Tappet – 9. Distributing shaft
 EW--3--25

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4HE0684J valve control

Figure 11

003198t

1.Rocker arm -- 2. Shaft -- 3. Adjustment screw -- 4. Rod -- 5. Bridge -- 6. Half--cones --

7. Retainer -- 8. Spring -- 9. Tappet -- 10. Timing shaft
EW--3--26

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F cylinder head

The seats of the following parts are obtained on the Moreover, the following components are inserted on
cast--iron cylinder head: the heads:
- inserted valve seats (4); - single--block exhaust manifold (1);
- injectors (6); - intake manifold (2) with seat for cold start air
- thermostat (5); heater (3).
Figure 12

84043

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

 EW--3--27

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F cylinder head

The seats of the following parts are obtained on the Moreover, the following components are inserted on
cast--iron cylinder head (8): the heads:
- inserted valve seats (10); - exhaust manifold (1) in two parts;
- intake manifold (5) with seat for cold start air
- injectors (2); heater (6);
- thermostat (4); - support (7) with injector harness (3).
Figure 13

86487
EW--3--28

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F valves and valve seats

Figure 14

84044

1. Intake valve -- 2. Exhaust valve -- A. Intake side -- S. Exhaust side

The valve seats inserted on the cylinder head have The exhaust valves (2) differ from intake valves in
the following inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)
- 60° (intake valves).

Figure 15

84045

Figure 15, shows the oil seals mounted on valve

stems.
 EW--3--29

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4HE0684J valves and valve seats

Figure 16

70319

1. Intake valves -- 2. Exhaust valves -- A. Lato aspirazione -- S. Exhaust side.

The angles of the valve seats are as follows: The exhaust valves 2 have a distinctive hollow at the
- 45° for the exhaust valves center of the mushroom.
- 60° for the intake valves

Figure 17

70334

The figures shows the oil gaskets fitted on the valve rods
EW--3--30

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F valve guides

Figure 18

INTAKE EXHAUST

84046

DETAIL OF VALVE GUIDES AND SEATS

 EW--3--31

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4HE0684J valve guides

The valve guides are not shown.
Figure 19

INTAKE EXHAUST
70328

Valve control bridges F4HE0684J engine The bridges must be positioned with the notches
When re--assembling the cylinder head, observe the (→)facing towards the exhaust manifold.
direction of the valve control bridges.

Figure 20

70345

1. Bridge -- 2. Rod
Grinding of the F4HE0684J cylinder head not exceed 0.13 mm.
A single thickness gasket is available as spare part
The nominal thickness of the cylinder head is
105 ± 0,25 mm mm; maximum metal removal must
Figure 21

70325
EW--3--32

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine flywheel
The flywheel (1) does not need being positioned in sors or timing. The equidistance of fastening screw
a fixed manner on the drive shaft, since it does not holes (2) allows it to be mounted in any position.
bear any stamping, notch or reference hole for sen-

Figure 22

86454

ENGINE FEHE0684J
Figure 23

86488

ENGINE F4GE0684F
 EW--3--33

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F auxiliary component drive

A Poly--V belt (4) transmits the motion of drive shaft
(5) to water pump (1) and alternator (2).
The belt is stretched by means of automatic belt
stretcher (3).

Figure 24

86489

1. Water pump -- 2. Alternator -- 3. Automatic belt stretcher -- 4. Poly--V belt -- 5. Drive shaft
EW--3--34

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4HE0684J auxiliary component drive

A Poly--V belt (4) transmits the motion of drive shaft The belt is stretched by means of automatic belt
(5) to water pump (1) and alternator (2). stretcher (3).

Figure 25

86490

1. Conditioner compressor -- 2. Alternator -- 3. Water pump -- 4. Automatic belt stretcher -- 5. Poly-- V

belt -- 6. Drive shaft

ENGINE F4GE0684F -- F4HE0684J OVERHAUL
ENGINE F4GE0684F LUBRICATION
Forced circulation lubrication is performed by the fol-
lowing components:
- rotor--equipped oil pump housed in the crank-
case front part, controlled by the straight--tooth
gear force--fitted on the drive shaft shank;
Figure 26
Oil return drop--type path
Pressure oil path
EW--3--35
- water / oil heat exchanger housed in the engine
crankcase,
- oil pressure control valve;
- by--pass valve for clogged oil filter cut--off, built
into the oil filter adapter;
- cartridge--type oil filter.
86491
EW--3--36

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4HE0684J LUBRICATION

Forced circulation lubrication is afforded by the follo-
wing components:
- vane type oil pump (5), housed in the front part
of the engine block, controlled by the straight--
toothed gear splined on the tail of the crankshaft;
- water/oil heat exchanger (3), housed in the engi-
ne block, with oil filter support;
- oil pressure regulation valve (1 incorporated in
the filter support;
- by--pass valve (4) to bypass the clogged oil filter,
incorporated in the filter support;
- cartridge type oil filter (2).

Figure 27

Pressure oil path

Oil return drop--type path
Introduction oil

86492
 EW--3--37

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Heat exchanger

Figure 28

86458

1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block
EW--3--38

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Oil pump

Figure 29

84052

Figure 30

70150

1. Drive shaft with oil pump drive gear

 EW--3--39

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F oil sump

The oil sump (1) is secured elastically to the crank-
case by means of an aluminium plate (3), Figure 32.
The C--section rubber gasket (2), fitted onto the oil
sump leading profile, enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.

Figure 31

84054

Figure 32

84055
EW--3--40

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4HE0684J oil sump

The sump is bolted to the engine block with a thin
gasket

Figure 33

003202t

003203t
 EW--3--41

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4GE0684F oil vapour recirculation

Oil vapour recirculation takes place by means of The vapour condensed therein fall below the tappet
valve (1) placed above the tappet cover (2). cover (2) due to gravity, whereas the remaining va-
pour is recovered by vent (3) and properly conveyed
to the intake phase.

Figure 34

86460
EW--3--42

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Engine F4HE0684J oil vapour recirculation

A pre--separator (1) is housed in the tappet cover, In the blow--by (3), part of the vapors condense and
whose shape and position determine an increase in return to the oil sump while the remaining vapors are
the outfeed speed of the oil vapors and, at the same recycled through suction via the hose (2).
time, condense part of these.
The condensed oil returns to the oil sump while the
remaining vapors are routed, collected and filtered in
the blow--by (3).

Figure 35

oil condensation

oil vapors
000966t

1. Pre-- separator -- 2. Suction recycling -- 3. Filter -- 4. Return to the engine

 EW--3--43

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4GE0684F COOLING

The engine cooling system is of the forced, closed-- - centrifugal water pump, housed in the engine
circuit circulation type and is made up of the following crankcase front part;
components:
- heat exchanger, used to cool the lubricating oil; - thermostat, used to regulate coolant flow.

Figure 36

86493

Water flowing out Water flowing in

Water recirculating
EW--3--44

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4HE0684J COOLING

The forced circulation, closed loop engine cooling - a centrifugal type water pump housed in the front
system comprises the following components: part of the engine block;
- a heat exchanger to cool the lubrication oil (see - a thermostat that regulates circulation of the coo-
lubrication); ling fluid.

Figure 37

86494

Water in output from the thermostat Water supplied to the pump

Water recirculating in the engine

 EW--3--45

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Water pump
The water pump is housed in a seat obtained from the The engine temperature is controlled by a thermo-
crankcase and is controlled by means of a poly--V stat.
belt. The coolant flows also in the oil heat exchanger.
The nearly total absence of outer pipes, sleeves and
clamps eliminates many connections, thus reducing
possible leak points.

Figure 38

84058

Figure 39

84059
EW--3--46

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4GE0684F MECHANIC INJEC-

TION FEEDING SYSTEM
Fuel prefilter
The filter support (1) incorporates: manual priming
pump (4), screw (2) used to blow air off the system,
and cartridge (3).
Figure 40

84060

Fuel filters
The support (2) incorporates: fuel temperature sen- Maximum working pressure: 5 bar.
sor (1), heater resistors (4), air bleeding screws (3) Working temperature: --25 °C to + 90 °C.
and filter (5).
Degree of filtration of cartridge: 10 micron.
Figure 41

84061
 EW--3--47

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

MECHANIC FUEL PUMP

Displacement pump mounted on the injection pump
left side; it is used to feed the injection pump.

Figure 42

84062

1. Injection pump -- 2. Fuel outflow to the filter -- 3. Fuel pump -- 4. Fuel inflow from the tank -- 5. Manual
control lever
EW--3--48

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4GE0684F INJECTION ASSEMBLY

Figure 43

86495

1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Injector 5 fuel pipe -- 7. Injector 6 fuel pipe -- -- 8. Injection pump --
9. Injector
 EW--3--49

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4HE0684J FUEL SUPPLY SYSTEM \

The Common Rail system features a special pump
that maintains the fuel constantly at high pressure
regardless of the phase and of the cylinder to be
injected and accumulates it in a duct common to all the
electro--injectors.
This means that fuel at the injection pressure
calculated by the electronic control unit is always
available at the infeed to the electro--injectors.
When the solenoid valve of an electro--injector is
energized by the electronic control unit, fuel tapped
directly from the rail is injected in the related cylinder.

Figure 44

High pressure
Low pressure
Fuel drainage
003205t

1.Electro--injector -- 2. Common Rail -- 3. Pressure limiting device for fuel return --

4.Common Rail overpressure valve -- 5.Prefilter fitted on the chassis -- 6.High pressure pump -- 7. Mecha-
nical vane pump -- 8. Fuel filter

The hydraulic system consists of a low pressure
circuit and a high pressure circuit.
The high pressure circuit comprises the following
pipes:
- pipe connecting the outlet of the high pressure
pump to the Common Rail;
- pipes that supply the electro--injectors from the
Common Rail.
The low pressure circuit comprises the following
pipes:
- suction pipe of the fuel from the tank to the
prefilter;
- pipes that supply the mechanical fuel pump
through the heat exchanger of the control unit, the
manual priming pump and the prefilter;
- pipes that supply the high pressure pump through
the fuel filter.
The supply system also includes the fuel drainage
system from the Common Rail, from the injectors and
the cooling circuit of the high pressure pump
EW--3--50

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE F4HE0684J FUEL SYSTEM DIAGRAM

Figure 45

Exhaust

Intake (low pressure)

High pressure pump supply (low pressure)

Alta pressure

Intake (low pressure)

000909t

1. High pressure pump -- 2. Limiting valve on the high pressure pump, 5 bar -- 3. Regulating valve fitted
on the fuel return from the electro--injectors, 1,3 -- 2 bar-- 4. Common Rail overpressure valve -- 5. Com-
mon Rail -- 6. Pressure sensor -- 7. Electro--injector -- 8. Return pipe -- 9.Heat exchanger of the control unit
-- 10.Mechanical priming pump -- 11. Prefilter fitted on chassis -- 12. Fuel tank -- 13. Mechanical fuel pump
-- 14.Fuel filter -- 15. Pressure regulator -- 16. . Return pipe from high pressure pump -- 17. By--pass valve
-- 18. By--pass valve

The pressure regulator located ahead of the high
pressure pump regulates the flow of fuel required on
the low pressure system. Subsequently, the high
pressure pump supplies the Common Rail correctly.
This solution, which pressurizes only the fuel
required, improves energy efficiency and restricts
heating of the fuel in the system.
The limiting valve (2), fitted on the high pressure
pump, maintains a constant pressure of 5 bar at the
infeed to the pressure regulator.
The limiting valve (3) housed on the cylinder head,
fitted on the return of the electro--injectors, regulates
return flow of the fuel from the electro--injectors to a
pressure of 1.3 P 2 bar.
Two by--pass valves are installed in parallel with the
mechanical fuel pump.
By--pass valve 18 permits return of the fuel from the
outlet of the mechanical pump to its infeed when the
pressure at the entrance to the fuel filter exceeds the
permitted limit. By pass valve 17 makes it possible to
fill the fuel system through the manual priming pump
(10).

ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Fuel prefilter
The high water separation type fuel filter is fitted on
the base of the cartridge (3), with the sensor (4) that
indicates the presence of water in the fuel.
The manual priming pump (5) and the system air
vent screw (2) are present on the filter support.
Figure 46
EW--3--51
IMPORTANT -- If the light switches on, take action
immediately in order to remove the cause; the pre-
sence of water or impurities in the fuel causes fast
downgrading of Common Rail system compo-
nents.
000910t
EW--3--52

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Fuel filter The heater is activated if the temperature of the fuel

Located on the engine block in the circuit between the
fuel pump and the high pressure pump (CP3).
The fuel temperature sensor and the resistor of the
heater are located on the support
is < = 0 °C and continues to heat until a temperature
of 5 °C. is reached. The temperature of the fuel, com-
municated to the EDC 7 control unit by the related
sensor, permits very precise calculation of the
amount of fuel to be injected in the cylinders.

Figure 47

003206t

1. Fuel filter support -- 2. Heater connector -- 3. electric fuel heater --

4.Fuel filter -- 5. Fuel temperature sensor -- A. Outlet fitting to the high pressure pump
-- B. Inlet fitting fuel drainage from the Common Rail and from the cylinder head (injectors) --
C. Drainage fitting from high pressure pump -- D.Inlet fitting from fuel pump --
E. Outlet fitting fuel drainage to the tank
 EW--3--53

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Mechanical feed pump In normal operating conditions, the flow of fuel inside
Normal operating condition the mechanical pump is shown in the figure
Gear pump fitted on the rear part of the high pressure
pump, with the function of supplying this. It is control-
led by the shaft of the high pressure pump.

Figure 48

001237t

A. Fuel infeed from tank -- B. Fuel outfeed to the filter

1 -- 2. By--pass valves in closed position

Outlet overpressure condition The pressure present, overcoming the elastic resi-
The by--pass valve (1) is tripped in the case of over- stance of the spring (1), puts the outfeed and infeed
pressure in outfeed (B). in communication through the duct (2).

001238t
EW--3--54

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Bleed conditions In this situation, the by--pass valve (2) opens, due to
The by--pass valve (2) is tripped when, with the engine the effect of the inlet pressure and the fuel flows out
off, the fuel system is to be filled through the priming (B).
pump.

Figure 49

001239t

High pressure pump The mechanical fuel pump controlled by the shaft of
The pump with 3 radial pumping elements, controlled the high pressure pump is fitted on the rear side of the
by a timing gear, does not require phasing. high pressure pump.

Figure 50

001250t

1. Fuel outlet fitting to the rail-- 2. High pressure pump -- 3. Pressure regulator -- 4. Fuel inlet fitting from
filter -- 5. Fuel outlet fitting to the filter support -- 6. Fuel infeed fitting from the heat exchanger of the con-
trol unit --7. Fuel outlet fitting from mechanical pump to the filter -- 8. Mechanical fuel pump.
 EW--3--55

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 51

001967t

1. Mechanical fuel pump -- 2. Fuel return from high pressure pump --

3. Delivery valve to the Common Rail-- 4. Single pumping element -- 5. By--pass valves on fuel pump --
6. Pump shaf -- 7. Fuel inlet from filter -- 8.Limiting valve 5 bar --9. Pressure regulator
EW--3--56

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Operating principle
Figure 52

0021111t

SEZ. B -- B
001242t

1. Outlet for delivery to the rail -- 2. Delivery valve to the rail -- 3. Pumping element -- 4. Pump shaft --
5. Pumping element supply duct -- 6. Pressure regulator supply duct --
7. Pressure regulator

The pumping element (3) rests on the cam present on
the shaft of the pump.
In the suction phase, the pumping element is supplied
through the supply duct (5). The amount of fuel to be
sent to the pumping element is established by the
pressure regulator (7).
According to the PWM command received from the
control unit, the pressure regulator partializes the flow
of fuel to the pumping element. During the compres-
sion phase of the pumping element, the fuel, reaching
a pressure sufficient to open the delivery valve to the
Common Rail (2), supplies this through the outlet (1).
 EW--3--57

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

The figure illustrates the paths of the low pressure
fuel present inside the pump showing the main pum-
ping element supply duct (4), the pumping element
supply ducts (1 -- 3 -- 6), the ducts used for lubrica-
tion of the pump (2), the pressure regulator (5), the
5 bar limiting valve (8) and the fuel drain (7).
The shaft of the pump is lubricated by the fuel
through the delivery and return ducts (2).
The pressure regulator (5) establishes the amount
of fuel to be supplied to the pumping elements; any
excess fuel flows out through the duct (9).
In addition to acting as manifold for fuel drainage,
the 5 bar limiting valve also maintains a constant
pressure of 5 bar at the infeed of the regulator.

Figure 53

SEZ. C -- C
001244t 001244t

1--3--6. Infeed to the pumping element -- 2. Pump lubrication ducts -- 4. Pumping element main supply
ducts -- 5. Pressure regulator -- 7. Drainage duct of the regulator --
8. bar limiting valve -- 9. Fuel drainage from regulator inlet.
EW--3--58

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

The figure shows the flow of high pressure fuel

through the outfeed ducts of the pumping elements.

Figure 54

001240t

001241t

SEZ. A -- A

1. 2. Fuel outfeed ducts -- 3. Fuel outfeed from the pump with fitting for high pressure pipe for the
common rail.

ENGINE F4GE0684F -- F4HE0684J OVERHAUL
ENGINE F4GE0684F BENCH--OVERHAUL
Disassembling the engine
- Disconnect electric wiring;
- drain the engine oil by taking the cap off the sump
and the oil filling cap off the head cover;
- fit bracket 380000995 (which fastens the engine
to the overhaul stand) to the crankcase;
- disconnect the engine oil vapour recovery pipe
from blow--by (2);
- take off tappet covers (3);
- take off intake manifold unit (1);
- disconnect the piping from L.D.A. system (5);
Figure 55
EW--3--59
- disconnect quick--coupling pipes (9) by following
the indications given in Figure 56;
- take off fuel filters (8);
- take off fuel filter support (10).
- disconnect injector feed pipes (4) from injection
pump (6); remove the brackets fastening pipe (7),
and (11) unit on the cylinder head;
- take off injection pump lubrication pipes;
- take off oil level check piping.
86496
EW--3--60

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 56 Figure 58

70126 86464

Act on fork (1) as shown in the figure (detail A), then - Take off the feed pipe assembly from injectors (1).
remove the adapter. To avoid deformations, bring - Take off the pipe (2) for discharging fuel from the
fork (1) back to the locking position (detail B) after the injectors by removing screw (4) and gasket (3).
adapter has been removed.

Figure 59

Figure 57

86465

- Remove screws (3 and take off turbine (1).

5 - Remove the exhaust manifold (2).

Figure 60
4

86463

In order to be able to fit bracket 75301886 to the en-

gine crankcase on the right side, it is necessary to re-
move:
- the fastening bracket (2) of the harness (1);
- the harness (1);
- the starter motor (3);
- take off turbine lubrication delivery pipe (5);
84068
- detach the heat exchanger assy with the oil filter
(4).
Apply tool 380000990 (1) to the flywheel cover case
Secure the engine to rotary stand 380000978. to stop flywheel rotation.
 EW--3--61

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

- Remove automatic belt stretcher (5). - Remove engine cooling system adapter from the
- Remove Poly--V belt (70). crankcase.
- Remove alternator fastening bracket (1). - Remove damper flywheel (8) with underlying
- Remove the alternator (2), the water pump (4), the pulley (9).
guide pulleys (3) and (6).

Figure 61

86467
EW--3--62
ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Figure 62
78256
Apply tool 380000980 (4) on drive shaft front shank
(2). Drill inner seal ring (1), through tool 380000980
(4) guide holes, with an inset (∅ 3.5 mm) down to a
depth of 5 mm. Secure tool 380000980 (4) to ring (1)
by screwing the six screws (5) provided. Take off ring
(1) by fastening screw (3).
Figure 63
78257
Apply the proper tension rod (3) of tool 380000996 to
outer seal ring (2) as shown in the figure, then take the
same off front cover (1) by means of lever (4).
Remove the front cover.
Figure 64
84237
Remove screws (1) and take off gear oil pump.
IMPORTANT -- Oil pump (1) cannot be recondi-
tioned.
Removing the injection pump
Figure 65
84071
Prior to removing the injection pump, take off the fly-
wheel locking tool described in Figure 60.
Rotate the drive shaft until it reaches the condition of
1° cylinder at top dead centre.
Such condition is obtained when, by pushing pin (1)
shown by the arrow, it is housed in its own seat ob-
tained on distributing shaft drive gear (2).
 EW--3--63

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 66 Figure 68

84261

84260
To correctly preset the injection pump prior to remov-
ing it, loosen screw (2) and remove L--shaped spacer
(1).
Loosen the three nuts (2) (4) (5) securing the injection
pump (1) to the flywheel covering case (3), then take
the pump out of its housing by means of tool
380000322 through proper application to gear (4) in
Figure 67B.

Fasten again screw (2) to its abutting end. Figure 69

IMPORTANT -- Carefully store the L--shaped

spacer with the pump body.

84075

Apply tool 380000990 (2) to unlock screws (3).

Remove tool 380000990 (2).
Figure 67
Remove screws (3) fastening engine flywheel (4) to
the drive shaft.

Figure 70

84073

- Remove cover (1) from gear covering case (2). 84076

- Lock the engine flywheel as described in Screw two pins (2) of adequate length into drive shaft
Figure 60. holes (3).
- Loosen nut (3) securing the injection pump drive Take out engine flywheel (1) so that it can be har-
gear (4). nessed by means of a hoist and placed into its own
container.
EW--3--64

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 71 Figure 73

84077

Remove screws (2) and take off rear cover (1).

78258
IMPORTANT -- Take note of the mounting position
Apply tool 380000981 (3) on drive shaft rear shank of screws (2), due to the different size of the latter.
(5).
Drill inner seal ring (1), through tool 380000981 (3)
guide holes, with an inset (∅ 3.5 mm) down to a depth
of 5 mm.
Secure tool 380000981 (3) to ring (1) by screwing the
six screws (4) provided.
Take off ring (1) by fastening screw (2).

Figure 72 Figure 74

78257
Apply the proper tension rod (3) of tool 380000996 to 84078

outer seal ring (2) as shown in the figure, then take the Turn the engine upside down, remove screws (2),
same off flywheel cover case (1) by means of lever take off both plate (3) and oil sump (1).
(4).
 EW--3--65

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 75 Figure 78

86516 84082

Remove screws (1) and (4) and dismantle oil suction Take out injectors (2) by means of tool (1) 380000982.
strainer (5).
Remove screws (2) and dismantle stiffening plate (3).

Figure 76 Figure 79

70156 84083
Remove screws (1) and take gear (3) off distributing Remove screws (1) securing the head to the crank-
shaft (2). case.
Removing the rocker arm assembly
Figure 77 Figure 80

84081 84084

For each cylinder, remove rocker arm assembly (1), Hook the wire ropes to brackets (1) and (2), then sep-
loosen adjusting nuts (3), unscrew registers (2) and arate the cylinder head from the crankcase by means
remove screws (4). of a hoist.
EW--3--66

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 81 Figure 84

84085 70160

Remove screws (2) and take off timing gear case (1). The penultimate bed cap (1) and its respective sup-
port have half bearing (2) provided with shoulder.

IMPORTANT -- Take note of the mounting position IMPORTANT -- Take note of the mounting position
of screws (2), due to the different size of the latter. of lower and upper half bearings; in fact, if they
have to be used again, they must be mounted in the
Figure 82 same position they had prior to being taken off.

Figure 85

70158
Remove connecting rod cap (2) fastening screws
(1), then take off the caps.
Remove the pistons (complete with connecting 84086
rods) from the crankcase upper part.
Remove drive shaft (2) from crankcase by means of
tool 380000992 (1) and a hoist.
IMPORTANT -- Half bearings must be kept in their
respective housings; in fact, if they have to be
used again, they must be mounted in the same
position they had prior to being taken off. Figure 86
Figure 83

70162
70159
Take off main half bearings (1).
Remove screws (1) and take off bed caps (2). Remove screws (2) and take off oil nozzles (3).
 EW--3--67

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 87 REPAIR WORK ON CYLINDER CLUSTER

Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.

70163

Remove screws (1) and take off distributing shaft (3)

retaining plate (2). Figure 90

IMPORTANT -- Take note of plate (2) mounting

position.

Figure 88

84087

The check of cylinder liner inner diameter (in order to

measure the amount of out--of--roundness, taper and
70164 wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
Carefully remove distributing shaft (1) from the engine ring gauge (2) of the cylinder liner diameter.
crankcase.
Figure 89 NOTE -- If no ring gauge is available, use a micro-
meter to perform reset.

70165

Remove tappets (1) from the engine crankcase.

EW--3--68

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 91 Checking the surface supporting the head on

the cylinder cluster
Figure 93

70167

Measurements must be taken for each single cylinder,

at three different heights of the liner and on two planes
perpendicular to each other: one parallel to the engine
longitudinal axis (A), the other perpendicular (B); the
greatest amount of wear is usually found on the latter
plane and during the first measurement. When detect-
ing out--of--roundness, taper or wear, the cylinder
liners must be bored and refaced. Cylinder liner re-
conditioning must be performed with regard to the
spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.
Figure 92
84088
Verify that the head supporting plane on the cylinder
cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
The flatness error must not be greater than 0.075 mm.

NOTE -- Crankcase flattening may be carried out

only after making sure, when the repair work has
been completed, that the protrusion of the piston
from the cylinder liner is not greater than the speci-
fied value.
Check the condition of cylinder cluster working caps
(1); they must be replaced if they are rusty or their
sealing properties are in doubt.
After flattening, restore the cylinder liner countersink,
as shown in Figure 92.

80585

IMPORTANT -- In case of reconditioning, all the

liners must be machined to the same increase (0.5
mm).
Check the main bearing seats as follows:
- mount the bed caps on the supports without bear-
ings;
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com-
parator, that the seat diameter is the same as the
specified value.
If a greater value is found, replace the crankcase.
 EW--3--69

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

VALVE GEAR
Distributing shaft
Figure 94

84089

MAIN FEATURES OF DISTRIBUTING SHAFT

The features described given below refer to the normal diameter of pins.

The shaft support pin and eccentric surfaces must be Figure 95

perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft. Also check the ec-
centric lift, which must be equal to 7.239 mm (for ex-
haust eccentrics) and 6.045 mm (for intake eccen-
trics). If different values are found, replace the shaft.

70171

Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
EW--3--70

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

BUSHINGS Figure 96
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.

70172

Figure 97

sec. A-A

70173

MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushings
 EW--3--71

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Replacing the bushings Figure 101

Figure 98

70174 70164
To replace front and rear bushings (1), use beater Lubricate the distributing shaft support bushings and
380000991 (2) and handle 380000999 (3) to remove mount distributing shaft (1) taking care not to damage
and reassemble the bushings. the bushings or supporting seats.

IMPORTANT -- Bushings (1) must, upon mount-

ing, be turned in such a way that the lubricating
holes match with the holes available on the crank-
case seats.
Tappets
Figure 99

84053
MAIN FEATURES OF TAPPETS AND THEIR RE-
SPECTIVE SEATS ON THE CRANKCASE Figure 102
Mounting the tappets – Distributing shaft
Figure 100

70238

Place distributing shaft (3) retaining plate (1) with

70176 the slotted hole facing the crankcase upper side and
Lubricate tappets (1) and fit them to their respective the stamping facing the operator, then fasten
seats of the crankcase. screws (2) to the specified torque.
EW--3--72

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 103 DRIVE SHAFT

Measuring the journals and crankpins

Figure 105

70179

Check the distributing shaft end play (1).

70182

Figure 104 If traces of excessive seizing, scoring or out--of--

roundness are found on journals and crankpins, it is
necessary to reface the pins by grinding. Prior to
grinding pins (2), measure the journals by means of
a micrometer (1) so as to determine the amount (di-
ameter) by which the pins have to be reduced.

NOTE -- It is advisable to write down the measured

values on a table.
See Figure 106.

Reduction classes are 0.250 and 0.500 mm.

70180
IMPORTANT -- Journals and crankpins must al-
Mount nozzles (2) and tighten fastening screws (1) to ways be ground to the same reduction class.
the specified torque. The reduction carried out on journals and crank-
pins must be marked with a special stamping made
on the side of crank arm 1.
For reduced crankpins, use letter M.
For reduced journals, use letter B.
For reduced crankpins and journals, use letters
MB.
 EW--3--73

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 106

84090

DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
EW--3--74

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 107

84091

MAIN TOLERANCES OF DRIVE SHAFT

TOLERANCES GRAPHIC SYMBOL
TOLERANCE--RELATED FEATURE
CONCERNING:
Roundness f
SHAPE
Cylindricality /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL

CRITICAL 
IMPORTANT
SECONDARY

Figure 108

BEARINGS ON TIMING INTERMEDI- FIRST

SIDE ATE BEARINGS BEARING ON
UPPER SIDE

84275
 EW--3--75

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Replacing the oil pump drive gears Measuring the journal assembling play
Figure 109 Figure 111

70184 84092
Verify that the teeth of gear (1) are not damaged or Mount drive shaft (1).
worn; otherwise, proceed with removal by means of Check the play between the drive shaft journals and
a suitable extractor (3) foce--fitted on drive shaft (2). their respective bearings by following the procedure
When fitting the new gear, the latter must be heated below:
for 10 minutes in a small furnace at a temperature of
180 °C and force--fitted onto the drive shaft by putting
the key in between.

Mounting the main bearings

Figure 110

Figure 112

70185

IMPORTANT -- If main bearings do not need re-

placing, they must be fitted in the same order and
positions they had prior to being taken off.

Main bearings (1) are supplied as spares reduced on

their inner diameter by 0.250 – 0.500 mm. 70186

Check the play between the drive shaft journals and

IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided
with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided with
shoulder half rings.
their respective bearings by following the procedure
below:
- clean thoroughly the parts and eliminate traces (if
any) of oil;
- place a piece of gauged wire (3) (parallel to the
longitudinal axis) on drive shaft pins (4);
- mount caps (1), complete with half bearings (2),
on their respective supports.
EW--3--76

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 113 Figure 115

70187 70189

Fasten pre--lubricated screws (1) by tightening them
in three subsequent phases.
- 1st phase with a torque wrench at 50 ± 6 Nm.
- 2nd phase with a torque wrench at 80 ± 6 Nm.
- take the caps off the supports.
The play between the main bearings and their re-
spective pins can be measured by comparing the
width taken on by gauged wire (2) at the point where
it is flattened most, with the scale graduation shown
on gauged wire envelope (1).
The numbers shown on the scale indicate the match-
ing play (mm).
If the measured play is different from the specified
one, replace half bearings and repeat the check; once
the prescribed play has been obtained, lubricate main
bearings and mount the supports definitely by tighten-
ing the fastening screws as described above.

Checking the drive shaft shoulder play

Figure 116

Figure 114

70190

The shoulder play is checked by placing a magnetic

70188
- 3rd phase with tool 380001001 (1) placed as
shown in the figure: tighten screws (2) further to
an angle of 60° ± 5°.
comparator (2) on drive shaft (3) as shown in the fig-
ure: normal assembling play is 0.068 to 0.410 mm.
If a greater play is found, replace the main thrust half
bearings of the penultimate support (1), then check
again the play between the drive shaft pins and the
main half bearings.
 EW--3--77

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

CONNECTING ROD--PISTON ASSEMBLY

Figure 117

70191

PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

1. Retaining rings -- 2. Pin -- 3. Piston -- 4. Piston rings -- 5. Screws -- 6. Half bearings -- 7. Connecting rod --
8. Bushing

NOTE -- Pistons are supplied as spares increased

by 0.5 mm.

Figure 118 Figure 119

84093 84094

Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
EW--3--78

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 120

86497

MAIN DATA OF PISTON

Pistons
Measuring the piston diameter
Figure 121 Figure 122

84096 70192

Measuring the piston diameter (1) by means of a The play between the piston and the cylinder liner can
micrometer (2) to determine the assembling play. also be measured by means of a thickness gauge (1)
as shown in the figure.

NOTE -- The diameter must be measured 61 mm far

from the piston skirt base.
 EW--3--79

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Gudgeon pins Figure 126

Figure 123

84097 84100

Measuring the gudgeon pin diameter (1) by means of Use a thickness gauge (1) to check the play between
a micrometer (2). the seal rings (3) of the 3rd slot and the respective
seats on piston (2).
Conditions for correct pin/piston matching

Figure 124

Figure 127
84098

Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.

Piston rings
Figure 125

84101

SCHEME FOR MEASURING PLAY X FOR THE

TRAPEZOIDAL RING
Due to the peculiar shape of the two trapezoidal
cross--sectioned seal ring, the play between the slot
and the ring itself must be measured as follows; allow
piston (1) to protrude from the crankcase so that ring
(2) at issue comes out of about half from cylinder liner
(3).
84099 In this position, check, by means of a thickness
Check the thickness of seal rings (2) by means of a gauge, the play (X) between the ring and the slot: it
micrometer (1). must correspond to the specified value.
EW--3--80

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 128 Figure 130

70194

Measuring the play between the ends of piston rings

(2) inserted into cylinder liner (3), by means of a thick-
ness gauge (1).

Connecting rods
Figure 129

80339

IMPORTANT -- Each connecting rod is marked as

follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted.
In case of replacement, it is therefore necess-
ary to number the new connecting rod with the
same number as the replaced one.
- By a letter (on the connecting rod body) which
indicates the weight class of the factory--as-
sembled connecting rod:
-- V, 1600 to 1640 (marked in yellow);
-- W, 1641 to 1680 (marked in green);
-- X, 1681 to 1720 (marked in blue);
Replacement rods are supplied class W and
marked in green *.
Material removal is not permitted.
86498

MAIN DATA OF CONNECTING ROD, GUDGEON

PIN BUSHING AND HALF BEARINGS
* Dimension of inner diameter to be obtained after
driving into the connecting rod small--end and refacing
by means of a reamer.
** This dimension cannot be measured in a free state.

IMPORTANT -- The connecting rod--connecting

rod cap matching surfaces are knurled to ensure
better match.
Therefore, it is recommended not to remove
knurls.
 EW--3--81

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Bushings Checking the torsion

Verify that the bushing in the connecting rod small-- Figure 132
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods

Figure 131

61694
Check connecting rod torsion (5) by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis.
Place comparator (2) support (1) so that the compara-
tor is preloaded by ~ 0.5 mm on pin (3) at point A, then
set comparator (2) to zero. Move spindle (4) with con-
necting rod (5), then compare the deviation (if any) on
opposite side (B) of pin (3): the difference between A
and B must not be greater than 0.08 mm.

Checking the flexion

Figure 133

61696

Check the parallelism of connecting rod axes (1) by

means of device 380001003 (5). Proceed as follows:
- mount connecting rod (1) on tool 380001003 (5)
spindle, then secure it by means of screw (4);
- place spindle (3) on V--shaped block squares by
putting connecting rod (1) on stop bar (2).

61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
EW--3--82

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Mounting the connecting rod--piston assembly Figure 136

Connecting rod--piston match
Figure 134

72705

Insert pin (1) fastening piston rings (2).

86550

The following references are engraved on the crown

of the piston:
1. Spare part number and design change number.
2. Arrow indicating the assembly sign of the piston
in the cylindrical liner; this must be facing towards
the front side of the engine block.
3. Date of manufacture.
4. Stamp indicating testing of the 1st groove insert
Mounting the piston rings
Figure 137

Figure 135

84093

Use pliers 380000986 (3) to fit piston rings (1) on pis-

ton (2).
The rings must be mounted with the writing “TOP”
facing upwards; moreover, the ring apertures must be
turned in such a way that they are offset to each other
by 120°.

IMPORTANT -- Spare piston rings are supplied in

86551 the following dimensions:
Connect piston (2) to connecting rod (4) by means of
-- standard, marked with yellow paint;
pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner and the numbers -- increased by 0.5 mm, marked with yellow/green
stamped on connecting rod (4) can be seen as shown paint;
in the figure.

ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Figure 138
70200
Mount half bearings (1) both on the connecting rod
and the cap.
IMPORTANT -- If connecting rod bearings do not
need replacing, they must be fitted in the same
order and positions they had prior to being taken
off.
No matching operation must be carried out on half
bearings.
Mounting the connecting rod/piston assemblies
in the cylinder liners
Figure 139
70201
Lubricate thoroughly the pistons, including the piston
rings and the cylinder liner inside.
Use band 380000994 (2) to mount the connecting
rod--piston assemblies (1) into the cylinder liners;
moreover, verify that:
- the number of each connecting rod corresponds
to the cap matching number.
EW--3--83
Figure 140
84040
SCHEME FOR MOUNTING THE CONNECTING
ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
by 120°;
- all the connecting rod/piston assemblies weigh
the same;
- the writing stamped on the piston crown faces the
crankcase front side, or the notch obtained on the
piston skirt corresponds to the position of oil nozz-
les.
Measuring the crankpin assembling play
Figure 141
70203
The play can be measured by following the procedure
below:
- clean thoroughly the parts and eliminate any trace
of oil;
- place a piece of gauged wire (2) on drive shaft
pins (1);
- mount the connecting rod caps (3) with their re-
spective half bearings (4).
EW--3--84

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 142 Figure 145

70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a 70207
torque wrench (2); If the measured play is different from the specified
one, replace half bearings and repeat the check.
Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them defi-
nitely by tightening the connecting rod cap fastening
Figure 143 screws as described.
IMPORTANT -- Prior to mounting the connecting
α rod cap fastening screws definitely, verify that the
diameter of the same (as measured at the middle
of the thread length) is not smaller than 0.1 mm of
the diameter measured at about 10 mm from the
screw end.

Check manually that connecting rods (1) run axially

on the drive shaft pins, and that the end play of the
same (as measured by means of a thickness gauge
(2)) is 0.10 to 0.33 mm.

70205

- Apply tool 380001001 (1) on the compass

wrench, then tighten screws (2) further in a criss--
cross sequence.
Checking piston protrusion
Figure 144 Figure 146

70206 70208

- take off the cap and calculate the existing play by
comparing the width of gauged wire (1) with the
scale graduation shown on the wire envelope (2).
After the connecting rod--piston assemblies have
been mounted, check, by means of comparator
380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane. Said protrusion
must be 0.28 to 0.52 mm.
 EW--3--85

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Valve gear Figure 148

Distribution gearbox case
Figure 147

84105 84106

SCHEME FOR SEALANT LOCTITE 5999 AP- SCHEME FOR REAR GEARBOX CASE FASTEN-
PLICATION AREA ING SCREW TIGHTENING SEQUENCE
Clean thoroughly distribution gearbox case (1) and Reassemble case to the crankcase.
the engine crankcase. Tighten the fastening screws in the same positions
Cleaning the surface to be sealed is necessary and they had prior to being taken off, then fasten the
unavoidable in order to ensure optimum seal. screws to the specified torque.
Apply sealant LOCTITE 5999 on the case so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes). Valve timing
Figure 149

70211

Mark, with a felt--tip pen, the tooth of drive gear (1)

mounted on drive shaft (2), the side surface of which
bears a stamped notch (→) for timing.
EW--3--86

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 150 Figure 153

84107 84273

Turn drive shaft (4) and distributing shaft (2) in such Mount the injection pump body (1) in the gearbox seat
a direction that when mounting driven gear (1) on the (2), then secure it by means of screws (3).
distributing shaft, the stamped marks on gears (1 and
3) correspond to each other.
Figure 151

70213
Tighten gear (2) fastening screws (1) to distributing
shaft (3), then fasten them to the specified torque.
Injection pump – 1st phase
Timing
Figure 152 Figure 154

84071
Bring cylinder 1 to the top dead centre. This condition
occurs when pin (1) (shown by an arrow) is housed
in the seat available on distributing shaft drive gear
(2).
84108
Force--fit gear (1) transmitting the motion to the
pump, then fasten nut (2) by hand.
 EW--3--87

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Flywheel cover case Figure 156

Figure 155

84109 84110

SCHEME FOR SEALANT LOCTITE 5999 AP- SCHEME FOR FLYWHEEL COVER CASE
PLICATION AREA FASTENING SCREW TIGHTENING SEQUENCE
Clean thoroughly the attaching surfaces of flywheel Fit case (1) back to the crankcase, tighten the fasten-
case (1) and distribution gearbox case. ing screws in the positions they had prior to being
Cleaning the surface to be sealed is necessary and taken off, then fasten them to the specified torque.
unavoidable in order to ensure optimum seal. Screws:
Apply sealant LOCTITE 5999 on the case (1) so as to - M12 x 1.75 x 100 80 ± 10 Nm
make a bead with a diameter of a few millimetres. - M16 x 1.50 x 80 200 ± 20 Nm
The bead must be smooth (no lumps) and free from - M12 x 1.75 x 78 80 ± 10 Nm
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on Figure 157
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).

70216
Apply part (5) of tool 380000983 on drive shaft rear
shank (6), secure it by means of screws (4) and
force--fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--3--88

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE FLYWHEEL Figure 160

Figure 158

84111 84075

Check the clutch disc supporting surface and turn it if
scoring is detected.
NOTE -- The rated thickness of the engine flywheel
is 45 ± 0.25 mm.
Apply tool 380000990 (2) to the flywheel cover case
(1) to stop engine flywheel (3) rotation.
Tighten screws (4) fastening engine flywheel (3) to
the drive shaft.

Replacing the engine flywheel ring gear

Check the condition of ring gear (2) teeth. If breaks or
excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 158) by using a
normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’; the
countersink made on the gear ring inner diameter Figure 161
must face the engine flywheel.

Figure 159

84114

Tighten engine flywheel (2) fastening screws (1) in

two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
- 2nd phase: angle--tighten to 60° ± 5°.
84076

Screw down two pins (2) of adequate length into the

IMPORTANT -- Angle tightening is carried out by
shaft holes (3), then remove the engine flywheel (1)
means of tool 380001001.
by means of suitable harnesses and a hoist.
 EW--3--89

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Injection pump – 2nd phase Mounting the oil and water pumps
Mounting the injection pump – 2nd phase Figure 165
Figure 162

84115 70220

Torque--tighten nut (1) by means of torque wrench (2). Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
the specified torque.
Figure 163
Figure 166

84116
Apply sealant (1) as shown in the figure, then put on
small cover (2), then tighten screws to the specified 70221
torque.
Apply a new seal ring (2) onto water pump (1).
Figure 164

Figure 167

84072

Remove plug (1) from the distribution gear seat

Figure 43. 70222

Remove presetting screw (2) and insert L--shaped Mount water pump (1). Fasten screws (2) and tighten
spacer (1). Fasten again the screw to its abutting end. them to the specified torque.
EW--3--90

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 168 Figure 170

70223 70225

Take seal ring (2) off front cover (1), clean thoroughly
the attaching surface and apply sealant LOCTITE
5999 onto the same.
Apply part (5) of tool 380000983 on drive shaft front
shank (6), secure it by means of screws (4) and force--
fit the new seal ring (3) onto the same. Position part
(1) on part (5), then screw nut (2) to fully mount seal
ring (3) in front cover (7).

Mounting the oil sump

Figure 169 Figure 171

70224 86516

Clean thoroughly the surface of front cover (2) attach- Mount plate (3) and strainer (5), then screw down
ing base, then mount front cover. fastening screws (2) and (4) and tighten them to the
Fasten screws (1) and tighten them to the specified specified torque.
torque.
 EW--3--91

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 172 Figure 174

84117 86514

Place gasket (1) on oil sump (2).
IMPORTANT -- The gasket can be used again,
provided it is not damaged.
Force--fit pulley (3) with damper flywheel (4) onto the
drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
Secure guide pulley (1) to the front cover by means of
screws (2) and tighten them to the specified torque.

Figure 173

Mounting the water / oil heat exchanger

Figure 175

84118

Mount oil sump (1) and apply plate (3) on the same.
Fasten screws (2) and tighten them to the specified
torque.
Screws:
- M10 x 1.50 x 90 70 ± 5 Nm
- M10 x 1.50 x 45 50 ± 5 Nm
- M10 x 1.50 x 190 70 ± 5 Nm
- M10 x 1.50 x 125 70 ± 5 Nm
84175
Mount the following items on the crankcase: a new
gasket (1), heat exchanger (2), a new gasket (3), and
oil filter support (4). Fasten screws (5) and tighten
them to the specified torque.
Fit the new oil filter cartridge.
EW--3--92

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 176 Cylinder head

Removing the valves

Figure 178

84177 84179

Position alternator support (1) in such a way that pins
(3 and 4) are placed against the engine crankcase.
Fasten screws (2) and tighten them to the specified
torque.
Valves can be removed by means of tool 380000987
(1) by pressing slightly on collar (3) so that lock cones
(2) can be removed by compressing springs (4). Then
remove collar (3) and springs (4).
Repeat the operation on all valves.

Figure 179
Figure 177

84180

Take off oil seals (1) fitted to the valve stems.

84178 To remove the valves, properly turn the head upside
Fit alternator (1) back to alternator support (3). down.
Fasten screws (2) without torque--tightening them.
Fit automatic belt stretcher (4) back to alternator sup-
IMPORTANT -- Mark the exhaust and intake
port (3).
valves prior to removing them.
 EW--3--93

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 180 Checking the cylinder head water seal

Check the water seal by means of suitable equipment.
Use a pump to feed water heated to ∼ 90 °C at a pres-
sure of 2 to 3 bar.
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassembling/
assembling operations.

IMPORTANT -- Prior to mounting the caps, apply

water--repellent sealant on the sealing surface of
the same.

INTAKE EXHAUST If leaks are detected from the cylinder head, the latter
84181
must be replaced.
In addition to the head dimensions, the exhaust
valves differ from intake valves in that they are Figure 183
equipped with a supplementary notch (1) obtained on
the stem for intake valves.

Figure 181

84184

The rated thickness A of the cylinder head is 95 ± 0,25

mm; maximum allowed metal removal must not ex-
ceed thickness B by 0.13 mm.
84182

Remove the thermostat unit (2) and brackets (1) and IMPORTANT -- After reconditioning, check valve
(3). hollow and recondition, if necessary, the valve
Checking the cylinder head supporting surface seats to obtain the prescribed hollow.
Figure 182
VALVES
Figure 184
EXHAUST INTAKE
VALVE VALVE

84183

The plane of the supporting surface of head (1) to cyl-

inder cluster is checked by means of a ruler (2) and
a thickness gauge (3).
The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
84185
If greater values are found, reface the cylinder head
according to the values and instructions given in the MAIN DATA OF INTAKE AND EXHAUST VALVES
next figure.
EW--3--94

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Valve descaling, check and grinding VALVE GUIDE

Figure 185 Figure 188

84186
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns. INTAKE EXHAUST
Reface, if necessary, the valve seats by means of
grinder 380000975, by removing as less material as 84046

possible. Use a bore gauge to measure the valve guide inner

Figure 186 diameter, which must be equal to the value shown in
the figure.

84187

Use a micrometer (2) to measure valve stem (1), VALVE SEATS

which must be equal to 7.96 to 7.98.
Valve seat reconditioning -- replacement
Checking the play between the valve stem,
Figure 189
valve guide and valve centring
Figure 187

84188
Check can be made by means of a magnetic com-
parator (1) placed as shown. Assembling play must
be equal to 0.039 to 0.079 mm.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
84189
Check valve seats (2). If slight burns or scoring are
found, proceed with reconditioning by means of tool
380000975 (1) according to the inclination values
shown in Figure 190.
 EW--3--95

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 190

INTAKE EXHAUST

84190

VALVE SEAT DIMENSIONS

Figure 191

INTAKE EXHAUST

86591

VALVE SEAT HOUSING DIMENSIONS

If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool 380000975 (1, Figure 189) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of tool 75301453, according to the values shown in Figure 190.
EW--3--96

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 192 MOUNTING THE CYLINDER HEAD

Figure 194

84180

Lubricate the valve stem and insert into the respective

valve guide according to the position marked upon
disassembling.
84192
Mount seal rings (1) onto the valve guide.
Figure 195
After the reconditioning operations, verify, by means
of base 380001000 (2) and comparator 380001004
(1), that valve hollow (3) corresponds to the specified
value.

VALVE SPRINGS
Figure 193

84179

Position spring (4) and upper collar (3) on the cylinder

head: use tool 380000987 (1) to compress spring (4)
and link the parts to the valve by means of lock cones
(2).
Reattaching the cylinder head
Figure 196

84193

MAIN DATA FOR INTAKE AND EXHAUST VALVE

SPRING CHECK
Prior to mounting, check the valve spring flexibility by
means of tool 380000976. Compare the elastic strain
and load data with those relative to the new springs
shown in the table below. 84113

Verify that the cylinder head attaching plane and the

crankcase attaching plane are both clean.
Height Under a load of Do not spoil the cylinder head gasket.
mm N
H (free) 63.50 No load IMPORTANT -- Prior to reusing the cylinder head
H1 49.02 P1 329 fastening screws, verify that they do not show
H2 38.20 P2 641 traces of wear or deformations; otherwise, replace
them.

ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Figure 197
84194
Mount the cylinder head on the crankcase by fasten-
ing screws (1) without torque--tightening them.
Figure 198
84209
Prior to inserting the pushrods, verify their state of
preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
take and exhaust valves are identical and, therefore,
they are interchangeable.
Rocker arm assembly
Figure 199
84195
PARTS MAKING UP THE ROCKER ARM ASSEM-
BLY:
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
EW--3--97
Figure 200
84196
MAIN DATA OF ARBOUR--ROCKER ARM
Verify that the arbour/rocker arm matching surfaces
do not show excessive wear or damages.
Figure 201
84197
Verify that the tappet adjusters are unscrewed to pre-
vent the latter from crawling on the rods when the
rocker arm assembly (1) is mounted. Mount the
rocker arm assembly made up of the arbours and
rocker arm support, then secure them to the head
without torque--tightening screws (2).
Figure 202
84198
Fasten the head screws (1) according to the instruc-
tions given Figure 203.
EW--3--98

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 203 Mounting the injectors

Figure 205

84199

Scheme of cylinder head fastening screw tightening

sequence:
- 1st phase: pre--fastening by means of a torque
wrench: 84201

screw M12 x 1.75 x 70 [ ] 50 Nm ± 5 Nm;

s

screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm;
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm;
- 2nd phase: angle tightening: 90°
- 3rdphase: angle tightening only for screws 140
and 180 mm long: 90°.
Mount a new seal ring (2) lubricated with petrolatum
and a new seal washer (3) on injector (1).
Mount the injectors on their seats on the cylinder
head, then tighten them by means of a torque wrench.

Figure 204 Figure 206

84200
Ad just the play between the rocker arms and the
valves by means of an Allen wrench (2), box wrench 84202

(3) and thickness gauge (1). Mount the injector feeding pipe assembly (1).
The operation play is: Mount the pipes for fuel discharge (2) from injectors,
-- intake valves: 0,25 ± 0,05 mm by using gaskets (3) and by tightening screws (4).
-- exhaust valves: 0,50 ± 0,05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--6, 2--5 and 3--4.
FIRING ORDER 1--5--3--6--2--4
Adjuting cylinder
1 5 3 6 2 4
valve no.
Adjusting clearance
6 2 4 1 5 3
of cylinder valve no.

ENGINE F4GE0684F -- F4HE0684J OVERHAUL
- Mount tappet covers (3);
- mount intake manifold unit (1);
- connect the engine oil vapour recovery pipe to
blow--by (2);
- mount injection pump (6);
- mount fuel filter support (10);
- mount fuel filters (8);
Figure 207
EW--3--99
- mount the injector feed pipes to injection pump
(6), then secure brackets (7) and (11) fastening
the pipe assembly onto the cylinder head;
- mount injection pump lubricating pipes;
- mount oil level check pipe;
- mount L.D.A. system piping (5);
- mount quick coupling pipes (9) by following the in-
dications given in Figure 208.
86496
EW--3--100

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 208 Figure 210

70126
86478

Act on fork (1) as shown in the figure (detail A), then - Mount starter motor (3);
remove the adapter. To avoid deformations, bring fork - montare la staffa fissaggio (2) ed il cablaggio
(1) back to the locking position (detail B) after the (1).
adapter has been removed.

Figure 209 Figure 211

86465 86479

- Mount exhaust manifold (2). - Mount thermostat unit (1) to cylinder head (3) by
- Mount turbine (1) by means of screws (3). torque--tightening screws (2).
- Mount water temperature sensor (4) by fastening
with a torque wrench.
 EW--3--101

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 212 Figure 214

???? 84082

Remove injectors (2) by means of tool 380000982 (1)

and take them off the cylinder head.

86481

Fit the Poli--V belt (1) on the crankshaft pulley, on the

guide pulleys, on the water pump and on the alterna-
tor; stretch the belt using the automatic take--up unit
(2).
Reassembling
Figure 215
REPLACING THE INJECTORS
Removal
Figure 213

86515 84201

Place the vehicle in safe conditions. Mount a new seal ring (2) lubricated with petrolatum
Lift the engine compartment cover, disconnect the and a new seal washer (3) on injector (1).
battery cables and proceed as follows: Mount the injectors on their seats on the cylinder
- disconnect engine oil vapour recovery pipe (2) head, then tighten them by means of a torque wrench.
from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).
EW--3--102

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Mount new seal rings (1) on fuel manifolds (2). Reassemble the tappet cover.
Connect the manifolds to the injectors, by tightening Re--connect the engine oil vapour recovery pipe to the
the fastening nuts to a torque of 50 Nm. blow--by.

Figure 216

86499
 EW--3--103

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ADJUSTING THE TAPPETS ROCKER ARM REMOVAL/REASSEMBLING

Figure 217 Removal
Figure 218

84200
84081
Ad just the play between the rocker arms and the Loosen tappet adjuster fastening nuts (3), then un-
valves by means of an Allen wrench (2), box wrench screw adjusters (2).
(3) and thickness gauge (1).
Remove screws (4) and dismount rocker arm assem-
The operation play is: bly (1) made up of the rocker arm support and ar-
-- ± 0,05 mm bours, then take off valves.
– intake valves: 0,25 ± 0,05 mm Reassembling
-- exhaust valves: 0,50 ± 0,05 mm. Verify that the tappet adjusters are unscrewed to pre-
Take the cylinder where clearance must be adjusted vent the latter from crawling on the rods when the
to the bursting phase; its valves are closed while bal- rocker arm assembly is mounted.
ancing the symmetric cylinder valves. Mount the rocker arm assemblies made up of rocker
Symmetric cylinders are 1--6, 2--5 and 3--4. arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
FIRING ORDER 1--5--3--6--2--4 torque of 36 Nm.
Adjuting cylinder Ad just the tappets as described above.
1 5 3 6 2 4
valve no.
Adjusting clearance
6 2 4 1 5 3
of cylinder valve no.

VALVE TIMING
Valve timing control is obtained by means of a Timing is obtained by making marks (⇐) (stamped on
straight--tooth gear force--fitted onto the drive shaft the same) to match.
rear shank which engages with the one fixed to the
distributing shaft.
Figure 219

84210
EW--3--104

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

ENGINE OVERHAUL AT THE BENCH F4HE0684J Figure 222

Disassembly of the engine
- Drain the engine oil removing the cap from the
sump.

Figure 220

86500

Disconnect the fuel hose (1) from the rail and from the
high pressure pump (5) and detach it removing the
lock screws (2).
70125

IMPORTANT -- When unlocking the pipe (2) union

In order to apply to the engine block the engine fixing (7), it is necessary to prevent the union (10) rotation
brackets to the stand for the overhaul, operating on the of the high--pressure pump (9), by using the proper
engine left side, it is necessary: wrench.
- to remove the fuel filter (5) from the support (1) by
means of tool 380000985;
- to remove the low pressure fuel pipe (2--3--4) from
the support (1); On the right side
- to remove the support (1) bracket from the block.

Figure 221 Figure 223

70126 70128

Remove the screws (2) and remove the oil pipe (3)
IMPORTANT -- In order to remove the low--pres-
from the supercharger pipe (1) and from the engine
sure fuel pipe (2--3--4, Figure 220) from the rele-
block.
vant connection unions, it is necessary to press
Remove the starting engine (5) from the flywheel cover
the fastener (1) as shown in figure B. After remov-
(4).
ing the pipe, position the fastener (1) into its lock
Apply to the block the bracket 380000995 and fix by
position, figure A, in order to avoid possible de-
means of these latter the engine to the revolving stand
formations.
380000978.
 EW--3--105

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 224

70129

1. Connections for injectors -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil
pressure and temperature sensor -- 5. Engine shaft sensor -- 6. Injector -- 7. Temperature--air pressure sensor
-- 8. Timing phase sensor -- 9. Fuel temperature sensor and fuel heater -- 10. Pressure adjuster -- 11. Control
unit EDC7

Disconnect the engine wire by disconnecting the con- Figure 225 (Demonstration)
nectors: (1) from the injector harness (6); (7) air tem-
perature /pressure sensor: (3) fuel pressure sensor;
(11) control unit; (10) high pressure pump sensor; (8)
timing phase sensor; (2) engine coolant temperature
sensor on thermostat (5) rpm sensor;

70236

Remove from the rail: the fuel pipe (7) according to the
procedures described in Figure 4. Remove the fuel
pipe (5) from the rail (2) and from the manifolds (6) for
injectors.

IMPORTANT -- During the unlocking operation of

the pipe (6) fixing unions (4) from the rail (2), it is
necessary to prevent the possible flow limiting de-
vice rotation (3) by means of a proper wrench.

Remove the screws (1) and the rail (2).

EW--3--106

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 226 Figure 228

70130 70132

Remove from the fuel return pressure limiting device
(1), the pipe (2) as described in Figure 221. Remove
the pipe (4) from the air supercharger (3) and from the
union (5). Remove the nut (10) Loosen the elastic
hose clamp (6) and remove the oil vapor pipe (9).Re-
move the unions (13--11) and remove the pipe (12).
Remove the nuts (7) and remove the tappet (8) cover
complete of gasket.
Loosen the tappet adjuster fixing nuts (1) and unscrew
the adjuster.
Remove the screws (2), remove the equalizer unit (3)
composed by the support (6), equalizers (4), shafts (5)
and remove the bonds (7) from the valves. Remove
the rods (8)

Figure 227

Figure 229

86501

Remove the nuts (7) and disconnect the electric wires

from the injectors (8). Remove the screws (1) and re-
move the injector harness support (2) complete of
gasket. Remove the screws (5) and remove the air
pressure/temperature sensor (6). Remove the nuts
(3) and withdraw the fuel manifolds (4). 70133

IMPORTANT -- The removed fuel manifold (4)

shall not be used again and they must be replaced Remove the injector fixing screws and by means of
by new ones. tool 380001099 (1) withdraw the injectors (2) from the
cylinder head.
 EW--3--107

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 230 Figure 231

86502 70511

Detach the conveyor (5) from the turboblower (1). Remove the lock screws (1) and detach the exhaust
Disconnect the oil hose from the heat exchange/oil manifold in two parts (2--3) with the related gaskets
filter support.
Remove the nuts (2) and detach the turboblower (1)
from the exhaust manifold (3).
Figure 232

86503

- Remove the automatic take--up device (5);
- remove the Poly--V belt (4);
- remove the conditioner compressor (1), the alter-
nator (3) and the fixed guide pulley (2);
- remove the fitting of the engine cooling system
from the engine block;
- remove the damper flywheel (6) with the pulley
underneath (7);
- remove the phonic wheel (8).
EW--3--108

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 233 Figure 236

86504

Remove the screws (1) and detach the air conveyor

(2) c/w heater. Remove the screws (4), remove the 72504

cover (3) and the thermostat below. Remove the cyl- Using tool 380000985, remove the oil filter (1).
inder head (6) lock screws (5).
Figure 237
IMPORTANT -- The outside screws highlighted
are shorter.

Figure 234 (Demonstration)

70141

Remove the screws (4) and disassemble the oil tem-

perature pressure sensor (3).
Remove the screws (1) and disassemble the support
70137
(2) oil filter heat exchanger , intermediate plate (6)
Attach the brackets (1) using metal ropes and using and related gaskets.
the lifting device detach the cylinders head (2) from
Remove the oil level sensor (5).
the engine block.
Figure 238
Figure 235

70142
72498
Remove the screws (1) and detach the electronic
Remove the cylinder head gasket (1). control unit (2) c/w heat exchanger.
 EW--3--109

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 239 Figure 242

70145
70149
Remove the nut (1) and disassemble the phase sen-
Remove the screws (1) and detach the front cover
sor (2).
(2).
Remove the nuts (3) and detach the high pressure
pump (4) c/w fuel pump (5). IMPORTANT -- Note the assembly position of the
screws (1) as they are of different length.
Figure 240
Figure 243

70146

Apply tool 380000990 (2) to the flywheel cover box

70150
(1) in order to block rotation of the flywheel (3). Loos-
en the screws (4). Remove the screws (1) and detach the oil pump (2).

Figure 241 IMPORTANT -- The oil pump (2) cannot be servi-

ced.

Figure 244

70148
Remove the screws (1) and detach the water pump 70151
(2).
Remove the screw (3) and disassemble the roller (4). Remove tool 380000990 (2).
Remove the screw (5) and detach the engine speed Remove the screws (1) that fasten the engine fly-
sensor (6). wheel (3) to the crankshaft (4).
EW--3--110

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 245 Figure 248

70152 86506

Screw two pins (2) of suitable length in the holes of Remove the screws (1) and (4) and disassemble the
the crankshaft (3). Slide out the engine flywheel (1) oil suction rose (5).
so that it can be rigged using the lifting device and Remove the screws (2) and disassemble the rein-
place it in the container. forcement plate (3).
Figure 249
Figure 246

70156
70153
Remove the screws (1) and disassemble the gear
Remove the screws (1) and detach the rear cover (3) from the camshaft (2).
(2).

IMPORTANT -- Note the assembly position of the Figure 250

screws (1) as they are of different size

Figure 247

70157

Remove the screws (2) and detach the timing gear

box (1).
86505

Turn the engine over, remove the screws (2) and de- IMPORTANT -- Note the assembly position of the
tach the oil sump (1) with the gasket underneath. screws (2) as they are of different size
 EW--3--111

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 251 Figure 253

70158
Remove the screws (1) that fasten the con--rod caps
(2) and disassemble these.
Slide out the pistons c/w con--rods from the upper
part of the engine block.
IMPORTANT -- Leave the bearing halves in their
respective housings as, if these are re--used, they
must be fitted in the position found during disas-
sembly
70160
The last but one main bearing cap (1) and the related
support have the bearing halves (2) with shoulder
IMPORTANT --Note the assembly position of the
lower and upper bearing halves as, if these are re--
used, they must be fitted in the position found dur-
ing disassembly.

Figure 252

Figure 254

70159 84086

Remove the screws (1) and disassemble the main Using tool 380000992 (1) and lifting device, remove
bearing caps (2). the crankshaft (2) from the engine block.
EW--3--112

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 255 Figure 257

70162 70164

Disassemble the main bearing halves (1). Remove the camshaft (1) carefully from the engine
Remove the screws (2) and disassemble the oil block.
sprayers (3).

Figure 256 Figure 258

70163 70165

Remove the screws (1) and disassemble the cam- Remove the tappets (1) from the engine block.
shaft (3) retention plate (2).
IMPORTANT -- Note the assembly position of the
plate (2).
 EW--3--113

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

REPAIR INTERVENTIONS Cam lift check and pin alignment check

CYLINDER GROUP Position the shaft on counterpoints and, by means of
Controls and measurements a centesimal gauge, located on the central support,
Figure 259 check that the alignment error is not higher than 0.04
mm: on the contrary, replace the shaft. Then, check
the cam lifting: it must result of 6.045 mm for the ex-
haust ones and of 7.582 mm for the suction ones; if
you detect different values, replace the shaft.

Figure 261
s

70166

Carefully clean the cylinder--block group, when per-

formed the engine disassembly.Use the proper rings
to transfer the cylinder group. Carefully check that
the block does not present any cracks. Check the
working plug conditions. Replace them if they are
rusty or in case of doubt about their conditions.
Examine the cylinder barrel surfaces; they must not
present any seizing, scoring, ovalization, taper, and
excessive wearing traces. The internal diameter
check of the cylinder barrels, to verify the ovalization,
taper and wearing entity, is performed by means of 70171
bore meter (1) equipped with comparator previously
set to zero on the ring gauge (2) of the cylinder barrel Check the camshaft (2) support pin diameter by
diameter. means of a micrometer (1) on two perpendicular sur-
faces.
IMPORTANT -- If you do not have at your disposal
the ring gauge, use a micrometer for the zero set- BUSHES
ting operation. Figure 262
Figure 260

70167
The measurements must be performed for each indi-
vidual cylinder at three different heights from the bar-
rel and on two perpendicular surfaces: one parallel
to the longitudinal engine axis (A) and the other one
perpendicular (B); usually the max wear is detected
on this latter surface and in correspondence with the
first measurement.If you detect any ovalization,
taper or wear, ream and grind the cylinder barrels.
The cylinder barrel regrinding must be performed in
relation to the diameter of the spare pistons over-
sized of 0.5 mm in respect of the nominal value and
prescribed assembling clearance.
70172
The camshaft bushes (2) must result forced in their
relevant seats.
The inner surfaces must result without seizing and
wearing traces.
By means of a bore meter (3), measure the diameter
of the rear and front bushes (2) and intermediate
seats (1) for camshaft.
The measurements must be performed on two per-
pendicular axes.
EW--3--114

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 263

sez. A-A

79460

MAIN DATA OF THE CAMSHAFT BUSHES AND RELEVANT SEATS

* Dimensions to be obtained after the bush driving

ENGINE F4GE0684F - F4HE0684J OVERHAUL
Figure 264
80585
IMPORTANT -- In the event of grinding operation,
all the barrels must result of the same oversize
(0.5 mm)
Check the bench bearing seats, proceeding as fol-
lows:
- mount the bench caps on the supports without
bearings;
- screw the fixing screws to the torque prescribed;
- by means of an adequate gauge, verify that the
internal diameter of the seats correspond to the
value prescribed.
If you detect a higher value, replace its block.
CAMSHAFT MAIN DATA
The data listed are refereed to the standard pin diameter.
The surfaces of the camshaft support pins and cams
must be very smooth;
EW--3--115
Head face check on the cylinder group
Figure 265
84088
Check that the head face, on the cylinder group,
does not present deformations. This check can be
carried out, after a previous grains (4) extraction by
means of a calibrated ruler (2) and feeler gauge (3).
After verified the deformation areas, perform the
flattening of the face by means of grinding machine.
The flatness error must not be higher than 0.075 mm.
IMPORTANT -- The block flattening could be per-
formed only after you have checked that, at fin-
ished work, the piston projection from the cylinder
barrel is not higher than the value prescribed.
Check the conditions of the working plugs (1) of the
cylinder groups; replace them if rusty or in case of
doubt about their conditions.
When flattening is finished, restore the cylinder bar-
rel bevel as shown in Figure 264.
TIMING SYSTEM
Camshaft
Figure 266
79459
if they present seizing and scoring traces, it is better
to replace the shaft and relevant bushes.
EW--3--116

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Bush replacement Fitting tappets – camshaft

Figure 267 Figure 269

70174 70176

To replace front and rear bushes (1), use for their re- Lubricate the tappets (1) and fit them into the rel-
moval and refitting the tool 380000991 (2) and hand- evant housings on the engine block.
grip 380000999 (3).
Figure 270

IMPORTANT -- When refitting bushes (1) direct

them so that lubrication holes coincide with engine
block housing holes.

70164

Lubricate the camshaft bushes and fit the camshaft

(1) taking care not to damage the bushes or the hou-
sings.
Tappets
Figure 268 Figure 271

70238

86507 Set camshaft (3) retaining plate (1) with the slot
MAIN DATA CONCERNING THE TAPPETS AND facing the top of the engine block and the marking
THE RELEVANT HOUSINGS ON THE ENGINE facing the operator, then tighten the screws (2) to the
BLOCK specified torque.
 EW--3--117

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 272 OUTPUT SHAFT

Measuring journals and crankpins
Figure 274

70179

Check camshaft end float (1). 70182

It shall be 0.23 ± 0.13 mm. Grind journals and crankpins if seizing, scoring or ex-
cessive ovalisation are found. Before grinding the
pins (2) measure them with a micrometer (1) to de-
Figure 273 cide the final diameter to which the pins are to be
ground.

IMPORTANT -- It is recommended to insert the

found values in the proper table. See Figure 275.

Undersize classes are: 0.250 – 0.500 mm

IMPORTANT -- Journals and crankpins shall al-

ways be ground to the same undersize class.
Journals and crankpins undersize shall be marked
on the side of the crank arm No.1.
For undersized crankpins: letter M
70180 For undersized journals: letter B
Fit nozzles (2) and tighten the fastening screws (1) For undersized crankpins and journals: letters MB
to the specified torque.

Figure 275

70514

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
EW--3--118

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 276

84091

MAIN TOLERANCES OF DRIVE SHAFT

TOLERANCES GRAPHIC SYMBOL
TOLERANCE--RELATED FEATURE
CONCERNING:
Roundness f
SHAPE
Cylindricality /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL

CRITICAL 
IMPORTANT
SECONDARY

Figure 277

BEARINGS ON TIMING INTERMEDI- FIRST

SIDE ATE BEARINGS BEARING ON
UPPER SIDE

84275
 EW--3--119

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Replacing oil pump control gear Finding journal clearance

Figure 278 Figure 280

84092

70184 Mount drive shaft (1).

Check that gear toothing (1) is not damaged or worn,
otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180°C for 10 min-
utes in an oven and then key it to the output shaft.
Check the play between the drive shaft journals and
their respective bearings by following the procedure
below:
Figure 281

Fitting main bearings

Figure 279

70186
- clean accurately the parts and remove any trace
of oil;
- position a piece of calibrated wire (3) on the out-
put shaft pins (4) so that it is parallel to the longi-
tudinal axis;
- fit caps (1), including the half bearings (2) on the
relevant supports.
Figure 282
70185

IMPORTANT -- Refit the main bearings that have

not been replaced, in the same position found at
removal.

Main bearings (1) are supplied spare with 0.250 –

0.500 mm undersize on the internal diameter.
IMPORTANT -- Do not try to adapt the bearings.

Clean accurately the main half bearings (1) having
the lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with
shoulder half rings.
70187
Tighten the pre--lubricated screws (1) in the following
three successive stages:
- 1st stage, with dynamometric wrench to 50 ± 6 Nm.
- 2nd stage, with dynamometric wrench to 80 ± 6
Nm.
EW--3--120

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 283 Checking output shaft shoulder clearance

Figure 285
α

70188

- 3rd stage, with tool 380001001 (1) set as shown

in the figure, tighten the screws (2) with 90° ± 5° 70190

angle. This check is performed by setting a magnetic--base

dial gauge (2) on the output shaft (3) as shown in the
figure, standard value is 0.068 – 0.41.
If higher value is found, replace main thrust half bear-
ings of the second last rear support (1) and repeat
the clearance check between output shaft pins and
main half bearings.

Figure 284 CONNECTING ROD – PISTON ASSEMBLY

Figure 286

70189 70191

- Remove caps from supports. CONNECTING ROD – PISTON ASSEMBLY

The backlash between the main bearings and the COMPONENTS
pins is found by comparing the width of the calibrated 1. Stop rings -- 2. Pin -- 3. Piston -- 4. Split rings --
wire (2) at the narrowest point with the scale on the 5. Screws -- 6. Half bearings -- 7. Connecting rod --
envelope (1) containing the calibrated wire. 8. Bush
The numbers on the scale indicate the backlash in
mm. IMPORTANT -- Pistons are supplied spare with
Replace the half bearings and repeat the check if a 0.5 mm oversize.
different backlash value is found. Once the specified
backlash is obtained, lubricate the main bearings
and fit the supports by tightening the fastening
screws as previously described.
 EW--3--121

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 287 Pistons

Measuring piston diameter
Figure 290

32613

Remove split rings (1) from piston (2) using pliers 32615
380000986 (3). Using a micrometer (2), measure the diameter of the
piston (1) to determine the assembly clearance.
Figure 288

IMPORTANT -- The diameter shall be measured

at 12 mm from the piston skirt.

Figure 291

32614

Piston pin (1) split rings (2) are removed using a

scriber (3).
70192

The clearance between the piston and the cylinder

barrel can be checked also with a feeler gauge (1)
as shown in the figure.
Figure 289

86497

MAIN DATA CONCERNING PISTON, PINS AND SPLIT RINGS

* Value measured on 99 mm diameter
EW--3--122

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Gudgeon pins Figure 295

Figure 292

32620

18857
Check the clearance between the sealing rings (3) of
the 2nd and 3rd slot and the relevant housings on the
To measure the piston pin (1) diameter use the piston (2), using a feeler gauge (1).
micrometer (2).

Conditions for proper pin--piston coupling

Figure 293

Figure 296

32619

Lubricate the pin (1) and its seat on piston hubs with
engine oil; the pin shall be fitted into the piston with
a slight finger pressure and shall not be withdrawn by
gravity.

Split rings

Figure 294

41104

DIAGRAM FOR MEASURING THE CLEARANCE

16552
Use a micrometer (1) to check split ring (2) thickness.
X BETWEEN THE FIRST PISTON SLOT AND
THE TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the
clearance between the slot and the ring shall be
measured as follows: make the piston (1) protrude
from the engine block so that the ring (2) protrudes
half--way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clear-
ance (X) between ring and slot: found value shall be
the specified one.
 EW--3--123

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 297 Figure 299

70194

Use feeler gauge (1) to measure the clearance be-

tween the ends of the split rings (2) fitted into the cyl-
inder barrel (3).

Connecting rods
Figure 298
80339

IMPORTANT -- Every connecting rod is marked as

follows:
- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necess-
ary to mark the new connecting rod with the
same numbers of the replaced one.
- On body with a letter showing the weight of the
connecting rod assembled at production:
S V, 1600 -- 1640 (yellow marking);
S W, 1641 -- 1680 (green marking);
S X, 1681 -- 1720 (blue marking);
Spare connecting rods are of the W class with
green marking*.
Material removal is not allowed.

Bushes
Check that the bush in the connecting rod small end
86498
is free from scoring or seizing and that it is not loosen.
MAIN DATA FOR CONNECTING ROD, BUSH, Otherwise replace.
PISTON PIN AND HALF BEARINGS
Removal and refitting shall be performed using the
* Value for inside diameter to be obtained after proper beater.
driving in connecting rod small end and grinding
When refitting take care to make coincide the oil
holes set on the bush with those set on the connect-
** Value not measurable in released condition
ing rod small end. Grind the bush to obtain the speci-
fied diameter.
IMPORTANT -- To obtain best coupling the con-
necting rod--cap coupling surfaces are knurled.
It is therefore recommended to not remove knur-
ling.
EW--3--124
ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Checking connecting rods
Figure 300
61696
Check that the axes of the connecting rods (1) are
parallel using tool 99395363 (5) as follows:
- fit the connecting rod (1) on tool 380001003 (5)
spindle and lock it with screw (4);
- set the spindle (3) on V--blocks by resting the
connecting rod (1) on the stop bar (2).
Checking torsion
Figure 301
61694
Check connecting rod (5) torsion by comparing two
points (A and B) of pin (3) on the horizontal plane of
the connecting rod axis. Position the dial gauge (2)
support (1) to obtain a preload of approx. 0.5 mm on
the pin (3) in point A and then set the dial gauge (2)
to zero. Move the spindle (4) with the connecting rod
(5) and compare any deviation on the opposite side
(B) of the pin (3): the difference between A and B
shall not exceed 0.08 mm.
Checking bending
Figure 302
61695
Check connecting rod (5) bending by comparing two
points C and D of the pin (3) on the vertical plane of
the connecting rod axis.
Position the vertical support (1) of the dial gauge (2)
to rest the latter on pin (3), point C.
Move the connecting rod forwards and backwards to
find pin top position, then in this condition reset the
dial gauge (2).
Move the spindle with the connecting rod (5) and re-
peat the check of the top point on the opposite side
D of the pin (3). The difference between point C and
point D shall not exceed 0.08 mm.
Fitting connecting rod--piston assembly
Connecting rod--piston coupling
Figure 303
86550
The piston crown is marked as follows:
1. Part number and design modification number;
2. Arrow showing piston assembling direction into
cylinder barrel, this arrow shall face the front key
of the engine block;
3. Manufacturing date.
4. Marking showing 1st slot insert testing;
 EW--3--125

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 304 IMPORTANT -- Split rings are supplied spare with

the following sizes:
- standard, yellow marking;
- 0.5 mm oversize, yellow/green marking;

Figure 307

86551

Connect piston (2) to connecting rod (4) with pin (3)

so that the reference arrow (1) for fitting the piston (2)
into the cylinder barrel and the numbers marked on
the connecting rod (5) are read as shown in the fi-
gure.
Figure 305
70200

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

IMPORTANT -- Refit the main bearings that have

not been replaced, in the same position found at
removal.
Do not try to adapt the half bearings.

Fitting connecting rod--piston assembly into

cylinder barrels
72705
Figure 308
Fit pin (1) split rings (2).
Fitting split rings

Figure 306

32613
Use pliers 99360183 (3) to fit the split rings (1) on the
piston (2).
Split rings shall be fitted with the marking “TOP”
facing upwards and their openings shall be displaced
with each other by 120°.
70201
Lubricate accurately the pistons, including the split
rings and the cylinder barrel inside.
Use band 380000994 (2) to fit the connecting rod--
piston assembly (1) into the cylinder barrels and
check the following:
- the number of each connecting rod shall corre-
spond to the cap coupling number.
EW--3--126

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 309 Figure 311

70202 70204

DIAGRAM FOR CONNECTING ROD--PISTON - lubricate the screws (1) with engine oil and then
ASSEMBLY FITTING INTO BARREL tighten them to the specified torque using the dy-
- split ring openings shall be displaced with each namometric wrench (2).
other by 120°;
- connecting rod--piston assemblies shall have the Figure 312
same weight;
- the arrow marked on the piston crown shall be α
facing the front side of the engine block or the slot
obtained on the piston skirt shall be correspon-
ding to the oil nozzle position.

Finding crankpin clearance

Figure 310 70205

- apply tool 380001001 (1) to the socket wrench

and tighten screws (2) of 60°.

Figure 313

70203

To measure the clearance proceed as follows:

- clean the parts accurately and remove any trace
of oil;
- set a piece of calibrated wire (2) on the output
70206
shaft pins (1); - remove the cap and find the existing clearance
- fit the connecting rod caps (3) with the relevant by comparing the calibrated wire width (1) with
half bearings (4). the scale on the wire envelope (2).

ENGINE F4GE0684F - F4HE0684J OVERHAUL
Figure 314
70207
If a different clearance value is found, replace the half
bearings and repeat the check. Once the specified
clearance has been obtained, lubricate the main half
bearings and fit them by tightening the connecting
rod cap fastening screws to the specified torque.
IMPORTANT -- Before the final fitting of the con-
necting rod cap fastening screws, check that their
diameter measured at the centre of the thread
length is not < 0.1 mm than the diameter
measured at approx. 10 mm from screw end.
Check manually that the connecting rods (1) are slid-
ing axially on the output shaft pins and that their end
float, measured with feeler gauge (2) is 0.10 – 0.33
mm..
Checking piston protrusion
Figure 315
70208
Once connecting rod--piston assemblies refitting is
over, use dial gauge 380001004 (1) fitted with base
380001000 (2) to check piston (3) protrusion at
T.D.C. with respect to the top of the engine block.
Protrusion shall be 0.28 – 0.52 mm.
EW--3--127
Timing gear case
Figure 316
70209
IVECO N. 2992545 SEALANT APPLICATION
AREAS
Clean accurately the timing gear case (1) and the en-
gine block. Perfect seal is only obtained by cleaning
accurately the surface to seal. Smear the case with
IVECO N. 2992545 to obtain a bead of few mm diam-
eter. It shall be uniform (no clots), without air bubbles,
thin areas or discontinuities. Any imperfection shall
be corrected as soon as possible. Avoid to use ex-
cess material to seal the joint. Excessive sealant
could come out from joint sides and cause lubricant
passage clogging. After applying the sealant, the
joint shall be assembled immediately (10 – 20 min-
utes).
Figure 317
70210
DIAGRAM FOR TIGHTENING THE REAR TIM-
ING GEAR CASE FASTENING SCREWS
Refit the case (1) to the engine block. Screw the
fastening screws in the same position found at re-
moval and tighten them to the following torque va-
lues in the sequence shown in the figure:
Screws M12 65 -- 89 Nm
Screws M8 20 -- 28 Nm
Screws M10 42 -- 52 Nm
EW--3--128

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Timing Flywheel housing

Figure 318 Figure 321

70211 70214

Use a felt pen to mark the driving gear (1) tooth fitted
on the output shaft (2) having the mark (→) for timing
on the side surface.
Figure 319
IVECO N. 2992545 SEALANT APPLICATION
AREAS
Clean accurately the flywheel housing (1) and timing
gear case coupling surfaces. Perfect seal is only ob-
tained by cleaning accurately the surface to seal.
Smear housing (1) with IVECO N. 2992545 to obtain
a bead of few mm diameter. It shall be uniform (no
clots), without air bubbles, thin areas or discontinu-
ities. Any imperfection shall be corrected as soon as
possible. Avoid to use excess material to seal the
joint. Excessive sealant could come out from joint
sides and cause lubricant passage clogging. After
applying the sealant, the joint shall be assembled im-
mediately (10 – 20 minutes).

70212
Figure 322
Direct the output shaft (4) and the camshaft (2) so
that when fitting the driven gear (1) on the camshaft
the marks on the gears (1 and 3) are coinciding.

Figure 320

70215

SEQUENCE FOR TIGHTENING THE FLYWHEEL

HOUSING FASTENING SCREWS
Refit the housing (1) to the engine block and screw
the fastening screws in the same position found at re-
70213 moval and tighten them to the following torque va-
Tighten the screws (1) fastening gear (2) to camshaft lues in the sequence shown in the figure:
(3) to the specified torque. Screws M12 75 -- 95 Nm
Screws M10 44 -- 53 Nm
 EW--3--129

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 323 Figure 325

70152
Screw two pins (2) having suitable length into shaft
70216 holes (3) and remove the engine flywheel (1) using
proper sling and hoister.
Apply tool 380000983 part (5) to the rear output shaft
tang (6), secure it by screws (4) and fit the new seal- Figure 326
ing ring (3).
Position part (1) on part (5), screw nut (2) until com-
pleting sealing ring (3) fitting into flywheel housing
(7).

ENGINE FLYWHEEL
Figure 324

70218
Tighten the screws (4) fastening the engine flywheel
(3) to the output shaft. Apply tool 380000990 (2) to
the flywheel housing (1) to stop engine flywheel (3)
rotation.
Figure 327

70217

Check clutch plate supporting surface and turn it if

scored.

IMPORTANT -- Engine flywheel rated thickness is

70,5 mm.

Replacing engine flywheel ring gear 70219

Check ring gear teeth (2), if breakage or excessive
wear is found remove the ring gear from the engine
flywheel (1, Figure 324) using a generic beater and
fit the new one, previously heated to 150 °C for 15 –
20 minutes. Chamfering on ring gear inside diameter
shall be facing the engine flywheel.
Tighten engine flywheel (2) fastening screws (1) in
two stages:
- 1st stage, tightening to 30 – 4 Nm torque with dy-
namometric wrench;
- 2nd stage, tightening to 60° ± 5° angle.
IMPORTANT -- Tightening to angle is performed
using tool 380001001.
EW--3--130

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 328 Figure 331

70223

70220
Remove the sealing ring (2) from the front cover (1),
Fit the oil pump (1). clean accurately the coupling surfaces and smear
them with IVECO N. 2992545.
Tighten the fastening screws (2) to the specified tor-
que. Figure 332
Figure 329

70224

70221 Clean accurately the front cover (2) surface and refit
it. Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1).
Figure 333

Figure 330

70225

Apply tool 380000983 part (5) to the front output

70222 shaft tang (6), secure it by screws (4) and fit the new
Fit the water pump (1). sealing ring (3). Position part (1) on part (5), screw
nut (2) until completing sealing ring (3) fitting into
Tighten the screws (2) to the specified torque. front cover (7).
 EW--3--131

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 334 Figure 336

86506 70363

Fit the plate (3), the rose pipe (5) and tighten the
fastening screws (1 -- 2 and 4) to the specified torque.
Fit the phonic wheel (1) and the hub (2) on the output
shaft.
Tighten the fastening screws (3) in two stages:
- 1st stage, tightening to 50 ± 5 Nm torque with dy-
namometric wrench;
- 2nd stage, tightening to 90° angle.

IMPORTANT -- Tightening to angle is performed

using tool 380001001(4).

Fit the damper flywheel (5) and the pulley (6).

Tighten the fastening screws (7) to 68 ± 7 Nm torque.

Figure 335 Figure 337

86505 70230

Fit the oil sump (1) and apply the plate (3) to the Fit a new sealing ring on the speed sensor (3).
gasket underneath. Fit the speed sensor (3) on the front cover (1) and
Tighten the screws (2) to the specified torque. tighten the screw (2) to the specified torque.
EW--3--132

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 338 Figure 340

70231 70234

Fit on the engine block: a new gasket (1), the heat ex-
changer (2) a new gasket (3) and the oil filter support
(4).
Tighten the screws (5) to the specified torque.
Position the alternator support (1) so that pins (3 and
4) are set against the engine block.
Tighten the screws (2) to the specified torque.
Figure 341

Figure 339

86509

Re--attach the conditioner (1)

Refit the alternator (2).
70232

Lubricate the sealing ring (2) with engine oil and set Figure 342
it on the oil filter (3).
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3)
by 3/4 turn.
Apply a new sealing ring on the oil temperature/pres-
sure sensor (4) and fit it on the support (1).
Tighten the screws (5) to the specified torque.
Fit a new sealing ring (6) in the engine block seat.

86510
Refit the automatic belt tensioner (2).
Tighten the screw (3) to the specified torque using
the proper wrench, turn the automatic belt tensioner
(2) to fit the belt (1) on pulleys and guide rollers.

ENGINE F4GE0684F - F4HE0684J OVERHAUL
Figure 343
70145
Refit the high pressure pump (5) including the feed
pump (6) and tighten the nuts (3) to the specified
torque. Fit the support (4) with a new sealing ring, the
timing sensor (2) with a new sealing ring and tighten
the relevant fastening nut (1) to the specified torque.
Figure 344
70320
Refit the ECU (3) including the heat exchanger to the
engine block and tighten the screws (2) to the speci-
fied torque.
IMPORTANT -- Replace support elastic elements
(1).
EW--3--133
CYLINDER HEAD
Removing the valves
Figure 345
70319
Intake (1) and exhaust (2) valves have heads with
the same diameter.
The central notch (→) of the exhaust valve (2) head
distinguishes it from the intake valve.
IMPORTANT -- Should cylinder head valves be
not replaced, number them before removing in
order to refit them in the same position.
A = intake side – S = exhaust side
Figure 346
70321
Valve removal shall be performed using tool
380000987 (1) and pressing the cap (3) so that when
compressing the springs (4) the cotters (2) can be re-
moved. Then remove the cap (3) and the springs (4).
Repeat this operation for all the valves.
Overturn the cylinder head and withdraw the valves
(5).
EW--3--134

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 347 Checking cylinder head supporting surface

Figure 349

70322

Remove the sealing rings (1 and 2) from the relevant

valve guides.
70324

IMPORTANT -- Sealing rings (1) for intake valves
are yellow.
Sealing rings (2) for exhaust valves are green.
Use a rule (2) and a feeler gauge (3) to check the cyl-
inder head (1) supporting surface.
Distortion found along the whole cylinder head shall
not exceed 0.20 mm.
If higher values are found grind the cylinder head ac-
cording to values and indications shown in the follow-
ing figure.

Checking cylinder head wet seal

Figure 348

Figure 350

70323

This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90°C
and 2 – 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the
proper beater for their removal/refitting. 70325

The rated thickness A for the cylinder head is 105 ±

0.25 mm, max. metal removal shall not exceed thick-
ness B by 0.13 mm.
IMPORTANT -- Before refitting, smear the plug
surfaces with water--repellent sealant.
IMPORTANT -- After grinding, check valve sink-
ing. Regrind the valve seats, if required, to obtain
Replace the cylinder head if leaks are found. the specified value.
 EW--3--135

ENGINE F4GE0684F - F4HE0684J OVERHAUL

VALVES Checking clearance between valve stem and

Figure 351 valve guide and valve centering
Figure 354
EXHAUST INTAKE
VALVE VALVE

70327

70326 Use a magnetic base dial gauge (1) set as shown in

INTAKE AND EXHAUST VALVE MAIN DATA the figure, the assembling clearance shall be 0.052
± 0.092 mm.
Removing carbon deposits, checking and
grinding valves Turn the valve (2) and check that the centering error
Figure 352 is not exceeding 0.03 mm.

18625

Remove carbon deposits from valves using the VALVE GUIDE

proper metal brush. Figure 355
Check that the valves show no signs of seizing, scor-
ing or cracking.
Regrind the valve seats, if required, using tool
99305018 and removing as less material as poss-
ible.
Figure 353

INTAKE EXHAUST
70328

18882 Use a bore dial gauge to measure the inside diam-

Check the valve stem (1) using a micrometer (2), it eter of the valve guides, the read value shall comply
shall be 6.970 ± 6.999. with the value shown in the figure.
EW--3--136

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

VALVE SEATS
Regrinding – replacing the valve seats
Figure 356

70330

Check the valve seats (2). If slight scoring or burnout

is found, regrind seats using tool 38000097 (1) ac-
cording to the angle values shown in Figure 357.

Figure 357

INTAKE
ASPIRAZIONE EXHAUST
SCARICO

85486

VALVE SEAT MAIN DATA

 EW--3--137

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 358

EXHAUST INTAKE

70332

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD

Should valve seats be not reset just by regrinding, re-
place them with the spare ones. Use tool 380000975
(Figure 356) to remove as much material as possible
from the valve seats (take care not to damage the cyl-
inder head) until they can be extracted from the cylin-
der head using a punch.
Heat the cylinder head to 80° -- 100°C and using the
proper beater, fit the new valve seats, previously
cooled, into the cylinder head.
Use tool 99305018 to regrind the valve seats accord-
ing to the values shown in Figure 357.

VALVE SPRINGS
Figure 359 Figure 360

50676

MAIN DATA TO CHECK INTAKE AND EXHAUST

VALVE SPRINGS
Before refitting use tool 380000976 to check spring
flexibility. Compare load and elastic deformation data
70333 with those of the new springs shown in the following
After regrinding, check that valve (3) sinking value is table.
the specified one by using the base 380001000 (2)
and the dial gauge 380001004 (1).
Height Under a load of
mm kg
H 47,75 Free
H1 35,33 P 339,8 ± 9 N
H2 25,2 P1 741 ± 39 N
EW--3--138

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

FITTING CYLINDER HEAD Refitting the cylinder head

Figure 361 Figure 363

70334 70335

Lubricate the valve stems (1) and fit them into the rel-
evant valve guides according to the position marked
at removal.
Fit the sealing rings (2 and 3) on the valve guide.
IMPORTANT -- Sealing rings (2) for intake valves
are yellow and sealing rings (3) for exhaust valves
are green.
Check cleanness of cylinder head and engine block
coupling surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking
“TOP” (1) facing the head.
The arrow shows the point where the gasket thick-
ness is given.

IMPORTANT -- Before reusing the cylinder head

fastening screws check whether they are free from
damages or distortions, otherwise replace.

Figure 362 Figure 364

77032 70336

Position on the cylinder head: the spring (4), the
upper cap (3); use tool 380000987 (1) to compress
the spring (4) and lock the parts to the valve (5) by
the cotters (2).
Refit the cylinder head (1), tighten the screws (2) in
three successive stages according to the sequence
and procedure shown in the following figure.
IMPORTANT -- Use tool 380001001 (3) to tighten
to angle.
 EW--3--139

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 365 Figure 367

70476 70339

Cylinder head fastening screw tightening sequence: Fit injectors (1) on the cylinder head seats, directed
- 1st stage pre--tightening, with dynamometric so that the fuel inlet hole (2) is facing the fuel manifold
wrench: seat (3) side.
• Screw 12x1.75x130 ( ) 35 ± 5 Nm
• Screw 12x1.75 x 150 ( ) 55 ± 5 Nm
s

- 2nd stage, tightening to 90° ± 5° angle

- 3rd stage, tightening to 90° ± 5° angle
A = front side

Figure 368

Fitting injectors
Figure 366

70338 70133

Fit a new sealing ring (2) lubricated with vaseline and Use tool 380001099 (1) to fit the injector (2) into its
a new sealing washer (3) on injector (1). seat.
Screw injector fastening screws without tightening
them.
EW--3--140

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 369 RODS

Figure 371

32655

Rocker control rods shall not be distorted; the ball

70341
Fit a new sealing ring (3) lubricated with vaseline on
the fuel manifold (2) and fit it into the cylinder head
seat so that the positioning ball (5) is coinciding with
the relevant housing (4).
IMPORTANT -- Removed fuel manifolds (2) shall
not be reused but replaced with new ones.
seats in touch with the rocker adjusting screw and
with tappets (arrows) shall not show seizing or wear;
otherwise replace them. Intake and exhaust valve
control rods are identical and are therefore inter-
changeable.
Rocker assembly
Figure 372

Screw the fastening nuts (2, Figure 370) without

locking them.
IMPORTANT -- During this operation, the injector
(1) shall be moved so that the manifold (2) is
properly inserted into the fuel inlet hole (2,
Figure 367).

70343

ROCKER ASSEMBLY COMPONENTS:

Figure 370 1. Screws -- 2. Bracket -- 3. Shafts -- 4. Rockers.

Figure 373

70342

Use the dynamometric wrench to tighten gradually 70344

and alternately the injector fastening screws (1) to
8.5 ± 0.8 Nm torque.
Tighten the fuel manifold (3) fastening nuts (2) to 50
Nm torque.
SHAFT--ROCKER MAIN DATA
Check that shaft/rocker coupling surfaces are not
showing excessive wear or damages.
 EW--3--141

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 374 Tappet clearance adjustment

Figure 376

70345 70520

Fit the rods (2). Adjust clearance between rockers and valves using
Position jumpers (1) on valves with marks (→) facing setscrew wrench (1), box wrench (3) and feeler
the exhaust manifold. gauge (2).
Working clearance shall be as follows:
-- intake valves 0.25 ± 0.05 mm
-- exhaust valves 0.51 ± 0.05 mm

IMPORTANT -- In order to more quickly perform

the operating clearance adjustment for rocker
arms – valves, proceed as follows:
rotate the drive shaft, balance cylinder 1 valves
and adjust the valves marked by the asterisk as
shown in the table:

Figure 375 cylinder n. 1 2 3 4 5 6

intake -- -- * -- * *
exhaust -- * -- * -- *

Rotate the drive shaft, balance cylinder 6 valves and adjust

the valves marked by the asterisk as shown in the table:

cylinder n. 1 2 3 4 5 6
intake * * -- * -- --
exhaust * -- * -- * --

70346

Check that tappet adjusters (1) are loosen to prevent

their balking on the rods (2, Figure 374) when refit-
ting the rocker assembly.
Then refit the rocker assembly consisting of: bracket
(5), rockers (3), shafts (4) and secure them to the cyl-
inder head by tightening the fastening screws (2) to
36 Nm torque.
EW--3--142

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 377 (Demonstration) Figure 379 (Demonstration)

70349 70351

Fit the rail (2) and tighten the screws (1) to the speci-
fied torque, connect the ground cable (3) to the in-
take manifold (4) and tighten the fastening nut (5) to
the specified torque.
IMPORTANT -- Pipe (7) connections shall be tigh-
tened to 20 Nm torque, using the proper wrench
(5) and the dynamometric wrench 3800001858
(4). Connections (6) shall be tightened by holding
the flow limiting valve hexagon (1) with the proper
wrench.

Connect the fuel pipe (3) to the rail (2) following the
procedure shown in the following figure.

Figure 378 (Demonstration) Figure 380

70350 70126

Connect new fuel pipes (1) to rail (3) and injector Press the clamp (1) in arrow direction (Figure B) and
manifolds (2). connect the pipe to the rail (2, Figure 379), reset the
clamp to the initial locking position “A”.

IMPORTANT -- When removed, pipes (1) shall al- IMPORTANT -- Check proper fuel pipe connec-
ways be replaced. tion.

ENGINE F4GE0684F - F4HE0684J OVERHAUL
Harness support
Figure 381
72501
Check the condition of the electric cables (5), if they
are damaged, replace by cutting the clips that fasten
them to the support (2) and removing the screws (4)
that fasten the connectors (3) to this.
Fit a new gasket (1) on the support (2).
Figure 382
70353
Fit the harness support (2), draw up the screws (1)
and tighten them to the prescribed torque.
Figure 383
70354
Connect the electric cables (1) to the electro--injec-
tors (3) and using torque wrench 380000158 (4)
tighten the lock nuts (2) to the prescribed torque.
EW--3--143
Figure 384
72502
Fit a new gasket (2) on the tappet cover (1).
Figure 385
72511
Fit the tappet cover (1), draw up the nuts (2) and
tighten them to the prescribed torque
Figure 386
86511
Re--attach the exhaust manifold (3) with new gas-
kets. Draw up the lock screws (6) and tighten them
to the prescribed torque.
Re--attach the turbo--blower (1) with a new gasket to
the exhaust manifold (3) and tighten the lock nuts (2)
to the prescribed torque.
Connect the oil hose (5) to the heat exchanger sup-
port (7) and to the turbocompressor (1). Attach the
oil duct (4) to the heat exchanger support.
EW--3--144

ENGINE F4GE0684F -- F4HE0684J OVERHAUL

Figure 387 Figure 389

86512 70126

Connect the air conveyor (2) to the turbo--blower (3) Press the clip (1) in the direction of the arrow (fig. B)
and secure it to this with the clip (1). and connect the pipe.
Return the clip to the initial clamping position A.

IMPORTANT -- Make sure the fuel hose is con-

nected correctly.

Figure 388

86513

With the fittings (13--15) and new copper washers,

connect the pipe (14) to the tappet cover (10) and to
the timing case (6).
Connect the pipe (7) to the fitting located on the tim-
ing box (6) and secure it with a clamp (8).
Fit the new snap ring on the fitting of the pipe (11) and
assemble it in the tappet cover (10).
Fasten the pipe (11) to the tappet cover (10) with the
bracket and nut (12), connect the pipe (4) to the fitting
(5) and to the air compressor (3).
Connect the pipe (2) to the pressure limiting device
(1) as shown in the figure below.
 EW--3--145

ENGINE F4GE0684F - F4HE0684J OVERHAUL

Figure 390

70129

70129

1. Injector connections -- 2. Engine coolant temperature sensor -- 3. Fuel pressure sensor -- 4. Engine oil
temperature and pressure sensor -- 5. Output shaft sensor -- 6. Injector -- 7. Air temperature/pressure sen-
sor -- 8. Timing sensor -- 9. Fuel heater and fuel temperature sensor -- 10. Pressure regulator -- 11. Control
unit

Reconnect the engine cable by connecting injector
wiring (6) connectors (1); (7) air pressure/temperature
sensor; (3) rail pressure sensor; (11) control unit; (10)
high pressure pump sensor; (8) timing sensor; (2) en-
gine coolant temperature sensor on thermostat; (5)
engine speed sensor.
Apply to engine lifting hooks the lifting rig 380000216,
hook the latter to the hoister and remove the engine
from the revolving stand. Remove the brackets
380000995.
EW--3--146
ENGINE F4GE0684F -- F4HE0684J OVERHAUL
Figure 391
70128
Complete engine refitting as follows:
Form the right side:
Refit the starter (5) to the flywheel housing (4) and
tighten the fastening nuts to the specified torque.
Fit the oil pipe (3) with a new sealing ring into the en-
gine block and secure it to the turbosupercharger (1)
by the screws (2) tightened to the specified torque.
Figure 392
70362
Refit the bracket (2) including the fuel filter support
(1) to the engine block, tighten the screws (3) to the
specified torque.
Figure 393
70125
Screw manually the fuel filter to the support (1),
screw the filter by ¾ turn, connect the pipes (2--3--4)
to the relevant support connections (1) as shown in
the following figure.
Figure 394
70126
Press the clamp (1) as shown in figure B.
After disconnecting the pipe, reset the clamp (1) to
the initial locking position A, to prevent deformations.
When refitting is over, fill engine with the prescribed
lubricating oil in the specified quantity.
SECTION 4

RECHARGE AND START--UP

INDEX
Starter motor . . . . . . . . . . . . . . . . . . . . . EW--4--3 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . EW--4--5

Quick diagnosis . . . . . . . . . . . . . . . . . . . . EW--4--3 Quick diagnosis . . . . . . . . . . . . . . . . . . . . EW--4--5

Bosch 24 V -- 4 kW . . . . . . . . . . . . . . . . . EW--4--4 Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--4--6

INDEX
 EW--4--3

RECHARGE AND START--UP

STARTER MOTOR

BOSCH -- 24 V -- 4 kW

Quick diagnosis

Fault Possible causes Remedy

Dragging torque insufficient 1. Batteries run down Restore

Dragging torque sufficient, but
the engine won’t start.
Pinion won’t engage.
2. Circuit connections oxidized or
loose
3. Brushes not in working order
4. Short--circuited field windings
5. Interruptedor short circuited ar-
mature
6. Out--of--round collector
1. Free wheel or faulty electro--ma-
gnet
1. Bevelled ring gear
Replace the component
Replace the component
Replace the component
Replace the component
Replace the component
Replace the component
Restore
EW--4--4

RECHARGE AND START--UP

Bosch 24 V -- 4 kW
6--pole type with series excitation and engagement by means of a fork controlled by an electromagnet.
Clockwise direction of rotation
Rated voltage 24 V
Power 4 kW

84262 84267

WIRING DIAGRAM 3/4 VIEW

84268 84269

CHARACTERISTIC CURVES PINION ADJUSTER

 EW--4--5

RECHARGE AND START--UP

ALTERNATOR

BOSCH NCBI 28 V 35--70 A

Quick diagnosis

Fault Possible causes Remedy

No recharge 1. Interruption of recharge circuit Check the recharge circuit con-

(warning light, fuse, connector,
etc.)
2. Voltage regulator not in wor-
king order
3. Interrupted rotor winding
4. Worn brushes
nections, clean and tighten the
cable terminals on the alterna-
tor and battery
Replace the component
Replace the component
Replace the component

Poor recharge 1. Loose belt Apply correct tension

2. Faulty voltage regulator
3. Excessive wear of rotor rings
or brushes
4. Short--circuited diodes
5. Short--circuited rotor winding(s)
Replace the component
Replace the component
Replace the component
Replace the component

Excessive recharge 1. Loose circuit connections Check the connections to ter-

minals and cable terminals of
batteries, starter motor and al-
ternator
2. Voltage regulator not in wor- Replace the component
king order
3. Earth fault Check earth connections
EW--4--6

RECHARGE AND START--UP

Bosch NCBI 28 V 35--70 A

Thrre--phase type, claw--type rotor, 11--diode rectifier and electronic voltage regulator.
Direction of rotation (control side) clockwise
Current delivered at 6.000 min --1 ≥ 55A
Rated voltage 28,5V

84270 84271

WIRING DIAGRAM 3/4 VIEW

84272 84274

CHARACTERISTIC CURVES OF CURRENT CHARACTERISTIC CURVES OF VOLTAGE

DELIVERY REGULATOR