New Holland Service Manual lb115

SERVICE MANUAL
F4CE9484 / F4CE9487A / F4CE9487N /

F4CE9684 / F4DE9484 / F4DE9684B*J111 /
F4DE9684M*J101 / F4DE9684M*J103 /
F4DE9684 / F4DE9687 / F4GE9484C*J601 /
F4GE9484 / F4GE9684 / F4HE0484G*J102 /
F4HE0484G*J109 / F4HE9484C*J102 /
F4HE9484C*J103 / F4HE9484 / F4HE9684 /
F4HE9687G*J100 / F4HE9687
NEF Tier 3
Engine
Part number 47597675

1st edition English
October 2013
Printed in U.S.A.
Copyright © 2013 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
Mechanical fuel injection / Structural engine block
F4CE9454H*J601 F4CE9484J*J602 F4CE9484M*J603 F4CE9487M*J605 F4CE9684J*J601
F4CE9454H*J605 F4CE9484J*J604 F4CE9484M*J606 F4CE9487N*J601 F4CE9684J*J606
F4CE9484A*J600 F4CE9484L*J600 F4CE9484M*J607 F4CE9487N*J602 F4CE9684J*J607
F4CE9484A*J602 F4CE9484L*J602 F4CE9484M*J608 F4CE9487N*J603 F4CE9684J*J609
F4CE9484C*J600 F4CE9484L*J603 F4CE9484N*J601 F4CE9487N*J605 F4CE9684K*J601
F4CE9484C*J601 F4CE9484L*J604 F4CE9484N*J604 F4CE9487N*J606 F4CE9684K*J606
F4CE9484G*J600 F4CE9484L*J605 F4CE9487A*J600 F4CE9684B*J600 F4CE9684K*J607
F4CE9484G*J604 F4CE9484L*J606 F4CE9487A*J601 F4CE9684C*J600 F4CE9684K*J608
F4CE9484G*J607 F4CE9484M*J601 F4CE9487M*J602 F4CE9684H*J603 F4CE9684L*J600
F4CE9484G*J608 F4CE9484M*J602 F4CE9487M*J603 F4CE9684H*J604 F4CE9684L*J605
Mechanical fuel injection / Non-structural engine block

F4GE9454C*J601 F4GE9484C*J603 F4GE9484F*J615 F4GE9684C*J602 F4GE9684F*J604
F4GE9454C*J602 F4GE9484C*J605 F4GE9484H*J600 F4GE9684D*J600 F4GE9684G*J600
F4GE9454C*J607 F4GE9484C*J606 F4GE9484J*J600 F4GE9684D*J603 F4GE9684G*J601
F4GE9454C*J608 F4GE9484C*J607 F4GE9484J*J601 F4GE9684D*J604 F4GE9684G*J602
F4GE9454J*J605 F4GE9484D*J600 F4GE9484J*J603 F4GE9684E*J600 F4GE9684G*J603
F4GE9454J*J607 F4GE9484D*J603 F4GE9484J*J604 F4GE9684E*J601 F4GE9684G*J605
F4GE9454K*J602 F4GE9484D*J606 F4GE9484J*J605 F4GE9684E*J603 F4GE9684G*J606
F4GE9454K*J604 F4GE9484D*J607 F4GE9484P*J600 F4GE9684E*J604 F4GE9684H*J600
F4GE9454K*J605 F4GE9484D*J617 F4GE9484P*J601 F4GE9684E*J605 F4GE9684H*J601
F4GE9484A*J602 F4GE9484D*J618 F4GE9684A*J603 F4GE9684E*J606 F4GE9684R*J600
F4GE9484A*J605 F4GE9484D*J619 F4GE9684A*J605 F4GE9684E*J607 F4GE9684R*J601
F4GE9484A*J607 F4GE9484D*J620 F4GE9684B*J601 F4GE9684E*J610 F4GE9684R*J602
F4GE9484A*J608 F4GE9484E*J600 F4GE9684B*J602 F4GE9684E*J611 F4GE9684R*J603
F4GE9484A*J612 F4GE9484E*J603 F4GE9684B*J606 F4GE9684E*J615
F4GE9484C*J600 F4GE9484F*J600 F4GE9684B*J607 F4GE9684F*J600
F4GE9484C*J601 F4GE9484F*J610 F4GE9684C*J600 F4GE9684F*J602
F4GE9484C*J602 F4GE9484F*J614 F4GE9684C*J601 F4GE9684F*J603
Electronic fuel injection / Structural engine block
F4DE0484B*J100 F4DE9684B*J100 F4DE9684J*J101 F4DE9684R*J103 F4DE9687J*J104
F4DE0484C*J100 F4DE9684B*J101 F4DE9684J*J102 F4DE9684R*J104 F4DE9687R*J101
F4DE9484A*J100 F4DE9684B*J102 F4DE9684J*J104 F4DE9684R*J105 F4DE9687U*J100
F4DE9484A*J103 F4DE9684B*J104 F4DE9684J*J105 F4DE9684S*J100 F4DE9687U*J102
F4DE9484A*J104 F4DE9684B*J106 F4DE9684L*J100 F4DE9684S*J103 F4DE9687V*J100
F4DE9484B*J101 F4DE9684B*J107 F4DE9684L*J103 F4DE9684S*J106 F4DE9687V*J101
F4DE9484D*J101 F4DE9684B*J108 F4DE9684L*J106 F4DE9684S*J107 F4DE9687V*J104
F4DE9484E*J100 F4DE9684B*J109 F4DE9684L*J107 F4DE9684U*J100 F4DE9687X*J100
F4DE9484F*J100 F4DE9684B*J110 F4DE9684L*J108 F4DE9684Y*J100 F4DE9687X*J101
F4DE9484F*J101 F4DE9684B*J111 F4DE9684L*J109 F4DE9684Y*J101 F4DE9687X*J102
F4DE9484G*J100 F4DE9684C*J100 F4DE9684M*J100 F4DE9684Y*J102 F4DE9687X*J103
F4DE9484H*J100 F4DE9684D*J100 F4DE9684M*J101 F4DE9684Z*J102 F4DE9687X*J104
F4DE9487A*J103 F4DE9684E*J100 F4DE9684M*J103 F4DE9687A*J100 F4DE9687X*J105
F4DE9487A*J104 F4DE9684F*J100 F4DE9684N*J100 F4DE9687A*J103 F4DE9687X*J106
F4DE9487B*J100 F4DE9684F*J102 F4DE9684N*J104 F4DE9687A*J104 F4DE9687Y*J100
F4DE9487B*J101 F4DE9684G*J100 F4DE9684N*J107 F4DE9687C*J100 F4DE9687Y*J101
F4DE9487C*J100 F4DE9684G*J101 F4DE9684N*J108 F4DE9687J*J100 F4DE9687Y*J102
F4DE9487D*J101 F4DE9684H*J100 F4DE9684R*J100 F4DE9687J*J101
F4DE9487L*J100 F4DE9684J*J100 F4DE9684R*J102 F4DE9687J*J102
Electronic fuel injection / Non-structural engine block

F4HE0454D*J102 F4HE9484F*J105 F4HE9684E*J104 F4HE9684S*J102 F4HE9687L*J100
F4HE0454D*J104 F4HE9484F*J106 F4HE9684E*J106 F4HE9684S*J103 F4HE9687L*J101
F4HE0484A*J101 F4HE9484M*J100 F4HE9684E*J107 F4HE9684T*J100 F4HE9687M*J101
F4HE0484A*J103 F4HE9484M*J101 F4HE9684F*J100 F4HE9684T*J101 F4HE9687M*J103
F4HE0484G*J100 F4HE9684B*J100 F4HE9684F*J102 F4HE9684U*J101 F4HE9687M*J104
F4HE0484G*J101 F4HE9684B*J101 F4HE9684F*J103 F4HE9684U*J103 F4HE9687M*J105
F4HE0484G*J102 F4HE9684B*J103 F4HE9684F*J104 F4HE9684V*J102 F4HE9687N*J101
F4HE0484G*J103 F4HE9684B*J104 F4HE9684F*J105 F4HE9684V*J103 F4HE9687N*J103
F4HE0484G*J105 F4HE9684C*J100 F4HE9684F*J107 F4HE9687C*J100 F4HE9687N*J104
F4HE0484G*J106 F4HE9684C*J101 F4HE9684F*J108 F4HE9687C*J101 F4HE9687P*J101
F4HE0484G*J108 F4HE9684C*J102 F4HE9684F*J109 F4HE9687C*J103 F4HE9687Q*J101
F4HE0484G*J109 F4HE9684C*J104 F4HE9684J*J100 F4HE9687F*J100 F4HE9687Q*J103
F4HE0484G*J110 F4HE9684C*J105 F4HE9684J*J101 F4HE9687F*J101 F4HE9687S*J101
F4HE0684T*J100 F4HE9684C*J106 F4HE9684J*J102 F4HE9687G*J100 F4HE9687S*J103
F4HE0684T*J101 F4HE9684D*J100 F4HE9684J*J104 F4HE9687G*J101 F4HE9687S*J104
F4HE0684T*J103 F4HE9684D*J101 F4HE9684J*J106 F4HE9687G*J102 F4HE9687S*J105
F4HE9484C*J100 F4HE9684D*J102 F4HE9684K*J100 F4HE9687G*J104 F4HE9687T*J101
F4HE9484C*J102 F4HE9684D*J103 F4HE9684K*J102 F4HE9687H*J100 F4HE9687T*J103
F4HE9484C*J103 F4HE9684D*J105 F4HE9684L*J101 F4HE9687H*J101 F4HE9687T*J104
F4HE9484C*J104 F4HE9684D*J106 F4HE9684L*J102 F4HE9687H*J102 F4HE9687W*J100
F4HE9484C*J105 F4HE9684D*J107 F4HE9684M*J100 F4HE9687H*J103 F4HE9687W*J101
F4HE9484C*J106 F4HE9684D*J109 F4HE9684M*J101 F4HE9687K*J100 F4HE9687W*J102
F4HE9484C*J107 F4HE9684E*J100 F4HE9684P*J102 F4HE9687K*J101 F4HE9687Z*J100
F4HE9484C*J108 F4HE9684E*J101 F4HE9684P*J103 F4HE9687K*J102 F4HE9687Z*J101
F4HE9484F*J103 F4HE9684E*J102 F4HE9684S*J100 F4HE9687K*J103
F4HE9484F*J104 F4HE9684E*J103 F4HE9684S*J101 F4HE9687K*J105
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Electrical systems ....................................................................... 55

[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
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[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
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INTRODUCTION
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Contents
INTRODUCTION
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687,
F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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INTRODUCTION
Foreword
Engine Overhaul
Part of the operations illustrated within this manual can be partially executed while the engine is assembled on the
vehicle, depending on the room available for access to the engine and on the equipment application as well.
NOTE: With regard to the engine disassembly operations, please apply for information consulting the specific manual.
The following information relates to the engine overhaul operations only for what concerns the different components
customizing the engine, according to its specific duties.
In section "General Overhaul", all the operations of engine block overhaul have been contemplated. Therefore the
above mentioned section is to be considered as following the part hereby described.
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INTRODUCTION
Safety rules
Standard safety prescriptions
Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working
area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the
personnel in charge of maintenance.
Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation
available for consultation.
• Keep working areas as clean as possible, ensuring adequate aeration.
• Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided
with adequate sanitary equipment.
• Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency
must be checked on a regular basis and the personnel must be trained on interventon methods and priorities.
• Organize and identify specific exit points to evacuate the areas in case of an emergency, providing for adequate
indications of the emergency indications of the emergency exit lines.
• Smoking in working areas subject to fire danger must be strictly prohibited.
• Provide warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy com-
prehension of the instructions even in case of an emergency.
Prevention of injury
• Do not wear unsuitable clothes for work, with fluttering ends, nor jewels such as and chains when working close to
engines and equipment in motion.
• Wear safety gloves and goggles when performing the following operations:
• • filling inhibitors or anti-frost

• lubrication oil topping or replacement
• utilization of compressed air or liquids under pressure (pressure allowed < 2 bar (29 psi)).
• Wear safety helmet when working close to hanging loads or equipment working at head height level.
• Always wear safety shoes and clothes adhering to the body, better if provided with elastics at the ends.
• Use protection cream for hands.
• Change wet clothes as soon as possible.
• In presence of electrical current exceeding 48 - 60 V verify efficiency of earth and mass electrical connections.
Ensure that hands and feet are dry and execute working operations utilizing isolating foot boards. Do not carry out
working operations if not trained for.
• Do not smoke nor light up flames close to batteries and to any fuel material.
• Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.
• Do not execute any intervention if not provided with necessary instructions.
• Do not use any tool or equipment for any different operation from the ones they've been designed and provided for.
Serious injury may occur.
• In case of test or calibration operations requiring engine running, ensure that the area is sufficiently ventilated or
utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning or death.
During maintenance
• Never open filler cap of cooling system when the engine is hot. Operating pressure would provoke high temperature
with serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F).
• Never top up an overheated engine with cooler and utilize only appropriate liquids.
• Always operate when the engine is tuned off; when particular circumstances require maintenance intervention on
running engine, be aware of all risks involved with such operation.
• Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.
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INTRODUCTION
• Keep the engine clean from oil spills, diesel fuel and or chemical solvents.
• Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas venti-
lated. Whenever necessary wear safety mask.
• Do not leave rags impregnated with flammable substances close to the engine.
• Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of a runaway
speed rate.
• Do not utilize fast screw tightening tools.
• Never disconnect batteries when the engine is running.
• Disconnect batteries before any intervention on the electrical system.
• Disconnect batteries from system before applying a load to them with the battery loader.
• After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from
accidental short circuit and oxidation.
• Do not disconnect and connect electrical connections in presence of electrical feed.
• Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air
under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves.
Always wear adequate safety mask or goggles. Non fulfillment of these precautions may cause serious injury and
poisoning.
• Avoid incorrect tightening or out of sequence. Danger: incorrect tightening may seriously damage engine's com-
ponents, affecting engine's duration.
• Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters.
• Do not modify cable wires: their lengths shall not be changed.
• Do not connect to the engine electrical equipment unless specifically approved by Iveco.
• Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized
modification will compromise warranty assistance and furthermore may affect engine correct working and duration.
For engines equipped with electronic controller:

• Do not execute electric arc welding without having previously removed electronic controller.
• Remove electronic controller in case of any intervention requiring heating over 80 °C (176 °F) temperature.
• Do not paint the components and the electronic connections.
• Do not vary or alter any data filed in the electronic controller driving the engine. Any manipulation or alteration
of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine
correct working and duration.
Respect of the Environment

• Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel's safety
and health shall be adopted.
• Be informed and inform personnel as well of the laws in force regulating use and exhaust of liquids and engine
drain oil. Provide for adequate board indications and organic specific training courses to ensure that personnel is
fully aware of such law prescriptions and of basic preventative safety measures.
• Collect drain oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in
specific, properly identified areas that shall be ventilated far from heat sources and not exposed to fire danger,
• Handle the batteries with care, storing them in ventilated environment and within anti-acid containers. Warning:
Battery exhalation represent serious danger of intoxication and environment contamination.
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INTRODUCTION
Torque
F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687,
F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
Component Size Specification

Cylinder Head and Components
Plug ¼" 10 - 14 Nm (7.4 - 10.3 lb ft)
½" 20 - 28 Nm (14.8 - 20.7 lb ft)
¾" 31 - 41 Nm (22.9 - 30.2 lb ft)
Grid Heater M6 Nut 6 - 10 Nm (4.4 - 7.4 lb ft)
Intake Manifold M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Engine Lifting Bracket
Rear M12 65 - 89 Nm (47.9 - 65.6 lb ft)
Front M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Cylinder Head M12x1.75x130 mm
First Phase 30 - 40 Nm (22.1 - 29.5 lb ft)
Second Phase 85 - 95 °
Third Phase 85 - 95 °
Cylinder Head M12x1.75x150 mm
Rocker Bracket 31 - 41 Nm (22.9 - 30.2 lb ft)
Rocker Arm Jam Nuts 20 - 28 Nm (14.8 - 20.7 lb ft)
Exhaust Manifold 48 - 58 Nm (35.4 - 42.8 lb ft)
Valve Cover M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Turbocharger
6 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 37 - 49 Nm (27.3 - 36.1 lb ft)
4 Cylinder M8 Screw 6 - 8 Nm (4.4 - 5.9 lb ft)
M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Front Case
Front Cover M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Rear Case
Gear Case M12 Screw 65 - 89 Nm (47.9 - 65.6 lb ft)
M10 Screw 42 - 52 Nm (31.0 - 38.4 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Flywheel Housing M10 75 - 95 Nm (55.3 - 70.1 lb ft)
M12 44 - 54 Nm (32.5 - 39.8 lb ft)
Cylinder Block and Crankshaft Components
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INTRODUCTION

Camshaft Retaining Plate M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Camshaft Gear M8 Screw 32 - 40 Nm (23.6 - 29.5 lb ft)
Crankcase Plate M10 Screw 38 - 48 Nm (28.0 - 35.4 lb ft)
Vibration Damper and Adapter M12
Second Phase 90 °
Drive Pulley M10 61 - 75 Nm (45.0 - 55.3 lb ft)
Engine Flywheel M12
Main Caps M12
Second Phase 74 - 86 Nm (54.6 - 63.4 lb ft)
Connecting Rod Caps
Lubrication System and Components
Oil Pump
First Phase M8 7 - 9 Nm (5.2 - 6.6 lb ft)
Second Phase M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Pressure Relief Valve M22 72 - 88 Nm (53.1 - 64.9 lb ft)
Oil Cooler and Oil Filter Base M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Filter Contact + ¾ Turn
Connection on Filter Base for Turbo Oil 1 ⅛" 20 - 28 Nm (14.8 - 20.7 lb ft)
Supply
Turbo Lubrication Pipe M12 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
Turbo Lubrication Pipe Adapter M12 30 - 40 Nm (22.1 - 29.5 lb ft)
Oil Pan 20 - 28 Nm (14.8 - 20.7 lb ft)
Piston Spray Nozzles M8 12 - 18 Nm (8.9 - 13.3 lb ft)
Electrical Components
Camshaft Sensor M6 Studs 6 - 10 Nm (4.4 - 7.4 lb ft)
M6 Nut 8 - 12 Nm (5.9 - 8.9 lb ft)
M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Wiring Bulkhead M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Support Bracket for Injector Wiring M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector Wiring 1.25 - 1.75 Nm (0.92 - 1.29 lb ft)
ECU Cooling Plate M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Outlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Fuel Inlet M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Crankshaft Speed Sensor M6 Screw 6 - 10 Nm (4.4 - 7.4 lb ft)
Coolant Temperature Sensor M14 Screw 17 - 23 Nm (12.5 - 17.0 lb ft)
Oil Pressure / Temperature Sensor M5 Screw 5 - 7 Nm (3.7 - 5.2 lb ft)
Fuel Pressure Sensor 30 - 40 Nm (22.1 - 29.5 lb ft)
Fuel Temperature Sensor M14 17 - 23 Nm (12.5 - 17.0 lb ft)
Air Pressure / Temperature Sensor 5 - 7 Nm (3.7 - 5.2 lb ft)
Engine Oil Level Sensor M12 10 - 14 Nm (7.4 - 10.3 lb ft)
Alternator Support Bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Alternator Tension Bracket M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Starter 37 - 49 Nm (27.3 - 36.1 lb ft)
Fuel System and Components
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INTRODUCTION

Feed Pump M8 Studs 10 - 14 Nm (7.4 - 10.3 lb ft)
High Pressure Pump Gear M18 Nut 100 - 110 Nm (73.8 - 81.1 lb ft)
Fuel Pump M8 Nut 20 - 28 Nm (14.8 - 20.7 lb ft)
Injector
First Phase M6 Screw 8.15 - 8.85 Nm (6.0 - 6.5 lb ft)
Second Phase M6 Screw 70 - 80 °
Injector Feed Connector 45 - 55 Nm (33.2 - 40.6 lb ft)
Common Rail M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
High Pressure Fuel Line M14 Fitting 18 - 22 Nm (13.3 - 16.2 lb ft)
High Pressure Pipe Connector M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Filter Bracket M12 Screw 71 - 85 Nm (52.4 - 62.7 lb ft)
Fuel Filter Holder M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Fuel Filter Contact + ¾ Turn
Cooling System and Components
Engine Coolant Inlet M10 Screw 37 - 49 Nm (27.3 - 36.1 lb ft)
Fitting on Coolant Inlet 90 ° Elbow 20 - 28 Nm (14.8 - 20.7 lb ft)
Compressor Cooling Pipe 20 - 24 Nm (14.8 - 17.7 lb ft)
Engine Coolant Drain Collector M6 Screw 8 - 12 Nm (5.9 - 8.9 lb ft)
Water Pump M8 Screw 20 - 28 Nm (14.8 - 20.7 lb ft)
Belt Tensioner M10 37 - 49 Nm (27.3 - 36.1 lb ft)
Idler Pulleys M10 37 - 49 Nm (27.3 - 36.1 lb ft)
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INTRODUCTION
Torque

Rocker Assembly M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Cylinder Head M12x70
Phase 1 50 Nm (36.9 lb ft)
Phase 2 90 °
Phase 2 180 °
Phase 2 180 °
Valve Cover M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
Intake manifold M8x1.25 20 - 28 Nm (14.8 - 20.7 lb ft)
Air intake elbow M8x1.25 20 - 28 Nm (14.8 - 20.7 lb ft)
Exhaust manifold M10x1.5x65 37 - 49 Nm (27.3 - 36.1 lb ft)
Rear lifting bracket M12x1.75x30 65 - 89 Nm (47.9 - 65.6 lb ft)
Turbocharger M10 37 - 49 Nm (27.3 - 36.1 lb ft)
Front Case
Front cover assembly M8x1.25x45 20 - 28 Nm (14.8 - 20.7 lb ft)
M8x1.25x30 20 - 28 Nm (14.8 - 20.7 lb ft)
Rear Case
Gear Case M8x1.25x40 20 - 28 Nm (14.8 - 20.7 lb ft)
M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
M10x1.5 44 - 54 Nm (32.5 - 39.8 lb ft)
Flywheel housing M12x120 75 - 95 Nm (55.3 - 70.1 lb ft)
M12x80 75 - 95 Nm (55.3 - 70.1 lb ft)
M10x80 44 - 54 Nm (32.5 - 39.8 lb ft)
M10x40 44 - 54 Nm (32.5 - 39.8 lb ft)
Phase 1 M12x1.25 26 - 34 Nm (19.2 - 25.1 lb ft)
Phase 2 M12x1.25 55 - 65 °
Main bearing cap
Phase 1 44 - 56 Nm (32.5 - 41.3 lb ft)
Phase 2 74 - 86 Nm (54.6 - 63.4 lb ft)
Phase 3 85 - 95 °
Connecting rod M11x1.25
Phase 1 27 - 33 Nm (19.9 - 24.3 lb ft)
Phase 2 55 - 65 Nm (40.6 - 47.9 lb ft)
Phase 3 55 - 65 °
Timing Pin 4 - 6 Nm (3.0 - 4.4 lb ft)
Crankshaft pulley M12x1.75 105 - 115 Nm (77.4 - 84.8 lb ft)
Camshaft retaining plate M8 20 - 28 Nm (14.8 - 20.7 lb ft)
Camshaft gear M8 32 - 40 Nm (23.6 - 29.5 lb ft)
Lubrication System and Components
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INTRODUCTION

Piston Cooling Nozzles M8x1.25x10 12 - 18 Nm (8.9 - 13.3 lb ft)
Oil pump M8x1.25x30 7 - 9 Nm (5.2 - 6.6 lb ft)
Stiffening Plate M10x1.25x25 38 - 48 Nm (28.0 - 35.4 lb ft)
Oil plug M10x1 5 - 7 Nm (3.7 - 5.2 lb ft)
M14x1.5 9 - 13 Nm (6.6 - 9.6 lb ft)
Oil Pick up tube M8x1.25x20 20 - 28 Nm (14.8 - 20.7 lb ft)
Oil Pan M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
M18x1.50 51 - 69 Nm (37.6 - 50.9 lb ft)
Oil Bypass Valve M22x1.5x10 72 - 88 Nm (53.1 - 64.9 lb ft)
Turbo Lubrication Lines
Turbo end M12x1.5 20 - 28 Nm (14.8 - 20.7 lb ft)
Filter base end 20 - 28 Nm (14.8 - 20.7 lb ft)
Drain M8x1.25x16 20 - 28 Nm (14.8 - 20.7 lb ft)
Electrical Components
Alternator
M8x1.25x30 20 - 28 Nm (14.8 - 20.7 lb ft)
M10x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
M10 44 - 54 Nm (32.5 - 39.8 lb ft)
M12x1.75x120 37 - 49 Nm (27.3 - 36.1 lb ft)
Alternator wiring M6x1.0 nut 8 - 11 Nm (5.9 - 8.1 lb ft)
Starter M10 54 - 44 Nm (39.8 - 32.5 lb ft)
Fuel System and Components
Fuel pump M8 screw 20 - 28 Nm (14.8 - 20.7 lb ft)
M6 screw 9 - 11 Nm (6.6 - 8.1 lb ft)
M6 nut 9 - 11 Nm (6.6 - 8.1 lb ft)
Fuel Pump Drive Gear
Phase 1 15 - 20 Nm (11.1 - 14.8 lb ft)
Phase 2 85 - 90 Nm (62.7 - 66.4 lb ft)
Timing Pin Cap 30 - 35 Nm (22.1 - 25.8 lb ft)
Fuel injectors 55 - 65 Nm (40.6 - 47.9 lb ft)
Fuel lift pump 20 - 28 Nm (14.8 - 20.7 lb ft)
Cooling System and Components
Water Pump M8x1.25x25 20 - 28 Nm (14.8 - 20.7 lb ft)
Water outlet connection M8x1.25x35 20 - 28 Nm (14.8 - 20.7 lb ft)
M8x1.25x70 20 - 28 Nm (14.8 - 20.7 lb ft)
Fan support M10x1.5x20 28 - 38 Nm (20.7 - 28.0 lb ft)
Fan pulley M6 8 - 12 Nm (5.9 - 8.9 lb ft)
M10 27 - 49 Nm (19.9 - 36.1 lb ft)
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INTRODUCTION
Special tools
Tool No. Description Image

380000301 Revolving engine stand
REVOLVING STAND 1
380000665 Crankshaft front seal puller
FRONTSEALPULLER 2
380000663 Crankshaft rear seal puller
REARSEALPULLER 3
380001099 Injector puller
INJECTORPULLER 4
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INTRODUCTION

380000666 Crankshaft front seal
installer
FRONTSEALINSTAL 5
380000664 Crankshaft rear seal
installer
CRANKREARSEALIN 6
380000670 Oil filter wrench
OILFILTERWRENCH 7
380000302 Valve spring compressor
VALVESPRINGCOMP 8
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INTRODUCTION

380000221 Pliers for removing/refitting
piston rings 65 - 110 mm
(2.559 - 4.331 in)
PISTONRINGPLIER 9
380000667 Beater for removing/refitting
camshaft bushes
CAMBUSHBEATER 10
380000362 Tool for lifting the crankshaft
CRANKHOIST 11
380000216 Engine lifting rig
ENGINEHOIST 12
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INTRODUCTION

380000661 Brackets for fastening the
engine to the revolving
stand
STANDBRACKETS 13
380000669 Seal remover
SEALREMOVER 14
380000668 Hand grip for
interchangeable beaters
HANDGRIP 15
380000364 Gauge base for dial indicator
GAUGEBASE 16
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INTRODUCTION

N/A Torque wrench
TORQUEWRENCH 17
380000158 Torque screwdriver
TORQUESCREWDRIV 18
380000304 Tool for angle tightening
ANGLETIGHTENING 19
380000988 Flywheel rotation tool
ROTATOR 20
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INTRODUCTION

Piston ring compressor
PISTONRINGCOMP 21
Dial indicator ( 0 - 5 mm
(0.000 - 0.197 in))
DIALINDICATOR 22
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INTRODUCTION
Special tools

380000979 Injection pump gear puller
PUMPGEARPULLER 1
380000665 Crankshaft front seal puller
FRONTSEALPULLER 2
380000663 Crankshaft rear seal puller
REARSEALPULLER 3
380000671 Injector puller
INJECTORPULLERG 4
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INTRODUCTION

380000666 Crankshaft front seal
installer
FRONTSEALINSTAL 5
380000664 Crankshaft rear seal
installer
CRANKREARSEALIN 6
380000670 Oil filter wrench
OILFILTERWRENCH 7
380000302 Valve spring compressor
VALVESPRINGCOMP 8
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INTRODUCTION

380000221 Pliers for removing/refitting
piston rings 65 - 110 mm
(2.559 - 4.331 in)
PISTONRINGPLIER 9
380000732 Flywheel crank handle
FLYWHEELCRANK 10
380000988 Flywheel rotation tool
ROTATOR 11
380000667 Beater for removing/refitting
camshaft bushes
CAMBUSHBEATER 12
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INTRODUCTION

380000362 Tool for lifting the crankshaft
CRANKHOIST 13
380000216 Engine lifting rig
ENGINEHOIST 14
380000994 Piston ring compressor
PISTONRINGCOMP 15
380002729 Engine TDC positioning
tool (non-structural engines
only)
TIMINGPIN 16
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INTRODUCTION

380000661 Brackets for fastening the
engine to the revolving
stand
STANDBRACKETS 17
380000669 Seal remover
SEALREMOVER 18
380000668 Hand grip for
interchangeable beaters
HANDGRIP 19
380000364 Gauge base for dial indicator
GAUGEBASE 20
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INTRODUCTION

380000229 Dial gauge holder and 0 -
5 mmDial gauge for rotary
injection pump timing.
PUMPTIMEADAPT 21
380000304 Tool for angle tightening
ANGLETIGHTENING 22
380001005 Dial gauge 0 - 10 mm
DIALGAUGE 23
380001006 Diesel engine compression
tester
COMPTESTER 24
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INTRODUCTION

380000140 Adapter for engine
compression tester
COMPADAPTER 25
380000301 Revolving engine stand
REVOLVING STAND 26
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INTRODUCTION
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24
SERVICE MANUAL
Engine
F4CE9484 , F4CE9487A , F4CE9487N , F4CE9684 , F4DE9484 ,

F4DE9684B*J111 , F4DE9684M*J101 , F4DE9684M*J103 , F4DE9684 ,
F4DE9687 , F4GE9484C*J601 , F4GE9484 , F4GE9684 , F4HE0484G*J102
, F4HE0484G*J109 , F4HE9484C*J102 , F4HE9484C*J103 , F4HE9484 ,
F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
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10
CONSUMABLES INDEX
Consumable Reference PAGE

Loctite® 518 Gasket Engine block cover Rear - Cleaning 10.2 / 21
Eliminator®
Molykote® G-N Metal Cylinder head - Install 10.4 / 15
assembly paste
assembly paste
assembly paste
assembly paste
Loctite® 5999 Intake manifold - Install 10.13 / 9
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10
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10
Engine - 10
Engine and crankcase - 001

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687,
F4HE9687G*J100
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4GE9484, F4GE9484C*J601, F4GE9684
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
FUNCTIONAL DATA
Engine
Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4HE9687G*J100
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
F4GE9484, F4GE9484C*J601, F4GE9684
SERVICE
Engine
Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F4HE9687G*J100
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F4GE9484, F4GE9484C*J601, F4GE9684
Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

F4HE9687G*J100
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F4GE9484, F4GE9484C*J601, F4GE9684

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Crankcase
Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Engine - Engine and crankcase
Engine - General specification

F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100
NHIL13ENG0290FA 1
The NEF F4HE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves
per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by FPT.
Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for
which the engine has been designed.
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General Specifications
Engine Type 4 Cylinders 6 Cylinders
Cycle Four-Stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total Displacement 4485 cm³ 6728 cm³
Timing
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start before B.D.C. 67 °
End after T.D.C. 35 °
Valve Clearance
Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Fuel Feed
Injection Type Bosch high pressure common rail
Control EDC7 ECU
Injector CRIU 2
Nozzle Type DSLA and DLLA
Injection Sequence 1-3-4-2 1-5-3-6-2-4
Injection pressure
250 - 1600 bar (3625 - 23200 psi)
Aspiration
Turbocharging Intercooled
Turbocharger Type Holset HX35
Lubrication
Oil Pressure @ Low Idle 0.7 bar (10 psi)
Oil Pressure @ Fast Idle 3.5 bar (51 psi)
Oil Pan Capacity 15 l (15.85 US qt)
Oil Filter Capacity 1 l (1.06 US qt)
Cooling
Water Pump Belt Driven
Thermostat 79 - 83 °C (174 - 181 °F)
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Clearance Data
Cylinder Barrels 104.000 - 104.024 mm (4.094 - 4.095 in)
Oversize 0.4 mm (0.016 in)
103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Skirt Height 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Piston (oversize) 0.4 mm (0.016 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Piston Pin - Pin Housing 0.01 - 0.022 mm (0.0004 - 0.001 in)
Piston ring landings
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Intermediate 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Intermediate 2.350 - 2.380 mm (0.093 - 0.094 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Piston Ring and Ring Landing Clearance
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Intermediate 0.060 -
0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in)
Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in)
Small end bushing Inside
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
Big end bearing shell
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
Piston Pin and Bushing
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
Oversize Big end bearing
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Main Journals 82.99 - 83.01 mm (3.267 - 3.268 in)
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
Main Bearing Shell Thickness 2.456 - 2.464 mm (0.097 - 0.098 in)
Big end Bearing Shell
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
Bearing Shell and Journal Clearance
No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
Bearing Shell and Crankpin
0.033 - 0.041 mm (0.001 - 0.002 in)
Clearance
Thrust Journal 37.475 - 37.545 mm (1.475 - 1.478 in)
Thrust Bearing Bore 32.180 - 32.280 mm (1.267 - 1.271 in)
(*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A
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Clearance Data
Thrust Bearing 37.28 - 37.38 mm (1.468 - 1.472 in)
Crankshaft End Play 0.095 - 0.265 mm (0.004 - 0.010 in)
Valve Guide Bore 7.042 - 7.062 mm (0.277 - 0.278 in)
Intake Valves
Stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Face angle 59.75 - 60.25 °
Exhaust Valves
Face angle 44.75 - 44.25 °
Valve Stem and Guide
0.052 - 0.092 mm (0.002 - 0.004 in)
Clearance
Valve Seat Bore
Intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
Valve seat Outside Diameter:
Intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve Seat Angle
Intake 60 °
Exhaust 45 °
Valve Sink
Intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Interference Between Valve Seat and Cylinder Head
Intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve Spring Height
Free 47.75 mm (1.880 in)
Under a load equal to:
330.8 - 348.8 N (74.4 -
35.33 mm (1.391 in)
78.4 lb)
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft Bore
No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in)
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft Journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in)
Bushing and Journal Clearance 0.038 - 0.162 mm (0.001 - 0.006 in)
Cam Lift
Intake 7.582 mm (0.299 in)
Exhaust 6.045 mm (0.238 in)
Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Tappet outside diameter
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Tappets and Bore Clearance 0.025 - 0.070 mm (0.001 - 0.003 in)
Rocker shaft 21.965 - 21.977 mm (0.865 - 0.865 in)
Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
Rockers and Shaft Clearance 0.024 - 0.162 mm (0.001 - 0.006 in)
(*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A
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NHIL13ENG0291FA 1
The NEF F4DE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves
per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by FPT.
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General Specifications
Engine Type 4 Cylinders 6 Cylinders
Cycle Four-Stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total Displacement 4485 cm³ 6728 cm³
Timing
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start before B.D.C. 67 °
End after T.D.C. 35 °
Valve Clearance
Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Fuel Feed
Injection Type Bosch high pressure common rail
Control EDC7 ECU
Injector CRIU 2
Nozzle Type DSLA and DLLA
Injection Sequence 1-3-4-2 1-5-3-6-2-4
Injection pressure
250 - 1600 bar (3625 - 23200 psi)
Aspiration
Turbocharging Intercooled
Turbocharger Type Holset HX35
Lubrication
Oil Pressure @ Low Idle 0.7 bar (10 psi)
Oil Pressure @ Fast Idle 3.5 bar (51 psi)
Oil Pan Capacity 15 l (15.85 US qt)
Oil Filter Capacity 1 l (1.06 US qt)
Cooling
Thermostat 79 - 83 °C (174 - 181 °F)
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Clearance Data
103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Intermediate 0.060 -
0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
0.033 - 0.041 mm (0.001 - 0.002 in)
Clearance
(*) Valid for engines: F4DE9684A.
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Clearance Data
Intake Valves
Face angle 59.75 - 60.25 °
Exhaust Valves
Face angle 44.75 - 44.25 °
0.052 - 0.092 mm (0.002 - 0.004 in)
Clearance
Valve Seat Bore
Intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
Intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve Seat Angle
Intake 60 °
Exhaust 45 °
Valve Sink
Intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve Spring Height
Free 47.75 mm (1.880 in)
330.8 - 348.8 N (74.4 -
35.33 mm (1.391 in)
78.4 lb)
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft Bore
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft Journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Cam Lift
Intake 7.582 mm (0.299 in)
Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
(*) Valid for engines: F4DE9684A.
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F4GE9484, F4GE9484C*J601, F4GE9684
NHIL13ENG0292FA 1
NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment
in general.
They are characterized by diesel cycle 4 stroke atmospheric or turbocharged 4 and 6 cylinders each with 2 valves.
Feed is provided by rotary mechanical pump or on line according to the equipment application.
It differs from other applications because of the provision of different power, power take-off for the different collector
configuration, priming pump, oil pan and boost turbine.
NOTE: The picture shows application designed for 6 cylinder versions, 2 valves per cylinder, having fuel feed by a
mechanical pump.
NOTICE: Data, technical specifications and performances granted shall be valid only if the setter will follow and com-
ply with all installation prescriptions provided by FPT.
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Engine Type 4 cylinder 6 cylinder

Compression ratio 17.5 : 1
Bore 104 mm (4.1 in)
Stroke 132 mm (5.2 in)
Displacement 4485 cm³ 6728 cm³
Turbocharger type Intercooled Holset HX25W Intercooled Holset HX35W
Lubrication
Oil Pressure (warm engine)
Idling 0.7 bar (10.2 psi)
Peak RPM 3.5 bar (50.8 psi)
Cooling
Thermostat opening temperature 79 - 83 °C (174.2 - 181.4 °F)
Capacity
Oil Pan 13 l (13.7 US qt) 15 l (15.9 US qt)
Oil Filter 1 l (1.1 US qt) 1 l (1.1 US qt)
Clearance Data
103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
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Clearance Data
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
No. 1,5 / 1,7 0.064 - 0.095 mm (0.003 - 0.004 in)
No. 2,3,4 / 2,3,4,5,6 0.059 - 0.100 mm (0.002 - 0.004 in)
0.064 - 0.090 mm (0.003 - 0.004 in)
Clearance
Intake Valves
Face angle 59.75 - 60.25 °
Exhaust Valves
Face angle 44.75 - 44.25 °
0.059 - 0.086 mm (0.002 - 0.003 in)
Clearance
Valve Seat Bore
Intake 46.987 - 47.013 mm (1.850 - 1.851 in)
Exhaust 43.637 - 43.663 mm (1.718 - 1.719 in)
Intake 47.063 - 47.089 mm (1.853 - 1.854 in)
Exhaust 43.713 - 43.739 mm (1.721 - 1.722 in)
Valve Seat Angle
Intake 60 °
Exhaust 45 °
Valve Sink
Intake 1 - 1.52 mm (0.039 - 0.060 in)
Exhaust 1 - 1.52 mm (0.039 - 0.060 in)
Intake 0.050 - 0.102 mm (0.002 - 0.004 in)
Exhaust 0.050 - 0.102 mm (0.002 - 0.004 in)
Valve Spring Height
Free 63.50 mm (2.500 in)
330.8 - 348.8 N (74.4 -
49.02 mm (1.930 in)
78.4 lb)
702 - 780 N (157.8 - 175.4 lb) 38.20 mm (1.504 in)
Camshaft Bore
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
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Clearance Data
Camshaft Journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Rockers 19.000 - 19.026 mm (0.748 - 0.749 in)
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
NHIL13ENG0293FA 1
NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment
in general.
They are characterized by diesel cycle 4 stroke atmospheric or turbocharged 4 and 6 cylinders each with 2 valves.
Feed is provided by rotary mechanical pump or on line according to the equipment application.
It differs from other applications because of the provision of different power, power take-off for the different collector
configuration, priming pump, oil pan and boost turbine.
NOTE: The picture shows application designed for 6 cylinder versions, 2 valves per cylinder, having fuel feed by a
mechanical pump.
NOTICE: Data, technical specifications and performances granted shall be valid only if the setter will follow and com-
ply with all installation prescriptions provided by FPT.
47597675 27/09/2013
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Engine Type 4 cylinder 6 cylinder

Compression ratio 17.5 : 1
Bore 104 mm (4.1 in)
Stroke 132 mm (5.2 in)
Displacement 4485 cm³ 6728 cm³
Turbocharger type Intercooled Holset HX25W Intercooled Holset HX35W
Lubrication
Oil Pressure (warm engine)
Idling 0.8 bar (11.6 psi)
Peak RPM 3.5 bar (50.8 psi)
Cooling
Thermostat opening temperature 79 - 83 °C (174.2 - 181.4 °F)
Capacity
Oil Pan - 16 l (16.9 US qt)
Oil Filter - 1 l (1.1 US qt)
Clearance Data
103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 -
Pistons
4.086 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Oil Control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Oil Control 3.970 - 3.990 mm (0.156 - 0.157 in)
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Oil Control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston Ring End Gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Oil Control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Diameter
1.955 - 1.968 mm (0.077 - 0.077 in)
thickness
0.019 - 0.039 mm (0.001 - 0.002 in)
Clearance
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Clearance Data
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Shells
Crankshaft
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
1.955 - 1.968 mm (0.077 - 0.078 in)
Thickness
Main Bearing Bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
No. 1,5 / 1,7 0.064 - 0.095 mm (0.003 - 0.004 in)
No. 2,3,4 / 2,3,4,5,6 0.059 - 0.100 mm (0.002 - 0.004 in)
0.033 - 0.041 mm (0.001 - 0.002 in)
Clearance
Intake Valves
Face angle 59.75 - 60.25 °
Exhaust Valves
Face angle 44.75 - 44.25 °
0.039 - 0.079 mm (0.002 - 0.003 in)
Clearance
Valve Seat Bore
Intake 46.987 - 47.013 mm (1.850 - 1.851 in)
Exhaust 43.637 - 43.663 mm (1.718 - 1.719 in)
Intake 47.063 - 47.089 mm (1.853 - 1.854 in)
Exhaust 43.713 - 43.739 mm (1.721 - 1.722 in)
Valve Seat Angle
Intake 60 °
Exhaust 45 °
Valve Sink
Intake 1 - 1.52 mm (0.039 - 0.060 in)
Exhaust 1 - 1.52 mm (0.039 - 0.060 in)
Intake 0.050 - 0.102 mm (0.002 - 0.004 in)
Exhaust 0.050 - 0.102 mm (0.002 - 0.004 in)
Valve Spring Height
Free 63.50 mm (2.500 in)
330.8 - 348.8 N (74.4 -
49.02 mm (1.930 in)
78.4 lb)
702 - 780 N (157.8 - 175.4 lb) 38.20 mm (1.504 in)
Camshaft Bore
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
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Clearance Data
Camshaft Journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Cam Lift
Intake 11.02 mm (0.434 in)
Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Rockers 19.000 - 19.026 mm (0.748 - 0.749 in)
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Engine - Component localisation

Location of main electrical components
NHIL13ENG0294GA 1
(1) Coolant Temperature Sensor - (2) Electro-Injector - (3) Rail Pressure Sensor - (4) Air Temperature/Pressure
Sensor - (5) Engine Starter - (6) Timing Sensor - (7) Solenoid Valve for Pressure Regulator - (8) Fuel
Temperature Sensor - (9) EDC Electronic Control Unit - (10) Crankshaft Sensor - (11) Oil Level Sensor - (12)
Engine Oil Temperature/Pressure Sensor - (13) Heating Element for Pre-Post Heating
The NEF F4HE engines are fully driven by the electronic engine control module, which is assembled directly to the
engine by means of a heat exchanger enabling it's cooling, utilizing rubber buffers to reduce vibration originated by
the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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Location of main electrical components
NHIL13ENG0294GA 1
(1) Coolant temperature sensor - (2) Electro-injector - (3) Starter - (4) Fuel pressure sensor - (5) Air
pressure/temperature sensor - (6) Timing sensor - (7) fuel temperature sensor - (8) EDC7 electronic control
module - (9) Crankshaft speed sensor - (10) Engine oil pressure/temperature sensor - (11) Pre-post heating
resistor.
The NEF F4DE engines are fully driven by the electronic engine control module, which is mounted remotely on the
unit utilizing rubber buffers to reduce vibration originated by the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
NHIL13ENG0295GA 1
(1) Coolant temperature sensor (6) Oil pressure switch

(2) Starter (7c) Fuel heater (if equipped)
(3) Grid heater (7d) Water in fuel sensor
(4) KSB water temperature sensor (8) Speed sensor (if equipped)
(5a) Electromagnet on the pump head (9) Alternator
(5b) Electromagnet on the KSB
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F4GE9484, F4GE9484C*J601, F4GE9684
NHIL13ENG0296GA 1
(1) Coolant temperature sensor - (2) Starter - (3) KSB water temperature sensor - (4) Electromagnets
assembled on feed pump: (A) on hydraulic head unit (B) on KSB - (5) Oil pressure sensor - (6) Grid
heater - (7) Alternator.
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Engine - Compression test

1. Make sure that all pressure is relieved from the fuel

system.
2. Disable the fuel system by disconnecting the fuel shut
off electrical connector (1).
NHIL13ENG0718AA 1
3. Remove all fuel injectors (1) and their O-ring seals (2)
from the cylinder head.
NOTE: Use new injector O-ring seals during reinstallation.
4. Install cylinder compression test adapter 380000989
into cylinder No. 1 fuel injector port.
5. Be sure the compression gauge is reset to zero psi.
6. Crank the engine over until the compression gauge
needle meets it’s peak level and will not increase fur-
ther.
NOTICE: Do not crank the engine excessively. This could
cause wear to the starter motor. NHIL13ENG0602AA 2
NOTICE: Keep the compression testing equipment away

from all moving parts on the engine.
7. Record the compression test reading and repeat Step
6 until all cylinders have been tested and recorded.
8. The cylinder psi values should be between 24 bar
(350 psi) +100/-50.
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Engine - Place on stand

NOTE: In order to apply the brackets 380000661 to the engine block, it is necessary to perform the following opera-
tions on the left hand side of the engine.
1. Using the tool 380000670 remove the fuel filter from
the support.
2. Disconnect the electrical connection from the support.
3. Disconnect the low pressure fuel line from the support.
4. Remove the fuel line from the support.
5. Remove the sustaining support bracket from the engine
block.
6. Disconnect the high pressure fuel line from the fuel
rail diffuser and from the high pressure pump. Re-
move it from the engine block by removing the retaining
clamps. NHIL13ENG0297AA 1
7. Disconnect the fuel line supplying the mechanical

pump that is combined to the high pressure pump
through the exchanger of the engine control module.
8. Remove the oil fill tube (if present) by removing the
bolts. Remove the O-ring from the tube.
NOTICE: Because of the high pressure fuel in the fuel lines running from the high pressure pump to the rail and
from the rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while engine
is running or reuse the removed pipelines.
9. Remove the retaining bolts securing the turbocharger
(1) oil return line (2) and remove the line from the oil
filter base on the engine block.
NHIL13ENG0298AA 2
10. Remove the starter motor (2) from the flywheel hous-
ing (1) by removing the retaining bolts (3).
11. Apply brackets 380001298 to the engine block and
use them to secure the engine to a rotary engine
stand.
12. Remove the drain plug from the engine oil pan and
drain out the engine oil.
13. Remove the fan from the output shaft pulley.
NHIL13ENG0299AA 3
NOTICE: Collect and dispose of engine oil according to regulations in your area.
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NOTE: In order to apply the brackets 380000661 to the engine block, it is necessary to perform the following opera-
tions on the left hand side of the engine.
1. Using the tool 380000670, remove the fuel filter (6) and
remove it from the support (1).
2. Disconnect the electrical connection (2) from the sup-
port (1).
3. Disconnect the low pressure fuel lines (3), (4) and (5)
from the support (1).
4. Remove the fuel line (9) from the support (1).
5. Remove the sustaining support bracket (1) from the
engine block.
6. Disconnect the high pressure fuel line (7) from the fuel
rail diffuser and from the high pressure pump (8). Re- NHIL13ENG0300AA 1
move it from the engine block by removing the retaining
clamps.
7. Disconnect the fuel line feeding the mechanical pump
that is combined to the high pressure pump through the
exchanger of the engine control module.
8. Remove the oil fill tube (if applicable) by removing the
bolts, O-ring, and then removing the tube.
NOTICE: Because of the high pressure fuel in the fuel lines running from the high pressure pump to the fuel rail
and from the fuel rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while
engine is running or reuse the disassembled pipelines.
9. Remove mounting bolts (1) securing the starter motor
(2), then remove the starter motor (2) from the flywheel
housing.
NHIL13ENG0299AA 2
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10. Remove the oil return line (1) from the turbocharger
outlet (2) and at the return fitting at the engine block
(3).
NHIL13ENG0301BA 3
11. Remove the turbocharger oil feed line (2) from the
turbocharger (1) inlet.
12. Remove the retaining bolts (4) and remove the sup-
port (3).
13. Remove the thermostat body including the seal.
NHIL13ENG0302AA 4
14. In order to hoist the engine onto a rotary engine stand,

use the provided holes (1) and (2) on both sides of the
engine block to install brackets 380000661.
15. Drain the engine oil by removing the drain plug from
the bottom of the engine oil pan.
NOTE: Collect and dispose of the engine oil according to
enforced regulations.
NHIL13ENG0303FA 5
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F4GE9484, F4GE9484C*J601, F4GE9684
1. In order to apply the brackets 380000661 to the engine

block for a rotary engine stand for the overhaul, it is
necessary to perform the following operations.
2. Remove the engine oil filter (1) from the support using
tool 380000670.
NOTICE: The oil filter contains inside approximately 1 kg
(2.2 lb) of engine oil. Provide for oil recovery and disposal
in compliance with the laws and regulations in force.
NHIL13ENG0304AA 1
3. Remove the two bolts (2) from underneath the tur-

bocharger and loosen the fitting (3) retaining the line
throughout the stop collar (4) secured to the engine
block.
4. Finally, remove the fitting (5) from the engine block and
remove the turbocharger oil return line.
5. Plug the pipe ends and the exhaust outlet of the tur-
bocharger.
NHIL13ENG0305BA 2
6. Remove the starter motor (1) by removing he retaining

bolts (3).
7. Install the brackets 380000661 using the four provided
threaded bolt holes (2).
NHIL13ENG0306AA 3
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8. From the left hand side, assemble the second bracket

380000661 using the provided threaded bolt holes (1).
9. Lift the engine using the hoist 380000216 and mount it
onto the rotary engine stand .
10. Drain the engine oil through the drain plug in the en-
gine oil pan.
NOTICE: Avoid contact of engine oil with the skin. In case
of skin contamination, rinse in running water.
NOTE: Engine oil is highly pollutant. Provide for disposal
in compliance with the law and regulations in force.
NHIL13ENG0307AA 4
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Install the brackets 380000661 onto the engine block

and mount the engine on a rotary engine stand to per-
form the following operations.
2. Remove the bolts securing the turbocharger oil return
line to the turbocharger oil outlet (2).
3. Remove the turbocharger oil return line from the stop
collar (3).
4. Remove the turbocharger oil return line fitting (4) at the
engine block.
5. Remove the engine oil dipstick (5).
6. Remove the engine oil filter (1) using the tool NHIL13ENG0308AA 1
380000670.
NOTICE: Provide for oil recovery and disposal in compli-
ance with the law and regulations in force.
7. Remove the starter motor (2) by removing the retaining
bolts (1).
NHIL13ENG0309AA 2
8. Assemble the supporting brackets 380000661 using

the existing threaded bolt holes (1) on the engine block.
9. Assemble the second bracket 380000661 using the
threaded bolt holes (2) on the engine block.
10. Lift the engine using the hoist 380000216 and mount
it to a rotary engine stand.
11. Drain the engine oil by removing the oil drain plug from
the bottom of the engine oil pan.
NOTICE: Avoid contact of engine oil with the skin. In the
case of skin contamination, rinse in running water.
NOTE: Engine oil is highly pollutant. Provide for disposal NHIL13ENG0310AA 3
in compliance with the law and regulations in force.
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Engine - Service instruction Maintenance Procedures

CHECKS AND INSPECTIONS
Engine oil level check

The check can be made using the engine oil dipstick (1)
located on the right hand side of the EDC.
NOTICE: The check must be executed when the engine is
off and possibly cool.
Remove the dipstick from it's tube and check that the level
is within the etched markings of minimum and maximum
level.
If it is difficult to make the level evaluation, proceed clean-
ing the dipstick using a clean cloth with no contamination
and put it back in it's tube. Remove the dipstick again and
check the level.
In case the level results are close to the marking indicating
minimum level, add the correct engine oil through the upper NHIL13ENG0311AA 1
engine oil cap or lateral cap of the engine (2) and check
level until level reaches the maximum level marking.
WARNING
Chemical hazard!
When handling fuel, lubricants, and other ser-
vice chemicals, follow the manufacturer's in-
structions. Wear Personal Protective Equip-
ment (PPE) as instructed. Do not smoke or use
open flame. Collect fluids in proper contain-
ers. Obey all local and environmental regula-
tions when disposing of chemicals.
Failure to comply could result in death or seri-
ous injury.
W0371A
During filling operation, the engine oil caps must be

removed as well as the engine oil dipstick in order to make
the oil flow easier.
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Combustion system inspection
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under
pressure can penetrate the skin and cause
infection or other injury. To prevent personal
injury: Relieve all pressure before discon-
necting fluid lines or performing work on the
hydraulic system. Before applying pressure,
make sure all connections are tight and all
components are in good condition. Never use
your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood
for this purpose. If injured by leaking fluid, see
your doctor immediately.
ous injury.
W0178A
The check must be executed both with the engine off and
when it is running.
The check operation consists of examining the fuel lines
running from the tank to the pre-filter (if provided in the
specific equipment), to the filter, to the high pressure
pump, to the rail diffuser and to the cylinder head.
Special attention must be paid to the connections on the
high pressure pipelines.
Cooling system inspection
CAUTION
Burn hazard!
Take care if removing the filler cap while the
system is hot. Before removing the cap: com-
pletely cover the cap using a thick cloth, and
slowly open the filler cap to allow the pressure
to escape. Do not add cold water to a hot
coolant reservoir.
Failure to comply could result in minor or mod-
erate injury.
C0031A
The check must be executed both when the engine is off

and when it is running.
Check the hoses from the engine to the radiator, from the
expansion tank and vice-versa. If any engine coolant
blow-by is detected, check for breakage in hoses,
especially at any outlets or inlets.
Verify that the radiator is clean, the engine cooling fans
are working properly, check for any leakage from the
connectors, from the manifold or from the radiator.
The density of the engine coolant must be checked every
year before winter season and be replaced in any case
every two years.
NOTE: In case of new filling, proceed bleeding the system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious inconve-
nience might be caused to the engine due to the presence
of air pockets in the engine's head.
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Lubricating system inspection
WARNING
Chemical hazard!
ous injury.
W0371A

Verify the presence of any engine oil leakage or engine
oil blow-by from the cylinder head, engine oil pan or from
the engine oil cooler.
Inspection of water presence within the fuel

filter or pre-filter
The components of the common rail system can be dam-
aged very quickly in presence of water or impurity within
the fuel.
Timely proceed operating on the pre-filter (not available on
the engine block) to carry out the drainage of the water
within the feed circuit.
Inspection / replacement of blow-by filter

The filter in subject has been developed and equipped for
the collection , filtering and condensing of the lubricating oil
vapors.
Within the filter unit (1) two cartridge filters are included (2).
The check of the filtering element is carried out by removing
the cover and drawing off the cartridges (2).
86070785_RESIZE 2
Inspection of drive belt tensioning

The drive belt tensioning control is made using an auto-
matic tensioning device therefore no adjustments are re-
quired apart from checking the wear status of the belt itself.
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Inspection and setting of tappet clearance

Adjust clearance between rockers and valves using
setscrew wrench (1), box wrench (2) and feeler gauge (3).
Valve clearance:
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
NOTICE: On TIER 3 engines, due to the additional lobe
for the INTERNAL E.G.R., it is not possible to use the valve
clearance adjustment procedure that requires adjusting the
clearance of all the valves by positioning the crankshaft 2
times only.
Each cylinder must be checked by taking it to the T.D.C.
(top dead center) at the end of compression and adjusting NHIL13ENG0312AA 3
the clearance of both valves on the cylinder in question.
Engine oil and filter replacement
WARNING
Chemical hazard!
ous injury.
W0371A
Due to the several applications, the engine oil pan shape

and the oil quantity can change slightly. However, the
following operations are valid for all applications.
We recommend to carry out the oil drainage when the
engine is hot.
Place a proper container for the oil collecting under the
pan connected with drain plug.
Remove the drain plug and then remove engine oil
dipstick as well as the oil filling cap to ease the downflow
of the engine oil.
After the complete drainage, tighten the plug and carry out
the clean oil filling.
NOTICE: Use only recommended oil or oil having the re-
quested features for the correct engine functioning. In case
of topping up, don't mix oils having different features. If you
don't comply with these rules, the service warranty is no
more valid.
Check the level through the dipstick until the filling is next
to the maximum level notch indicated on the dipstick.
When you replace the engine oil, it is also necessary to
replace the engine oil filter. According to the application,
the filter can be located in different positions: the following
procedure is a valid guide for all applications.
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WARNING
Chemical hazard!
ous injury.
W0371A
The filter is composed of a support and a filtering cartridge.

For the cartridge replacement use the tool 380000670.
ATTENTION: The oil filter contains inside a quantity of oil
of about 1 kg.
Replace the filtering cartridge with a new one and tighten
manually until when the gasket is in contact with the sup-
port.
Tighten the oil filter using the tool 380000670 making a
three fourth rotation turn.
Operate the engine for some minutes and check the level
through the dipstick again. If it is necessary, top off engine
oil to compensate for the quantity of oil used for the filling
of the filtering cartridge.
Fuel filter replacement

According to the applications, the filters position and the
quantity can change.
However the following operations are valid for all applica-
tions.
Drain the fuel inside the filter operating the water release
drain valve. Collect the fuel in a container without impuri-
ties.
remove the cartridge by using the 380000670.
Collect the eventual fuel inside the filtering cartridge.
Clean the gasket seat on the support and oil slightly the
gasket on the new filtering cartridge.
Manually tighten the new filtering cartridge until the gasket
is completely on its seat.
Torque the bolts using the tool 380000670 to 10 - 15 Nm
(7 - 11 lb ft).
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Alternator belt replacement
WARNING
Rotating parts!
The engine is running. Keep clear of rotating
fans and belts.
ous injury.
W0275A
Due to several applications the belt run can change very

much.
For applications with an automatic belt tensioner, the pro-
cedure is the following:
By means of square wrench of proper size, act on point
NHIL13ENG0313AA 4
(A), indicated in the figure, of the automatic belt tensioner
(1) and release the pressure.
Remove the control belt (2) from the driven and intermedi-
ate pulleys.
Replace the worn belt with a new one.
Place the belt on the pulleys and guide rollers.
Place the automatic tightener in order to place the belt in
the functioning position.
Check proper position in the races of the pulleys.
47597675 27/09/2013
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The check can be made using the engine oil dipstick (1)
located on the right hand side of the EDC.
Remove the dipstick from the tube and check that the level
is within the etched markings of minimum and maximum
level.
If it is difficult to make the evaluation, clean the dipstick
using a clean cloth with no contamination and put it back
in it's tube Remove it again and check the level.
In case the level results are close to the marking indicating
minimum level, add the correct engine oil through the upper
engine oil cap or lateral cap of the engine.
NHIL13ENG0314FA 1
WARNING
Chemical hazard!
ous injury.
W0371A
NHIL13ENG0265AA 2
Add oil through the upper engine oil cap (1) or through the
lateral oil cap (2). During filling operation, the engine oil
caps must be removed as well as the engine oil dipstick in
order to make the oil flow easier.
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Combustion system inspection
WARNING
Escaping fluid!
ous injury.
W0178A

The check operation consists of examining the fuel lines
running from the tank to the pre-filter (if provided in the
specific equipment), to the filter, to the high pressure
pump, to the rail diffuser and to the cylinder head.
CAUTION
Burn hazard!
Hot coolant can spray out if you remove the
filler cap while the system is hot. After the sys-
tem has cooled, turn the filler cap to the first
notch and wait for all pressure to release be-
fore proceeding.
Failure to comply could result in minor or mod-
erate injury.
C0043A

Check the hoses from the engine to the radiator, from the
expansion tank and vice-versa. If any engine coolant
blow-by is detected, check for breakage in hoses,
especially at any outlets or inlets.
Verify that the radiator is clean, the engine cooling fans
are working properly, check for any leakage from the
connectors, from the manifold or from the radiator.
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any
case every two years.
47597675 27/09/2013
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WARNING
Chemical hazard!
ous injury.
W0371A

Verify the presence of any engine oil leakage or engine
oil blow-by from the cylinder head, engine oil pan or from
the engine oil cooler.

the fuel.

The drive belt tensioning control is made using an auto-
matic tensioning device therefore no adjustments are re-
quired apart from checking the wear status of the belt itself.

Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
times only.
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WARNING
Chemical hazard!
ous injury.
W0371A
Due to the several applications, the pan shape and the

oil quantity can change slightly. However, the following
operations are valid for all applications.
engine is hot.
Remove the drain plug and then remove engine oil
dipstick as well as the oil filling cap to ease the downflow
of the engine oil.
After the complete drainage, tighten the plug and carry out
more valid.
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
When you replace the engine oil, it is also necessary to
replace the engine oil filter. According to the application
the filter can be located in different positions: the following
procedure is a valid guide for all applications.
WARNING
Chemical hazard!
ous injury.
W0371A

of about 1 kg.
Replace the filtering cartridge with a new one and tighten
manually until the gasket is in contact with the support.
47597675 27/09/2013
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Tighten by means of the tool 380000670 making a three

fourth rotation turn.
through the dipstick again. If it is necessary, top off engine
oil to compensate for the quantity of oil used for the filling
of the filtering cartridge.

According to the applications the filters position and the
tions.
drain valve. Collect the fuel in a container without impuri-
ties.
Remove the cartridge by using the 380000670.
Manually tighten the new filtering cartridge until the when
the gasket is completely on its seat.
Tighten through the tool 380000670 at a 10 - 15 Nm (7 -
11 lb ft) torque.
WARNING
Rotating parts!
fans and belts.
ous injury.
W0275A

much.
For applications with automatic belt tensioner, the proce-
dure is the following:
By means of square wrench of proper of proper size, act
on point (A), indicated in the figure, of the automatic belt
tensioner (1) and release the pressure.
ate pulleys.
Place the automatic tightener in order to key the belt in the
functioning position.
NHIL13ENG0313AA 4
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F4GE9484, F4GE9484C*J601, F4GE9684

The check can be made using the dipstick (1) placed on
the right hand side of the EDC.
Draw off the rod from it's slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, pro-
ceed cleaning the rod using a clean cloth with no contami-
nation and put it back in it's slot. Draw it off again and check
the level.
In case the level results being close to the tag showing min-
imum level, provide filling lubrication of the engines com-
ponents. NHIL13ENG0267AA 1
WARNING
Chemical hazard!
ous injury.
W0371A
NHIL13ENG0268AA 2
Add oil through the upper top (1) or through the lateral top
(2). During filling operation, the tops must be removed as
well as the rod in order to make the oil flow easier.
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Fuel system inspection
WARNING
Escaping fluid!
ous injury.
W0178A

The check operation consists in examining the fuel
pipelines running from the tank to the pre-filter (if provided
in the specific equipment), to the filter, to the high pressure
pump and to the rail diffuser and from this last one to the
head.
WARNING
Hot liquid under pressure!
Never remove the filler cap or the recovery tank
cap while the engine is running or the coolant
is hot. Let the system cool. Turn the filler cap
to the first notch and allow any pressure to es-
cape, and then remove the filler cap. Loosen
the recovery tank cap slowly to allow any pres-
sure to escape.
ous injury.
W0296A

Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
verify the status of the pipes specially close to the holding
strips.
Verify that the radiator is clean, the correct working of
the fan flywheels, the presence of any leakage from the
connectors, from the manifold and from the radiating unit.
47597675 27/09/2013
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WARNING
Chemical hazard!
ous injury.
W0371A

Verify the presence of any oil leakage or blow-by from the
head, from the engine pan or from the heat exchanger.

the fuel.

The drive belt tensioning control is made using an au-
tomatic tensioning device therefore no intervention is
required apart from checking the wear status of the belt
itself.
47597675 27/09/2013
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Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
times only.
WARNING
Chemical hazard!
ous injury.
W0371A

engine is hot.
Unscrew the plug and then take out the control dipstick
and the inserting plug to ease the downflow of the
lubrication oil.
After the complete drainage, screw the plug and carry out
more valid.
Whereas you replace the lubrication oil, it is necessary to
replace the filter. According to the application the filter can
be located in different positions: the following procedure is
a valid guide for all applications.
47597675 27/09/2013
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WARNING
Chemical hazard!
ous injury.
W0371A

of about 1 kg.
Replace the filtering cartridge with a new one and screw
port.
Tighten by means of the tool 380000670 of three fourth
turn.
through the dipstick again. If it is necessary, carry out a
topping up to compensate the quantity of oil used for the
filling of the filtering cartridge.

tions.
screw. Collect the fuel in a container without impurities.
Unscrew the cartridge by using the 380000670.
Screw manually the new filtering cartridge until the gasket
11 lb ft) torque.
47597675 27/09/2013
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WARNING
Rotating parts!
fans and belts.
ous injury.
W0275A

much.
NHIL13ENG0271AA 4
ate pulleys.
47597675 27/09/2013
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

The check can be made using the dipstick (1).
Draw off the rod from it's slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, pro-
ceed cleaning the rod using a clean cloth with no contami-
nation and put it back in it's slot. Draw it off again and check
the level.
In case the level results being close to the tag showing min-
imum level, provide filling lubrication of the engines com-
ponents.
NHIL13ENG0275AA 1
WARNING
Chemical hazard!
ous injury.
W0371A
Add oil through the upper top (1) or through the lateral top
(2). During filling operation, the tops must be removed as
well as the rod in order to make the oil flow easier.
NHIL13ENG0269BA 2
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10.1 [10.001] / 48
Fuel system inspection
WARNING
Escaping fluid!
ous injury.
W0178A

The check operation consists in examining the fuel
pipelines running from the tank to the pre-filter (if provided
in the specific equipment), to the filter, to the high pressure
pump and to the rail diffuser and from this last one to the
head.
WARNING
Hot liquid under pressure!
Never remove the filler cap or the recovery tank
cap while the engine is running or the coolant
is hot. Let the system cool. Turn the filler cap
to the first notch and allow any pressure to es-
cape, and then remove the filler cap. Loosen
the recovery tank cap slowly to allow any pres-
sure to escape.
ous injury.
W0296A

Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
verify the status of the pipes specially close to the holding
strips.
Verify that the radiator is clean, the correct working of
the fan flywheels, the presence of any leakage from the
connectors, from the manifold and from the radiating unit.
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WARNING
Chemical hazard!
ous injury.
W0371A

Verify the presence of any oil leakage or blow-by from the
head, from the engine pan or from the heat exchanger.

the fuel.

The drive belt tensioning control is made using an au-
tomatic tensioning device therefore no intervention is
required apart from checking the wear status of the belt
itself.
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Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in).
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in).
times only.
WARNING
Chemical hazard!
ous injury.
W0371A

engine is hot.
Unscrew the plug and then take out the control dipstick
and the inserting plug to ease the downflow of the
lubrication oil.
After the complete drainage, screw the plug and carry out
more valid.
Whereas you replace the lubrication oil, it is necessary to
replace the filter. According to the application the filter can
be located in different positions: the following procedure is
a valid guide for all applications.
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WARNING
Chemical hazard!
ous injury.
W0371A

of about 1 kg.
Replace the filtering cartridge with a new one and screw
port.
Tighten by means of the tool 380000670 of three fourth
turn.
through the dipstick again. If it is necessary, carry out a
topping up to compensate the quantity of oil used for the
filling of the filtering cartridge.

tions.
screw. Collect the fuel in a container without impurities.
Unscrew the cartridge by using the 380000670.
Screw manually the new filtering cartridge until the gasket
11 lb ft) torque.
WARNING
Rotating parts!
fans and belts.
ous injury.
W0275A

much.
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ate pulleys.
NHIL13ENG0271AA 4
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Crankcase Bore - Check

Prior operation:
Connecting rod and piston - Remove (10.105)
Once engine is disassembled, perform the following:

Clean the engine block assembly
Use the proper rings to handle the cylinder unit.
Inspect engine block for cracks.
Check operating plug conditions and replace them in case
of uncertain seal or if rusted.
Inspect cylinder bore surfaces for seizing and scoring.
Inspect cylinder bores for ovalization, taper, and wear by
using a bore dial gauge OEM1032 (1) fitted with the dial
gauge previously set to zero on the ring gauge (2) of the
cylinder bore diameter.
NOTE: Should a ring gauge not be available, use a mi-
crometer for zero-setting. NHIL13ENG0270AA 1
Measurements should be performed on each cylinder at

three different heights in the cylinder and on two planes
perpendicular with each other: one parallel to the longitu-
dinal axis of the engine (A), and the other perpendicular
(B).
Maximum wear is usually found on plane (B) in correspon-
dence with the first measurement.
Should ovalization, taper, or wear be found, bore and hone
the cylinder bores. Cylinder boring should be performed
according to the new piston diameter oversize by 0.4 mm
(0.016 in) and to the specified assembling clearance.
NOTE: In case of boring, all cylinder bores should have the
same oversize 0.4 mm (0.016 in). NHIL13ENG0286AA 2
Next operation:
Crankcase - Check (10.001)
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Crankcase - Check
Prior operation:
Crankshaft - Remove (10.103)
Main Bearing Housings

Check main bearing housings as follows:
• Install the main bearing caps onto the engine block
without bearings
• Torque the main cap bolts in the following three
stages. Torque the bolts to 44 - 55 N·m (32 - 41 lb
ft) . Then torque the bolts to 74 - 86 N·m (55 -
63 lb ft). Using the angular torquing gauge tool
380001001, turn the bolts an additional 85 - 95 °.
• Use a dial bore gauge 380000827 to check main
bearing bore diameter. The values for four and six
cylinder engines should be as follows:
• No. 1,5 or 1,7 should be within 87.982 - 88.008 mm
(3.464 - 3.465 in).
• No. 2,3,4 or 2,3,4,5,6 should be within 87.977 -
88.013 mm (3.464 - 3.465 in).
Replace if a higher value is found.
Checking head supporting surface on cylinder unit

Use a straightedge (2) placed diagonally across the cylin-
der head dowel pins (4) and use a feeler gauge (3) to check
across the cylinder block for distortion.
The planar surface distortion should not exceed 0.075 mm
(0.003 in). If the value is higher than the specified value,
the cylinder block will need to be resurfaced.
Check cylinder unit operating plug (1) conditions, replace
them in case of uncertain seal or if rusted.
CRIL04J058A01 1
Next operation:
Crankshaft Journal - Clearance (10.103)
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Index
Engine - 10

Crankcase - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
F4GE9484, F4GE9484C*J601, F4GE9684
Engine - Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4GE9484, F4GE9484C*J601, F4GE9684
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Engine - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Engine - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
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Engine - 10
Pan and covers - 102

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
SERVICE
Engine oil pan

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101,
F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4DE9684M*J103, F4DE9684B*J111
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4GE9484, F4GE9484C*J601, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9484, F4GE9484C*J601, F4GE9684
Engine block cover

Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4GE9484, F4GE9484C*J601, F4GE9684
Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4GE9484, F4GE9484C*J601, F4GE9684
Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4GE9484, F4GE9484C*J601, F4GE9684
Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4HE9687G*J100
Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4HE9687G*J100
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4HE9687G*J100
Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4DE9684M*J103, F4DE9684B*J111
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F4DE9684M*J103, F4DE9684B*J111
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Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4DE9684M*J103, F4DE9684B*J111
Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F4GE9484, F4GE9484C*J601, F4GE9684
Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
F4GE9484, F4GE9484C*J601, F4GE9684
Timing gear housing

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103,
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F4DE9684M*J103, F4DE9684B*J111
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F4DE9684M*J103, F4DE9684B*J111
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CONSUMABLES INDEX

Loctite® 518 Gasket Engine block cover Rear - Cleaning 10.2 / 21
Eliminator®
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10.2 [10.102] / 4
Engine - Pan and covers
Engine oil pan - Remove

1. Remove the bolts (2) retaining the oil pan (1).

2. Remove the oil pan (1) from the engine block.
NOTE: The shape and dimensions of the oil pan and of
the oil pick up tube may vary according to the application
of the engine. However, the procedures described are still
applicable.
NHIL13ENG0273AA 1
3. Remove the oil pick up tube (2) by removing the bolts

(3) and (1).
4. Remove the bolts (5) retaining the stiffening plate (4)
and then remove the stiffening plate (4).
NHIL13ENG0282AA 2
Next operation:
Engine oil pan - Install (10.102)
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Engine oil pan - Install

Prior operation:
Engine oil pan - Remove (10.102)
1. Install the stiffening plate (4), the oil pick up tube (2)
and torque the bolts (1), (3) and (5) to 20 - 28 N·m (15
- 21 lb ft).
NHIL13ENG0282AA 1
2. Set the gasket (1) onto the oil pan (2) .

NOTE: The pictures of the instructions relating to the oil
pan and to the oil pick up tube may not reflect the actual
shape and dimensions of your engine equipment. How-
ever, the procedures described are still applicable.
NHIL13ENG0315AA 2
3. Install the oil pan (1) and the mounting plate (3) onto
the engine block. Torque the bolts (4) to 15 - 21 N·m
(11 - 15 lb ft).
4. Install the oil drain plug (2) into the oil pan. Torque the
bolt to 5 - 7 N·m (44 - 62 lb in).
NOTE: Before any assembly operation always verify that
the hole and bolt threads have no evidence of dirt or wear.
NHIL13ENG0277AA 3
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F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
1. Remove the bolts (2) and remove the oil pan (1).
NHIL13ENG0287AA 1
Next operation:
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Prior operation:
1. Install the oil pan (1) onto the engine block.

2. Torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft).
3. Install the oil drain plug (3) into the oil pan and torque
the bolt to 5 - 7 N·m (44 - 62 lb in).
the hole and bolt threads have no evidence of wear or dirt.
NHIL13ENG0287AA 1
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F4GE9484, F4GE9484C*J601, F4GE9684
1. Turn the engine upside down.

2. Remove the bolts (2), the mounting plate (3), and then
remove the oil pan (1).
NOTE: The shape and dimensions of the pan and of the oil
pick up tube may vary according to the engine application.
The relating illustrations provide general guidelines of the
operation to be performed.
NHIL13ENG0316BA 1
Version with oil pick up type A

(1) and (3).
2. Remove the bolts (5) and remove the stiffening plate
(4).
NHIL13ENG0285AA 2
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Version with oil pick up type B

(1) and (3).
2. Remove the bolts (5) and remove the stiffening plate
(4).
NHIL13ENG0276AA 3
Version with dynamic balancer

(5) and (3).
2. By means of pin (1), lock the dynamic balancer (4) in
the TDC (Top Dead Center) position.
3. Remove the bolts (2) and remove the dynamic balancer
(4).
NHIL13ENG0279AA 4
Next operation:
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10.2 [10.102] / 10

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
Oil pick up tube A

1. Install the stiffening plate (3) and the oil pick up tube
(2).
2. Torque bolts (1) to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0284AA 1
Oil pick up tube B

1. Install the stiffening plate (4).
2. Install the oil pick up tube (2).
3. Torque the bolts (1), (3), and (5) to 20 - 28 N·m (15 -
21 lb ft).
NHIL13ENG0276AA 2
Version with dynamic balancer

1. Install the dynamic balancer (3) on the engine block.
3. Remove the lock pin (1).
4. Refer to Balancer - Install (10.110) for proper timing
procedures.
NHIL13ENG0279AA 3
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5. Set the gasket (1) onto the oil pan (2).

NOTE: The pictures of the instructions relating to the oil
pan and to the pick up tube may not reflect the actual shape
and dimensions of your engine equipment. However, the
procedures described are still applicable.
NHIL13ENG0315AA 4
6. Place the oil pan (1) and the mounting plate (4) onto
the engine block.
8. Install the oil drain plug (3) into the oil pan and torque
the bolt to 5 - 7 N·m (44 - 62 lb in).
NHIL13ENG0316BA 5
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Engine block cover Front - Remove

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
Crankshaft damper - Remove (10.110)
1. Remove the bolts (1) from the front cover (2). Also be
sure to remove the two bolts (3) from underneath the
cover.
NOTE: Take note of bolt (1) assembling positions since
they have different lengths.
2. Remove the front cover (2) from the engine block.
NHIL13ENG0317AA 1
Next operation:
Engine block cover Front - Cleaning (10.102)
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Engine block cover Front - Cleaning

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
Engine block cover Front - Remove (10.102)
1. Remove the sealing ring (2) from the front cover (1).
NHIL13ENG0318AA 1
2. Clean the sealing surfaces and apply LOCTITE 5205.
NHIL13ENG0319AA 2
Next operation:
Engine block cover Front - Install (10.102)
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Engine block cover Front - Install

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
1. Install the front cover (2) and torque the mounting bolts
(1) to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0320AA 1
Next operation:
Crankshaft damper - Install (10.110)
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Engine block cover Front - Remove

Prior operation:
1. Remove the bolts (3) from the front cover (2). Also be
sure to remove the four bolts (1) from underneath the
cover (2).
NOTE: Take note of the bolt installation positions because
of different lengths.
2. Remove the front cover (2).
NHIL13ENG0321AA 1
Next operation:
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Engine block cover Front - Install

Prior operation:
1. place the front cover seal (1) onto the engine block.
NHIL13ENG0322AA 1
2. Install the front cover (1) on the block and torque the
bolts (2) to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0323AA 2
Next operation:
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Engine block cover Rear - Remove

Prior operation:
Engine flywheel - Remove (10.103)
1. Remove the retaining bolts (2) from the rear cover (1)
and then remove the cover.
NOTE: Take note of the retaining bolts (2) location due to
the different lengths. This will aid in ease of installation.
NHIL13ENG0324AA 1
Next operation:
Engine block cover Rear - Cleaning (10.102)
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Engine block cover Rear - Cleaning

Prior operation:
Engine block cover Rear - Remove (10.102)
1. Clean the rear cover and it's mating surface on the tim-
ing gear cover.
NOTE: A perfect seal is only obtained by completely clean-
ing the surface to seal. Any imperfection should be cor-
rected as soon as possible. Avoid using excess sealant.
Excessive sealant could squeeze out the sides and cause
blockage of lubrication passages.
2. Apply a thin bead of LOCTITE 5205 (1), a few millime-
ters thick, to the sealing surface of the cover.
NOTE: After applying the sealant, the cover should be in-
stalled within 10 to 20 minutes.
NHIL13ENG0325AA 1
Next operation:
Engine block cover Rear - Install (10.102)
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10.2 [10.102] / 19
Engine block cover Rear - Install

Prior operation:
NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or
dirt.
1. Install the cover (1) onto the timing gear housing and
torque the bolts in same location that they were re-
moved.
2. Torque the bolts to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0326AA 1
Next operation:
Engine flywheel - Install (10.103)
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10.2 [10.102] / 20

Prior operation:
1. Clean the rear cover and it's mating surface on the tim-
ing gear cover.
2. Apply a thin bead of LOCTITE® 518 GASKET
ELIMINATOR®, a few millimeters thick, to the sealing
surface (1) of the cover.
NOTE: After applying the sealant, the cover should be as-
sembled within 10 to 20 minutes. NHIL13ENG0327AA 1
Next operation:
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10.2 [10.102] / 21

Prior operation:
NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.
1. Install the rear cover (1) onto the engine.
2. Torque the retaining bolts (2) in the same position from
where they have been removed to 20 - 28 N·m (15 -
21 lb ft).
NHIL13ENG0328AA 1
Next operation:
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10.2 [10.102] / 22
Engine block cover Rear - Remove

Prior operation:
1. Remove the retaining bolts (2) and remove the rear

engine cover (1).
NHIL13ENG0329AA 1
Next operation:
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10.2 [10.102] / 23

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
1. Clean the rear cover (2) and it's mating surface on the
timing gear cover.
2. Apply a thin bead of LOCTITE 5205, a few millimeters
thick, to the sealing surface (1) of the cover.
NOTE: After applying the sealant, the cover should be as-
sembled within 10 to 20 minutes.
NHIL13ENG0330AA 1
Next operation:
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10.2 [10.102] / 24

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or
dirt.
1. Install the rear cover (1) onto the timing gear housing.
2. Install and torque the bolts in the same position from
which they were removed to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0331AA 1
Next operation:
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10.2 [10.102] / 25
Timing gear housing - Remove

F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684,
F4HE9687, F4HE9687G*J100
1. Remove the retaining bolts (2) and remove the timing

gear case (1) from the engine block.
NHIL13ENG0332AA 1
Next operation:
Timing gear housing - Cleaning (10.102)
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Timing gear housing - Cleaning

F4HE9687, F4HE9687G*J100
Prior operation:
Timing gear housing - Remove (10.102)
1. Clean the timing gear housing (1) and it's mating sur-
face on the engine block.
2. Apply a thin bead of LOCTITE 5205, a few millimeters
thick, to the sealing surface (2) of the housing.
NOTE: After applying the sealant, the housing should be
assembled within 10 to 20 minutes.
NHIL13ENG0333AA 1
Next operation:
Timing gear housing - Install (10.102)
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Timing gear housing - Install

F4HE9687, F4HE9687G*J100
Prior operation:
NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.
1. Install the housing (1) onto the engine block.
2. Install the retaining bolts in the same position found
upon removal and torque the bolts to 20 - 28 N·m (15 -
21 lb ft).
NHIL13ENG0334AA 1
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10.2 [10.102] / 28
Timing gear housing - Remove

1. Disconnect the high pressure fuel pump stroke sensor

(3).
2. Remove the bolts (2) and remove the timing gear hous-
ing (1) from the engine block.
NHIL13ENG0335AA 1
Next operation:
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Timing gear housing - Cleaning

Prior operation:
Timing gear housing - Remove (10.102)
1. Clean the timing gear housing (2) and it's mating sur-
face on the engine block.
2. Apply a thin bead of LOCTITE 5205 (1), a few millime-
ters thick, to the sealing surface of the housing.
NOTE: After applying the sealant, the housing should be
assembled within 10 to 20 minutes.
NHIL13ENG0340AA 1
Next operation:
Timing gear housing - Install (10.102)
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Timing gear housing - Install

Prior operation:
NOTE: Before any assembly operation, be sure that the hole and bolt threads have no wear or dirt.
1. Install the housing (1) onto the engine block.
2. Install the retaining bolts in the same position found
upon removal and torque the bolts to 20 - 28 N·m (15 -
21 lb ft).
NHIL13ENG0336AA 1
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Index
Engine - 10

Engine block cover Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4GE9484, F4GE9484C*J601, F4GE9684
Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4GE9484, F4GE9484C*J601, F4GE9684
Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4GE9484, F4GE9484C*J601, F4GE9684
Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine block cover Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103,
F4DE9684B*J111
F4GE9484, F4GE9484C*J601, F4GE9684
Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4DE9684B*J111
F4GE9484, F4GE9484C*J601, F4GE9684
Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4DE9684B*J111
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4DE9684B*J111
Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9484, F4GE9484C*J601, F4GE9684
Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4DE9684B*J111
F4GE9484, F4GE9484C*J601, F4GE9684
Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F4DE9684B*J111
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F4DE9684B*J111
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
F4DE9684B*J111
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Engine - 10
Valve drive and gears - 106

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
FUNCTIONAL DATA
Valve drive and gears

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Rocker arm
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684,
F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rocker shaft
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100,
F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102,
F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101,
F4DE9684M*J103, F4DE9684B*J111
Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4DE9684M*J103, F4DE9684B*J111
Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Camshaft bushings
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Camshaft gear
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684,
F4HE9687, F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F4DE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687,
F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Engine - Valve drive and gears
Valve drive and gears - Overview

Exhaust Gas Re-Circulation System (EGR)
In the Tier III version, the profile of the exhaust cam lobe has been modified in order to allow the partial opening of the
exhaust valve during the aspiration phase and introduces part of the exhaust gases into the engine cylinders. The
exhaust gases can partially be redirected into the cylinders so as to reduce the maximum combustion temperature
values responsible for the production of nitrogen oxides (NOx). The EGR system reduces the combustion temperature
by means of diminishing the concentration of oxygen in the combustion chamber. This process is an efficient control
system of the emission of NOx. The internal EGR system is not equipped with any electronically controlled elements.
The system is always active and does not require any additional components such as check valves, piping, or heat
exchangers. The exhaust cam has an additional lobe apart from the major lobe. The additional lobe, during the
aspiration phase of a cylinder, allows a brief opening of the exhaust valve generating recirculation due the intake of
the exhaust gases caused by the suction which is created in the aspiration phase inside the cylinder.
NHIL13ENG0337AA 1
(1) Intake valve control - (2) Exhaust valve control
Rocker Assembly Components
NHIL13ENG0338AA 2
(1) Bolts- (2) Bracket - (3) Shafts - (4) Rockers.
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Rocker arm - Disassemble

Prior operation:
Valve cover - Remove (10.101)
1. Loosen tappet adjustment jam nuts (1) and loosen the

adjusting bolts.
2. Remove the rocker shaft mounting bolts (2).
3. Remove the rocker assembly (3), which consists of the
pedestal (6), rockers (4), and shaft (5).
4. Remove the valve bridges (7).
5. Remove the push rods (8).
NHIL13ENG0339AA 1
Next operation:
Rocker shaft - Clearance (10.106)
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Rocker arm - Install

Prior operation:
Camshaft - Install (10.106)
1. Check that the tappet adjusters (1) are loose to prevent

their binding on the push rods when installing the rocker
assembly.
2. Install the rocker assembly onto the cylinder head con-
sisting of:
• Bracket (5)
• rockers (3)
• shafts (4)
3. Torque the bolts (2) to 36 Nm (27 lb ft).
NHIL13ENG0339AA 1
Next operation:
Rocker arm - Adjust (10.106)
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Rocker arm - Adjust

Prior operation:
Rocker arm - Install (10.106)
1. Adjust the clearance between the rockers and valves

using a set screw wrench (2), box wrench (1), and
feeler gauge (3).
2. Set the clearance to the following specifications.
• Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022 in)
on the camshaft for INTERNAL E.G.R, it is not possible
to use the valve clearance adjustment procedure that re-
quires adjusting the clearance of all the valves by position-
ing the crankshaft two times only.
Each cylinder must be checked by taking it to TDC (top NHIL13ENG0272AA 1
dead center) at the end of the compression stroke and ad-
justing the clearance of both valve on the cylinder in ques-
tion.
Next operation:
Valve cover - Install (10.101)
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Rocker arm - Remove

Prior operation:
1. Remove the rocker arm supports by removing the two

retaining bolts (1) and then remove the entire assembly
as one unit.
2. Remove the push rods.
NHIL13ENG0347AA 1
Next operation:
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Rocker arm - Check

Prior operation:
Rocker arm - Remove (10.106)
NHIL13ENG0344AA 1
(1) Elastic ring - (2) Spacer - (3) Rocker arms - (4) Support.
1. Carry out the assembly of the rocker arms after check-
ing the components.
NHIL13ENG0345AA 2
A B C
19.000 - 19.026 mm (0.748 - 18.975 - 18.963 mm (0.747 - 19.000 - 19.026 mm (0.748 -
0.749 in) 0.747 in) 0.749 in)
2. Check the coupling surfaces of the bearings and shaft

for excessive wear or damages. Replace if necessary.
3. Torque the threaded nut (1) to 4 - 6 N·m (35 - 53 lb in).
ROCKERCOMPCG3 3
Next operation:
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Rocker arm - Install

Prior operation:
Rocker arm - Check (10.106)
1. Install the rocker arm assembly (2) onto the cylinder

head and torque the bolts (1) to 20 - 28 N·m (15 - 21 lb
ft).
NHIL13ENG0347AA 1
Next operation:
Rocker arm - Adjust (10.106)
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Rocker arm - Adjust

Prior operation:
1. Adjust the clearance between the rockers and valves

using a set screw wrench (2), box wrench (3), and
feeler gauge (1).
2. Set the valve clearance to the following specifications.
• Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022 in)
on the camshaft for INTERNAL E.G.R., it is not possible
to use the valve clearance adjustment procedure that re-
quires adjusting the clearance of all the valves by position-
ing the crankshaft two times only.
Each cylinder must be checked by taking it to TDC (top NHIL13ENG0312AA 1
dead center) at the end of the compression stroke and ad-
justing the clearance of both valve on the cylinder in ques-
tion.
Next operation:
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Rocker shaft - Clearance

Prior operation:
Rocker arm - Disassemble (10.106)
1. Check that the shaft/rocker coupling surfaces are not

showing excessive wear or damage. Follow the pro-
vided rocker surface specifications.
SHAFTMEASURE 1
Next operation:
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Camshaft - Remove
Prior operation:
Camshaft gear - Remove (10.106)
1. Remove the bolts (1) and remove camshaft (2) retain-

ing plate (3).
NOTE: Take note of the retaining plate (3) assembly posi-
tion.
NHIL13ENG0350AA 1
2. Carefully remove the camshaft (1) from the cylinder

block (2).
NHIL13ENG0351AA 2
Next operation:
Camshaft - Measure (10.106)
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Camshaft - Measure
Prior operation:
Camshaft - Remove (10.106)
1. Set the camshaft on the tailstock and using a 1/100

gauge set on the central support, check the alignment
error.
The alignment error should not exceed 0.04 mm
(0.002 in).
If the error is exceeded, replace the camshaft.
2. Check the camshaft lift. The values should be as fol-
lows:
Exhaust lobe lift — 6.045 mm (0.238 in)
Intake lobe lift — 7.582 mm (0.299 in)
If the values are not within the specifications, replace
the camshaft.
3. Check the camshaft (2) pin diameter using a microme-
ter 380000645 (1) on two perpendicular axes.
The diameter should be within 53.995 - 54.045 mm
(2.126 - 2.128 in).
If the values are not within the specifications, replace
the camshaft.
NHIL13ENG0352AA 1
BAIL07APH360FSA 2
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NOTE: Camshaft pin and cam surfaces should be absolutely smooth; if they show any signs of seizing or scoring
replace the camshaft and the bearings.
Next operation:
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Camshaft - Install
Prior operation:
1. Lubricate the camshaft bearings with clean engine oil

and carefully install the camshaft (1) into the engine
block.
NOTE: Be careful not to damage the camshaft bearings or
housings while sliding the camshaft into the engine block.
CRIL04J056A01 1
2. Set the camshaft (3) retaining plate (1) with the slot fac-
ing the top of the engine block and the marking facing
the operator.
CRIL04J064A01 2
Next operation:
Camshaft - End play (10.106)
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Camshaft - End play

Prior operation:
1. Check camshaft (1) end play using a dial indicator

17270.
End play should be between 0.10 - 0.36 mm (0.004 -
0.014 in).
CRIL04J065A01 1
Next operation:
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Camshaft Push rod - Install

F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103,
F4DE9684B*J111
Prior operation:
1. Before installation be sure to check that there is no

signs of wear or distortion. Intake and exhaust push
rods are identical and therefore interchangeable.
PUSHROD 1
2. Install the push rods (2).

3. Install the valve bridges (1) with the marks facing the
exhaust manifold.
NHIL13ENG0358AA 2
Next operation:
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Camshaft Tappets - Remove

F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103,
F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
Prior operation:
1. Remove the tappets (1) from the engine block.
NHIL13ENG0359AA 1
Next operation:
Camshaft Tappets - Measure (10.106)
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Camshaft Tappets - Measure

F4DE9684B*J111
Prior operation:
Camshaft Tappets - Remove (10.106)
NHIL13ENG0363FA 1
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK
A B C D E F G
16.000 - 15.924 - 15.960 - 15.924 - 8 mm 26 mm 44 mm
16.030 mm 15.954 mm 15.975 mm 15.954 mm
Next operation:
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Camshaft Tappets - Install

Prior operation:
Camshaft Tappets - Measure (10.106)
Lubricate the tappets (1) with clean engine oil and install
them into the relevant housings on the engine block.
CRIL04J063A01 1
Next operation:
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Camshaft Push rod - Install

Prior operation:
1. Inspect the push rods for signs of deformation.

2. Inspect both ends of the push rods for evidence of
seizure or wear.
NOTE: The push rods driving the intake and exhaust
valves are identical and therefore interchangeable. Re-
place any failed push rods with new.
3. Install the push rods.
NOTICE: Ensure that the push rods are properly seated in
the tappets.
PUSHROD 1
Next operation:
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Camshaft Tappets - Measure

Prior operation:
Camshaft Tappets - Remove (10.106)
NHIL13ENG0363FA 1
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK
A B C D E F G
16.000 - 15.929 - 15.965 - 15.929 - 14 mm 32 mm 50 mm
16.030 mm 15.959 mm 15.980 mm 15.959 mm
Next operation:
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Camshaft bushings - Measure

Prior operation:
1. Camshaft bearings (2) are pressed into their housings.

Check the internal surface of the bearings for seizing or
wear. Use a bore dial gauge OEM1032 (3) to measure
the camshaft bearings (2) and intermediate housing (1)
diameter. The measurements should be performed on
two perpendicular axis'.
Camshaft bearing inside diameter should be within
54.083 - 54.147 mm (2.129 - 2.132 in).
CRIL04J060A01 1
NHIL13ENG0365AA 2
*Height to be obtained after installing the bearing.
A B C
59.222 - 59.248 mm 54.089 - 54.139 mm 54.083 - 54.147 mm
Next operation:
Camshaft - Replace (10.106)
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Camshaft bushings - Replace

Prior operation:
Remove and install the bushing (1) using the beater with
hand grip (2) 380000145.
NOTICE: When installing the bushing , take note of orien-
tation to make sure the lubricating holes on the bushing
coincide with the holes on the block housing.
NHIL13ENG0366AA 1
Next operation:
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Camshaft gear - Remove

F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100
Prior operation:
1. Remove the bolts (1) securing the camshaft gear (2) to

the camshaft (3).
2. Remove the camshaft gear (2) from the camshaft (3).
NHIL13ENG0367AA 1
Next operation:
Camshaft gear - Install (10.106)
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Prior operation:
1. Remove the retaining bolts (1).

2. Remove the camshaft gear (2) from the camshaft (3).
NHIL13ENG0368AA 1
Next operation:
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Camshaft gear - Install

F4DE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9687, F4HE9687G*J100,
Prior operation:
1. With a felt tip pen, highlight the timing mark on the

crankshaft gear (1) mounted on the crankshaft (2) upon
the upright surface on which a groove (3) has been cre-
ated for the injection timing.
NOTE: For ease of crankshaft rotation, install two pins in
the end of the crankshaft.
NHIL13ENG0369AA 1
2. Turn the crankshaft (1) and the camshaft (2) so that the
camshaft gear (3) can be mounted on the camshaft (2)
to coincide with the timing mark on the crankshaft gear
(4).
NHIL13ENG0370AA 2
3. Position a dial indicator gauge 380001543 (1) on the

camshaft gear (2).
4. Check that the clearance between gears (2) and (3) is
within 0.076 - 0.280 mm (0.003 - 0.011 in).
NHIL13ENG0371AA 3
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5. Torque the bolts (1) that secure the gear (2) to camshaft
(3) to 32 - 40 N·m (24 - 30 lb ft).
NHIL13ENG0372AA 4
Next operation:
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Prior operation:
1. Remove the retaining bolts (1) and remove the gears

(2) from the camshaft (3).
NHIL13ENG0373AA 1
Next operation:
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Prior operation:

NHIL13ENG0374AA 1
2. Turn the crankshaft (3) and the camshaft (4) so that the
camshaft gear (1) can be mounted on the camshaft (4)
to coincide with the timing marks on the gears (2).
NHIL13ENG0375BA 2
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camshaft gear (2).
within 0.076 - 0.280 mm (0.003 - 0.011 in).
NHIL13ENG0376AA 3
5. Torque the bolts (1) securing the gears (2) to the

camshaft (3) to 32 - 40 N·m (24 - 30 lb ft).
NHIL13ENG0377AA 4
Next operation:
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Prior operation:

NHIL13ENG0378AA 1
2. Turn the engine crankshaft (3) and the camshaft (2)

so that the camshaft gears (1) can be mounted on the
camshaft (2) to coincide with the mark on the crankshaft
gear.
NHIL13ENG0379AA 2

camshaft gear (2).
within 0.076 - 0.280 mm (0.003 - 0.011 in).
NHIL13ENG0380AA 3
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5. Torque the bolts (1) installing the gears (2) to the

camshaft (3) to 32 - 40 N·m (24 - 30 lb ft).
NHIL13ENG0381AA 4
Next operation:
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Index
Engine - 10

Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101,
F4DE9684M*J103, F4DE9684B*J111
Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Camshaft Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102,
F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4DE9684M*J103, F4DE9684B*J111
Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Camshaft bushings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Camshaft bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Camshaft gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
F4DE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9687,
Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684,
F4HE9687, F4HE9687G*J100
Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rocker arm - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rocker arm - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rocker shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Valve drive and gears - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Cylinder heads - 101

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
SERVICE
Valve cover
Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103,
F4DE9684B*J111
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cylinder head
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F4CE9684, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
F4CE9684, F4GE9684
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
F4GE9484, F4GE9484C*J601, F4GE9684
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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Valves
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Valve guide
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve seat
Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
47597675 27/09/2013
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CONSUMABLES INDEX

assembly paste
assembly paste
assembly paste
assembly paste
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Engine - Cylinder heads
Valve cover Rocker housing - Remove

Prior operation:
1. Remove the nuts (2) securing the electro-injectors (3)

and disconnect the electrical wires.
2. Remove the bolts (1) securing the rocker arm housing
(4).
3. Remove the rocker arm housing (4) and gasket from
the cylinder head.
NHIL13ENG0382AA 1
Next operation:
Valve cover Rocker housing - Install (10.101)
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Valve cover Rocker housing - Install

Prior operation:
1. Check the condition of the electrical cables (2) and

their electrical connectors (4). Replace if damage was
caused from removing the retaining bolt (3).
2. Install a new gasket (1) onto the support (5).
NHIL13ENG0383AA 1
NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.
3. Install the housing (2) and torque the bolts (1) to 1 -
2 N·m (11 - 15 lb in).
NHIL13ENG0384AA 2
4. Connect the electrical cables (1) to the injectors (3).

5. Use a torque wrench (2) to torque the retaining nuts (4)
to 1 - 2 N·m (11 - 15 lb in).
NHIL13ENG0385AA 3
Next operation:
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Valve cover - Remove

1. Remove the nuts (1) securing the valve cover (2) to the
base.
2. Remove the valve cover (2) and the gasket.
NHIL13ENG0386AA 1
Next operation:
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Valve cover - Install

Prior operation:
1. Install a new gasket (1) onto the valve cover (2).

2. Install the valve cover (2) onto the cylinder head.
NHIL13ENG0387AA 1
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F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111
1. Remove the nuts (1) securing the valve cover (2).

2. Remove the valve cover (2) from the cylinder head.
NHIL13ENG0388AA 1
Next operation:
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10.4 [10.101] / 9

1. Remove the retaining bolts (1) from the valve covers

(2).
2. Remove the valve covers (2) and the related gaskets.
NHIL13ENG0389AA 1
3. On one of the valve covers there is a blow-by valve for

the lubrication oil vapors. This can be removed along
with the relevant valve cover (2) by removing the re-
taining bolts (1).
NOTE: All gaskets should be replaced upon reassembly.
NHIL13ENG0390AA 2
Next operation:
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Valve cover - Install

Prior operation:
1. Install the valve covers (2) with the new gaskets.

NHIL13ENG0391AA 1
3. Install the valve cover (2) that incorporates the blow-by

valve with a new gasket and torque the bolts (1) to 20
- 28 N·m (15 - 21 lb ft).
NHIL13ENG0392AA 2
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Cylinder head - Remove

Prior operation:
Fuel injectors - Remove (10.218)
1. Remove the cylinder head bolts (1) from the cylinder

head (2).
NOTE: The highlighted bolts are shorter.
NHIL13ENG0393BA 1
2. Hook the provided cylinder head lifting brackets (1) to

suitable lifting chains.
3. Remove the cylinder head (2) from the engine block
using a suitable hoist.
NHIL13ENG0394AA 2
Next operation:
Cylinder head - Check (10.101)
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Cylinder head - Check

Prior operation:
Cylinder head - Remove (10.101)
Checking cylinder head wet seal

This check should be performed using the proper tools.
1. Use a pump to fill with water heated to approximately
90 °C (194.0 °F) and 2 - 3 bar (29.0 - 43.5 psi) of pres-
sure.
2. Replace the core plugs (1) if any leakage is found. Use
the proper punch for their removal and installation.
NOTE: Before refitting, smear the plug surfaces with water
repellent sealant.
3. Replace the cylinder head if leaks are found.
NHIL13ENG0395AA 1
Checking cylinder head supporting surface

1. Distortion found along the whole cylinder head should
not exceed 0.20 mm (0.008 in).
If higher values are found, resurface the cylinder head
according to values and indications shown in the fol-
lowing figure.
2. The rated thickness (A) for the cylinder head is 104.75
- 105.25 mm (4.124 - 4.144 in). Maximum metal
removal shall not exceed thickness (B) by 1 mm
(0.039 in).
NOTE: After resurfacing, check valve sinking. Regrind the
valve seats, if required, to obtain the specified value.
NHIL13ENG0396AA 2
A B
104.750 - 105.250 mm (4.124 - 4.144 in) 1 mm
Next operation:
Cylinder head - Install (10.101)
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Cylinder head - Install

Prior operation:
Cylinder head - Check (10.101)
1. Check the cleanliness of the cylinder head and engine

block coupling surface.
2. Without damaging the gasket, set the gasket (1) onto
the engine block with the marking "TOP" facing the
cylinder head.
3. The reference arrow (2) shows the point at where the
head gasket thickness is given.
NHIL13ENG0397AA 1
4. There are two head gasket thicknesses, ( 1.25 mm

Type A and 1.15 mm Type B). To determine the cor-
rect head gasket to use, piston protrusion must be mea-
sured.
• For each piston, measure protrusion in two places
180 ° apart, at a distance of 45 mm (1.8 in) from the
center of the piston S1 and S2. Then calculate the
average:
NHIL13ENG0398AA 2
• Repeat the operation for pistons 2, 3, 4, 5 and 6 and
calculate the average value.
• If S is > 0.40 mm (0.016 in) use seal type A.

• If S is < 0.40 mm (0.016 in) use seal type B.
A B
45 mm 45 mm
5. Before reusing the cylinder head bolts, measure them

twice as indicated in the picture. Check the D1 and D2
diameters for the following specifications:
if D1 - D2 < 0.1 mm (0.004 in) the bolt can be utilized
again.
If D1 - D2 > 0.1 mm (0.004 in) the bolt must be re-
placed.
NHIL13ENG0399AA 3
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6. Hook the provided cylinder head lifting brackets (1) with

a suitable hoist.
7. Set the cylinder head (2) onto the engine block.
8. Lubricate the cylinder head bolts with MOLYKOTE® G-N
METAL ASSEMBLY PASTE.
9. Install the bolts into the cylinder head.
NHIL13ENG0400AA 4
10. Torque the cylinder head bolts by bolt size (1) in the
following order using tool DM370(3/4) (2) for the angle
torquing procedure.
1. Torque the bolts (1) with a torque wrench to the
following specifications:
• 12x1.75x130 are torqued to 30 - 40 Nm (22 -
30 lb ft).
• 12x1.75x150 are torqued to 50 - 60 Nm (37 -
44 lb ft).
2. Turn the bolt clockwise 85 - 95 °.
3. Turn the bolt clockwise an additional 85 - 95 °.
NHIL13ENG0401AA 5
NHIL13ENG0402AA 6
Tightening sequence for the 6 cylinder engine.
A = Front of engine
Next operation:
Fuel injectors - Install (10.218)
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Prior operation:
Fuel injectors Mechanical - Remove (10.218)
1. Remove the bolts (1) securing the cylinder head (3) to

the engine block.
2. Hook the provided cylinder head lifting brackets to a
suitable hoist.
3. Using the hoist, remove the cylinder head from the en-
gine block.
4. Remove the cylinder head gasket (2).
NHIL13ENG0403AA 1
Next operation:
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F4CE9684, F4GE9684
Prior operation:
1. Remove the bolts (1) securing the cylinder head (3) to

the engine block.
2. Hook the provided cylinder head lifting brackets to a
suitable hoist.
3. Using the hoist, remove the cylinder head from the en-
gine block.
4. Remove the cylinder head gasket (2).
NHIL13ENG0404AA 1
Next operation:
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10.4 [10.101] / 17

Prior operation:

cylinder head.
gasket thickness is given.
NOTE: Do not grease the gasket. It is recommended to
keep the gasket inside its packaging until assembly to the
cylinder head.
Gasket assembly shall be made following the direction of
wording printed on the gasket itself so that this will be read- NHIL13ENG0405AA 1
able as indicated in the picture.
sured.
average:
NHIL13ENG0398AA 2

A B
45 mm 45 mm
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10.4 [10.101] / 18
5. Hook the provided cylinder head lifting brackets (1) with

a suitable hoist.
6. Set the cylinder head (2) onto the engine block.
NOTE: If the valves have been removed, it is necessary
to install them before installing the cylinder head onto the
engine block.
NHIL13ENG0400AA 3
7. Lubricate the cylinder head bolts with MOLYKOTE® G-N

METAL ASSEMBLY PASTE.
8. Install the bolts (1) into the cylinder head (2).
NHIL13ENG0408AA 4
9. If reusing the bolts, measure them twice as indicated in

the picture. Check for the following specifications:
- If D1 - D2 < 0.1 mm (0.004 in) the bolt can be used
again.
- If D1 - D2 > 0.1 mm (0.004 in) the bolt must be re-
placed.
NHIL13ENG0414AA 5
10. The bolts must be torqued starting with the center

bolts and moving out. The bolts should be torqued
in the following stages using the tool DM370(3/4) for
the angular torquing procedure. Refer to the bolt se-
quencing diagram.
• Make all the bolts snug tight, then turn 90 °.
• Turn the bolts M12x140 and M12x180 an additional
90 °.
11. The end result should look like this.
• M12x70 = 50 Nm (36.9 lb ft) + 90 °.
• M12x140 = 40 Nm (29.5 lb ft) + 180 °.
• M12x180 = 70 Nm (51.6 lb ft) + 180 °.
TORQUEPATTERNG2 6
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Next operation:
Fuel injectors Mechanical - Install (10.218)
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F4CE9684, F4GE9684
Prior operation:

cylinder head.
NOTE: Do not grease the gasket. It is recommended to
keep the gasket inside its packaging until assembly to the
cylinder head.
Gasket assembly shall be made following the direction of
wording printed on the gasket itself so that this will be read- NHIL13ENG0420AA 1
able as indicated in the picture.
sured.
average:
NHIL13ENG0398AA 2

A B
45 mm 45 mm
47597675 27/09/2013
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5. Place the cylinder head (2) onto the engine block. Lu-
bricate the bolts (1) with MOLYKOTE® G-N METAL AS-
SEMBLY PASTE and install the bolts (1) into the cylinder
head.
to install them before installing the cylinder head onto the
engine block.
NHIL13ENG0422AA 3
6. Before using the bolts again, measure them twice as

indicated in the picture. Refer to the following specifi-
cations:
- If D1 - D2 < 0.1 mm (0.004 in) the bolt can be used
again.
- If D1 - D2 > 0.1 mm (0.004 in) the bolt must be re-
placed.
NHIL13ENG0423AA 4
7. The bolts must be torqued starting with the center

bolts and moving out. Torque the bolts in the following
sequence using the tool DM370(3/4) for the angular
torquing procedure. Refer to bolt torquing sequence
diagram.
• Make all the bolts snug tight, then turn the bolts 90 °.
• Turn the bolt sizes M12x140 and M12x180 an addi-
tional 90 °.
TORQUEPATTERNG2 5

• M12x70 = 50 Nm (36.9 lb ft) + 90 °
• M12x140 = 40 Nm (29.5 lb ft) + 180 °
• M12x180 = 70 Nm (51.6 lb ft) + 180 °
Next operation:
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F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:

90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pres-
sure.
repellent sealant.
NHIL13ENG0416AA 1

lowing figure.
removal should not exceed thickness (B) by 1 mm
(0.039 in).
NHIL13ENG0419AA 2
A B
104.750 - 105.250 mm (4.124 - 4.144 in) 1 mm
Next operation:
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Prior operation:

90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pres-
sure.
repellent sealant.
NHIL13ENG0416AA 1

lowing figure.
removal should not exceed thickness (B) by 1 mm
(0.039 in).
NHIL13ENG0419AA 2
A B
104.750 - 105.250 mm (4.124 - 4.144 in) 1 mm
Next operation:
47597675 27/09/2013
10.4 [10.101] / 24


cylinder head.
NHIL13ENG0420AA 1
NOTE: Do not grease the gasket. It is recommended to keep the gasket inside its packaging until assembly to the
cylinder head.
Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be
readable as indicated in the picture.
sured.
average:
NHIL13ENG0398AA 2

A B
45 mm 45 mm
47597675 27/09/2013
10.4 [10.101] / 25
5. Place the cylinder head (2) onto the engine block. Lu-
bricate the cylinder head bolts (1) with MOLYKOTE® G-N
METAL ASSEMBLY PASTE and install the bolts (1) into the
cylinder head.
to install them before installing the head onto the engine
block.
NHIL13ENG0422AA 3
6. Before using the bolts again, measure them twice as

indicated in the picture, checking D1 and D2 diameters:
If D1 - D2 < 0.1 mm (0.004 in) the bolt can be used
again.
If D1 - D2 > 0.1 mm (0.004 in) the bolt must be re-
placed.
NHIL13ENG0423AA 4
7. The bolts must be torqued starting with the center bolts

and moving out. Torque the bolts in the following stages
using the tool DM370(3/4) for the angular torquing pro-
cedure.
• Make all the bolts snug tight, then turn 90 °.
• Turn the bolt sizes M12x140 and M12x180 an addi-
tional 90 °.
• M12x70 = 50 Nm (36.9 lb ft) + 90 °
• M12x140 = 40 Nm (29.5 lb ft) + 180 °
• M12x180 = 70 Nm (51.6 lb ft) + 180 °
TORQUEPATTERNG2 5
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Valves - Remove
Prior operation:
1. Intake (1) and exhaust (2) valves have the same diam-
eter valve head. The central notch of the exhaust valve
(2) head distinguishes it from the intake valve.
NOTE: Should cylinder head valves not be replaced, num-
ber them before removing in order to reinstall them in the
same position.
A = intake side - S = exhaust side
NHIL13ENG0425AA 1
2. Valve removal should be performed using tool

75291050 (1) and pressing the cap (3) so that when
compressing the springs (4) the keepers (2) can be
removed. Then remove the cap (3) and the springs (4).
3. Repeat this operation for all the valves.
4. Turn over the cylinder head and remove the valves (5).
NHIL13ENG0426AA 2
5. Remove the sealing rings (1) and (2) from the valve
guides.
NOTE: Sealing rings (1) for intake valves are yellow.
Sealing rings (2) for exhaust valves are green.
NHIL13ENG0427AA 3
Next operation:
Valves - Install (10.101)
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Valves - Measure
Prior operation:
Valves - Cleaning (10.101)
NHIL13ENG0428AA 1
INTAKE AND EXHAUST VALVE MAIN DATA
1. Check the valve stem (2) using a micrometer (1).
The valve stem diameter for intake and exhaust
valves should be between 6.970 - 6.990 mm (0.274 -
0.275 in).
NHIL13ENG0429AA 2
Next operation:
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Valves - Cleaning
Prior operation:
Valves - Remove (10.101)
1. Remove carbon deposits from valves using the proper

metal brush.
2. Check that the valves show no signs of seizing, scoring,
or cracking.
3. If necessary, grind the valve seats, taking away the
least amount of material possible.
NHIL13ENG0430AA 1
Next operation:
Valves - Measure (10.101)
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Valves Spring - Check

F4DE9684B*J111
Prior operation:
Before installing the valve springs, use a valve spring load

checking tool 99305047 to check spring load. Compare
load and elastic deformation data with those of the new
springs in the following table:
NHIL13ENG0431AA 1
Height Weight applied

(H) - 47.75 mm (1.880 in) None
(H1) - 35.33 mm (1.391 in) (P) - 320.8 - 358.8 N (72.1 - 80.7 lb)
(H2) - 25.2 mm (0.992 in) (P1) - 702 - 780 mm (27.6 - 30.7 in)
Next operation:
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Valves - Install
Prior operation:
1. Lubricate the valve stems (2) and install them into the
relevant valve guides according to the position marked
at removal.
2. install the sealing rings (1) and (3) on the valve guides.
NOTE: Sealing rings (1) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
NHIL13ENG0432AA 1
3. Position the springs (4) and the upper cap (3) on the
cylinder head. Use tool 75291050 (1) to compress the
spring (4) and lock the parts to the valve (5) by the
keepers (2).
NHIL13ENG0433AA 2
Next operation:
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10.4 [10.101] / 31
Valves - Remove
Prior operation:
1. Intake (1) and exhaust (2) valves have the same diam-
eter valve head.
NOTE: Should cylinder head valves not be replaced, num-
ber them before removing in order to reinstall them in the
same position.
A = intake side
NHIL13ENG0434AA 1
2. To remove the valves, use tool 75291050 (1). Using

the tool, press the cap (3) to compress the valve spring
(4) and remove the keepers (2). Then remove the cap
(3) and the springs (4).
3. Repeat this operation for all the valves.
4. Turn over the cylinder head and remove the valves (5).
NHIL13ENG0435AA 2
5. Remove the sealing rings (1) and (2) from the valve
guides.
NHIL13ENG0440AA 3
Next operation:
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Valves - Measure
Prior operation:
NHIL13ENG0437AA 1
INTAKE AND EXHAUST VALVE MAIN DATA
1. Check the valve stem (1) using a micrometer (2).
The valve stem diameter for intake and exhaust
valves should be between 7.960 - 7.980 mm (0.313 -
0.314 in).
NHIL13ENG0438AA 2
Next operation:
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Valves Spring - Check

Prior operation:
Before installing the valve springs, use a valve spring load

checking tool 99305047 to check spring load. Compare
load and elastic deformation data with those of the new
springs in the following table:
NHIL13ENG0439AA 1
Height Under a load of

H 63.50 mm (2.500 in) Free
H1 49.02 mm (1.930 in) P1 320.8 - 358.8 N (72.1 - 80.7 lb)
H2 38.20 mm (1.504 in) P2 702 - 780 mm (27.6 - 30.7 in)
Next operation:
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Valves - Install
Prior operation:
1. Lubricate the valve stems (1) and install them into the
relevant valve guides according to the position marked
at removal.
2. Install the sealing rings (2) and (3) onto the valve
guides.
NHIL13ENG0440AA 1
3. Position the valve springs (4) and the upper cap (3)
onto the cylinder head. Use the valve spring compres-
sor tool 75291050 (1) to compress the spring (4) and
install the valve keepers (2) to lock the parts to the valve
(5).
NHIL13ENG0441AB 2
Next operation:
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Valve guide - Clearance

Prior operation:
1. Use a magnetic base dial bore gauge (1) set as shown

in the figure. The assembling clearance should be be-
tween 0.052 - 0.092 mm (0.002 - 0.004 in).
2. Turn the valve (2) and check that the centering error is
not exceeding 0.03 mm (0.001 in).
NHIL13ENG0442AA 1
3. Use a bore dial gauge to measure the inside bore di-

ameter of the valve guides. The values for both in-
take and exhaust valve guides should be within 7.042
- 7.062 mm (0.277 - 0.278 in).
NHIL13ENG0443AA 2
A B C
7.042 - 7.062 mm (0.277 - 0.278 in) Intake Exhaust
Next operation:
47597675 27/09/2013
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Valve guide - Clearance

Prior operation:
1. Use a magnetic base dial bore gauge (1) set as shown

in the figure. The assembling clearance should be be-
tween 0.052 - 0.092 mm (0.002 - 0.004 in).
2. Turn the valve (2) and check that the centering error is
not exceeding 0.03 mm (0.001 in).
NHIL13ENG0444AA 1
3. Use a bore dial gauge to measure the inside bore di-

ameter of the valve guides. The values for both in-
take and exhaust valve guides should be within 7.042
- 7.062 mm (0.277 - 0.278 in).
NHIL13ENG0443AA 2
A B C
8.0190 - 8.0390 mm (0.3157 - Intake Exhaust
0.3165 in)
Next operation:
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Valve seat - Regrind

Prior operation:
Should slight scratches or burns be found, go over the

valve seat (2) using a valve seat grinding tool kit 99305019
(1) according to the inclination values indicated as follows:
NHIL13ENG0446AA 1
NHIL13ENG0447FA 2
VALVE SEAT MAIN DATA (4 CYL.)
A B C D E F G H
69.5 - 70.5 ° 45 °
29.5 - 30.5 ° 69.5 - 70.5 ° 60 °
29.5 - 30.5 ° 3.370 - 3.020 -
(69.5 - (29.5 - (69.5 - (29.5 - 3.630 mm 3.280 mm
70.5 °) 30.5 °) 70.5 °) 30.5 °) (0.133 - (0.119 -
0.143 in) 0.129 in)
If valve seats can not be reground within specification, re-

place them with new ones. Using a valve seat grinding tool
99305019, remove as much material as possible from the
valve seats without damaging the cylinder head until they
can be extracted from the cylinder head using a punch.
1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F)
and using the proper punch, install the new, previously
cooled valve seats into the cylinder head.
2. Using a valve seat grinding tool kit 99305019, go over
the valve seats according to the values stated in the
previous figure.
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NHIL13ENG0448FA 3
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
A B C D E F G H I J
1.10 - 39.50 - 27.25 - 34.837 - 3 36.78 mm 27.25 - 34.837 - 3 36.78 mm Exhaust Intake
1.50 mm 40.50 mm 27.75 mm 4.863 mm 27.75 mm 4.863 mm
(0.04 - (1.56 - (1.07 - (1.372 - (1.07 - (1.372 -
0.06 in) 1.59 in) 1.09 in) 1.373 in) 1.09 in) 1.373 in)
3. After regrinding, check the valve (3) sinking value by
using the base 380000364 (2) and the dial bore gauge
380000228 (1).
Intake valve sink should between 0.59 - 1.11 mm
(0.023 - 0.044 in).
Exhaust valve sink should be between 0.96 - 1.48 mm
(0.038 - 0.058 in).
NHIL13ENG0449AA 4
Next operation:
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Valve seat - Regrind

Prior operation:
Should slight scratches or burns be found, go over the

valve seat (2) with a valve seat grinding tool kit 99305019
(1) according to the inclination values indicated as follows:
NHIL13ENG0446AA 1
VALVESEAT2 2
VALVE SEAT MAIN DATA (dimensions in mm)
If valve seats can not be reground within specification, re-
place them with new ones. Using a valve seat grinding tool
99305019, remove as much material as possible from the
valve seats without damaging the cylinder head until they
can be extracted from the cylinder head using a punch.
1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F).
Using the proper punch, install the new, previously
cooled valve seat into the cylinder head.
2. Using a valve seat grinding tool 99305019, go over the
valve seats according to the values stated in the previ-
ous figure.
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NHIL13ENG0452AA 3
VALVE SEAT HOUSING MAIN DATA
A B C D E F
4.38 - 4.64 mm 45 ° 30 ° 4.06 - 4.32 mm 39.500 mm 42.500 mm
(0.17 - 0.18 in) (0.16 - 0.17 in)
3. After regrinding, check that the valve (3) sinking value
is the specified one by using the base 380000364 (2)
and the dial bore gauge 380000228 (1).
Intake and exhaust valve seat sinking should be be-
tween 1 - 1.52 mm (0.039 - 0.060 in).
NHIL13ENG0449AA 4
Next operation:
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Index
Engine - 10

Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4CE9684, F4GE9684
Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9684, F4GE9684
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Valve cover Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Valve cover Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
F4DE9684M*J103, F4DE9684B*J111
Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Engine - 10
Connecting rods and pistons - 105

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
FUNCTIONAL DATA
Connecting rod and piston

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Connecting rod and piston

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Piston
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4DE9684M*J103, F4DE9684B*J111
Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4DE9684M*J103, F4DE9684B*J111
Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4DE9684M*J103, F4DE9684B*J111
Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4DE9684M*J103, F4DE9684B*J111
Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4DE9684M*J103, F4DE9684B*J111
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting rod bearing
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Piston pin bushings
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - Connecting rods and pistons
Connecting rod and piston - Overview
NHIL13ENG0454AA 1
(1) Piston (5) Connecting rod

(2) Split rings (6) Bearing
(3) Bolts (7) Snap rings
(4) Half bearings (8) Pin
NOTE: The pistons are supplied spare with the following sizes:
- Standard
- 0.4 mm (0.016 in) oversize.
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Connecting rod and piston - Remove

Prior operation:
1. Remove the connecting rod nuts (2) and remove the

connecting rod caps (1).
2. Remove the piston and connecting rod as one unit from
the top of the engine block.
3. Repeat these steps for the remaining cylinders.
NOTE: Keep the half bearings into their housing since in
case of use they shall be installed in the same position
found at removal.
NHIL13ENG0455AA 1
Next operation:
Connecting rod and piston - Install (10.105)
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Connecting rod and piston Connecting rod - Measure
NHIL13ENG0456GA 1
* Value for the inside diameter to be obtained after driving in connecting rod small end and grinding.
A B C D E F
40.987 - 40.987 - 38.019 - 38.000 - 72.987 - 1.9550 -
41.013 mm 41.013 mm 38.033 mm 38.006 mm 73.013 mm 1.9680 mm
(1.614 - 1.615 in) (1.614 - 1.615 in) (1.497 - 1.497 in) (1.496 - 1.496 in) (2.874 - 2.875 in) (0.0770 -
0.0775 in)
NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recom-
mended not to smooth the knurls.
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NHIL13ENG0457AA 2
NOTE: Every connecting rod is marked as follows:
(1) - On the body and cap with a number showing their coupling and the corresponding cylinder. In case of replace-
ment, it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.
(2) - On the body with a letter showing the weight of the connecting rod assembled at production:
- V - 1820 - 1860 g (64.2 - 65.6 oz) (yellow marking)
- W - 1861 - 1900 g (65.6 - 67.0 oz) (green marking)
- X - 1901 - 1940 g (67.1 - 68.4 oz) (blue marking)
Spare connecting rods are of the - W - class with a green marking. Material removal is not allowed.
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Connecting rod and piston - Assemble

Prior operation:
Piston Pin - Remove (10.105)
1. The piston crown is marked as follows:

1. Part number and design modification number.
2. Arrow showing piston installation direction into
cylinder.
3. Manufacturing date.
4. Stamp indicating the ring carrier US inspection.
NHIL13ENG0458AA 1
2. Connect the piston (1) to the connecting rod (4) with

the piston pin (5) so that the reference arrow (2) for in-
stalling the piston (1) into the cylinder and the numbers
(3) marked on the connecting rod (4) are read as shown
in the figure.
NHIL13ENG0459AA 2
3. Position the piston (1) on the connecting rod (2) accord-

ing to the diagram shown in the figure and install the pin
(3) and stop at the snap rings (4).
NHIL13ENG0460AA 3
Next operation:
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Connecting rod and piston - Install

Prior operation:
Connecting rod and piston Connecting rod - Install (10.105)
1. Well lubricate the pistons, including the split rings and

the cylinder walls with clean engine oil.
2. Use the piston band clamp 380000325 (1) to install pis-
ton and connecting rod assembly (2) into the cylinders
and check for the following:
NHIL13ENG0461AA 1
The number of each connecting rod should correspond to

the number on the connecting rod cap.
Split ring end gaps should be displaced with each other by
120 °.
Piston and connecting rod assemblies should have the
same weight.
The arrow (1) marked on the piston crown should be facing
the front side of the engine block or the slot obtained on
the piston skirt should l be corresponding to the oil nozzle
position.
NOTE: Split Rings are supplied spare with the following
sizes:
- standard NHIL13ENG0462AB 2
- 0.4 mm (0.016 in) oversize.
Next operation:
Connecting rod and piston Connecting rod - Install (10.105)
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Piston - Measure
Prior operation:
Piston - Remove (10.105)
1. Using a micrometer (2), measure the diameter of the

piston (1) to determine the assembly clearance. The
value should be between the following specifications:
103.714 - 103.732 mm (4.083 - 4.084 in)
103.759 - 103.777 mm (4.085 - 4.086 in)(*)
(*) Valid for engines: F4HE9684P, F4HE9684A,
F4HE9687P, F4HE9687A
NHIL13ENG0463AA 1
2. The clearance between the piston and the cylinder bore

can be checked also with a feeler gauge (1) as shown
in the figure.
NHIL13ENG0464AA 2
Next operation:
Connecting rod and piston - Assemble (10.105)
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Piston Ring - Remove

Prior operation:
1. Remove the split rings (1) from the piston (3) using split
ring pliers 380000324 (2).
NHIL13ENG0465AA 1
Next operation:
Piston Ring - Measure (10.105)
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Piston Ring - Measure

Prior operation:
1. Use a micrometer (2) to check piston split ring (1) thick-

ness.
The values should be as follows:
Combustion ring: 2.560 - 2.605 mm (0.101 - 0.103 in)
Intermediate ring: 2.350 - 2.380 mm (0.093 - 0.094 in)
Oil control ring: 3.970 - 3.990 mm (0.156 - 0.157 in)
NHIL13ENG0466AA 1
2. Check the clearance between the piston rings (1) of

the 2nd and 3rd slot and the relevant housings on the
piston (3), using a feeler gauge (2).
NHIL13ENG0467AA 2
3. Since the first piston ring is trapezoidal, the clearance

between the slot and the ring should be measured as
follows:
Make the piston (1) protrude from the engine block (2)
so that the ring (4) protrudes half-way from the cylinder
bore (3). In this position, use a feeler gauge to check
the clearance (X) between the ring and the slot.
Values should be as follows:
/ 0.040 - 0.090 mm (0.002 - 0.004 in)(*)
(*) Valid for engines: F4HE9684P, F4HE9684A,
F4HE9687P, F4HE9687A
Oil control ring: 0.040 - 0.080 mm (0.002 - 0.003 in) NHIL13ENG0468AA 3
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4. Use the feeler gauge (1) to measure the piston split ring
(2) end gap installed into the cylinder bore (3).
Values should be as follows:
Oil Control ring: 0.30 - 0.55 mm (0.012 - 0.022 in)
NHIL13ENG0469AA 4
Next operation:
Piston - Install (10.105)
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Piston Ring - Install

Prior operation:
1. Use pliers 380000221 (2) to install the piston split rings

(1) onto the piston (3).
2. Split ring end gaps should be displaced with each other
by 120 °.
NOTICE: Split rings shall be fitted with the marking "TOP"
(4) facing upwards.
NOTE: Split Rings are supplied spare with the following
sizes:
- standard
- 0.4 mm (0.016 in) oversize
NHIL13ENG0470AA 1
Next operation:
Piston - Install (10.105)
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Piston Pin - Remove

Prior operation:
1. Remove the piston pin (1) by removing the snap rings

(3) using a scriber (2).
NHIL13ENG0471AA 1
Next operation:
Piston Pin - Measure (10.105)
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Piston Pin - Measure

Prior operation:
1. To measure the piston pin (2) diameter, use a mi-

crometer (1). The diameter should be within 37.994 -
38.000 mm (1.496 - 1.496 in).
NHIL13ENG0472AA 1
2. Lubricate the pin (1) and its seat on the piston hubs
with clean engine oil. The pin should be installed into
the piston with slight finger pressure. The piston pin
housing diameter should be within 38.010 - 38.016 mm
(1.496 - 1.497 in).
NHIL13ENG0473AA 2
Next operation:
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Piston - Check
1. Once piston and connecting rod assemblies installation
is completed, use the dial bore gauge 380000228 (1)
equipped with the base 380000364 (3) to check piston
(2) protrusion at T.D.C. with respect to the top of the
engine block.
Protrusion should be between 0.28 - 0.52 mm (0.011 -
0.020 in).
NHIL13ENG0474AA 1
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Connecting rod bearing - Install

Prior operation:
1. Install the half-bearings (1) onto the connecting rods

and connecting rod caps.
NOTE: Reinstall the bearings that have not been replaced
in the same position found at removal. Do not relocate the
half-bearings.
NHIL13ENG0475AA 1
Next operation:
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Connecting rod bearing - Clearance

Prior operation:
1. Clean and remove all oil from the connecting rod and
bearing parts thoroughly.
2. Set a piece of calibrated wire (1) on the crankshaft pins
(2).
3. Install the connecting rod caps (4) with the correct half
bearings (3).
NOTE: Before the final fitting of the connecting rod cap
retaining bolts, check that their diameter measured at the
center of the thread length is not < 0.1 mm (0.004 in) than
the diameter measured at approximately 10 mm (0.394 in)
from the bolt end.
NHIL13ENG0476AA 1
4. Lubricate the bolts (2) with engine oil and use a torque
wrench (1) to torque the bolts to 55 - 65 N·m (41 - 48 lb
ft).
NHIL13ENG0477AA 2
5. Attach an angular torque gauge tool 380001001 (1) to

the torque wrench (2) and turn the bolts (3) 60 °.
NHIL13ENG0478AA 3
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6. Remove the connecting rod cap and find the existing

clearance by comparing the calibrated wire width (2)
with the scale on the provided wire envelope (1).
7. If a different clearance value is found, replace the con-
necting rod half bearings and repeat the check.
8. Once the specified clearance has been obtained, lubri-
cate the connecting rod half bearings with engine oil
and install them onto the connecting rod. Torque the
bolts to 55 - 65 N·m (41 - 48 lb ft). Attach the angular
torque gauge 380001001 to the torque wrench and turn
the bolts 60 °.
NHIL13ENG0479AA 4
9. Check manually that the connecting rods (1) are sliding

axially on the crank pins. Using a feeler gauge (2),
make sure that the connecting rod end float is between
0.10 - 0.33 mm (0.004 - 0.013 in).
NHIL13ENG0480AA 5
Next operation:
Piston - Check (10.105)
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Piston pin bushings - Service instruction

Prior operation:
1. Check the connecting rod small side bearing (1) for

scoring or seizing and make sure that it is not loose. If
the bearing shows signs to scoring, seizing or is loose,
replace the bearing.
2. Removal and reinstalling the bearing should be per-
formed using the proper beater.
3. When reinstalling, make sure the oil holes in the bear-
ing coincide with the holes in the connecting rod small
end.
4. Check the connecting rod small end bearing diameter
by using the dial bore gauge OEM1032. The bearing
diameter should be within 38.019 - 38.033 mm (1.497 NHIL13ENG0457AA 1
- 1.497 in).
Next operation:
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Index
Engine - 10

Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting rod and piston - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting rod bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connecting rod bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Piston pin bushings - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Engine - 10
Crankshaft and flywheel - 103

F4HE9684 , F4HE9687G*J100 , F4HE9687
47597675 27/09/2013
10.6 [10.103] / 1
Contents
Engine - 10
SERVICE
Engine flywheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4GE9484, F4GE9484C*J601, F4GE9684
Drive plate - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F4GE9684
Drive plate - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

F4GE9684
Crankshaft oil seal

Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankshaft
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4DE9684M*J103, F4DE9684B*J111
Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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Crankshaft gears
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Main bearings
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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Engine - Crankshaft and flywheel
Engine flywheel - Remove

F4HE9687, F4HE9687G*J100
1. Insert flywheel rotation locking tool 380000988 (1) into

flywheel housing (3) to keep the flywheel (2) from rotat-
ing.
NHIL13ENG0481AB 1
2. Remove two bolts opposite each other and place two

guide pins (3) in place of the bolts.
3. Remove the remaining bolts (4) figure 1 securing the
flywheel (1) to the crankshaft.
4. Remove the flywheel locking tool from the flywheel
housing.
5. Install two bolts of medium length into the threaded
holes (2) at the top of the flywheel to sling the flywheel
with a hoist.
6. Remove the flywheel (1) from it's housing.
NHIL13ENG0482AA 2
Next operation:
Engine flywheel - Check (10.103)
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10.6 [10.103] / 4
Engine flywheel - Check

F4HE9687, F4HE9687G*J100
Prior operation:
1. Check the clutch supporting side of the engine flywheel

(1) for any scoring or scratching. If any scratching is
found, the flywheel should be resurfaced.
2. Check the flywheel ring gear teeth (2) for breakage or
excessive wear. If wear is found, remove the ring gear
from the engine flywheel using a suitable hammer.
3. Heat the new ring gear to 150 °C (302 °F) for 15 to 20
minutes.
4. Install the new ring gear with the chamfering on the
inside diameter facing the flywheel.
NHIL13ENG0483AA 1
Next operation:
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Engine flywheel - Install

Prior operation:
1. Install two guide pins (1) having suitable length into the
engine crankshaft holes.
2. Using the proper sling and hoist, install the flywheel (2)
onto the engine crankshaft (3).
NHIL13ENG0484AA 1
3. Install the flywheel rotation locking tool 380000988 (4)

to the flywheel housing to stop rotation of the flywheel
(2).
4. Install the flywheel bolts (1) securing the flywheel (2) to
the crankshaft (3).
NHIL13ENG0485AB 2
5. Torque the flywheel bolts (1) to the engine crankshaft

(2) in two stages:
1. Torque the bolts to 26 - 34 Nm (19 - 25 lb ft).
2. Using the angular torque gauge tool 380001001,
turn the flywheel bolts an additional 55 - 65 °.
NHIL13ENG0486AA 3
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10.6 [10.103] / 6

1. Install the flywheel locking tool 380000988 (4) into the

flywheel housing to keep the flywheel (3) from rotating.
2. Remove two opposing flywheel bolts (1) and install two
guide pins in place of the bolts.
3. Remove the remaining flywheel retaining bolts from the
crankshaft (2) and remove the flywheel locking tool (4).
NHIL13ENG0487AB 1
4. Install two bolts of medium length into flywheel holes

(2) to sling the flywheel with a suitable hoist.
5. Using the two guide pins (1) previously installed into
the flywheel mounting holes, (5) remove the engine fly-
wheel (3) after slinging it with the hoist.
NHIL13ENG0488AA 2
Next operation:
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Engine flywheel - Check

Prior operation:
1. Check the clutch supporting side of the engine flywheel

(1) for any scoring or scratching. If any scratching is
found, the flywheel should be resurfaced.
2. Check ring gear teeth (2) for any breakage or excessive
wear. If any wear is found, remove the ring gear from
the engine flywheel using a suitable hammer.
3. Heat the new ring gear to 150 °C (302 °F) for 15 to 20
minutes.
4. Install the new ring gear with the chamfering on the
inside diameter facing the flywheel.
NHIL13ENG0489AA 1
Next operation:
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Prior operation:
1. Install two bolts of medium length into the engine fly-

wheel using holes (2).
2. Install two guide pins (1) with suitable length into the
engine crankshaft holes (5).
NHIL13ENG0488AA 1
4. Secure the engine flywheel retaining bolts (1) onto the

engine crankshaft (3).
5. Install the flywheel rotation locking tool 380000988 to
the flywheel housing (2) to stop the rotation of the fly-
wheel.
NHIL13ENG0487AB 2
6. Torque the flywheel bolts (1) to the engine crankshaft

(2) in two stages:
1. Torque the bolts using a torque wrench (3) to 26 -
34 Nm (19 - 25 lb ft).
2. Using an angular torque gauge tool 380001001,
NHIL13ENG0517AA 3
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Using the flying rotation locking tool 380000988, lock

the engine flywheel (2) rotation.
2. Loosen the flywheel retaining bolts (1) from the engine
crankshaft (3).
NHIL13ENG0518AA 1
3. Remove two opposing flywheel bolts and install two

guide pins (1) in their place.
4. Remove the remaining flywheel retaining bolts from the
engine crankshaft (3).
5. Remove the flywheel locking tool.
6. Install two medium length bolts into the existing fly-
wheel holes (2) to sling the flywheel with a hoist.
7. Using the two guide pins (1), previously installed into
the engine crankshaft holes (4), remove the engine fly-
wheel (5) from the crankshaft (3) using a suitable hoist.
NHIL13ENG0519AA 2
Next operation:
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Prior operation:
1. Install two guide pins (1) with suitable length into crank-
shaft (2) holes.
NHIL13ENG0520AA 1
3. Install the flywheel locking tool 380000988 to the fly-

wheel housing (3) to stop rotation of the flywheel (4).
4. Install the bolts (1) securing the flywheel (4) to the
crankshaft (2).
NHIL13ENG0521AA 2
5. Torque the flywheel bolts (1) using a torque wrench (2)

to the crankshaft in two stages:
1. Torque bolts to 26 - 34 Nm (19 - 25 lb ft).
2. Using the angular torque gauge tool 380001001,
NHIL13ENG0522AA 3
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F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
1. Install two bolts of medium length into the engine fly-

wheel (1) using holes (2).
2. Insert two guide pins (3) of appropriate length into the
flywheel mounting holes.
NHIL13ENG0523AA 1
3. Using a suitable hoist, install the flywheel (2) onto the

crankshaft.
4. Secure the flywheel retaining bolts (4) to mount the en-
gine flywheel (2) onto the engine crankshaft.
5. Install the flywheel locking tool 380000988 (3) into the
flywheel housing to lock engine flywheel rotation.
NHIL13ENG0524AA 2
6. Torque the engine flywheel retaining bolts (1) to the

engine crankshaft in two stages.
• Torque the bolts to 26 - 34 Nm (19 - 25 lb ft).
• Use the angular torquing gauge tool 380001001 to
turn the bolts an additional 55 - 65 °.
NOTE: Before assembly, always check that the threads of
the ports and of the screws have no evidence of wear or
dirt.
NHIL13ENG0525AA 3
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Engine flywheel Drive plate - Remove

F4GE9684
1. Remove the bolts (1).

2. Remove the plate (2), drive plate (3) and hub (4) from
the crankshaft.
NHIL13ENG0076AA 1
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Engine flywheel Drive plate - Install

F4GE9684
1. Install the hub (4) onto the crankshaft.

2. Install the dive plate (3), plate (2) and bolts (1) onto the
hub.
NHIL13ENG0076AA 1
3. Follow the sequence shown to torque the bolts to 27 -

41 N·m (20 - 30 lb ft). Then, using the angular torque
gauge tool 380001001, turn the bolts an additional 60
- 70 °.
NHIL13ENG0077AA 2
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Crankshaft oil seal Front seal - Remove

Prior operation:
1. Remove the crankshaft front oil seal from the front

cover (6). Use the tool (4) to operate on the front bar
hold of the crankshaft. Through the steering holes of
the tool, perforate the inside holding ring (1) with a
straight way drill with a diameter of 3.5 mm (0.138 in)
for the depth of 5 mm (0.197 in). Install the tool to
the ring and tighten the six bolts (5) provided with the
equipment. Then proceed removing the ring (2) by
tightening the bolt (3).
NHIL13ENG0526AA 1
2. Using the specific tie rod (3) of the seal extracting tool
380000669, and the ancillary lever (4), remove the ex-
ternal holding ring (2) from the front cover (1).
NHIL13ENG0527AA 2
Next operation:
Crankshaft oil seal Front seal - Install (10.103)
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Crankshaft oil seal Front seal - Install

Prior operation:
Crankshaft oil seal Front seal - Remove (10.103)
1. Apply tool 5-8840-2061-0 (4) to the front crankshaft

tang (6), secure it by bolts, (5) and install the new seal-
ing ring (7). Position part (2) on part (4), tighten nut (3)
until completing installation of the sealing ring (7) into
the front cover (1).
NHIL13ENG0528AA 1
Next operation:
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Crankshaft oil seal Rear seal - Remove

Prior operation:
1. Remove the holding ring of the flywheel cover box using

the tool (3) to operate on the driving shaft's back bar
hold (5).
2. Through the steering holes of the tool, perforate the
inside holding ring with a straight way drill bit with a
diameter of 3.5 mm (0.138 in) for the depth of 5 mm
(0.197 in).
3. Install the tool (3) to the ring and tighten the six bolts
(4) provided with the equipment.
4. Then proceed removing the ring (1) by tightening the
bolt (2).
NHIL13ENG0529AA 1
5. Using a specific tie rod (3) of the tool 380000669 and

an ancillary lever (4), remove the external holding ring
(2) from the rear cover (1).
NHIL13ENG0530AA 2
Next operation:
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Crankshaft oil seal Rear seal - Install

Prior operation:
Crankshaft oil seal Rear seal - Remove (10.103)
1. Apply tool 380000664 (6) to the rear crankshaft tang

(5), secure it by bolts (4), and install the new sealing
ring (3). Position part (1) on part (5) and tighten nut (2)
until completing installation of the sealing ring (3) into
the flywheel housing (7).
NHIL13ENG0531AA 1
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Crankshaft - Remove
F4HE9687, F4HE9687G*J100
Prior operation:
Main bearings - Remove (10.103)
1. Use tool 99360500 (1) to hoist and remove the crank-

shaft (2) from the engine block.
NHIL13ENG0532AA 1
Next operation:
Main bearings - Install (10.103)
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Crankshaft - Remove
Prior operation:
1. Use tool 99360500 (1) to hoist and remove the crank-

shaft (2) from the engine block.
NHIL13ENG0533AA 1
Next operation:
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Crankshaft - Measure
Prior operation:
Crankshaft - Remove (10.103)
Check the crankshaft journals and pins for seizing, scoring

or excessive ovalization. If any are present, machining of
the crankshaft is necessary.
Crankshaft main journals should be measured using a mi-
crometer (1) and should be within 82.99 - 83.01 mm (3.267
- 3.268 in).
Crankshaft pins (2) should measured using a microme-
ter (1) and should be within 68.987 - 69.013 mm (2.716
- 2.717 in).
NOTE: Before grinding the crankshaft pins (2), measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
NOTE: It is recommended to insert the found values in the NHIL13ENG0534AA 1
table below.
NOTICE: Journals and crank pins shall always be ground
to the same undersize class.
Journals and crank pins undersize shall be marked on the
side of the crank arm No.1.
For undersized crank pins: letter M
For undersized journals: letter B
For undersized crank pins and journals: letters MB.
Measuring journals and crank pins
NHIL13ENG0535AA 2
Fill the provided table with crankshaft journal and crank pin measured values
* Rated value
A B
82.99 - 83.01 mm (3.27 - 3.27 in) 68.987 - 69.013 mm (2.716 - 2.717 in)
47597675 27/09/2013
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ZEIL06EN0183F0B 3
Crankshaft tolerances
* Measured on a radius greater than 45.5 mm (1.791 in)

** 0.500 mm (0.020 in) between adjacent main journals
Tolerances Tolerance Characteristic Graphic Symbol

Roundness
Shape
Cilindricity
Parallelism
Direction Verticality
Straightness
Position Concentricity or coaxiality
Circular oscillation
Oscillation
Total oscillation
Levels of importance for product characteristics Graphic Symbol

Critical
Important
Secondary
Next operation:
Crankshaft Journal - Clearance (10.103)
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Crankshaft Journal - Clearance

Prior operation:
Crankshaft - Measure (10.103)
1. Install the crankshaft (1) into the engine block (2).

2. Check the backlash between crankshaft main journals
and the relevant bearings as follows:
NHIL13ENG0537AA 1
3. Thoroughly clean all parts and remove any traces of oil.

4. Position a piece of calibrated wire on the crankshaft
pins (2) so that it is parallel to the longitudinal axis.
5. Install the crankshaft main journal caps (1) and the half
bearings (2) on the relevant supports.
NHIL13ENG0538AA 2
NOTE: Before using the bearing cap bolts again, measure

them twice as indicated in the picture, checking (D1) and
(D2) diameters:
If (D1)- (D2) < 0.1 mm (0.004 in) the bolt can be used
again.
If (D1)- (D2) > 0.1 mm (0.004 in) the bolt must be replaced.
NHIL13ENG0539AA 3
47597675 27/09/2013
10.6 [10.103] / 23
6. Torque the pre-lubricated bolts (2) in the following three

successive stages:
STAGE 1: Torque the bolts (2) using a torque wrench
(1) to 44 - 56 Nm (33 - 41 lb ft).
STAGE 2: Torque the bolts (2) using a torque wrench
(1) to 74 - 86 Nm (55 - 63 lb ft).
NHIL13ENG0540AA 4
7. STAGE 3: Use an angular torquing gauge tool

380001001 (1) and turn the bolts (2) an additional 85
- 95 °.
NHIL13ENG0541AA 5
8. Remove the caps from the supports.

9. The backlash between the main bearings and the pins
is found by comparing the width of the calibrated wire
(2) at the narrowest point with the scale on the provided
envelope (1) containing the calibrated wire.
The numbers on the scale indicate the backlash in mm.
Replace the half bearings and repeat the check if a
different backlash value is found. Once the specified
backlash is obtained, lubricate the main bearings and
fit the supports by torquing the retaining bolts as previ-
ously described.
NHIL13ENG0542AA 6
Checking crankshaft end play

1. This check is performed by setting a magnetic base dial
bore gauge (2) on the crankshaft (3) as shown in the
figure. The end play value should be within 0.095 -
0.265 mm (0.004 - 0.010 in).
If higher value is found, replace the main thrust half
bearings of the second last rear support (1) and repeat
the clearance check between crankshaft pins and main
half bearings.
NHIL13ENG0543AA 7
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Crankshaft gears - Replace

Check that the teeth on the crankshaft gear (1) are not
damaged or worn. If damage or wear is present, then re-
move the gear from the crankshaft (2) using the crankshaft
gear puller tool 380001717 (3).
When installing the new gear, heat the gear to 180 °C
(356 °F) for 10 minutes in an oven and then install it onto
the crankshaft.
CRIL04J068A01 1
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Main bearings - Remove

Prior operation:
1. Remove the retaining bolts (1) and the main bearing

caps (2).
NHIL13ENG0544AA 1
2. The second to last main bearing cap (1) and the it’s
support are fitted with a shouldered half-bearing (2).
NOTE: Take note of the lower and upper half-bearing as-
sembling positions since in case of reuse they should be
fitted in the same position found at removal.
NHIL13ENG0545AA 2
Next operation:
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Main bearings - Install

Prior operation:
NOTE: Reinstall 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 (0.010 - 0.020 in) undersize on the internal
diameter.
Thoroughly clean the main bearings (1), lubricate them with
clean engine oil and install them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.
NHIL13ENG0546AA 1
NOTICE: Do not try to adapt the bearings.

NOTE: Do not lubricate the connecting rod side housing side of the bearing. Only lubricate the internal side of the
bearing which rides along the crankshaft pins.
Next operation:
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Index
Engine - 10

Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4DE9684B*J111
Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Crankshaft gears - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4DE9684B*J111
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4GE9484, F4GE9484C*J601, F4GE9684
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Engine flywheel Drive plate - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4GE9684
Engine flywheel Drive plate - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4GE9684
Main bearings - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Main bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Engine - 10
Balancer and damper - 110

F4HE9684 , F4HE9687G*J100 , F4HE9687
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10.7 [10.110] / 1
Contents
Engine - 10
SERVICE
Balancer
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Crankshaft damper
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4DE9684M*J103, F4DE9684B*J111
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Engine - Balancer and damper
Balancer - Remove
F4HE9687, F4HE9687G*J100
Prior operation:
1. Remove the retaining bolts (3) and (5) and remove the
oil pickup tube.
2. By means of pin (1), lock the dynamic balancer (4) in
the Top Dead Center (TDC) position.
3. Remove the bolts (2) and remove the dynamic balancer
(4).
NHIL13ENG0547AA 1
Next operation:
Balancer - Install (10.110)
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Balancer - Install
F4HE9687, F4HE9687G*J100
Prior operation:
Balancer - Remove (10.110)
1. Set the engine to cylinder number one Top Dead Center

(TDC).
2. Match the marks (A) engraved on the gears for timing.
3. Torque the mounting bolts to 40 - 56 N·m (30 - 41 lb ft).
4. Once the balancer is mounted on the engine, remove
the pin from point (B).
NHIL13ENG0548AA 1
Next operation:
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Crankshaft damper - Remove

F4HE9687, F4HE9687G*J100
Prior operation:
Belt - Remove (10.414)
1. Remove the bolts (3) retaining the crankshaft vibration

damper (1).
2. Remove the damper (1).
3. Remove the pulley (2).
NHIL13ENG0549AA 1
Next operation:
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Crankshaft damper - Install

F4HE9687, F4HE9687G*J100
Prior operation:
1. Mount the vibration damper (2) and the pulley (1) onto
the crankshaft (3).
2. Torque the mounting bolts (4) to 45 - 55 N·m (33 - 41 lb
ft).
3. Use the angular torque gauge tool 380001001 and turn
the bolts 90 °.
NHIL13ENG0550AA 1
Next operation:
Belt - Install (10.414)
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Crankshaft damper - Remove

Prior operation:
1. Remove the bolts (1) retaining the crankshaft vibration

damper (2).
2. Remove the damper (2).
3. Remove the pulley (3).
NHIL13ENG0551AA 1
Next operation:
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Crankshaft damper - Install

Prior operation:
1. Mount the vibration damper (2) and the pulley (3) onto
the crankshaft (4).
2. Torque the mounting bolts (1) to 105 - 115 N·m (77 -
85 lb ft).
NHIL13ENG0551AA 1
Next operation:
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Index
Engine - 10

Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4DE9684B*J111
Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4DE9684B*J111
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Engine - 10
Pump drives - 114

F4HE9684 , F4HE9687G*J100 , F4HE9687
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10.8 [10.114] / 1
Contents
Engine - 10
Pump drives - 114
SERVICE
Pump drives
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4GE9484, F4GE9484C*J601, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE9484, F4GE9484C*J601, F4GE9684
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
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Engine - Pump drives
Pump drives - Remove

1. Remove the cover bolts (3) and remove the cover (1).
Make sure to save the cover gasket (2).
2. Remove the power take-off adapter (5). Make sure to
save the gasket (4).
NHIL13ENG0553AA 1
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Pump drives - Install

1. Insert the power take-off adapter (5) with gasket the (4)
and the front cover (1) with the gasket (2).
NHIL13ENG0553AA 1
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F4GE9484, F4GE9484C*J601, F4GE9684
1. Remove the two bolts (3) retaining the cover plate (1)
and gasket (2).
2. Remove the cover plate (1), power take-off adapter (5),
and gasket (4).
NOTE: The gasket cannot be used again. It must be re-
placed upon reassembly.
NHIL13ENG0554AA 1
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F4GE9484, F4GE9484C*J601, F4GE9684
1. Install the power take-off (5) in its housing with a new

gasket (4). Be sure that the gears mesh properly.
2. Install the cover plate (1) also with a new gasket (2).
Torque the bolts (3) to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0554AA 1
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Remove the two bolts (2) and remove the cover (1).
NHIL13ENG0555AA 1
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Install the power take-off gear (where equipped) into

the specially provided housing and torque the nut (1)
to 98 - 112 N·m (72 - 83 lb ft).
NHIL13ENG0556AA 1
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Index
Engine - 10
Pump drives - 114

Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
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Engine - 10
Lift pump and lines - 210

F4HE9684 , F4HE9687G*J100 , F4HE9687
47597675 27/09/2013
10.9 [10.210] / 1
Contents
Engine - 10
FUNCTIONAL DATA
Fuel lift pump

Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Priming pump
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Priming pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel supply lines

Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

F4GE9484, F4GE9484C*J601, F4GE9684
Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F4GE9484, F4GE9484C*J601, F4GE9684
Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - Lift pump and lines
Fuel lift pump - Sectional view

Gear pump, placed on the rear part of the high pressure pump, whose function is to feed the high pressure pump. It
is driven by the high pressure pump's shaft.
Normal operating condition
NHIL13ENG0557AA 1
(A) Fuel supply from the primary filter (1) Fuel supply relief valve 5 bar (73 psi)
(B) Fuel supply to the secondary filter (2) Supply pump bypass valve (for bleeding)
Overpressure condition
NHIL13ENG0558AA 2
The by-pass valve (1) is activated in case of overpressure on (B) Exhaust unit. The actual pressure, overcoming the
resistance of the valve's spring (1), connects the exhaust with the entry through the gallery (2).
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Jettison condition
NHIL13ENG0559AA 3
The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system
through the priming pump. In this condition the by-pass (1) keeps closed while the dump by-pass valve (2) opens up
due to the pressure effect on the entry unit so the fuel flows to the exhaust unit (B).
NOTE: The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the
high pressure pump.
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Priming pump - Overview

This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is
assembled to the engine block and driven by the camshaft.
NHIL13ENG0560AA 1
(1) Fuel output to the filter - (2) Drive lever - (3) Fuel inlet from the tank
NHIL13ENG0561AA 2
(1) Priming pump - (2) Drive lever - (3) Camshaft
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Priming pump - Remove

Prior operation:
Fuel supply lines Low pressure - Disconnect (10.210)
1. Remove the two retaining bolts (1).

2. Remove the priming pump (2).
NHIL13ENG0562AA 1
Next operation:
Priming pump - Install (10.210)
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Priming pump - Install

Prior operation:
Priming pump - Remove (10.210)
1. Install the priming pump (2) with a new gasket.

2. Torque the bolts (1) to 10 - 14 N·m (89 - 124 lb in).
NHIL13ENG0563AA 1
Next operation:
Fuel supply lines Low pressure - Connect (10.210)
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Fuel supply lines Low pressure - Connect

1. Connect the fuel line to the pressure limiter (1).

2. Connect all the fuel lines between the fuel filter base
(2) and the high pressure pump.
3. Connect the pipeline from the high pressure pump to
the engine control module cooling plate (3).
4. Connect the pipeline from the high pressure pump (4)
to high pressure common rail.
NHIL13ENG0564AA 1
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Fuel supply lines Low pressure - Disconnect

1. Disconnect the fuel return pressure limiter (1). Refer to

Common rail lines - Disconnect (10.218).
NHIL13ENG0490AA 1
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F4GE9484, F4GE9484C*J601, F4GE9684
1. Place a container under the fuel filter (5) and remove

the drain faucet (4) underneath the filter. Carry out
complete drainage of the fuel contained in the filter.
2. Remove the drain faucet (4) completely and by using
the tool 380000670, then remove the fuel filter.
3. Disconnect the fuel lines (2) and (3) respectively from
priming pump to filter bearing and from the filter bear-
ing to the feed pump. Refer to Common rail lines -
Disconnect (10.218) for proper removal procedures.
4. Remove the fuel filter base (1) from the engine cylinder
head.
NHIL13ENG0491AA 1
5. Disconnect the LDA pipe (1) from the engine cylinder

head and from the feed pump.
6. Plug the ends of the fuel lines as well as the feed pump
and the cylinder head.
NHIL13ENG0492AA 2
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Place a container under the fuel filter (4) and remove

the faucet drain (3) underneath the filter . Carry out
complete drainage of the filter.
2. Completely remove the faucet drain (3) and then use
tool 380000670 to remove the filter cartridge from the
housing.
3. Disconnect fuel lines (1) and (5) respectively from the
priming pump to the fuel filter base and from the fuel fil-
ter base to the feed pump. Refer to Common rail lines
- Disconnect (10.218) for proper removal procedures.
4. Remove the filter base (2) from the engine cylinder
head. NHIL13ENG0493AA 1
5. Disconnect the LDA pipe (1) from the cylinder head and
from the feed pump.
6. Plug the ends of the pipelines as well as the feed pump
and the engine cylinder head.
NHIL13ENG0494AA 2
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Fuel supply lines Low pressure - Install

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Install the fuel filter support (3) onto the engine cylinder
head and torque the bolts (2) to 20 - 28 N·m (15 - 21 lb
ft).
2. Connect the fuel pipelines (1) and (5) respectively from
priming pump to filter support (3), and from the support
to the feed pump.
3. Install the fuel filter (4) using tool 380000670.
NOTE: The fuel filter should be filled with fuel prior to as-
sembly. This will help facilitate fuel system bleeding.
4. Connect the electrical connections for the water pres-
ence sensor and the fuel heater (If applicable).
NHIL13ENG0495AA 1
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Fuel supply lines Low pressure - Install

F4GE9484, F4GE9484C*J601, F4GE9684
1. Install the fuel filter support (1) onto the engine cylinder
head and torque the bolts to 20 - 28 N·m (15 - 21 lb ft).
2. Connect the fuel pipelines (2) and (3) respectively from
the priming pump to the filter support and from the sup-
port to the fuel feed pump.
3. Install the fuel filter (4) using tool 380000670.
NOTE: NOTE: The filter should be filled with fuel prior to
assembly. This will help facilitate fuel system bleeding.
4. Connect the electrical connections for the water pres-
ence sensor and the fuel heater (If applicable).
NHIL13ENG0496AA 1
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Fuel supply lines Low pressure - Bleed

1. Disconnect the fuel line (1) of the fuel filter and work
the drain lever (2) of the priming pump.
2. Continue the operation until fuel flows out.
3. Connect the fuel line (1) to the fuel filter.
NHIL13ENG0497AA 1
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Index
Engine - 10

Fuel lift pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel supply lines Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel supply lines Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4GE9484, F4GE9484C*J601, F4GE9684
Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Fuel supply lines Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Fuel supply lines Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4GE9484, F4GE9484C*J601, F4GE9684
Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - 10
Fuel filters - 206

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
Fuel filters - 206
FUNCTIONAL DATA
Fuel heater
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel-water separator filter
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Fuel filters
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - Fuel filters
Fuel heater - Overview

The ECU drives the filter heater at a fuel temperature less than or equal to 5 °C (41 °F).
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Fuel-water separator filter - Overview

The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities
and separation of water from fuel.
On the filter cartridge, there is a water dump screw throughout which it is possible to provide regular drainage. For
those equipment applications requiring it, a heater can be installed along with a temperature sensor. On some ver-
sions, a water presence sensor is mounted to the filtering cartridge.
NHIL13ENG0498AA 1
(1) Fuel filter base - (2) Filter cartridge - (3) Water dump screw.
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Fuel filters - Remove

Prior operation:
1. Using the fuel filter wrench 34591-00100, loosen the

fuel filter (1) and remove it from the support (5).
2. Disconnect the electrical connections (2) from the sup-
port (5) including the connection for the fuel heater.
3. Disconnect the fuel low pressure fuel lines (3) from the
support (5).
4. Disconnect fuel line (4) from the support (5).
5. Remove the sustaining support bracket (5) from the
engine block.
4442596398GHDC 1
Next operation:
Fuel filters - Install (10.206)
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Fuel filters - Install

Prior operation:
Fuel filters - Remove (10.206)
1. Install the fuel filter (9) bracket and support (1) and
torque the bracket bolts to 20 - 28 N·m (15 - 21 lb ft).
2. Proceed connecting in sequence the pipelines (5) (2)
(3) (4) (6) of the support (1) to the high pressure pump
(7).
3. Connect the pipeline (8) from the high pressure pump
to the common rail.
NOTE: Refer to Common rail lines - Connect (10.218)
for the proper operation of the clamps on the low pressure
fuel lines.
NHIL13ENG0499AA 1
Next operation:
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Index
Engine - 10
Fuel filters - 206

Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel-water separator filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Engine - 10
Fuel injection system - 218

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
FUNCTIONAL DATA
Fuel injection system

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4HE9687G*J100
Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rotary injection pump

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4CE9684, F4GE9684
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High pressure pump

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4HE9687G*J100
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure regulating valve

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Common rail
Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel injectors
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
F4HE9687G*J100
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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SERVICE
Fuel injection system

Test Mechanical fuel injection – Fuel supply/Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Test Common rail fuel injection – Fuel supply/Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Rotary injection pump

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4GE9484, F4GE9484C*J601, F4GE9684
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F4GE9484, F4GE9484C*J601, F4GE9684
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F4GE9484, F4GE9484C*J601, F4GE9684
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
High pressure pump

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Test Pressure Relief Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Pressure regulating valve

Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Common rail
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Common rail lines

Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Fuel injectors
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mechanical - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Mechanical - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Test Fuel injector testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Cross tube - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Cross tube - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Injector fuel lines

Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F4HE9687G*J100
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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Engine - Fuel injection system
Fuel injection system - Dynamic description

NHIL13ENG0500AA 1
(1) Electro-injector (5) Pre-filter mounted on the frame

(2) Common rail (6) High-pressure pump
(3) Pressure limiting device for fuel return (7) Mechanical vane pump
(4) Common rail pressure relief valve (8) Fuel filter
The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke
and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
The hydraulic system is implemented by a low pressure circuit and a high pressure circuit.
The high pressure circuit is composed of the following pipings:

• piping connecting high pressure pump outlet to rail
• pipings supplying injectors from rail
The low pressure circuit is composed of the following pipings:

• fuel suction piping from tank to pre-filter
• pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and
pre-filter
• pipings supplying the high pressure pump through the fuel filter
The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.
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Fuel injection system - Plumbing schema

The fuel system is a Common Rail injection system with a CP3 high pressure pump.
The pressure regulator, placed upstream of the high pressure pump, adjusts the fuel flow that is necessary on the low
pressure system. Afterwards, the high pressure pump takes care of supplying the rail properly. This arrangement, by
pressurizing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.
Function of the pressure relief valve (2), assembled on the high pressure pump, is keeping the pressure, at the pres-
sure regulator inlet, constant at 5 bar (73 psi). Based on the efficiency the fuel filter.
The pressure relief valve (2) increases fuel flow in the high pressure pump cooling circuit, through inlet and drain
piping (16) from piping (8).
The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from
injectors at a pressure of 1.3 - 2 bar (19 - 29 psi).
Two bypass valves are placed in parallel with the mechanical supply pump.
The bypass valve (18) allows fuel to flow from the mechanical pump outlet to it's inlet, when the fuel filter inlet pressure
exceeds the allowed threshold value.
The bypass valve (17) allows filling the supply system through the manual priming pump (10).
NHIL13ENG0501AA 1
(1) High-pressure pump (7) Electro-injector (13) Mechanical supply pump

(2) Low pressure relief valve (8) Return fuel line (14) Fuel filter
(3) Return fuel relief valve (9) ECU cooling plate (15) Pressure regulator
(4) Common rail relief valve (10) Priming pump (16) High pressure pump cooling passage
(5) Common rail (11) Pre-filter (17) By-pass valve
(6) Common rail pressure sensor (12) Fuel tank (18) Charge pressure relief valve
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NHIL13ENG0502AA 1
(1) Electro-injector (5) Common rail pressure relief valve

(2) Common rail (6) Pressure limiter for fuel return
(3) Prefilter mounted on the block (7) Mechanical rotor pump
(4) Fuel filter (8) High pressure pump
The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke
and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
The hydraulic system is implemented by a low pressure circuit and a high pressure circuit.
The high pressure circuit is composed of the following pipings:

• piping connecting high pressure pump outlet to rail
• pipings supplying injectors from rail
The low pressure circuit is composed of the following pipings:

• fuel suction piping from tank to pre-filter
• pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and
pre-filter
• pipings supplying the high pressure pump through the fuel filter
The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.
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NHIL13ENG0503AA 1
(1) Fuel filter - (2) Feed pipeline from filter to fuel pump - (3) Feed pipeline from priming pump to filter -
(4) Priming pump.
Description of working principles

Fuel is sucked from the tank by the priming pump. This last one is placed on the engine block and is driven by the
camshaft.
Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For application to
be equipped in cold climate areas, the fuel filter is provided with a heater).
The transfer pump is placed inside the feed pump, and is bladed type. Its duty is to increase fuel pressure in corre-
spondence with the increase of the number of revolutions.
The fuel arrives therefore to the valve gauging the pressure inside the feed pump.
The distribution plunger further increases this pressure and delivers fuel throughout the delivery pipe fitting to the
injectors.
The fuel drawing from the injectors is recovered and delivered to the tank again.
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Rotary injection pump - Overview

Fuel feed system is composed by:

• Fuel tank (placed on the machine)
• Fuel delivery and back-flow to tank
• Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)
• Priming pump, assembled to the engine and driven by the camshaft
• Fuel filter (assembled to the engine in different positions according to equipment application and duty)
• Fuel feed rotary pump
• Injector feed pipeline (from fuel feed pump to injectors)
• Injectors
NHIL13ENG0504AA 1
(1) Injector feed pipes - (2) Fuel return pipes from injectors - (3) Fuel feed rotary pump - (4) Connector
for LDA pressure gauge pipe with suction collector - (5) KSB thermal bulb - (6) Fuel cut-off switch - (7)
Electro-valve Injector.
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Rotary injection pump - Overview

F4CE9684, F4GE9684
Fuel feed system is composed by:

• Fuel tank (placed on the machine)
• Fuel delivery and back-flow to tank
• Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)
• Priming pump, assembled to the engine and driven by the camshaft
• Fuel filter (assembled to the engine in different positions according to equipment application and duty)
• Fuel feed rotary pump
• Injector feed pipeline (from fuel feed pump to injectors)
• Injectors
NHIL13ENG0505AA 1
(1) Injector feed pipes - (2) Injector - (3) Electro-valve - (4) KSB thermal bulb - (5) Fuel feed rotary pump
- (6) Fuel return pipes from injectors.
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Rotary injection pump - Sectional view

Decoding the identification tag

V = Distribution rotary plunger
E = Pump dimensions
4 = Four cylinder engines (3 = Three cylinder engines and 6 = Six cylinder engines)
12 = Distribution plunger in mm
1150 = Number of pump revolutions per minute
LV = Left direction of rotation
NHIL13ENG0506AA 1
(1) Diaphragm - (2) Locking nut - (3) Pivot - (4) Drive lever - (5) Speed gauge - (6) Transfer pump - (7) Drive
shaft - (8) Cam disk - (9) Advance converter - (10) Distribution plunger - (11) Delivery pipe fitting - (12)
Hydraulic head - (13) Drive plate - (14) Gauge pin - (15) Counteracting spring.
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High pressure pump - Overview

Fuel system operation

The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves
set on the pumping elements at about 2 bar (29 psi).
The amount of fuel supplying the high pressure pump is metered by the pressure regulator placed on the low pressure
system. The pressure regulator is controlled by the EDC7 control unit through a PWM signal.
When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, unable to be
released, is compressed above the supply pressure value existing in the rail.
The generated pressure makes the exhaust valve open and the compressed fuel reaches the high pressure circuit.
The pumping element compresses the fuel until top dead center of the delivery stroke, is reached. Afterwards, the
pressure decreases till the exhaust valve is closed.
The pumping element piston goes back towards bottom dead center and the remaining fuel is decompressed.
When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again
opened and the cycle is repeated.
The delivery valves must always be free in their movements, free from impurities and oxidation.
The rail delivery pressure is modulated between 250 - 1600 bar (3625 - 23200 psi) by the electronic control unit,
through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel.
The radialjet pump disconnection - reconnection time on the engine is greatly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high pressure pump is to be removed or installed, be sure that hands and compo-
nents are absolutely clean.
Rail
NHIL13ENG0507AA 1
(1) Rail (2) Fuel inlet from (3) Overpressure valve (4) Pressure sensor
high-pressure pump
The rail volume is comparatively small to allow quick pressurization at start-up, at idle and in case of high flow rates.
It has enough volume to minimize system spikes and the use of plenum chambers caused by the opening and closing
of the injectors and by the high pressure pump operation. This function is further enabled by a calibrated hole being
set downstream of the high pressure pump.
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A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is feedback
information, where the rail pressure value is checked and if necessary, corrected.
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High pressure pump - External view

Introduction
Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system
makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision
obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and
fuel consumption.
For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure
of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at
pressures up to 1450 bar (21025 psi).
Description of system
The injection system is composed of an electrical part and a hydraulic part.
Electrical system
The electronic control unit monitors engine control parameters by means of the various sensors on the engine.
HARNESS 1
(1) Fuel pressure sensor - (2) Coolant temperature sensor - (3) Oil temperature/pressure sensor - (4)
Crankshaft sensor- (5) Connection to electro-injectors - (6) Air temperature/pressure sensor - (7) Camshaft
sensor - (8) Fuel heater cable and fuel temperature sensor - (9) Pressure gauge cabling - (10) EDC 7
gearbox - (11) Electro-injector
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High pressure pump - External view

Introduction
Extremely high injection pressures are necessary in order to reduce particulate emissions. The common rail system
makes it possible to inject fuel at pressures of up to 1450 - 1600 bar (21025 - 23200 psi), while the injection precision
obtained by electronic control of the system serves to optimize operation of the engine while limiting emissions and
fuel consumption.
For engines more powerful than 152 kW (207 Hp), the CRIN2 injectors have DLLA nozzles that work up to a pressure
of 1600 bar (23200 psi), for engines less powerful than 152 kW (207 Hp), DSLA nozzles are fitted which work at
pressures up to 1450 bar (21025 psi).
Description of system
The injection system is composed of an electrical part and a hydraulic part.
Electrical system
The electronic control unit monitors engine control parameters by means of the various sensors on the engine.
Air pressure/temperature system

It is a component integrating a temperature sensor and a pressure sensor. Fitted on the intake manifold, it measures
the maximum inlet air capacity to calculate precisely the fuel quantity to inject at every cycle. The outlet voltage is
proportional to the pressure or temperature obtained by the sensor.
Engine oil temperature and pressure sensor

Same as the air pressure/temperature sensor, it is fitted on the engine oil filter base, in a horizontal position. It mea-
sures engine oil temperature and pressure.
Fuel pressure sensor

Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The
injection pressure value is used to control the pressure and to determine the electric injection control length.
Coolant temperature sensor

It is a variable resistance sensor suitable to measure the coolant temperature to provide the control unit with an index
of the engine thermal state.
Output shaft sensor

It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that
are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used
by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it
has a different outside shape.
System functionality
The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.
FPT Code recognition

The EDC 7 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent.
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NHIL13ENG0508AA 1
(1) Connection to electro-injectors (5) Crankshaft sensor (9) Fuel heater cable and fuel
temperature sensor
(2) Coolant temperature sensor (6) Electro-injector (10) Pressure gauge cabling
(3) Fuel pressure sensor (7) Air temperature/pressure sensor (11) EDC 7 UC31
(4) Oil temperature/pressure sensor (8) Camshaft sensor
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High pressure pump - Sectional view

CP3 HIGH PRESSURE PUMP

Pump provided with 3 radial pumping elements driven by the timing system gear, no need for timing. The mechanical
feeding pump driven by the high pressure pump's shaft is assembled to the rear side of the high pressure pump.
NOTE: The high pressure pump unit - feeding pump is not subject to overhaul. Do not disassemble or tamper with
the retaining bolts.
The only serviceable components are the control gear and pressure regulator.
NHIL13ENG0509AA 1
(1) Fuel exhaust collector to rail - (2) High pressure pump - (3) Pressure regulating gauge - (4) Driving gear -
(5) Connector to fuel entry flowing from filter - (6) Connector to fuel exhaust to filter support - (7) Connector
to fuel entry flowing from engine control module heat exchanger - (8) Connector to fuel exhaust flowing
from mechanical pump to filter - (9) Mechanical feeding pump
HIGH PRESSURE PUMP
Inside Structure
NHIL13ENG0510FA 2
(1) Cylinder - (2) Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft -
(7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts.
Every pumping unit is composed of:

• A piston actuated by a three-lobe element floating on the pump shaft. The element, which is floating on an offset
part of the shaft, uses the highest part of the element to actuate the three pistons alternately.
• Cap intake valve.
• Ball delivery valve.
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Working Principle
NHIL13ENG0511GA 3
(1) Cylinder - (2)Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft -
(7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts
The pumping element is oriented towards the pump's camshaft. During the intake phase, the pumping element is fed
through the feeding line. The quantity of fuel to flow to the pumping element is determined by the pressure regulating
gauge. The pressure regulating gauge, according to the PWM command received by the engine control module,
stops the fuel flow to the pumping element. During the compression phase of the pumping element, the fuel achieves
the level of pressure determining the opening of the by-pass valve to the common rail, feeding it through the exhaust
unit.
NHIL13ENG0512AA 4
(1) Cylinder - (2)Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft -
(7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts
The figure shows the fuel runs at low pressure inside the pump. The following elements are clearly visible: the main
feeding line to the pumping elements, the feeding lines to the pumping elements, the duct lines run for the pump
lubrication, the pressure gauge, the flow limiting valve to 5 bar (73 psi) and the fuel exhaust flue
The pump shaft is lubricated by the fuel from the feeding and recovery lines.
The pressure gauge determines the quantity of fuel to feed the pumping elements. The excess fuel flows through the
exhaust gallery.
The 5 bar (73 psi) limiting valve, in addition to recovering exhaust fuel as a collector, also functions to keep the pres-
sure at a constant 5 bar (73 psi) limit at gauge entry.
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NHIL13ENG0513AA 5
(1) Fuel exhaust flue - (2) Fuel exhaust gallery -
(3) Fuel exhaust flowing from pump with connector to high pressure pipe for common rail
This figure shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.
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Pressure regulating valve - Overview

Pressure Regulator
The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure
system; the pressure regulator is managed by the EDC7 control unit.
Delivery pressure to the rail is modulated between 250 - 1450 bar (3625 - 21025 psi) by the electronic control unit by
controlling the pressure regulator solenoid valve.
This component is a N.O. solenoid valve.
The solenoid valve impedance is approximately 3.2 Ω.
Pressure Limiter for Fuel Return

It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at pressures of
1.3 - 2 bar (19 - 29 psi). By guaranteeing this pressure to the return fuel, the fuel vapor formation inside the injectors
is avoided, optimizing fuel spraying and combustion.
NHIL13ENG0514AA 1
(A) - To Tank
(B) - From Injectors
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Common rail Relief valve - Overview

Mounted on the end of the rail, it has the function of protecting the system's components in case the failure of the
rail pressure sensor or the pressure regulator of the CP3 pump causes an excessive pressure increase in the high
pressure plant.
When the rail pressure reaches 1800 bar (26100 psi), the valve initially opens in order to allow the fuel to flow and
subsequently reduce the pressure within the safety limits and then it mechanically regulates the rail pressure to ap-
proximately 800 bar (11600 psi).
This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of
the fuel preserving the return pipes to tank.
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Fuel injectors - Overview

On NEF TIER III engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power
developed by the engine.
Jet Power Pressure

DLLA Up to 152 kW (207 Hp) 250 - 1600 bar (3625 - 23200 psi)
DSLA 152 kW (207 Hp) and above. 250 - 1450 bar (3625 - 21025 psi)
The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs.
The injector is composed of two parts:
• actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.
• control solenoid valve composed of a coil, and pilot valve.
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position
93095366 1
(1) Pressure Rod (6) Ball Shutter (11) Supply Duct

(2) Plunger (7) Control Area (12) Control Fuel Outlet
(3) Nozzle (8) Pressure Chamber (13) Electrical Connection
(4) Coil (9) Control Volume (14) Spring
(5) Pilot Valve (10) Control Duct (15) High Pressure Fuel Inlet
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Injection Start
93095367 2
When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct
(12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8)
makes plunger (2) lift, following fuel injection into the cylinder.
Injection End
When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance
as to make plunger (2) go back to its closing position and end the injection process.
NOTE: The injector cannot be overhauled and therefore it must not be disassembled.
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Electro-Injector Solenoid Valves

The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The Impedance of the coil of each injector is 0.56 - 0.57 Ω.
COVERBASE 3
Reference Description ECU Pin

Connector (1)
Pin #1 Cylinder 2 injector 11A
Connector (2)
Connector (3)
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Fuel injectors - Overview

On NEF TIER III engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power
developed by the engine.
Jet Power Pressure

DLLA Up to 152 kW (207 Hp) 250 - 1600 bar (3625 - 23200 psi)
DSLA 152 kW (207 Hp) and above 250 - 1450 bar (3625 - 21025 psi)
The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs.
The injector is composed of two parts:
• actuator - spray nozzle composed of a pressure rod, plunger, and nozzle.
• control solenoid valve composed of a coil, and pilot valve.
The solenoid valve controls spray nozzle plunger lift.
Injector in rest position
93095366 1
(1) Pressure Rod (6) Ball Shutter (11) Supply Duct

(2) Plunger (7) Control Area (12) Control Fuel Outlet
(3) Nozzle (8) Pressure Chamber (13) Electrical Connection
(4) Coil (9) Control Volume (14) Spring
(5) Pilot Valve (10) Control Duct (15) High Pressure Fuel Inlet
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Injection Start
93095367 2
When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct
(12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8)
makes plunger (2) lift, following fuel injection into the cylinder.
Injection End
When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance
as to make plunger (2) go back to its closing position and end the injection process.
NOTE: The injector cannot be overhauled and therefore it must not be disassembled.
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Electro-Injector Solenoid Valves

The electro-injectors are effectively N.O. solenoid valves.
Each injector is connected to the EDC control unit on connector A.
The Impedance of the coil of each injector is 0.56 - 0.57 Ω.
COVERBASE 3
Reference Description ECU Pin

Connector (1)
Connector (2)
Connector (3)
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Fuel injection system - Test Mechanical fuel injection – Fuel

supply/Leakage Test
NOTE: This diagnostic procedure requires using NEF test kit # 380140055.
ATTENTION: If possible, test the fuel system as described before removing the BOSCH VE fuel injection pump for
repair. If leakage is too severe, complete the test procedure immediately following the pump repair or replacement.
Failure to test the system may result in continued pump leakage/failure.
1. Install special tool # 380100056 pressure gauge (1) be-
tween the outlet of the fuel filter (3) and the inlet of the
BOSCH VE fuel injection pump (2).
NHIL12ENG0044AA 1
2. Operate the engine to purge air from the system which

entered during gauge installation.
3. When air is no longer visible in the clear test line, mea-
sure and record the operating pressure, while continu-
ally observing for air in the fuel.
NOTE: The clear line could be left in place over night to check for a slow air ingress leak.
4. Measure and record the following pressures:
Condition: Fuel Pressure Specification between fuel filter and

injection pump:
Test the fuel pressure at LOW idle; apply no load to the
engine.
Test the fuel pressure at Pressure at HIGH idle; apply 0.276 bar to 0.414 bar
no load to the engine. 27.6 kPa (4.0 psi) to 41.4 kPa (6.0 psi)
Test the fuel pressure at HIGH idle; apply load to the
engine using the hydraulics (over relief), hydrostatic stall,
converter stall, or dynamometer. Load the engine to its
rated RPM.
5. If the fuel pressure is below 0.276 bar / 27.6 kPa

(4.0 psi) at any time during the test, check/replace the
following as needed:
Component: Inspection:
Fuel pre-filter (if equipped) Some applications do not use a fuel pre-filter.
Fuel filter(s) Replace
Fuel lines The lines and connections from the fuel lift pump inlet
back to the fuel tank, checking for damaged lines (kinks
create restriction; rub marks may allow air to enter) and
leakage at the Voss o-ring fittings.
Fuel tank Clean the fuel tank as required.
The fuel pick-up tube located in the fuel tank. Check for cracks, plugging, or contact with the
bottom/sidewalls of the tank.
Check the valve at the fuel tank outlet (if equipped). Ensure that fuel supplied to and from the valve assembly
is properly connected.
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Fuel tank cap Be sure a vacuum is not being formed in the fuel tank. A
vacuum at the tank would reduce the fuel supply pressure
to the injection fuel pump inlet. Vacuum in the fuel tank
might not be observable during short-term running.
6. If the fuel pressure is below 0.276 bar / 27.6 kPa

(4.0 psi) install special tool # 380100056 pressure
gauge (2) between the outlet of the fuel tank (3) and
the inlet of the fuel lift pump (1). Check the following:
NHIL12ENG0045AA 2
Condition: Action:
Continuous air bubbles. Inspect the fuel lines and connections from the fuel lift
pump inlet back to the fuel tank, checking for damaged
lines (kinks create restriction; rub marks may allow air to
enter) and leakage at the Voss o-ring fittings.
Vacuum between the inlet of the low pressure pump and If vacuum reading exceeds 50.8 mm Hg (2.0 in Hg),
the tank should not exceed 50.8 mm Hg (2.0 in Hg) inspect fuel lines for plugging or debris in the fuel tank.
under full load.
7. Supply fuel from an alternate fuel source located not

more than 1 m (3.3 ft) below the engine with a known
good supply line.
NHIL12ENG0046AA 3
8. This bypasses:
• Fuel tank
• Inlet lines
• Connections
• Pre-filter (if equipped)
9. Rerun the filter outlet pressure test. If pressures return
to normal, check the fuel supply line and the fuel tank
of the machine for leaks or restrictions.
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Fuel injection system - Test Common rail fuel injection – Fuel

supply/Leakage test
NOTE: This diagnostic procedure requires using NEF test kit # 380140055.
1. Install special tool # 380100056 pressure gauge at the
inlet of the low pressure pump (after the primary filter).
NOTE: This test line contains a compound gauge – 0 mm
(0.0 in) to 762 mm (30 in) of Hg vacuum and 0 bar / 0 kPa
(0 psi) to 2.07 bar / 207 kPa (159.5 psi) positive pressure.
NHIL12ENG0050AA 1
2. Install special tool # 380100057 between the outlet of

the fuel filter and the inlet of the high pressure pump.
NOTE: This test line contains a pressure gauge – 0 bar /
0 kPa (0 psi) to 11 bar / 1100 kPa (159.5 psi)
NHIL12ENG0050AA 2
3. Operate the engine to purge air from the system which

entered during gauge installation.
4. When air is no longer visible in the clear test line, mea-
sure and record operating pressure, while continually
observing for air in the fuel.
NOTE: The clear line could be left in place over night to check for a slow air ingress leak.
Condition: Fuel pressure specification between filter and high

pressure pump:
Test the fuel pressure at LOW idle; no load to the engine.
Test the fuel pressure at 1500 RPM; no load to the engine 5 bar / 500 kPa (72.5 psi)
Test the fuel pressure at HIGH idle; apply load to the
engine using the hydraulics (over relief), hydrostatic stall,
converter stall, or dynamometer. Load the engine to its
rated RPM.
5. If the fuel pressure testing point between the primary

filter outlet to the low pressure pump inlet drops below
5 bar / 500 kPa (72.5 psi) at any time during the test,
check/replace the following as needed:
Component: Action:
Fuel Pre-filter (if equipped) Some applications do not use a fuel pre-filter.
Primary fuel filter Replace
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Fuel tank Clean the fuel tank as required.

Fuel lines and connections The line from the fuel supply pump inlet to the fuel tank.
Check for damaged lines (a kink creates a restriction, rub
marks may allow air to enter) and leakage at the Voss
o-ring fittings.
The fuel pick-up tube in the fuel tank. Check for cracks, plugging, or contact with the
bottom/sidewalls of the tank.
Fuel tank cap Be sure a vacuum is not being formed in the fuel tank. A
vacuum at the tank would reduce the fuel supply pressure
to the injection fuel pump inlet. Vacuum in the fuel tank
might not be observable during short-term running.
Fuel tank outlet valve Check the valve at the fuel tank outlet (if equipped).
Ensure that fuel supplied to and from the valve assembly
is properly connected.
6. Rerun the fuel pressure test. If the pressure is still be-

low 5 bar 500 kPa (72.5 psi) supply fuel from an alter-
nate fuel source (a separate container, 380100058) (1),
located not more than 1 m (3.3 ft) below the engine with
a known good fuel supply line.
NHIL12ENG0054AA 3
7. This bypasses:
• Fuel tank
• Inlet lines
• Connections
• Pre-filter (if equipped)
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Rotary injection pump - Remove

Prior operation:
Injector fuel lines - Disconnect (10.218)
1. Remove the gear (1) transmitting motion to the injection

pump.
2. Remove the adjustable gear that lies behind the pri-
mary drive gear.
NHIL13ENG0565AA 1
Next operation:
Rotary injection pump - Install (10.218)
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Rotary injection pump - Install

Prior operation:
Rotary injection pump - Remove (10.218)
1. Install the adjustable gear that lies behind the primary

drive gear.
2. Install the gear (1) transmitting motion to the injection
pump.
NHIL13ENG0565AA 1
Next operation:
Injector fuel lines - Connect (10.218)
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Rotary injection pump - Disassemble

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been
disconnected, and the accelerator cable shall also be disconnected.
1. Remove the starter from the flywheel housing (1) and
use tools 380000988 (2) and 380002822 (3) to rotate
the flywheel.
NHIL13ENG0566AB 1
NOTE: In the case of pump replacement, the spare part should be supplied preset. If the pump is to be disassembled
and reassembled later on without being repaired, it will be necessary to preset the pump while it is still assembled to
the engine and disassembled afterwards.
Finding TDC with the false injector

2. Remove the rocker cover of the first cylinder.
3. Remove the injector and use a dial indicator
380001543 (1) to set the number one cylinder to the
TDC (top dead center) position at the end of the com-
pression phase. Pre-load the gauge.
4. This condition is obtained by rotating the engine shaft
properly until you find the maximum value on the gauge
and then checking that the intake and exhaust valves
are both closed.
5. Once TDC is obtained, lock the flywheel by means of
tool 380000988.
NHIL13ENG0567AA 2
Finding TDC with the timing gear blocking pin

6. Install the pin 380002729 (1) in the housing on the rear
cover.
7. Turn the flywheel while pushing on the pin (1) until it
blocks the gear (2) obtaining TDC of the number one
cylinder.
8. Check that the piston is in the compression phase by
making sure the intake and exhaust valves are both
closed.
NHIL13ENG0568AB 3
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9. Loosen the side bolt (1) that is used to lock the pump
shaft and remove the spacer (2). The spacer must be
kept. It is recommended to fix it to the pump with a wire
or a clip.
10. Tighten the bolt (1) blocking rotation of the pump shaft.
NHIL13ENG0569AB 4
11. Remove the bolts (1) that retain the plate (2) covering
the pump drive gear.
12. Remove the nut (3) securing the gear to the pump
shaft and remove the relating washer.
NHIL13ENG0570AB 5
13. From the pump side, loosen the nuts (1) without re-
moving them in order to move the pump backwards
using the injection pump gear extractor.
14. Assemble the extractor throughout the two threaded
ports (2) and withdraw the gear from the pump shaft.
15. Properly hold the pump and remove the nuts com-
pletely.
16. Remove the pump from its mounting studs, together
with the gasket.
NOTE: Hold the pump drive gear to avoid interference or
crawling during timing gear rotation.
NHIL13ENG0571AB 6
ATTENTION: When the pump is to be installed, the engine must be at TDC of the compression phase on cylinder
number one.
Next operation:
Rotary injection pump - Assemble (10.218)
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Rotary injection pump - Assemble

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
Rotary injection pump - Disassemble (10.218)
1. Install the pump in its housing on the engine, while in-

stalling the gear onto the pump shaft.
2. Tighten the nuts (1) securing the pump to the engine.
NOTE: The gasket removed during disassembly shall not
be utilized again. Always use original spare parts.
NHIL13ENG0572AA 1
3. On the timing side, install the washer and the retaining

nut (3) on the pump shaft.
4. Torque the nut to 90 - 95 Nm (66.4 - 70.1 lb ft).
5. Install the plate (2) with new gasket and tighten bolts
(1).
NHIL13ENG0573AB 2
6. Loosen the bolt (1) that prevents pump shaft rotation

and insert spacer (2). By doing this the pump shaft will
be able to rotate freely.
7. Remove the flywheel rotation/locking tool 380000988
and install the starter motor.
8. Connect all pipelines in the fuel system.
9. Connect the electrical connections to electro-magnets
on the hydraulic head and on the KSB.
NOTE: If the engine is installed in the application, connect
the accelerator cable.
NHIL13ENG0574AB 3
Next operation:
Rotary injection pump - Timing adjust (10.218)
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Rotary injection pump - Timing adjust

F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
1. Use engine turn tool 380000988 to rotate the engine

until the gap between the slots of the tone wheel (1) is
at the top. This indicates that cylinder number one is at
Top Dead Center (TDC).
2. Remove the engine valve cover and verify that the en-
gine is at TDC by checking that the cylinder number
one push rods move freely.
NOTE: If the push rods are tight (holding the valves open),
rotate the engine one full turn.
NHIL13ENG0714AA 1
3. Install the valve gauge tool 380001435 (1) onto the

No. 1 cylinder rocker arm assembly and open the No.1
cylinder intake valve.
4. Carefully rotate the engine in a clockwise direction (as
viewed from the front) until the piston makes light con-
tact with the intake valve.
NHIL13ENG0715AA 2
5. Fabricate a pointed rod from a piece of heavy wire.

6. Attach the pointed rod to the bracket (1) near the AC
belt pulley.
NHIL13ENG0716AA 3
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7. Mark the pulley (1) using the pointed rod (3) as a refer-
ence point (2).
NHIL13ENG0717AA 4
8. Remove the tool 380001435 (1) to close the intake

valve. Rotate the engine clockwise approximately 20 °
until the piston is on its down cycle.
9. Repeat 3.
10. Rotate the engine counterclockwise until the piston
makes light contact with the intake valve.
NHIL13ENG0715AA 5
11. Make another reference mark (1) on the AC belt pulley

using the pointed rod (2) as a reference.
NHIL13ENG0707AA 6
12. Measure between the two marks and make a third

mark (1) at the midpoint.
13. Rotate the engine to align the center mark with the
reference rod (2). This marks cylinder number one
TDC.
NHIL13ENG0710AA 7
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14. Remove the valve gauge tool 380001435 (1) to close

the intake valve.
NHIL13ENG0715AA 8
Checking static timing

15. Locate the timing plug (2) at the center of the injection
lines and remove it.
16. Replace the timing plug with adapter (1) and insert
indicator gauge (3) into the pump.
17. Preload the gauge approximately 2.5 mm.
18. Turn the engine counterclockwise until the gauge nee-
dle stops moving and then zero out the gauge.
NHIL13ENG0588AA 9
19. Turn the engine clockwise until the TDC mark (1)
aligns with the reference rod (2).
20. Note the timing prelift shown on the gauge. The spec-
ifications are as follows:
Engines without a turbocharger - 1.10 - 1.25 mm
Engines with a turbocharger - 0.95 - 1.10 mm
21. If the timing prelift is out of specification, refer to “Static
timing reset - Minor adjustment”.
NHIL13ENG0710AA 10
Static timing reset - Minor adjustment

22. With the engine at TDC and dial indicator installed,
loosen the three nuts (1) that secure the pump to the
gear housing.
NOTE: Use a 38 cm (15 in) socket extension (minimum)
to loosen the back bolt so that the gauge reading will not
be altered.
NHIL13ENG0708AA 11
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23. Use the slots in the injection pump mount to rotate

(fine-tune) the pump clockwise to retard the timing or
counterclockwise to advance the timing until the spec-
ification in 21 is reached.
NHIL13ENG0709AA 12
NHIL13ENG0708AA 13
25. If the timing prelift specification cannot be obtained,

see “Static timing - Major adjustment.”
Static timing - Major adjustment

1. Remove the drive gear access cover (1) and loosen
the injection pump nut (2) slightly without removing the
gear from the shaft.
2. Turn the engine over until the pre-lift is:
Engines without a turbocharger - 1.10 - 1.25 mm (0.04
- 0.05 in)
Engines with a turbocharger - 0.95 - 1.10 mm (0.04 -
0.04 in)
NHIL13ENG0573AB 14
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3. Lock the pump by removing the spacer (2) from under

the bolt head (1) on the mounting flange.
NHIL13ENG0569AB 15
4. From the pump side, loosen the nuts (1) without remov-
ing them in order to move the pump backwards.
5. Install the drive gear puller 380000835 throughout the
two threaded ports (2) and remove the gear from the
pump shaft in order to remove the pump.
6. Hold the pump and remove the nuts completely.
7. Remove the pump and gasket from its mounting studs.
8. Turn the engine back to TDC.
NHIL13ENG0571AB 16
NOTE: Use solvent to remove oil from the injection pump driveshaft and gear tapers. Tapers must be dried completely.
9. Install the pump onto the engine and torque the nuts to
20 - 28 N·m (15 - 21 lb ft).
10. Snug the drive gear nut (1) to temporarily hold the gear
to the shaft.
11. Replace spacer under the lock bolt head.
12. Torque the drive gear nut (1) to 89 - 95 N·m (66 - 70 lb
ft).
NHIL13ENG0571AB 17
13. Verify that the pump prelift is within the following spec-
ifications:
- 0.05 in)
0.04 in)
14. Test running and starting performance.
Next operation:
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Rotary injection pump - Disassemble

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Prior operation:
NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been
disconnected, and the accelerator cable should also be disconnected.
1. Remove the bolts (1) and remove the starter (2).
NHIL13ENG0576AA 1
2. Install the bracket of the tool 380000988 (1) holding the

flywheel provided with the rotation coil (2).
3. Carefully rotate the flywheel in the direction of normal
rotation to remove the slack in the gear.
4. Rotate the flywheel until the pin (4) provide with the tool
380000988 engages in the tooth of the flywheel (3).
NHIL13ENG0577AB 2
Finding TDC with the false injector

5. Remove the rocker cover of the first cylinder.
6. Remove the injector and place a dial indicator gauge
380001543 (1) to set the number one cylinder to the
TDC (top dead center) position at the end of the com-
pression stroke. Pre-load the gauge.
7. This condition is obtained by rotating the engine shaft
properly until you find the maximum value on the gauge
and then checking that the intake and exhaust valves
are both closed.
8. Once TDC is obtained, lock the flywheel by means of
tool 380000988.
NHIL13ENG0578AA 3
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9. Disconnect the fuel lines from the priming pump (1).

10. Remove the retaining bolts (2) and remove the pump
(1).
NHIL13ENG0579AA 4
11. Check through priming pump hole in the block, that

camshaft (1) is in TDC at the compression phase by
the visible notches (2) on the camshaft. If the notches
are not visible, unlock the flywheel and rotate the en-
gine 360 ° until the notches are visible. Lock the fly-
wheel.
NHIL13ENG0580AB 5
12. Loosen the bolt (2), remove the "L" spacer (1) and
tighten the bolt (2) to keep the pump timed with the
engine flywheel. The spacer must be kept. It is rec-
ommended to secure it to the pump with a wire or a
clip.
NHIL13ENG0581AA 6
13. Remove the bolts (1) that secure the plate (2) covering
the pump drive gear.
14. Remove the nut (3) securing the gear to the pump
shaft and remove the relating washer.
NHIL13ENG0582AB 7
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15. Remove the three nuts (2), (3), and (5) fastening the
pump (1) to the housing (4) and remove it from the
housing.
NHIL13ENG0583AA 8
Next operation:
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Rotary injection pump - Assemble

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Prior operation:
Rotary injection pump - Disassemble (10.218)
1. When installing the feed pump to the engine, it is nec-

essary to ensure that the number one cylinder is at TDC
of the compression stroke.
2. Install the pump unit (1), preset, into the gearbox hous-
ing (2).
3. Install the mounting nuts (3) and finger tighten them.
NOTE: The gasket removed during disassembly should not
be utilized again. Always use original spare parts.
NHIL13ENG0584AA 1
4. On the timing side, install the washer and the retaining

nut (3) on the pump shaft.
5. Torque the nut (3) to 90 - 95 Nm (66.4 - 70.1 lb ft).
6. Install the plate (2) with new gasket and torque the bolts
(1) to . 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0585AB 2
7. Loosen the bolt (2) that prevents pump shaft rotation

and insert spacer (2).
8. Tighten the bolt (2) so that it locks the spacer (2) in
place. By doing this, the pump shaft will be able to
rotate freely.
9. Remove the flywheel rotation locking tool 380000988
and install the starter.
NHIL13ENG0586AB 3
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10. Install the priming pump (1) to the engine block and
torque the retaining bolts (2) to 20 - 28 N·m (15 - 21 lb
ft).
11. Connect all pipelines in the fuel system.
12. Connect the electrical connections to electro-magnets
on the hydraulic head and on the KSB.
NOTE: If the engine is installed in the application, connect
the accelerator cable.
NHIL13ENG0587AA 4
Next operation:
Rotary injection pump - Timing adjust (10.218)
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Rotary injection pump - Timing adjust

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Prior operation:
1. Use engine turn tool 380000988 to rotate the engine

until the gap between the slots of the tone wheel (1) is
at the top. This indicates that cylinder number one is at
Top Dead Center (TDC).
2. Remove the engine valve cover and verify that the en-
gine is at TDC by checking that the cylinder number
one push rods move freely.
NOTE: If the push rods are tight (holding the valves open),
rotate the engine one full turn.
NHIL13ENG0714AA 1
3. Install the valve gauge tool 380001435 (1) onto the

No. 1 cylinder rocker arm assembly and open the No.1
cylinder intake valve.
4. Carefully rotate the engine in a clockwise direction (as
viewed from the front) until the piston makes light con-
tact with the intake valve.
NHIL13ENG0715AA 2
5. Fabricate a pointed rod from a piece of heavy wire.

6. Attach the pointed rod to the bracket (1) near the AC
belt pulley.
NHIL13ENG0716AA 3
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7. Mark the pulley (1) using the pointed rod (3) as a refer-
ence point (2).
NHIL13ENG0717AA 4
8. Remove the tool 380001435 (1) to close the intake

valve. Rotate the engine clockwise approximately 20 °
until the piston is on its down cycle.
9. Repeat 4.
10. Rotate the engine counterclockwise until the piston
makes light contact with the intake valve.
NHIL13ENG0715AA 5
11. Make another reference mark (1) on the AC belt pulley

using the pointed rod (2) as a reference.
NHIL13ENG0707AA 6
12. Measure between the two marks and make a third

mark (1) at the midpoint.
13. Rotate the engine to align the center mark with the
reference rod (2). This marks cylinder number one
TDC.
NHIL13ENG0710AA 7
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14. Remove the valve gauge tool 380001435 (1) to close

the intake valve.
NHIL13ENG0715AA 8
Checking static timing

15. Locate the timing plug (2) at the center of the injection
lines and remove it.
16. Replace the timing plug with adapter (1) and insert
indicator gauge (3) into the pump.
17. Preload the gauge approximately 2.5 mm.
18. Turn the engine counterclockwise until the gauge nee-
dle stops moving and then zero out the gauge.
NHIL13ENG0588AA 9
19. Turn the engine clockwise until the TDC mark (1)
aligns with the reference rod (2).
20. Note the timing prelift shown on the gauge. The spec-
ifications are as follows:
Engines without a turbocharger - 1.10 - 1.25 mm
Engines with a turbocharger - 0.95 - 1.10 mm
21. If the timing prelift is out of specification, refer to “Static
timing reset - Minor adjustment”.
NHIL13ENG0710AA 10
Static timing reset - Minor adjustment

22. With the engine at TDC and dial indicator installed,
loosen the three nuts (1) that secure the pump to the
gear housing.
NOTE: Use a 38 cm (15 in) socket extension (minimum)
to loosen the back bolt so that the gauge reading will not
be altered.
NHIL13ENG0708AA 11
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23. Use the slots in the injection pump mount to rotate

(fine-tune) the pump clockwise to retard the timing or
counterclockwise to advance the timing until the spec-
ification in 21 is reached.
NHIL13ENG0709AA 12
NHIL13ENG0708AA 13
25. If the timing prelift specification cannot be obtained,

see “Static timing - Major adjustment.”
Static timing - Major adjustment

1. Remove the drive gear access cover (1) and loosen
the injection pump nut (2) slightly without removing the
gear from the shaft.
2. Turn the engine over until the pre-lift is:
- 0.05 in)
0.04 in)
NHIL13ENG0573AB 14
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3. Lock the pump by removing the spacer (2) from under

the bolt head (1) on the mounting flange.
NHIL13ENG0569AB 15
4. From the pump side, loosen the nuts (1) without remov-
ing them in order to move the pump backwards.
5. Install the drive gear puller 380000835 throughout the
two threaded ports (2) and remove the gear from the
pump shaft in order to remove the pump.
6. Hold the pump and remove the nuts completely.
7. Remove the pump and gasket from its mounting studs.
8. Turn the engine back to TDC.
NHIL13ENG0571AB 16
NOTE: Use solvent to remove oil from the injection pump driveshaft and gear tapers. Tapers must be dried completely.
9. Install the pump onto the engine and torque the nuts to
20 - 28 N·m (15 - 21 lb ft).
10. Snug the drive gear nut (1) to temporarily hold the gear
to the shaft.
11. Replace spacer under the lock bolt head.
12. Torque the drive gear nut (1) to 89 - 95 N·m (66 - 70 lb
ft).
NHIL13ENG0571AB 17
13. Verify that the pump prelift is within the following spec-
ifications:
- 0.05 in)
0.04 in)
14. Test running and starting performance.
Next operation:
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High pressure pump - Remove

Prior operation:
Prior operation:
1. Disconnect all of the fuel lines (4) from the high pres-
sure pump (2).
2. Remove the mounting nuts (1) and remove the high
pressure pump (2) and the feed pump (3) together as
one unit.
NHIL13ENG0589AA 1
Next operation:
High pressure pump - Install (10.218)
47597675 27/09/2013
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High pressure pump - Install

Prior operation:
High pressure pump - Remove (10.218)
Prior operation:
1. Mount the high pressure pump (2) with the feed pump
(3) into place on the rear cover.
2. Install the retaining nuts (1) securing the high pressure
pump to the rear cover and torque the bolts to 20 -
28 N·m (15 - 21 lb ft).
3. Connect all of the fuel lines (4).
NHIL13ENG0589AA 1
Next operation:
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High pressure pump - Test Pressure Relief Valve Testing

Electronic Fuel Systems

1. The Pressure Relief Valve (1) is located at the rear end
of the fuel rail. This valve protects the fuel system com-
ponents from excessive pressure.
NHIL13ENG0591AA 1
2. Check the ECU for:

• Fault codes related to over pressurization of the
common rail.
3. Disconnect the pressure relief valve return line and cap
the line with special tool # 380100060 line cap.
4. Install special tool # 380100057 pressure gauge and
hose assembly on the relief valve to direct any leakage
to special tool #380100062 container if the relief valve
is leaking.
NOTE: Under normal circumstances, fuel should not come out of the relief valve.
5. If the diagnostic system does not indicate a fault code
and fuel is leaking from the pressure relief valve, re-
place the pressure relief valve.
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Pressure regulating valve - Test

1. If the high pressure flow regulator has an open circuit

(the flow regulator is disconnected, the harness is bro-
ken, etc.) or a short circuit (resistance value is much
lower than 3.2 Ω):
• The pump will be in maximum delivery mode
and pressure in the rail will exceed 1700 bar
(24650.0 psi) for a very short amount of time.
• The high pressure relief valve will open.
• The ECU senses the over pressure condition and
stores fault codes in the ECU memory.
• The engine will derate.
NHIL13ENG0592AA 1
2. Check the resistance (on the ECU connector pins). The

resistance specification is approximately 3.2 Ω.
3. When in parameter mode on the Electronic Service
Tool, the duty cycle reading indicates the position of
the regulator.
4. If all of the system components have been checked,
inspect for the following symptoms:
The duty cycle tends to fluctuate irregularly and the
engine idle speed is irregular.
The engine stalls when idling and no fault is stored in
the ECU.
Starting is difficult (takes longer than 4 seconds).
5. If any of these symptoms are present, replace the high
pressure flow regulator.
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Common rail - Install

Prior operation:
1. Install the common rail (6) onto the cylinder head.

2. Torque the mounting mounts (1) to 20 - 28 N·m (15 -
21 lb ft).
3. Connect new fuel lines (2) to the common rail (6) and
to the manifold for the fuel injectors (5).
4. Torque the fuel line fittings (3) to 20 Nm (15 lb ft).
5. Install the low pressure fuel line (4) to the common rail
(6). Refer to Common rail lines - Connect (10.218)
for the proper procedure.
NHIL13ENG0593AA 1
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Common rail lines - Disconnect Low Pressure

1. Hold down the clasp (1) and release the quick fitting
joint.
NHIL13ENG0594AA 1
Next operation:
Common rail lines - Connect (10.218)
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Common rail lines - Connect Low Pressure

Prior operation:
Common rail lines - Disconnect (10.218)
1. Connect low pressure lines to the common rail l by in-

serting the rapid fitting joint into the connection joint and
press until the clip (1) fastens securely.
2. Check for proper fuel connection.
NHIL13ENG0595AA 1
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Fuel injectors - Remove

Prior operation:
Fuel fillers - Remove (10.218)
1. Remove the bolts securing the fuel injectors to the cylin-

der head.
2. Use tool 380001099 (1) to remove the fuel injectors (2)
from the cylinder head.
NHIL13ENG0596BA 1
Next operation:
Fuel injectors - Install (10.218)
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Fuel injectors - Install

Prior operation:
Fuel injectors - Remove (10.218)
1. Install a new O-ring (2) and sealing washer (3) onto the
fuel injector (1).
2. Lubricate the O-ring (2) with petroleum jelly.
NHIL13ENG0597AA 1
3. Install the fuel injectors (1) into the cylinder head di-
rected so the fuel inlet hole (2) is facing the cross tube
seat (3).
NHIL13ENG0598AA 2
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4. Use tool 380001099 (1) to seat the injector (2) in place.
NHIL13ENG0599BA 3
5. Install the injector bolts (2) without tightening them.

NOTICE: You must install the cross tube before tightening
the injector bolts. Refer to Fuel fillers - Install (10.218).
NHIL13ENG0600AA 4
6. Torque the injector bolts (1) in the two stages. Torque

the bolts to 8 - 9 N·m (6 - 7 lb ft).
7. Using the angular torquing gauge tool 380001001 turn
the bolts an additional 70 - 80 °.
NOTICE: Be sure to also torque the bolt (2) securing the
cross tube (3) after torquing the injector. Refer to Fuel
fillers - Install (10.218) for the proper procedure.
NHIL13ENG0601AA 5
Next operation:
Fuel fillers - Install (10.218)
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Fuel injectors Mechanical - Remove

Prior operation:
1. Remove the retaining bolt (1) on the mechanical fuel

injector.
2. Remove the injector and seal (2) from its seat in the
cylinder head.
NHIL13ENG0602AA 1
Next operation:
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Fuel injectors Mechanical - Install

Prior operation:
1. Install the injectors after having replaced the sealing

gasket (3).
2. Verify that the positioning ball (1) is aligned in the cylin-
der head housing facing the cross tube threads (2).
3. Torque the injector bolts to 55 - 65 N·m (41 - 48 lb ft).
NHIL13ENG0603AA 1
Next operation:
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Fuel injectors - Test Fuel injector testing

Symptom: Excessive cranking time and no fault codes present.

1. Warm the engine to 50 °C (122.0 °F) minimum.
2. Use NEF fuel supply/leakage test kit special tool kit #
380140055 for the following tests.
NHIL12ENG0041AA 1
NOTE: Return leakage can be checked at various locations (at the filter base or the cylinder head depending on ease
of the connection). If excessive leakage is found, additional testing will be required to determine the exact location(s)
of the leakage. Each fuel injector connector and the pressure relief valve could be a source of excessive return flow.
More than one component could be responsible for excessive return.
3. Disconnect the return line at the fuel filter base and plug
special tool #380100059 in to the filter base port.
4. Drain the fuel return line at the fuel filter base into a
100 ml (3.4 US fl oz) cup special tool #380100062.
5. Start and run the engine at low idle, with no load. Mea-
sure the amount of fuel that escapes from the drain
line in one minute. Leakage should not exceed 80 ml
(2.7 US fl oz) per minute.
6. Disconnect special tool #380100059 from the fuel filter
base and reconnect fuel line.
7. Disconnect the fuel line on the engine cylinder head
and cap the line with special tool #380100060.
8. Connect a drain line (use special tool #380100057) to
the fuel return outlet on the cylinder head.
9. Drain the fuel return outlet drain line at the cylinder
head into a 100 ml (3.4 US fl oz) cup special tool
#380100062.
10. Start and run the engine at low idle, with no load. Mea-
sure the amount of fuel that escapes from the drain
line. Leakage should not exceed 80 ml (2.7 US fl oz)
per minute.
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Fuel injectors Cross tube - Remove

Prior operation:
NOTICE: Make sure the area around the cross tube is clean. Once they are removed, there is a greater risk of
contaminating the internal components.
1. Remove the bolts (1) and remove the cross tubes (2).
NOTE: Disassembled cross tubes must not be used again.
Replace them with new ones during reassembly.
NHIL13ENG0605AA 1
Next operation:
Fuel injectors Cross tube - Install (10.218)
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Fuel injectors Cross tube - Install

Prior operation:
Fuel injectors Cross tube - Remove (10.218)
1. Install the sealing ring (4) lubricated with petroleum jelly

on the cross tube (5).
2. Install the cross tube (5) into the cylinder head so that
the positioning ball (3) is coinciding with the relevant
housing (2).
NOTE: After removing cross tubes they cannot be used
again. Replace them with new ones.
3. Install the cross tube nut but do not tighten.
NOTE: During this operation, the injector (1) can be moved
so that the cross tube (5) can be properly inserted into the
inlet hole.
NHIL13ENG0606AA 1
4. After everything is in place, torque the cross tube nuts

(2) to 50 Nm (37 lb ft).
NOTICE: Be sure to also torque the bolts (1) securing the
injector to 8 - 9 N·m (6 - 7 lb ft). Then turn the bolts using
the angular torquing gauge tool 380001001 an additional
70 - 80 ° Refer to Fuel injectors - Install (10.218) for the
proper procedure.
NHIL13ENG0607AA 2
Next operation:
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Injector fuel lines - Connect

1. Connect new fuel lines (1) between the high pressure

common rail (3) and the fuel injectors (2).
NHIL13ENG0608AA 1
2. Torque the nuts (1) to 20 Nm (15 lb ft) using the proper
wrench (2) and torque wrench (3).
Connections should be tightened by holding the flow
limiting valve hexagon with the proper wrench.
NHIL13ENG0609AA 2
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Injector fuel lines - Disconnect

1. Disconnect the fuel line (3) from the common rail (1).
Refer to Common rail lines - Disconnect Low Pres-
sure (10.218). Disconnect the fuel lines (5) from the
common rail (1) and from the fuel injectors (4) .
2. Remove the retaining bolts (2) and remove the com-
mon rail (1).
NHIL13ENG0610AA 1
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1. Disconnect the fuel line (4) from the cylinder head. Re-
fer to Common rail lines - Disconnect Low Pressure
(10.218). Disconnect the fuel lines (3) from the com-
mon rail (2) and from the fuel injectors (4).
NOTICE: When releasing the fuel line (3) connections (6)
from the common rail (2), use the proper wrench to avoid
rotation of flow limiters.
2. Remove the bolts (1) and remove the common rail (2).
NHIL13ENG0611AB 1
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1. Disconnect the fuel lines that provide feed (1) and fuel
recovery (2) between the pump and the injectors.
NHIL13ENG0612AA 1
2. Loosen and remove the pipe fittings securing the pipes

to the pumping elements.
3. Loosen and remove the fuel recovery line (2) collar on
the injection pump (3).
4. Remove the bolts securing the fuel injectors and re-
move the bolts securing the fuel recovery line.
5. Remove the bolts holding the mounting brackets fuel
lines (1), (6) and (7).
6. After removal, plug the ends of the lines to reduce the
risk of dirt contamination.
NHIL13ENG0613FB 2
(1) Rear bracket retaining bolt (on suction selector plate) - (2) Fuel recovery line to pump - (3) Rotary feed
pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket retaining bolt to injection pump
side - (7) Front bracket retaining bolt (on suction collector plate).
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Injector fuel lines - Install

1. Install the fuel line mounting brackets.

2. Install the lines (1) and (2) that provide fuel feed and
recovery between the pump and the fuel injectors.
3. Torque the locknuts and the mounting bolts securing
the fuel recovery manifold to 20 - 28 N·m (15 - 21 lb
ft).
4. Install the fuel lines to the fuel injectors and to the brack-
ets securing them.
NHIL13ENG0614AA 1
NHIL13ENG0615FA 2
(1) Rear bracket mounting bolt (on suction selector plate) - (2) Fuel recovery line to pump - (3) Rotary feed
pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket mounting bolt to injection pump
side - (7) Front bracket mounting bolt (on suction collector plate).
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Index
Engine - 10

Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Common rail Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Common rail lines - Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Common rail lines - Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel injection system - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel injection system - Test Common rail fuel injection – Fuel supply/Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel injection system - Test Mechanical fuel injection – Fuel supply/Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fuel injectors - Test Fuel injector testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Fuel injectors Cross tube - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fuel injectors Cross tube - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fuel injectors Mechanical - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fuel injectors Mechanical - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
High pressure pump - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High pressure pump - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
High pressure pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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High pressure pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
High pressure pump - Test Pressure Relief Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Injector fuel lines - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Injector fuel lines - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Injector fuel lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Pressure regulating valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure regulating valve - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
F4GE9484, F4GE9484C*J601, F4GE9684
Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
F4GE9484, F4GE9484C*J601, F4GE9684
Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Rotary injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4CE9684, F4GE9684
Rotary injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Rotary injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
F4GE9484, F4GE9484C*J601, F4GE9684
Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
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Engine - 10
Turbocharger and lines - 250

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
SERVICE
Turbocharger
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger oil supply line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Turbocharger oil return line
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Engine - Turbocharger and lines
Turbocharger - Remove
1. Remove the oil supply line retaining nut (1) and remove
the oil supply line from the turbocharger (3).
2. Remove the line nut from the other end of the supply
line to remove it from the upper part of the heat ex-
changer.
3. Remove the four mounting bolts (2) securing the tur-
bocharger to the exhaust manifold.
4. Lift and remove the turbocharger (3) from it's seat and
remove the mounting gasket.
NHIL13ENG0616AA 1
Next operation:
Turbocharger - Install (10.250)
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Turbocharger - Install
Prior operation:
Turbocharger - Remove (10.250)
1. Install a new gasket for the turbocharger.

2. Hold the turbocharger and place it on the exhaust man-
ifold.
3. Install the turbocharger nuts (2) securing the tur-
bocharger to the exhaust manifold and torque the
mounting nuts to the following specifications:
Six Cylinder Engines: 37 - 49 N·m (27 - 36 lb ft)
Four Cylinder Engines: 20 - 28 N·m (15 - 21 lb ft)
4. Install the oil supply line retaining nut (1) to the tur-
bocharger and torque the nut to 8 - 12 N·m (71 - 106 lb
in). Install the opposite end of the line on the upper part
of the oil filter support and torque the nut to 20 - 28 N·m NHIL13ENG0616AA 1
(15 - 21 lb ft).
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Turbocharger oil supply line - Install

F4HE9687, F4HE9687G*J100
Turbo oil lines

1. Install the oil supply line (2) between the turbocharger
(1) and the oil filter base. Torque the oil line retaining
nuts to 8 - 12 N·m (6 - 9 lb ft) on the turbocharger inlet
and to 20 - 28 N·m (15 - 21 lb ft) on the oil filter base
outlet.
NHIL13ENG0617AA 1
2. Install the oil return line (1) onto the turbocharger and
tighten the retaining bolts.
3. Connect the oil return line fitting (2) to the engine block.
NHIL13ENG0618AA 2
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Turbocharger oil supply line - Remove

1. Remove the turbocharger oil supply line (2) between
the turbocharger (1) and the oil filter base.
NHIL13ENG0617AA 1
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Turbocharger oil return line - Install

1. Install the oil return line (1) on the turbocharger by in-
serting the one end into the block joint (5).
2. Install and tighten the two bolts (2) underneath the tur-
bocharger securing the return line.
3. Install the retaining brackets (3) and (4) which secure
the line to the block.
NHIL13ENG0619BA 1
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Turbocharger oil return line - Remove

1. Remove the turbocharger oil return line (2) from the
turbocharger by removing the bolts (1), the retaining
brackets (3) and (4), and removing the fitting (5) from
the engine block.
NHIL13ENG0619BA 1
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Index
Engine - 10

Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger oil return line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Turbocharger oil return line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Turbocharger oil supply line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Engine - 10
Intake and exhaust manifolds and muffler - 254

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
FUNCTIONAL DATA
Intake and exhaust manifolds and muffler

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Intake manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exhaust manifold
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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CONSUMABLES INDEX

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Engine - Intake and exhaust manifolds and muffler
Intake and exhaust manifolds and muffler - Overview

The turbocharger is composed of the following main parts: one turbine, one transforming valve to regulate the boost
feeding pressure, one main body and one compressor.
During engine working process, the exhaust emissions flow through the body of the turbine, causing the turbine disk
wheel's rotation.
The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air that is then cooled by the radiator and flown through the piston collector.
The turbocharger is equipped with a transforming valve to regulate the pressure. It is located on the exhaust collector
before the turbine and connected by piping to the induction collector. It's function is to restrict the exhaust of the
emissions, releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor,
reaches the prescribed pressure.
The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
BOOSTDIAGRAM 1
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Intake and exhaust manifolds and muffler - Overview

Exhaust Gas Re-Circulation System (EGR)
In the Tier 3 version, the profile of the exhaust cam has been modified in order to allow partial opening of the relative
valve during the intake stroke (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the
exhaust gas into the engine cylinders.
The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion tempera-
ture values responsible for the production of nitrogen oxides (NOx).
The exhaust gas recirculation system (EGR), reduces the combustion temperature by means of the diminishing of
the concentration of oxygen in the combustion chamber and therefore represents an efficient control system of the
emission of NOx.
The internal EGR system is not equipped with any electronically controlled elements. The system is always active.
It's configuration does not need additional elements. (i.e. checking valves, piping or heat exchangers.)
The exhaust cam (B) has another lobe apart from the major lobe (C) with respects to the configuration without EGR.
The additional lobe, during the intake stroke in the cylinder in question, allows a brief opening of the exhaust valve
generating recirculation. This is due to the induction of the exhaust gases caused by the piston-induced vacuum
which is created in the intake stroke inside the cylinder.
NHIL13ENG0621GA 1
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Intake manifold - Remove

1. Remove the retaining bolts (1) securing the intake man-

ifold (2), the retaining nuts securing the intake air heater
(3) for the cold start aid, and then remove the heater.
NHIL13ENG0622FA 1
Next operation:
Intake manifold - Install (10.254)
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Intake manifold - Install

Prior operation:
Intake manifold - Remove (10.254)
1. Apply LOCTITE 5999 to the mounting surface of the air

intake heater (3) and the intake manifold (2).
2. Install the air intake heater (3) and torque the nuts to 6
- 10 N·m (4 - 7 lb ft).
3. Install the intake manifold onto the cylinder head and
torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0622FA 1
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1. Remove the retaining bolts (2) securing the intake man-

ifold (1) and remove the joint for the air intake heater
grid for the cold start aid.
NHIL13ENG0623AA 1
Next operation:
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Prior operation:
1. Apply LOCTITE® 5999 to the mounting surface of the

intake air heater mounted onto the intake manifold (1).
2. Install the intake air heater nuts and torque the nuts to
6 - 10 N·m (4 - 7 lb ft).
3. Install the intake manifold (1) onto the cylinder head
and torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft).
NHIL13ENG0623AA 1
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1. Remove the bolts (2) securing the intake manifold plate

(1) to the cylinder head.
2. Remove the plate (1) and the relative gasket from the
cylinder head.
NHIL13ENG0624AA 1
Next operation:
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Prior operation:
1. Apply a new gasket to the mounting surface of the in-

take manifold (1) plate and torque the bolts (2) to 20 -
28 N·m (15 - 21 lb ft).
2. If the duct from the intake manifold has been removed,
install new gaskets and apply LOCTITE® 5999 to the
intake air heater mounting surface (if applicable).
NHIL13ENG0624AA 1
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Exhaust manifold - Remove

Prior operation:
Turbocharger Turbine - Remove (10.250)
1. Remove the bolts (1) and remove the exhaust manifold

(2) from the cylinder head.
NHIL13ENG0625AA 1
Next operation:
Exhaust manifold - Install (10.254)
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Exhaust manifold - Install

Prior operation:
Exhaust manifold - Remove (10.254)
1. Install the exhaust manifold (2) onto the cylinder head.

2. Torque the bolts (1) to the following specifications:
4 cylinder engines – 20 - 30 N·m (15 - 22 lb ft)
6 cylinder engines – 75 - 85 N·m (55 - 63 lb ft)
NHIL13ENG0626AA 1
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Exhaust manifold - Remove

Prior operation:
Turbocharger - Remove (10.250)
1. Remove the retaining bolts (1) securing the exhaust

manifold (2) to the cylinder head.
2. Remove the exhaust manifold (2) and the relative gas-
kets from the cylinder head.
NHIL13ENG0627AA 1
Next operation:
Exhaust manifold - Install (10.254)
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Exhaust manifold - Install

Prior operation:
Exhaust manifold - Remove (10.254)
1. Install the exhaust manifold (1) with new gaskets (2)

onto the cylinder head and torque the bolts to 37 -
49 N·m (27 - 36 lb ft).
NOTE: The illustration of the exhaust manifold may not
match your model. However, the described procedure is
applicable.
NHIL13ENG0628AA 1
Next operation:
Turbocharger - Install (10.250)
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Index
Engine - 10

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Intake and exhaust manifolds and muffler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intake and exhaust manifolds and muffler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Engine - 10
Engine cooling system - 400

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
FUNCTIONAL DATA
Engine cooling system

F4HE9687G*J100
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
SERVICE
Water pump
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F4DE9684M*J103, F4DE9684B*J111
Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F4DE9684M*J103, F4DE9684B*J111
Coolant thermostat
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F4GE9484, F4GE9484C*J601, F4GE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F4GE9484, F4GE9484C*J601, F4GE9684
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
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Engine - Engine cooling system
Engine cooling system - Dynamic description

The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:
• Expansion Tank - Placement, shape and dimension are subject to change according to the engine's equipment.
• Radiator - Has the duty to dissipate the heat produced by the engine. The heat is conducted to the cooling liquid
which is then ran through the radiator. Application determines placement and dimensions.
• Viscous Fan - Increases the heat dissipating power of the radiator by pulling fresh air over the fins of the radiator.
Also moves ambient air over the engine itself to increase cooling power. This item is also dependant on application.
• Heat Exchanger - Cools the lubrication oil. Also application specific.
• Centrifugal Water Pump - Used to circulate the cooling liquid. Usually belt driven.
• Thermostat - regulates the circulation of the cooling liquid.
• If applicable, the circuit may be extended to the compressor.
NHIL13ENG0629GA 1
6 cylinder version
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NHIL13ENG0630GA 1
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F4GE9484, F4GE9484C*J601, F4GE9684
NHIL13ENG0631AA 1
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
NHIL13ENG0632GA 1
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Water pump - Remove

Prior operation:
1. Remove the retaining bolts (1) and remove the water

pump (2).
NHIL13ENG0633AA 1
Next operation:
Water pump - Install (10.400)
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Water pump - Install

Prior operation:
Water pump - Remove (10.400)
1. Install a new sealing ring (2) on the water pump (1).
NHIL13ENG0634AA 1
2. Install the water pump (1) onto the engine block using
the two mounting bolts (2).
NHIL13ENG0635AA 2
3. Torque the water pump (1) mounting bolts (2) to 20 -

28 N·m (15 - 21 lb ft).
NHIL13ENG0636AA 3
Next operation:
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Water pump Water manifold - Remove

F4HE9687, F4HE9687G*J100
Prior operation:
Alternator - Remove (55.301)
1. Remove the retaining bolts (2) and remove the water

manifold (1).
NHIL13ENG0637AA 1
Next operation:
Water pump Water manifold - Install (10.400)
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Water pump Water manifold - Install

F4HE9687, F4HE9687G*J100
Prior operation:
Water pump Water manifold - Remove (10.400)
1. Position the water manifold/alternator support (1) so

that the pins (2) and (3) are set against the engine
block.
2. Torque the retaining bolts (4) to 37 - 49 N·m (27 - 36 lb
ft).
NHIL13ENG0638AA 1
Next operation:
Alternator - Install (55.301)
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Water pump Water manifold - Remove

Prior operation:
1. Remove the bolts (1) securing the water manifold (2).

2. Remove the water manifold (1) from the block.
NHIL13ENG0639AA 1
Next operation:
Water pump Water manifold - Install (10.400)
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Water pump Water manifold - Install

Prior operation:
Water pump Water manifold - Remove (10.400)
1. Install the water manifold (1) onto the engine block.

ft).
NHIL13ENG0639AA 1
Next operation:
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Coolant thermostat - Remove

1. Remove the three bolts securing the thermostat hous-

ing (1) to the top of the cylinder head.
2. Remove the thermostat (2) and the seal (3) from the
housing (1).
86082981 1
Next operation:
Coolant thermostat - Install (10.400)
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Coolant thermostat - Install

Prior operation:
Coolant thermostat - Remove (10.400)
1. Install the seal (3) around the flange of the thermostat

(2).
2. Install the thermostat (2) into the housing (1) and se-
cure the assembly to the cylinder head using the three
mounting bolts.
86082981 1
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F4GE9484, F4GE9484C*J601, F4GE9684
1. Remove the three bolts (1) and remove the thermostat

housing (2) together with the bracket (3) and the thick
rubber seal (4).
2. Remove the seal (6) and the thermostat (5).
3. Assemble the bracket (3) in the original position, fixing
it with the screws (1) of the thermostat housing.
86082982 1
Next operation:
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F4GE9484, F4GE9484C*J601, F4GE9684
Prior operation:
1. Install the thermostat housing (2) including the thermo-

stat (5) and gasket (6).
2. Install the thick rubber seal (4) inside the bracket (3)
and the thermostat housing (2).
NOTE: The bracket (3) may not be available on some ap-
plications. Always replace the gasket with new upon re-
assembly.
86082982 1
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Remove the three bolts securing the thermostat hous-

ing (2).
2. Remove the housing (2), the thick rubber seal (3), the
thermostat (4) and relevant seal (1) from the cylinder
head.
86082980 1
Next operation:
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Prior operation:
1. Install the thermostat (4) with the appropriate seal (1).

2. Install the housing (2) and the thick rubber seal (3)
Torque the bolts to 20 - 28 N·m (15 - 21 lb ft).
86082980 1
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Index
Engine - 10

Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Water pump Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Water pump Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4DE9684B*J111
Water pump Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Water pump Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4DE9684B*J111
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Engine - 10
Fan and drive - 414

F4HE9684 , F4HE9687G*J100 , F4HE9687
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10.15 [10.414] / 1
Contents
Engine - 10
Fan and drive - 414
SERVICE
Fan and drive

Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Belt
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Belt tensioner
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102,
F4HE9484C*J103, F4GE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101,
F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4DE9684M*J103, F4DE9684B*J111
Idler pulley
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Engine - Fan and drive
Fan and drive - Remove Support - Remove

Prior operation:
1. Remove the retaining bolts (3) and remove the pulley

(2) controlling the engine cooling fan.
2. Remove the engine cooling fan support (1).
NHIL13ENG0669AA 1
Next operation:
Fan and drive - Install (10.414)
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Fan and drive - Install Support - Install

Prior operation:
Fan and drive - Remove (10.414)
1. Install the cooling fan support (1), pulley (2), and torque
the pulley bolts (3) to 28 - 38 N·m (21 - 28 lb ft).
NHIL13ENG0669AA 1
Next operation:
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Fan and drive - Remove -Drive Pulley

Prior operation:
1. Remove the bolts (1) and remove the cooling fan pulley
(2) from the crankshaft.
NHIL13ENG0666AA 1
Next operation:
Fan and drive - Install (10.414)
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Fan and drive - Install -Drive Pulley

Prior operation:
1. Install the pulley (2) on the crankshaft and torque the

bolts (1) to 8 - 12 N·m (71 - 106 lb in).
NHIL13ENG0666AA 1
Next operation:
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Fan and drive - Install

Prior operation:
1. Install the fan pulley support (1) and torque the bolts to
28 - 38 N·m (21 - 28 lb ft).
NHIL13ENG0667BA 1
2. Install the alternator (1) tensioning bracket (3) and

NHIL13ENG0649AA 2
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3. Install the fan pulley (1) and torque the bolts (2) to 8 -
12 N·m (71 - 106 lb in).
4. Install the idler pulley (3) and torque the bolt to 37 -
49 N·m (27 - 36 lb ft).
5. Install the new belt onto the pulleys and guide rollers.
NOTE: If the old belt is to be reused, examine it carefully in
order to see if there may be any incisions or evident signs
of yielding.
NHIL13ENG0667BA 3
Next operation:
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Fan and drive - Install

Prior operation:
1. Install the fan pulley support (1) and torque the bolts (2)
to 28 - 38 N·m (21 - 28 lb ft).
NHIL13ENG0668AA 1
2. Install the fan pulley (2) to the support (1) and torque
the bolts (3) to 8 - 12 N·m (71 - 106 lb in).
3. Install the idler pulley (4) and torque the bolt (5) to 37 -
49 N·m (27 - 36 lb ft).
NHIL13ENG0669AA 2
4. Install the automatic belt tensioner support (3) and

5. Install the automatic belt tensioner (2) and torque the
bolt (1) to 37 - 49 N·m (27 - 36 lb ft).
NHIL13ENG0670AA 3
Next operation:
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Belt - Remove
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Using the proper square drive ratchet in the provided

opening (2), release the tension on the belt (3) by
pulling back on the belt tensioner (1).
2. Remove the belt (3) from all of the pulleys.
NHIL13ENG0671AA 1
Next operation:
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Belt - Install
Prior operation:
1. Release the tension off of the belt tensioner using the

proper square drive ratchet and install the belt on the
pulleys.
66070776 1
Belt Configuration
(1) - Crankshaft (3) - Fan (5) - Alternator

(2) - Fixed Idler Pulley (4) - Water Pump (6) - Tensioner
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Belt - Remove
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
1. Loosen the bolt (1) and the relevant nut on the alterna-
tor bracket (2).
2. Loosen the bolt on the bottom side of the alternator (4)
in order to slide out the POLY-V belt (3).
NHIL13ENG0672AA 1
Next operation:
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Belt - Install
Prior operation:
1. Install the Poli-V belt (4) on the drive pulley, water pump
(5), alternator (1), fan pulley (2) and on the idler pulley
(3).
2. Insert a square drive ratchet into the relative hole on
the belt tensioner.
3. Pull on the tensioner (6) and slide the belt (4) into place.
NOTE: In case the old belt is to be reused, examine it
carefully first in order to detect any incision or evidence of
stress.
NHIL13ENG0673AA 1
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Belt tensioner - Remove

F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684,
Prior operation:
1. Remove the bolt (1) from the center of the belt tensioner
(2) and remove the tensioner.
NHIL13ENG0670AA 1
Next operation:
Belt tensioner - Install (10.414)
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Belt tensioner - Install

F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684,
Prior operation:
Belt tensioner - Remove (10.414)
1. Install the belt tensioner (1) and torque the mounting

bolt (2) to 37 - 49 N·m (27 - 36 lb ft).
NHIL13ENG0670AA 1
Next operation:
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Idler pulley - Remove

Prior operation:
1. Remove the retaining bolt (2) from the center of the idler
pulley (1).
2. Remove the idler pulley (1).
NHIL13ENG0670AA 1
Next operation:
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Idler pulley - Install

Prior operation:
Idler pulley - Remove (10.414)
1. Install the idler pulley (1) and torque the bolt (2) to 37 -
49 N·m (27 - 36 lb ft).
NHIL13ENG0670AA 1
Next operation:
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Index
Engine - 10
Fan and drive - 414

Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4DE9684M*J103, F4DE9684B*J111
Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4DE9684M*J103, F4DE9684B*J111
Fan and drive - Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fan and drive - Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fan and drive - Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan and drive - Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Engine - 10
Engine lubrication system - 304

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Engine - 10
FUNCTIONAL DATA
Engine lubrication system

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9687G*J100
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4GE9484, F4GE9484C*J601, F4GE9684
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Blow-by recirculation system

SERVICE
Engine oil filter

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4DE9684M*J103, F4DE9684B*J111
Bypass valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687,
Bypass valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

F4DE9684M*J103, F4DE9684B*J111
Engine oil pump

Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4DE9684M*J103, F4DE9684B*J111
Blow-by recirculation system

Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Piston cooling
Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Engine - Engine lubrication system
Engine lubrication system - Exploded view

Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the
block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the
crankshaft, camshaft and to the valve drive.
4C0O200406CRIL0 1
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Lubrication by forced circulation is achieved through oil pump, placed in the front part of the engine block. From the
pan, the lubrication oil flows to the crankshaft, to the camshaft and to the valve train. Lubrication involves the heat
exchanger as well, the turbocharger and the eventual compressor for any eventual compressed air system. All these
components may often vary according to the specific duty and will therefore be examined in the specific section.
NHIL13ENG0674GA 1
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F4GE9484, F4GE9484C*J601, F4GE9684
Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the
block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the
crankshaft, camshaft and to the valve train.
NHIL13ENG0675BA 1
LUBRICATION SYSTEM LAYOUT (4 cylinder engine)
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Lubrication by forced circulation is achieved through the oil pump, placed in the front part of the engine block. From
the pan, the lubrication oil flows to the crankshaft, to the camshaft and to the valve train. Lubrication involves the heat
exchanger as well, the turbocharger and the eventual compressor for any eventual compressed air system. All these
components may often vary according to the specific duty and will therefore be examined in the specific section.
NHIL13ENG0676GA 1
LUBRICATION SYSTEM LAYOUT (6 cylinder engines)
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Blow-by recirculation system - Dynamic description

Version with blow-by filter

The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet
speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil pan and the residual
vapors are removed by piping and filtered by the blow-by filter. In the blow-by filter, part of the vapors condense and
return to the oil pan. The remaining vapors are put back into circulation.
Version without blow-by filter

The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet
speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil pan and the residual
vapors are conveyed, collected and discharged into the open air through a bleeder.
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Blow-by recirculation system - Dynamic description

On the valve cover (3) there is a valve (1) whose duty is to condense oil vapor inducing the oil to fall back down to
the valve cover because of gravity.
The remaining non-condensed vapors should be properly conveyed through the breather pipe (2).
NHIL13ENG0677AA 1
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Engine oil filter - Remove

F4HE9687, F4HE9687G*J100
1. Use the oil filter wrench tool 380000670 to remove the

oil filter (1).
NOTE: The oil filter is equipped with an internal check valve
to minimize the amount oil loss when removing the filter.
NOTE: Be sure that the oil filter gasket is removed with the
filter.
NHIL13ENG0678AA 1
Next operation:
Engine oil filter - Install (10.304)
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Engine oil filter - Install

F4HE9687, F4HE9687G*J100
Prior operation:
Engine oil filter - Remove (10.304)
1. Lubricate the oil filter O-ring (5) with clean engine oil.
NOTE: Be sure that the O-ring seal from the old engine
oil filter is not still stuck on the oil filter housing and was
removed with the old oil filter.
2. Install the filter (4) onto the oil filter base (1) until contact
is made with sealing surface.
3. Tighten the oil filter an additional 3/4 of a turn by hand.
4. Apply a new sealing ring on the oil temperature/pres-
sure sensor (2).
5. Install the sensor (2) onto the filter base (1) and torque
the bolts (3) to the specified torque. NHIL13ENG0679AA 1
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Engine oil filter - Install

Prior operation:
1. Lubricate the oil filter O-ring (2) with clean engine oil.
NOTE: Be sure that the O-ring from the old engine oil filter
is not still stuck on the oil filter housing and was removed
with the oil filter.
2. Install the filter (1) onto the oil filter base (3) until contact
is made with sealing surface.
3. Tighten the oil filter an additional 3/4 of a turn by hand.
NHIL13ENG0680AA 1
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Engine oil filter Bypass valve - Remove

F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101,
F4DE9684M*J103, F4DE9684B*J111
1. Drain the engine coolant.

2. Disconnect the engine oil pressure/temperature sen-
sor.
3. Remove the oil filter head (1) and oil cooler (2).
NHIL12ENG0061AA 1
4. Slide the oil filter bypass valve (1) out of the housing
(2).
NOTE: A seal pick may be necessary to pull valve from the
housing.
NHIS12ENG0060AA 2
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Engine oil filter Bypass valve - Install

1. Install the oil filter bypass valve (1) into the housing (2).
NOTE: Light pressure may be necessary to fully seat the
valve.
NHIS12ENG0060AA 1
2. Install the oil cooler and the oil filter head using new
gaskets.
4. Install the connector for the oil temperature/pressure
sensor.
5. Fill with coolant.
NHIL12ENG0061AA 2
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Engine oil pump Gear driven - Remove

F4HE9687, F4HE9687G*J100
Prior operation:
Engine block cover Front - Remove (10.102)
1. Remove the retaining bolts (1) and remove the oil pump
(2) from the engine block.
NHIL13ENG0681AA 1
Next operation:
Engine oil pump Gear driven - Install (10.304)
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Engine oil pump Gear driven - Install

F4HE9687, F4HE9687G*J100
Prior operation:
Engine oil pump Gear driven - Remove (10.304)
1. Install the oil pump (2) onto the engine block.

2. Torque the bolts (1) in two stages. First torque the bolts
to 7 - 9 N·m (62 - 80 lb in). Then torque the bolts to 20
- 28 N·m (15 - 21 lb ft).
NHIL13ENG0682AA 1
Next operation:
Engine block cover Front - Install (10.102)
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Engine oil pump - Remove

Prior operation:
1. Please refer to Engine block cover Front - Remove

(10.102) for oil pump removal instructions.
Next operation:
Engine oil pump - Install (10.304)
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Engine oil pump - Install

Prior operation:
Engine oil pump - Remove (10.304)
1. Position the front cover seal (1) on the engine block.
NHIL13ENG0683AA 1
2. Install the front cover seal (1) onto the engine block and
NHIL13ENG0684AA 2
Next operation:
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Blow-by recirculation system - Remove - External filter

F4HE9687, F4HE9687G*J100
1. Remove the clamp (1) securing the blow-by tube and

remove the tube.
2. Remove the bolts (2) and remove the blow-by filter, if
applicable.
86070784_RESIZE 1
Next operation:
Blow-by recirculation system - Install (10.304)
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Blow-by recirculation system - Install - External filter

F4HE9687, F4HE9687G*J100
Prior operation:
Blow-by recirculation system - Remove (10.304)
1. Install the blow-by filter (1) and torque the bolts (2) to
20 - 28 N·m (15 - 21 lb ft).
86070785_RESIZE 1
2. Install the cover (1) on the blow-by filter housing (2) and
86070784_RESIZE 2
3. Connect the oil vapor lines (1) and secure them with
retaining clamps (2).
86070784_RESIZE 3
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Piston cooling Spray nozzle - Remove

1. Remove the main half bearings (1) to avoid damaging
them.
2. Remove the bolts (2) and remove the oil nozzles (3).
NHIL13ENG0685AA 1
Next operation:
Piston cooling Spray nozzle - Install (10.304)
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Piston cooling Spray nozzle - Install

Prior operation:
Piston cooling Spray nozzle - Remove (10.304)
1. Install the nozzles (2) and torque the bolts (1) to 8 -

12 N·m (71 - 106 lb in).
CRIL04J066A01 1
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Index
Engine - 10

Blow-by recirculation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Blow-by recirculation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Blow-by recirculation system - Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Blow-by recirculation system - Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9484, F4GE9484C*J601, F4GE9684
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4DE9684B*J111
Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine oil filter Bypass valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4DE9684B*J111
Engine oil filter Bypass valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100,
Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
F4DE9684B*J111
Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
F4DE9684B*J111
Engine oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Piston cooling Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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Engine - 10
Oil cooler and lines - 408

F4HE9684 , F4HE9687G*J100 , F4HE9687
47597675 27/09/2013
10.17 [10.408] / 1
Contents
Engine - 10
SERVICE
Engine oil cooler

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4DE9684M*J103, F4DE9684B*J111
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4DE9684M*J103, F4DE9684B*J111
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Engine - Oil cooler and lines
Engine oil cooler - Remove

F4HE9687, F4HE9687G*J100
Prior operation:
1. Remove the mounting bolts (3).

2. Remove the oil filter base (1), oil cooler (2), and all of
the gaskets.
NHIL13ENG0686AA 1
Next operation:
Engine oil cooler - Install (10.408)
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Engine oil cooler - Install

F4HE9687, F4HE9687G*J100
Prior operation:
Engine oil cooler - Remove (10.408)
1. Place a new gasket (1) on the engine block.

2. Install the oil cooler (2).
3. Place a new gasket (3) on the oil cooler.
4. Install the oil filter base (4).
ft).
NHIL13ENG0687AA 1
Next operation:
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Engine oil cooler - Remove

Prior operation:
1. Remove the bolts (5) that secure the oil filter base (4)
to the engine block.
2. Remove the oil filter base (4) and the oil cooler (2).
NOTE: Be sure to remove all the relevant gaskets and
seals (1) and (3).
NHIL13ENG0688AA 1
Next operation:
Engine oil cooler - Install (10.408)
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Engine oil cooler - Install

Prior operation:
Engine oil cooler - Remove (10.408)
1. Place a new gasket (1) on the engine block.

2. Install the oil cooler (2).
3. Place a new gasket (3) on the oil cooler.
4. Install the oil filter base (4).
ft).
NHIL13ENG0688AA 1
Next operation:
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Index
Engine - 10

Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4DE9684B*J111
Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100
Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
F4DE9684B*J111
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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2013 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any
time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CNH Dealer.
47597675 27/09/2013
EN
SERVICE MANUAL
Electrical systems

F4HE9684 , F4HE9687G*J100 , F4HE9687
47597675 27/09/2013
55
Contents
Electrical systems - 55
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8
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55
Engine control system - 015

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
FUNCTIONAL DATA
Engine Control Unit (ECU)

Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine wire harness

Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine speed/RPM sensor

Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F4HE9687G*J100
Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine timing sensors

Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4HE9687G*J100


F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
SERVICE
Engine Control Unit (ECU)

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine wire harness

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
F4HE9687G*J100
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine speed/RPM sensor

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine timing sensors

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Electrical systems - Engine control system
Engine Control Unit (ECU) - Detailed view

EDC7 ECU
CRIL04D082G01 1
(A) - Connector to injectors; (B) - Connector (Provide reference of the vehicle to which the engine is
assembled);
(C) - Connector to sensors.
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Engine Control Unit (ECU) - Overview

EDC 7 OPERATION
Engine preheating element control

Pre-post heating is activated when any of the following requirements are met. Water, air, or fuel temperature sensors
detect a temperature less than or equal to 5 °C (41 °F).
Phase recognition
Signals transmitted by the camshaft and crankshaft sensors determine which cylinder fuel is to be injected at the time
of starting.
Injection control
On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and
modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds.
Injection pressure closed loop control

On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control
unit administrates the regulator to maintain injection pressure at constantly optimal values.
Pilot and main injection advance control

On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on
the basis of internal mapping.
Idle speed control

The control unit processes signals transmitted by the various sensors and adjust the quantity of fuel injected.
It also controls the pressure regulator and modulates injection duration of the electro-injectors.
Within specific limits, the control unit also monitors battery voltage.
Overheating protection
If the water temperature reaches 110 °C (230 °F), the control unit reduces engine performance.
When the temperature returns below 100 °C (212 °F), the engine resumes normal operation, (in some applications,
the over boosting temperature is the reference temperature).
Maximum engine speed limiting

Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine
speed surpasses these limits the control unit activates power reduction strategies by controlling the electro-injectors.
In some applications the maximum limiting response consists in stopping the engine.
Cut Off
Fuel cut off in release phases is managed by the control unit with the following logical interventions:
• Deactivation of the electro-injectors.
• Reactivation of electro-injectors immediately prior to reaching idle speed.
• Control of fuel pressure regulator.
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Smoke control under acceleration

With heavy load demands, in accordance with signals received from the air inlet meter and the engine speed sensor,
the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent
the emission of smoke from the exhaust.
After Run
After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, in-
cluding the faults log so that they will be available the next time the engine is started.
Control of working speed in normal operating conditions

Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions.
If the load causes a reduction in power, the control unit increases torque by increasing the amount of fuel injected in
order to restore the engine to maximum power.
Recovery strategies
Recovery strategies are characterized by certain differences as application varies:
• Control of fuel leaks
In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained
with a low number of RPMs and high torque values in order to inject the maximum quantity of fuel.
• Control of pressure in the rail
When the pressure in the rail exceeds the safety values, the engine reduces power.
• Synchronism problems
In the case of synchronism problems, faulty RPM sensors, the system controls the engine by increasing the number
of RPMs in order to improve interpretation of the signals.
• Power restrictions as operating temperature increases
When the temperature of the charge air rises above 88 °C (190 °F), power reduction is started. When a temperature
of 120 °C (248 °F) is reached, performance is further reduced and is comparable to a naturally aspirated engine.
• Reduction of power as reference temperature varies
In normal operating conditions, the system knows the charge air, oil and water temperatures.
If the temperature of the engine water is not available, the system takes the temperature of the oil as a reference
and when this reaches the threshold of 103 °C (217 °F), it starts to reduce the power available. Upon reaching
113 °C (235 °F), power is reduced to 50 %.
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Engine wire harness - Electrical schema

NHIL13ENG0689FA 1
(1) Injectors cylinders 1 and 2 (6) Engine oil pressure/temperature (11) Pressure regulator
(2) Injectors cylinders 3 and 4 (7) Fuel temperature (12) Connector C - Sensors
(3) Injectors cylinders 5 and 6 (8) Coolant temperature (13) Connector A - Injectors
(4) Engine RPM sensor (9) Air pressure/temperature
(5) Timing sensor (10) Fuel pressure
Connector A - Injectors
EDC pin # Function
1 Cylinder 5 injector
7 -
8 -
9 Pressure Regulator
10 Pressure Regulator
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Connector C - Sensors
EDC pin # Function
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8 -
9 Timing sensor
10 Timing sensor
11 -
12 Negative for rail temperature and pressure sensor
13 Positive for rail temperature and pressure sensor
14 Signal from rail temperature and pressure sensor
15 Coolant temperature sensor
16 -
17 -
18 signal from fuel temperature sensor
19 Engine RPM sensor
20 -
21 -
22 -
23 Engine RPM sensor
24 Negative for engine oil pressure and temperature sensor
25 Negative for air temperature and pressure sensor
26 Coolant temperature sensor
27 Signal from engine oil pressure sensor
28 Signal from engine oil temperature
29 -
30 -
31 -
32 Positive for engine oil pressure and temperature sensor
33 Positive for air temperature and pressure sensor
34 Signal from air pressure sensor
35 Negative for fuel temperature sensor
36 Signal from air temperature sensor
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Engine wire harness - Electrical schema

NHIL13ENG0690AA 1
Connector A - Injectors
EDC pin # Wire color Function
1 - -
2 - -
3 MN Injector Cylinder 2
4 MV Injector Cylinder 3
5 VB Injector Cylinder 4
6 HR Injector Cylinder 2
7 - Earth
8 - -
9 MB Injector Cylinder 1
10 VN Injector Cylinder 6
11 VG Injector Cylinder 5
12 HN Injector Cylinder 3
13 HG Injector Cylinder 1
14 CN Injector Cylinder 4
15 CB Injector Cylinder 6
16 CL Injector Cylinder 5
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CONNECTORB 2
Connector B - Vehicle
EDC pin # Wire # Function
1 8150 Positive driven by battery
2 0087 Negative for switch of fuel filter heater/starter
3 0000 Earth
4 8885/0159 Positive for pre-post heating resistor
7 8150 Positive driven by battery
8 7777 Positive for blink-code button, low oil pressure LED, pre-heating LED, Air
conditioner switch (if available), EDC
9 0000 Earth
12/13 8150 Positive driven by battery
14/15 0000 Earth
16 0094 Negative for post-heating resistor
19 0150 Negative start/stop push buttons from eng./accelerator pressed
20 8153 Positive from change over switch to key in starting phase (+50)
27 0156 Positive from blink-code button
28 5535 Positive for EDC diagnostic LED
31 2298 K line for diagnostic connector, 30 poles (pin 2)
32 - Negative for multi-switch couple-limiter
36 8837 Positive for fuel heating switch
37 8888 Positive for starter
39 8051 Positive from key switch/ L line for diagnosis connector, 30 poles (pin 11)
44 9905 Negative from starter push button from engine
45 9906 Negative from engine stop push button from engine
46 5553 Negative for pre-heating LED in on position
49 5584 Diagnosis connector (pin 28)
50 0158 Negative from accelerator push button pressed
52 6109 CAN Line (if equipped), diagnosis connector (pin 22)
53 6108 CAN Line (if equipped), diagnosis connector (pin 22)
55 5158 Positive for sensor of foot accelerator pedal pos. / Earth multi-switch
62 0160 Negative for clutch sensor
63 5503 Negative for low engine oil pressure LED
64 0535 Negative for EDC diagnosis LED
72 0159 Positive from pressed accelerator push button / multi-switch signal
73 0159 Positive redundant from pressed accelerator push button
78 8162 Positive air conditioner device (if equipped)
81 0157 Negative sensor of foot accelerator pedal pos. / Earth Multi-switch
83 5157 Signal from sensor of foot accelerator pedal pos. / Signal Multi-switch
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EDC pin # Wire # Function

87 - Positive for couple multi-switch limiter
CONNECTORC 3
Connector C - Sensors
EDC pin # Wire color Function
5 C Earth for pressure regulator
7 V Pressure regulating device
9 MN Feed for engine oil temperature/pressure sensor
10 CR Feed for air pressure/temperature sensor
12 HN Feed for rail pressure sensor
17 BL Earth for fuel temperature sensor
18 CV Earth for coolant temperature sensor
19 GV Earth for engine oil temperature sensor
20 BZ Feed for rail pressure sensor
21 GN Feed for air pressure/temperature sensor
23 R Timing system sensor
24 B Driving shaft sensor
25 R Driving shaft sensor
27 RV Signal from rail pressure sensor
28 LN signal from air pressure sensor
29 BH Signal from air pressure sensor
30 B Earth for timing system sensor
33 GR Signal from engine oil temperature sensor
34 CN Signal from fuel temperature sensor
35 NS Signal from engine oil pressure sensor
36 BG Signal from coolant temperature sensor
Color legend
Symbol Color Symbol Color
C Orange N Black
A Sky Blue W Light Brown
B White S Pink
L Blue R Red
G Yellow V Green
H Gray Z Purple
M Brown
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Engine speed/RPM sensor Camshaft - Overview

NHIL13ENG0640AA 1
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals
obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated
by this sensor is utilized by the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are not interchangeable because of the different exter-
nal shape.
The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance is ~900 Ω.
Reference Description EDC pin

1 Signal 10C
2 Signal 9C
3 Shield -
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Engine speed/RPM sensor Camshaft - Overview

NHIL13ENG0640AA 1
This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals
obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated
by this sensor is utilized by the electronic control unit as an injection phase signal.
Although it is similar to the flywheel sensor, these two devices are not interchangeable because of the different exter-
nal shape.
The timing sensor is connected to the control unit on pins 23C - 30C. The sensor impedance is ~900 Ω.
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Engine timing sensors Crankshaft sensor - Overview

NHIL13ENG0641AA 1
This is an inductive sensor located at the left hand side of the engine. The crankshaft sensor produces signals ob-
tained from a magnetic flux field closing through the openings in a tone wheel installed on the crankshaft.
The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ~900 Ω.
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NHIL13ENG0641AA 1
The crankshaft sensor is an inductive type sensor that is located on the front of the engine.
The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone
wheel installed on the crankshaft. The same signal is utilized to control the eventual electronic engine speed indicator
placed on the vehicle instrument board.
It is connected to the engine control module by pin 25C (signal) and 24C (signal). The third pin is for screening.
The resistance value of the sensor is about 900 Ω.
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F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
NHIL13ENG0641AA 1
The crankshaft sensor is an induction type sensor and it is placed on the front part of the engine above the crankshaft.
The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone
wheel installed on the crankshaft.
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Engine Control Unit (ECU) - Remove

Prior operation:
1. Disconnect the main wiring harness from the electronic

control module (2).
2. Disconnect the low pressure fuel lines that are attached
to the control module cooling plate.
3. Remove the three mounting bolts (1) that secure the
control module and the cooling plate to the engine
block.
4. Remove the control module and cooling plate as one
unit.
NHIL13ENG0642AA 1
Next operation:
Engine Control Unit (ECU) - Install (55.015)
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Engine Control Unit (ECU) - Install

Prior operation:
Engine Control Unit (ECU) - Remove (55.015)
1. Install the electronic control module (2) and cooling

plate on the side of the engine block.
2. Install the retaining bolts (1) and rubber isolators and
torque the bolts to 8 - 12 N·m (71 - 106 lb in).
NOTE: If the rubber isolators are cracked or excessively
deformed, replace them before installation.
NHIL13ENG0642AA 1
Next operation:
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Engine wire harness - Disconnect

NHIL13ENG0508AA 1
(1) Connections for electro-injectors (5) Driving shaft sensor (9) Fuel temperature sensor
(2) Coolant temperature sensor (6) Electro-injector (10) Pressure regulating gauge
(3) Fuel pressure sensor (7) Air pressure/temperature sensor (11) EDC 7 UC31
(4) Oil pressure/temperature sensor (8) Timing system sensor
1. Disconnect the engines cable from the connectors (1)

to electro-injector (6), air pressure/temperature sen-
sor (7), fuel pressure sensor (3), engine control mod-
ule (11), high pressure pump sensor (10), timing sys-
tem sensor (8), coolant temperature sensor (2), driving
shaft sensor (5).
2. Remove the engine wire harness from the engine block
by removing the holding clamps.
NHIL13ENG0508AA 2
Next operation:
Engine wire harness - Connect (55.015)
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Engine wire harness - Disconnect

HARNESS 1
(1) Fuel pressure Sensor (5) Electro-injector (9) Fuel pressure regulator
(2) Coolant temperature sensor (6) Air pressure/temperature sensor (10) EDC 7 UC31
(3) Engine oil temperature sensor (7) Timing sensor (11) Connectors for electro-injectors
(4) Crankshaft speed sensor (8) Fuel temperature sensor
1. Disconnect the engine's cable from the connectors

wiring harness to Electro-Injectors (11); Air Pres-
sure/Temperature Sensor; (6) Fuel Pressure Sensor
(1); Engine Control Module (10); Timing Sensor (7);
Coolant Temperature Sensor (2); Crankshaft Speed
Sensor (4).
HARNESS 2
Next operation:
Engine wire harness - Connect (55.015)
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Engine wire harness - Connect

Prior operation:
Engine wire harness - Disconnect (55.015)
1. Reconnect the engine wiring harness to all the sensors,

the engine control module and the common rail.
NHIL13ENG0508AA 1
(1) Connections for electro-injectors (5) Driving shaft sensor (9) Fuel temperature sensor
(2) Coolant temperature sensor (6) Electro-injector (10) Pressure regulating gauge
(3) Fuel pressure sensor (7) Air pressure/temperature sensor (11) EDC 7 UC31
(4) Oil pressure/temperature sensor (8) Timing system sensor
2. Connect the engines cable from the connectors (1)

to electro-injector (6), air pressure/temperature sen-
sor (7), fuel pressure sensor (3), engine control mod-
ule (11), high pressure pump sensor (10), timing sys-
tem sensor (8), coolant temperature sensor (2), driving
shaft sensor (5).
NHIL13ENG0508AA 2
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Engine speed/RPM sensor - Install

1. Install a new O-ring on the speed sensor (3).

2. Install the speed sensor (3) on the front cover (1).
3. Torque the bolt (2) to 6 - 10 N·m (53 - 89 lb in).
NHIL13ENG0644AA 1
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Engine timing sensors - Remove

1. Remove the mounting nut and slide the timing sensor

out of the timing gear housing.
Next operation:
Engine timing sensors - Install (55.015)
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Engine timing sensors - Install

Prior operation:
Engine timing sensors - Remove (55.015)
1. Install a new O-ring on the timing sensor.

2. Slide the sensor over the mounting stud and install the
nut. Tighten to the specified torque.
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Index

Engine Control Unit (ECU) - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Control Unit (ECU) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine Control Unit (ECU) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Control Unit (ECU) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine speed/RPM sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine timing sensors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Engine timing sensors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
Engine wire harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine wire harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine wire harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine wire harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine wire harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Engine starting system - 201

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
SERVICE
Engine starter
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical systems - Engine starting system
Engine starter - Remove

1. Disconnect the starter cables from the solenoid and the
starter body (2).
2. Remove the three mounting bolts (3) securing the
starter (2) to the flywheel housing (1).
3. Remove the starter (2).
NHIL13ENG0645AA 1
Next operation:
Engine starter - Install (55.201)
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Electrical systems - Engine starting system
Engine starter - Install

Prior operation:
Engine starter - Remove (55.201)
1. Install the starter (2) on the flywheel housing (1) using

the three mounting bolts (3).
NOTE: Before any assembly operation verify that the hole
and bolt threads have no evidence of wear or dirt.
NHIL13ENG0645AA 1
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Index

Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Alternator - 301

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
Alternator - 301
FUNCTIONAL DATA
Alternator
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Alternator
Alternator - Overview
NHIL13ENG0646AA 1
The alternator is placed on the front right hand side of the engine and is driven by a Poly V-belt.
Specifications:
• Working voltage:
• 12 V
• Current delivered:
• 90 A @ 6000 RPM
• Absorption in stand-by:
• Less than or equal to 1 mA
• Direction of rotation:
• Clockwise
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Alternator - Remove
Prior operation:
1. Remove the bolt (1).

2. Hold the alternator (2) and loosen the bolt (3).
NHIL13ENG0647AA 1
3. Remove the bolt (2).

4. Remove the alternator (1).
NHIL13ENG0648AA 2
Next operation:
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Alternator - Install
Prior operation:
1. Mount the alternator (1) onto the support.

2. Tighten the bolt (2) without locking it.
NHIL13ENG0648AA 1
3. Install the alternator (2) bracket (1) to the engine block

and torque the engine block side bolt to 20 - 28 N·m
(15 - 21 lb ft).
4. Torque the upper alternator pivot to support bolt to 44 -
54 N·m (32 - 40 lb ft).
5. Torque the lower alternator bolt (3) securing the alter-
nator (2) to the alternator support to 20 - 28 N·m (15 -
21 lb ft).
NHIL13ENG0649AA 2
Next operation:
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Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Alternator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cold start aid - 202

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
FUNCTIONAL DATA
Cold start aid

Cold start control Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, 4 Cylinder Common Rail, F4CE9684, F4GE9684,
6 Cylinder Common Rail
Grid heater
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Cold start aid
Cold start control Temperature sensor - Overview

F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, 4 Cylinder Common Rail, F4CE9684, F4GE9684, 6 Cylinder Common Rail
Electrical Cold-start Accelerator (KKSB)
NHIL13ENG0650AA 1
(1) Hydraulic head electro-magnet - (2) KKSB electro-magnet.
The KKSB is located on the fuel injection pump. During engine start-up, the KKSB advances the injection pump timing
to reduce white smoke and emissions until the cylinders warm to normal operating temperature. By shifting the start
of injection in the advanced direction, the KKSB improves the cold-start characteristics of the emissionized engine.
Operation is triggered automatically by means of a temperature sensitive thermostatic switch, which is located in the
cylinder head on the engine's left hand side.
NHIL13ENG0651AA 2
Specifications:
• Working tensions:
• 12 - 24 V
• Electrical Power load:
• 2.5 A (induction)
• 5.0 A (resistance)
• Settings:
• 60 - 66 °C (140 - 151 °F) Contact opening upon increasing temperature.
• 50 - 56 °C (122 - 133 °F) Contact closure upon decreasing temperature.
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Grid heater - Overview

NHIL13ENG0652AA 1
WARNING
Explosion hazard!
DO NOT use ether starting fluid. Serious engine damage, explosion, death, or serious personal injury
could occur.
Failure to comply could result in death or serious injury.
W0148A
The pre-post heating resistance is located on the intake manifold.

The resistance serves to heat the air in pre / post heating operations. The resistance is powered by a contactor.
The resistance impedance is approximately 0.5 Ω.
The control contactor is connected to the control unit (B) connector.

The contactor is tripped with water and/or fuel temperature below 5 °C (41 °F).
The contactor impedance is approximately 15 Ω.
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Grid heater - Overview

NHIL13ENG0653AA 1
It is a resistor assembled to the intake manifold and is utilized to heat the air during pre-post heating operations. It is
fed by a tele-switch usually placed very close to the engine.
Specifications:
• Working voltage:
• 12 V
• Maximum possible air flow:
• 0.034 cm³/sec at a pressure of 138 kPa (20 psi)
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Index

Cold start control Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, 4 Cylinder Common Rail, F4CE9684, F4GE9684, 6 Cylinder
Common Rail
Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
FUNCTIONAL DATA
Fuel temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4HE9687G*J100
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel pressure sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water-In-Fuel sensor
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
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Electrical systems - Fuel injection system
Fuel temperature sensor - Overview

NHIL13ENG0654FA 1
(1) Fuel Temperature Sensor (2) Filter heating resistance
This sensor is identical to the coolant temp sensor.

This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of
the fuel.
The fuel temperature sensor is connected to the control unit on pins 35C - 18C.
The sensor impedance at 20 °C (68 °F) is approximately 2.50 Ω.

1 Ground 35C
2 Temperature signal 18C
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Fuel temperature sensor - Overview

Fuel Temperature Sensor
NHIL13ENG0655FA 1
(1) Fuel Temperature Sensor
This sensor has a variable resistor able to detect the fuel temperature to provide the engine control module an index
of the fuel thermal status.
It is connected to the control module by pin 17C (Earth) and 34C (temperature signal).
The resistor to 20 °C (68 °F) = 2.5 k Ω.
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Fuel pressure sensor - Overview

NHIL13ENG0656AA 1
Mounted on the end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the
value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the
duration of the electrical injection command.
The power supply is 5 Volt.
Reference Description
1 Ground
2 Signal
3 Power supply
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Water-In-Fuel sensor - Overview

F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
NHIL13ENG0657AA 1
(1) Heater - (2) Water detecting sensor.
On the bottom of the fuel filter cartridge, there is a sensor (2) that detects the presence of water in the system. For
the applications in cold climate conditions, a heater (1) may be interposed between the filter base and the filtering
cartridge.
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Index

Fuel pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Water-In-Fuel sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4CE9484, F4CE9487N, F4CE9487A, F4CE9684
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Engine intake and exhaust system - 014

F4HE9684 , F4HE9687G*J100 , F4HE9687
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55.6 [55.014] / 1
Contents
FUNCTIONAL DATA
Intake air pressure and temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4HE9687G*J100
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Intake air pressure and temperature sensor

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Engine intake and exhaust system
Intake air pressure and temperature sensor - Overview

NHIL13ENG0658AA 1
This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make
an accurate calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 25C - 36C for temperature and 33C - 34C for pressure.
The power supply is 5 volts.
Voltage at the sensor output is proportional to the detected pressure or temperature.

1 Ground 25C
2 NTC signal (temperature) 36C
3 +5 V power input 33C
4 Signal (pressure) 34C
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Intake air pressure and temperature sensor - Overview

NHIL13ENG0658AA 1
This component incorporates a temperature sensor and a pressure sensor.

Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make
an accurate calculation of the quantity of fuel to be injected in each cycle.
The sensor is connected to the control unit on pins 21C - 29C for temperature and 10C - 28C for pressure.
The power supply is 5 volts.
Voltage at the sensor output is proportional to the detected pressure or temperature.

1 Ground 21C
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Intake air pressure and temperature sensor - Remove

1. Disconnect the wiring harness from the sensor (1).

2. Remove the retaining bolt (2).
3. Remove the sensor (1) and the O-ring seal.
NHIL13ENG0658AA 1
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Index

Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Intake air pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
FUNCTIONAL DATA
Engine coolant temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
F4HE9687G*J100
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Engine cooling system
Engine coolant temperature sensor - Overview

NHIL13ENG0659AA 1
This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an
indication of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
The sensor is connected to the control unit on pins 15C - 26C.
The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.

1 Ground 15C
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NHIL13ENG0659AA 1
This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an
indication of the thermal status of the engine.
The same signal is utilized by the control unit to drive an instrument panel gauge, if present.
The sensor is connected to the control unit on pins 18C - 36C.
The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω.
Reference Description ECU pin

1 Ground 18C
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NHIL13ENG0660AA 1
The coolant temp sensor is assembled to the engine head close to the thermostat unit and its duty is to detect engine
coolant temperature.
Specifications:
• Range of working temperatures
• Connection side: -40 - +150 °C ( -40 - +302 °F) for less than 10 minutes
• Bulb side on engine: -40 - +140 °C ( -40 - +284 °F)
• Working tensions: 6 - 28 V
• Settings:
• 80 °C (176 °F) - 304 - 342 Ω
• 20 °C (68 °F) - 2262 - 2760 Ω
• -10 °C (14 °F) - 8244 - 10661 Ω
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Index

Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine oil system - 013

F4HE9684 , F4HE9687G*J100 , F4HE9687
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Contents
FUNCTIONAL DATA
Engine oil pressure sensor and switch

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine oil pressure and temperature sensor

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
F4HE9687G*J100
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Engine oil pressure and temperature sensor

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
F4HE9687G*J100
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Electrical systems - Engine oil system
Engine oil pressure sensor and switch - Overview

NHIL13ENG0661AA 1
The sensor is located on the engine block on the left hand side.
Specifications:
• Working tensions:
• 12 - 24 V
• Contact closure upon lower pressure:
• 0.2 bar (2.9 psi)
• Contact opening upon higher pressure:
• 0.9 bar (13.1 psi)
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Engine oil pressure and temperature sensor - Overview

NHIL13ENG0662AA 1
This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.
The sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 24C - 28C for temperature and 32C- 27C for pressure.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls
the relative device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

1 Ground 24C
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Engine oil pressure and temperature sensor - Overview

NHIL13ENG0662AA 1
This component is analogous to the air pressure-temperature sensor.

The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position.
The sensor measures the engine oil temperature and pressure.
The sensor is connected to the control unit on pins 19C - 33C for temperature and 9C- 35C for pressure.
The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls
the relative device on the instrument panel (gauge + low pressure warning light).
The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit.

1 Ground 19C
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Engine oil pressure and temperature sensor - Remove

1. Disconnect the wiring harness from the sensor (1).

2. Remove the mounting bolts (2), the sensor (1), and the
O-ring seal from the oil filter base.
NHIL13ENG0663AA 1
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Engine oil pressure and temperature sensor - Remove

1. Disconnect the electrical connector (1) from the oil tem-

perature pressure sensor (3).
2. Remove the mounting bolts (2) securing the sensor to
the oil filter base (4) and remove it from its seat.
NHIL13ENG0664AA 1
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Engine oil pressure and temperature sensor - Install

1. Install a new O-ring on the oil temperature/pressure

sensor (4).
2. Install the sensor on the oil filter base (1) and torque
the mounting bolts (3) to 5 - 7 N·m (44 - 62 lb in).
3. Connect the electrical connection (2) for the sensor.
NHIL13ENG0664AA 1
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Index

Engine oil pressure and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine oil pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine oil pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine oil pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine oil pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine oil pressure sensor and switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
47597675 27/09/2013
EN
SPECIAL TOOL INDEX
Genuine Reference PAGE

380000301 [Rotating Engine Special tools . / 11
Stand]
380000665 [Crankshaft Front Special tools . / 11
Seal Extractor]
380000663 [Crankshaft Rear Special tools . / 11
Gasket Remover]
380001099 [Fuel Injector Special tools . / 11
Extractor]
Seal Installer]
Seal Installer ]
380000670 [Oil Filter Wrench] Special tools . / 12
380000302 [Cylinder Head Special tools . / 12
Valve Spring Compressor]
380000221 [Pliers For Special tools . / 13
Piston Rings Removal And
Installation (65 -110 mm)]
380000667 [Camshaft Bush Special tools . / 13
Assembly And Disassembly
Punch]
380000362 [Crankshaft Lifting Special tools . / 13
Hook]
380000216 [Engine Lifting Special tools . / 13
Hook]
380000661 [Brackets Special tools . / 14
Securing Engine To Rotary
Stand]
380000669 [Seal Extraction Special tools . / 14
Tool]
380000668 [Handle Special tools . / 14
Interchangeable Driver]
380000364 [Comparator Special tools . / 14
Holder Base For Different
Surveys]
380000158 [Electrovalve Special tools . / 15
Connector Nut Torque
Wrench]
380000304 [Angle Torque Special tools . / 15
Thightening Screw Tool]
380000988 [Starter opening Special tools . / 15
plate and Flywheel Rotation
Blocker]
380000979 [Puller For Gear Special tools . / 17
Connecting Injection Pump To
Engine]
Seal Extractor]
Gasket Remover]
380000671 [Injector Extractor] Special tools . / 17
Seal Installer]
Seal Installer ]
380000670 [Oil Filter Wrench] Special tools . / 18
47597675 27/09/2013
380000302 [Cylinder Head Special tools . / 18
380000221 [Pliers For Special tools . / 19
380000732 [Engine Turning Special tools . / 19
Tool]
380000988 [Starter opening Special tools . / 19
Blocker]
380000667 [Camshaft Bush Special tools . / 19
Assembly And Disassembly
Punch]
380000362 [Crankshaft Lifting Special tools . / 20
Hook]
380000216 [Engine Lifting Special tools . / 20
Hook]
380000994 [Band For Special tools . / 20
Inserting The Piston Into
The Cylinder Liner (60--125
mm)]
380002729 [Engine Timing Special tools . / 20
Pin]
380000661 [Brackets Special tools . / 21
Stand]
380000669 [Seal Extraction Special tools . / 21
Tool]
380000668 [Handle Special tools . / 21
Interchangeable Driver]
380000364 [Comparator Special tools . / 21
Surveys]
380000304 [Angle Torque Special tools . / 22
Thightening Screw Tool]
380001005 [Dial Gauge (0--10 Special tools . / 22
mm)]
380001006 [Diesel Engine Special tools . / 22
Cylinder Compression Tester]
380000140 [Compression Tool Special tools . / 23
For Checking The Protrusion
Of Cylinder Liners]
380000301 [Rotating Engine Special tools . / 23
Stand]
380000989 [Adapter Cylinder Engine - Compression test 10.1 / 24
Compression Tester]
380000661 [Brackets Engine - Place on stand 10.1 / 25
Stand]
380000670 [Oil Filter Wrench] Engine - Place on stand 10.1 / 25
Stand]
Stand]
Stand]
47597675 27/09/2013
Stand]
Stand]
380000216 [Engine Lifting Engine - Place on stand 10.1 / 29
Hook]
Stand]
Stand]
Stand]
380000216 [Engine Lifting Engine - Place on stand 10.1 / 30
Hook]
380000670 [Oil Filter Wrench] Engine - Service instruction Maintenance Procedures 10.1 / 35
380001001 [Set Of 2 Gauges Crankcase - Check 10.1 / 55
For Angular Tightening With
1/2” And 3/4” Square Mount]
380000827 [Bore Gauge] Crankcase - Check 10.1 / 55
380000645 [Micrometer Set] Camshaft - Measure 10.3 / 14
17270 [Magnetic Base (For Camshaft - End play 10.3 / 17
Dial Indicators) ]
380000145 [Camshaft Camshaft bushings - Replace 10.3 / 25
Bushing Remover And
Installer]
380001543 [Dial Indicator Camshaft gear - Install 10.3 / 28
With Magnetic Base]
With Magnetic Base]
With Magnetic Base]
DM370(3/4) [Torque Cylinder head - Install 10.4 / 15
Tightening Angle Gauges
(1/2 Inch And 3/4 Inch)]
47597675 27/09/2013
75291050 [Cylinder Head Valves - Remove 10.4 / 27
99305047 [Valve Spring Load Valves Spring - Check 10.4 / 30
Checking Tool]
75291050 [Cylinder Head Valves - Install 10.4 / 31
75291050 [Cylinder Head Valves - Remove 10.4 / 32
99305047 [Valve Spring Load Valves Spring - Check 10.4 / 34
Checking Tool]
75291050 [Cylinder Head Valves - Install 10.4 / 35
99305019 [Valve Seat Valve seat - Regrind 10.4 / 38
Grinding Kit]
Grinding Kit]
Grinding Kit]
380000364 [Comparator Valve seat - Regrind 10.4 / 39
Surveys]
380000228 [Dial Gauge (0 - 5 Valve seat - Regrind 10.4 / 39
mm)]
Grinding Kit]
Grinding Kit]
Grinding Kit]
380000364 [Comparator Valve seat - Regrind 10.4 / 41
Surveys]
380000228 [Dial Gauge (0 - 5 Valve seat - Regrind 10.4 / 41
mm)]
380000325 [90 - 175mm Connecting rod and piston - Install 10.5 / 8
Diameter Piston Assembly
Band Clamp]
380000324 [Pliers Piston Ring - Remove 10.5 / 10
For Assembling And
Disassembling Piston Split
Rings (110-150 mm)]
380000221 [Pliers For Piston Ring - Install 10.5 / 13
380000228 [Dial Gauge (0 - 5 Piston - Check 10.5 / 16
mm)]
380000364 [Comparator Piston - Check 10.5 / 16
Surveys]
380001001 [Set Of 2 Gauges Connecting rod bearing - Clearance 10.5 / 18
380001001 [Set Of 2 Gauges Connecting rod bearing - Clearance 10.5 / 19
380000988 [Starter opening Engine flywheel - Remove 10.6 / 4
Blocker]
47597675 27/09/2013
380000988 [Starter opening Engine flywheel - Install 10.6 / 6
Blocker]
380001001 [Set Of 2 Gauges Engine flywheel - Install 10.6 / 6
Blocker]
Blocker]
Blocker]
Blocker]
Blocker]
380001001 [Set Of 2 Gauges Engine flywheel Drive plate - Install 10.6 / 14
380000669 [Seal Extraction Crankshaft oil seal Front seal - Remove 10.6 / 15
Tool]
5-8840-2061-0 [Crankshaft Crankshaft oil seal Front seal - Install 10.6 / 16
Front Oil Seal Installer]
380000669 [Seal Extraction Crankshaft oil seal Rear seal - Remove 10.6 / 17
Tool]
380000664 [Crankshaft Rear Crankshaft oil seal Rear seal - Install 10.6 / 18
Seal Installer ]
99360500 [Crankshaft Lifting Crankshaft - Remove 10.6 / 19
Hook]
99360500 [Crankshaft Lifting Crankshaft - Remove 10.6 / 20
Hook]
380001001 [Set Of 2 Gauges Crankshaft Journal - Clearance 10.6 / 24
380001717 [Crankshaft Gear Crankshaft gears - Replace 10.6 / 25
Puller]
380001001 [Set Of 2 Gauges Crankshaft damper - Install 10.7 / 6
380000670 [Oil Filter Wrench] Fuel supply lines Low pressure - Disconnect 10.9 / 10
380000670 [Oil Filter Wrench] Fuel supply lines Low pressure - Disconnect 10.9 / 11
380000670 [Oil Filter Wrench] Fuel supply lines Low pressure - Install 10.9 / 12
380000670 [Oil Filter Wrench] Fuel supply lines Low pressure - Install 10.9 / 13
34591-00100 [Oil Filter Fuel filters - Remove 10.10 / 5
Wrench]
380140055 [Fuel Supply / Fuel injection system - Test Mechanical fuel injection – Fuel 10.11 / 28
Leakage Test Kit] supply/Leakage Test
47597675 27/09/2013
380100056 [Gauge and Hose Fuel injection system - Test Mechanical fuel injection – Fuel 10.11 / 28
Assembly] supply/Leakage Test
380100056 [Gauge and Hose Fuel injection system - Test Mechanical fuel injection – Fuel 10.11 / 29
Assembly] supply/Leakage Test
380140055 [Fuel Supply / Fuel injection system - Test Common rail fuel injection – Fuel 10.11 / 30
Leakage Test Kit] supply/Leakage test
380100056 [Gauge and Hose Fuel injection system - Test Common rail fuel injection – Fuel 10.11 / 30
Assembly] supply/Leakage test
380100057 [Pressure Gauge Fuel injection system - Test Common rail fuel injection – Fuel 10.11 / 30
and Hose Assembly] supply/Leakage test
380000988 [Starter opening Rotary injection pump - Disassemble 10.11 / 34
Blocker]
380002822 [Engine Turning Rotary injection pump - Disassemble 10.11 / 34
Tool]
380001543 [Dial Indicator Rotary injection pump - Disassemble 10.11 / 34
With Magnetic Base]
Blocker]
380002729 [Engine Timing Rotary injection pump - Disassemble 10.11 / 34
Pin]
380000988 [Starter opening Rotary injection pump - Assemble 10.11 / 36
Blocker]
380000988 [Starter opening Rotary injection pump - Timing adjust 10.11 / 37
Blocker]
380001435 [Engine Timing Rotary injection pump - Timing adjust 10.11 / 37
Tool ]
Tool ]
Tool ]
380000835 [Injection Pump Rotary injection pump - Timing adjust 10.11 / 41
Gear Puller]
Blocker]
Blocker]
380001543 [Dial Indicator Rotary injection pump - Disassemble 10.11 / 42
With Magnetic Base]
Blocker]
380000988 [Starter opening Rotary injection pump - Assemble 10.11 / 45
Blocker]
380000988 [Starter opening Rotary injection pump - Timing adjust 10.11 / 47
Blocker]
Tool ]
Tool ]
Tool ]
380000835 [Injection Pump Rotary injection pump - Timing adjust 10.11 / 51
Gear Puller]
380100060 [Tool] High pressure pump - Test Pressure Relief Valve Testing 10.11 / 54
47597675 27/09/2013
380100057 [Pressure Gauge High pressure pump - Test Pressure Relief Valve Testing 10.11 / 54
and Hose Assembly]
380001099 [Fuel Injector Fuel injectors - Remove 10.11 / 59
Extractor]
380001099 [Fuel Injector Fuel injectors - Install 10.11 / 61
Extractor]
380001001 [Set Of 2 Gauges Fuel injectors - Install 10.11 / 61
380140055 [Fuel Supply / Fuel injectors - Test Fuel injector testing 10.11 / 64
Leakage Test Kit]
380001001 [Set Of 2 Gauges Fuel injectors Cross tube - Install 10.11 / 66
380000670 [Oil Filter Wrench] Engine oil filter - Remove 10.16 / 10
OEM Reference PAGE
OEM1032 [Dial Bore Gauge ] Crankcase Bore - Check 10.1 / 54
OEM1032 [Dial Bore Gauge ] Camshaft bushings - Measure 10.3 / 24
OEM1032 [Dial Bore Gauge ] Piston pin bushings - Service instruction 10.5 / 20
Kit Reference PAGE
380000229 [Dial Gauge Special tools . / 22
Holder Tool For Rotary
Injection Pump Timing]
47597675 27/09/2013
PRINTED IN U.S.A.
47597675 27/09/2013
EN

New Holland Service Manual lb115

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Copyright:

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New Holland Service Manual lb115

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SERVICE MANUAL

F4CE9484 / F4CE9487A / F4CE9487N /

Part number 47597675

Mechanical fuel injection / Non-structural engine block

Electronic fuel injection / Non-structural engine block

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

[10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

[10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

Electrical systems ....................................................................... 55

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3

[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4

[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

[55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

• • filling inhibitors or anti-frost

For engines equipped with electronic controller:

Respect of the Environment

Component Size Specification

Component Size Specification

Component Size Specification

Component Size Specification

Component Size Specification

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

Tool No. Description Image

F4CE9484 , F4CE9487A , F4CE9487N , F4CE9684 , F4DE9484 ,

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

[10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

[10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

[10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

[10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

[10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

[10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

[10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8

[10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

[10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13