REPAIR MANUAL FOR IVECO NEF ENGINES

F4GE0454C -- F4GE0484G

F4GE0484G

F4GE0454C

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

MOTORI

2
 IN--1

INTRODUCTION

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

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

Example:: T 1 -- 2 -- 3

Progressive page number for each group

Group number (if any)

Section number

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

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

This symbol regards safety.

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

INTRODUCTION

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

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

INDEX OF SECTIONS

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

Section 2 -- Engine F4GE0454C -- F4GE0484G overhaul EW--2--1

Section 3 -- Recharging and start--up EW--3--1

4 WE

MOTORI
SECTION 1

DIAGNOSTICS

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

DIAGNOSTICS

Main engine operating anomalies:

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

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

1 ENGINE WON’T START

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

YES

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

YES

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

YES

Thermal starter in working order Replace.

NO

YES

Injection pump timed Verify correct timing as described in the relevant

NO chapter.

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

DIAGNOSTICS

Injectors in working order Check operation and adjust.

NO

YES

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

YES

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

YES

Prescribed compression ratio Overhaul the engine or make repairs only on

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

YES

Fuel filters in working order Replace.

NO

YES

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

YES

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

YES

Fuel tank supplied correctly Refuel.

NO
 EW--1--5

DIAGNOSTICS

2 ENGINE OVERHEATS

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

YES

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

YES

Water pump in working order Overhaul or replace the unit.

NO

YES

Thermostat in working order Replace.

NO

YES

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

YES

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

YES

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

DIAGNOSTICS

Valve timing correct Check and perform correct timing.

NO

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

Cylinder head gasket in working order Replace.

NO

YES

Fan in working order Replace.

NO

3 ENGINE LACKS POWER AND WORKS

ERRATICALLY

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

YES

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

YES

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

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

DIAGNOSTICS

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

YES

Thermostat in working order Replace.

NO

YES

Fuel pump in working order Replace.

NO

YES

Injectors in working order Check operation and adjust them.

NO

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

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

YES

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

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

DIAGNOSTICS

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

YES

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

YES

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

NO

YES

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

YES

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

YES

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

NO

YES

Turbocharger in working order Repair or replace the unit.

NO

YES

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

DIAGNOSTICS

4 ENGINE EXHAUST SMOKE BLACK OR

DARK GREY

Air filter in working order Replace.

NO

YES

Thermal starter in working order Replace.

NO

YES

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

YES

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

NO

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

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

NO

YES

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

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

DIAGNOSTICS

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

YES

Prescribed compression ratio Check by means of a Motometer 75301430 tool

NO and carry out the necessary operations.

YES

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

5 ENGINE EXHAUST SMOKE GREY (VERG-

ING ON WHITE)

The thermostat comes into operation correctly Replace.

NO

YES

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

NO 1094.

YES

Injection pump timed Check correct timing as described in the relevant

NO paragraph.

YES

Coolant level correct Possible flow of coolant into the combustion

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

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

DIAGNOSTICS

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

6 ENGINE EXHAUST SMOKE LIGHT BLUE

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

7 ENGINE KNOCKS IRREGULARLY

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

NO

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

NO

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

NO

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

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

DIAGNOSTICS

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

NO

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

NO

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

NO

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

NO

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

8 ENGINE STOPS

Fuel tank filled Refuel and drain (if necessary).

NO

YES

Fuel filters in working order Replace.

NO

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

DIAGNOSTICS

Feeling circuit in working order Check the circuit and drain.

NO

YES

Regular idle speed Adjust.

NO

YES

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

NO

YES

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

YES

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

YES

Intact valves Replace the valves.

NO

9 ENGINE EXCEEDS MAX. REVS NUMBER

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

DIAGNOSTICS

10 EXCESSIVE OR INSUFFICIENT OIL

PRESSURE

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

YES

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

YES

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

YES

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

11 EXCESSIVE FUEL CONSUMPTION

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

YES

Air filter in working order Replace.

NO

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

DIAGNOSTICS

Correct injector adjustment Check operation and adjust them.

NO

YES

Correct injection pump adjustment Check and bench--adjust.

NO

YES

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

NO

YES

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

NO

12 ENGINE WON’T STOP

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

NO

YES

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

DIAGNOSTICS

NOTES
SECTION 2
ENGINE F4GE0454C -- F4GE0484G
OVERHAUL
INDEX
F4GE0454C Engine . . . . . . . . . . . . . . . . EW--2--3
F4GE0484G Engines . . . . . . . . . . . . . . . EW--2--3
Coding of source engines . . . . . . . . . EW--2--4
Main engine features . . . . . . . . . . . . . . EW--2--5
General engine features . . . . . . . . . . . EW--2--6
Assembling play -- specifications . . . EW--2--8
Tightening torque . . . . . . . . . . . . . . . . . EW--2--14
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15
Graphic indications and symbols . . . EW--2--16
General remarks . . . . . . . . . . . . . . . . . . EW--2--17
F4GE0454C engine . . . . . . . . . . . . . . . . EW--2--17
F4GE0484G engines . . . . . . . . . . . . . . . EW--2--18
Description of main mechanic engine
components . . . . . . . . . . . . . . . . . . . . . . EW--2--19
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--19
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--20
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--21
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--22
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--23
Valve control . . . . . . . . . . . . . . . . . . . . . . . EW--2--24
F4GE0454C engine cylinder head . . . . EW--2--25
F4GE0484G engine cylinder head . . . . EW--2--26
Valves and valve seats . . . . . . . . . . . . . . EW--2--27
Valve guides . . . . . . . . . . . . . . . . . . . . . . . EW--2--28
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--29
Auxiliary component drive . . . . . . . . . . . EW--2--30
Additional weights . . . . . . . . . . . . . . . . . . EW--2--31
Lubrication . . . . . . . . . . . . . . . . . . . . . . . EW--2--32
Heat exchanger . . . . . . . . . . . . . . . . . . . . EW--2--33
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--34
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--35
F4GE0484G *D660 / F4GE0454C * D660 Engines .
EW--2--35
F4GE0484G *D665 Engine . . . . . . . . . . EW--2--35
Oil vapour recirculation . . . . . . . . . . . . . . EW--2--36
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--37
Water pump . . . . . . . . . . . . . . . . . . . . . . . EW--2--38
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--39
Mechanic injection feeding system . EW--2--39
Mechanic fuel pump . . . . . . . . . . . . . . . . EW--2--40
Injection assembly . . . . . . . . . . . . . . . . EW--2--41
Version F4GE0484G . . . . . . . . . . . . . . . . EW--2--42
F4GE0454C -- F4GE0484G
Engine bench--overhaul . . . . . . . . . . . . EW--2--42
Disassembling the engine . . . . . . . . . . . EW--2--42
Replacing the seal ring . . . . . . . . . . . . . . EW--2--44
Removing the injection pump . . . . . . . . . EW--2--45
Removing the rocker arm assembly . . . EW--2--47
Repair work on cylinder cluster . . . . . EW--2--50
Checks and measurements . . . . . . . . . . EW--2--50
Checking the surface supporting the head on the
cylinder cluster . . . . . . . . . . . . . . . . . . . . . EW--2--51
Checking the eccentric lift and the pin alignment . . .
EW--2--52
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . EW--2--52
Distributing shaft . . . . . . . . . . . . . . . . . . . EW--2--52
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--53
Replacing the bushings . . . . . . . . . . . . . . EW--2--54
Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--54
Mounting the tappets – Distributing shaft EW--2--54
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . EW--2--55
Measuring the journals and crankpins . EW--2--55
Replacing the oil pump drive gears . . . . EW--2--58
Mounting the main bearings . . . . . . . . . . EW--2--58
Measuring the journal assembling play EW--2--58
Checking the drive shaft shoulder play . EW--2--59
Connecting rod--piston assembly . . . EW--2--60
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--61
Measuring the piston diameter . . . . . . . EW--2--61
Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Conditions for correct pin/piston matching EW--2--62
Piston rings . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--63
Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--64
Checking the connecting rods . . . . . . . . EW--2--64
Checking the torsion . . . . . . . . . . . . . . . . EW--2--64
Checking the flexion . . . . . . . . . . . . . . . . EW--2--64
Mounting the connecting rod--piston
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--65
Connecting rod--piston match . . . . . . . . EW--2--65
Mounting the piston rings . . . . . . . . . . . . EW--2--65
Mounting the connecting rod/piston
assemblies in the cylinder liners . . . . . . EW--2--66
Measuring the crankpin assembling play EW--2--66
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--67
INDEX

Distribution gearbox case . . . . . . . . . . . . EW--2--67 Valve descaling, check and grinding . . . EW--2--77
Checking piston protrusion . . . . . . . . . . . EW--2--67 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--77
Valve timing . . . . . . . . . . . . . . . . . . . . . . . EW--2--68 Valve seats . . . . . . . . . . . . . . . . . . . . . . . EW--2--78
Injection pump – 1st phase . . . . . . . . . . EW--2--69 Valve seat reconditioning -- replacement EW--2--78
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69 Valve guide . . . . . . . . . . . . . . . . . . . . . . . EW--2--78
Assembly of additional masses . . . . . . . EW--2--69 Checking the play between the valve stem,
valve guide and valve centring . . . . . . . EW--2--78
Timing of additional masses . . . . . . . . . . EW--2--70
Mounting the cylinder head . . . . . . . . EW--2--80
Flywheel cover case . . . . . . . . . . . . . . . . EW--2--71
Valve springs . . . . . . . . . . . . . . . . . . . . . EW--2--80
Engine flywheel . . . . . . . . . . . . . . . . . . . EW--2--72
Rocker arm assembly . . . . . . . . . . . . . . . EW--2--81
Replacing the engine flywheel ring gear EW--2--72
Reattaching the cylinder head . . . . . . . . EW--2--81
Injection pump – 2nd phase . . . . . . . . . . EW--2--73
Mounting the injectors . . . . . . . . . . . . . . . EW--2--82
Mounting the injection pump – 2nd phase EW--2--73
Replacing the injectors . . . . . . . . . . . . EW--2--85
Mounting the oil and water pumps . . . . EW--2--73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--85
Mounting the water / oil heat exchanger EW--2--75
Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW--2--75
Rocker arm removal/reassembling . EW--2--86
Removing the valves . . . . . . . . . . . . . . . . EW--2--75
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Checking the cylinder head supporting
surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--76 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Checking the cylinder head water seal . EW--2--77 Adjusting the tappets . . . . . . . . . . . . . . EW--2--87
 EW--2--3

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0454C ENGINE

Figure 1

86607

F4GE0484G ENGINES

Figure 2

86606
EW--2--4

ENGINES F4GE0454C - F4GE0484G OVERHAUL

CODING OF SOURCE ENGINES

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

Emission level

Approved rating

Use

Feeding / Injection
D = TIER 2
Cylinder no.

Cylinder pattern:
0 = 4 strokes, vertical

Engine

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

Group
Engines

8 = Direct injection turbo

diesel with intercooler
5 = Direct injection turbo
diesel

4 = Earthmovers

X Y Y Y Y Y Y Y Y

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

Y = Engine model
 EW--2--5

ENGINES F4GE0454C - F4GE0484G OVERHAUL

MAIN ENGINE FEATURES

A Applications

B FAGE0454C FAGE0484G FAGE0484G

C *D660 *D655

E 4485

71 kW 82 kW
F
2200 rpm 220 rpm

G Direct injection

H Rotary injection pump

T.C. T.A.A.
I (turbo--blower) (Boosted by intercooler)

A Backhoe loader value application code

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

ENGINES F4GE0454C - F4GE0484G OVERHAUL

GENERAL ENGINE FEATURES

F4GE0484G F4GE0454C
Type
*D660 *D655 *D660
Cycle 4--stroke diesel engine
Super--
Feeding Boosted by intercooler
charged
Injection Direct

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

Bore mm 104

Stroke mm 132

Total displacement cm3 4485

Compression ratio 17.5 : 1

Max. rating kW 82
71
min --1 2000
2000

Max. torque Nm (kgm) 480 (48) 398 (39.8)

min --1 1400 1400

No--load idle rpm min --1

--

No--load peak rpm min --1

--

BOOSTING Con intercooler HOLSET

Type of turbocompressor: HOLSET HX25W HX25W

Forced by means of gear pump, pressure

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

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G F4GE0454C
Type
*D660 *D665 *D660
COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81± 2
REFUELLING
Full filling capacity 1° litres --
Ambra Super Gold
15W40 kg
-- engine sump litres --
kg
-- engine sump + filter litres 7.6
kg

FEEDING
VE4 / 12 F 1100 L
Bosch--type injection

Pump setting 0° ± 0°.5

Start of delivery mm 1

Type of nozzle DSLA 145 1174

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

Injection pressure (bar) 245 bar

EW--2--8

ENGINES F4GE0454C - F4GE0484G OVERHAUL

ASSEMBLING PLAY -- SPECIFICATIONS

F4GE0484G F4GE0454C
Tipo
*D660 *D655 *D660
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Cylinder liners ∅1 104

Pistons: supplied with standard

spares
Measurement dimension X 61
Outer diameter ∅1 103.730 to 103.748
Pin seat ∅2 38.010 to 38.016
Piston -- cylinder liners --

Piston diameter ∅1 0.5

Position of pistons from crank-

0.28 to 0.52
case X

Gudgeon pin ∅3 37.994 to 38.000

Gudgeon pin -- Pin seat 0.010 to 0.022

X1
2.705 to 2.735
Piston ring slots X2
2.44 to 2.46
X3
4.03 to 4.05

S1
2.560 to 2,605
Piston rings S2
2.35 to 2.38
S3
3.97 to 3.99

1 0.100 to 0.175
Piston rings – Slots 2 0.060 to 0.110
3 0.040 to 0.083

Piston rings 0.5

 EW--2--9

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G F4BE0454C
Type
*D660 *D655 *D660
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Piston ring end opening in cyl-
inder liner:
X1 0.3 to 0.4
X2 0.6 to 0.8
X3 0.3 to 0.55

Connecting rod small--end

bushing seat ∅1 40.987 to 41.013
Connecting rod bearing seat ∅ 72.987 to 73.013
2

Connecting rod small--end

bushing diameter
41.279 to 41.553
Outer ∅4
38.019 to 38.033
Inner ∅3

Connecting rod small--end

0.266 to 0.566
bushing – seat
Gudgeon pin – Bushing 0.019 to 0.039

Measurement dimension X --

Max. error on connecting rod

axis parallelism = --

Journals ∅1
82.99 to 83.01
Crankpins ∅2
68.987 to 69.013
Main half bearings S1*
2.456 to 2.464
Connecting rod half bearings S
1.955 to 1.968
2*
* supplied with spares

Bed supports no.:

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

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G F4GE0454C
Type
*D660 *D665 *D660
CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm
Half bearings -- journals:
n. 1--5 0.041 to 0.119
n. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
+ 0.250; + 0.500
Connecting rod half bearings

Shoulder journal X1
37.475 to 37.545

Shoulder bed support X2

25.98 to 26.48

Shoulder half rings X3 37.28 to 37.38

Drive shaft shoulder 0.068 to 0.410

 EW--2--11

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G F4GE0454C
Type
*D660 *D665 *D660
VALVE GEAR – CYLINDER ASSEMBLY mm

Valve guide seats on

cylinder head ∅1 8.019 to 8.039

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

Valve stem and respective gui-

0.052 to 0.092
de

Seat on head for valve seat:

∅1 46.987 to 47.013

∅1 43.637 to 43.663

Valve seat outer diameter;

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

X 0.104 to 0.840

Between the valve 0.050 to 0.102

seat and the head
0.050 to 0.102

Valve seats --
EW--2--12

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G F4GE0454C
Type
*D660 *D655 *D660
VALVE GEAR – CYLINDER ASSEMBLY mm
Valve spring height:
free spring H 63.5
under a load of:
329 N H1 49.02
641 N H2 38.20

Injector protrusion X not adjustable

Seats for distributing shaft

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

Distributing shaft support pins:

1⇒5 ∅
53.995 to 54.045

Bushing outer diameter for

distributing shaft: ∅ --

Bushing inner diameter ∅ 54.083 to 54.147

Bushings and seats in crank-

--
case
Bushings and support pins 0.038 to 0.162
Eccentric working lift:
6.045

7.239
 EW--2--13

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G F4GE0454C
Type
*D660 *D655 *D660
VALVE GEAR – CYLINDER ASSEMBLY mm

∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030

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

Between the tappets and the

0.020 to 0.065
seats

Tappets --

∅1

Rocker arm shaft ∅1 18.963 to 18.975

Rocker arms ∅2 19.000 to 19.026

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

ENGINES F4GE0454C - F4GE0484G OVERHAUL

TIGHTENING TORQUE

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

-- Lubrication with oil

 EW--2--15

ENGINES F4GE0454C - F4GE0484G OVERHAUL

TOOLS
380000150 Tool for rotating the engine flywheel
380000229 Comparator holder tool for rotary injection pump timing (to be used with 380001004)
380000975 Box with equipment complete with tools for valve seat reconditioning
380000976 Unit for spring load check
380000977 Tool for checking the top dead centre (to be used with 380001005)
380000978 Rotary stand for unit overhaul (capacity 1000 daN, torque 120 daN/m)
380000979 Extractor for the gear linking the injection pump to the engine
380000980 Tool for removing the drive shaft front gasket
380000981 Tool for removing the drive shaft rear gasket
380000982 Injector extracting tool
380000983 Coupler for mounting the drive shaft front gasket
380000984 Coupler for mounting the drive shaft rear gasket
380000985 Cartridge filter removing tool
380000986 Pliers for removing and reassembling the piston rings (65--110 mm)
380000987 Tool for removing and reassembling the engine valves
380000989 Adapter for compressor check in cylinders (380001006)
380000991 Beater for removing and reassembling the distributing shaft bushings (to be used with
380000999)
380000992 Drive shaft lifting tool
380000993 Swing bar for engine detachment and reattachment
380000994 Band for inserting the piston into the cylinder liner (60--125 mm)
380000995 Brackets for fastening the engine to the rotary stand 380000978
380000996 Gasket extracting tool
380000998 Manual pump for pressure and vacuum measurements
380000999 Handle for interchangeable beaters
380001000 Comparator holder base for miscellaneous measurements (to be used with 380001004)
380001001 Set of 2 gauges for angular tightening with 1/2” and 3/4” square mount
380001002 All--purpose inclinometer/Goniometer
380001003 Full square for connecting rod squaring check
380001004 Comparator (0--5 mm)
380001005 Comparator (0--10 mm)
380001006 Device for checking diesel engine cylinder compression
EW--2--16

ENGINES F4GE0454C - F4GE0484G OVERHAUL

GRAPHIC INDICATIONS AND SYMBOLS

Detachment
Intake
Disconnect

Reattachment
Exhaust
Connect

Removing
Operation
Disassembling

Mounting
Assembling
ρ Compression ratio

Tolerance
Torque--tighten
Weight difference

Torque--tighten + angular value Dragging torque

α

Replacement
Countersink
Genuine spares

Adjustment
Rotation
Setting

Warning Angle
! Note Angular value

Visual check
Preload
Mounting position check

Measurement
Dimension to be measured Revs number
Check

Equipment Temperature

Surface to be machined
Pressure
Machining finish bar

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

ENGINES F4GE0454C - F4GE0484G OVERHAUL

GENERAL REMARKS
F4GE0454C ENGINE

Figure 3

86552

1. Turbo--charger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Crankshaft pulley --
6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by
EW--2--18

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G ENGINES

Figure 4

86553

1. Turbo--charger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Crankshaft pulley --
6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by
 EW--2--19

ENGINES F4GE0454C - F4GE0484G OVERHAUL

DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the fol- It also incorporates the coolant circulation chambers
lowing items are realized: cylinder liners (1); bed and the engine member lubricating circuit ducts.
supports (5) and seats for: distributing shaft bush-
ings (3), tappets, water pump (2) and oil pump (4).

Figure 5

86554
EW--2--20

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Drive shaft
It is made of steel and rests on five induction--har-
dened supports.
Inside the drive shaft are the lubricating oil ducts.
The following items are force--fitted on the front
shank: oil pump drive gear (1), phonic wheel,
damper flywheel and auxiliary component drive pul-
ley.
The following items are force--fitted on the rear
shank: distributing shaft drive gear (2) and engine
flywheel mounting hub (5).
The main half bearings are made of steel with anti--
friction alloy coating.
The second main half bearing (4) is equipped with a
shoulder to restrain the drive shaft end play.

Figure 6

4
86555

1. Oil pump control gear -- 2. Crankshaft control gear -- 3. Main half bearing --
4. Shoulder half--bearings -- 5. Hub for engine flywheel
 EW--2--21

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Connecting rods
They are steel--stamped, of the oblique cut type,
with separation of the cap obtained by an advanced
technology (fracture split) instead of mechanic ma-
chining.
The connecting rod half bearings are made of steel,
with anti--friction alloy coating.

Figure 7

84038
EW--2--22
ENGINES F4GE0454C - F4GE0484G OVERHAUL
Pistons
The combustion chamber is machined in the piston
crown. The crown of the piston is cooled by the engi-
ne oil supplied by the sprayer.
There are three grooves that house the compres-
sion rings; the 1st of which is V shaped and is obtai-
ned using a cast iron insert.
The following references are engraved on the crown
Figure 8
of the piston:
1. Spare part and engineering change number.
2. Arrow indicating the direction of insertion of the
piston in the cylindrical liner; it must be facing to-
wards the front side of the engine block.
3. Date of manufacture.
4. Stamp indicating testing of the 1st hollow insert.
86549
 EW--2--23

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
B. Exhaust valve control
The supports (front and rear) are equipped with steel
bushings mounted in an interfering manner and The camshaft is controlled directly by the crankshaft
coated with anti--friction material; two control eccen- through the gear (C). Gear (D) transmits movement
trics are provided for each cylinder. to the injection pump.

Figure 9

86556
EW--2--24

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Valve control

Figure 10

86557

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

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0454C engine cylinder head

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

Figure 11

86558

DETAIL OF THE CYLINDER HEAD WITH VALVE SEATS

EW--2--26

ENGINES F4GE0454C - F4GE0484G OVERHAUL

F4GE0484G engine cylinder head

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

Figure 12

86559

DETAIL OF THE CYLINDER HEAD WITH VALVE SEATS

 EW--2--27

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Valves and valve seats

Figure 13

S 1

84241

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

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

Figure 14

84242

Figure 14 shows the oil seals mounted on valve

stems.
EW--2--28

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Valve guides

Figure 15

INTAKE EXHAUST
84046

DETAIL OF VALVE GUIDES AND SEATS

 EW--2--29

ENGINES F4GE0454C - F4GE0484G OVERHAUL

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

Figure 16

86560
EW--2--30

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Auxiliary component drive

A Poly--V belt (4) transmits the motion of drive shaft
(5) to water pump (1), alternator (2) and fan (6).
The belt is stretched by means of automatic belt
stretcher (3).

Figure 17

86561

1. Water pump -- 2. Alternator -- 3. Belt stretcher -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan pulley
 EW--2--31

ENGINES F4GE0454C - F4GE0484G OVERHAUL

ADDITIONAL WEIGHTS
The additional weights are located inside the oil Match the signs (A) engraved on the gears for ti-
sump, fastened to the engine block. ming, insert the pin in the hole (B) on the balancing
mass to block rotation of this temporarily.
The additional weights must be timed as indicated
below:

Figure 18

80354

Lock screws -- 2. Support -- 3. Lock screws -- 4. Gear -- 5. Balancing mass -- 6. O--Ring -- 7. Ring --
8. Gear -- 9. Counter--rotating shaft -- 10. Half bearings
EW--2--32

ENGINES F4GE0454C - F4GE0484G OVERHAUL

LUBRICATION
Forced circulation lubrication is performed by the fol-
lowing components:
- oil pump housed in the crankcase front part, con-
trolled by the straight--tooth gear force--fitted on
the drive shaft shank;
- water / oil heat exchanger housed in the crank-
case, with oil filter adapter;
- Oil pressure regulation valve incorporated in the
heat exchanger assy;
- by--pass valve for bypassing the clogged oil
filter, incorporated in the heat exchanger assy;
- cartridge--type oil filter.

Figure 19

86562

Oil return drop--type path Oil supply

Pressure oil path

 EW--2--33

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Heat exchanger

Figure 20

86458

1. Heat exchanger body – 2. Inner gasket – 3. Water / oil heat exchanger -- 4. Gasket between ex-
changer unit and engine block
EW--2--34

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Oil pump

Figure 21

84052

Figure 22

70150

1. Drive shaft with oil pump drive gear

 EW--2--35

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Oil sump
The oil sump (1) is bolted to the engine block by a In addition to improving seal, the plate (2) fitted on
plate (2). the attachment profile of the oil sump also reduces
noise.
F4GE0484G *D660 / F4GE0454C * D660 Engines

Figure 23

86563
F4GE0484G *D665 Engine

Figure 24

86564
EW--2--36

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Oil vapour recirculation

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

Figure 25

84056
 EW--2--37

ENGINES F4GE0454C - F4GE0484G OVERHAUL

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

Figure 26

86565

Water flowing out of the thermostat Water flowing into the pump

Water recirculating in the engine

EW--2--38

ENGINES F4GE0454C - F4GE0484G OVERHAUL

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

Figure 27

84058

Figure 28

84059
 EW--2--39

ENGINES F4GE0454C - F4GE0484G OVERHAUL

MECHANIC INJECTION FEEDING SYS-

TEM

Fuel filter
The fuel temperature sensor (5) and the water drain- Degree of filtration of cartridge: 6 micron.
age screw (3), the air bleed screw (6) and the filter (4) Maximum working pressure: 5 bar.
are located on the support. Working temperature: – 40 °C to + 90 °C.

Figure 29

86566
EW--2--40

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Mechanic fuel pump

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

Figure 30

84249

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

Figure 31

84250

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

 EW--2--41

ENGINES F4GE0454C - F4GE0484G OVERHAUL

INJECTION ASSEMBLY

Figure 32

84251

1. Injector 1 fuel pipe -- 2. Injector 2 fuel pipe -- 3. Injector 3 fuel pipe -- 4. Injector 4 fuel pipe -- 5. Pipe for
fuel discharge from injectors -- 6. Connector for pipe measuring the pressure inside the L.D.A. intake
manifold -- 7. Thermal bulb for KKSB -- 8. Injection pump – 9. Solenoid valve -- 10. Injector
EW--2--42

ENGINES F4GE0454C - F4GE0484G OVERHAUL

ENGINE BENCH--OVERHAUL Figure 35

Disassembling the engine
Figure 33

86568
86567

Drain the engine oil by taking the cap off the sump
and the oil filling cap off the head cover.
Remove the fan unit from the fan pulley.
In order to be able to fit bracket 380000995 (which
fastens the engine to the overhaul stand) to the
crankcase, it is necessary to:
- remove electric wiring (1).
from the engine left side.
Figure 34
5
Version F4GE0484G
- take off intake manifold (3);
- disconnect the engine oil vapour recovery pipe
from blow--by (1);
- take off tappet covers (4);
- disconnect electric wiring (8);
- take off fuel filter (9);
- take off container (2);
- take off container control unit (5);
- disconnect the piping from L.D.A. system (13);
- disconnect quick--coupling pipes (7), (10), (11)
and (13), by following the indications given in
Figure 36;
- take off fuel filter support (6).

Figure 36
4

86463

In order to be able to fit bracket 380000995 to the

crankcase on the right side, it is necessary to re-
move:
- the fastening bracket (2) of the harness (1);
- the harness (1);
- the starter motor (3);
Secure the engine to rotary stand 380000978. 70126

- take off turbine lubrication delivery pipe (5);
- detach the oil filter (4).
Act on fork (1) as shown in the figure (detail A), then
remove the adapter. To avoid damaging the same,
bring fork (1) back to the locking position (detail B)
after the adapter has been removed.

ENGINES F4GE0454C - F4GE0484G OVERHAUL
Figure 37
84255
- Remove injector (5) feed pipes (5) from injection
pump (6); remove the rackets fastening the pipe
unit (1), (2) and (3) on the cylinder head.
- Remove the priming pump (4).
Figure 38
86569
- Remove the feed pipe unit from injectors (1).
- Remove fuel drain pipe (2) from injectors by re-
moving the screw (4) and the seal (3).
EW--2--43
Figure 39
86570
- Remove the screws (3) and then remove the tur-
bine (1).
- Remove the exhaust manifold (2).
Figure 40
86571
- Remove the belt tightener (2).
- Remove the auxiliary component belt (4) operat-
ing the alternator fastening bracket (1).
- Remove the alternator (3), the water pump (6),
the fan pulley (5) and the guide pulleys (7).
- Remove the pulley support (8).
- Remove the engine cooling system connection
from the cylinder block.
EW--2--44

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 41 Figure 43

86572 78257

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

Block the flywheel in order to prevent rotation, back outer seal ring (2) as shown in the figure, then take the
off the lock screws (1) from the pulley (2). same off front cover (1) by means of lever (4).
Remove the front cover.

Replacing the seal ring

Figure 42 Figure 44

78256 84237

Apply tool 380000980 (4) on drive shaft front shank Remove gear oil pump (1).
(2).
Drill inner seal ring (1), through tool 380000980 (4)
guide holes, with an inset (∅ 3.5 mm) down to a depth IMPORTANT -- Oil pump (1) cannot be recondi-
of 5 mm. tioned.
Secure tool 380000980 (4) to ring (1) by screwing the
6 screws (5) provided.
Take off ring (1) by fastening screw (3).
 EW--2--45

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Removing the injection pump Figure 47

Figure 45

86573
84071

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

Figure 46 Figure 48

84260 84261

To correctly preset the injection pump prior to remov-
ing it, loosen screw (2) and remove L--shaped spacer
(1).
Fasten again screw (2) to its abutting end.
Loosen the three nuts (2) (4) (5) securing the injection
pump (1) to the flywheel covering case (3), then take
the pump out of its housing by means of tool
380000979 through proper application to gear (4) in
Figure 47.

IMPORTANT -- Carefully store the L--shaped

spacer with the pump body.
EW--2--46

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 49 Figure 51

86574 78258

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

Figure 50

Figure 52

78257
86575

Screw two pins (2) of adequate length into drive shaft Apply the proper torsion bar (3) of tool 380000996 to
holes (3). outer seal ring (2) as shown in the figure, then take the
same off flywheel cover case (1) by means of lever
Remove tool 380000990 (2).
(4).
Take out engine flywheel (1) so that it can be har-
nessed by means of a hoist and placed into its own
container.
 EW--2--47

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 53 Figure 55

86608

Remove the screws (1) and disassemble the gears (3)

86576 and (4) from the crankshaft (2).

Remove the screws (2) and detach the flywheel cover Figure 56
box (1).

IMPORTANT -- Take note of the mounting position

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

86578

Remove screws (1) and (4) and take off oil suction
strainer (5).
Remove screws (2) and take off stiffening plate (3).
Figure 54
Removing the rocker arm assembly

Figure 57

84081
86577
For each cylinder, remove rocker arm assembly (1),
Turn the engine over, remove the screws (2) and de- loosen adjusting nuts (3), unscrew registers (2) and
tach the oil sump (1). remove screws (4).
EW--2--48

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 58 Figure 61

84082

Take out injectors (2) by means of tool (1) 380000982.

86609

Remove screws (2) and take off timing gear case (1).

Figure 59 IMPORTANT -- Take note of the mounting position

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

Figure 62

86579

Remove screws (1) securing the head to the crank-

case.
Figure 60

70158

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

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

86580 IMPORTANT -- Half bearings must be kept in their

respective housings; in fact, if they have to be used
Hook the wire ropes to brackets (1) and (2), then sep-
again, they must be mounted in the same position
arate the cylinder head from the crankcase by means
they had prior to being taken off.
of a hoist.
 EW--2--49

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 63 Figure 66

70159

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

Take off main half bearings (1).

Figure 64
Remove screws (2) and take off oil nozzles (3).

Figure 67

70160

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

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

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

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

Figure 65
Figure 68

70161
70164
Remove drive shaft (2) from crankcase by means of Carefully remove the distributing shaft from the
tool 380000992(1) and a hoist. crankcase.
EW--2--50
ENGINES F4GE0454C - F4GE0484G OVERHAUL
Figure 69
70165
Remove tappets (1) from the engine crankcase.
REPAIR WORK ON CYLINDER CLUSTER
Checks and measurements
After the engine has been dismantled, clean the
crankcase--cylinder cluster thoroughly.
Use proper rings to move the cylinder cluster.
Check the crankcase carefully for cracks.
Check the condition of working caps. They must be
replaced if they are rusty or their sealing properties
are in doubt.
Inspect the cylinder liner surfaces; they must not
show traces of seizing, scoring, out--of--roundness,
taper and excessive wear.
Figure 70
70166
The check of cylinder liner inner diameter (in order to
measure the amount of out--of--roundness, taper and
wear) is carried out by means of bore gauge (1)
equipped with a comparator previously reset on the
ring gauge (2) of the cylinder liner diameter.
NOTE – If no ring gauge is available, use a micro-
meter to perform reset.
Figure 71
70167
Measurements must be taken for each single cylin-
der, at three different heights of the liner and on two
planes perpendicular to each other: one parallel to the
engine longitudinal axis (A), the other perpendicular
(B); the greatest amount of wear is usually found on
the latter plane and during the first measurement.
When detecting out--of--roundness, taper or wear, the
cylinder liners must be bored and refaced. Cylinder
liner reconditioning must be performed with regard to
the spare piston diameter increased by 0.5 mm of the
rated value, and to the prescribed assembling play.

ENGINES F4GE0454C - F4GE0484G OVERHAUL
Figure 72
80585
IMPORTANT -- In case of reconditioning, all the
liners must be machined to the same increase (0.5
mm).
Check the main bearing seats as follows:
- mount the bed caps on the supports without bear-
ings;
- tighten the fastening screws to the specified
torque;
- check, by means of an adequate internal com-
parator, that the seat diameter is the same as the
specified value.
If a greater value is found, replace the crankcase.
EW--2--51
Checking the surface supporting the head on
the cylinder cluster
Figure 73
70170
Verify that the head supporting plane on the cylinder
cluster does not show deformations.
This check can be carried out by taking off dowels (4)
by means of a gauged rule (2) and thickness gauge
(3).
After detecting the deformed areas, flatten the sup-
porting surface by means of a grinder.
The flatness error must not be greater than 0.075 mm.
NOTE -- Crankcase flattening may be carried out
only after making sure, when the repair work has
been completed, that the protrusion of the piston
from the cylinder liner is not greater than the speci-
fied value.
Check the condition of cylinder cluster working caps
(1); they must be replaced if they are rusty or their
sealing properties are in doubt.
After flattening, restore the cylinder liner countersink,
as shown in Figure 72.
EW--2--52

ENGINES F4GE0454C - F4GE0484G OVERHAUL

VALVE GEAR
Distributing shaft
Figure 74

86581

MAIN FEATURES OF DISTRIBUTING SHAFT

The features given below refer to the normal diameter of pins

The shaft support pin and eccentric surfaces must be Figure 75

perfectly smooth; if, on the contrary, they show traces
of seizing and scoring, it is advisable to replace the
shaft and its respective bushings.
Checking the eccentric lift and the pin align-
ment
Place the shaft on back centres and check, by means
of a centesimal comparator placed on the middle sup-
port, that the alignment error is not greater than 0.04
mm; otherwise, replace the shaft.

70171

Check the diameter of distributing shaft support pins

(2) by means of a micrometer (1) on two axes perpen-
dicular to each other.
 EW--2--53

ENGINES F4GE0454C - F4GE0484G OVERHAUL

BUSHINGS Figure 76
The distributing shaft bushings (2) must be force--
fitted into their respective seats.
The inner surfaces must show no traces of seizing or
wear.
Use bore gauge (3) to measure the diameter of front
and rear bushings (2) and of distributing shaft inter-
mediate seats (1).
Measurements must be taken on two axes perpen-
dicular to each other.

70172

Figure 77

sec. A-A

70173

MAIN FEATURES OF DISTRIBUTING SHAFT BUSHINGS AND THEIR RESPECTIVE SEATS

* Dimension to be obtained after driving the bushings
EW--2--54

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Replacing the bushings Mounting the tappets – Distributing shaft

Figure 78 Figure 80

70174 70176

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

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

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

Tappets

Figure 79 Figure 81

84053 70164

MAIN FEATURES OF TAPPETS AND THEIR Lubricate the distributing shaft support bushings and
RESPECTIVE SEATS ON THE CRANKCASE mount distributing shaft taking care not to damage the
bushings or supporting seats during operation.
 EW--2--55

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 82 Figure 84

70238 70180

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

DRIVE SHAFT
Measuring the journals and crankpins

Figure 85

Figure 83

70182

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

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

NOTE -- It is advisable to write down the measured

values on a table.
See Figure 86.

70179

Check the distributing shaft end play (1).

EW--2--56

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Reduction classes are 0.250 and 0.500 mm.

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

Figure 86

70181

DATA ON WHICH DRIVE SHAFT JOURNAL AND CRANKPIN MEASURING VALUES MUST BE
WRITTEN DOWN
* Rated value
 EW--2--57

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 87

70183

MAIN TOLERANCES OF DRIVE SHAFT

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

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT FEATURES GRAPHIC SYMBOL

CRITICAL 
IMPORTANT
SECONDARY
EW--2--58

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Replacing the oil pump drive gears Measuring the journal assembling play
Figure 88 Figure 90

70184 70161

Verify that the teeth of gear (1) force--fitted on drive Mount the drive shaft (1) on which gears (2) and (3)
shaft (2) are not damaged or worn; otherwise, pro- are force--fitted.
ceed with removal by means of a suitable extractor
(3).
When fitting the new gear, the latter must be heated
for 10 minutes in a small furnace at a temperature
of 180 °C and force--fitted onto the drive shaft by put-
ting the key in between.
Mounting the main bearings
Figure 89 Figure 91

70185 70186

Check the play between the drive shaft journals and

IMPORTANT -- If main bearings do not need re- their respective bearings by following the procedure
placing, they must be fitted in the same order and below:
positions they had when removed. - clean thoroughly the parts and eliminate traces (if
any) of oil;
- place a piece of gauged wire (3) (parallel to the
Main bearings (1) are supplied as spares reduced on longitudinal axis) on drive shaft pins (4);
their inner diameter by 0.250 – 0.500 mm.
- mount caps (1), complete with half bearings (2),
on their respective supports.
IMPORTANT -- No matching operation must be
carried out on bearings.
Clean thoroughly the main half bearings (1) provided
with lubrication holes, then fit them to their seats.
The penultimate main half bearing (1) is provided with
shoulder half rings.
 EW--2--59

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 92 Figure 94

70187 70189

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

Checking the drive shaft shoulder play

Figure 93 Figure 95

70188 70190

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

ENGINES F4GE0454C - F4GE0484G OVERHAUL

CONNECTING ROD--PISTON ASSEMBLY

Figure 96

70191

PARTS MAKING UP THE CONNECTING ROD--PISTON ASSEMBLY

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

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

Figure 97 Figure 98

84093 84094

Taking piston rings (1) off piston (2) by means of pliers The piston rings (2) retaining the piston pin (1) are re-
380000986 (3). moved by means of a mark scraper (3).
 EW--2--61

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 99

86497

MAIN DATA OF PISTON

Pistons
Measuring the piston diameter
Figure 100 Figure 101

84096 70192

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

NOTE -- The diameter must be measured 61 mm far

from the piston skirt base.
EW--2--62

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Gudgeon pins Figure 105

Figure 102

84097 84100

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

Figure 103

Figure 106

84098

Lubricate pin (1) and its respective seat on piston

hubs with engine oil; the pin must be inserted into the
piston by pressing with your fingers slightly and must
not come out of the same due to gravity.
Piston rings
Figure 104

84101

DIAGRAM FOR MEASURING BACKLASH X OF

THE V--SHAPED RING
Due to the peculiar shape of the first trapezoidal cross--
sectioned seal ring, the play between the slot and the
ring itself must be measured as follows; allow piston (1)
to protrude from the crankcase so that ring (2) at issue
comes out of about half from cylinder liner (3).
In this position, check, by means of a thickness
84099 gauge, the play (X) between the ring and the slot: it
must correspond to the specified value.
Check the thickness of seal rings (2) by means of a
micrometer (1).
 EW--2--63

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 107 Figure 109

70194

Measuring the play between the ends of piston rings

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

Connecting rods

Figure 108

80339

IMPORTANT -- Each connecting rod is marked as

86498
MAIN DATA OF CONNECTING ROD, GUDGEON
PIN BUSHING AND HALF BEARINGS
* Dimension of inner diameter to be obtained after
driving into the connecting rod small--end and refacing
by means of a reamer.
** This dimension cannot be measured in a free state.
follows:
- By a number (on the body and cap) which indi-
cates the connecting rod match and the cylin-
der on which it is mounted. In case of replace-
ment, it is therefore necessary to number the
new connecting rod with the same number as
the replaced one.
- By a letter (on the connecting rod body) which
indicates the weight class of the factory--as-
sembled connecting rod:
-- V, 1600 to 1640 (marked in yellow);
-- W, 1641 to 1680 (marked in green);
-- X, 1681 to 1720 (marked in blue);
Replacement rods are supplied class W and
marked in green.
Material removal is not permitted.

IMPORTANT -- The connecting rod--connecting

rod cap matching surfaces are knurled to ensure
better match.
Therefore, it is recommended not to remove
knurls.
EW--2--64

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Bushings Checking the torsion

Figure 111
Verify that the bushing in the connecting rod small--
end is not loosened and does not show traces of scor-
ing or seizing. Otherwise, replace it.
Removing and reassembling are carried out with the
same suitable beater.
When driving, take the greatest care that the holes al-
lowing oil to flow onto the bushing and the connecting
rod small--end correspond to each other. Use a re-
amer to reface the bushing so as to obtain the re-
quired diameter.
Checking the connecting rods
Figure 110

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

Checking the flexion

Figure 112

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

61695
Check connecting rod flexion (5) by comparing two
points C and D of pin (3) on the vertical plane of the
connecting rod axis. Place comparator (2) vertical
support (1) so that the comparator rests on pin (3) at
point C. Swing the connecting rod to and fro, looking
for the highest position of the pin; under such condi-
tion, set comparator (2) to zero. Move the spindle with
connecting rod (5) and repeat the highest point check
on opposite side (D) of pin (3). The difference be-
tween points C and D must not be greater than 0.08
mm.
 EW--2--65

ENGINES F4GE0454C - F4GE0484G OVERHAUL

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

Connecting rod--piston match Figure 116
Figure 113

86550

The following references are engraved on the crown of

the piston: 84093

1. Spare part and engineering change number.
2. Arrow indicating the direction of insertion of the pis-
ton in the cylindrical liner; it must be facing towards
the front side of the engine block.
3. Date of manufacture.
4. Stamp indicating testing of the 1st hollow insert.
Figure 114
Use pliers 380000986 (3) to fit piston rings (1) on pis-
ton (2).
IMPORTANT -- Spare piston rings are supplied in
the following dimensions:
-- standard, marked with yellow paint;
-- increased by 0.5 mm, marked with yellow/green
paint;

Figure 117

86551

Connect piston (2) to connecting rod (4) by means of

pin (3) so that reference inscription (1) for mounting
piston (2) in the cylinder liner.
Figure 115

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

IMPORTANT -- If connecting rod bearings do not

need replacing, they must be fitted in the same
order and positions they had prior to being taken
off.
No matching operation must be carried out on half
72705 bearings.
Insert pin (1) fastening piston rings (2).
EW--2--66

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Mounting the connecting rod/piston assemblies Measuring the crankpin assembling play
in the cylinder liners Figure 120
Figure 118

70201 70203
Lubricate thoroughly the pistons, including the piston The play can be measured by following the procedure
rings and the cylinder liner inside. below:
Use band 380000994 (2) to mount the connecting - clean thoroughly the parts and eliminate any trace
rod--piston assemblies (1) into the cylinder liners. of oil;
- place a piece of gauged wire (2) on drive shaft
pins (1);
- mount the connecting rod caps (3) with their re-
spective half bearings (4);
Figure 121

Figure 119

70204
- tighten screws (1) (previously lubricated with en-
gine oil) to the specified torque by means of a
torque wrench (2).
Figure 122

80612

SCHEME FOR MOUNTING THE CONNECTING

ROD--PISTON ASSEMBLY INTO THE TUNNEL
- the piston ring apertures are offset to each other
by 120°;
- all the connecting rod/piston assemblies weigh
the same;
- the arrow stamped on the piston crown faces the 70205
crankcase front side, or the notch obtained on the - Apply tool 380001001 (1) on the compass
piston skirt corresponds to the position of oil nozz- wrench, then tighten screws (2) further in a criss--
les. cross sequence.

ENGINES F4GE0454C - F4GE0484G OVERHAUL
Figure 123
70206
- Take off the cap and calculate the existing play by
comparing the width of gauged wire (1) with the
scale graduation shown on the wire envelope (2).
Figure 124
70207
If the measured play is different from the specified
one, replace half bearings and repeat the check.
Once the specified play has been obtained, lubricate
the connecting rod half bearings and mount them defi-
nitely by tightening the connecting rod cap fastening
screws as described.
IMPORTANT -- Prior to mounting the connecting
rod cap fastening screws definitely, verify that the
diameter of the same (as measured at the middle
of the thread length) is not smaller than 0.1 mm of
the diameter measured at about 10 mm from the
screw end.
Check manually that connecting rods (1) run axially
on the drive shaft pins, and that the end play of the
same (as measured by means of a thickness gauge
(2) is 0.10 to 0.33 mm.
EW--2--67
Checking piston protrusion
Figure 125
70208
After the connecting rod--piston assemblies have
been mounted, check, by means of comparator
380001004 (1) equipped with base 380001000 (2),
the protrusion of pistons (3) at the top dead centre
relative to the crankcase upper plane.
Said protrusion must be 0.28 to 0.52 mm.
Valve gear
Distribution gearbox case
Figure 126
86582
SCHEME FOR SEALANT LOCTITE 5999
APPLICATION AREA
Clean thoroughly distribution gearbox case (1) and
the engine crankcase.
Cleaning the surface to be sealed is necessary and
unavoidable in order to ensure optimum seal.
Apply sealant LOCTITE 5999 on the case so as to
make a bead with a diameter of a few millimetres.
The bead must be smooth (no lumps) and free from
air bubbles, thin areas or gaps.
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint.
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).
EW--2--68

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 127 Figure 129

86610
86611

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

Valve timing
Figure 128 Figure 130

70211 86612

Mark, with a felt--tip pen, the tooth of drive gear (1) Tighten gear (2) fastening screws (1) to distributing
mounted on drive shaft (2), the side surface of which shaft (3), then fasten them to the specified torque.
bears a stamped notch (→) for timing.
 EW--2--69

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Injection pump – 1st phase Figure 133

Timing
Figure 131

86613

Force--fit gear (1) transmitting the motion to the pump,

84071 then fasten nut (2) by hand.
Bring cylinder 1 to the top dead centre. This condition Rotate the engine and remove the additional weights.
occurs when pin (1) (shown by an arrow) is housed in
the seat available on the distributing shaft drive gear
(2).

Assembly of additional masses

Figure 134

Figure 132

86578

Fit the additional masses (2) and tighten the screws

(3) on the engine block.
84273
Mount the injection pump body (1) in the gearbox seat Remove the lock pin (1) of the additional masses.
(2), then secure it by means of screws (3).
EW--2--70

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Timing of additional masses

Match the signs (A) engraved on the gears for timing,
insert the pin in the hole (B) on the balancing mass.

Figure 135

86614

1. Injection pump gear -- 2. Camshaft control gear -- 3. Injection pump control gear -- 4. Additional masses
 EW--2--71

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Flywheel cover case Figure 137

Figure 136

86576
86583

SCHEME FOR FLYWHEEL COVER CASE

SCHEME FOR SEALANT LOCTITE 5999 AP- FASTENING SCREW TIGHTENING SEQUENCE
PLICATION AREA
Fit case (1) back to the crankcase, tighten the fasten-
Clean thoroughly the attaching surfaces of flywheel ing screws in the positions they had prior to being
case (1) and distribution gearbox. taken off, then fasten them to the specified torque.
Cleaning the surface to be sealed is necessary and Screws:
unavoidable in order to ensure optimum seal.
- M12 x 1.75 x 100 80 ± 10 Nm
Apply sealant LOCTITE 5999 on the case (1) so as to
make a bead with a diameter of a few millimetres. - M16 x 1.50 x 80 200 ± 20 Nm
The bead must be smooth (no lumps) and free from - M16 x 1.50 x 100 200 ± 20 Nm
air bubbles, thin areas or gaps. - M12 x 1.75 x 78 80 ± 10 Nm
Any defect must be corrected as soon as practicable.
Avoid using excess material to seal the joint. Figure 138
An excessive amount of sealant tends to come out on
both sides of the joint and obstruct lubricant flowing
passages.
After completing sealant application, the joints must
be mounted immediately (within 10 -- 20 minutes).

70216
Apply part (5) of tool 380000983 on drive shaft rear
shank (6), secure it by means of screws (4) and force--
fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in flywheel cover case (7).
EW--2--72

ENGINES F4GE0454C - F4GE0484G OVERHAUL

ENGINE FLYWHEEL Figure 141

Figure 139

1 2

86584 86574

Check the clutch disc supporting surface and turn it if

scoring is detected. Block rotation of the engine flywheel appropriately (3).
Tighten screws (2) fastening engine flywheel (3) to the
drive shaft.
NOTE -- The rated thickness of the engine flywheel
is 51 mm.

Replacing the engine flywheel ring gear

Check the condition of ring gear (2) teeth. If breaks or
excessive tooth wear is found, remove the ring gear
from the engine flywheel (1, Figure 139) by using a
normal beater, then mount the new gear ring after
previously heating it to 150 °C for 15’ to 20’. Figure 142

Figure 140

86585

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

two separate phases:
- 1st phase: tighten to a torque of 30 ± 5 Nm by
means of a torque wrench;
86575
- 2nd phase: tighten to an angle of 60° ± 5°.

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

shaft holes (3), then remove the engine flywheel (1) IMPORTANT -- Angle tightening is carried out by
by means of suitable harnesses and a hoist. means of tool 380001001.
 EW--2--73

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Injection pump – 2nd phase Mounting the oil and water pumps
Mounting the injection pump – 2nd phase Figure 146
Figure 143

86586 70220
Torque--tighten nut (1) by means of torque wrench (2). Mount oil pump (1).
Screw down fastening screws (2) and tighten them to
Figure 144 the specified torque.

Figure 147

86587

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

70221
small cover (2).
Apply a new seal ring (2) onto water pump (1).
Figure 145

Figure 148

84260

Remove plug (1) from the distribution gear seat

Figure 45. 70222
Mount water pump (1).
Remove presetting screw (2) and insert L--shaped Fasten screws (2) and tighten them to the specified
spacer (1). Fasten again the screw to its abutting end. torque.
EW--2--74

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 149 Figure 152

70223
86557
Take seal ring (2) off front cover (1), clean thoroughly
the attaching surface and apply sealant LOCTITE Mount oil sump (1) and apply plate (3) on the same.
5999 onto the same. Fasten screws (2) and tighten them to the specified
Figure 150 torque.

70224

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

ing base, then mount front cover (2).
Fasten screws (1) and tighten them to the specified
torque.
Figure 153
Figure 151

70225
Apply part (5) of tool 380000983 on drive shaft front
shank (6), secure it by means of screws (4) and force--
fit the new seal ring (3) on the same.
Position part (1) on part (5), then screw nut (2) to fully
mount seal ring (3) in front cover (7).
86588
Force--fit pulley (1) complete with spacer (2) onto the
drive shaft, then torque--tighten and angle--tighten the
screws by means of tool 380001001.
Secure guide pulleys (4) to the front cover by means
of screws (3).
 EW--2--75

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Mounting the water / oil heat exchanger Figure 156

Figure 154

86589
84175 Fit alternator (1).

Mount the following items on the crankcase: a new

gasket (1), heat exchanger (2), a new gasket (3), and
oil filter support (4).
Fasten screws (5) and tighten them to the specified
torque.
Fit the new oil filter cartridge.

Cylinder head
Removing the valves
Figure 155 Figure 157

84179

Valves can be removed by means of tool 380000987

84177
Position alternator support (1) in such a way that pins
(3 and 4) are placed against the engine crankcase.
Fasten screws (2) and tighten them to the specified
torque.
(1) by pressing slightly on collar (3) so that lock cones
(2) can be removed by compressing springs (4). Then
remove collar (3) and springs (4).
Repeat the procedure on all valves.
EW--2--76

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 158 Figure 160

86590
84282

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

IMPORTANT -- Mark the exhaust and intake

valves prior to removing them.

Checking the cylinder head supporting surface

Figure 159 Figure 161

INTAKE EXHAUST
84181 84183

In addition to the head dimensions, the exhaust
valves differ from intake valves in that they are
equipped with a supplementary notch (1) obtained on
the stem for intake valves.
The plane of the supporting surface of head (1) to cyl-
inder cluster is checked by means of a ruler (2) and
a thickness gauge (3).
The deformation found on the entire length of the cyl-
inder head must not be greater than 0.20 mm.
If greater values are found, reface the cylinder head
according to the values and instructions given in the
next figure.
 EW--2--77

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Checking the cylinder head water seal VALVES

Check the water seal by means of suitable equipment. Figure 163
Use a pump to feed water heated to ∼ 90 °C at a pres- EXHAUST INTAKE
sure of 2 to 3 bar. VALVE VALVE
If leaks are detected from the caps, the latter must be
replaced by using a suitable beater for disassembling/
assembling operations.

IMPORTANT -- Prior to mounting the caps, apply

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

If leaks are detected from the cylinder head, the latter

must be replaced. 84185

MAIN DATA OF INTAKE AND EXHAUST VALVES

Valve descaling, check and grinding

Figure 162
Figure 164

84284

Nominal thickness A of the cylinder head is 95 ± 0.25

mm, max. admitted metal removal shall not exceed
thickness B, i.e. 0.13 mm.
IMPORTANT -- After regrinding, check valve sink-
ing and regrind valve seats if required, to obtain
the required value.
84186
Remove the carbon deposits from the valves by
means of the special metal brush.
Verify that the valves do not show traces of seizing,
crimping or burns.
Reface, if necessary, the valve seats by means of a
grinder 380000975, by removing as less material as
possible.
EW--2--78

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 165 VALVE GUIDE

Figure 167

84187

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

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

Use a bore gauge to measure the valve guide inner

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

Checking the play between the valve stem, VALVE SEATS

valve guide and valve centring
Valve seat reconditioning -- replacement
Figure 166 Figure 168

84188 84189

Check can be made by means of a magnetic com-
parator (1) placed as shown. Assembling play must
be equal to 0.039 to 0.079 mm.
Check, by making valve (2) rotate, that the centring
error is not greater than 0.03 mm.
Check valve seats (2). If slight burns or scoring are
found, proceed with reconditioning by means of tool
380000975 (1) according to the inclination values
shown in Figure 169.
 EW--2--79

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 169

INTAKE EXHAUST

84190

VALVE SEAT DIMENSIONS

Figure 170

EXHAUST INTAKE

86591
VALVE SEAT HOUSING DIMENSIONS

If the valve seats cannot be restored by simply reconditioning them, they can be replaced with spare parts. By
using the same tool 380000975 (1, Figure 168) and taking care not to indent the cylinder head, remove as much
material as possible from the valve seats until the latter can be taken off the cylinder head by means of a punch.
Heat the cylinder head to 80 to 100 °C, then mount the new valve seats (previously cooled) onto the head by
means of a suitable beater.
Recondition the valve seats by means of tool 380000975, according to the values shown in Figure 169.
EW--2--80

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 171 MOUNTING THE CYLINDER HEAD

Figure 173

84192 84282

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

VALVE SPRINGS
Figure 172

Figure 174
84193

MAIN DATA FOR INTAKE AND EXHAUST VALVE

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

Height Under a load of

mm N 84179
H(Free) 63.50 No load Position spring (4) and upper collar (3) on the cylinder
H1 49.02 P1 329 head: use tool 380000987 (1) to compress spring (4)
H2 38.20 P2 641 and link the parts to the valve by means of lock cones
(2).

ENGINES F4GE0454C - F4GE0484G OVERHAUL
Reattaching the cylinder head
Figure 175
84113
Verify that the cylinder head attaching plane and the
crankcase attaching plane are both clean.
Do not spoil the cylinder head gasket.
IMPORTANT -- Prior to reusing the cylinder head
fastening screws, verify that they do not show
traces of wear or deformations; otherwise, replace
them.
Figure 176
84265
Mount the cylinder head on the crankcase by fastening
screws (1) without torque--tightening them.
EW--2--81
Figure 177
84209
Prior to inserting the pushrods, verify their state of
preservation: the spherical seats in contact with the
rocker arm adjusting screw and tappet (arrows) must
not show traces of seizing or wear; otherwise, the
seats must be replaced. The rods controlling the in-
take and exhaust valves are identical and, therefore,
they are interchangeable.
Rocker arm assembly
Figure 178
84195
PARTS MAKING UP THE ROCKER ARM
ASSEMBLY:
1. Support -- 2. Rocker arm -- 3. Arbour -- 4. Screws
Figure 179
84196
MAIN DATA OF ARBOUR--ROCKER ARM
Verify that the arbour/rocker arm matching sur-
faces do not show excessive wear or damages.
EW--2--82

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 180 Figure 183

84197

Verify that the tappet adjusters are unscrewed to pre- 84200

vent the latter from crawling on the rods when the Ad just the play between the rocker arms and the
rocker arm assembly (1) is mounted. valves by means of an Allen wrench (2), box wrench
Mount the rocker arm assembly made up of the ar- (3) and thickness gauge (1).
bours and rocker arm support, then secure them to
the head without torque--tightening screws (2) and The operation play is:
(3). -- intake valves: 0.25 ± 0.05 mm
Figure 181 -- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
FIRING ORDER 1--3--4--2
Adjusting cylinder
1 3 4 2
valve no.
Adjusting clearance
4 2 1 3
of cylinder valve no.

Mounting the injectors

Figure 184
84198

Fasten the head screws according to the instructions

given in NO TAG.
Figure 182

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

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

screw M12 x 1.75 x 140 [ ] 40 Nm ± 5 Nm;
screw M12 x 1.75 x 180 [ ] 70 Nm ± 5 Nm;
- 2nd phase: angle tightening: 90°
- 3rd phase: angle tightening only for screws 140
and 180 mm long: 90°.
Mount a new seal ring (2) lubricated with petrolatum
and a new seal washer (3) on injector (1).
Mount the injectors on their seats on the cylinder
head, then tighten them by means of a torque wrench.
 EW--2--83

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 185 Figure 187

86570
86615
- Mount exhaust manifold (2).
Mount the injector feeding pipe assembly (1). Mount - Mount turbine (1) by means of screws (3).
the pipes for fuel discharge (2) from injectors, by using
gaskets (3) and by tightening screws (4). Figure 188

86592

APPLICATION ON F4GE0454C
Figure 186

86593

APPLICATION ON F4GE0484G

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

84255
Mount the injection pump (6) injector feeding pipes
(5), then secure brackets (1), (2) and (3) fastening the
pipe assembly onto the cylinder head.
Mount priming pump (4).
the cylinder head, cover (5), seal gaskets (2) and (4),
cold--start heater (3) and elbow (1).
Apply sealant LOCTITE 5999 between cover (5) and
manifold (6), then tighten the screws to the specified
torque.
EW--2--84

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 189 Figure 191

84252

86568

- Mount electric wiring (1).

- Mount tappet covers (4).

- Mount container (2).
- Mount intake manifold elbow (3).
- Mount container control unit (5).
- Mount fuel filter support (6).
- Mount fuel filter (9).
- Attach quick coupling pipes (7), (10), (11) and (12)
by following the indications given in Figure 191.
- Mount electric wiring (8).
- Mount L.D.A. system piping (13).
- Connect the engine oil vapour recovery pipe to
blow--by (1).
Figure 192

Figure 190

86463

- Mount the starter motor (3).

70126
Press clip (1) in the direction of the arrow (detail B),
then connect the piping. Bring the clip back to the in-
itial locking position (detail A).
- Mount turbine lubricating oil return piping with its
respective fastening bracket.
- Mount turbine lubricating oil delivery pipe and en-
gine oil pipes to water / oil heat exchanger unit.
 EW--2--85

ENGINES F4GE0454C - F4GE0484G OVERHAUL

Figure 193 REPLACING THE INJECTORS

Removal
Figure 196

86594

- Mount thermostat unit (1) to cylinder head (3) by

torque--tightening screws (2).
- Mount water temperature sensor (5) by screwing 86596

it by means of a torque wrench.

Place the vehicle in safe conditions.
- Mount fan pulley support (6) on head (3) by
torque--tightening screws (4). Lift the engine compartment cover, disconnect the
battery cables and proceed as follows:

Figure 194 - disconnect engine oil vapour recovery pipe (2)

from blow--by;
- take off tappet cover (1);
- disconnect the fuel manifold pipes from injectors
(3).

84288

Mount fan pulley (2) on support (1) by torque--tighten-

ing screws (3).
Figure 195 Figure 197

86571
84082
Mount Poli--V belt (4) on pulley (5), drive shaft pulley,
guide pulleys (2), water pump (6) and on alternator
(3); then, stretch the belt by acting on automatic belt Remove injectors (2) by means of tool 380000982 (1)
stretcher. and take them off the cylinder head.
EW--2--86
ENGINES F4GE0454C - F4GE0484G OVERHAUL
Reassembling
Figure 198
84201
Mount a new seal ring (2) lubricated with petrolatum
and a new seal washer (3) on injector (1).
Mount the injectors on their seats on the cylinder
head, then tighten them by means of a torque wrench.
Figure 199
84290
Mount new seal rings (1) on fuel manifolds (2).
Connect the manifolds to the injectors, by tightening
the fastening nuts to a torque of 50 Nm.
Reassemble the tappet cover.
Re--connect the engine oil vapour recovery pipe to the
blow--by.
ROCKER ARM REMOVAL/REASSEMBLING
Removal
Figure 200
84081
Loosen tappet adjuster fastening nuts (3), then un-
screw adjusters (2).
Remove screws (4) and dismount rocker arm assem-
bly (1) made up of the rocker arm support and ar-
bours, then take off valves.
Reassembling
Verify that the tappet adjusters are unscrewed to pre-
vent the latter from crawling on the rods when the
rocker arm assembly is mounted.
Mount the rocker arm assemblies made up of rocker
arm support and arbours, then secure them to the cyl-
inder head by tightening the fastening screws to a
torque of 36 Nm.
Ad just the tappets as described above.
 EW--2--87

ENGINES F4GE0454C - F4GE0484G OVERHAUL

ADJUSTING THE TAPPETS

Figure 201

84200

Ad just the play between the rocker arms and the FIRING ORDER 1--3--4--2
valves by means of an Allen wrench (2), box wrench
(3) and thickness gauge (1).
Adjusting cylinder
1 3 4 2
The operation play is: valve no.
Adjusting clearance
-- ± 0.05 mm of cylinder valve no.
4 2 1 3
– intake valves: 0.25 ± 0.05 mm
-- exhaust valves: 0.50 ± 0.05 mm.
Take the cylinder where clearance must be adjusted
to the bursting phase; its valves are closed while bal-
ancing the symmetric cylinder valves.
Symmetric cylinders are 1--4 and 3--2.
EW--2--88

ENGINES F4GE0454C - F4GE0484G OVERHAUL

SECTION 3

RECHARGE AND START--UP

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

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

Bosch 24 V -- 4 kW . . . . . . . . . . . . . . . . . EW--3--4 Bosch NCBI 28 V 35--70 A . . . . . . . . . . EW--3--6

INDEX
 EW--3--3

RECHARGE AND START--UP

STARTER MOTOR

BOSCH -- 24 V -- 4 kW

Quick diagnosis

Fault Possible causes Remedy

Dragging torque insufficient 1. Batteries run down Restore

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

RECHARGE AND START--UP

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

84262 84267

WIRING DIAGRAM 3/4 VIEW

84268 84269

CHARACTERISTIC CURVES PINION ADJUSTER

 EW--3--5

RECHARGE AND START--UP

ALTERNATOR

BOSCH NCBI 28 V 35--70 A

Quick diagnosis

Fault Possible causes Remedy

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

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

Poor recharge 1. Loose belt Apply correct tension

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

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

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

RECHARGE AND START--UP

Bosch NCBI 28 V 35--70 A

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

84270 84271

WIRING DIAGRAM 3/4 VIEW

84272 84274

CHARACTERISTIC CURVES OF CURRENT CHARACTERISTIC CURVES OF VOLTAGE

DELIVERY REGULATOR