C

o
p
y
ri
g
h
t
©
N
e
w
H
o
ll
a
n
d

P R O V E N P E R F OR MA N C E PR OV E N PE RF O RM AN CE
 Copyright © New Holland

REPAIR MANUAL FOR CNH U.K. ENGINES

F4GE0404B -- F4GE0454C -- F4GE0484G
The following models are to integrate repair manuals:
NEW HOLLAND LM1330 ---- LM1333 ---- LM1330 Turbo ---- LM1333 Turbo
LM1340 Turbo -- LM 1343 Turbo -- LM1345 Turbo
LM1443 Turbo -- LM 1445 Turbo -- LM1745 Turbo
 F4GE0404B F4GE0454C

F4GE0484G
Every
Every inf
inform
ormati
ation,
on, illust
illustrati
ration
on and specif
specifica
icatio
tion
n contain
contained
ed in the pres
present
ent man
manual
ual is based
based on the mos
mostt recent
recent inf
inform
orma-
a--
tion available
available at the time of printing.
printing.
NEW HOLLAND
HOLLAND reserves the right, to modify the text at any time without prior communication.
communication.

NEW HOLLAND
Print No. 604.13.694
Edition -- May 2006
 Copyright © New Holland
2 WE

MOTORI
2
 Copyright © New Holland
IN--1

INTRODUCTION

TO THE READER
- This manual was written
written for a skilled technician
technician - For any question or comment, or should you n no-
o--
and contai
contains
ns all the techni
technical
cal inf
inform
ormati
ation
on needed
needed tice any mistake concerning the content of this
to repair this vehicle. manual, please contact:
- Read this manual carefully for the information NEW HOLLAND
concerning repairing operations. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax ++39 011 0077357

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

Example:: T 1 -- 2 -- 3

Progressive
Progressive page number for each group

Group number (if any)

 Section number

S: Safety rules

Operation principle
T: Tec
echn
hnic
ical
al se
sect
ctio
ion
n Perf
Perfor
orma
manc
nce
e test
tests
s
Fault diagnosis
W: Instruction section for excavator repairing
EW: Instruction section for engine repairing

SYMBOLS
This
This manual
manual contai
contains
ns safety
safety warning
warning symbol
symbols
s and indica
indicatio
tions
ns referri
referring
ng to possib
possible
le inj
injuri
uries
es or vehicl
vehicle
e damage
damages.
s.

This symbol regards safety.

! Use great care when you see this symbol because possible
possible injuries to the personnel may occur.
occur.
Strictly observe the precautions marked with this symbol.
Th
The
e safe
safety
ty warni
warning
ng symb
symbol
ol is us
used
ed al
also
so to dr
draw
aw atten
attentio
tion
n on theweig
theweight
ht of a comp
compon
onen
entt or an el
elem
emen
ent.
t.
Make sure you are always using the right equipment and lifting techniques when handling heavy
loads,, in order to prevent
loads prevent injuries or damages.
damages.
 Copyright © New Holland
IN--2

INTRODUCTION

UNIT OF MEASURE
This manual adopts the units of measu
measure
re based on the International
International System.
System.
Th
The
e MKSA
MKSA syst
system
em un
units
its of meas
measur
ure
e ar
are
e in
indi
dica
cate
ted
d with
within
in brack
brackets
ets afte
afterr the unit
units
s of meas
measur
ure
e of the
the Inte
Intern
rnat
atio
iona
nall
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
conver t in To conver
convertt in
Quantity Multiply by Quant
ntiity Multiply by
from (IS) (Others) from (IS) (Others)
mm in 0.
0.03937 MPa kgf/cm2 10.197
eng ressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
ower
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
pee
N kgf 0.10197 min--1 rpm 1.0
orce
N lbf 0.2248 L/min US gpm 0
0..2642
ap
apac
ac y
orque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
 Copyright © New Holland

REPAIR MANUAL
ENGINES

INDEX OF SECTIONS
SECTIONS

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

Section 2 -- Engines overhaul:

-- FAGE0404B EW--2--1
-- FAGE0454C
-- FAGE0484G

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

 Copyright © New Holland
4 WE

MOTORI
 Copyright © New Holland

SECTION 1

DIAGNOSTICS

INDEX

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW--1--3
Main engine operating anomalies . . . EW--1--3
 Copyright © New Holland

INDICE
 Copyright © New Holland
EW--1--3

DIAGNOSTICS

MAIN ENGINE OPERATING ANOMALIES

1 -- En
Engi
gine
ne won’
won’tt star
start;
t; 6 -- Eng
Engine
ine exh
exhaus
austt smo
smoke ke light
light blu
blue;
e;
2 -- En
Engi
gine
ne ov
over
erhe
heat
ats;
s; 7 -- Engi
Engine
ne kn
knoc
ocks
ks ir
irre
regu
gulalarl
rly;
y;
3 -- Engine
Engine lac
lacks
ks power
power and works
works errati
erratical
cally;
ly; 8 -- Engi
Engine
ne st
stop
ops;
s;
4 -- Engi
Engine
ne ex
exha
haus
ustt smok
smoke
e bl
blac
ack
k or da
dark
rk gr
grey
ey;; 9 -- Eng
Engine
ine exc
exceed
eedss max.
max. revs
revs num
number;
ber;
5 -- Engi
Engine
ne ex
exha
haus
ustt smok
smoke
e grey
grey (v
(ver
ergi
ging
ng on 10 -- Exc
Excess
essive
ive or ins
insuff
uffici
icient
ent oil pre
pressu
ssure;
re;
white); 11 ----
12 Exc
Excess
essive
Engi
En ne ive
gine fuel
fue
won’
won’t l con
t stconsum
op.. sumpti
stop ption;
on;

1 ENGINE WON’T START

START

Connections to battery terminals are in working Clean, check, tighten or replac

replace
e 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 conti
continued)
nued)
 Copyright © New Holland
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

Th
Thee feed
feedin
ing
g circu
circuit
it or pu
pump
mp does
does notshowtraces
notshowtraces Check and clean
Check clean the feedin
feeding
g cir
circui
cuitt (in
(inclu
cludin
ding
g 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
concerned parts.
device both in working
working order NO

YES

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

YES

Fuel tank supplied correctly Refuel.

NO
 Copyright © New Holland
EW--1--5

DIAGNOSTICS

2 ENGINE OVERHEATS

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

YES

Fan and water

water pump drive
drive belts
belts in working
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 p
parts.
arts.
NO

YES

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

DIAGNOSTICS

Valve timing correct Check and perform correct timing.

NO

YES

Injection pump timed Check c

coorrect ttiiming as
as de
described in
in th
the re
relevant
NO paragraph.

YES

Cylinder head gasket in working order Replace.

NO

YES

Fan in working order Replace.

NO
 ENGINE LACKS POWER AND WORKS
3 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 f ol

ollowing the i ns
nstructions g iv
iven in
i n t he
he
NO “Owner Handbook”.

YES

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

(to be contin
continued)
ued)
 Copyright © New Holland
EW--1--7

DIAGNOSTICS

The feeling circuit does not show impurities and/ Take offthe pip
pipes
es and inj
inject
ection
ion pump,
pump, cle
clean
an 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 co

correct ttiiming as
as de
described in
in th
the rre
elevant
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 conti
continued)
nued)
 Copyright © New Holland
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

Ci
Circ
rcui
uitt and
and L.D.
L.D.A.
A. devi
device
ce bot
oth
h in wor
orki
king
ng or
orde
derr Che
heck
ck..
NO

YES

Injection pump with peak adjusting--screw fine-- Fine--tune

Fine--tune the peak adjusting--screw.
adjusting--screw.
tuned NO
 YES

Corr
Correc
ectt playbet
playbetwe
weenthe
enthe va
valv
lvesand
esand ro
rock
ckerarm
erarms
s Adju
Adjust
st the
the pl
play
ay be
betw
twee
een
n the
the valv
valves
es an
and
d rock
rocker
er
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
 Copyright © New Holland
EW--1--9

DIAGNOSTICS

ENGINE EXHAUST SMOKE BLACK OR

4 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 co

correct ttiiming as
paragraph. as de
described in
in th
the rre
elevant
NO

YES

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

NO

YES

In
Inje
ject
ctio
ion
n pump
pump adj
adjuste
usted
d as pr
pres
escr
crib
ibe
ed Chec
Check
k and
and benc
bench-
h--a
-adj
djus
ustt the
the inj
njec
ecti
tion
on pump
pump..
NO

(to be continued)
 Copyright © New Holland
EW--1--10

DIAGNOSTICS

Injection pipes intact Check tth

he c
coondition of
of pi
pipes an
and re
replace th
them ((iif
NO necessary).

YES

Prescribed compression ratio Check by means of a Motometer 75301430 tool

NO and carry out the necess
necessary
ary operations.

YES

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

5 ENGINE EXHAUST SMOKE GREY

(VERGING ON WHITE)
The th
ther
erm
mosta
ostatt comes
omes into
into op
oper
erat
atio
ion
n co
corr
rrec
ectl
tly
y Repl
Replac
ace.
e.
NO

YES

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

NO 1094.

YES

Injection pump timed Check c

coorrect ttiiming as
as de
described in
in th
the re
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 contin
continued)
ued)
 Copyright © New Holland
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. Ove
sion. Overhau
rhaul,l, if necessa
necessary
ry,, the cyl
cylind
inder
er head
head or
engine.

7 ENGINE KNOCKS IRREGULARLY

IRREGULARLY
Knock detect
ected in the injection pump Perf
rfo
orm correc
ectt ti
tim
ming 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
engine..

NO

Knock detect
ected in the connecting rods Check the following items: crankpi pin
n pl
pla
ay and
YES out--of--roundness;
out--of--round ness; screw
scr ew fastening
fasten ing for co
connect-
nnect--
ing rod caps; connectin
connectingg 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
ri
ring
ngs;
s; pl
Replac
Replaceplay
eay betw
beparts
the tween
eenorthe
thoverhau
e pi
pins
ns and
overhaul the
theengine
l the pi
pist
ston
on. hubs.
engine. hubs.

(to be continu
continued)
ed)
 Copyright © New Holland
EW--1--12

DIAGNOSTICS

Knock det
ete
ected in the cylinder hea
head Check the fol
following items: operatitio
on 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
ive pl
play
ay bet
betwe
ween
en the
the st
stem
emss and
and guid
guides
es,, the
tappets and seats. Adjust the play between the
valves and rocker arms.

NO

Knock detected in injectors Check a

an nd a
addjust as d
deescribed in
i n S.
S .I. 10
1 094, tth
hen
YES replace.

NO

Knock
ock det
ete
ected in the engine flywhee
eell Repl
eplace loose screws and tighte
hten al
alll screw
rews to
 YES the specified torque and angles
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 contin
continued)
ued)
 Copyright © New Holland
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 contr

tro
ols in working order
rder Replace worn part
rts
s and adjust.
NO
 YES

Corr
Correc
ectt playbet
playbetwe
weenthe
enthe va
valv
lvesand
esand ro
rock
cker
er ar
arms
ms Ad ju
just
arms.st the
the pl
play
ay be
betw
twee
een
n the
the valv
valves
es and
and rock
rocker
er
NO

YES

Intact valves Replace the valves.

NO

9 ENGINE EXCEEDS MAX. REVS

REVS NUMBER

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

DIAGNOSTICS

10 EXCESSIVE OR INSUFFICIENT OIL

PRESSURE

Pressure control
rol valve in working order Chec
heck and
and replace (i
(iff necessary
ry)).
NO

YES

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

YES
Main bearin
Main bearings
gs and con
connec
nectin
ting
g rod bearin
bearings
gs both
both Replace the bearings and reface (if necessary)
in working order NO the drive shaft.

YES

Engine oil SAE vis

Engine viscos
cosity
ity conform
conforming
ing to stan-
stan-- Replace the engine oil with equivalent of ad--
Replace
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 contin
continued)
ued)
 Copyright © New Holland
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--of
offf electrom
romagnet in working orde
derr Replace the electromagnet
gnet..
NO

YES

Spee
Speed
d go
gove
vern
rnor
or in work
workin
ing
g or
orde
derr at al
alll sp
spee
eeds
ds Over
Overha
haul
ul the
the in
inje
ject
ctio
ion
n pu
pump
mp an
and
d be
benc
nch-
h--a
-adj
djus
ustt it
NO according
according to the relevant adjustmen
adjustmentt table.
 Copyright © New Holland
EW--1--16

DIAGNOSTICS

NOTES
 Copyright © New Holland

SECTION 2 F4GE0404B -- F4GE0454C -- F4GE0484G

ENGINES F4GE0404B F4GE0454C

F4GE0484G
F4GE0484G OVERHAUL

INDEX
Engine F4GE0404B . . . . . . . . . . . . . . . . . EW--2--3 Dismounting rear seal ring
Engine F4GE0454C . . . . . . . . . . . . . . . . . EW--2--3 (dismounting operation to be executed
Engine F4GE0484G . . . . . . . . . . . . . . . . . EW--2--3 wi
with
th en
engi
gine
ne moun
mounte ted d on vehivehicl cle)
e) . . . . . . EW
EW---2-
-2--47
-47
Coding of source engines . . . . . . . . . . EW--2--4 Remo
Re moviving
ng the
the roc
rockekerr arm asse assemb mbly ly . . . EW-
EW--2-
-2--48
-48
Main engines features . . . . . . . . . . . . . . EW--2--5 Repa
Re pair
ir wo
work
rk on cy cyli lind
nder er clus
cluste terr . . . . . EW
EW---2-
-2--51
-51
General engines features . . . . . . . . . . . EW--2--6 Checks and measurements . . . . . . . . . . . EW--2--51
Assem
Assembli
bling
ng play
play -- specifi
specificati
cation ons s ... EW-
EW--2-
-2--8
-8 Checking the surface supporting
the
the head
head on the
the cy cylilind
nderer clclus
usteterr . . . . . . . EW-
W--2
-2---52
-52
Tightening torque . . . . . . . . . . . . . . . . . . EW--2--14 Valve
Va lve gear . . . . . . . . . . . . . . . . . . . . . . . . . EW--2-
EW--2--53
-53
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--15
Grap
Graphi
hic
c indi
indica cati tion
ons s anand d symb
symbol ols s . . . EW-EW--2
-2---1
-16
6 Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--53
General remarks . . . . . . . . . . . . . . . . . . . EW--2--17 Checking
Check ing the eccent
eccentric ric lift and
F4GE0404B engine . . . . . . . . . . . . . . . . . EW--2--17 the pin alignment . . . . . . . . . . . . . . . . . . . . EW--2--53
General remarks . . . . . . . . . . . . . . . . . . . EW--2--18 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--54
F4GE0454C engine . . . . . . . . . . . . . . . . . EW--2--18 Replacing the bushings . . . . . . . . . . . . . . EW--2--55
General remarks . . . . . . . . . . . . . . . . . . . EW--2--19 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--55
F4GE0484G engine . . . . . . . . . . . . . . . . . EW--2--19 Mounting the tappets – Distributing shaft EW-
EW--2-
-2--55
-55
Description of main mechanic Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--56
engine components . . . . . . . . . . . . . . . . EW--2--20 Measur
Mea suring
ing the jou
journal
rnals s and cra crankpnkpinsins . . EW--2-
EW--2--56
-56
Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--20 Repl
Re plac
acin
ingg the
the oi
oill pump
pump dri drive
ve gears
gears . . . . EW-
EW--2-
-2--59
-59
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--21 Mounting the main bearings . . . . . . . . . . EW--2--59
Connecting rods . . . . . . . . . . . . . . . . . . . . EW--2--22 Measuring
Measu ring the journal assembling
assembling play . EW-
EW--2-
-2--59
-59
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--23 Checking
Checki ng the drive shaft shouldershoulder play . EW--2-
EW--2--60
-60
Distributing shaft . . . . . . . . . . . . . . . . . . . . EW--2--24 Conn
Co nnec
ecti
ting
ng rod-
rod--p -pisisto
tonn as
assesemb mbly ly . . . . . . EW-
EW--2-
-2--61
-61
Valve control . . . . . . . . . . . . . . . . . . . . . . . . EW--2--25 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--62
Cylind
Cylinder
er hea
headd of engine
engine F4GE04F4GE0404B 04B . . EW--2-
EW--2--26
-26 Measu
easuri
ring
ng the
the pipistston
on didiam
amet eter
er . . . . . . . . EW--2-
-2--62
-62
Cylind
Cylinder
er hea
headd of engine
engine F4GE04F4GE0454C 54C . . EW--2-
EW--2--27
-27 Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . EW--2--63
Cylind
Cylinder
er hea
headd of engine
engine F4GE04F4GE0484G 84G . . EW--2-
EW--2--28
-28 Conditions for correct pin/piston
Valves and valve seats . . . . . . . . . . . . . . . EW--2--29 matching . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--63
Valve guides . . . . . . . . . . . . . . . . . . . . . . . . EW--2--30 Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--63

Engine flywheel . . . . . . . . . . . . . . . . . . . . . EW--2--31 C

Buosnhniencgtsin.g. r.o.d. s. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. EW
E W----2
2----6
65
4
Auxiliary component drive . . . . . . . . . . . . EW-
EW--2-
-2--32
-32
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . EW--2--33 Checking the connec nnectting rods . . . . . . . . . EW--2--65
Heat exchanger . . . . . . . . . . . . . . . . . . . . . EW--2--34 Checking the torsion . . . . . . . . . . . . . . . . . EW--2--65
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--35 Checking the flexion . . . . . . . . . . . . . . . . . EW--2--65
Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--36 Mounting the connecting
Oil vapour recirculation . . . . . . . . . . . . . . . EW--2--37 rod--piston assembly . . . . . . . . . . . . . . . . . EW--2--66
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--38 Connecti ting
ng rod--piston match . . . . . . . . . EW--2--66
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW--2--39 Mounting the piston rings . . . . . . . . . . . . . EW--2--66
Mechan
Mec hanicic inject
injection ion feeding
feeding system system . . EW-
EW--2--40
-2--40 Mounting the connecting rod/piston
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--40 as
asse
sembmbli lies
es in thethe cy cyli lind
nder er li line
ners rs . . . . . . . EW
EW---2-
-2--67
-67
Mechanic fuel pump . . . . . . . . . . . . . . . . . EW--2--41 Measuring
Measu ring the crankpin
crankpin assem assembling bling play EW--2-
EW--2--67
-67
Injection assembly . . . . . . . . . . . . . . . . . EW--2--42 Checking piston protrusion . . . . . . . . . . . EW--2--68
Engine bench--overhaul . . . . . . . . . . . . EW--2--43 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--68
Disassembling the engine . . . . . . . . . . . . EW--2--43 Distribution gearbox case . . . . . . . . . . . . EW--2--68
Dismounting front seal ring Valve timing . . . . . . . . . . . . . . . . . . . . . . . . EW--2--69
(dismounting operation to be executed Injection pump – 1st phase . . . . . . . . . . . EW--2--70
with
with en
engigine
ne moun
mounte ted d on ve vehihicl
cle)
e) . . . . . . EW-
EW--2
-2---4
-45
5 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--70
Removi
oving the
the injection pump . . . . . . . . . EW--2--46 Flywheel cover case . . . . . . . . . . . . . . . . . EW--2--70
 Copyright © New Holland

INDEX

Engine flywheel . . . . . . . . . . . . . . . . . . . . EW--2--71 Valve guide . . . . . . . . . . . . . . . . . . . . . . . . EW-

EW--2-
-2--78
-78
Replacing the engine
Replacing engine fflywhe
lywheel el ring
ring gear
gear EW--2-
EW--2--71
-71 Valve seats . . . . . . . . . . . . . . . . . . . . . . . . EW-
EW--2-
-2--78
-78
Flywheel installation . . . . . . . . . . . . . . . . . EW--2--71 Valve seat reconditioning -- replacem replacement ent EW--2-
EW--2--78
-78
Injection pump – 2nd phase . . . . . . . . . . EW--2--72 Valve springs . . . . . . . . . . . . . . . . . . . . . . EW-
EW--2-
-2--80
-80
Mounting the injection pump Mountitin
ng the
the cylinder head . . . . . . . . . EW--2-
-2--80
– 2nd phase . . . . . . . . . . . . . . . . . . . . . . . . EW-
EW--2-
-2--72
-72 Reattaching the cylinder head . . . . . . . . . EW--2--81
Moun
Mo unti
ting
ng the
the oil
oil an
andd wate
waterr pu pump mps s . . . . . EW-
EW--2
-2---7
-73
3 Pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--81
Mounting th
Mounting thee water
water / oil heat exchang exchanger er EW--2-
EW--2--74
-74 Rocker arm assembly . . . . . . . . . . . . . . . . EW--2--82
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . EW--2--75
Mounting the injectors . . . . . . . . . . . . . . . EW--2--83
Removing the valves . . . . . . . . . . . . . . . . EW--2--75
Replacing the injectors . . . . . . . . . . . . . EW--2--85
Checking the cylinder head
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--85
supporting surface . . . . . . . . . . . . . . . . . . . EW--2--76
Checki
Che cking
ng the cylcylind
inder er hea
head d wate
waterr sealseal . EW--2-
EW--2--77
-77 Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2-
EW--2--77
-77 Rocker
Rocker arm rem
remova oval/rl/reass
eassemb emblin ling g .. EW-
EW--2--86
-2--86
Valve
alve descal
descaling
ing,, che
check ck and grindigrinding ng . . . EW-
EW--2-
-2--77
-77 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . EW--2--86
Checking the play between Reassembling . . . . . . . . . . . . . . . . . . . . . . EW--2--86
the valve stem, valve guide and Adjusting the tappets . . . . . . . . . . . . . . EW--2--87
valve centring . . . . . . . . . . . . . . . . . . . . . . . EW--2--78 Chec
Check
k pri
primi
ming
ng of the
the ininje
ject
ctio
ionn pump
pump . . . EW EW---2-
-2--87
-87
 Copyright © New Holland
EW--2--3

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Figure 1 Figure 2

114298

114299
 ENGINE F4GE0404B ENGINE F4GE0454C

Figure 3

114297

ENGINE F4GE0484G
 Copyright © New Holland
EW--2--4

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

CODING OF SOURCE ENGINES

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

Emission level

Approved
Approved rating

Use

Feeding / Injection
D = TIER 2
Cylinder no.

Cylinder pattern:
0 = 4 strokes, vertical

Engine
 Type of crankcase:
crankcase:
B = non--structural 4 = 4--cylinder

Group
Engines

8 = Direct
Direct injection
injection turbo
turbo
diesel with intercooler
intercooler
5 = Direct
Direct injecti
injection
on turbo
turbo
diesel
0 = Aspirate
Aspirated d
4 = Earthmovers

X Y Y Y Y Y Y Y Y

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

Y = Engine model
 Copyright © New Holland
EW--2--5

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

MAIN ENGINES FEATURES

LM1340 Turbo -- LM1343 Turbo

A LM1330 LM1330 Turbo
LM1345 Turbo -- LM1443 Turbo
LM1333 LM1333 Turbo
LM1445 Turbo -- LM1745 Turbo

F4GE0404B F4GE0454C F4GE0484G

B

C *D600

E 4485

60 kW 71 kW 82 kW
F
2200 min--1 2200 min--1 2200 min--1

Net power at flywheel (ISO 14396)

G Direct injection

H Rotary injection
injection pump

N.A. T.C. T.A.A.

I
(Aspirated) (Boosted) (Boosted by intercooler)

A Telescopic Handlers initials

B Type of engine
ng ne mo e
D Number of cylinders
cylinders
E Total displacement
F Max. p
power
ower currently available
available
G Type of injection
H In ectio
ection
n s stem
I Air supply system
 Copyright © New Holland
EW--2--6

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

GENERAL ENGINES FEATURES

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

Cycle 4--stroke diesel engine

supercharged
Feeding aspirated with
--
intercooler
Injection Direct

Number of cylinders 4 in--line

Bore mm 104

Stroke mm 132
Tot
otal
al di
disp
spla
lace
ceme
ment
nt cm3 4485

Compression ratio 17.5 : 1

Max. rating kW 60 71 82
min --1 2200 2200 2200

Max. torque Nm 320 (32) 398 (39.8) 480 (48)

min --1 1400 1400 1400

No---loa
No -load
d id
idle
le rpm
rpm min --1
min --

No--loa
No--load
d pea
peak
k rpm min --1 --

with
BOOSTING -- --
intercooler

Type of turbocompressor: -- HOLSET HX25W

Forced by means of gear pump, pressure
pressure
LUBRICATION
relief valve, oil filter
Oil pressure with hot en-
gine: --
at idle rpm bar
at peak rpm bar --
 Copyright © New Holland
EW--2--7

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

COOLING By fluid
Water pump drive: By means of belt
Thermostat:
Start of opening: °C 81 ± 2
FILLING
Total ca acit
Ambra Mastergold HSP 1st filling: litres --
15W40 kg

-- engine sump litres --

kg

-- engine sump + filter litres --

kg

FEEDING
Bosch--type injection VE4 / 12 F 1100 L 954
Pump setting 0° ± 0.5°

Start of delivery mm 1

DSLA
Type of nozzle DSLA 145 P 1174
145 PV

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

Injection pressure (bar) 260 + 14 245

 Copyright © New Holland
EW--2--8

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

ASSEMBLING PLAY -- SPECIFICATIONS

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Cylinder liners ∅1 104.000 to 104.024

Pistons: supplied with stan-

dard
spares
Measurement dimension
Measurement dimension X 52,4 55.9
103.755 to 103.773 103.714 to 103.732
Outer diameter ∅1
38.010 to 38.016 38.010 to 38.016
Pin seat ∅2

Pisto
ton
n -- cylinder liners 0.227 to 0.2
.26
69 0.268 to 0.3
.31
10

Piston diameter ∅1 0.4

Position of pistons from
0.28 to 0.52
crankcase X

Gudgeon pin ∅3 37.994 to 38.000

Gudgeon pin -- Pin seat 0.010 to 0.022

X1 2.600 to 2.620 2.705 to 2.735*

Piston ring slots X2 2.550 to 2.570 2.440 to 2.460
X3 4.030 to 4.050 4.030 to 4.050
* measure
measured
d on ∅ of 101
mm
S1 2.470 to 2.500 2.602 to 2.606*
Piston rings S2 2.478 to 2.490 2.350 to 2.380
S3 3.970 to 3.990 3.970 to 3.990
* measure
measured d 1,5 mm away
from the external ∅
1 0.100 to 0.175
Pisto
ton
n rings – Slots 2 0.060 to 0.110
3 0.040 to 0.080

Piston rings 0.4

 Copyright © New Holland
EW--2--9

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Piston ring end opening in
cylinder liner:
X1 0.25 to 0.55 0.3 to 0.4
X2 0.30 to 0.55 0.6 to 0.8
X3 0.30 to 0.55 0.3 to 0.55

Connecting rod small--end

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

Connecting rod small--end

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

Connecting rod small--end

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

Measurement
Measurement dimensio
dimension
n X
--

Max. error on connecting

rod axis
--
parallelism =

Journals ∅1 82.99 to 83.01

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

Bed supports no.:

no. 1--5 ∅3 87.982 to 88.008
no. 2--3--4 87.977 to 88.013
 Copyright © New Holland
EW--2--10

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

CRANK GEAR COMPONENTS AND CYLINDER ASSEMBLY mm

Half bearings -- journals:
no. 1--5 0.041 to 0.119
no. 2--3--4 0.041 to 0.103
Half bearings -- crankpins 0.033 to 0.041
Main half bearings
Connecting rod half bea- + 0.250; + 0.500
rings

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 0.095 to 0.265

 Copyright © New Holland
EW--2--11

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

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

0.039 to 0.079
guide

Seat on head for valve

seat: 46.987 to 47.013
∅1
43.637 to 43.663
∅1

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 1.00 to 1.42

X 1.00 to 1.42

Between the valve 0.050 to 0.102

seat and the head
0.050 to 0.102

Valve seats --
 Copyright © New Holland
EW--2--12

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

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. 5 59.222 to 59.248
Distributing shaft seats no.
1--2--3--4 54.089 to 54.139
Distributing shaft suppor
Distributing supportt
pins:
53.995 to 54.045
1⇒5 ∅

Bushing outer diameter for

distributing
distributing shaft: ∅ 59.222 to 59.248
under a load of 3.3 kN

Bushing inner diameter ∅ 54.083 to 54.147

Bushings
crankcaseand seats in 0.113
0.113 to 0.165

Bushings and support pins 0.038 to 0.162

Eccentric working lift:

6.045

7.239
 Copyright © New Holland
EW--2--13

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

F4
F4GE
GE04
0404
04B
B F4
F4GE
GE04
0454
54C
C F4
F4GE
GE04
0484
84G
G
ype
*D600

VALVE GEAR – CYLINDER ASSEMBLY mm

∅1 Seat for tappet

collar
in the crankcase ∅1 16.000 to 16.030

∅2
Outer diameter of tappet
collar:
∅3
∅2 15.929 to 15.959
15.965 to 15.980
∅2 ∅3
Between the tappets and
0.020 to 0.065
the 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
0.025 to 0.063
and the shaft
 Copyright © New Holland
EW--2--14

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

TIGHTENING TORQUE
PART TORQUE
Nm (kgm)
Cylinder
Cylinder head fastening screw 1st phase:
head 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 phase: 90°
3rd phase: (onl
(only
y for
for scre
screws
ws 140
140 and
and 18
180
0 mm lon
long)
g) 90°
Bed
Bed ca
cap
p fast
fasten
enin
ing
g sc
scre
rews
ws 1st phase 50 ± 6 (5 ± 0.6)
2nd phase 80 ± 6 (8 ± 0.6)
3rd phase 90°
Conn
Connec
ectin
ting
g rod
rod cap
cap fas
fasten
tenin
ing
g screw
screwss 1st phase 60 ± 5 (6 ± 0.5)

3rd phase 60° ± 5°

Engine flywheel fastening screws 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

 Copyright © New Holland
EW--2--15

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

TOOLS
380000
380000977
977 Tool for che
checkin
cking
g the top dead
dead cen
centre
tre (to be used
used with 380001
380001005
005))
380000
380000978
978 Rotary
Rotary stan
stand
d for uni
unitt overha
overhaul
ul (cap
(capacity
acity 1000
1000 daN,
daN, torque
torque 120 daN/m)
daN/m)
3800
380000
0097
979
9 Ex
Extra
tracto
ctorr for the ge
gear
ar lin
linki
king
ng the in
inje
jecti
ction
on pu
pump
mp to the en
engi
gine
ne
3800
380000
0098
980
0 Tool
ool for remo
removin
ving
g the drive
drive shaft
shaft front
front ga
gask
sket
et

3800
380000
0098
981
1 Tool
ool for remo
removin
vingg the drive
drive shaft
shaft rear
rear ga
gask
sket
et
3800
380000
0098
982
2 Inje
Inject
ctor
or extr
extrac
acti
ting
ng to
tool
ol
3800
380000
0098
983
3 Coup
Couple
lerr for mou
mounti
nting
ng the drive
drive shaft
shaft front
front ga
gaske
skett
3800
380000
0098
984
4 Coup
Couple
lerr for mou
mounti
nting
ng the drive
drive shaft
shaft rear
rear ga
gaske
skett
3800
380000
0098
985
5 Cart
Cartri
ridg
dge
e fil
filte
terr remo
removi
ving
ng to
tool
ol

380000
380000986
986 Pli
Pliers
ers for remo
removing
ving and reasse
reassembli
mbling
ng the piston
piston rin
rings
gs (65-
(65--1
-110
10 mm)
380000987
380000987 Tool for remo
removing
ving and reasse
reassembli
mbling
ng the engine
engine valves
valves
3800
380000
0098
988
8 Tool
ool for rotat
rotatin
ing
g the en
engi
gine
ne fly
flywh
whee
eell
380000
380000989
989 Joint
Joint for pres
pressur
sure
e con
control
trol in the cylinde
cylinders
rs (us
(use
e with 380001
380001006
006))
3800
380000
0099
990
0 En
Engi
gine
ne fly
flywh
whee
eell retai
retaini
ning
ng tool
tool
3800
380000
0099
991
1 Be
Beate
aterr for remo
removi
ving
ng and
and rea
reass
ssemb
emblin
ling
g the dist
distrib
ributi
uting
ng shaft
shaft bus
bushi
hing
ngs
s (to be
be used
used with
with
380000999)
3800
380000
0099
992
2 Dr
Driv
ive
e sh
shaf
aftt li
lifti
fting
ng to
tool
ol
3800
380000
0099
993
3 Sw
Swin
ing
g bar
bar for en
engi
gine
ne de
detac
tachm
hmen
entt an
and
d re
reatt
attach
achmen
mentt
380000
380000994
994 Band
Band for ins
insertin
erting
g the piston
piston into the cylinde
cylinderr liner
liner (60-
(60--125
-125 mm)
3800
380000
0099
995
5 Bra
Brack
ckets
ets for fas
fasten
tenin
ing
g the en
engi
gine
ne to the rot
rotar
ary
y stand
stand 38
3800
0000
0097
978
8

3800
380000
0099
996
6 Ga
Gask
sket
et extra
extract
ctin
ing
g to
tool
ol
3800
380000
0099
998
8 Man
Manua
uall pu
pump
mp for pres
pressu
sure
re and
and depr
depres
essio
sion
n measu
measurin
ring
g
3800
380000
0099
999
9 Hand
Handle
le for in
inter
terch
chan
ange
geab
able
le beate
beaters
rs
380001
380001000
000 Compar
Comparator
ator hol
holder
der bas
base
e for misc
miscella
ellaneo
neous
us measure
measuremen
ments
ts (to be used
used with 380001
380001004
004))
380001
380001001
001 Set of 2 gau
gauges
ges for ang
angula
ularr tigh
tighteni
tening
ng with 1/2” and 3/4” square
square mount
mount

3800
380001
0100
004
4 Co
Comp
mpar
arat
ator
or (0-
(0--5 mm)
mm)
3800
380001
0100
005
5 Co
Comp
mpar
arat
ator
or (0-
(0--10
-10 mm
mm))
380001
380001006
006 Diesel
Diesel engine
engine cyli
cylinde
nderr compre
compressio
ssion
n con
control
trol device
device
380001
380001084
084 Compar
Comparator
ator hol
holder
der tool for rota
rotary
ry injecti
injection
on pump
pump timing
timing (to be used
used with 380001
380001004
004))
3800
380002
0273
730
0 En
Engi
gine
ne PMS
PMS posi
positi
tion
onin
ing
g to
tool
ol
 Copyright © New Holland
EW--2--16

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

GRAPHIC INDICATIONS AND SYMBOLS

Detachment
Intake
Disconnect

Reattachment
Exhaust
Connect
Removing
Operation
Disassembling

Mounting
ρ Compression ratio
Assembling
Assembl ing

Torque--tighten Tolerance
Weight difference

Torque--tighten + angular value Dragging torque

α

Countersink Rotation
 Adjustmentt
Adjustmen Angle
Setting Angularr value
Angula

Warning
! Preload
Note

Visual check Revs number

Mounting position check

Measurement
Dimension to be measured Temperature
Check

Equipment bar
Pressure

Increase
Surface to be machined
Greater
Grea ter than .....
Machining
Machining finish
Maximum
Decrease
Interference
Smaller than ....
Forced mounting
Minimum

Thickness Selection
Classes
Play
Increases
Lubricate Temperature < 0 ° C
Moisten Cold
Grease Winter
Temperature < 0 ° C

Sealant Hot
Summer

Air bleed
 Copyright © New Holland
EW--2--17

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

GENERAL REMARKS
F4GE0404B ENGINE

Figure 4
 114300

1. Fan pulley -- 2. Water pump -- 3. Fixed guide pulley -- 4. Output shaft pulley --
5. Priming pump -- 6. Fuel filter -- 7. Rotary injection pump -- 8. Blow--by
 Copyright © New Holland
EW--2--18

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

GENERAL REMARKS
F4GE0454C ENGINE

Figure 5
 114301

1. Turbosupercharger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Output shaft pulley --
6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by
 Copyright © New Holland
EW--2--19

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

GENERAL REMARKS
F4GE0484G ENGINE

Figure 6
 114302

1. Turbosupercharger -- 2. Fan pulley -- 3. Water pump -- 4. Fixed guide pulley -- 5. Output shaft pulley --
6. Priming pump -- 7. Fuel filter -- 8. Rotary injection pump -- 9. Blow--by
 Copyright © New Holland
EW--2--20

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

DESCRIPTION OF MAIN MECHANIC

ENGINE COMPONENTS
Crankcase
It consists of a cast--iron structure in which the fol- It alsoincorpora
alsoincorporates
tes the coolan
coolantt circula
circulation
tion chambe
chambers
rs
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 7
86554
 Copyright © New Holland
EW--2--21

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

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

Figure 8
 5

4
86555

1. Oil pump control gear -- 2. Camshaft control gear --

3. Main half bearings --
-- 4. Should
Shoulder
er half bearings -- 5. Engine flywheel
flywheel hub
 Copyright © New Holland
EW--2--22

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Connecting rods
They are steel--stamped, of the oblique cut type,
wi
with
th sepa
separaratio
tion
n of the cap
cap ob
obtai
taine
nedd by an
an ad
adva
vanc
nced
ed
technology (fracture split) instead of mechanic ma-
chining.
The conn
connec
ectin
ting
g rod
rod half
half be
bear
aring
ingss are
are mad
madee of steel
steel,,
with anti--friction alloy coating.

Figure 9
84038
 Copyright © New Holland
EW--2--23

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Pistons
The combustion chamber is found on the piston On piston
piston crown,
crown, follo
followin
wing
g referen
references
ces are engrave
engraved:
d:
crown. The crown is cooled by the engine oil deliv-
ered by the nozzle fitted to the crankcase. 1. Part no., spare no,
no, and design
design modification
modification no.
2. Arrow showing
showing piston assembly
assembly mark
mark into cylin-
Cavities, housing spring rings, are three; 1st cavity: der barrel, it shall be directed towards the front
-- for engine
engine F4GE040
F4GE0404B,
4B, has rectang
rectangula
ularr section
section;; side of the cylinder block.
-- for eng
engine
iness F4GE045
F4GE0454C 4C --
-- F4GE048
F4GE0484G,4G, has 3. Date of
of manufactu
manufacture.
re.
trapezo
trapezoida
idall sec
section
tion and is obtaine
obtained
d thro
through
ugh a
cast iron insert. 4. Marking
Marking showing 1st slot insert testing.
showing

Figure 10
 114303

ENGINE F4GE0404B
F4GE0404B

Figure 11

86549
 ENGINES F4GE0454C -- F4GE0484G

Copyright © New Holland

EW--2--24

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Distributing shaft
The distributing shaft rests on five supports in the A. Intake valve control
crankcase.
B. Exhaust valve control
The supp
support
orts
s (fron
(frontt and
and rear)
rear) are equi
equipp
pped
ed wi
with
th steel
steel
bush
bushinings
gs moun
mountedted in an in inter
terfer
ferin
ing
g manne
mannerr an
and
d The camshaft
camshaft is directly
directly controlled
controlled by the output
coated with anti--friction material; two control eccen- shaft through the gear (C).
trics are provided for each cylinder. Gear (D) transmits motion to the injection pump.

Figure 12
86556
 Copyright © New Holland
EW--2--25

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Valve
Valve control

Figure 13
86557
 1. Rocker arm 2. Arbour support 3. Adjusting screw 4. Rod 5. Lock cones 6. Cup 7. Spring
8. Tappet – 9. Distributing shaft

Copyright © New Holland

EW--2--26

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Cylinder head of engine F4GE0404B

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

Figure 14
 114304

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

 Copyright © New Holland
EW--2--27

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Cylinder head of engine F4GE0454C

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

Figure 15
 86558

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

 Copyright © New Holland
EW--2--28

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Cylinder head of engine F4GE0484G

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

Figure 16
 114305

DETAIL OF CYLINDER HEAD WITH INSERTED VALVE SEATS

 Copyright © New Holland
EW--2--29

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Valves
Valves and valve seats

Figure 17

S
1

A
 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
following inclination:
inclination: that they have only one notch at the stem end.
- 45° (exhaust valves)

- 60° (intake valves).

Figure 18

84242
 Figure 18
Figure 18 shows
shows the oil seals
seals mou
mounted
nted on valve
valve
stems.

Copyright © New Holland

EW--2--30

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Valve
Valve guides

Figure 19
INTAKE EXHAUST
84046

DETAIL OF VALVE GUIDES AND SEATS

 Copyright © New Holland
EW--2--31

ENGINES F4GE0404B -- 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 20
114306
 Copyright © New Holland
EW--2--32

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Auxiliary component drive

A Poly--V
Poly--V belt (4) transmits the motion of drive shaft Beltt is tension
Bel tensioned
ed by manual
manually
ly adjuste
adjusted
d belt
belt tension
tensioner
er
(5) to water pump (1), alternator (2) and fan (6). (3).

Figure 21
 114307

1. Water pump -- 2. Alternator -- 3. Manual belt tensioner -- 4. Poly--V belt -- 5. Drive shaft -- 6. Fan pulley
 Copyright © New Holland
EW--2--33

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

LUBRICATION
Forced circula
Forced circulation
tionlub
lubrica
rication
tion is performe
performedd by the fol- - oil pressure regulating valve embodied in ex-
lowing components: changer assembly;
- oil
oil pu
pump
mp hous
houseded in the cran
crankc
kcas
asee front
front pa
part,
rt, con-
con-
- by-
by--pass
-pass valv
valve,
e, to cut
cut ou
outt cl
clog
ogge
ged
d oil
oil filter
filter,, embo
embo--
trolled by the straight--tooth gear force--fitted on
died in exchanger
exchanger assembly;
the drive shaft shank;
- water / oil cooler,
cooler, housed in cylinder block; - cartridge oil
oil filter.

Figure 22
 Pressure
Pressure oil pat
path
h

Oil return
drop--type path

Oil supply

112885

LUBRICATION SYSTEM LAYOUT

1. Lubrication oil pipe to4.supercharger -- 2. Heat

Oil rotary expansion exchanger
pump -- 5. Oilbody
filter-- 3. Heat exchanger --
 A. Only engines F4GE0454C ---- F4GE0484
F4GE0484G
G

Copyright © New Holland

EW--2--34

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Heat exchanger
Figure 23
 84051

1. Heat exchanger
exchanger body – 2. Inner
I nner gasket
gasket – 3. Water
Water / oil heat exchan
exchanger
ger -- 4. Gasket between ex-
changer unit and engine block – 5. Oil return to filter – 6. Oil inflow from filter

Oil pressure regulation valve By--pass valve

Figure 24 Figure 25

107419 70482

PRINCIPAL DATA FOR OIL PRESSURE Blow--by max:

REGULATION VALVE SPRING CHECKING 20 cm3/l’ with 0.83 bar pressure and 26.7 _
_CC oil
temperature.
Pressure regulating calibration at 100_
ature 100_C oil temper-
-- mini
minimum
mum spee
speed
d 1.2 bar;
bar;
-- maximum speed 3.8 bar.
bar.

Copyright © New Holland

EW--2--35

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Oil pump

Figure 26
 84052

Figure 27

70150
 1. Drive shaft with oil pump drive gear

Copyright © New Holland

EW--2--36

ENGINES F4GE0404B -- F4GE0454C -- F4GE0484G OVERHAUL

Oil sump
The steel oil sump (1) is flexibly secured to the en-
gine block by an aluminium plate (3), Figure 29.
The C--section rubber gasket (2), fitted onto the oil
sump leading profile, enhances sealing properties
and also deaden noise.
This type of gasket can only be replaced in case of
deterioration or break, and not necessarily at every
single disassembling operation.

Figure 28
 84245

Figure 29

84246