ENGINESNEF SERVICEMANUAL Issued12-2009 84250518 Tier3 F4CE9484,F4CE9684, F4DE9484,F4DE9684, F4DE9687,F4GE9484, F4GE9684,F4HE9484, F4HE9684
Contents INTRODUCTION DISTRIBUTIONSYSTEMS.............................................................A POWERPRODUCTION.................................................................B ENGINE...................................................................................B.10.A FUELANDINJECTIONSYSTEM.........................................................B.20.A AIRINTAKESYSTEM.....................................................................B.30.A EXHAUSTSYSTEM.......................................................................B.40.A ENGINECOOLANTSYSTEM............................................................B.50.A LUBRICATIONSYSTEM..................................................................B.60.A STARTINGSYSTEM......................................................................B.80.A 8425051809/11/2009
INTRODUCTION 8425051809/11/2009 1
Thanks very much for your reading, Want to get more information,
Please click here, Then get the complete manual
NOTE:
If there is no response to click on the link above, please download the PDF document first, and then click on it.
Have any questions please write to me: admin@servicemanualperfect.com
Contents INTRODUCTION Foreword........................................................................................3 Safetyrules.....................................................................................4 Torque..........................................................................................6 Torque..........................................................................................9 Specialtools..................................................................................18 8425051809/11/2009 2
Foreword EngineOverhaul
NOTE:
Partoftheoperationsillustratedwithinthismanualcanbepartiallyexecutedwhiletheengineisassembledonthe vehicle,dependingontheroomavailableforaccesstotheengineandontheequipmentapplicationaswell.
Thefollowinginformationrelatestotheengineoverhauloperationsonlyforwhatconcernsthedifferentcomponents customizingtheengine,accordingtoitsspecificduties. Insection"GeneralOverhaul",alltheoperationsofengineblockoverhaulhavebeencontemplated.Thereforethe
8425051809/11/2009
INTRODUCTION
3
Safetyrules
Standardsafetyprescriptions
Particularattentionshallbedrawnonsomeprecautionsthatmustbefollowedabsolutelyinastandardworking areaandwhosenonfulfillmentwillmakeanyothermeasureuselessornotsufficienttoensuresafetytothe availableforconsultation. •
•
Preventionofinjury
• Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
••
• lubricationoiltoppingorreplacement
• utilizationofcompressedairorliquidsunderpressure(pressureallowed< 2bar ( 29psi
•
• Inpresenceofelectricalcurrentexceeding outworkingoperationsifnottrainedfor.
•
• Putthedirtyragswithoil,dieselfuelorsolventsinanti-firespeciallyprovidedcontainers.
•
• • utilizespecificvacuumequipmenttoeliminateexhaustgas.Danger:poisoningordeath.
Duringmaintenance
• 50°C ( 122°F
• Nevertopupanoverheatedenginewithcoolerandutilizeonlyappropriateliquids.
• Alwaysoperatewhentheengineistunedoff;whenparticularcircumstancesrequiremaintenanceinterventionon
• 8425051809/11/2009
INTRODUCTION
• Ensurethatworkingareasareprovidedwithemergencyboxes,thatmustbeclearlyvisibleandalwaysprovided
• • indicationsoftheemergencyindicationsoftheemergencyexitlines. • •
• • •
4
8425051809/11/2009
Torque Component Size Specification CylinderHeadandComponents Plug ( ) ( ) 31-41Nm ( ) GridHeater M6Nut 6-10Nm ( ) IntakeManifold M8Screw ( ) EngineLiftingBracket Rear M12 65-89Nm ( ) Front 20-28Nm ( ) CylinderHead M12x1.75x130mm FirstPhase 30-40Nm ( ) SecondPhase ThirdPhase CylinderHead FirstPhase ( ) SecondPhase ThirdPhase RockerBracket 31-41Nm ( ) RockerArmJamNuts 20-28Nm ( ) ExhaustManifold ( ) ValveCover M8Nut ( ) Turbocharger 6Cylinder M8Screw 6-8Nm ( ) M8Nut 37-49Nm ( ) 4Cylinder M8Screw ( ) M8Nut 20-28Nm ( ) FrontCase FrontCover M8Screw 20-28Nm ( ) RearCase GearCase M12Screw 65-89Nm ( ) M10Screw ( ) M8Screw 20-28Nm ( ) FlywheelHousing M10 75-95Nm ( ) M12 44-54Nm ( ) CylinderBlockandCrankshaftComponents
INTRODUCTION
6
Component Size Specification CamshaftRetainingPlate M8Screw 20-28Nm ( ) CamshaftGear M8Screw ( ) CrankcasePlate M10Screw 38-48Nm ( ) VibrationDamperandAdapter M12 FirstPhase 45-55Nm ( ) SecondPhase 90° DrivePulley M10 61-75Nm ( ) EngineFlywheel M12 FirstPhase ( ) SecondPhase MainCaps M12 FirstPhase ( ) SecondPhase ( ) ThirdPhase ConnectingRodCaps FirstPhase 55-65Nm ( ) SecondPhase LubricationSystemandComponents OilPump FirstPhase ( ) SecondPhase 20-28Nm ( ) OilPressureReliefValve M22 72-88Nm ( ) OilCoolerandOilFilterBase M8Screw ( ) OilFilter Contact+¾Turn ConnectiononFilterBaseforTurboOil Supply 1⅛" 20-28Nm ( ) TurboLubricationPipe M12Nut 8-12Nm ( ) TurboLubricationPipeAdapter M12 ( ) OilPan ( ) PistonSprayNozzles M8 12-18Nm ( ) ElectricalComponents CamshaftSensor M6Studs 6-10Nm ( ) M6Nut ( ) M6Screw ( ) WiringBulkhead M6Screw 8-12Nm ( ) SupportBracketforInjectorWiringM8Screw 20-28Nm ( ) InjectorWiring ( ) ECUCoolingPlate M6Screw 8-12Nm ( ) M8Screw 20-28Nm ( ) FuelOutlet M12 10-14Nm ( ) FuelInlet M12 ( ) CrankshaftSpeedSensor M6Screw 6-10Nm ( ) CoolantTemperatureSensor M14Screw 17-23Nm ( ) OilPressure/TemperatureSensorM5Screw 5-7Nm ( ) FuelPressureSensor ( ) FuelTemperatureSensor M14 17-23Nm ( ) AirPressure/TemperatureSensor 5-7Nm ( ) EngineOilLevelSensor M12 ( ) AlternatorSupportBracket M10Screw ( ) AlternatorTensionBracket M10Screw 37-49Nm ( ) Starter 37-49Nm ( ) 8425051809/11/2009 7
INTRODUCTION
Component Size Specification FuelSystemandComponents FeedPump M8Studs 10-14Nm ( ) HighPressurePumpGear M18Nut ( ) FuelPump M8Nut 20-28Nm ( ) Injector FirstPhase M6Screw ( ) SecondPhase M6Screw InjectorFeedConnector 45-55Nm ( ) CommonRail M8Screw 20-28Nm ( ) HighPressureFuelLine M14Fitting ( ) HighPressurePipeConnector M8Screw 20-28Nm ( ) FuelFilterBracket M12Screw 71-85Nm ( ) FuelFilterHolder M8Screw ( ) FuelFilter Contact+¾Turn CoolingSystemandComponents EngineCoolantInlet M10Screw 37-49Nm ( ) FittingonCoolantInlet 90° Elbow 20-28Nm ( ) CompressorCoolingPipe ( ) EngineCoolantDrainCollector M6Screw 8-12Nm ( ) WaterPump M8Screw 20-28Nm ( ) BeltTensioner M10 ( ) IdlerPulleys M10 37-49Nm ( ) 8425051809/11/2009 8
INTRODUCTION
INTRODUCTION
Component Size Specification CylinderHeadandComponents RockerAssembly M8 ( ) CylinderHead M12x70 Phase1 50Nm ( 36.9lbft ) Phase2 90° CylinderHead M12x140 Phase1 40Nm ( ) Phase2 180° CylinderHead M12x180 Phase1 70Nm ( ) Phase2 180° ValveCover 20-28Nm ( ) Intakemanifold 20-28Nm ( ) Airintakeelbow ( ) Exhaustmanifold 37-49Nm ( ) Rearliftingbracket 65-89Nm ( ) Turbocharger M10 37-49Nm ( ) FrontCase Frontcoverassembly ( ) 20-28Nm ( ) RearCase GearCase 20-28Nm ( ) 20-28Nm ( ) ( ) Flywheelhousing M12x120 75-95Nm ( ) M12x80 75-95Nm ( ) M10x80 44-54Nm ( ) M10x40 ( ) Phase1 26-34Nm ( ) Phase2 CylinderBlockandCrankshaftComponents Mainbearingcap Phase1 ( ) Phase2 74-86Nm ( ) Phase3 Connectingrod Phase1 27-33Nm ( ) Phase2 55-65Nm ( ) Phase3 TimingPin 4-6Nm ( ) Crankshaftpulley ( ) Camshaftretainingplate M8 ( ) Camshaftgear M8 32-40Nm ( ) LubricationSystemandComponents 8425051809/11/2009 9
Torque
Component Size Specification PistonCoolingNozzles 12-18Nm ( ) Oilpump M8x1.25x30 ( ) StiffeningPlate 38-48Nm ( ) Oilplug M10x1 5-7Nm ( ) ( ) OilPickuptube M8x1.25x20 20-28Nm ( ) OilPan 20-28Nm ( ) 51-69Nm ( ) OilBypassValve ( ) TurboLubricationLines Turboend 20-28Nm ( ) Filterbaseend ( ) Drain 20-28Nm ( ) ElectricalComponents Alternator 20-28Nm ( ) M10x1.25x25 ( ) M10 44-54Nm ( ) 37-49Nm ( ) Alternatorwiring ( ) Starter M10 ( ) FuelSystemandComponents Fuelpump M8screw 20-28Nm ( ) M6screw 9-11Nm ( ) M6nut ( ) FuelPumpDriveGear Phase1 15-20Nm ( ) Phase2 85-90Nm ( ) TimingPinCap 30-35Nm ( ) Fuelinjectors ( ) Fuelliftpump 20-28Nm ( ) CoolingSystemandComponents WaterPump 20-28Nm ( ) Wateroutletconnection 20-28Nm ( ) M8x1.25x70 ( ) Fansupport 28-38Nm ( ) Fanpulley 8-12Nm ( ) M10 27-49Nm ( ) 8425051809/11/2009
INTRODUCTION
INTRODUCTION
ToolNo. Description Image 380000301 Revolvingenginestand REVOLVINGSTAND 1 380000665 Crankshaftfrontsealpuller FRONTSEALPULLER 2 380000663 Crankshaftrearsealpuller REARSEALPULLER 3 8425051809/11/2009 11
Specialtools
INTRODUCTION ToolNo. Description Image 380001099 Injectorpuller INJECTORPULLER 4 380000666 Crankshaftfrontseal
FRONTSEALINSTAL 5 380000664
CRANKREARSEALIN 6 8425051809/11/2009
installer
Crankshaftrearseal installer
INTRODUCTION ToolNo. Description Image 380000670 Oilfilterwrench OILFILTERWRENCH 7 380000302 Valvespringcompressor VALVESPRINGCOMP 8 380000221 Pliersforremoving/refitting pistonrings 65-110mm ( ) PISTONRINGPLIER 9 8425051809/11/2009
Beaterforremoving/refitting camshaftbushes
CAMBUSHBEATER 380000362
Toolforliftingthecrankshaft
CRANKHOIST 11
380000216
Engineliftingrig
8425051809/11/2009
ENGINEHOIST
INTRODUCTION ToolNo. Description Image 380000667
380000669
Bracketsforfasteningthe enginetotherevolving
380000668
Sealremover
SEALREMOVER
Handgripfor interchangeablebeaters HANDGRIP
380000364
Gaugebasefordialindicator
INTRODUCTION ToolNo. Description Image
380000661
stand
STANDBRACKETS
8425051809/11/2009
GAUGEBASE
INTRODUCTION ToolNo. Description Image N/A Torquewrench TORQUEWRENCH 380000158 Torquescrewdriver TORQUESCREWDRIV 380000304 Toolforangletightening ANGLETIGHTENING 380000988 Flywheelrotationtool ROTATOR 8425051809/11/2009
INTRODUCTION ToolNo. Description Image Pistonringcompressor PISTONRINGCOMP
0-5mm ( DIALINDICATOR
Dialindicator(
8425051809/11/2009
INTRODUCTION
ToolNo. Description Image 380000979 Injectionpumpgearpuller PUMPGEARPULLER 1 380000665 Crankshaftfrontsealpuller FRONTSEALPULLER 2 380000663 Crankshaftrearsealpuller REARSEALPULLER 3 8425051809/11/2009
Specialtools