New Holland F4CE9484 - F4HE9687 NEF Tier 3 Service Manual Engine by www.heydownloads.com

SERVICE MANUAL F4CE9484 / F4CE9487A / F4CE9487N / F4CE9684 / F4DE9484 / F4DE9684B*J111 / F4DE9684M*J101 / F4DE9684M*J103 / F4DE9684 / F4DE9687 / F4GE9484C*J601 / F4GE9484 / F4GE9684 / F4HE0484G*J102 / F4HE0484G*J109 / F4HE9484C*J102 / F4HE9484C*J103 / F4HE9484 / F4HE9684 / F4HE9687G*J100 / F4HE9687 NEF Tier 3 Engine

Part number 47597675 1st edition English October 2013 Printed in U.S.A. Copyright © 2013 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

Mechanical fuel injection / Structural engine block F4CE9454H*J601 F4CE9454H*J605 F4CE9484A*J600 F4CE9484A*J602 F4CE9484C*J600 F4CE9484C*J601 F4CE9484G*J600 F4CE9484G*J604 F4CE9484G*J607 F4CE9484G*J608

F4CE9484J*J602 F4CE9484J*J604 F4CE9484L*J600 F4CE9484L*J602 F4CE9484L*J603 F4CE9484L*J604 F4CE9484L*J605 F4CE9484L*J606 F4CE9484M*J601 F4CE9484M*J602

F4CE9484M*J603 F4CE9484M*J606 F4CE9484M*J607 F4CE9484M*J608 F4CE9484N*J601 F4CE9484N*J604 F4CE9487A*J600 F4CE9487A*J601 F4CE9487M*J602 F4CE9487M*J603

F4CE9487M*J605 F4CE9487N*J601 F4CE9487N*J602 F4CE9487N*J603 F4CE9487N*J605 F4CE9487N*J606 F4CE9684B*J600 F4CE9684C*J600 F4CE9684H*J603 F4CE9684H*J604

F4CE9684J*J601 F4CE9684J*J606 F4CE9684J*J607 F4CE9684J*J609 F4CE9684K*J601 F4CE9684K*J606 F4CE9684K*J607 F4CE9684K*J608 F4CE9684L*J600 F4CE9684L*J605

F4GE9684C*J602 F4GE9684D*J600 F4GE9684D*J603 F4GE9684D*J604 F4GE9684E*J600 F4GE9684E*J601 F4GE9684E*J603 F4GE9684E*J604 F4GE9684E*J605 F4GE9684E*J606 F4GE9684E*J607 F4GE9684E*J610 F4GE9684E*J611 F4GE9684E*J612 F4GE9684E*J613 F4GE9684E*J615 F4GE9684F*J600 F4GE9684F*J602 F4GE9684F*J603

F4GE9684F*J604 F4GE9684G*J600 F4GE9684G*J601 F4GE9684G*J602 F4GE9684G*J603 F4GE9684G*J605 F4GE9684G*J606 F4GE9684H*J600 F4GE9684H*J601 F4GE9684R*J600 F4GE9684R*J601 F4GE9684R*J602 F4GE9684R*J603 F4GE9684R*J605 F4GE9684R*J606

Mechanical fuel injection / Non-structural engine block F4GE9454C*J601 F4GE9454C*J602 F4GE9454C*J607 F4GE9454C*J608 F4GE9454J*J605 F4GE9454J*J607 F4GE9454K*J602 F4GE9454K*J604 F4GE9454K*J605 F4GE9484A*J602 F4GE9484A*J605 F4GE9484A*J607 F4GE9484A*J608 F4GE9484A*J610 F4GE9484A*J611 F4GE9484A*J612 F4GE9484C*J600 F4GE9484C*J601 F4GE9484C*J602

F4GE9484C*J603 F4GE9484C*J605 F4GE9484C*J606 F4GE9484C*J607 F4GE9484D*J600 F4GE9484D*J603 F4GE9484D*J606 F4GE9484D*J607 F4GE9484D*J617 F4GE9484D*J618 F4GE9484D*J619 F4GE9484D*J620 F4GE9484E*J600 F4GE9484E*J601 F4GE9484E*J602 F4GE9484E*J603 F4GE9484F*J600 F4GE9484F*J610 F4GE9484F*J614

F4GE9484F*J615 F4GE9484H*J600 F4GE9484J*J600 F4GE9484J*J601 F4GE9484J*J603 F4GE9484J*J604 F4GE9484J*J605 F4GE9484P*J600 F4GE9484P*J601 F4GE9684A*J603 F4GE9684A*J605 F4GE9684B*J601 F4GE9684B*J602 F4GE9684B*J604 F4GE9684B*J605 F4GE9684B*J606 F4GE9684B*J607 F4GE9684C*J600 F4GE9684C*J601

Electronic fuel injection / Structural engine block F4DE0484B*J100 F4DE0484C*J100 F4DE9484A*J100 F4DE9484A*J103 F4DE9484A*J104 F4DE9484B*J101 F4DE9484D*J101 F4DE9484E*J100 F4DE9484F*J100 F4DE9484F*J101 F4DE9484G*J100 F4DE9484H*J100 F4DE9487A*J103 F4DE9487A*J104 F4DE9487B*J100 F4DE9487B*J101 F4DE9487C*J100 F4DE9487D*J101 F4DE9487L*J100

F4DE9684B*J100 F4DE9684B*J101 F4DE9684B*J102 F4DE9684B*J104 F4DE9684B*J106 F4DE9684B*J107 F4DE9684B*J108 F4DE9684B*J109 F4DE9684B*J110 F4DE9684B*J111 F4DE9684C*J100 F4DE9684D*J100 F4DE9684E*J100 F4DE9684F*J100 F4DE9684F*J102 F4DE9684G*J100 F4DE9684G*J101 F4DE9684H*J100 F4DE9684J*J100

F4DE9684J*J101 F4DE9684J*J102 F4DE9684J*J104 F4DE9684J*J105 F4DE9684L*J100 F4DE9684L*J103 F4DE9684L*J106 F4DE9684L*J107 F4DE9684L*J108 F4DE9684L*J109 F4DE9684M*J100 F4DE9684M*J101 F4DE9684M*J103 F4DE9684N*J100 F4DE9684N*J104 F4DE9684N*J107 F4DE9684N*J108 F4DE9684R*J100 F4DE9684R*J102

F4DE9684R*J103 F4DE9684R*J104 F4DE9684R*J105 F4DE9684S*J100 F4DE9684S*J103 F4DE9684S*J106 F4DE9684S*J107 F4DE9684U*J100 F4DE9684Y*J100 F4DE9684Y*J101 F4DE9684Y*J102 F4DE9684Z*J102 F4DE9687A*J100 F4DE9687A*J103 F4DE9687A*J104 F4DE9687C*J100 F4DE9687J*J100 F4DE9687J*J101 F4DE9687J*J102

F4DE9687J*J104 F4DE9687R*J101 F4DE9687U*J100 F4DE9687U*J102 F4DE9687V*J100 F4DE9687V*J101 F4DE9687V*J104 F4DE9687X*J100 F4DE9687X*J101 F4DE9687X*J102 F4DE9687X*J103 F4DE9687X*J104 F4DE9687X*J105 F4DE9687X*J106 F4DE9687Y*J100 F4DE9687Y*J101 F4DE9687Y*J102

F4HE9684S*J102 F4HE9684S*J103 F4HE9684T*J100 F4HE9684T*J101 F4HE9684U*J101 F4HE9684U*J103 F4HE9684V*J102 F4HE9684V*J103 F4HE9687C*J100 F4HE9687C*J101 F4HE9687C*J103 F4HE9687F*J100 F4HE9687F*J101 F4HE9687G*J100 F4HE9687G*J101 F4HE9687G*J102 F4HE9687G*J104 F4HE9687H*J100 F4HE9687H*J101 F4HE9687H*J102 F4HE9687H*J103 F4HE9687K*J100 F4HE9687K*J101 F4HE9687K*J102 F4HE9687K*J103 F4HE9687K*J105

F4HE9687L*J100 F4HE9687L*J101 F4HE9687M*J101 F4HE9687M*J103 F4HE9687M*J104 F4HE9687M*J105 F4HE9687N*J101 F4HE9687N*J103 F4HE9687N*J104 F4HE9687P*J101 F4HE9687Q*J101 F4HE9687Q*J103 F4HE9687S*J101 F4HE9687S*J103 F4HE9687S*J104 F4HE9687S*J105 F4HE9687T*J101 F4HE9687T*J103 F4HE9687T*J104 F4HE9687W*J100 F4HE9687W*J101 F4HE9687W*J102 F4HE9687Z*J100 F4HE9687Z*J101

Electronic fuel injection / Non-structural engine block F4HE0454D*J102 F4HE0454D*J104 F4HE0484A*J101 F4HE0484A*J103 F4HE0484G*J100 F4HE0484G*J101 F4HE0484G*J102 F4HE0484G*J103 F4HE0484G*J105 F4HE0484G*J106 F4HE0484G*J108 F4HE0484G*J109 F4HE0484G*J110 F4HE0684T*J100 F4HE0684T*J101 F4HE0684T*J103 F4HE9484C*J100 F4HE9484C*J102 F4HE9484C*J103 F4HE9484C*J104 F4HE9484C*J105 F4HE9484C*J106 F4HE9484C*J107 F4HE9484C*J108 F4HE9484F*J103 F4HE9484F*J104

F4HE9484F*J105 F4HE9484F*J106 F4HE9484M*J100 F4HE9484M*J101 F4HE9684B*J100 F4HE9684B*J101 F4HE9684B*J103 F4HE9684B*J104 F4HE9684C*J100 F4HE9684C*J101 F4HE9684C*J102 F4HE9684C*J104 F4HE9684C*J105 F4HE9684C*J106 F4HE9684D*J100 F4HE9684D*J101 F4HE9684D*J102 F4HE9684D*J103 F4HE9684D*J105 F4HE9684D*J106 F4HE9684D*J107 F4HE9684D*J109 F4HE9684E*J100 F4HE9684E*J101 F4HE9684E*J102 F4HE9684E*J103

F4HE9684E*J104 F4HE9684E*J106 F4HE9684E*J107 F4HE9684F*J100 F4HE9684F*J102 F4HE9684F*J103 F4HE9684F*J104 F4HE9684F*J105 F4HE9684F*J107 F4HE9684F*J108 F4HE9684F*J109 F4HE9684J*J100 F4HE9684J*J101 F4HE9684J*J102 F4HE9684J*J104 F4HE9684J*J106 F4HE9684K*J100 F4HE9684K*J102 F4HE9684L*J101 F4HE9684L*J102 F4HE9684M*J100 F4HE9684M*J101 F4HE9684P*J102 F4HE9684P*J103 F4HE9684S*J100 F4HE9684S*J101

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

Electrical systems ....................................................................... 55 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 47597675 27/09/2013

[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

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Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Foreword Engine Overhaul Part of the operations illustrated within this manual can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well. NOTE: With regard to the engine disassembly operations, please apply for information consulting the specific manual. The following information relates to the engine overhaul operations only for what concerns the different components customizing the engine, according to its specific duties. In section "General Overhaul", all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.

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INTRODUCTION

Safety rules Standard safety prescriptions Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in charge of maintenance. Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation. • Keep working areas as clean as possible, ensuring adequate aeration. • Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. • Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on a regular basis and the personnel must be trained on interventon methods and priorities. • Organize and identify specific exit points to evacuate the areas in case of an emergency, providing for adequate indications of the emergency indications of the emergency exit lines. • Smoking in working areas subject to fire danger must be strictly prohibited. • Provide warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of an emergency.

Prevention of injury • Do not wear unsuitable clothes for work, with fluttering ends, nor jewels such as and chains when working close to engines and equipment in motion. • Wear safety gloves and goggles when performing the following operations: • • filling inhibitors or anti-frost • lubrication oil topping or replacement • utilization of compressed air or liquids under pressure (pressure allowed < 2 bar (29 psi)). • Wear safety helmet when working close to hanging loads or equipment working at head height level. • Always wear safety shoes and clothes adhering to the body, better if provided with elastics at the ends. • Use protection cream for hands. • Change wet clothes as soon as possible. • In presence of electrical current exceeding 48 - 60 V verify efficiency of earth and mass electrical connections. Ensure that hands and feet are dry and execute working operations utilizing isolating foot boards. Do not carry out working operations if not trained for. • Do not smoke nor light up flames close to batteries and to any fuel material. • Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers. • Do not execute any intervention if not provided with necessary instructions. • Do not use any tool or equipment for any different operation from the ones they've been designed and provided for. Serious injury may occur. • In case of test or calibration operations requiring engine running, ensure that the area is sufficiently ventilated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning or death.

During maintenance • Never open filler cap of cooling system when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F). • Never top up an overheated engine with cooler and utilize only appropriate liquids. • Always operate when the engine is tuned off; when particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. • Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil. 47597675 27/09/2013

INTRODUCTION

• Keep the engine clean from oil spills, diesel fuel and or chemical solvents. • Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas ventilated. Whenever necessary wear safety mask. • Do not leave rags impregnated with flammable substances close to the engine. • Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of a runaway speed rate. • Do not utilize fast screw tightening tools. • Never disconnect batteries when the engine is running. • Disconnect batteries before any intervention on the electrical system. • Disconnect batteries from system before applying a load to them with the battery loader. • After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. • Do not disconnect and connect electrical connections in presence of electrical feed. • Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these precautions may cause serious injury and poisoning. • Avoid incorrect tightening or out of sequence. Danger: incorrect tightening may seriously damage engine's components, affecting engine's duration. • Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. • Do not modify cable wires: their lengths shall not be changed. • Do not connect to the engine electrical equipment unless specifically approved by Iveco. • Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic controller: • Do not execute electric arc welding without having previously removed electronic controller. • Remove electronic controller in case of any intervention requiring heating over 80 °C (176 °F) temperature. • Do not paint the components and the electronic connections. • Do not vary or alter any data filed in the electronic controller driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.

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

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Torque F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Component Cylinder Head and Components Plug

Grid Heater Intake Manifold Engine Lifting Bracket Rear Front Cylinder Head First Phase Second Phase Third Phase Cylinder Head First Phase Second Phase Third Phase Rocker Bracket Rocker Arm Jam Nuts Exhaust Manifold Valve Cover Turbocharger 6 Cylinder 4 Cylinder

Size

Specification

¼" ½" ¾" M6 Nut M8 Screw

10 - 14 Nm (7.4 - 10.3 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 31 - 41 Nm (22.9 - 30.2 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M12 M8 M12x1.75x130 mm

65 - 89 Nm (47.9 - 65.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 85 - 95 ° 85 - 95 °

M12x1.75x150 mm

M8 Nut

50 - 60 Nm (36.9 - 44.3 lb ft) 85 - 95 ° 85 - 95 ° 31 - 41 Nm (22.9 - 30.2 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 48 - 58 Nm (35.4 - 42.8 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 M8 M8 M8

Screw Nut Screw Nut

6 - 8 Nm (4.4 - 5.9 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 6 - 8 Nm (4.4 - 5.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 Screw

20 - 28 Nm (14.8 - 20.7 lb ft)

M12 Screw M10 Screw M8 Screw M10 M12

65 - 89 Nm (47.9 - 65.6 lb ft) 42 - 52 Nm (31.0 - 38.4 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 75 - 95 Nm (55.3 - 70.1 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft)

Front Case Front Cover

Rear Case Gear Case

Flywheel Housing

Cylinder Block and Crankshaft Components

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INTRODUCTION

Component Camshaft Retaining Plate Camshaft Gear Crankcase Plate Vibration Damper and Adapter First Phase Second Phase Drive Pulley Engine Flywheel First Phase Second Phase Main Caps First Phase Second Phase Third Phase Connecting Rod Caps First Phase Second Phase

Size

Specification 20 - 28 Nm (14.8 - 20.7 lb ft) 32 - 40 Nm (23.6 - 29.5 lb ft) 38 - 48 Nm (28.0 - 35.4 lb ft)

M8 Screw M8 Screw M10 Screw M12

45 - 55 Nm (33.2 - 40.6 lb ft) 90 ° 61 - 75 Nm (45.0 - 55.3 lb ft)

M10 M12

26 - 34 Nm (19.2 - 25.1 lb ft) 55 - 65 ° M12 44 - 56 Nm (32.5 - 41.3 lb ft) 74 - 86 Nm (54.6 - 63.4 lb ft) 85 - 95 ° 55 - 65 Nm (40.6 - 47.9 lb ft) 55 - 65 °

Lubrication System and Components Oil Pump First Phase Second Phase Oil Pressure Relief Valve Oil Cooler and Oil Filter Base Oil Filter Connection on Filter Base for Turbo Oil Supply Turbo Lubrication Pipe Turbo Lubrication Pipe Adapter Oil Pan Piston Spray Nozzles

7 - 9 Nm (5.2 - 6.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 72 - 88 Nm (53.1 - 64.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) Contact + ¾ Turn 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 M8 M22 M8 Screw 1 ⅛"

8 - 12 Nm (5.9 - 8.9 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 12 - 18 Nm (8.9 - 13.3 lb ft)

M12 Nut M12 M8

Electrical Components Camshaft Sensor

Wiring Bulkhead Support Bracket for Injector Wiring Injector Wiring ECU Cooling Plate Fuel Outlet Fuel Inlet Crankshaft Speed Sensor Coolant Temperature Sensor Oil Pressure / Temperature Sensor Fuel Pressure Sensor Fuel Temperature Sensor Air Pressure / Temperature Sensor Engine Oil Level Sensor Alternator Support Bracket Alternator Tension Bracket Starter

M6 M6 M6 M6 M8

6 - 10 Nm (4.4 - 7.4 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 1.25 - 1.75 Nm (0.92 - 1.29 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 6 - 10 Nm (4.4 - 7.4 lb ft) 17 - 23 Nm (12.5 - 17.0 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 30 - 40 Nm (22.1 - 29.5 lb ft) 17 - 23 Nm (12.5 - 17.0 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 10 - 14 Nm (7.4 - 10.3 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

Studs Nut Screw Screw Screw

M6 Screw M8 Screw M12 M12 M6 Screw M14 Screw M5 Screw M14 M12 M10 Screw M10 Screw

Fuel System and Components

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INTRODUCTION

Component Feed Pump High Pressure Pump Gear Fuel Pump Injector First Phase Second Phase Injector Feed Connector Common Rail High Pressure Fuel Line High Pressure Pipe Connector Fuel Filter Bracket Fuel Filter Holder Fuel Filter

Size

Specification

M8 Studs M18 Nut M8 Nut

10 - 14 Nm (7.4 - 10.3 lb ft) 100 - 110 Nm (73.8 - 81.1 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M6 Screw M6 Screw

8.15 - 8.85 Nm (6.0 - 6.5 lb ft) 70 - 80 ° 45 - 55 Nm (33.2 - 40.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 18 - 22 Nm (13.3 - 16.2 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 71 - 85 Nm (52.4 - 62.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) Contact + ¾ Turn

M8 Screw M14 Fitting M8 Screw M12 Screw M8 Screw

Cooling System and Components Engine Coolant Inlet Fitting on Coolant Inlet Compressor Cooling Pipe Engine Coolant Drain Collector Water Pump Belt Tensioner Idler Pulleys

37 - 49 Nm (27.3 - 36.1 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 24 Nm (14.8 - 17.7 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

M10 Screw 90 ° Elbow M6 Screw M8 Screw M10 M10

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INTRODUCTION

Torque F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Component Cylinder Head and Components Rocker Assembly Cylinder Head Phase 1 Phase 2 Cylinder Head Phase 1 Phase 2 Cylinder Head Phase 1 Phase 2 Valve Cover Intake manifold Air intake elbow Exhaust manifold Rear lifting bracket Turbocharger

Size

Specification 20 - 28 Nm (14.8 - 20.7 lb ft)

M8 M12x70

50 Nm (36.9 lb ft) 90 ° M12x140 40 Nm (29.5 lb ft) 180 ° M12x180

M8x1.25x25 M8x1.25 M8x1.25 M10x1.5x65 M12x1.75x30 M10

70 Nm (51.6 lb ft) 180 ° 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 65 - 89 Nm (47.9 - 65.6 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft)

M8x1.25x45 M8x1.25x30

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8x1.25x40 M8x1.25x25 M10x1.5 M12x120 M12x80 M10x80 M10x40 M12x1.25 M12x1.25

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 75 - 95 Nm (55.3 - 70.1 lb ft) 75 - 95 Nm (55.3 - 70.1 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 26 - 34 Nm (19.2 - 25.1 lb ft) 55 - 65 °

Front Case Front cover assembly

Rear Case Gear Case

Flywheel housing

Phase 1 Phase 2

Cylinder Block and Crankshaft Components Main bearing cap Phase 1 Phase 2 Phase 3 Connecting rod Phase 1 Phase 2 Phase 3 Timing Pin Crankshaft pulley Camshaft retaining plate Camshaft gear

44 - 56 Nm (32.5 - 41.3 lb ft) 74 - 86 Nm (54.6 - 63.4 lb ft) 85 - 95 ° M11x1.25 27 - 33 Nm (19.9 - 24.3 lb ft) 55 - 65 Nm (40.6 - 47.9 lb ft) 55 - 65 ° 4 - 6 Nm (3.0 - 4.4 lb ft) 105 - 115 Nm (77.4 - 84.8 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 32 - 40 Nm (23.6 - 29.5 lb ft)

M12x1.75 M8 M8

Lubrication System and Components

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INTRODUCTION

Component Piston Cooling Nozzles Oil pump Stiffening Plate Oil plug Oil Pick up tube Oil Pan Oil Bypass Valve Turbo Lubrication Lines Turbo end Filter base end Drain

Size

Specification

M8x1.25x10 M8x1.25x30 M10x1.25x25 M10x1 M14x1.5 M8x1.25x20 M8x1.25x25 M18x1.50 M22x1.5x10

12 - 18 Nm (8.9 - 13.3 lb ft) 7 - 9 Nm (5.2 - 6.6 lb ft) 38 - 48 Nm (28.0 - 35.4 lb ft) 5 - 7 Nm (3.7 - 5.2 lb ft) 9 - 13 Nm (6.6 - 9.6 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 51 - 69 Nm (37.6 - 50.9 lb ft) 72 - 88 Nm (53.1 - 64.9 lb ft)

M12x1.5 M8x1.25x16

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

M8x1.25x30 M10x1.25x25 M10 M12x1.75x120 M6x1.0 nut M10

20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 44 - 54 Nm (32.5 - 39.8 lb ft) 37 - 49 Nm (27.3 - 36.1 lb ft) 8 - 11 Nm (5.9 - 8.1 lb ft) 54 - 44 Nm (39.8 - 32.5 lb ft)

M8 screw M6 screw M6 nut

20 - 28 Nm (14.8 - 20.7 lb ft) 9 - 11 Nm (6.6 - 8.1 lb ft) 9 - 11 Nm (6.6 - 8.1 lb ft)

Electrical Components Alternator

Alternator wiring Starter

Fuel System and Components Fuel pump

Fuel Pump Drive Gear Phase 1 Phase 2 Timing Pin Cap Fuel injectors Fuel lift pump

15 - 20 Nm (11.1 - 14.8 lb ft) 85 - 90 Nm (62.7 - 66.4 lb ft) 30 - 35 Nm (22.1 - 25.8 lb ft) 55 - 65 Nm (40.6 - 47.9 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft)

Cooling System and Components Water Pump Water outlet connection Fan support Fan pulley

M8x1.25x25 M8x1.25x35 M8x1.25x70 M10x1.5x20 M6 M10

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20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 20 - 28 Nm (14.8 - 20.7 lb ft) 28 - 38 Nm (20.7 - 28.0 lb ft) 8 - 12 Nm (5.9 - 8.9 lb ft) 27 - 49 Nm (19.9 - 36.1 lb ft)

INTRODUCTION

Special tools F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Tool No.

Description

Image

380000301

Revolving engine stand

380000665

Crankshaft front seal puller

380000663

Crankshaft rear seal puller

380001099

REVOLVING STAND

FRONTSEALPULLER

REARSEALPULLER

INJECTORPULLER

Injector puller

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INTRODUCTION

Tool No.

Description

Image

380000666

Crankshaft front seal installer

380000664

Crankshaft rear seal installer

380000670

Oil filter wrench

380000302

Valve spring compressor

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FRONTSEALINSTAL

CRANKREARSEALIN

OILFILTERWRENCH

VALVESPRINGCOMP

INTRODUCTION

Tool No. 380000221

Description

Image

Pliers for removing/refitting piston rings 65 - 110 mm (2.559 - 4.331 in)

PISTONRINGPLIER

380000667

Beater for removing/refitting camshaft bushes

380000362

Tool for lifting the crankshaft

CAMBUSHBEATER

380000216

CRANKHOIST

ENGINEHOIST

Engine lifting rig

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INTRODUCTION

Tool No. 380000661

Description

Image

Brackets for fastening the engine to the revolving stand

STANDBRACKETS

380000669

Seal remover

380000668

Hand grip for interchangeable beaters

380000364

Gauge base for dial indicator

SEALREMOVER

HANDGRIP

GAUGEBASE

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INTRODUCTION

Tool No.

Description

Image

N/A

Torque wrench

380000158

Torque screwdriver

380000304

Tool for angle tightening

380000988

Flywheel rotation tool

TORQUEWRENCH

TORQUESCREWDRIV

ANGLETIGHTENING

ROTATOR

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INTRODUCTION

Tool No.

Description

Image

Piston ring compressor

PISTONRINGCOMP

Dial indicator ( 0 - 5 mm (0.000 - 0.197 in))

DIALINDICATOR

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INTRODUCTION

Special tools F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Tool No.

Description

Image

380000979

Injection pump gear puller

380000665

Crankshaft front seal puller

380000663

Crankshaft rear seal puller

380000671

Injector puller

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PUMPGEARPULLER

FRONTSEALPULLER

REARSEALPULLER

INJECTORPULLERG

INTRODUCTION

Tool No.

Description

Image

380000666

Crankshaft front seal installer

380000664

Crankshaft rear seal installer

380000670

Oil filter wrench

380000302

Valve spring compressor

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FRONTSEALINSTAL

CRANKREARSEALIN

OILFILTERWRENCH

VALVESPRINGCOMP

INTRODUCTION

Tool No. 380000221

Description

Image

Pliers for removing/refitting piston rings 65 - 110 mm (2.559 - 4.331 in)

PISTONRINGPLIER

380000732

Flywheel crank handle

380000988

Flywheel rotation tool

FLYWHEELCRANK

ROTATOR

380000667

Beater for removing/refitting camshaft bushes

CAMBUSHBEATER

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INTRODUCTION

Tool No.

Description

Image

380000362

Tool for lifting the crankshaft

380000216

Engine lifting rig

380000994

Piston ring compressor

380002729

Engine TDC positioning tool (non-structural engines only)

CRANKHOIST

ENGINEHOIST

PISTONRINGCOMP

TIMINGPIN

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INTRODUCTION

Tool No. 380000661

Description

Image

Brackets for fastening the engine to the revolving stand

STANDBRACKETS

380000669

Seal remover

380000668

Hand grip for interchangeable beaters

380000364

Gauge base for dial indicator

SEALREMOVER

HANDGRIP

GAUGEBASE

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INTRODUCTION

Tool No.

Description

Image

380000229

Dial gauge holder and 0 5 mmDial gauge for rotary injection pump timing.

380000304

Tool for angle tightening

380001005

Dial gauge 0 - 10 mm

380001006

Diesel engine compression tester

PUMPTIMEADAPT

ANGLETIGHTENING

DIALGAUGE

COMPTESTER

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INTRODUCTION

Tool No.

Description

Image

380000140

Adapter for engine compression tester

380000301

Revolving engine stand

COMPADAPTER

REVOLVING STAND

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INTRODUCTION

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SERVICE MANUAL Engine F4CE9484 , F4CE9487A , F4CE9487N , F4CE9684 , F4DE9484 , F4DE9684B*J111 , F4DE9684M*J101 , F4DE9684M*J103 , F4DE9684 , F4DE9687 , F4GE9484C*J601 , F4GE9484 , F4GE9684 , F4HE0484G*J102 , F4HE0484G*J109 , F4HE9484C*J102 , F4HE9484C*J103 , F4HE9484 , F4HE9684 , F4HE9687G*J100 , F4HE9687

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

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CONSUMABLES INDEX Consumable Loctite® 518 Gasket Eliminator® Molykote® G-N Metal assembly paste Molykote® G-N Metal assembly paste Molykote® G-N Metal assembly paste Molykote® G-N Metal assembly paste Loctite® 5999 Loctite® 5999

Reference

PAGE

Engine block cover Rear - Cleaning

10.2 / 21

Cylinder head - Install

10.4 / 15

Cylinder head - Install

10.4 / 19

Cylinder head - Install

10.4 / 22

Cylinder head - Install

10.4 / 26

Intake manifold - Install Intake manifold - Install

10.13 / 9 10.13 / 11

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Engine - 10 Engine and crankcase - 001

F4CE9484 , F4CE9487A , F4CE9487N , F4CE9684 , F4DE9484 , F4DE9684B*J111 , F4DE9684M*J101 , F4DE9684M*J103 , F4DE9684 , F4DE9687 , F4GE9484C*J601 , F4GE9484 , F4GE9684 , F4HE0484G*J102 , F4HE0484G*J109 , F4HE9484C*J102 , F4HE9484C*J103 , F4HE9484 , F4HE9684 , F4HE9687G*J100 , F4HE9687

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10.1 [10.001] / 1

Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4GE9484, F4GE9484C*J601, F4GE9684

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

FUNCTIONAL DATA Engine Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4GE9484, F4GE9484C*J601, F4GE9684

SERVICE Engine Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4GE9484, F4GE9484C*J601, F4GE9684

Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4GE9484, F4GE9484C*J601, F4GE9684

Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Engine - Engine and crankcase

Engine - General specification F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0290FA

The NEF F4HE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder. They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the working process in accordance to the operation, limiting pollution emissions and consumption as much as possible. NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed.

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Engine - Engine and crankcase

General Specifications Engine Type Cycle Power Injection Number of cylinders Bore Stroke Total Displacement Timing Start before T.D.C. End after B.D.C. Start before B.D.C. End after T.D.C. Valve Clearance Intake Exhaust Fuel Feed Injection Type Control Injector Nozzle Type Injection Sequence Injection pressure Aspiration Turbocharging Turbocharger Type Lubrication Oil Pressure @ Low Idle Oil Pressure @ Fast Idle Oil Pan Capacity Oil Filter Capacity Cooling Water Pump Thermostat

4 Cylinders

6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 ECU CRIU 2 DSLA and DLLA 1-3-4-2 1-5-3-6-2-4 250 - 1600 bar (3625 - 23200 psi) Intercooled Holset HX35 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt) Belt Driven 79 - 83 °C (174 - 181 °F)

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Engine - Engine and crankcase

Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 4.086 in) (*) 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in)

Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings 2.705 - 2.735 mm (0.106 - 0.108 in) Combustion 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*) Intermediate 4.030 - 4.050 mm (0.159 - 0.159 in) Oil Control Piston Rings 2.560 - 2.605 mm (0.101 - 0.103 in) Combustion 2.350 - 2.380 mm (0.093 - 0.094 in) Intermediate 3.970 - 3.990 mm (0.156 - 0.157 in) Oil Control Piston Ring and Ring Landing Clearance 0.100 - 0.175 mm (0.004 - 0.007 in) Combustion 0.060 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) Intermediate 0.040 - 0.080 mm (0.002 - 0.003 in) Oil Control Piston Ring End Gap 0.30 - 0.40 mm (0.012 - 0.016 in) Combustion 0.60 - 0.80 mm (0.024 - 0.031 in) Intermediate 0.30 - 0.55 mm (0.012 - 0.022 in) Oil Control Connecting Rod Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in) Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in) Small end bushing Inside 38.019 - 38.033 mm (1.497 - 1.497 in) Diameter Big end bearing shell 1.955 - 1.968 mm (0.077 - 0.077 in) thickness Piston Pin and Bushing 0.019 - 0.039 mm (0.001 - 0.002 in) Clearance Oversize Big end bearing 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) Shells Crankshaft 82.99 - 83.01 mm (3.267 - 3.268 in) Main Journals 68.987 - 69.013 mm (2.716 - 2.717 in) Crankpins Main Bearing Shell Thickness 2.456 - 2.464 mm (0.097 - 0.098 in) Big end Bearing Shell 1.955 - 1.968 mm (0.077 - 0.078 in) Thickness Main Bearing Bore 87.982 - 88.008 mm (3.464 - 3.465 in) No. 1,5 / 1,7 87.977 - 88.013 mm (3.464 - 3.465 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance 0.041 - 0.119 mm (0.002 - 0.005 in) No. 1,5 / 1,7 0.041 - 0.103 mm (0.002 - 0.004 in) No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin 0.033 - 0.041 mm (0.001 - 0.002 in) Clearance 37.475 - 37.545 mm (1.475 - 1.478 in) Thrust Journal Thrust Bearing Bore 32.180 - 32.280 mm (1.267 - 1.271 in) (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A 47597675 27/09/2013

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Engine - Engine and crankcase

Clearance Data Thrust Bearing Crankshaft End Play

37.28 - 37.38 mm (1.468 - 1.472 in) 0.095 - 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 7.042 - 7.062 mm (0.277 - 0.278 in) Valve Guide Bore Intake Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.052 - 0.092 mm (0.002 - 0.004 in) Clearance Valve Seat Bore 34.837 - 34.863 mm (1.372 - 1.373 in) Intake 34.837 - 34.863 mm (1.372 - 1.373 in) Exhaust Valve seat Outside Diameter: 34.917 - 34.931 mm (1.375 - 1.375 in) Intake 34.917 - 34.931 mm (1.375 - 1.375 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 0.59 - 1.11 mm (0.023 - 0.044 in) Intake 0.96 - 1.48 mm (0.038 - 0.058 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.054 - 0.094 mm (0.002 - 0.004 in) Intake 0.054 - 0.094 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 47.75 mm (1.880 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 35.33 mm (1.391 in) 78.4 lb) Under a load equal to: 25.2 mm (0.992 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 53.995 - 54.045 mm (2.126 - 2.128 in) 1-5 / 1-7 Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in) Bushing and Journal Clearance 0.038 - 0.162 mm (0.001 - 0.006 in) Cam Lift 7.582 mm (0.299 in) Intake 6.045 mm (0.238 in) Exhaust Tappet Bore 16.000 - 16.030 mm (0.630 - 0.631 in) Tappet outside diameter Top 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) Middle 15.924 - 15.954 mm (0.627 - 0.628 in) Bottom 0.025 - 0.070 mm (0.001 - 0.003 in) Tappets and Bore Clearance 21.965 - 21.977 mm (0.865 - 0.865 in) Rocker shaft 22.001 - 22.027 mm (0.866 - 0.867 in) Rockers 0.024 - 0.162 mm (0.001 - 0.006 in) Rockers and Shaft Clearance (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A

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Engine - Engine and crankcase

Engine - General specification F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0291FA

The NEF F4DE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder. They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the working process in accordance to the operation, limiting pollution emissions and consumption as much as possible. NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed.

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Engine - Engine and crankcase

4 Cylinders

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Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

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Engine - Engine and crankcase

Clearance Data Thrust Bearing Crankshaft End Play

37.28 - 37.38 mm (1.468 - 1.472 in) 0.095 - 0.265 mm (0.004 - 0.010 in)

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Engine - Engine and crankcase

Engine - General specification F4GE9484, F4GE9484C*J601, F4GE9684

NHIL13ENG0292FA

NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment in general. They are characterized by diesel cycle 4 stroke atmospheric or turbocharged 4 and 6 cylinders each with 2 valves. Feed is provided by rotary mechanical pump or on line according to the equipment application. It differs from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine. NOTE: The picture shows application designed for 6 cylinder versions, 2 valves per cylinder, having fuel feed by a mechanical pump. NOTICE: Data, technical specifications and performances granted shall be valid only if the setter will follow and comply with all installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed.

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Engine - Engine and crankcase

Engine Type Compression ratio Bore Stroke Displacement Turbocharger type

4 cylinder

6 cylinder 17.5 : 1 104 mm (4.1 in) 132 mm (5.2 in)

4485 cm³ Intercooled Holset HX25W

6728 cm³ Intercooled Holset HX35W

Lubrication Oil Pressure (warm engine) Idling Peak RPM

0.7 bar (10.2 psi) 3.5 bar (50.8 psi)

Cooling Water Pump Thermostat opening temperature

Belt Driven 79 - 83 °C (174.2 - 181.4 °F)

Capacity Oil Pan Oil Filter

13 l (13.7 US qt) 1 l (1.1 US qt)

15 l (15.9 US qt) 1 l (1.1 US qt)

Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

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Clearance Data Oversize Big end bearing Shells Crankshaft Main Journals Crankpins Main Bearing Shell Thickness Big end Bearing Shell Thickness Main Bearing Bore No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin Clearance Thrust Journal Thrust Bearing Bore Thrust Bearing Crankshaft End Play

0.250 mm (0.010 in) ; 0.500 mm (0.020 in) 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) 2.456 - 2.464 mm (0.097 - 0.098 in) 1.955 - 1.968 mm (0.077 - 0.078 in) 87.982 - 88.008 mm (3.464 - 3.465 in) 87.977 - 88.013 mm (3.464 - 3.465 in) 0.064 - 0.095 mm (0.003 - 0.004 in) 0.059 - 0.100 mm (0.002 - 0.004 in) 0.064 - 0.090 mm (0.003 - 0.004 in) 37.475 32.180 37.28 0.095

37.545 mm (1.475 - 1.478 in) 32.280 mm (1.267 - 1.271 in) 37.38 mm (1.468 - 1.472 in) 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 8.019 - 8.039 mm (0.3157 - 0.3165 in) Valve Guide Bore Intake Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.059 - 0.086 mm (0.002 - 0.003 in) Clearance Valve Seat Bore 46.987 - 47.013 mm (1.850 - 1.851 in) Intake 43.637 - 43.663 mm (1.718 - 1.719 in) Exhaust Valve seat Outside Diameter: 47.063 - 47.089 mm (1.853 - 1.854 in) Intake 43.713 - 43.739 mm (1.721 - 1.722 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 1 - 1.52 mm (0.039 - 0.060 in) Intake 1 - 1.52 mm (0.039 - 0.060 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.050 - 0.102 mm (0.002 - 0.004 in) Intake 0.050 - 0.102 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 63.50 mm (2.500 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 49.02 mm (1.930 in) 78.4 lb) Under a load equal to: 38.20 mm (1.504 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7

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Clearance Data Camshaft Journals 1-5 / 1-7 Bushing inside diameter Bushing and Journal Clearance Tappet Bore Tappet outside diameter Top Middle Bottom Rocker shaft Rockers Rockers and Shaft Clearance

53.995 54.083 0.038 16.000

54.045 mm (2.126 - 2.128 in) 54.147 mm (2.129 - 2.132 in) 0.162 mm (0.001 - 0.006 in) 16.030 mm (0.630 - 0.631 in)

15.924 15.960 15.924 18.963 19.000 0.025

15.954 mm (0.627 - 0.628 in) 15.975 mm (0.628 - 0.629 in) 15.954 mm (0.627 - 0.628 in) 18.975 mm (0.747 - 0.747 in) 19.026 mm (0.748 - 0.749 in) 0.063 mm (0.001 - 0.002 in)

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Engine - Engine and crankcase

Engine - General specification F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

NHIL13ENG0293FA

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Engine - Engine and crankcase

Engine Type Compression ratio Bore Stroke Displacement Turbocharger type

4 cylinder

6 cylinder 17.5 : 1 104 mm (4.1 in) 132 mm (5.2 in)

4485 cm³ Intercooled Holset HX25W

6728 cm³ Intercooled Holset HX35W

Lubrication Oil Pressure (warm engine) Idling Peak RPM

0.8 bar (11.6 psi) 3.5 bar (50.8 psi)

Cooling Water Pump Thermostat opening temperature

Belt Driven 79 - 83 °C (174.2 - 181.4 °F)

Capacity -

Oil Pan Oil Filter

16 l (16.9 US qt) 1 l (1.1 US qt)

Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize Pistons

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0.250 mm (0.010 in) ; 0.500 mm (0.020 in) 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) 2.456 - 2.464 mm (0.097 - 0.098 in) 1.955 - 1.968 mm (0.077 - 0.078 in) 87.982 - 88.008 mm (3.464 - 3.465 in) 87.977 - 88.013 mm (3.464 - 3.465 in) 0.064 - 0.095 mm (0.003 - 0.004 in) 0.059 - 0.100 mm (0.002 - 0.004 in) 0.033 - 0.041 mm (0.001 - 0.002 in) 37.475 32.180 37.28 0.095

37.545 mm (1.475 - 1.478 in) 32.280 mm (1.267 - 1.271 in) 37.38 mm (1.468 - 1.472 in) 0.265 mm (0.004 - 0.010 in)

Cylinder Head and Components 8.019 - 8.039 mm (0.3157 - 0.3165 in) Valve Guide Bore Intake Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 59.75 - 60.25 ° Exhaust Valves 7.960 - 7.980 mm (0.313 - 0.314 in) Stem diameter Face angle 44.75 - 44.25 ° Valve Stem and Guide 0.039 - 0.079 mm (0.002 - 0.003 in) Clearance Valve Seat Bore 46.987 - 47.013 mm (1.850 - 1.851 in) Intake 43.637 - 43.663 mm (1.718 - 1.719 in) Exhaust Valve seat Outside Diameter: 47.063 - 47.089 mm (1.853 - 1.854 in) Intake 43.713 - 43.739 mm (1.721 - 1.722 in) Exhaust Valve Seat Angle Intake 60 ° Exhaust 45 ° Valve Sink 1 - 1.52 mm (0.039 - 0.060 in) Intake 1 - 1.52 mm (0.039 - 0.060 in) Exhaust Interference Between Valve Seat and Cylinder Head 0.050 - 0.102 mm (0.002 - 0.004 in) Intake 0.050 - 0.102 mm (0.002 - 0.004 in) Exhaust Valve Spring Height 63.50 mm (2.500 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 49.02 mm (1.930 in) 78.4 lb) Under a load equal to: 38.20 mm (1.504 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7

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Engine - Engine and crankcase

Clearance Data Camshaft Journals 1-5 / 1-7 Bushing inside diameter Bushing and Journal Clearance Cam Lift Intake Exhaust Tappet Bore Tappet outside diameter Top Middle Bottom Tappets and Bore Clearance Rocker shaft Rockers Rockers and Shaft Clearance

53.995 - 54.045 mm (2.126 - 2.128 in) 54.083 - 54.147 mm (2.129 - 2.132 in) 0.038 - 0.162 mm (0.001 - 0.006 in) 11.02 mm (0.434 in) 10.74 mm (0.423 in) 16.000 - 16.030 mm (0.630 - 0.631 in) 15.924 15.960 15.924 0.020 18.963 19.000 0.025

15.954 mm (0.627 - 0.628 in) 15.975 mm (0.628 - 0.629 in) 15.954 mm (0.627 - 0.628 in) 0.065 mm (0.001 - 0.003 in) 18.975 mm (0.747 - 0.747 in) 19.026 mm (0.748 - 0.749 in) 0.063 mm (0.001 - 0.002 in)

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Engine - Engine and crankcase

Engine - Component localisation F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Location of main electrical components

NHIL13ENG0294GA

(1) Coolant Temperature Sensor - (2) Electro-Injector - (3) Rail Pressure Sensor - (4) Air Temperature/Pressure Sensor - (5) Engine Starter - (6) Timing Sensor - (7) Solenoid Valve for Pressure Regulator - (8) Fuel Temperature Sensor - (9) EDC Electronic Control Unit - (10) Crankshaft Sensor - (11) Oil Level Sensor - (12) Engine Oil Temperature/Pressure Sensor - (13) Heating Element for Pre-Post Heating The NEF F4HE engines are fully driven by the electronic engine control module, which is assembled directly to the engine by means of a heat exchanger enabling it's cooling, utilizing rubber buffers to reduce vibration originated by the engine. Through the engine control module it is possible to verify the correct working of the engine.

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Engine - Engine and crankcase

Engine - Component localisation F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Location of main electrical components

NHIL13ENG0294GA

(1) Coolant temperature sensor - (2) Electro-injector - (3) Starter - (4) Fuel pressure sensor - (5) Air pressure/temperature sensor - (6) Timing sensor - (7) fuel temperature sensor - (8) EDC7 electronic control module - (9) Crankshaft speed sensor - (10) Engine oil pressure/temperature sensor - (11) Pre-post heating resistor. The NEF F4DE engines are fully driven by the electronic engine control module, which is mounted remotely on the unit utilizing rubber buffers to reduce vibration originated by the engine. Through the engine control module it is possible to verify the correct working of the engine.

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Engine - Engine and crankcase

Engine - Component localisation F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

NHIL13ENG0295GA

(1) Coolant temperature sensor (2) Starter (3) Grid heater (4) KSB water temperature sensor (5a) Electromagnet on the pump head (5b) Electromagnet on the KSB

(6) Oil pressure switch (7c) Fuel heater (if equipped) (7d) Water in fuel sensor (8) Speed sensor (if equipped) (9) Alternator

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Engine - Engine and crankcase

Engine - Component localisation F4GE9484, F4GE9484C*J601, F4GE9684

NHIL13ENG0296GA

(1) Coolant temperature sensor - (2) Starter - (3) KSB water temperature sensor - (4) Electromagnets assembled on feed pump: (A) on hydraulic head unit (B) on KSB - (5) Oil pressure sensor - (6) Grid heater - (7) Alternator.

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Engine - Engine and crankcase

Engine - Compression test F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

1. Make sure that all pressure is relieved from the fuel system. 2. Disable the fuel system by disconnecting the fuel shut off electrical connector (1).

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NHIL13ENG0602AA

3. Remove all fuel injectors (1) and their O-ring seals (2) from the cylinder head. NOTE: Use new injector O-ring seals during reinstallation. 4. Install cylinder compression test adapter 380000989 into cylinder No. 1 fuel injector port. 5. Be sure the compression gauge is reset to zero psi. 6. Crank the engine over until the compression gauge needle meets it’s peak level and will not increase further. NOTICE: Do not crank the engine excessively. This could cause wear to the starter motor. NOTICE: Keep the compression testing equipment away from all moving parts on the engine. 7. Record the compression test reading and repeat Step 6 until all cylinders have been tested and recorded. 8. The cylinder psi values should be between 24 bar (350 psi) +100/-50.

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Engine - Place on stand F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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

NHIL13ENG0297AA

7. Disconnect the fuel line supplying the mechanical pump that is combined to the high pressure pump through the exchanger of the engine control module. 8. Remove the oil fill tube (if present) by removing the bolts. Remove the O-ring from the tube. NOTICE: Because of the high pressure fuel in the fuel lines running from the high pressure pump to the rail and from the rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while engine is running or reuse the removed pipelines. 9. Remove the retaining bolts securing the turbocharger (1) oil return line (2) and remove the line from the oil filter base on the engine block.

NHIL13ENG0298AA

NHIL13ENG0299AA

10. Remove the starter motor (2) from the flywheel housing (1) by removing the retaining bolts (3). 11. Apply brackets 380001298 to the engine block and use them to secure the engine to a rotary engine stand. 12. Remove the drain plug from the engine oil pan and drain out the engine oil. 13. Remove the fan from the output shaft pulley.

NOTICE: Collect and dispose of engine oil according to regulations in your area.

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Engine - Place on stand F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NOTE: In order to apply the brackets 380000661 to the engine block, it is necessary to perform the following operations on the left hand side of the engine. 1. Using the tool 380000670, remove the fuel filter (6) and remove it from the support (1). 2. Disconnect the electrical connection (2) from the support (1). 3. Disconnect the low pressure fuel lines (3), (4) and (5) from the support (1). 4. Remove the fuel line (9) from the support (1). 5. Remove the sustaining support bracket (1) from the engine block. 6. Disconnect the high pressure fuel line (7) from the fuel rail diffuser and from the high pressure pump (8). Remove it from the engine block by removing the retaining clamps.

NHIL13ENG0300AA

7. Disconnect the fuel line feeding the mechanical pump that is combined to the high pressure pump through the exchanger of the engine control module. 8. Remove the oil fill tube (if applicable) by removing the bolts, O-ring, and then removing the tube. NOTICE: Because of the high pressure fuel in the fuel lines running from the high pressure pump to the fuel rail and from the fuel rail to the electro-injectors, DO NOT, under any circumstances, disconnect or crack pipelines while engine is running or reuse the disassembled pipelines. 9. Remove mounting bolts (1) securing the starter motor (2), then remove the starter motor (2) from the flywheel housing.

NHIL13ENG0299AA

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10. Remove the oil return line (1) from the turbocharger outlet (2) and at the return fitting at the engine block (3).

NHIL13ENG0301BA

NHIL13ENG0302AA

NHIL13ENG0303FA

11. Remove the turbocharger oil feed line (2) from the turbocharger (1) inlet. 12. Remove the retaining bolts (4) and remove the support (3). 13. Remove the thermostat body including the seal.

14. In order to hoist the engine onto a rotary engine stand, use the provided holes (1) and (2) on both sides of the engine block to install brackets 380000661. 15. Drain the engine oil by removing the drain plug from the bottom of the engine oil pan. NOTE: Collect and dispose of the engine oil according to enforced regulations.

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Engine - Engine and crankcase

Engine - Place on stand F4GE9484, F4GE9484C*J601, F4GE9684

1. In order to apply the brackets 380000661 to the engine block for a rotary engine stand for the overhaul, it is necessary to perform the following operations. 2. Remove the engine oil filter (1) from the support using tool 380000670. NOTICE: The oil filter contains inside approximately 1â&#x20AC;&#x2026;kg (2.2â&#x20AC;&#x2026;lb) of engine oil. Provide for oil recovery and disposal in compliance with the laws and regulations in force.

NHIL13ENG0304AA

NHIL13ENG0305BA

NHIL13ENG0306AA

3. Remove the two bolts (2) from underneath the turbocharger and loosen the fitting (3) retaining the line throughout the stop collar (4) secured to the engine block. 4. Finally, remove the fitting (5) from the engine block and remove the turbocharger oil return line. 5. Plug the pipe ends and the exhaust outlet of the turbocharger.

6. Remove the starter motor (1) by removing he retaining bolts (3). 7. Install the brackets 380000661 using the four provided threaded bolt holes (2).

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8. From the left hand side, assemble the second bracket 380000661 using the provided threaded bolt holes (1). 9. Lift the engine using the hoist 380000216 and mount it onto the rotary engine stand . 10. Drain the engine oil through the drain plug in the engine oil pan. NOTICE: Avoid contact of engine oil with the skin. In case of skin contamination, rinse in running water. NOTE: Engine oil is highly pollutant. Provide for disposal in compliance with the law and regulations in force. NHIL13ENG0307AA

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Engine - Engine and crankcase

Engine - Place on stand F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Install the brackets 380000661 onto the engine block and mount the engine on a rotary engine stand to perform the following operations. 2. Remove the bolts securing the turbocharger oil return line to the turbocharger oil outlet (2). 3. Remove the turbocharger oil return line from the stop collar (3). 4. Remove the turbocharger oil return line fitting (4) at the engine block. 5. Remove the engine oil dipstick (5). 6. Remove the engine oil filter (1) using the tool 380000670.

NHIL13ENG0308AA

NHIL13ENG0309AA

NHIL13ENG0310AA

NOTICE: Provide for oil recovery and disposal in compliance with the law and regulations in force. 7. Remove the starter motor (2) by removing the retaining bolts (1).

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

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Engine - Service instruction Maintenance Procedures F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

CHECKS AND INSPECTIONS Engine oil level check The check can be made using the engine oil dipstick (1) located on the right hand side of the EDC. NOTICE: The check must be executed when the engine is off and possibly cool. Remove the dipstick from it's tube and check that the level is within the etched markings of minimum and maximum level. If it is difficult to make the level evaluation, proceed cleaning the dipstick using a clean cloth with no contamination and put it back in it's tube. Remove the dipstick again and check the level. In case the level results are close to the marking indicating minimum level, add the correct engine oil through the upper engine oil cap or lateral cap of the engine (2) and check level until level reaches the maximum level marking.

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

During filling operation, the engine oil caps must be removed as well as the engine oil dipstick in order to make the oil flow easier.

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NHIL13ENG0311AA

Engine - Engine and crankcase

Combustion system inspection WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

The check must be executed both with the engine off and when it is running. The check operation consists of examining the fuel lines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump, to the rail diffuser and to the cylinder head. Special attention must be paid to the connections on the high pressure pipelines.

Cooling system inspection CAUTION Burn hazard! Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir. Failure to comply could result in minor or moderate injury. C0031A

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

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Lubricating system inspection WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

The check must be executed both when the engine is off and when it is running. Verify the presence of any engine oil leakage or engine oil blow-by from the cylinder head, engine oil pan or from the engine oil cooler.

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

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

86070785_RESIZE

Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no adjustments are required apart from checking the wear status of the belt itself.

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

Engine oil and filter replacement WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

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

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Engine - Engine and crankcase

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

Fuel filter replacement According to the applications, the filters position and the quantity can change. However the following operations are valid for all applications. Drain the fuel inside the filter operating the water release drain valve. Collect the fuel in a container without impurities. remove the cartridge by using the 380000670. Collect the eventual fuel inside the filtering cartridge. Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge. Manually tighten the new filtering cartridge until the gasket is completely on its seat. Torque the bolts using the tool 380000670 to 10 - 15 Nm (7 - 11 lb ft).

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Alternator belt replacement WARNING Rotating parts! The engine is running. Keep clear of rotating fans and belts. Failure to comply could result in death or serious injury. W0275A

Due to several applications the belt run can change very much. For applications with an automatic belt tensioner, the procedure is the following: By means of square wrench of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure. Remove the control belt (2) from the driven and intermediate pulleys. Replace the worn belt with a new one. Place the belt on the pulleys and guide rollers. Place the automatic tightener in order to place the belt in the functioning position. Check proper position in the races of the pulleys.

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Engine - Engine and crankcase

Engine - Service instruction Maintenance Procedures F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

CHECKS AND INSPECTIONS Engine oil level check The check can be made using the engine oil dipstick (1) located on the right hand side of the EDC. NOTICE: The check must be executed when the engine is off and possibly cool. Remove the dipstick from the tube and check that the level is within the etched markings of minimum and maximum level. If it is difficult to make the evaluation, clean the dipstick using a clean cloth with no contamination and put it back in it's tube Remove it again and check the level. In case the level results are close to the marking indicating minimum level, add the correct engine oil through the upper engine oil cap or lateral cap of the engine. NHIL13ENG0314FA

NHIL13ENG0265AA

Add oil through the upper engine oil cap (1) or through the lateral oil cap (2). During filling operation, the engine oil caps must be removed as well as the engine oil dipstick in order to make the oil flow easier.

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The check must be executed both when the engine is off and when it is running. The check operation consists of examining the fuel lines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump, to the rail diffuser and to the cylinder head. Special attention must be paid to the connections on the high pressure pipelines.

Cooling system inspection CAUTION Burn hazard! Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding. Failure to comply could result in minor or moderate injury. C0043A

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

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Engine - Engine and crankcase

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

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NHIL13ENG0312AA

Engine - Engine and crankcase

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

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Engine - Engine and crankcase

Tighten by means of the tool 380000670 making a three fourth rotation turn. Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, top off engine oil to compensate for the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change. However the following operations are valid for all applications. Drain the fuel inside the filter operating the water release drain valve. Collect the fuel in a container without impurities. Remove the cartridge by using the 380000670. Collect the eventual fuel inside the filtering cartridge. Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge. Manually tighten the new filtering cartridge until the when the gasket is completely on its seat. Tighten through the tool 380000670 at a 10 - 15 Nm (7 11 lb ft) torque.

Alternator belt replacement WARNING Rotating parts! The engine is running. Keep clear of rotating fans and belts. Failure to comply could result in death or serious injury. W0275A

Due to several applications the belt run can change very much. For applications with automatic belt tensioner, the procedure is the following: By means of square wrench of proper of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure. Remove the control belt (2) from the driven and intermediate pulleys. Replace the worn belt with a new one. Place the belt on the pulleys and guide rollers. Place the automatic tightener in order to key the belt in the functioning position. Check proper position in the races of the pulleys. NHIL13ENG0313AA

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Engine - Engine and crankcase

Engine - Service instruction Maintenance Procedures F4GE9484, F4GE9484C*J601, F4GE9684

CHECKS AND INSPECTIONS Engine oil level check The check can be made using the dipstick (1) placed on the right hand side of the EDC. NOTICE: The check must be executed when the engine is off and possibly cool. Draw off the rod from it's slot and check that the level is within the etched tags of minimum and maximum level. Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no contamination and put it back in it's slot. Draw it off again and check the level. In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components.

NHIL13ENG0267AA

NHIL13ENG0268AA

Add oil through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier.

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Fuel system inspection WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

The check must be executed both when the engine is off and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head. Special attention must be paid to the connections on the high pressure pipelines.

Cooling system inspection WARNING Hot liquid under pressure! Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool. Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape. Failure to comply could result in death or serious injury. W0296A

The check must be executed both when the engine is off and when it is running. Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips. Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.

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Engine - Engine and crankcase

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two years. NOTE: In case of new filling, proceed bleeding the system, through the bleeds on the engine. If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine's head.

The check must be executed both when the engine is off and when it is running. Verify the presence of any oil leakage or blow-by from the head, from the engine pan or from the heat exchanger.

Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.

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

Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications. We recommend to carry out the oil drainage when the engine is hot. Place a proper container for the oil collecting under the pan connected with drain plug. Unscrew the plug and then take out the control dipstick and the inserting plug to ease the downflow of the lubrication oil. After the complete drainage, screw the plug and carry out the clean oil filling. NOTICE: Use only recommended oil or oil having the requested features for the correct engine functioning. In case of topping up, don't mix oils having different features. If you don't comply with these rules, the service warranty is no more valid. Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick. Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

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NHIL13ENG0272AA

Engine - Engine and crankcase

The filter is composed of a support and a filtering cartridge. For the cartridge replacement use the tool 380000670. ATTENTION: The oil filter contains inside a quantity of oil of about 1 kg. Replace the filtering cartridge with a new one and screw manually until when the gasket is in contact with the support. Tighten by means of the tool 380000670 of three fourth turn. Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change. However the following operations are valid for all applications. Drain the fuel inside the filter operating the water release screw. Collect the fuel in a container without impurities. Unscrew the cartridge by using the 380000670. Collect the eventual fuel inside the filtering cartridge. Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge. Screw manually the new filtering cartridge until the gasket is completely on its seat. Tighten through the tool 380000670 at a 10 - 15 Nm (7 11 lb ft) torque.

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Alternator belt replacement WARNING Rotating parts! The engine is running. Keep clear of rotating fans and belts. Failure to comply could result in death or serious injury. W0275A

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Engine - Engine and crankcase

Engine - Service instruction Maintenance Procedures F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

CHECKS AND INSPECTIONS Engine oil level check The check can be made using the dipstick (1). NOTICE: The check must be executed when the engine is off and possibly cool. Draw off the rod from it's slot and check that the level is within the etched tags of minimum and maximum level. Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no contamination and put it back in it's slot. Draw it off again and check the level. In case the level results being close to the tag showing minimum level, provide filling lubrication of the engines components. NHIL13ENG0275AA

NHIL13ENG0269BA

Add oil through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier.

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The check must be executed both when the engine is off and when it is running. Verify the presence of any oil leakage or blow-by from the head, from the engine pan or from the heat exchanger.

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Engine - Engine and crankcase

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

Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications. We recommend to carry out the oil drainage when the engine is hot. Place a proper container for the oil collecting under the pan connected with drain plug. Unscrew the plug and then take out the control dipstick and the inserting plug to ease the downflow of the lubrication oil. After the complete drainage, screw the plug and carry out the clean oil filling. NOTICE: Use only recommended oil or oil having the requested features for the correct engine functioning. In case of topping up, don't mix oils having different features. If you don't comply with these rules, the service warranty is no more valid. Check the level through the dipstick until when the filling is next to the maximum level notch indicated on the dipstick. Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

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NHIL13ENG0272AA

Engine - Engine and crankcase

The filter is composed of a support and a filtering cartridge. For the cartridge replacement use the tool 380000670. ATTENTION: The oil filter contains inside a quantity of oil of about 1 kg. Replace the filtering cartridge with a new one and screw manually until when the gasket is in contact with the support. Tighten by means of the tool 380000670 of three fourth turn. Operate the engine for some minutes and check the level through the dipstick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

Fuel filter replacement According to the applications the filters position and the quantity can change. However the following operations are valid for all applications. Drain the fuel inside the filter operating the water release screw. Collect the fuel in a container without impurities. Unscrew the cartridge by using the 380000670. Collect the eventual fuel inside the filtering cartridge. Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge. Screw manually the new filtering cartridge until the gasket is completely on its seat. Tighten through the tool 380000670 at a 10 - 15 Nm (7 11 lb ft) torque.

Alternator belt replacement WARNING Rotating parts! The engine is running. Keep clear of rotating fans and belts. Failure to comply could result in death or serious injury. W0275A

Due to several applications the belt run can change very much. 47597675 27/09/2013

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Engine - Engine and crankcase

For applications with automatic belt tensioner, the procedure is the following: By means of square wrench of proper of proper size, act on point (A), indicated in the figure, of the automatic belt tensioner (1) and release the pressure. Remove the control belt (2) from the driven and intermediate pulleys. Replace the worn belt with a new one. Place the belt on the pulleys and guide rollers. Place the automatic tightener in order to key the belt in the functioning position. Check proper position in the races of the pulleys. NHIL13ENG0271AA

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Engine - Engine and crankcase

Crankcase Bore - Check Prior operation: Connecting rod and piston - Remove (10.105) Once engine is disassembled, perform the following: Clean the engine block assembly Use the proper rings to handle the cylinder unit. Inspect engine block for cracks. Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspect cylinder bore surfaces for seizing and scoring. Inspect cylinder bores for ovalization, taper, and wear by using a bore dial gauge OEM1032 (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder bore diameter. NOTE: Should a ring gauge not be available, use a micrometer for zero-setting.

NHIL13ENG0270AA

NHIL13ENG0286AA

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

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Engine - Engine and crankcase

Crankcase - Check Prior operation: Crankshaft - Remove (10.103)

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

Checking head supporting surface on cylinder unit Use a straightedge (2) placed diagonally across the cylinder head dowel pins (4) and use a feeler gauge (3) to check across the cylinder block for distortion. The planar surface distortion should not exceed 0.075 mm (0.003 in). If the value is higher than the specified value, the cylinder block will need to be resurfaced. Check cylinder unit operating plug (1) conditions, replace them in case of uncertain seal or if rusted.

CRIL04J058A01

Next operation: Crankshaft Journal - Clearance (10.103)

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Index Engine - 10 Engine and crankcase - 001 Crankcase - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Crankcase Bore - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Engine - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4GE9484, F4GE9484C*J601, F4GE9684

Engine - Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4GE9484, F4GE9484C*J601, F4GE9684

Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4GE9484, F4GE9484C*J601, F4GE9684

Engine - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4GE9484, F4GE9484C*J601, F4GE9684

Engine - Service instruction Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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Engine - 10 Pan and covers - 102

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Contents Engine - 10 Pan and covers - 102

SERVICE Engine oil pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4GE9484, F4GE9484C*J601, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9484C*J601, F4GE9684

Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9484, F4GE9484C*J601, F4GE9684

Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4GE9484, F4GE9484C*J601, F4GE9684

Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4GE9484, F4GE9484C*J601, F4GE9684

Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4GE9484, F4GE9484C*J601, F4GE9684

Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4GE9484, F4GE9484C*J601, F4GE9684

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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CONSUMABLES INDEX Consumable Loctite® 518 Gasket Eliminator®

Reference Engine block cover Rear - Cleaning

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PAGE 10.2 / 21

Engine - Pan and covers

Engine oil pan - Remove F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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

NHIL13ENG0273AA

NHIL13ENG0282AA

3. Remove the oil pick up tube (2) by removing the bolts (3) and (1). 4. Remove the bolts (5) retaining the stiffening plate (4) and then remove the stiffening plate (4).

Next operation: Engine oil pan - Install (10.102)

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Engine - Pan and covers

Engine oil pan - Install F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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

NHIL13ENG0282AA

NHIL13ENG0315AA

NHIL13ENG0277AA

2. Set the gasket (1) onto the oil pan (2) . NOTE: The pictures of the instructions relating to the oil pan and to the oil pick up tube may not reflect the actual shape and dimensions of your engine equipment. However, the procedures described are still applicable.

3. Install the oil pan (1) and the mounting plate (3) onto the engine block. Torque the bolts (4) to 15 - 21 N·m (11 - 15 lb ft). 4. Install the oil drain plug (2) into the oil pan. Torque the bolt to 5 - 7 N·m (44 - 62 lb in). NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

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Engine - Pan and covers

Engine oil pan - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Remove the bolts (2) and remove the oil pan (1).

NHIL13ENG0287AA

Next operation: Engine oil pan - Install (10.102)

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Engine - Pan and covers

Engine oil pan - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine oil pan - Remove (10.102) 1. Install the oil pan (1) onto the engine block. 2. Torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft). 3. Install the oil drain plug (3) into the oil pan and torque the bolt to 5 - 7 N·m (44 - 62 lb in). NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

NHIL13ENG0287AA

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Engine - Pan and covers

Engine oil pan - Remove F4GE9484, F4GE9484C*J601, F4GE9684

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

NHIL13ENG0316BA

NHIL13ENG0285AA

Version with oil pick up type A 1. Remove the oil pick up tube (2) by removing the bolts (1) and (3). 2. Remove the bolts (5) and remove the stiffening plate (4).

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Engine - Pan and covers

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

NHIL13ENG0276AA

NHIL13ENG0279AA

Version with dynamic balancer 1. Remove the oil pick up tube (2) by removing the bolts (5) and (3). 2. By means of pin (1), lock the dynamic balancer (4) in the TDC (Top Dead Center) position. 3. Remove the bolts (2) and remove the dynamic balancer (4).

Next operation: Engine oil pan - Install (10.102)

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Engine - Pan and covers

Engine oil pan - Install F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Engine oil pan - Remove (10.102)

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

NHIL13ENG0284AA

NHIL13ENG0276AA

NHIL13ENG0279AA

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

Version with dynamic balancer 1. Install the dynamic balancer (3) on the engine block. 2. Torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft). 3. Remove the lock pin (1). 4. Refer to Balancer - Install (10.110) for proper timing procedures.

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Engine - Pan and covers

5. Set the gasket (1) onto the oil pan (2). NOTE: The pictures of the instructions relating to the oil pan and to the pick up tube may not reflect the actual shape and dimensions of your engine equipment. However, the procedures described are still applicable.

NHIL13ENG0315AA

NHIL13ENG0316BA

6. Place the oil pan (1) and the mounting plate (4) onto the engine block. NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear. 7. Torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft). 8. Install the oil drain plug (3) into the oil pan and torque the bolt to 5 - 7 N·m (44 - 62 lb in).

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Engine - Pan and covers

Engine block cover Front - Remove F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Crankshaft damper - Remove (10.110) 1. Remove the bolts (1) from the front cover (2). Also be sure to remove the two bolts (3) from underneath the cover. NOTE: Take note of bolt (1) assembling positions since they have different lengths. 2. Remove the front cover (2) from the engine block.

NHIL13ENG0317AA

Next operation: Engine block cover Front - Cleaning (10.102)

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Engine - Pan and covers

Engine block cover Front - Cleaning F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Engine block cover Front - Remove (10.102) 1. Remove the sealing ring (2) from the front cover (1).

NHIL13ENG0318AA

NHIL13ENG0319AA

2. Clean the sealing surfaces and apply LOCTITE 5205.

Next operation: Engine block cover Front - Install (10.102)

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Engine - Pan and covers

Engine block cover Front - Install F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Engine block cover Front - Cleaning (10.102) 1. Install the front cover (2) and torque the mounting bolts (1) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0320AA

Next operation: Crankshaft damper - Install (10.110)

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Engine - Pan and covers

Engine block cover Front - Remove F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Crankshaft damper - Remove (10.110) 1. Remove the bolts (3) from the front cover (2). Also be sure to remove the four bolts (1) from underneath the cover (2). NOTE: Take note of the bolt installation positions because of different lengths. 2. Remove the front cover (2).

NHIL13ENG0321AA

Next operation: Engine block cover Front - Cleaning (10.102)

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Engine - Pan and covers

Engine block cover Front - Install F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine block cover Front - Cleaning (10.102) 1. place the front cover seal (1) onto the engine block.

NHIL13ENG0322AA

NHIL13ENG0323AA

2. Install the front cover (1) on the block and torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

Next operation: Crankshaft damper - Install (10.110)

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Engine - Pan and covers

Engine block cover Rear - Remove F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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

NHIL13ENG0324AA

Next operation: Engine block cover Rear - Cleaning (10.102)

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Engine - Pan and covers

Engine block cover Rear - Cleaning F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine block cover Rear - Remove (10.102) 1. Clean the rear cover and it's mating surface on the timing gear cover. NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant. Excessive sealant could squeeze out the sides and cause blockage of lubrication passages. 2. Apply a thin bead of LOCTITE 5205 (1), a few millimeters thick, to the sealing surface of the cover. NOTE: After applying the sealant, the cover should be installed within 10 to 20 minutes. NHIL13ENG0325AA

Next operation: Engine block cover Rear - Install (10.102)

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Engine - Pan and covers

Engine block cover Rear - Install F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine block cover Rear - Cleaning (10.102) NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or dirt. 1. Install the cover (1) onto the timing gear housing and torque the bolts in same location that they were removed. 2. Torque the bolts to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0326AA

Next operation: Engine flywheel - Install (10.103)

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Engine - Pan and covers

Engine block cover Rear - Cleaning F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine block cover Rear - Remove (10.102) 1. Clean the rear cover and it's mating surface on the timing gear cover. NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant. Excessive sealant could squeeze out the sides and cause blockage of lubrication passages. 2. Apply a thin bead of LOCTITEÂŽ 518 GASKET ELIMINATORÂŽ, a few millimeters thick, to the sealing surface (1) of the cover. NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes. Next operation: Engine block cover Rear - Install (10.102)

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NHIL13ENG0327AA

Engine - Pan and covers

Engine block cover Rear - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

NHIL13ENG0328AA

Next operation: Engine flywheel - Install (10.103)

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Engine - Pan and covers

Engine block cover Rear - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine flywheel - Remove (10.103) 1. Remove the retaining bolts (2) and remove the rear engine cover (1). NOTE: Take note of the retaining bolts (2) location due to the different lengths. This will aid in ease of installation.

NHIL13ENG0329AA

Next operation: Engine block cover Rear - Cleaning (10.102)

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Engine - Pan and covers

Engine block cover Rear - Cleaning F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Engine block cover Rear - Remove (10.102) 1. Clean the rear cover (2) and it's mating surface on the timing gear cover. NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant. Excessive sealant could squeeze out the sides and cause blockage of lubrication passages. 2. Apply a thin bead of LOCTITE 5205, a few millimeters thick, to the sealing surface (1) of the cover. NOTE: After applying the sealant, the cover should be assembled within 10 to 20 minutes. NHIL13ENG0330AA

Next operation: Engine block cover Rear - Install (10.102)

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Engine - Pan and covers

Engine block cover Rear - Install F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Engine block cover Rear - Cleaning (10.102) NOTE: Before any assembly operation always verify that the hole and the bolt threads have no evidence of wear or dirt. 1. Install the rear cover (1) onto the timing gear housing. 2. Install and torque the bolts in the same position from which they were removed to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0331AA

Next operation: Engine flywheel - Install (10.103)

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Engine - Pan and covers

Timing gear housing - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

1. Remove the retaining bolts (2) and remove the timing gear case (1) from the engine block. NOTE: Take note of the retaining bolts (2) location due to the different lengths. This will aid in ease of installation.

NHIL13ENG0332AA

Next operation: Timing gear housing - Cleaning (10.102)

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Engine - Pan and covers

Timing gear housing - Cleaning F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Timing gear housing - Remove (10.102) 1. Clean the timing gear housing (1) and it's mating surface on the engine block. NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant. Excessive sealant could squeeze out the sides and cause blockage of lubrication passages. 2. Apply a thin bead of LOCTITE 5205, a few millimeters thick, to the sealing surface (2) of the housing. NOTE: After applying the sealant, the housing should be assembled within 10 to 20 minutes. NHIL13ENG0333AA

Next operation: Timing gear housing - Install (10.102)

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Engine - Pan and covers

Timing gear housing - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

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

NHIL13ENG0334AA

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Engine - Pan and covers

Timing gear housing - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Disconnect the high pressure fuel pump stroke sensor (3). 2. Remove the bolts (2) and remove the timing gear housing (1) from the engine block.

NHIL13ENG0335AA

Next operation: Timing gear housing - Cleaning (10.102)

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Engine - Pan and covers

Timing gear housing - Cleaning F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Timing gear housing - Remove (10.102) 1. Clean the timing gear housing (2) and it's mating surface on the engine block. NOTE: A perfect seal is only obtained by completely cleaning the surface to seal. Any imperfection should be corrected as soon as possible. Avoid using excess sealant. Excessive sealant could squeeze out the sides and cause blockage of lubrication passages. 2. Apply a thin bead of LOCTITE 5205 (1), a few millimeters thick, to the sealing surface of the housing. NOTE: After applying the sealant, the housing should be assembled within 10 to 20 minutes. NHIL13ENG0340AA

Next operation: Timing gear housing - Install (10.102)

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Engine - Pan and covers

Timing gear housing - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0336AA

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Index Engine - 10 Pan and covers - 102 Engine block cover Front - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4GE9484, F4GE9484C*J601, F4GE9684

Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4GE9484, F4GE9484C*J601, F4GE9684

Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9484, F4GE9484C*J601, F4GE9684

Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine block cover Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine block cover Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine block cover Rear - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4GE9484, F4GE9484C*J601, F4GE9684

Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4GE9484, F4GE9484C*J601, F4GE9684

Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9484C*J601, F4GE9684

Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4GE9484, F4GE9484C*J601, F4GE9684

Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Timing gear housing - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Engine - 10 Valve drive and gears - 106

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Contents Engine - 10 Valve drive and gears - 106

FUNCTIONAL DATA Valve drive and gears Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Rocker arm Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rocker shaft Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Camshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Camshaft bushings Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Camshaft gear Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4DE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Engine - Valve drive and gears

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

NHIL13ENG0337AA

(1) Intake valve control - (2) Exhaust valve control

Rocker Assembly Components

NHIL13ENG0338AA

(1) Bolts- (2) Bracket - (3) Shafts - (4) Rockers.

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Engine - Valve drive and gears

Rocker arm - Disassemble F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valve cover - Remove (10.101) 1. Loosen tappet adjustment jam nuts (1) and loosen the adjusting bolts. 2. Remove the rocker shaft mounting bolts (2). 3. Remove the rocker assembly (3), which consists of the pedestal (6), rockers (4), and shaft (5). 4. Remove the valve bridges (7). 5. Remove the push rods (8).

NHIL13ENG0339AA

Next operation: Rocker shaft - Clearance (10.106)

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Engine - Valve drive and gears

Rocker arm - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Camshaft - Install (10.106) 1. Check that the tappet adjusters (1) are loose to prevent their binding on the push rods when installing the rocker assembly. 2. Install the rocker assembly onto the cylinder head consisting of: • Bracket (5) • rockers (3) • shafts (4) 3. Torque the bolts (2) to 36 Nm (27 lb ft). NHIL13ENG0339AA

Next operation: Rocker arm - Adjust (10.106)

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Engine - Valve drive and gears

Rocker arm - Adjust F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Rocker arm - Install (10.106) 1. Adjust the clearance between the rockers and valves using a set screw wrench (2), box wrench (1), and feeler gauge (3). 2. Set the clearance to the following specifications. • Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012 in) • Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022 in) NOTICE: On TIER 3 engines, due to the additional lobe on the camshaft for INTERNAL E.G.R, it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft two times only. Each cylinder must be checked by taking it to TDC (top dead center) at the end of the compression stroke and adjusting the clearance of both valve on the cylinder in question. Next operation: Valve cover - Install (10.101)

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NHIL13ENG0272AA

Engine - Valve drive and gears

Rocker arm - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Valve cover - Remove (10.101) 1. Remove the rocker arm supports by removing the two retaining bolts (1) and then remove the entire assembly as one unit. 2. Remove the push rods.

NHIL13ENG0347AA

Next operation: Rocker arm - Install (10.106)

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Engine - Valve drive and gears

Rocker arm - Check F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Rocker arm - Remove (10.106)

NHIL13ENG0344AA

(1) Elastic ring - (2) Spacer - (3) Rocker arms - (4) Support. 1. Carry out the assembly of the rocker arms after checking the components.

NHIL13ENG0345AA

A 19.000 - 19.026 mm (0.748 0.749 in)

B 18.975 - 18.963 mm (0.747 0.747 in)

C 19.000 - 19.026 mm (0.748 0.749 in)

2. Check the coupling surfaces of the bearings and shaft for excessive wear or damages. Replace if necessary. 3. Torque the threaded nut (1) to 4 - 6 N·m (35 - 53 lb in).

ROCKERCOMPCG3

Next operation: Rocker arm - Install (10.106)

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Engine - Valve drive and gears

Rocker arm - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Rocker arm - Check (10.106) 1. Install the rocker arm assembly (2) onto the cylinder head and torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0347AA

Next operation: Rocker arm - Adjust (10.106)

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Engine - Valve drive and gears

Rocker arm - Adjust F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Rocker arm - Install (10.106) 1. Adjust the clearance between the rockers and valves using a set screw wrench (2), box wrench (3), and feeler gauge (1). 2. Set the valve clearance to the following specifications. • Intake Valves - 0.20 - 0.30 mm (0.008 - 0.012 in) • Exhaust Valves - 0.45 - 0.55 mm (0.018 - 0.022 in) NOTICE: On TIER 3 engines, due to the additional lobe on the camshaft for INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft two times only. Each cylinder must be checked by taking it to TDC (top dead center) at the end of the compression stroke and adjusting the clearance of both valve on the cylinder in question. Next operation: Valve cover - Install (10.101)

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NHIL13ENG0312AA

Engine - Valve drive and gears

Rocker shaft - Clearance Prior operation: Rocker arm - Disassemble (10.106) 1. Check that the shaft/rocker coupling surfaces are not showing excessive wear or damage. Follow the provided rocker surface specifications.

SHAFTMEASURE

Next operation: Rocker arm - Install (10.106)

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Engine - Valve drive and gears

Camshaft - Remove Prior operation: Camshaft gear - Remove (10.106) 1. Remove the bolts (1) and remove camshaft (2) retaining plate (3). NOTE: Take note of the retaining plate (3) assembly position.

NHIL13ENG0350AA

NHIL13ENG0351AA

2. Carefully remove the camshaft (1) from the cylinder block (2).

Next operation: Camshaft - Measure (10.106)

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Engine - Valve drive and gears

Camshaft - Measure Prior operation: Camshaft - Remove (10.106) 1. Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check the alignment error. The alignment error should not exceed 0.04 mm (0.002 in). If the error is exceeded, replace the camshaft. 2. Check the camshaft lift. The values should be as follows: Exhaust lobe lift — 6.045 mm (0.238 in) Intake lobe lift — 7.582 mm (0.299 in) If the values are not within the specifications, replace the camshaft. 3. Check the camshaft (2) pin diameter using a micrometer 380000645 (1) on two perpendicular axes. The diameter should be within 53.995 - 54.045 mm (2.126 - 2.128 in). If the values are not within the specifications, replace the camshaft.

NHIL13ENG0352AA

BAIL07APH360FSA

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Engine - Valve drive and gears

NOTE: Camshaft pin and cam surfaces should be absolutely smooth; if they show any signs of seizing or scoring replace the camshaft and the bearings. Next operation: Camshaft - Install (10.106)

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Engine - Valve drive and gears

Camshaft - Install Prior operation: Camshaft - Measure (10.106) 1. Lubricate the camshaft bearings with clean engine oil and carefully install the camshaft (1) into the engine block. NOTE: Be careful not to damage the camshaft bearings or housings while sliding the camshaft into the engine block.

CRIL04J056A01

CRIL04J064A01

2. Set the camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator. 3. Torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

Next operation: Camshaft - End play (10.106)

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Engine - Valve drive and gears

Camshaft - End play Prior operation: Camshaft - Install (10.106) 1. Check camshaft (1) end play using a dial indicator 17270. End play should be between 0.10 - 0.36 mm (0.004 0.014 in).

CRIL04J065A01

Next operation: Engine block cover Rear - Install (10.102)

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Engine - Valve drive and gears

Camshaft Push rod - Install F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Camshaft - Install (10.106) 1. Before installation be sure to check that there is no signs of wear or distortion. Intake and exhaust push rods are identical and therefore interchangeable.

PUSHROD

NHIL13ENG0358AA

2. Install the push rods (2). 3. Install the valve bridges (1) with the marks facing the exhaust manifold.

Next operation: Rocker arm - Install (10.106)

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Engine - Valve drive and gears

Camshaft Tappets - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Camshaft - Remove (10.106) 1. Remove the tappets (1) from the engine block.

NHIL13ENG0359AA

Next operation: Camshaft Tappets - Measure (10.106)

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Engine - Valve drive and gears

Camshaft Tappets - Measure F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Camshaft Tappets - Remove (10.106)

NHIL13ENG0363FA

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK A 16.000 16.030 mm

B 15.924 15.954 mm

C 15.960 15.975 mm

D 15.924 15.954 mm

E 8 mm

Next operation: Camshaft - Install (10.106)

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F 26 mm

G 44 mm

Engine - Valve drive and gears

Camshaft Tappets - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

CRIL04J063A01

Next operation: Camshaft - Install (10.106)

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Engine - Valve drive and gears

Camshaft Push rod - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Camshaft - Install (10.106) 1. Inspect the push rods for signs of deformation. 2. Inspect both ends of the push rods for evidence of seizure or wear. NOTE: The push rods driving the intake and exhaust valves are identical and therefore interchangeable. Replace any failed push rods with new. 3. Install the push rods. NOTICE: Ensure that the push rods are properly seated in the tappets.

PUSHROD

Next operation: Rocker arm - Install (10.106)

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Engine - Valve drive and gears

Camshaft Tappets - Measure F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Camshaft Tappets - Remove (10.106)

NHIL13ENG0363FA

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK A 16.000 16.030 mm

B 15.929 15.959 mm

C 15.965 15.980 mm

D 15.929 15.959 mm

E 14 mm

Next operation: Camshaft - Install (10.106)

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F 32 mm

G 50 mm

Engine - Valve drive and gears

Camshaft bushings - Measure Prior operation: Camshaft - Remove (10.106) 1. Camshaft bearings (2) are pressed into their housings. Check the internal surface of the bearings for seizing or wear. Use a bore dial gauge OEM1032 (3) to measure the camshaft bearings (2) and intermediate housing (1) diameter. The measurements should be performed on two perpendicular axis'. Camshaft bearing inside diameter should be within 54.083 - 54.147 mm (2.129 - 2.132 in).

CRIL04J060A01

NHIL13ENG0365AA

*Height to be obtained after installing the bearing. A 59.222 - 59.248 mm

B 54.089 - 54.139 mm

Next operation: Camshaft - Replace (10.106)

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C 54.083 - 54.147 mm

Engine - Valve drive and gears

Camshaft bushings - Replace Prior operation: Camshaft - Measure (10.106) Remove and install the bushing (1) using the beater with hand grip (2) 380000145. NOTICE: When installing the bushing , take note of orientation to make sure the lubricating holes on the bushing coincide with the holes on the block housing.

NHIL13ENG0366AA

Next operation: Camshaft - Install (10.106)

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Engine - Valve drive and gears

Camshaft gear - Remove F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine block cover Rear - Remove (10.102) 1. Remove the bolts (1) securing the camshaft gear (2) to the camshaft (3). 2. Remove the camshaft gear (2) from the camshaft (3).

NHIL13ENG0367AA

Next operation: Camshaft gear - Install (10.106)

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Engine - Valve drive and gears

Camshaft gear - Remove F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine block cover Rear - Remove (10.102) 1. Remove the retaining bolts (1). 2. Remove the camshaft gear (2) from the camshaft (3).

NHIL13ENG0368AA

Next operation: Camshaft gear - Install (10.106)

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Engine - Valve drive and gears

Camshaft gear - Install F4DE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Camshaft gear - Remove (10.106) 1. With a felt tip pen, highlight the timing mark on the crankshaft gear (1) mounted on the crankshaft (2) upon the upright surface on which a groove (3) has been created for the injection timing. NOTE: For ease of crankshaft rotation, install two pins in the end of the crankshaft.

NHIL13ENG0369AA

NHIL13ENG0370AA

NHIL13ENG0371AA

2. Turn the crankshaft (1) and the camshaft (2) so that the camshaft gear (3) can be mounted on the camshaft (2) to coincide with the timing mark on the crankshaft gear (4).

3. Position a dial indicator gauge 380001543 (1) on the camshaft gear (2). 4. Check that the clearance between gears (2) and (3) is within 0.076 - 0.280 mm (0.003 - 0.011 in).

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Engine - Valve drive and gears

5. Torque the bolts (1) that secure the gear (2) to camshaft (3) to 32 - 40 N·m (24 - 30 lb ft).

NHIL13ENG0372AA

Next operation: Engine block cover Rear - Cleaning (10.102)

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Engine - Valve drive and gears

Camshaft gear - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Engine block cover Rear - Remove (10.102) 1. Remove the retaining bolts (1) and remove the gears (2) from the camshaft (3).

NHIL13ENG0373AA

Next operation: Camshaft gear - Install (10.106)

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Engine - Valve drive and gears

Camshaft gear - Install F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0374AA

NHIL13ENG0375BA

2. Turn the crankshaft (3) and the camshaft (4) so that the camshaft gear (1) can be mounted on the camshaft (4) to coincide with the timing marks on the gears (2).

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Engine - Valve drive and gears

3. Position a dial indicator gauge 380001543 (1) on the camshaft gear (2). 4. Check that the clearance between gears (2) and (3) is within 0.076 - 0.280 mm (0.003 - 0.011 in).

NHIL13ENG0376AA

NHIL13ENG0377AA

5. Torque the bolts (1) securing the gears (2) to the camshaft (3) to 32 - 40 N·m (24 - 30 lb ft).

Next operation: Engine block cover Rear - Install (10.102)

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Engine - Valve drive and gears

Camshaft gear - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

NHIL13ENG0378AA

NHIL13ENG0379AA

NHIL13ENG0380AA

2. Turn the engine crankshaft (3) and the camshaft (2) so that the camshaft gears (1) can be mounted on the camshaft (2) to coincide with the mark on the crankshaft gear.

3. Position a dial indicator gauge 380001543 (1) on the camshaft gear (2). 4. Check that the clearance between gears (2) and (3) is within 0.076 - 0.280 mm (0.003 - 0.011 in).

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Engine - Valve drive and gears

5. Torque the bolts (1) installing the gears (2) to the camshaft (3) to 32 - 40 N·m (24 - 30 lb ft).

NHIL13ENG0381AA

Next operation: Engine block cover Rear - Install (10.102)

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Index Engine - 10 Valve drive and gears - 106 Camshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Camshaft Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Camshaft Tappets - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Camshaft bushings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Camshaft bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Camshaft gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4DE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Camshaft gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Camshaft gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rocker arm - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rocker arm - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rocker arm - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rocker shaft - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Valve drive and gears - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Cylinder heads - 101

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10.4 [10.101] / 1

Contents Engine - 10 Cylinder heads - 101

SERVICE Valve cover Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4CE9684, F4GE9684

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4GE9484, F4GE9484C*J601, F4GE9684

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Valves Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valve guide Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valve seat Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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CONSUMABLES INDEX Consumable Molykote速 G-N assembly paste Molykote速 G-N assembly paste Molykote速 G-N assembly paste Molykote速 G-N assembly paste

Reference

PAGE

Metal

Cylinder head - Install

10.4 / 15

Metal

Cylinder head - Install

10.4 / 19

Metal

Cylinder head - Install

10.4 / 22

Metal

Cylinder head - Install

10.4 / 26

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Engine - Cylinder heads

Valve cover Rocker housing - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valve cover - Remove (10.101) 1. Remove the nuts (2) securing the electro-injectors (3) and disconnect the electrical wires. 2. Remove the bolts (1) securing the rocker arm housing (4). 3. Remove the rocker arm housing (4) and gasket from the cylinder head.

NHIL13ENG0382AA

Next operation: Valve cover Rocker housing - Install (10.101)

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Engine - Cylinder heads

Valve cover Rocker housing - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Rocker arm - Install (10.106) 1. Check the condition of the electrical cables (2) and their electrical connectors (4). Replace if damage was caused from removing the retaining bolt (3). 2. Install a new gasket (1) onto the support (5).

NHIL13ENG0383AA

NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt. 3. Install the housing (2) and torque the bolts (1) to 1 2 N·m (11 - 15 lb in).

NHIL13ENG0384AA

NHIL13ENG0385AA

4. Connect the electrical cables (1) to the injectors (3). 5. Use a torque wrench (2) to torque the retaining nuts (4) to 1 - 2 N·m (11 - 15 lb in).

Next operation: Valve cover - Install (10.101)

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Engine - Cylinder heads

Valve cover - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103

1. Remove the nuts (1) securing the valve cover (2) to the base. 2. Remove the valve cover (2) and the gasket.

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Next operation: Valve cover - Install (10.101)

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Engine - Cylinder heads

Valve cover - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valve cover - Remove (10.101) 1. Install a new gasket (1) onto the valve cover (2). 2. Install the valve cover (2) onto the cylinder head. 3. Torque the bolts to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0387AA

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Engine - Cylinder heads

Valve cover - Remove F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Remove the nuts (1) securing the valve cover (2). 2. Remove the valve cover (2) from the cylinder head.

NHIL13ENG0388AA

Next operation: Valve cover - Install (10.101)

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Engine - Cylinder heads

Valve cover - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

1. Remove the retaining bolts (1) from the valve covers (2). 2. Remove the valve covers (2) and the related gaskets.

NHIL13ENG0389AA

NHIL13ENG0390AA

3. On one of the valve covers there is a blow-by valve for the lubrication oil vapors. This can be removed along with the relevant valve cover (2) by removing the retaining bolts (1). NOTE: All gaskets should be replaced upon reassembly.

Next operation: Valve cover - Install (10.101)

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Engine - Cylinder heads

Valve cover - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Valve cover - Remove (10.101) 1. Install the valve covers (2) with the new gaskets. 2. Torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0391AA

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3. Install the valve cover (2) that incorporates the blow-by valve with a new gasket and torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft).

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Engine - Cylinder heads

Cylinder head - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Fuel injectors - Remove (10.218) 1. Remove the cylinder head bolts (1) from the cylinder head (2). NOTE: The highlighted bolts are shorter.

NHIL13ENG0393BA

NHIL13ENG0394AA

2. Hook the provided cylinder head lifting brackets (1) to suitable lifting chains. 3. Remove the cylinder head (2) from the engine block using a suitable hoist.

Next operation: Cylinder head - Check (10.101)

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Engine - Cylinder heads

Cylinder head - Check F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Cylinder head - Remove (10.101)

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

NHIL13ENG0395AA

NHIL13ENG0396AA

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

A 104.750 - 105.250 mm (4.124 - 4.144 in)

B 1 mm

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Cylinder head - Install F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Cylinder head - Check (10.101) 1. Check the cleanliness of the cylinder head and engine block coupling surface. 2. Without damaging the gasket, set the gasket (1) onto the engine block with the marking "TOP" facing the cylinder head. 3. The reference arrow (2) shows the point at where the head gasket thickness is given.

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NHIL13ENG0398AA

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4. There are two head gasket thicknesses, ( 1.25 mm Type A and 1.15 mm Type B). To determine the correct head gasket to use, piston protrusion must be measured. • For each piston, measure protrusion in two places 180 ° apart, at a distance of 45 mm (1.8 in) from the center of the piston S1 and S2. Then calculate the average:

• Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

• If S is > 0.40 mm (0.016 in) use seal type A. • If S is < 0.40 mm (0.016 in) use seal type B. A 45 mm

B 45 mm

5. Before reusing the cylinder head bolts, measure them twice as indicated in the picture. Check the D1 and D2 diameters for the following specifications: if D1 - D2 < 0.1 mm (0.004 in) the bolt can be utilized again. If D1 - D2 > 0.1 mm (0.004 in) the bolt must be replaced. NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

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Engine - Cylinder heads

6. Hook the provided cylinder head lifting brackets (1) with a suitable hoist. 7. Set the cylinder head (2) onto the engine block. 8. Lubricate the cylinder head bolts with MOLYKOTE® G-N METAL ASSEMBLY PASTE. 9. Install the bolts into the cylinder head.

NHIL13ENG0400AA

NHIL13ENG0401AA

10. Torque the cylinder head bolts by bolt size (1) in the following order using tool DM370(3/4) (2) for the angle torquing procedure. 1. Torque the bolts (1) with a torque wrench to the following specifications: • 12x1.75x130 are torqued to 30 - 40 Nm (22 30 lb ft). • 12x1.75x150 are torqued to 50 - 60 Nm (37 44 lb ft). 2. Turn the bolt clockwise 85 - 95 °. 3. Turn the bolt clockwise an additional 85 - 95 °.

NHIL13ENG0402AA

Tightening sequence for the 6 cylinder engine. A = Front of engine Next operation: Fuel injectors - Install (10.218)

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Engine - Cylinder heads

Cylinder head - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Prior operation: Fuel injectors Mechanical - Remove (10.218) 1. Remove the bolts (1) securing the cylinder head (3) to the engine block. 2. Hook the provided cylinder head lifting brackets to a suitable hoist. 3. Using the hoist, remove the cylinder head from the engine block. 4. Remove the cylinder head gasket (2).

NHIL13ENG0403AA

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Cylinder head - Remove F4CE9684, F4GE9684

NHIL13ENG0404AA

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Cylinder head - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Prior operation: Cylinder head - Remove (10.101) 1. Check the cleanliness of the cylinder head and engine block coupling surface. 2. Without damaging the gasket, set the gasket (1) onto the engine block with the marking "TOP" facing the cylinder head. 3. The reference arrow (2) shows the point at where the gasket thickness is given. NOTE: Do not grease the gasket. It is recommended to keep the gasket inside its packaging until assembly to the cylinder head. Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture.

NHIL13ENG0405AA

NHIL13ENG0398AA

• Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

• If S is > 0.40 mm (0.016 in) use seal type A. • If S is < 0.40 mm (0.016 in) use seal type B. A 45 mm

B 45 mm

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Engine - Cylinder heads

5. Hook the provided cylinder head lifting brackets (1) with a suitable hoist. 6. Set the cylinder head (2) onto the engine block. NOTE: If the valves have been removed, it is necessary to install them before installing the cylinder head onto the engine block.

NHIL13ENG0400AA

NHIL13ENG0408AA

NHIL13ENG0414AA

TORQUEPATTERNG2

7. Lubricate the cylinder head bolts with MOLYKOTE® G-N METAL ASSEMBLY PASTE. 8. Install the bolts (1) into the cylinder head (2).

9. If reusing the bolts, measure them twice as indicated in the picture. Check for the following specifications: - If D1 - D2 < 0.1 mm (0.004 in) the bolt can be used again. - If D1 - D2 > 0.1 mm (0.004 in) the bolt must be replaced.

10. The bolts must be torqued starting with the center bolts and moving out. The bolts should be torqued in the following stages using the tool DM370(3/4) for the angular torquing procedure. Refer to the bolt sequencing diagram. • Make all the bolts snug tight, then turn 90 °. • Turn the bolts M12x140 and M12x180 an additional 90 °. 11. The end result should look like this. • M12x70 = 50 Nm (36.9 lb ft) + 90 °. • M12x140 = 40 Nm (29.5 lb ft) + 180 °. • M12x180 = 70 Nm (51.6 lb ft) + 180 °.

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Engine - Cylinder heads

Next operation: Fuel injectors Mechanical - Install (10.218)

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Engine - Cylinder heads

Cylinder head - Install F4CE9684, F4GE9684

NHIL13ENG0420AA

NHIL13ENG0398AA

• Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

• If S is > 0.40 mm (0.016 in) use seal type A. • If S is < 0.40 mm (0.016 in) use seal type B. A 45 mm

B 45 mm

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Engine - Cylinder heads

5. Place the cylinder head (2) onto the engine block. Lubricate the bolts (1) with MOLYKOTE® G-N METAL ASSEMBLY PASTE and install the bolts (1) into the cylinder head. NOTE: If the valves have been removed, it is necessary to install them before installing the cylinder head onto the engine block.

NHIL13ENG0422AA

NHIL13ENG0423AA

TORQUEPATTERNG2

6. Before using the bolts again, measure them twice as indicated in the picture. Refer to the following specifications: - If D1 - D2 < 0.1 mm (0.004 in) the bolt can be used again. - If D1 - D2 > 0.1 mm (0.004 in) the bolt must be replaced.

7. The bolts must be torqued starting with the center bolts and moving out. Torque the bolts in the following sequence using the tool DM370(3/4) for the angular torquing procedure. Refer to bolt torquing sequence diagram. • Make all the bolts snug tight, then turn the bolts 90 °. • Turn the bolt sizes M12x140 and M12x180 an additional 90 °.

8. The end result should look like this. • M12x70 = 50 Nm (36.9 lb ft) + 90 ° • M12x140 = 40 Nm (29.5 lb ft) + 180 ° • M12x180 = 70 Nm (51.6 lb ft) + 180 ° Next operation: Fuel injectors Mechanical - Install (10.218)

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Engine - Cylinder heads

Cylinder head - Check F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Cylinder head - Remove (10.101)

Checking cylinder head wet seal This check should be performed using the proper tools. 1. Use a pump to fill with water heated to approximately 90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pressure. 2. Replace the core plugs (1) if any leakage is found. Use the proper punch for their removal and installation. NOTE: Before refitting, smear the plug surfaces with water repellent sealant. 3. Replace the cylinder head if leaks are found. NHIL13ENG0416AA

NHIL13ENG0419AA

Checking cylinder head supporting surface 4. Distortion found along the whole cylinder head should not exceed 0.20 mm (0.008 in). If higher values are found, resurface the cylinder head according to values and indications shown in the following figure. 5. The rated thickness (A) for the cylinder head is 104.75 - 105.25 mm (4.124 - 4.144 in). Maximum metal removal should not exceed thickness (B) by 1 mm (0.039 in). NOTE: After resurfacing, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

A 104.750 - 105.250 mm (4.124 - 4.144 in)

B 1 mm

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Cylinder head - Check F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Prior operation: Cylinder head - Remove (10.101)

Checking cylinder head wet seal This check should be performed using the proper tools. 1. Use a pump to fill with water heated to approximately 90 °C (194.0 °F)and 2 - 3 bar (29.0 - 43.5 psi) of pressure. 2. Replace the core plugs (1) if any leakage is found. Use the proper punch for their removal and installation. NOTE: Before refitting, smear the plug surfaces with water repellent sealant. 3. Replace the cylinder head if leaks are found. NHIL13ENG0416AA

NHIL13ENG0419AA

A 104.750 - 105.250 mm (4.124 - 4.144 in)

B 1 mm

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Cylinder head - Install F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Check the cleanliness of the cylinder head and engine block coupling surface. 2. Without damaging the gasket, set the gasket (1) onto the engine block with the marking "TOP" facing the cylinder head. 3. The reference arrow (2) shows the point at where the gasket thickness is given.

NHIL13ENG0420AA

NOTE: Do not grease the gasket. It is recommended to keep the gasket inside its packaging until assembly to the cylinder head. Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture. 4. There are two head gasket thicknesses, ( 1.25 mm Type A and 1.15 mm Type B). To determine the correct head gasket to use, piston protrusion must be measured. • For each piston, measure protrusion in two places 180 ° apart, at a distance of 45 mm (1.8 in) from the center of the piston S1 and S2. Then calculate the average:

NHIL13ENG0398AA

• Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

• If S is > 0.40 mm (0.016 in) use seal type A. • If S is < 0.40 mm (0.016 in) use seal type B. A 45 mm

B 45 mm

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Engine - Cylinder heads

5. Place the cylinder head (2) onto the engine block. Lubricate the cylinder head bolts (1) with MOLYKOTE® G-N METAL ASSEMBLY PASTE and install the bolts (1) into the cylinder head. NOTE: If the valves have been removed, it is necessary to install them before installing the head onto the engine block.

NHIL13ENG0422AA

NHIL13ENG0423AA

TORQUEPATTERNG2

6. Before using the bolts again, measure them twice as indicated in the picture, checking D1 and D2 diameters: If D1 - D2 < 0.1 mm (0.004 in) the bolt can be used again. If D1 - D2 > 0.1 mm (0.004 in) the bolt must be replaced. NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of dirt or wear.

7. The bolts must be torqued starting with the center bolts and moving out. Torque the bolts in the following stages using the tool DM370(3/4) for the angular torquing procedure. • Make all the bolts snug tight, then turn 90 °. • Turn the bolt sizes M12x140 and M12x180 an additional 90 °. 8. The end result should look like this. • M12x70 = 50 Nm (36.9 lb ft) + 90 ° • M12x140 = 40 Nm (29.5 lb ft) + 180 ° • M12x180 = 70 Nm (51.6 lb ft) + 180 °

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Engine - Cylinder heads

Valves - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Cylinder head - Remove (10.101) 1. Intake (1) and exhaust (2) valves have the same diameter valve head. The central notch of the exhaust valve (2) head distinguishes it from the intake valve. NOTE: Should cylinder head valves not be replaced, number them before removing in order to reinstall them in the same position. A = intake side - S = exhaust side

NHIL13ENG0425AA

NHIL13ENG0426AA

NHIL13ENG0427AA

2. Valve removal should be performed using tool 75291050 (1) and pressing the cap (3) so that when compressing the springs (4) the keepers (2) can be removed. Then remove the cap (3) and the springs (4). 3. Repeat this operation for all the valves. 4. Turn over the cylinder head and remove the valves (5).

5. Remove the sealing rings (1) and (2) from the valve guides. NOTE: Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valves - Measure F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valves - Cleaning (10.101)

NHIL13ENG0428AA

INTAKE AND EXHAUST VALVE MAIN DATA 1. Check the valve stem (2) using a micrometer (1). The valve stem diameter for intake and exhaust valves should be between 6.970 - 6.990 mm (0.274 0.275 in).

NHIL13ENG0429AA

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valves - Cleaning Prior operation: Valves - Remove (10.101) 1. Remove carbon deposits from valves using the proper metal brush. 2. Check that the valves show no signs of seizing, scoring, or cracking. 3. If necessary, grind the valve seats, taking away the least amount of material possible.

NHIL13ENG0430AA

Next operation: Valves - Measure (10.101)

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Engine - Cylinder heads

Valves Spring - Check F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valves - Remove (10.101) Before installing the valve springs, use a valve spring load checking tool 99305047 to check spring load. Compare load and elastic deformation data with those of the new springs in the following table:

NHIL13ENG0431AA

Height (H) - 47.75 mm (1.880 in) (H1) - 35.33 mm (1.391 in) (H2) - 25.2 mm (0.992 in)

Weight applied None (P) - 320.8 - 358.8 N (72.1 - 80.7 lb) (P1) - 702 - 780 mm (27.6 - 30.7 in)

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valves - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valves - Cleaning (10.101) 1. Lubricate the valve stems (2) and install them into the relevant valve guides according to the position marked at removal. 2. install the sealing rings (1) and (3) on the valve guides. NOTE: Sealing rings (1) for intake valves are yellow and sealing rings (3) for exhaust valves are green.

NHIL13ENG0432AA

NHIL13ENG0433AA

3. Position the springs (4) and the upper cap (3) on the cylinder head. Use tool 75291050 (1) to compress the spring (4) and lock the parts to the valve (5) by the keepers (2).

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Valves - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Cylinder head - Remove (10.101) 1. Intake (1) and exhaust (2) valves have the same diameter valve head. NOTE: Should cylinder head valves not be replaced, number them before removing in order to reinstall them in the same position. A = intake side

NHIL13ENG0434AA

NHIL13ENG0435AA

NHIL13ENG0440AA

2. To remove the valves, use tool 75291050 (1). Using the tool, press the cap (3) to compress the valve spring (4) and remove the keepers (2). Then remove the cap (3) and the springs (4). 3. Repeat this operation for all the valves. 4. Turn over the cylinder head and remove the valves (5).

5. Remove the sealing rings (1) and (2) from the valve guides.

Next operation: Valves - Cleaning (10.101)

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Engine - Cylinder heads

Valves - Measure F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Valves - Cleaning (10.101)

NHIL13ENG0437AA

INTAKE AND EXHAUST VALVE MAIN DATA 1. Check the valve stem (1) using a micrometer (2). The valve stem diameter for intake and exhaust valves should be between 7.960 - 7.980 mm (0.313 0.314 in).

NHIL13ENG0438AA

Next operation: Valves - Cleaning (10.101)

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Engine - Cylinder heads

Valves Spring - Check F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

NHIL13ENG0439AA

Height H H1 H2

63.50 mm (2.500 in) 49.02 mm (1.930 in) 38.20 mm (1.504 in)

Under a load of P1 P2

Free 320.8 - 358.8 N (72.1 - 80.7 lb) 702 - 780 mm (27.6 - 30.7 in)

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valves - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Valves - Remove (10.101) 1. Lubricate the valve stems (1) and install them into the relevant valve guides according to the position marked at removal. 2. Install the sealing rings (2) and (3) onto the valve guides.

NHIL13ENG0440AA

NHIL13ENG0441AB

3. Position the valve springs (4) and the upper cap (3) onto the cylinder head. Use the valve spring compressor tool 75291050 (1) to compress the spring (4) and install the valve keepers (2) to lock the parts to the valve (5).

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Valve guide - Clearance F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valves - Remove (10.101) 1. Use a magnetic base dial bore gauge (1) set as shown in the figure. The assembling clearance should be between 0.052 - 0.092 mm (0.002 - 0.004 in). 2. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm (0.001 in).

NHIL13ENG0442AA

NHIL13ENG0443AA

3. Use a bore dial gauge to measure the inside bore diameter of the valve guides. The values for both intake and exhaust valve guides should be within 7.042 - 7.062 mm (0.277 - 0.278 in).

A 7.042 - 7.062 mm (0.277 - 0.278 in)

B Intake

C Exhaust

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valve guide - Clearance F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

NHIL13ENG0444AA

NHIL13ENG0443AA

3. Use a bore dial gauge to measure the inside bore diameter of the valve guides. The values for both intake and exhaust valve guides should be within 7.042 - 7.062 mm (0.277 - 0.278 in).

A 8.0190 - 8.0390 mm (0.3157 0.3165 in)

B Intake

C Exhaust

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valve seat - Regrind F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Valves - Remove (10.101) Should slight scratches or burns be found, go over the valve seat (2) using a valve seat grinding tool kit 99305019 (1) according to the inclination values indicated as follows:

NHIL13ENG0446AA

NHIL13ENG0447FA

VALVE SEAT MAIN DATA (4 CYL.) A B 69.5 - 70.5 ° 45 ° (69.5 70.5 °)

C 29.5 - 30.5 ° (29.5 30.5 °)

D E 69.5 - 70.5 ° 60 ° (69.5 70.5 °)

If valve seats can not be reground within specification, replace them with new ones. Using a valve seat grinding tool 99305019, remove as much material as possible from the valve seats without damaging the cylinder head until they can be extracted from the cylinder head using a punch. 1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F) and using the proper punch, install the new, previously cooled valve seats into the cylinder head. 2. Using a valve seat grinding tool kit 99305019, go over the valve seats according to the values stated in the previous figure.

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F 29.5 - 30.5 ° (29.5 30.5 °)

G 3.370 3.630 mm (0.133 0.143 in)

H 3.020 3.280 mm (0.119 0.129 in)

Engine - Cylinder heads

NHIL13ENG0448FA

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD A 1.10 1.50 mm (0.04 0.06 in)

B 39.50 40.50 mm (1.56 1.59 in)

C 27.25 27.75 mm (1.07 1.09 in)

D E 34.837 - 3 36.78 mm 4.863 mm (1.372 1.373 in)

F 27.25 27.75 mm (1.07 1.09 in)

H I G 34.837 - 3 36.78 mm Exhaust 4.863 mm (1.372 1.373 in)

J Intake

3. After regrinding, check the valve (3) sinking value by using the base 380000364 (2) and the dial bore gauge 380000228 (1). Intake valve sink should between 0.59 - 1.11 mm (0.023 - 0.044 in). Exhaust valve sink should be between 0.96 - 1.48 mm (0.038 - 0.058 in).

NHIL13ENG0449AA

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valve seat - Regrind F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Valves - Remove (10.101) Should slight scratches or burns be found, go over the valve seat (2) with a valve seat grinding tool kit 99305019 (1) according to the inclination values indicated as follows:

NHIL13ENG0446AA

VALVESEAT2

VALVE SEAT MAIN DATA (dimensions in mm) If valve seats can not be reground within specification, replace them with new ones. Using a valve seat grinding tool 99305019, remove as much material as possible from the valve seats without damaging the cylinder head until they can be extracted from the cylinder head using a punch. 1. Heat the cylinder head to 80 - 100 °C (176.0 - 212.0 °F). Using the proper punch, install the new, previously cooled valve seat into the cylinder head. 2. Using a valve seat grinding tool 99305019, go over the valve seats according to the values stated in the previous figure.

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Engine - Cylinder heads

NHIL13ENG0452AA

VALVE SEAT HOUSING MAIN DATA A 4.38 - 4.64 mm (0.17 - 0.18 in)

B 45 °

D 4.06 - 4.32 mm (0.16 - 0.17 in)

C 30 °

E 39.500 mm

F 42.500 mm

3. After regrinding, check that the valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial bore gauge 380000228 (1). Intake and exhaust valve seat sinking should be between 1 - 1.52 mm (0.039 - 0.060 in).

NHIL13ENG0449AA

Next operation: Valves - Install (10.101)

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Index Engine - 10 Cylinder heads - 101 Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4GE9484, F4GE9484C*J601, F4GE9684

Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4CE9684, F4GE9684

Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4CE9684, F4GE9684

Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103

Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valve cover Rocker housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valve cover Rocker housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valve guide - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valve seat - Regrind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Contents Engine - 10 Connecting rods and pistons - 105

FUNCTIONAL DATA Connecting rod and piston Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Piston Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connecting rod bearing Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Piston pin bushings Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Connecting rod and piston - Overview

NHIL13ENG0454AA

(1) (2) (3) (4)

Piston Split rings Bolts Half bearings

(5) (6) (7) (8)

Connecting rod Bearing Snap rings Pin

NOTE: The pistons are supplied spare with the following sizes: - Standard - 0.4â&#x20AC;&#x2026;mm (0.016â&#x20AC;&#x2026;in) oversize.

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Connecting rod and piston - Remove Prior operation: Engine oil pan - Remove (10.102) 1. Remove the connecting rod nuts (2) and remove the connecting rod caps (1). 2. Remove the piston and connecting rod as one unit from the top of the engine block. 3. Repeat these steps for the remaining cylinders. NOTE: Keep the half bearings into their housing since in case of use they shall be installed in the same position found at removal.

NHIL13ENG0455AA

Next operation: Connecting rod and piston - Install (10.105)

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Connecting rod and piston Connecting rod - Measure

NHIL13ENG0456GA

* Value for the inside diameter to be obtained after driving in connecting rod small end and grinding. A 40.987 41.013 mm (1.614 - 1.615 in)

B 40.987 41.013 mm (1.614 - 1.615 in)

C 38.019 38.033 mm (1.497 - 1.497 in)

D 38.000 38.006 mm (1.496 - 1.496 in)

E 72.987 73.013 mm (2.874 - 2.875 in)

F 1.9550 1.9680 mm (0.0770 0.0775 in)

NOTE: The surface of the connecting rod and rod cap are knurled to ensure a better coupling. Therefore, it is recommended not to smooth the knurls.

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NHIL13ENG0457AA

NOTE: Every connecting rod is marked as follows: (1) - On the body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement, it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one. (2) - On the body with a letter showing the weight of the connecting rod assembled at production: - V - 1820 - 1860 g (64.2 - 65.6 oz) (yellow marking) - W - 1861 - 1900 g (65.6 - 67.0 oz) (green marking) - X - 1901 - 1940 g (67.1 - 68.4 oz) (blue marking) Spare connecting rods are of the - W - class with a green marking. Material removal is not allowed.

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Connecting rod and piston - Assemble Prior operation: Piston Pin - Remove (10.105) 1. The piston crown is marked as follows: 1. Part number and design modification number. 2. Arrow showing piston installation direction into cylinder. 3. Manufacturing date. 4. Stamp indicating the ring carrier US inspection.

NHIL13ENG0458AA

NHIL13ENG0459AA

NHIL13ENG0460AA

2. Connect the piston (1) to the connecting rod (4) with the piston pin (5) so that the reference arrow (2) for installing the piston (1) into the cylinder and the numbers (3) marked on the connecting rod (4) are read as shown in the figure.

3. Position the piston (1) on the connecting rod (2) according to the diagram shown in the figure and install the pin (3) and stop at the snap rings (4).

Next operation: Connecting rod and piston - Install (10.105)

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Connecting rod and piston - Install Prior operation: Connecting rod and piston Connecting rod - Install (10.105) 1. Well lubricate the pistons, including the split rings and the cylinder walls with clean engine oil. 2. Use the piston band clamp 380000325 (1) to install piston and connecting rod assembly (2) into the cylinders and check for the following:

NHIL13ENG0461AA

NHIL13ENG0462AB

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

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Piston - Measure Prior operation: Piston - Remove (10.105) 1. Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance. The value should be between the following specifications: 103.714 - 103.732 mm (4.083 - 4.084 in) 103.759 - 103.777 mm (4.085 - 4.086 in)(*) (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A

NHIL13ENG0463AA

NHIL13ENG0464AA

2. The clearance between the piston and the cylinder bore can be checked also with a feeler gauge (1) as shown in the figure.

Next operation: Connecting rod and piston - Assemble (10.105)

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Piston Ring - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Connecting rod and piston - Remove (10.105) 1. Remove the split rings (1) from the piston (3) using split ring pliers 380000324 (2).

NHIL13ENG0465AA

Next operation: Piston Ring - Measure (10.105)

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Piston Ring - Measure F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Piston - Remove (10.105) 1. Use a micrometer (2) to check piston split ring (1) thickness. The values should be as follows: Combustion ring: 2.560 - 2.605 mm (0.101 - 0.103 in) Intermediate ring: 2.350 - 2.380 mm (0.093 - 0.094 in) Oil control ring: 3.970 - 3.990 mm (0.156 - 0.157 in)

NHIL13ENG0466AA

NHIL13ENG0467AA

NHIL13ENG0468AA

2. Check the clearance between the piston rings (1) of the 2nd and 3rd slot and the relevant housings on the piston (3), using a feeler gauge (2).

3. Since the first piston ring is trapezoidal, the clearance between the slot and the ring should be measured as follows: Make the piston (1) protrude from the engine block (2) so that the ring (4) protrudes half-way from the cylinder bore (3). In this position, use a feeler gauge to check the clearance (X) between the ring and the slot. Values should be as follows: Combustion ring: 0.100 - 0.175 mm (0.004 - 0.007 in) Intermediate ring: 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in)(*) (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A Oil control ring: 0.040 - 0.080 mm (0.002 - 0.003 in)

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4. Use the feeler gauge (1) to measure the piston split ring (2) end gap installed into the cylinder bore (3). Values should be as follows: Combustion ring: 0.30 - 0.40 mm (0.012 - 0.016 in) Intermediate ring: 0.60 - 0.80 mm (0.024 - 0.031 in) Oil Control ring: 0.30 - 0.55 mm (0.012 - 0.022 in)

NHIL13ENG0469AA

Next operation: Piston - Install (10.105)

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Piston Ring - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Piston - Remove (10.105) 1. Use pliers 380000221 (2) to install the piston split rings (1) onto the piston (3). 2. Split ring end gaps should be displaced with each other by 120 °. NOTICE: Split rings shall be fitted with the marking "TOP" (4) facing upwards. NOTE: Split Rings are supplied spare with the following sizes: - standard - 0.4 mm (0.016 in) oversize NHIL13ENG0470AA

Next operation: Piston - Install (10.105)

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Piston Pin - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Connecting rod and piston - Remove (10.105) 1. Remove the piston pin (1) by removing the snap rings (3) using a scriber (2).

NHIL13ENG0471AA

Next operation: Piston Pin - Measure (10.105)

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Piston Pin - Measure F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Piston Pin - Remove (10.105) 1. To measure the piston pin (2) diameter, use a micrometer (1). The diameter should be within 37.994 38.000 mm (1.496 - 1.496 in).

NHIL13ENG0472AA

NHIL13ENG0473AA

2. Lubricate the pin (1) and its seat on the piston hubs with clean engine oil. The pin should be installed into the piston with slight finger pressure. The piston pin housing diameter should be within 38.010 - 38.016 mm (1.496 - 1.497 in).

Next operation: Connecting rod and piston - Assemble (10.105)

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Piston - Check 1. Once piston and connecting rod assemblies installation is completed, use the dial bore gauge 380000228 (1) equipped with the base 380000364 (3) to check piston (2) protrusion at T.D.C. with respect to the top of the engine block. Protrusion should be between 0.28 - 0.52 mm (0.011 0.020 in).

NHIL13ENG0474AA

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Engine - Connecting rods and pistons

Connecting rod bearing - Install Prior operation: Connecting rod and piston - Remove (10.105) 1. Install the half-bearings (1) onto the connecting rods and connecting rod caps. NOTE: Reinstall the bearings that have not been replaced in the same position found at removal. Do not relocate the half-bearings.

NHIL13ENG0475AA

Next operation: Connecting rod and piston - Install (10.105)

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Engine - Connecting rods and pistons

Connecting rod bearing - Clearance Prior operation: Connecting rod and piston - Install (10.105) 1. Clean and remove all oil from the connecting rod and bearing parts thoroughly. 2. Set a piece of calibrated wire (1) on the crankshaft pins (2). 3. Install the connecting rod caps (4) with the correct half bearings (3). NOTE: Before the final fitting of the connecting rod cap retaining bolts, check that their diameter measured at the center of the thread length is not < 0.1 mm (0.004 in) than the diameter measured at approximately 10 mm (0.394 in) from the bolt end. NHIL13ENG0476AA

NHIL13ENG0477AA

NHIL13ENG0478AA

4. Lubricate the bolts (2) with engine oil and use a torque wrench (1) to torque the bolts to 55 - 65 N·m (41 - 48 lb ft).

5. Attach an angular torque gauge tool 380001001 (1) to the torque wrench (2) and turn the bolts (3) 60 °.

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Engine - Connecting rods and pistons

6. Remove the connecting rod cap and find the existing clearance by comparing the calibrated wire width (2) with the scale on the provided wire envelope (1). 7. If a different clearance value is found, replace the connecting rod half bearings and repeat the check. 8. Once the specified clearance has been obtained, lubricate the connecting rod half bearings with engine oil and install them onto the connecting rod. Torque the bolts to 55 - 65 N·m (41 - 48 lb ft). Attach the angular torque gauge 380001001 to the torque wrench and turn the bolts 60 °. NHIL13ENG0479AA

NHIL13ENG0480AA

9. Check manually that the connecting rods (1) are sliding axially on the crank pins. Using a feeler gauge (2), make sure that the connecting rod end float is between 0.10 - 0.33 mm (0.004 - 0.013 in).

Next operation: Piston - Check (10.105)

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Engine - Connecting rods and pistons

Piston pin bushings - Service instruction Prior operation: Piston Pin - Remove (10.105) 1. Check the connecting rod small side bearing (1) for scoring or seizing and make sure that it is not loose. If the bearing shows signs to scoring, seizing or is loose, replace the bearing. 2. Removal and reinstalling the bearing should be performed using the proper beater. 3. When reinstalling, make sure the oil holes in the bearing coincide with the holes in the connecting rod small end. 4. Check the connecting rod small end bearing diameter by using the dial bore gauge OEM1032. The bearing diameter should be within 38.019 - 38.033 mm (1.497 - 1.497 in). Next operation: Connecting rod and piston - Assemble (10.105)

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NHIL13ENG0457AA

Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connecting rod and piston - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connecting rod bearing - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connecting rod bearing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Piston - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Piston Pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4CE9684, F4GE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Piston pin bushings - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Engine - 10 Crankshaft and flywheel - 103

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Contents Engine - 10 Crankshaft and flywheel - 103

SERVICE Engine flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4GE9484, F4GE9484C*J601, F4GE9684

Drive plate - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9684

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

Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Crankshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Crankshaft gears Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Main bearings Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Engine - Crankshaft and flywheel

Engine flywheel - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

1. Insert flywheel rotation locking tool 380000988 (1) into flywheel housing (3) to keep the flywheel (2) from rotating.

NHIL13ENG0481AB

NHIL13ENG0482AA

2. Remove two bolts opposite each other and place two guide pins (3) in place of the bolts. 3. Remove the remaining bolts (4) figure 1 securing the flywheel (1) to the crankshaft. 4. Remove the flywheel locking tool from the flywheel housing. 5. Install two bolts of medium length into the threaded holes (2) at the top of the flywheel to sling the flywheel with a hoist. 6. Remove the flywheel (1) from it's housing.

Next operation: Engine flywheel - Check (10.103)

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Engine - Crankshaft and flywheel

Engine flywheel - Check F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine flywheel - Remove (10.103) 1. Check the clutch supporting side of the engine flywheel (1) for any scoring or scratching. If any scratching is found, the flywheel should be resurfaced. 2. Check the flywheel ring gear teeth (2) for breakage or excessive wear. If wear is found, remove the ring gear from the engine flywheel using a suitable hammer. 3. Heat the new ring gear to 150 °C (302 °F) for 15 to 20 minutes. 4. Install the new ring gear with the chamfering on the inside diameter facing the flywheel. NHIL13ENG0483AA

Next operation: Engine flywheel - Install (10.103)

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Engine - Crankshaft and flywheel

Engine flywheel - Install F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine flywheel - Check (10.103) 1. Install two guide pins (1) having suitable length into the engine crankshaft holes. 2. Using the proper sling and hoist, install the flywheel (2) onto the engine crankshaft (3).

NHIL13ENG0484AA

NHIL13ENG0485AB

NHIL13ENG0486AA

3. Install the flywheel rotation locking tool 380000988 (4) to the flywheel housing to stop rotation of the flywheel (2). 4. Install the flywheel bolts (1) securing the flywheel (2) to the crankshaft (3).

5. Torque the flywheel bolts (1) to the engine crankshaft (2) in two stages: 1. Torque the bolts to 26 - 34 Nm (19 - 25 lb ft). 2. Using the angular torque gauge tool 380001001, turn the flywheel bolts an additional 55 - 65 °. NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

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Engine - Crankshaft and flywheel

Engine flywheel - Remove F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Install the flywheel locking tool 380000988 (4) into the flywheel housing to keep the flywheel (3) from rotating. 2. Remove two opposing flywheel bolts (1) and install two guide pins in place of the bolts. 3. Remove the remaining flywheel retaining bolts from the crankshaft (2) and remove the flywheel locking tool (4).

NHIL13ENG0487AB

NHIL13ENG0488AA

4. Install two bolts of medium length into flywheel holes (2) to sling the flywheel with a suitable hoist. 5. Using the two guide pins (1) previously installed into the flywheel mounting holes, (5) remove the engine flywheel (3) after slinging it with the hoist.

Next operation: Engine flywheel - Check (10.103)

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Engine - Crankshaft and flywheel

Engine flywheel - Check F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine flywheel - Remove (10.103) 1. Check the clutch supporting side of the engine flywheel (1) for any scoring or scratching. If any scratching is found, the flywheel should be resurfaced. 2. Check ring gear teeth (2) for any breakage or excessive wear. If any wear is found, remove the ring gear from the engine flywheel using a suitable hammer. 3. Heat the new ring gear to 150 °C (302 °F) for 15 to 20 minutes. 4. Install the new ring gear with the chamfering on the inside diameter facing the flywheel. NHIL13ENG0489AA

Next operation: Engine flywheel - Install (10.103)

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Engine - Crankshaft and flywheel

Engine flywheel - Install F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine flywheel - Check (10.103) 1. Install two bolts of medium length into the engine flywheel using holes (2). 2. Install two guide pins (1) with suitable length into the engine crankshaft holes (5). 3. Using the proper sling and hoist, install the flywheel (3) onto the engine crankshaft (4).

NHIL13ENG0488AA

NHIL13ENG0487AB

NHIL13ENG0517AA

4. Secure the engine flywheel retaining bolts (1) onto the engine crankshaft (3). 5. Install the flywheel rotation locking tool 380000988 to the flywheel housing (2) to stop the rotation of the flywheel.

6. Torque the flywheel bolts (1) to the engine crankshaft (2) in two stages: 1. Torque the bolts using a torque wrench (3) to 26 34 Nm (19 - 25 lb ft). 2. Using an angular torque gauge tool 380001001, turn the flywheel bolts an additional 55 - 65 °. NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

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Engine - Crankshaft and flywheel

Engine flywheel - Remove F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Using the flying rotation locking tool 380000988, lock the engine flywheel (2) rotation. 2. Loosen the flywheel retaining bolts (1) from the engine crankshaft (3).

NHIL13ENG0518AA

NHIL13ENG0519AA

3. Remove two opposing flywheel bolts and install two guide pins (1) in their place. 4. Remove the remaining flywheel retaining bolts from the engine crankshaft (3). 5. Remove the flywheel locking tool. 6. Install two medium length bolts into the existing flywheel holes (2) to sling the flywheel with a hoist. 7. Using the two guide pins (1), previously installed into the engine crankshaft holes (4), remove the engine flywheel (5) from the crankshaft (3) using a suitable hoist.

Next operation: Engine flywheel - Check (10.103)

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Engine - Crankshaft and flywheel

Engine flywheel - Install F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Prior operation: Engine flywheel - Check (10.103) 1. Install two guide pins (1) with suitable length into crankshaft (2) holes. 2. Using the proper sling and hoist, install the flywheel (4) onto the engine crankshaft (2).

NHIL13ENG0520AA

NHIL13ENG0521AA

NHIL13ENG0522AA

3. Install the flywheel locking tool 380000988 to the flywheel housing (3) to stop rotation of the flywheel (4). 4. Install the bolts (1) securing the flywheel (4) to the crankshaft (2).

5. Torque the flywheel bolts (1) using a torque wrench (2) to the crankshaft in two stages: 1. Torque bolts to 26 - 34 Nm (19 - 25 lb ft). 2. Using the angular torque gauge tool 380001001, turn the flywheel bolts an additional 55 - 65 °. NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

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Engine - Crankshaft and flywheel

Engine flywheel - Install F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Engine flywheel - Check (10.103) 1. Install two bolts of medium length into the engine flywheel (1) using holes (2). 2. Insert two guide pins (3) of appropriate length into the flywheel mounting holes.

NHIL13ENG0523AA

NHIL13ENG0524AA

NHIL13ENG0525AA

3. Using a suitable hoist, install the flywheel (2) onto the crankshaft. 4. Secure the flywheel retaining bolts (4) to mount the engine flywheel (2) onto the engine crankshaft. 5. Install the flywheel locking tool 380000988 (3) into the flywheel housing to lock engine flywheel rotation.

6. Torque the engine flywheel retaining bolts (1) to the engine crankshaft in two stages. • Torque the bolts to 26 - 34 Nm (19 - 25 lb ft). • Use the angular torquing gauge tool 380001001 to turn the bolts an additional 55 - 65 °. NOTE: Before assembly, always check that the threads of the ports and of the screws have no evidence of wear or dirt.

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Engine - Crankshaft and flywheel

Engine flywheel Drive plate - Remove F4GE9684

1. Remove the bolts (1). 2. Remove the plate (2), drive plate (3) and hub (4) from the crankshaft.

NHIL13ENG0076AA

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Engine - Crankshaft and flywheel

Engine flywheel Drive plate - Install F4GE9684

1. Install the hub (4) onto the crankshaft. 2. Install the dive plate (3), plate (2) and bolts (1) onto the hub.

NHIL13ENG0076AA

NHIL13ENG0077AA

3. Follow the sequence shown to torque the bolts to 27 41 N·m (20 - 30 lb ft). Then, using the angular torque gauge tool 380001001, turn the bolts an additional 60 - 70 °.

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Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Remove Prior operation: Crankshaft damper - Remove (10.110) 1. Remove the crankshaft front oil seal from the front cover (6). Use the tool (4) to operate on the front bar hold of the crankshaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in). Install the tool to the ring and tighten the six bolts (5) provided with the equipment. Then proceed removing the ring (2) by tightening the bolt (3).

NHIL13ENG0526AA

NHIL13ENG0527AA

2. Using the specific tie rod (3) of the seal extracting tool 380000669, and the ancillary lever (4), remove the external holding ring (2) from the front cover (1).

Next operation: Crankshaft oil seal Front seal - Install (10.103)

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Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Install Prior operation: Crankshaft oil seal Front seal - Remove (10.103) 1. Apply tool 5-8840-2061-0 (4) to the front crankshaft tang (6), secure it by bolts, (5) and install the new sealing ring (7). Position part (2) on part (4), tighten nut (3) until completing installation of the sealing ring (7) into the front cover (1).

NHIL13ENG0528AA

Next operation: Crankshaft damper - Install (10.110)

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Remove Prior operation: Engine flywheel - Remove (10.103) 1. Remove the holding ring of the flywheel cover box using the tool (3) to operate on the driving shaft's back bar hold (5). 2. Through the steering holes of the tool, perforate the inside holding ring with a straight way drill bit with a diameter of 3.5 mm (0.138 in) for the depth of 5 mm (0.197 in). 3. Install the tool (3) to the ring and tighten the six bolts (4) provided with the equipment. 4. Then proceed removing the ring (1) by tightening the bolt (2). NHIL13ENG0529AA

NHIL13ENG0530AA

5. Using a specific tie rod (3) of the tool 380000669 and an ancillary lever (4), remove the external holding ring (2) from the rear cover (1).

Next operation: Engine flywheel - Remove (10.103)

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Install Prior operation: Crankshaft oil seal Rear seal - Remove (10.103) 1. Apply tool 380000664 (6) to the rear crankshaft tang (5), secure it by bolts (4), and install the new sealing ring (3). Position part (1) on part (5) and tighten nut (2) until completing installation of the sealing ring (3) into the flywheel housing (7).

NHIL13ENG0531AA

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Engine - Crankshaft and flywheel

Crankshaft - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Main bearings - Remove (10.103) 1. Use tool 99360500 (1) to hoist and remove the crankshaft (2) from the engine block.

NHIL13ENG0532AA

Next operation: Main bearings - Install (10.103)

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Engine - Crankshaft and flywheel

Crankshaft - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Main bearings - Remove (10.103) 1. Use tool 99360500 (1) to hoist and remove the crankshaft (2) from the engine block.

NHIL13ENG0533AA

Next operation: Main bearings - Install (10.103)

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Engine - Crankshaft and flywheel

Crankshaft - Measure Prior operation: Crankshaft - Remove (10.103) Check the crankshaft journals and pins for seizing, scoring or excessive ovalization. If any are present, machining of the crankshaft is necessary. Crankshaft main journals should be measured using a micrometer (1) and should be within 82.99 - 83.01 mm (3.267 - 3.268 in). Crankshaft pins (2) should measured using a micrometer (1) and should be within 68.987 - 69.013 mm (2.716 - 2.717 in). NOTE: Before grinding the crankshaft pins (2), measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground. NOTE: It is recommended to insert the found values in the table below.

NHIL13ENG0534AA

NOTICE: Journals and crank pins shall always be ground to the same undersize class. Journals and crank pins undersize shall be marked on the side of the crank arm No.1. For undersized crank pins: letter M For undersized journals: letter B For undersized crank pins and journals: letters MB.

Measuring journals and crank pins

NHIL13ENG0535AA

Fill the provided table with crankshaft journal and crank pin measured values * Rated value A 82.99 - 83.01 mm (3.27 - 3.27 in)

B 68.987 - 69.013 mm (2.716 - 2.717 in)

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Engine - Crankshaft and flywheel

ZEIL06EN0183F0B

Crankshaft tolerances * Measured on a radius greater than 45.5 mm (1.791 in) ** 0.500 mm (0.020 in) between adjacent main journals Tolerances Shape

Direction Position Oscillation

Tolerance Characteristic

Graphic Symbol

Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation Levels of importance for product characteristics

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

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Graphic Symbol

Engine - Crankshaft and flywheel

Crankshaft Journal - Clearance Prior operation: Crankshaft - Measure (10.103) 1. Install the crankshaft (1) into the engine block (2). 2. Check the backlash between crankshaft main journals and the relevant bearings as follows:

NHIL13ENG0537AA

NHIL13ENG0538AA

NHIL13ENG0539AA

3. Thoroughly clean all parts and remove any traces of oil. 4. Position a piece of calibrated wire on the crankshaft pins (2) so that it is parallel to the longitudinal axis. 5. Install the crankshaft main journal caps (1) and the half bearings (2) on the relevant supports.

NOTE: Before using the bearing cap bolts again, measure them twice as indicated in the picture, checking (D1) and (D2) diameters: If (D1)- (D2) < 0.1 mm (0.004 in) the bolt can be used again. If (D1)- (D2) > 0.1 mm (0.004 in) the bolt must be replaced.

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Engine - Crankshaft and flywheel

6. Torque the pre-lubricated bolts (2) in the following three successive stages: STAGE 1: Torque the bolts (2) using a torque wrench (1) to 44 - 56 Nm (33 - 41 lb ft). STAGE 2: Torque the bolts (2) using a torque wrench (1) to 74 - 86 Nm (55 - 63 lb ft).

NHIL13ENG0540AA

NHIL13ENG0541AA

NHIL13ENG0542AA

NHIL13ENG0543AA

7. STAGE 3: Use an angular torquing gauge tool 380001001 (1) and turn the bolts (2) an additional 85 - 95 °.

8. Remove the caps from the supports. 9. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the provided envelope (1) containing the calibrated wire. The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by torquing the retaining bolts as previously described.

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

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Engine - Crankshaft and flywheel

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

CRIL04J068A01

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Engine - Crankshaft and flywheel

Main bearings - Remove Prior operation: Engine oil pan - Remove (10.102) 1. Remove the retaining bolts (1) and the main bearing caps (2).

NHIL13ENG0544AA

NHIL13ENG0545AA

2. The second to last main bearing cap (1) and the itâ&#x20AC;&#x2122;s support are fitted with a shouldered half-bearing (2). NOTE: Take note of the lower and upper half-bearing assembling positions since in case of reuse they should be fitted in the same position found at removal.

Next operation: Main bearings - Install (10.103)

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Engine - Crankshaft and flywheel

Main bearings - Install Prior operation: Main bearings - Remove (10.103) NOTE: Reinstall the main bearings that have not been replaced, in the same position found at removal. Main bearings (1) are supplied spare with 0.250 0.500 mm (0.010 - 0.020 in) undersize on the internal diameter. Thoroughly clean the main bearings (1), lubricate them with clean engine oil and install them into their housings. The second last main half bearing (1) is fitted with shoulder half rings.

NHIL13ENG0546AA

NOTICE: Do not try to adapt the bearings. NOTE: Do not lubricate the connecting rod side housing side of the bearing. Only lubricate the internal side of the bearing which rides along the crankshaft pins. Next operation: Engine oil pan - Install (10.102)

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Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Crankshaft gears - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine flywheel - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4GE9484, F4GE9484C*J601, F4GE9684

Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine flywheel Drive plate - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4GE9684

Engine flywheel Drive plate - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9684

Main bearings - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Main bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Engine - 10 Balancer and damper - 110

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Contents Engine - 10 Balancer and damper - 110

SERVICE Balancer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Crankshaft damper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

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Engine - Balancer and damper

Balancer - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine oil pan - Remove (10.102) 1. Remove the retaining bolts (3) and (5) and remove the oil pickup tube. 2. By means of pin (1), lock the dynamic balancer (4) in the Top Dead Center (TDC) position. 3. Remove the bolts (2) and remove the dynamic balancer (4).

NHIL13ENG0547AA

Next operation: Balancer - Install (10.110)

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Engine - Balancer and damper

Balancer - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Balancer - Remove (10.110) 1. Set the engine to cylinder number one Top Dead Center (TDC). 2. Match the marks (A) engraved on the gears for timing. 3. Torque the mounting bolts to 40 - 56 N·m (30 - 41 lb ft). 4. Once the balancer is mounted on the engine, remove the pin from point (B).

NHIL13ENG0548AA

Next operation: Engine oil pan - Install (10.102)

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Engine - Balancer and damper

Crankshaft damper - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Belt - Remove (10.414) 1. Remove the bolts (3) retaining the crankshaft vibration damper (1). 2. Remove the damper (1). 3. Remove the pulley (2).

NHIL13ENG0549AA

Next operation: Crankshaft damper - Install (10.110)

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Engine - Balancer and damper

Crankshaft damper - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Crankshaft damper - Remove (10.110) 1. Mount the vibration damper (2) and the pulley (1) onto the crankshaft (3). 2. Torque the mounting bolts (4) to 45 - 55 N·m (33 - 41 lb ft). 3. Use the angular torque gauge tool 380001001 and turn the bolts 90 °.

NHIL13ENG0550AA

Next operation: Belt - Install (10.414)

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Engine - Balancer and damper

Crankshaft damper - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Belt - Remove (10.414) 1. Remove the bolts (1) retaining the crankshaft vibration damper (2). 2. Remove the damper (2). 3. Remove the pulley (3).

NHIL13ENG0551AA

Next operation: Crankshaft damper - Install (10.110)

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Engine - Balancer and damper

Crankshaft damper - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Crankshaft damper - Remove (10.110) 1. Mount the vibration damper (2) and the pulley (3) onto the crankshaft (4). 2. Torque the mounting bolts (1) to 105 - 115 N·m (77 85 lb ft).

NHIL13ENG0551AA

Next operation: Belt - Install (10.414)

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Index Engine - 10 Balancer and damper - 110 Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Engine - 10 Pump drives - 114

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Contents Engine - 10 Pump drives - 114

SERVICE Pump drives Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4GE9684

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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Engine - Pump drives

Pump drives - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

NHIL13ENG0553AA

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Pump drives - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Insert the power take-off adapter (5) with gasket the (4) and the front cover (1) with the gasket (2). 2. Torque the bolts (3) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0553AA

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Engine - Pump drives

Pump drives - Remove F4GE9484, F4GE9484C*J601, F4GE9684

1. Remove the two bolts (3) retaining the cover plate (1) and gasket (2). 2. Remove the cover plate (1), power take-off adapter (5), and gasket (4). NOTE: The gasket cannot be used again. It must be replaced upon reassembly.

NHIL13ENG0554AA

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Engine - Pump drives

Pump drives - Install F4GE9484, F4GE9484C*J601, F4GE9684

1. Install the power take-off (5) in its housing with a new gasket (4). Be sure that the gears mesh properly. 2. Install the cover plate (1) also with a new gasket (2). Torque the bolts (3) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0554AA

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Engine - Pump drives

Pump drives - Remove F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Remove the two bolts (2) and remove the cover (1).

NHIL13ENG0555AA

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Pump drives - Install F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Install the power take-off gear (where equipped) into the specially provided housing and torque the nut (1) to 98 - 112 N·m (72 - 83 lb ft).

NHIL13ENG0556AA

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Index Engine - 10 Pump drives - 114 Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4GE9684

Pump drives - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4GE9684

Pump drives - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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Engine - 10 Lift pump and lines - 210

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Contents Engine - 10 Lift pump and lines - 210

FUNCTIONAL DATA Fuel lift pump Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Priming pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

SERVICE Priming pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Fuel supply lines Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4GE9484, F4GE9484C*J601, F4GE9684

Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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

Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9484, F4GE9484C*J601, F4GE9684

Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Fuel lift pump - Sectional view F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Gear pump, placed on the rear part of the high pressure pump, whose function is to feed the high pressure pump. It is driven by the high pressure pump's shaft.

Normal operating condition

NHIL13ENG0557AA

(A) Fuel supply from the primary filter (B) Fuel supply to the secondary filter

(1) Fuel supply relief valve 5 bar (73 psi) (2) Supply pump bypass valve (for bleeding)

Overpressure condition

NHIL13ENG0558AA

The by-pass valve (1) is activated in case of overpressure on (B) Exhaust unit. The actual pressure, overcoming the resistance of the valve's spring (1), connects the exhaust with the entry through the gallery (2).

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Engine - Lift pump and lines

Jettison condition

NHIL13ENG0559AA

The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system through the priming pump. In this condition the by-pass (1) keeps closed while the dump by-pass valve (2) opens up due to the pressure effect on the entry unit so the fuel flows to the exhaust unit (B). NOTE: The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the high pressure pump.

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Engine - Lift pump and lines

Priming pump - Overview F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to the engine block and driven by the camshaft.

NHIL13ENG0560AA

(1) Fuel output to the filter - (2) Drive lever - (3) Fuel inlet from the tank

NHIL13ENG0561AA

(1) Priming pump - (2) Drive lever - (3) Camshaft

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Engine - Lift pump and lines

Priming pump - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Fuel supply lines Low pressure - Disconnect (10.210) 1. Remove the two retaining bolts (1). 2. Remove the priming pump (2).

NHIL13ENG0562AA

Next operation: Priming pump - Install (10.210)

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Priming pump - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Priming pump - Remove (10.210) 1. Install the priming pump (2) with a new gasket. 2. Torque the bolts (1) to 10 - 14 N·m (89 - 124 lb in).

NHIL13ENG0563AA

Next operation: Fuel supply lines Low pressure - Connect (10.210)

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Fuel supply lines Low pressure - Connect F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Connect the fuel line to the pressure limiter (1). 2. Connect all the fuel lines between the fuel filter base (2) and the high pressure pump. 3. Connect the pipeline from the high pressure pump to the engine control module cooling plate (3). 4. Connect the pipeline from the high pressure pump (4) to high pressure common rail.

NHIL13ENG0564AA

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Fuel supply lines Low pressure - Disconnect F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Disconnect the fuel return pressure limiter (1). Refer to Common rail lines - Disconnect (10.218).

NHIL13ENG0490AA

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Engine - Lift pump and lines

Fuel supply lines Low pressure - Disconnect F4GE9484, F4GE9484C*J601, F4GE9684

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

NHIL13ENG0492AA

5. Disconnect the LDA pipe (1) from the engine cylinder head and from the feed pump. 6. Plug the ends of the fuel lines as well as the feed pump and the cylinder head.

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Engine - Lift pump and lines

Fuel supply lines Low pressure - Disconnect F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Place a container under the fuel filter (4) and remove the faucet drain (3) underneath the filter . Carry out complete drainage of the filter. 2. Completely remove the faucet drain (3) and then use tool 380000670 to remove the filter cartridge from the housing. 3. Disconnect fuel lines (1) and (5) respectively from the priming pump to the fuel filter base and from the fuel filter base to the feed pump. Refer to Common rail lines - Disconnect (10.218) for proper removal procedures. 4. Remove the filter base (2) from the engine cylinder head.

NHIL13ENG0493AA

NHIL13ENG0494AA

5. Disconnect the LDA pipe (1) from the cylinder head and from the feed pump. 6. Plug the ends of the pipelines as well as the feed pump and the engine cylinder head.

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Engine - Lift pump and lines

Fuel supply lines Low pressure - Install F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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

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Engine - Lift pump and lines

Fuel supply lines Low pressure - Install F4GE9484, F4GE9484C*J601, F4GE9684

1. Install the fuel filter support (1) onto the engine cylinder head and torque the bolts to 20 - 28 N·m (15 - 21 lb ft). 2. Connect the fuel pipelines (2) and (3) respectively from the priming pump to the filter support and from the support to the fuel feed pump. 3. Install the fuel filter (4) using tool 380000670. NOTE: NOTE: The filter should be filled with fuel prior to assembly. This will help facilitate fuel system bleeding. 4. Connect the electrical connections for the water presence sensor and the fuel heater (If applicable). NHIL13ENG0496AA

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Fuel supply lines Low pressure - Bleed F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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

NHIL13ENG0497AA

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Index Engine - 10 Lift pump and lines - 210 Fuel lift pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel supply lines Low pressure - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Fuel supply lines Low pressure - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4GE9484, F4GE9484C*J601, F4GE9684

Fuel supply lines Low pressure - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Fuel supply lines Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Fuel supply lines Low pressure - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4GE9484, F4GE9484C*J601, F4GE9684

Priming pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Priming pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Priming pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Engine - 10 Fuel filters - 206

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Contents Engine - 10 Fuel filters - 206

FUNCTIONAL DATA Fuel heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel-water separator filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Fuel filters Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Fuel filters

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

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Engine - Fuel filters

Fuel-water separator filter - Overview The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. On the filter cartridge, there is a water dump screw throughout which it is possible to provide regular drainage. For those equipment applications requiring it, a heater can be installed along with a temperature sensor. On some versions, a water presence sensor is mounted to the filtering cartridge.

NHIL13ENG0498AA

(1) Fuel filter base - (2) Filter cartridge - (3) Water dump screw.

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Engine - Fuel filters

Fuel filters - Remove Prior operation: Fuel supply lines Low pressure - Disconnect (10.210) 1. Using the fuel filter wrench 34591-00100, loosen the fuel filter (1) and remove it from the support (5). 2. Disconnect the electrical connections (2) from the support (5) including the connection for the fuel heater. 3. Disconnect the fuel low pressure fuel lines (3) from the support (5). 4. Disconnect fuel line (4) from the support (5). 5. Remove the sustaining support bracket (5) from the engine block.

4442596398GHDC

Next operation: Fuel filters - Install (10.206)

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Engine - Fuel filters

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

Next operation: Fuel supply lines Low pressure - Connect (10.210)

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Index Engine - 10 Fuel filters - 206 Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel-water separator filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Fuel injection system - 218

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Contents Engine - 10 Fuel injection system - 218

FUNCTIONAL DATA Fuel injection system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rotary injection pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9684, F4GE9684

Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

High pressure pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Pressure regulating valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Common rail Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

SERVICE Fuel injection system Test Mechanical fuel injection – Fuel supply/Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Test Common rail fuel injection – Fuel supply/Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rotary injection pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4GE9484, F4GE9484C*J601, F4GE9684

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4GE9484, F4GE9484C*J601, F4GE9684

Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4GE9484, F4GE9484C*J601, F4GE9684

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

High pressure pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Test Pressure Relief Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Pressure regulating valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Common rail Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Common rail lines Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors

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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Mechanical - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Mechanical - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Test Fuel injector testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Cross tube - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Cross tube - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Injector fuel lines Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Engine - Fuel injection system

Fuel injection system - Dynamic description F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0500AA

(1) Electro-injector (2) Common rail (3) Pressure limiting device for fuel return (4) Common rail pressure relief valve

(5) (6) (7) (8)

Pre-filter mounted on the frame High-pressure pump Mechanical vane pump Fuel filter

The common rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors. Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet. The hydraulic system is implemented by a low pressure circuit and a high pressure circuit. The high pressure circuit is composed of the following pipings: • piping connecting high pressure pump outlet to rail • pipings supplying injectors from rail The low pressure circuit is composed of the following pipings: • fuel suction piping from tank to pre-filter • pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and pre-filter • pipings supplying the high pressure pump through the fuel filter The fuel draining circuit from the rail, injectors and the high pressure pump cooling circuit complete the system.

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Engine - Fuel injection system

Fuel injection system - Plumbing schema F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

NHIL13ENG0501AA

(1) High-pressure pump (2) Low pressure relief valve (3) Return fuel relief valve (4) Common rail relief valve (5) Common rail (6) Common rail pressure sensor

(7) Electro-injector (8) Return fuel line (9) ECU cooling plate (10) Priming pump (11) Pre-filter (12) Fuel tank

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(13) Mechanical supply pump (14) Fuel filter (15) Pressure regulator (16) High pressure pump cooling passage (17) By-pass valve (18) Charge pressure relief valve

Engine - Fuel injection system

Fuel injection system - Dynamic description F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0502AA

(1) (2) (3) (4)

Electro-injector Common rail Prefilter mounted on the block Fuel filter

(5) Common rail pressure relief valve (6) Pressure limiter for fuel return (7) Mechanical rotor pump (8) High pressure pump

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Engine - Fuel injection system

Fuel injection system - Dynamic description F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

NHIL13ENG0503AA

(1) Fuel filter - (2) Feed pipeline from filter to fuel pump - (3) Feed pipeline from priming pump to filter (4) Priming pump.

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

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Engine - Fuel injection system

Rotary injection pump - Overview F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Fuel feed system is composed by: • Fuel tank (placed on the machine) • Fuel delivery and back-flow to tank • Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) • Priming pump, assembled to the engine and driven by the camshaft • Fuel filter (assembled to the engine in different positions according to equipment application and duty) • Fuel feed rotary pump • Injector feed pipeline (from fuel feed pump to injectors) • Injectors

NHIL13ENG0504AA

(1) Injector feed pipes - (2) Fuel return pipes from injectors - (3) Fuel feed rotary pump - (4) Connector for LDA pressure gauge pipe with suction collector - (5) KSB thermal bulb - (6) Fuel cut-off switch - (7) Electro-valve Injector.

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Engine - Fuel injection system

Rotary injection pump - Overview F4CE9684, F4GE9684

NHIL13ENG0505AA

(1) Injector feed pipes - (2) Injector - (3) Electro-valve - (4) KSB thermal bulb - (5) Fuel feed rotary pump - (6) Fuel return pipes from injectors.

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Engine - Fuel injection system

Rotary injection pump - Sectional view F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Decoding the identification tag V = Distribution rotary plunger E = Pump dimensions 4 = Four cylinder engines (3 = Three cylinder engines and 6 = Six cylinder engines) 12 = Distribution plunger in mm 1150 = Number of pump revolutions per minute LV = Left direction of rotation

NHIL13ENG0506AA

(1) Diaphragm - (2) Locking nut - (3) Pivot - (4) Drive lever - (5) Speed gauge - (6) Transfer pump - (7) Drive shaft - (8) Cam disk - (9) Advance converter - (10) Distribution plunger - (11) Delivery pipe fitting - (12) Hydraulic head - (13) Drive plate - (14) Gauge pin - (15) Counteracting spring.

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Engine - Fuel injection system

High pressure pump - Overview F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel system operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements at about 2 bar (29 psi). The amount of fuel supplying the high pressure pump is metered by the pressure regulator placed on the low pressure system. The pressure regulator is controlled by the EDC7 control unit through a PWM signal. When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, unable to be released, is compressed above the supply pressure value existing in the rail. The generated pressure makes the exhaust valve open and the compressed fuel reaches the high pressure circuit. The pumping element compresses the fuel until top dead center of the delivery stroke, is reached. Afterwards, the pressure decreases till the exhaust valve is closed. The pumping element piston goes back towards bottom dead center and the remaining fuel is decompressed. When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated. The delivery valves must always be free in their movements, free from impurities and oxidation. The rail delivery pressure is modulated between 250 - 1600 bar (3625 - 23200 psi) by the electronic control unit, through the pressure regulator solenoid valve. The pump is lubricated and cooled by the fuel. The radialjet pump disconnection - reconnection time on the engine is greatly reduced in comparison with traditional injection pumps, because it does not require setting. If the pipe between fuel filter and high pressure pump is to be removed or installed, be sure that hands and components are absolutely clean.

Rail

NHIL13ENG0507AA

(1) Rail

(2) Fuel inlet from high-pressure pump

(3) Overpressure valve

(4) Pressure sensor

The rail volume is comparatively small to allow quick pressurization at start-up, at idle and in case of high flow rates. It has enough volume to minimize system spikes and the use of plenum chambers caused by the opening and closing of the injectors and by the high pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high pressure pump. 47597675 27/09/2013

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Engine - Fuel injection system

A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is feedback information, where the rail pressure value is checked and if necessary, corrected.

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Engine - Fuel injection system

High pressure pump - External view F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

HARNESS

(1) Fuel pressure sensor - (2) Coolant temperature sensor - (3) Oil temperature/pressure sensor - (4) Crankshaft sensor- (5) Connection to electro-injectors - (6) Air temperature/pressure sensor - (7) Camshaft sensor - (8) Fuel heater cable and fuel temperature sensor - (9) Pressure gauge cabling - (10) EDC 7 gearbox - (11) Electro-injector

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Engine - Fuel injection system

High pressure pump - External view F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Description of system The injection system is composed of an electrical part and a hydraulic part.

Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

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

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

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

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

Output shaft sensor It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape.

System functionality The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data.

FPT Code recognition The EDC 7 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent.

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Engine - Fuel injection system

NHIL13ENG0508AA

(1) Connection to electro-injectors

(5) Crankshaft sensor

(2) Coolant temperature sensor (3) Fuel pressure sensor (4) Oil temperature/pressure sensor

(6) Electro-injector (7) Air temperature/pressure sensor (8) Camshaft sensor

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(9) Fuel heater cable and fuel temperature sensor (10) Pressure gauge cabling (11) EDC 7 UC31

Engine - Fuel injection system

High pressure pump - Sectional view F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

CP3 HIGH PRESSURE PUMP Pump provided with 3 radial pumping elements driven by the timing system gear, no need for timing. The mechanical feeding pump driven by the high pressure pump's shaft is assembled to the rear side of the high pressure pump. NOTE: The high pressure pump unit - feeding pump is not subject to overhaul. Do not disassemble or tamper with the retaining bolts. The only serviceable components are the control gear and pressure regulator.

NHIL13ENG0509AA

(1) Fuel exhaust collector to rail - (2) High pressure pump - (3) Pressure regulating gauge - (4) Driving gear (5) Connector to fuel entry flowing from filter - (6) Connector to fuel exhaust to filter support - (7) Connector to fuel entry flowing from engine control module heat exchanger - (8) Connector to fuel exhaust flowing from mechanical pump to filter - (9) Mechanical feeding pump

HIGH PRESSURE PUMP Inside Structure

NHIL13ENG0510FA

(1) Cylinder - (2) Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft (7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts. Every pumping unit is composed of: • A piston actuated by a three-lobe element floating on the pump shaft. The element, which is floating on an offset part of the shaft, uses the highest part of the element to actuate the three pistons alternately. • Cap intake valve. • Ball delivery valve.

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Engine - Fuel injection system

Working Principle

NHIL13ENG0511GA

(1) Cylinder - (2)Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft (7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts The pumping element is oriented towards the pump's camshaft. During the intake phase, the pumping element is fed through the feeding line. The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge. The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element. During the compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to the common rail, feeding it through the exhaust unit.

NHIL13ENG0512AA

(1) Cylinder - (2)Three-lobe element - (3) Cap intake valve - (4) Ball delivery valve - (5) Piston - (6) Pump shaft (7) Low pressure fuel inlet - (8) Pumping elements supplying fuel ducts The figure shows the fuel runs at low pressure inside the pump. The following elements are clearly visible: the main feeding line to the pumping elements, the feeding lines to the pumping elements, the duct lines run for the pump lubrication, the pressure gauge, the flow limiting valve to 5 bar (73 psi) and the fuel exhaust flue The pump shaft is lubricated by the fuel from the feeding and recovery lines. The pressure gauge determines the quantity of fuel to feed the pumping elements. The excess fuel flows through the exhaust gallery. The 5 bar (73 psi) limiting valve, in addition to recovering exhaust fuel as a collector, also functions to keep the pressure at a constant 5 bar (73 psi) limit at gauge entry.

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Engine - Fuel injection system

NHIL13ENG0513AA

(1) Fuel exhaust flue - (2) Fuel exhaust gallery (3) Fuel exhaust flowing from pump with connector to high pressure pipe for common rail This figure shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.

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Engine - Fuel injection system

Pressure regulating valve - Overview F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

Pressure Limiter for Fuel Return It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at pressures of 1.3 - 2 bar (19 - 29 psi). By guaranteeing this pressure to the return fuel, the fuel vapor formation inside the injectors is avoided, optimizing fuel spraying and combustion.

NHIL13ENG0514AA

(A) - To Tank (B) - From Injectors

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Engine - Fuel injection system

Common rail Relief valve - Overview F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

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Engine - Fuel injection system

Fuel injectors - Overview F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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

Jet DLLA DSLA

Power Up to 152 kW (207 Hp) 152 kW (207 Hp) and above.

Pressure 250 - 1600 bar (3625 - 23200 psi) 250 - 1450 bar (3625 - 21025 psi)

The injector is similar as construction to the traditional ones, apart from the absence of the plunger return springs. The injector is composed of two parts: • actuator - spray nozzle composed of a pressure rod, plunger, and nozzle. • control solenoid valve composed of a coil, and pilot valve. The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

93095366

(1) (2) (3) (4) (5)

Pressure Rod Plunger Nozzle Coil Pilot Valve

(6) Ball Shutter (7) Control Area (8) Pressure Chamber (9) Control Volume (10) Control Duct

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(11) Supply Duct (12) Control Fuel Outlet (13) Electrical Connection (14) Spring (15) High Pressure Fuel Inlet

Engine - Fuel injection system

Injection Start

93095367

When coil (4) is energized, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, following fuel injection into the cylinder.

Injection End When coil (4) is de-energized, shutter (6) goes back to its closing position, in order to recreate such a force balance as to make plunger (2) go back to its closing position and end the injection process. NOTE: The injector cannot be overhauled and therefore it must not be disassembled.

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Engine - Fuel injection system

Electro-Injector Solenoid Valves The electro-injectors are effectively N.O. solenoid valves. Each injector is connected to the EDC control unit on connector A. The Impedance of the coil of each injector is 0.56 - 0.57 Ω.

COVERBASE

Description

Reference Connector (1) Pin #1 Pin #2 Pin #3 Pin #4 Connector (2) Pin #1 Pin #2 Pin #3 Pin #4 Connector (3) Pin #1 Pin #2 Pin #3 Pin #4

ECU Pin

Cylinder Cylinder Cylinder Cylinder

2 2 1 1

injector injector injector injector

11A 6A 13A 4A

Cylinder Cylinder Cylinder Cylinder

4 4 3 3

injector injector injector injector

14A 3A 12A 5A

Cylinder Cylinder Cylinder Cylinder

6 6 5 5

injector injector injector injector

15A 2A 1A 16A

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Engine - Fuel injection system

Fuel injectors - Overview F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

Jet DLLA DSLA

Power Up to 152 kW (207 Hp) 152 kW (207 Hp) and above

Pressure 250 - 1600 bar (3625 - 23200 psi) 250 - 1450 bar (3625 - 21025 psi)

Injector in rest position

93095366

(1) (2) (3) (4) (5)

Pressure Rod Plunger Nozzle Coil Pilot Valve

(6) Ball Shutter (7) Control Area (8) Pressure Chamber (9) Control Volume (10) Control Duct

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(11) Supply Duct (12) Control Fuel Outlet (13) Electrical Connection (14) Spring (15) High Pressure Fuel Inlet

Engine - Fuel injection system

Injection Start

93095367

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Engine - Fuel injection system

COVERBASE

Description

Reference Connector (1) Pin #1 Pin #2 Pin #3 Pin #4 Connector (2) Pin #1 Pin #2 Pin #3 Pin #4 Connector (3) Pin #1 Pin #2 Pin #3 Pin #4

ECU Pin

Cylinder Cylinder Cylinder Cylinder

2 2 1 1

injector injector injector injector

3A 6A 13A 9A

Cylinder Cylinder Cylinder Cylinder

4 4 3 3

injector injector injector injector

5A 14A 12A 4A

Cylinder Cylinder Cylinder Cylinder

6 6 5 5

injector injector injector injector

10A 15A 16A 11A

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Engine - Fuel injection system

Fuel injection system - Test Mechanical fuel injection – Fuel supply/Leakage Test F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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

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2. Operate the engine to purge air from the system which entered during gauge installation. 3. When air is no longer visible in the clear test line, measure and record the operating pressure, while continually observing for air in the fuel. NOTE: The clear line could be left in place over night to check for a slow air ingress leak. 4. Measure and record the following pressures: Condition:

Fuel Pressure Specification between fuel filter and injection pump:

Test the fuel pressure at LOW idle; apply no load to the engine. 0.276 bar to 0.414 bar Test the fuel pressure at Pressure at HIGH idle; apply 27.6 kPa (4.0 psi) to 41.4 kPa (6.0 psi) no load to the engine. Test the fuel pressure at HIGH idle; apply load to the engine using the hydraulics (over relief), hydrostatic stall, converter stall, or dynamometer. Load the engine to its rated RPM. 5. If the fuel pressure is below 0.276 bar / 27.6 kPa (4.0 psi) at any time during the test, check/replace the following as needed: Component: Fuel pre-filter (if equipped) Fuel filter(s) Fuel lines

Fuel tank The fuel pick-up tube located in the fuel tank. Check the valve at the fuel tank outlet (if equipped).

Inspection: Some applications do not use a fuel pre-filter. Replace The lines and connections from the fuel lift pump inlet back to the fuel tank, checking for damaged lines (kinks create restriction; rub marks may allow air to enter) and leakage at the Voss o-ring fittings. Clean the fuel tank as required. Check for cracks, plugging, or contact with the bottom/sidewalls of the tank. Ensure that fuel supplied to and from the valve assembly is properly connected.

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Engine - Fuel injection system

Fuel tank cap

Be sure a vacuum is not being formed in the fuel tank. A vacuum at the tank would reduce the fuel supply pressure to the injection fuel pump inlet. Vacuum in the fuel tank might not be observable during short-term running.

6. If the fuel pressure is below 0.276 bar / 27.6 kPa (4.0 psi) install special tool # 380100056 pressure gauge (2) between the outlet of the fuel tank (3) and the inlet of the fuel lift pump (1). Check the following:

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Action: Inspect the fuel lines and connections from the fuel lift pump inlet back to the fuel tank, checking for damaged lines (kinks create restriction; rub marks may allow air to enter) and leakage at the Voss o-ring fittings. Vacuum between the inlet of the low pressure pump and If vacuum reading exceeds 50.8 mm Hg (2.0 in Hg), inspect fuel lines for plugging or debris in the fuel tank. the tank should not exceed 50.8 mm Hg (2.0 in Hg) under full load. Condition: Continuous air bubbles.

7. Supply fuel from an alternate fuel source located not more than 1 m (3.3 ft) below the engine with a known good supply line.

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8. This bypasses: • Fuel tank • Inlet lines • Connections • Pre-filter (if equipped) 9. Rerun the filter outlet pressure test. If pressures return to normal, check the fuel supply line and the fuel tank of the machine for leaks or restrictions.

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Engine - Fuel injection system

Fuel injection system - Test Common rail fuel injection – Fuel supply/Leakage test F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

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2. Install special tool # 380100057 between the outlet of the fuel filter and the inlet of the high pressure pump. NOTE: This test line contains a pressure gauge – 0 bar / 0 kPa (0 psi) to 11 bar / 1100 kPa (159.5 psi)

3. Operate the engine to purge air from the system which entered during gauge installation. 4. When air is no longer visible in the clear test line, measure and record operating pressure, while continually observing for air in the fuel. NOTE: The clear line could be left in place over night to check for a slow air ingress leak. Condition:

Fuel pressure specification between filter and high pressure pump:

Test the fuel pressure at LOW idle; no load to the engine. Test the fuel pressure at 1500 RPM; no load to the engine 5 bar / 500 kPa (72.5 psi) Test the fuel pressure at HIGH idle; apply load to the engine using the hydraulics (over relief), hydrostatic stall, converter stall, or dynamometer. Load the engine to its rated RPM. 5. If the fuel pressure testing point between the primary filter outlet to the low pressure pump inlet drops below 5 bar / 500 kPa (72.5 psi) at any time during the test, check/replace the following as needed: Component: Fuel Pre-filter (if equipped) Primary fuel filter

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Engine - Fuel injection system

Fuel tank Fuel lines and connections

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

The fuel pick-up tube in the fuel tank. Fuel tank cap

Fuel tank outlet valve

6. Rerun the fuel pressure test. If the pressure is still below 5 bar 500 kPa (72.5 psi) supply fuel from an alternate fuel source (a separate container, 380100058) (1), located not more than 1 m (3.3 ft) below the engine with a known good fuel supply line.

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7. This bypasses: • Fuel tank • Inlet lines • Connections • Pre-filter (if equipped)

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Engine - Fuel injection system

Rotary injection pump - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Injector fuel lines - Disconnect (10.218) 1. Remove the gear (1) transmitting motion to the injection pump. 2. Remove the adjustable gear that lies behind the primary drive gear.

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Next operation: Rotary injection pump - Install (10.218)

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Engine - Fuel injection system

Rotary injection pump - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Rotary injection pump - Remove (10.218) 1. Install the adjustable gear that lies behind the primary drive gear. 2. Install the gear (1) transmitting motion to the injection pump.

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Next operation: Injector fuel lines - Connect (10.218)

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Engine - Fuel injection system

Rotary injection pump - Disassemble F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Rotary injection pump - Remove (10.218) NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been disconnected, and the accelerator cable shall also be disconnected. 1. Remove the starter from the flywheel housing (1) and use tools 380000988 (2) and 380002822 (3) to rotate the flywheel.

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NOTE: In the case of pump replacement, the spare part should be supplied preset. If the pump is to be disassembled and reassembled later on without being repaired, it will be necessary to preset the pump while it is still assembled to the engine and disassembled afterwards.

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

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Finding TDC with the timing gear blocking pin 6. Install the pin 380002729 (1) in the housing on the rear cover. 7. Turn the flywheel while pushing on the pin (1) until it blocks the gear (2) obtaining TDC of the number one cylinder. 8. Check that the piston is in the compression phase by making sure the intake and exhaust valves are both closed.

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Engine - Fuel injection system

9. Loosen the side bolt (1) that is used to lock the pump shaft and remove the spacer (2). The spacer must be kept. It is recommended to fix it to the pump with a wire or a clip. 10. Tighten the bolt (1) blocking rotation of the pump shaft.

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11. Remove the bolts (1) that retain the plate (2) covering the pump drive gear. 12. Remove the nut (3) securing the gear to the pump shaft and remove the relating washer.

13. From the pump side, loosen the nuts (1) without removing them in order to move the pump backwards using the injection pump gear extractor. 14. Assemble the extractor throughout the two threaded ports (2) and withdraw the gear from the pump shaft. 15. Properly hold the pump and remove the nuts completely. 16. Remove the pump from its mounting studs, together with the gasket. NOTE: Hold the pump drive gear to avoid interference or crawling during timing gear rotation. ATTENTION: When the pump is to be installed, the engine must be at TDC of the compression phase on cylinder number one. Next operation: Rotary injection pump - Assemble (10.218)

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Engine - Fuel injection system

Rotary injection pump - Assemble F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Rotary injection pump - Disassemble (10.218) 1. Install the pump in its housing on the engine, while installing the gear onto the pump shaft. 2. Tighten the nuts (1) securing the pump to the engine. NOTE: The gasket removed during disassembly shall not be utilized again. Always use original spare parts.

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3. On the timing side, install the washer and the retaining nut (3) on the pump shaft. 4. Torque the nut to 90 - 95 Nm (66.4 - 70.1 lb ft). 5. Install the plate (2) with new gasket and tighten bolts (1).

6. Loosen the bolt (1) that prevents pump shaft rotation and insert spacer (2). By doing this the pump shaft will be able to rotate freely. 7. Remove the flywheel rotation/locking tool 380000988 and install the starter motor. 8. Connect all pipelines in the fuel system. 9. Connect the electrical connections to electro-magnets on the hydraulic head and on the KSB. NOTE: If the engine is installed in the application, connect the accelerator cable.

Next operation: Rotary injection pump - Timing adjust (10.218)

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Engine - Fuel injection system

Rotary injection pump - Timing adjust F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Rotary injection pump - Assemble (10.218) 1. Use engine turn tool 380000988 to rotate the engine until the gap between the slots of the tone wheel (1) is at the top. This indicates that cylinder number one is at Top Dead Center (TDC). 2. Remove the engine valve cover and verify that the engine is at TDC by checking that the cylinder number one push rods move freely. NOTE: If the push rods are tight (holding the valves open), rotate the engine one full turn.

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3. Install the valve gauge tool 380001435 (1) onto the No. 1 cylinder rocker arm assembly and open the No.1 cylinder intake valve. 4. Carefully rotate the engine in a clockwise direction (as viewed from the front) until the piston makes light contact with the intake valve.

5. Fabricate a pointed rod from a piece of heavy wire. 6. Attach the pointed rod to the bracket (1) near the AC belt pulley.

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Engine - Fuel injection system

7. Mark the pulley (1) using the pointed rod (3) as a reference point (2).

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8. Remove the tool 380001435 (1) to close the intake valve. Rotate the engine clockwise approximately 20 ° until the piston is on its down cycle. 9. Repeat 3. 10. Rotate the engine counterclockwise until the piston makes light contact with the intake valve.

11. Make another reference mark (1) on the AC belt pulley using the pointed rod (2) as a reference.

12. Measure between the two marks and make a third mark (1) at the midpoint. 13. Rotate the engine to align the center mark with the reference rod (2). This marks cylinder number one TDC.

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Engine - Fuel injection system

14. Remove the valve gauge tool 380001435 (1) to close the intake valve.

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Checking static timing 15. Locate the timing plug (2) at the center of the injection lines and remove it. 16. Replace the timing plug with adapter (1) and insert indicator gauge (3) into the pump. 17. Preload the gauge approximately 2.5 mm. 18. Turn the engine counterclockwise until the gauge needle stops moving and then zero out the gauge.

19. Turn the engine clockwise until the TDC mark (1) aligns with the reference rod (2). 20. Note the timing prelift shown on the gauge. The specifications are as follows: Engines without a turbocharger - 1.10 - 1.25 mm Engines with a turbocharger - 0.95 - 1.10 mm 21. If the timing prelift is out of specification, refer to “Static timing reset - Minor adjustment”.

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Static timing reset - Minor adjustment 22. With the engine at TDC and dial indicator installed, loosen the three nuts (1) that secure the pump to the gear housing. NOTE: Use a 38 cm (15 in) socket extension (minimum) to loosen the back bolt so that the gauge reading will not be altered.

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Engine - Fuel injection system

23. Use the slots in the injection pump mount to rotate (fine-tune) the pump clockwise to retard the timing or counterclockwise to advance the timing until the specification in 21 is reached.

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24. Torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft).

25. If the timing prelift specification cannot be obtained, see “Static timing - Major adjustment.”

Static timing - Major adjustment 1. Remove the drive gear access cover (1) and loosen the injection pump nut (2) slightly without removing the gear from the shaft. 2. Turn the engine over until the pre-lift is: Engines without a turbocharger - 1.10 - 1.25 mm (0.04 - 0.05 in) Engines with a turbocharger - 0.95 - 1.10 mm (0.04 0.04 in)

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Engine - Fuel injection system

3. Lock the pump by removing the spacer (2) from under the bolt head (1) on the mounting flange.

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4. From the pump side, loosen the nuts (1) without removing them in order to move the pump backwards. 5. Install the drive gear puller 380000835 throughout the two threaded ports (2) and remove the gear from the pump shaft in order to remove the pump. 6. Hold the pump and remove the nuts completely. 7. Remove the pump and gasket from its mounting studs. 8. Turn the engine back to TDC.

NOTE: Use solvent to remove oil from the injection pump driveshaft and gear tapers. Tapers must be dried completely. 9. Install the pump onto the engine and torque the nuts to 20 - 28 N·m (15 - 21 lb ft). 10. Snug the drive gear nut (1) to temporarily hold the gear to the shaft. 11. Replace spacer under the lock bolt head. 12. Torque the drive gear nut (1) to 89 - 95 N·m (66 - 70 lb ft).

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13. Verify that the pump prelift is within the following specifications: Engines without a turbocharger - 1.10 - 1.25 mm (0.04 - 0.05 in) Engines with a turbocharger - 0.95 - 1.10 mm (0.04 0.04 in) 14. Test running and starting performance. Next operation: Rotary injection pump - Install (10.218)

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Engine - Fuel injection system

Rotary injection pump - Disassemble F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Prior operation: Rotary injection pump - Remove (10.218) NOTE: This procedure assumes that all the fuel pipes have been removed, the electrical connections have been disconnected, and the accelerator cable should also be disconnected. 1. Remove the bolts (1) and remove the starter (2).

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2. Install the bracket of the tool 380000988 (1) holding the flywheel provided with the rotation coil (2). 3. Carefully rotate the flywheel in the direction of normal rotation to remove the slack in the gear. 4. Rotate the flywheel until the pin (4) provide with the tool 380000988 engages in the tooth of the flywheel (3).

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

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Engine - Fuel injection system

9. Disconnect the fuel lines from the priming pump (1). 10. Remove the retaining bolts (2) and remove the pump (1).

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11. Check through priming pump hole in the block, that camshaft (1) is in TDC at the compression phase by the visible notches (2) on the camshaft. If the notches are not visible, unlock the flywheel and rotate the engine 360 ° until the notches are visible. Lock the flywheel.

12. Loosen the bolt (2), remove the "L" spacer (1) and tighten the bolt (2) to keep the pump timed with the engine flywheel. The spacer must be kept. It is recommended to secure it to the pump with a wire or a clip.

13. Remove the bolts (1) that secure the plate (2) covering the pump drive gear. 14. Remove the nut (3) securing the gear to the pump shaft and remove the relating washer.

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Engine - Fuel injection system

15. Remove the three nuts (2), (3), and (5) fastening the pump (1) to the housing (4) and remove it from the housing.

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Next operation: Rotary injection pump - Assemble (10.218)

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Engine - Fuel injection system

Rotary injection pump - Assemble F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Prior operation: Rotary injection pump - Disassemble (10.218) 1. When installing the feed pump to the engine, it is necessary to ensure that the number one cylinder is at TDC of the compression stroke. 2. Install the pump unit (1), preset, into the gearbox housing (2). 3. Install the mounting nuts (3) and finger tighten them. NOTE: The gasket removed during disassembly should not be utilized again. Always use original spare parts.

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4. On the timing side, install the washer and the retaining nut (3) on the pump shaft. 5. Torque the nut (3) to 90 - 95 Nm (66.4 - 70.1 lb ft). 6. Install the plate (2) with new gasket and torque the bolts (1) to . 20 - 28 N·m (15 - 21 lb ft).

7. Loosen the bolt (2) that prevents pump shaft rotation and insert spacer (2). 8. Tighten the bolt (2) so that it locks the spacer (2) in place. By doing this, the pump shaft will be able to rotate freely. 9. Remove the flywheel rotation locking tool 380000988 and install the starter.

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Engine - Fuel injection system

10. Install the priming pump (1) to the engine block and torque the retaining bolts (2) to 20 - 28 N·m (15 - 21 lb ft). 11. Connect all pipelines in the fuel system. 12. Connect the electrical connections to electro-magnets on the hydraulic head and on the KSB. NOTE: If the engine is installed in the application, connect the accelerator cable.

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Next operation: Rotary injection pump - Timing adjust (10.218)

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Engine - Fuel injection system

Rotary injection pump - Timing adjust F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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5. Fabricate a pointed rod from a piece of heavy wire. 6. Attach the pointed rod to the bracket (1) near the AC belt pulley.

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Engine - Fuel injection system

7. Mark the pulley (1) using the pointed rod (3) as a reference point (2).

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8. Remove the tool 380001435 (1) to close the intake valve. Rotate the engine clockwise approximately 20 ° until the piston is on its down cycle. 9. Repeat 4. 10. Rotate the engine counterclockwise until the piston makes light contact with the intake valve.

11. Make another reference mark (1) on the AC belt pulley using the pointed rod (2) as a reference.

12. Measure between the two marks and make a third mark (1) at the midpoint. 13. Rotate the engine to align the center mark with the reference rod (2). This marks cylinder number one TDC.

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Engine - Fuel injection system

14. Remove the valve gauge tool 380001435 (1) to close the intake valve.

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Engine - Fuel injection system

23. Use the slots in the injection pump mount to rotate (fine-tune) the pump clockwise to retard the timing or counterclockwise to advance the timing until the specification in 21 is reached.

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24. Torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft).

25. If the timing prelift specification cannot be obtained, see “Static timing - Major adjustment.”

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Engine - Fuel injection system

3. Lock the pump by removing the spacer (2) from under the bolt head (1) on the mounting flange.

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Engine - Fuel injection system

High pressure pump - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Injector fuel lines - Disconnect (10.218) Prior operation: Fuel supply lines Low pressure - Disconnect (10.210) 1. Disconnect all of the fuel lines (4) from the high pressure pump (2). 2. Remove the mounting nuts (1) and remove the high pressure pump (2) and the feed pump (3) together as one unit.

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Next operation: High pressure pump - Install (10.218)

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Engine - Fuel injection system

High pressure pump - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: High pressure pump - Remove (10.218) Prior operation: Fuel supply lines Low pressure - Connect (10.210) 1. Mount the high pressure pump (2) with the feed pump (3) into place on the rear cover. 2. Install the retaining nuts (1) securing the high pressure pump to the rear cover and torque the bolts to 20 28 N·m (15 - 21 lb ft). 3. Connect all of the fuel lines (4).

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Next operation: Injector fuel lines - Connect (10.218)

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Engine - Fuel injection system

High pressure pump - Test Pressure Relief Valve Testing F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Electronic Fuel Systems 1. The Pressure Relief Valve (1) is located at the rear end of the fuel rail. This valve protects the fuel system components from excessive pressure.

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2. Check the ECU for: â&#x20AC;˘ Fault codes related to over pressurization of the common rail. 3. Disconnect the pressure relief valve return line and cap the line with special tool # 380100060 line cap. 4. Install special tool # 380100057 pressure gauge and hose assembly on the relief valve to direct any leakage to special tool #380100062 container if the relief valve is leaking. NOTE: Under normal circumstances, fuel should not come out of the relief valve. 5. If the diagnostic system does not indicate a fault code and fuel is leaking from the pressure relief valve, replace the pressure relief valve.

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Engine - Fuel injection system

Pressure regulating valve - Test F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

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

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Engine - Fuel injection system

Common rail - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

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Engine - Fuel injection system

Common rail lines - Disconnect Low Pressure F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Hold down the clasp (1) and release the quick fitting joint.

NHIL13ENG0594AA

Next operation: Common rail lines - Connect (10.218)

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Engine - Fuel injection system

Common rail lines - Connect Low Pressure F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Common rail lines - Disconnect (10.218) 1. Connect low pressure lines to the common rail l by inserting the rapid fitting joint into the connection joint and press until the clip (1) fastens securely. 2. Check for proper fuel connection.

NHIL13ENG0595AA

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Engine - Fuel injection system

Fuel injectors - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Fuel fillers - Remove (10.218) 1. Remove the bolts securing the fuel injectors to the cylinder head. 2. Use tool 380001099 (1) to remove the fuel injectors (2) from the cylinder head.

NHIL13ENG0596BA

Next operation: Fuel injectors - Install (10.218)

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Engine - Fuel injection system

Fuel injectors - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Fuel injectors - Remove (10.218) 1. Install a new O-ring (2) and sealing washer (3) onto the fuel injector (1). 2. Lubricate the O-ring (2) with petroleum jelly.

NHIL13ENG0597AA

NHIL13ENG0598AA

3. Install the fuel injectors (1) into the cylinder head directed so the fuel inlet hole (2) is facing the cross tube seat (3).

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Engine - Fuel injection system

4. Use tool 380001099 (1) to seat the injector (2) in place.

NHIL13ENG0599BA

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NHIL13ENG0601AA

5. Install the injector bolts (2) without tightening them. NOTICE: You must install the cross tube before tightening the injector bolts. Refer to Fuel fillers - Install (10.218).

6. Torque the injector bolts (1) in the two stages. Torque the bolts to 8 - 9 N·m (6 - 7 lb ft). 7. Using the angular torquing gauge tool 380001001 turn the bolts an additional 70 - 80 °. NOTICE: Be sure to also torque the bolt (2) securing the cross tube (3) after torquing the injector. Refer to Fuel fillers - Install (10.218) for the proper procedure.

Next operation: Fuel fillers - Install (10.218)

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Engine - Fuel injection system

Fuel injectors Mechanical - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Injector fuel lines - Disconnect (10.218) 1. Remove the retaining bolt (1) on the mechanical fuel injector. 2. Remove the injector and seal (2) from its seat in the cylinder head.

NHIL13ENG0602AA

Next operation: Fuel injectors Mechanical - Install (10.218)

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Engine - Fuel injection system

Fuel injectors Mechanical - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Fuel injectors Mechanical - Remove (10.218) 1. Install the injectors after having replaced the sealing gasket (3). 2. Verify that the positioning ball (1) is aligned in the cylinder head housing facing the cross tube threads (2). 3. Torque the injector bolts to 55 - 65 N·m (41 - 48 lb ft).

NHIL13ENG0603AA

Next operation: Injector fuel lines - Connect (10.218)

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Engine - Fuel injection system

Fuel injectors - Test Fuel injector testing F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Symptom: Excessive cranking time and no fault codes present. 1. Warm the engine to 50 °C (122.0 °F) minimum. 2. Use NEF fuel supply/leakage test kit special tool kit # 380140055 for the following tests.

NHIL12ENG0041AA

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

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Engine - Fuel injection system

Fuel injectors Cross tube - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

NHIL13ENG0605AA

Next operation: Fuel injectors Cross tube - Install (10.218)

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Engine - Fuel injection system

Fuel injectors Cross tube - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Fuel injectors Cross tube - Remove (10.218) 1. Install the sealing ring (4) lubricated with petroleum jelly on the cross tube (5). 2. Install the cross tube (5) into the cylinder head so that the positioning ball (3) is coinciding with the relevant housing (2). NOTE: After removing cross tubes they cannot be used again. Replace them with new ones. 3. Install the cross tube nut but do not tighten. NOTE: During this operation, the injector (1) can be moved so that the cross tube (5) can be properly inserted into the inlet hole. NHIL13ENG0606AA

NHIL13ENG0607AA

4. After everything is in place, torque the cross tube nuts (2) to 50 Nm (37 lb ft). NOTICE: Be sure to also torque the bolts (1) securing the injector to 8 - 9 N·m (6 - 7 lb ft). Then turn the bolts using the angular torquing gauge tool 380001001 an additional 70 - 80 ° Refer to Fuel injectors - Install (10.218) for the proper procedure.

Next operation: Injector fuel lines - Connect (10.218)

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Engine - Fuel injection system

Injector fuel lines - Connect F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Connect new fuel lines (1) between the high pressure common rail (3) and the fuel injectors (2).

NHIL13ENG0608AA

NHIL13ENG0609AA

2. Torque the nuts (1) to 20 Nm (15 lb ft) using the proper wrench (2) and torque wrench (3). Connections should be tightened by holding the flow limiting valve hexagon with the proper wrench.

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Engine - Fuel injection system

Injector fuel lines - Disconnect F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Disconnect the fuel line (3) from the common rail (1). Refer to Common rail lines - Disconnect Low Pressure (10.218). Disconnect the fuel lines (5) from the common rail (1) and from the fuel injectors (4) . 2. Remove the retaining bolts (2) and remove the common rail (1).

NHIL13ENG0610AA

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Engine - Fuel injection system

Injector fuel lines - Disconnect F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

1. Disconnect the fuel line (4) from the cylinder head. Refer to Common rail lines - Disconnect Low Pressure (10.218). Disconnect the fuel lines (3) from the common rail (2) and from the fuel injectors (4). NOTICE: When releasing the fuel line (3) connections (6) from the common rail (2), use the proper wrench to avoid rotation of flow limiters. 2. Remove the bolts (1) and remove the common rail (2).

NHIL13ENG0611AB

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Engine - Fuel injection system

Injector fuel lines - Disconnect F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

1. Disconnect the fuel lines that provide feed (1) and fuel recovery (2) between the pump and the injectors.

NHIL13ENG0612AA

2. Loosen and remove the pipe fittings securing the pipes to the pumping elements. 3. Loosen and remove the fuel recovery line (2) collar on the injection pump (3). 4. Remove the bolts securing the fuel injectors and remove the bolts securing the fuel recovery line. 5. Remove the bolts holding the mounting brackets fuel lines (1), (6) and (7). 6. After removal, plug the ends of the lines to reduce the risk of dirt contamination.

NHIL13ENG0613FB

(1) Rear bracket retaining bolt (on suction selector plate) - (2) Fuel recovery line to pump - (3) Rotary feed pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket retaining bolt to injection pump side - (7) Front bracket retaining bolt (on suction collector plate).

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Engine - Fuel injection system

Injector fuel lines - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

1. Install the fuel line mounting brackets. 2. Install the lines (1) and (2) that provide fuel feed and recovery between the pump and the fuel injectors. 3. Torque the locknuts and the mounting bolts securing the fuel recovery manifold to 20 - 28 N·m (15 - 21 lb ft). 4. Install the fuel lines to the fuel injectors and to the brackets securing them.

NHIL13ENG0614AA

NHIL13ENG0615FA

(1) Rear bracket mounting bolt (on suction selector plate) - (2) Fuel recovery line to pump - (3) Rotary feed pump - (4) Connection nut to pumping elements - (5) Injector - (6) Bracket mounting bolt to injection pump side - (7) Front bracket mounting bolt (on suction collector plate).

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Index Engine - 10 Fuel injection system - 218 Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Common rail Relief valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Common rail lines - Connect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Common rail lines - Disconnect Low Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injection system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Fuel injection system - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injection system - Test Common rail fuel injection – Fuel supply/Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . 30 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injection system - Test Mechanical fuel injection – Fuel supply/Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . 28 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors - Test Fuel injector testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors Cross tube - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors Cross tube - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel injectors Mechanical - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Fuel injectors Mechanical - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

High pressure pump - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

High pressure pump - External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

High pressure pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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High pressure pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

High pressure pump - Test Pressure Relief Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Injector fuel lines - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Injector fuel lines - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Injector fuel lines - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Injector fuel lines - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Injector fuel lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Pressure regulating valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Pressure regulating valve - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F4GE9484, F4GE9484C*J601, F4GE9684

Rotary injection pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 F4GE9484, F4GE9484C*J601, F4GE9684

Rotary injection pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Rotary injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601

Rotary injection pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9684, F4GE9684

Rotary injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rotary injection pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F4GE9484, F4GE9484C*J601, F4GE9684

Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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Engine - 10 Turbocharger and lines - 250

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Contents Engine - 10 Turbocharger and lines - 250

SERVICE Turbocharger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Turbocharger oil supply line Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Turbocharger oil return line Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Turbocharger and lines

Turbocharger - Remove 1. Remove the oil supply line retaining nut (1) and remove the oil supply line from the turbocharger (3). 2. Remove the line nut from the other end of the supply line to remove it from the upper part of the heat exchanger. 3. Remove the four mounting bolts (2) securing the turbocharger to the exhaust manifold. 4. Lift and remove the turbocharger (3) from it's seat and remove the mounting gasket.

NHIL13ENG0616AA

Next operation: Turbocharger - Install (10.250)

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Engine - Turbocharger and lines

Turbocharger - Install Prior operation: Turbocharger - Remove (10.250) 1. Install a new gasket for the turbocharger. 2. Hold the turbocharger and place it on the exhaust manifold. 3. Install the turbocharger nuts (2) securing the turbocharger to the exhaust manifold and torque the mounting nuts to the following specifications: Six Cylinder Engines: 37 - 49 N·m (27 - 36 lb ft) Four Cylinder Engines: 20 - 28 N·m (15 - 21 lb ft) 4. Install the oil supply line retaining nut (1) to the turbocharger and torque the nut to 8 - 12 N·m (71 - 106 lb in). Install the opposite end of the line on the upper part of the oil filter support and torque the nut to 20 - 28 N·m (15 - 21 lb ft).

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NHIL13ENG0616AA

Engine - Turbocharger and lines

Turbocharger oil supply line - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Turbo oil lines 1. Install the oil supply line (2) between the turbocharger (1) and the oil filter base. Torque the oil line retaining nuts to 8 - 12 N·m (6 - 9 lb ft) on the turbocharger inlet and to 20 - 28 N·m (15 - 21 lb ft) on the oil filter base outlet.

NHIL13ENG0617AA

NHIL13ENG0618AA

2. Install the oil return line (1) onto the turbocharger and tighten the retaining bolts. 3. Connect the oil return line fitting (2) to the engine block.

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Engine - Turbocharger and lines

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

NHIL13ENG0617AA

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Engine - Turbocharger and lines

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

NHIL13ENG0619BA

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Engine - Turbocharger and lines

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

NHIL13ENG0619BA

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Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger oil return line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Turbocharger oil return line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Turbocharger oil supply line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - 10 Intake and exhaust manifolds and muffler - 254

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Contents Engine - 10 Intake and exhaust manifolds and muffler - 254

FUNCTIONAL DATA Intake and exhaust manifolds and muffler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Intake manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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CONSUMABLES INDEX Consumable Loctite® 5999 Loctite® 5999

Reference Intake manifold - Install Intake manifold - Install

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PAGE 10.13 / 9 10.13 / 11

Engine - Intake and exhaust manifolds and muffler

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

BOOSTDIAGRAM

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Engine - Intake and exhaust manifolds and muffler

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

NHIL13ENG0621GA

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Remove F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

1. Remove the retaining bolts (1) securing the intake manifold (2), the retaining nuts securing the intake air heater (3) for the cold start aid, and then remove the heater.

NHIL13ENG0622FA

Next operation: Intake manifold - Install (10.254)

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Intake manifold - Remove (10.254) 1. Apply LOCTITE 5999 to the mounting surface of the air intake heater (3) and the intake manifold (2). 2. Install the air intake heater (3) and torque the nuts to 6 - 10 N·m (4 - 7 lb ft). 3. Install the intake manifold onto the cylinder head and torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0622FA

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Remove F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Remove the retaining bolts (2) securing the intake manifold (1) and remove the joint for the air intake heater grid for the cold start aid.

NHIL13ENG0623AA

Next operation: Intake manifold - Install (10.254)

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Intake manifold - Remove (10.254) 1. Apply LOCTITE® 5999 to the mounting surface of the intake air heater mounted onto the intake manifold (1). 2. Install the intake air heater nuts and torque the nuts to 6 - 10 N·m (4 - 7 lb ft). 3. Install the intake manifold (1) onto the cylinder head and torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0623AA

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

1. Remove the bolts (2) securing the intake manifold plate (1) to the cylinder head. 2. Remove the plate (1) and the relative gasket from the cylinder head.

NHIL13ENG0624AA

Next operation: Intake manifold - Install (10.254)

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Intake manifold - Remove (10.254) 1. Apply a new gasket to the mounting surface of the intake manifold (1) plate and torque the bolts (2) to 20 28 N·m (15 - 21 lb ft). 2. If the duct from the intake manifold has been removed, install new gaskets and apply LOCTITE® 5999 to the intake air heater mounting surface (if applicable).

NHIL13ENG0624AA

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Turbocharger Turbine - Remove (10.250) 1. Remove the bolts (1) and remove the exhaust manifold (2) from the cylinder head.

NHIL13ENG0625AA

Next operation: Exhaust manifold - Install (10.254)

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Exhaust manifold - Remove (10.254) 1. Install the exhaust manifold (2) onto the cylinder head. 2. Torque the bolts (1) to the following specifications: 4 cylinder engines – 20 - 30 N·m (15 - 22 lb ft) 6 cylinder engines – 75 - 85 N·m (55 - 63 lb ft)

NHIL13ENG0626AA

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Remove F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Prior operation: Turbocharger - Remove (10.250) 1. Remove the retaining bolts (1) securing the exhaust manifold (2) to the cylinder head. 2. Remove the exhaust manifold (2) and the relative gaskets from the cylinder head.

NHIL13ENG0627AA

Next operation: Exhaust manifold - Install (10.254)

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Install Prior operation: Exhaust manifold - Remove (10.254) 1. Install the exhaust manifold (1) with new gaskets (2) onto the cylinder head and torque the bolts to 37 49 N·m (27 - 36 lb ft). NOTE: The illustration of the exhaust manifold may not match your model. However, the described procedure is applicable.

NHIL13ENG0628AA

Next operation: Turbocharger - Install (10.250)

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Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Intake and exhaust manifolds and muffler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Intake and exhaust manifolds and muffler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Engine - 10 Engine cooling system - 400

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Contents Engine - 10 Engine cooling system - 400

FUNCTIONAL DATA Engine cooling system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4GE9684

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

SERVICE Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Coolant thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4GE9484, F4GE9484C*J601, F4GE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4GE9484, F4GE9484C*J601, F4GE9684

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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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Engine - Engine cooling system

Engine cooling system - Dynamic description F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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

NHIL13ENG0629GA

6 cylinder version

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Engine - Engine cooling system

Engine cooling system - Dynamic description F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0630GA

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Engine - Engine cooling system

Engine cooling system - Dynamic description F4GE9484, F4GE9484C*J601, F4GE9684

NHIL13ENG0631AA

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Engine - Engine cooling system

Engine cooling system - Dynamic description F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

NHIL13ENG0632GA

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Engine - Engine cooling system

Water pump - Remove Prior operation: Belt - Remove (10.414) 1. Remove the retaining bolts (1) and remove the water pump (2).

NHIL13ENG0633AA

Next operation: Water pump - Install (10.400)

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Engine - Engine cooling system

Water pump - Install Prior operation: Water pump - Remove (10.400) 1. Install a new sealing ring (2) on the water pump (1).

NHIL13ENG0634AA

NHIL13ENG0635AA

NHIL13ENG0636AA

2. Install the water pump (1) onto the engine block using the two mounting bolts (2).

3. Torque the water pump (1) mounting bolts (2) to 20 28 N·m (15 - 21 lb ft).

Next operation: Belt - Install (10.414)

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Engine - Engine cooling system

Water pump Water manifold - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Alternator - Remove (55.301) 1. Remove the retaining bolts (2) and remove the water manifold (1).

NHIL13ENG0637AA

Next operation: Water pump Water manifold - Install (10.400)

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Engine - Engine cooling system

Water pump Water manifold - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Water pump Water manifold - Remove (10.400) 1. Position the water manifold/alternator support (1) so that the pins (2) and (3) are set against the engine block. 2. Torque the retaining bolts (4) to 37 - 49 N·m (27 - 36 lb ft). NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

NHIL13ENG0638AA

Next operation: Alternator - Install (55.301)

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Engine - Engine cooling system

Water pump Water manifold - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Alternator - Remove (55.301) 1. Remove the bolts (1) securing the water manifold (2). 2. Remove the water manifold (1) from the block.

NHIL13ENG0639AA

Next operation: Water pump Water manifold - Install (10.400)

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Engine - Engine cooling system

Water pump Water manifold - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Water pump Water manifold - Remove (10.400) 1. Install the water manifold (1) onto the engine block. 2. Torque the retaining bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0639AA

Next operation: Alternator - Install (55.301)

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Engine - Engine cooling system

Coolant thermostat - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Remove the three bolts securing the thermostat housing (1) to the top of the cylinder head. 2. Remove the thermostat (2) and the seal (3) from the housing (1).

86082981

Next operation: Coolant thermostat - Install (10.400)

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Engine - Engine cooling system

Coolant thermostat - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Coolant thermostat - Remove (10.400) 1. Install the seal (3) around the flange of the thermostat (2). 2. Install the thermostat (2) into the housing (1) and secure the assembly to the cylinder head using the three mounting bolts.

86082981

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Engine - Engine cooling system

Coolant thermostat - Remove F4GE9484, F4GE9484C*J601, F4GE9684

1. Remove the three bolts (1) and remove the thermostat housing (2) together with the bracket (3) and the thick rubber seal (4). 2. Remove the seal (6) and the thermostat (5). 3. Assemble the bracket (3) in the original position, fixing it with the screws (1) of the thermostat housing.

86082982

Next operation: Coolant thermostat - Install (10.400)

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Engine - Engine cooling system

Coolant thermostat - Install F4GE9484, F4GE9484C*J601, F4GE9684

Prior operation: Coolant thermostat - Remove (10.400) 1. Install the thermostat housing (2) including the thermostat (5) and gasket (6). 2. Install the thick rubber seal (4) inside the bracket (3) and the thermostat housing (2). 3. Torque the bolts (1) to 20 - 28 N·m (15 - 21 lb ft). NOTE: The bracket (3) may not be available on some applications. Always replace the gasket with new upon reassembly.

86082982

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Engine - Engine cooling system

Coolant thermostat - Remove F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Remove the three bolts securing the thermostat housing (2). 2. Remove the housing (2), the thick rubber seal (3), the thermostat (4) and relevant seal (1) from the cylinder head.

86082980

Next operation: Coolant thermostat - Install (10.400)

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Engine - Engine cooling system

Coolant thermostat - Install F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Prior operation: Coolant thermostat - Remove (10.400) 1. Install the thermostat (4) with the appropriate seal (1). 2. Install the housing (2) and the thick rubber seal (3) Torque the bolts to 20 - 28 N·m (15 - 21 lb ft).

86082980

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Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4GE9484, F4GE9484C*J601, F4GE9684

Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4GE9484, F4GE9484C*J601, F4GE9684

Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4GE9684

Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Water pump Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Water pump Water manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Water pump Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Water pump Water manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Engine - 10 Fan and drive - 414

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Contents Engine - 10 Fan and drive - 414

SERVICE Fan and drive Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Belt Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Belt tensioner Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Idler pulley Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - Fan and drive

Fan and drive - Remove Support - Remove Prior operation: Belt - Remove (10.414) 1. Remove the retaining bolts (3) and remove the pulley (2) controlling the engine cooling fan. 2. Remove the engine cooling fan support (1).

NHIL13ENG0669AA

Next operation: Fan and drive - Install (10.414)

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Engine - Fan and drive

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

NHIL13ENG0669AA

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

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

NHIL13ENG0666AA

Next operation: Fan and drive - Install (10.414)

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Engine - Fan and drive

Fan and drive - Install -Drive Pulley Prior operation: Fan and drive - Remove (10.414) 1. Install the pulley (2) on the crankshaft and torque the bolts (1) to 8 - 12 N·m (71 - 106 lb in).

NHIL13ENG0666AA

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Fan and drive - Install Prior operation: Fan and drive - Remove (10.414) 1. Install the fan pulley support (1) and torque the bolts to 28 - 38 N·m (21 - 28 lb ft).

NHIL13ENG0667BA

NHIL13ENG0649AA

2. Install the alternator (1) tensioning bracket (3) and torque the bolts (2) to 37 - 49 N·m (27 - 36 lb ft).

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Engine - Fan and drive

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

NHIL13ENG0667BA

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

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

NHIL13ENG0668AA

NHIL13ENG0669AA

NHIL13ENG0670AA

2. Install the fan pulley (2) to the support (1) and torque the bolts (3) to 8 - 12 N·m (71 - 106 lb in). 3. Install the idler pulley (4) and torque the bolt (5) to 37 49 N·m (27 - 36 lb ft).

4. Install the automatic belt tensioner support (3) and torque the bolts (4) to 28 - 38 N·m (21 - 28 lb ft). 5. Install the automatic belt tensioner (2) and torque the bolt (1) to 37 - 49 N·m (27 - 36 lb ft).

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Belt - Remove F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Using the proper square drive ratchet in the provided opening (2), release the tension on the belt (3) by pulling back on the belt tensioner (1). 2. Remove the belt (3) from all of the pulleys.

NHIL13ENG0671AA

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Belt - Install Prior operation: Belt - Install (10.414) 1. Release the tension off of the belt tensioner using the proper square drive ratchet and install the belt on the pulleys.

66070776

Belt Configuration (1) - Crankshaft (2) - Fixed Idler Pulley

(3) - Fan (4) - Water Pump

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(5) - Alternator (6) - Tensioner

Engine - Fan and drive

Belt - Remove F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

1. Loosen the bolt (1) and the relevant nut on the alternator bracket (2). 2. Loosen the bolt on the bottom side of the alternator (4) in order to slide out the POLY-V belt (3).

NHIL13ENG0672AA

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Belt - Install Prior operation: Belt - Remove (10.414) 1. Install the Poli-V belt (4) on the drive pulley, water pump (5), alternator (1), fan pulley (2) and on the idler pulley (3). 2. Insert a square drive ratchet into the relative hole on the belt tensioner. 3. Pull on the tensioner (6) and slide the belt (4) into place. NOTE: In case the old belt is to be reused, examine it carefully first in order to detect any incision or evidence of stress.

NHIL13ENG0673AA

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Engine - Fan and drive

Belt tensioner - Remove F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Belt - Remove (10.414) 1. Remove the bolt (1) from the center of the belt tensioner (2) and remove the tensioner.

NHIL13ENG0670AA

Next operation: Belt tensioner - Install (10.414)

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Engine - Fan and drive

Belt tensioner - Install F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Belt tensioner - Remove (10.414) 1. Install the belt tensioner (1) and torque the mounting bolt (2) to 37 - 49 N·m (27 - 36 lb ft).

NHIL13ENG0670AA

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Idler pulley - Remove Prior operation: Belt - Remove (10.414) 1. Remove the retaining bolt (2) from the center of the idler pulley (1). 2. Remove the idler pulley (1).

NHIL13ENG0670AA

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Idler pulley - Install Prior operation: Idler pulley - Remove (10.414) 1. Install the idler pulley (1) and torque the bolt (2) to 37 49 N·m (27 - 36 lb ft).

NHIL13ENG0670AA

Next operation: Belt - Install (10.414)

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Index Engine - 10 Fan and drive - 414 Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4GE9484, F4GE9484C*J601, F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fan and drive - Install -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fan and drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fan and drive - Install Support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fan and drive - Remove -Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fan and drive - Remove Support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Engine - 10 Engine lubrication system - 304

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Contents Engine - 10 Engine lubrication system - 304

FUNCTIONAL DATA Engine lubrication system Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4GE9684

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Blow-by recirculation system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

SERVICE Engine oil filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Bypass valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Bypass valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

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Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Blow-by recirculation system Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Engine - Engine lubrication system

Engine lubrication system - Exploded view F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Lubrication by forced circulation is achieved through an oil rotary expansion pump. It is located on the front of the block and driven by a straight-tooth gear that is splined to the shafts bar hold. This pump provides lubrication for the crankshaft, camshaft and to the valve drive.

4C0O200406CRIL0

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Engine - Engine lubrication system

Engine lubrication system - Exploded view F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Lubrication by forced circulation is achieved through oil pump, placed in the front part of the engine block. From the pan, the lubrication oil flows to the crankshaft, to the camshaft and to the valve train. Lubrication involves the heat exchanger as well, the turbocharger and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.

NHIL13ENG0674GA

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Engine - Engine lubrication system

Engine lubrication system - Exploded view F4GE9484, F4GE9484C*J601, F4GE9684

NHIL13ENG0675BA

LUBRICATION SYSTEM LAYOUT (4 cylinder engine)

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Engine - Engine lubrication system

Engine lubrication system - Exploded view F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Lubrication by forced circulation is achieved through the oil pump, placed in the front part of the engine block. From the pan, the lubrication oil flows to the crankshaft, to the camshaft and to the valve train. Lubrication involves the heat exchanger as well, the turbocharger and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.

NHIL13ENG0676GA

LUBRICATION SYSTEM LAYOUT (6 cylinder engines)

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Engine - Engine lubrication system

Blow-by recirculation system - Dynamic description F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Version with blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil pan and the residual vapors are removed by piping and filtered by the blow-by filter. In the blow-by filter, part of the vapors condense and return to the oil pan. The remaining vapors are put back into circulation.

Version without blow-by filter The tappet cover houses the pre-seperator, whose shape and position determines an increase in oil vapor outlet speed and condenses a part of the vapors at the same time. Condensed oil returns to the oil pan and the residual vapors are conveyed, collected and discharged into the open air through a bleeder.

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Engine - Engine lubrication system

Blow-by recirculation system - Dynamic description F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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

NHIL13ENG0677AA

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Engine - Engine lubrication system

Engine oil filter - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

1. Use the oil filter wrench tool 380000670 to remove the oil filter (1). NOTE: The oil filter is equipped with an internal check valve to minimize the amount oil loss when removing the filter. NOTE: Be sure that the oil filter gasket is removed with the filter.

NHIL13ENG0678AA

Next operation: Engine oil filter - Install (10.304)

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Engine - Engine lubrication system

Engine oil filter - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

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

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NHIL13ENG0679AA

Engine - Engine lubrication system

Engine oil filter - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine oil filter - Remove (10.304) 1. Lubricate the oil filter O-ring (2) with clean engine oil. NOTE: Be sure that the O-ring from the old engine oil filter is not still stuck on the oil filter housing and was removed with the oil filter. 2. Install the filter (1) onto the oil filter base (3) until contact is made with sealing surface. 3. Tighten the oil filter an additional 3/4 of a turn by hand.

NHIL13ENG0680AA

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Engine - Engine lubrication system

Engine oil filter Bypass valve - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Drain the engine coolant. 2. Disconnect the engine oil pressure/temperature sensor. 3. Remove the oil filter head (1) and oil cooler (2).

NHIL12ENG0061AA

NHIS12ENG0060AA

4. Slide the oil filter bypass valve (1) out of the housing (2). NOTE: A seal pick may be necessary to pull valve from the housing.

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Engine - Engine lubrication system

Engine oil filter Bypass valve - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Install the oil filter bypass valve (1) into the housing (2). NOTE: Light pressure may be necessary to fully seat the valve.

NHIS12ENG0060AA

NHIL12ENG0061AA

2. Install the oil cooler and the oil filter head using new gaskets. 3. Torque the bolts to 20 - 28 N·m (15 - 21 lb ft). 4. Install the connector for the oil temperature/pressure sensor. 5. Fill with coolant.

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Engine - Engine lubrication system

Engine oil pump Gear driven - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine block cover Front - Remove (10.102) 1. Remove the retaining bolts (1) and remove the oil pump (2) from the engine block.

NHIL13ENG0681AA

Next operation: Engine oil pump Gear driven - Install (10.304)

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Engine - Engine lubrication system

Engine oil pump Gear driven - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine oil pump Gear driven - Remove (10.304) 1. Install the oil pump (2) onto the engine block. 2. Torque the bolts (1) in two stages. First torque the bolts to 7 - 9 N·m (62 - 80 lb in). Then torque the bolts to 20 - 28 N·m (15 - 21 lb ft).

NHIL13ENG0682AA

Next operation: Engine block cover Front - Install (10.102)

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Engine - Engine lubrication system

Engine oil pump - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Crankshaft damper - Remove (10.110) 1. Please refer to Engine block cover Front - Remove (10.102) for oil pump removal instructions. Next operation: Engine oil pump - Install (10.304)

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Engine - Engine lubrication system

Engine oil pump - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine oil pump - Remove (10.304) 1. Position the front cover seal (1) on the engine block.

NHIL13ENG0683AA

NHIL13ENG0684AA

2. Install the front cover seal (1) onto the engine block and torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

Next operation: Crankshaft damper - Install (10.110)

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Engine - Engine lubrication system

Blow-by recirculation system - Remove - External filter F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

1. Remove the clamp (1) securing the blow-by tube and remove the tube. 2. Remove the bolts (2) and remove the blow-by filter, if applicable.

86070784_RESIZE

Next operation: Blow-by recirculation system - Install (10.304)

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Engine - Engine lubrication system

Blow-by recirculation system - Install - External filter F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Blow-by recirculation system - Remove (10.304) 1. Install the blow-by filter (1) and torque the bolts (2) to 20 - 28 N·m (15 - 21 lb ft).

86070785_RESIZE

86070784_RESIZE

2. Install the cover (1) on the blow-by filter housing (2) and torque the bolts (3) to 20 - 28 N·m (15 - 21 lb ft).

3. Connect the oil vapor lines (1) and secure them with retaining clamps (2).

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Engine - Engine lubrication system

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

NHIL13ENG0685AA

Next operation: Piston cooling Spray nozzle - Install (10.304)

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Engine - Engine lubrication system

Piston cooling Spray nozzle - Install Prior operation: Piston cooling Spray nozzle - Remove (10.304) 1. Install the nozzles (2) and torque the bolts (1) to 8 12 N·m (71 - 106 lb in).

CRIL04J066A01

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Index Engine - 10 Engine lubrication system - 304 Blow-by recirculation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Blow-by recirculation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Blow-by recirculation system - Install - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Blow-by recirculation system - Remove - External filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4GE9484, F4GE9484C*J601, F4GE9684

Engine lubrication system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil filter Bypass valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil filter Bypass valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pump Gear driven - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil pump Gear driven - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Piston cooling Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Engine - 10 Oil cooler and lines - 408

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Contents Engine - 10 Oil cooler and lines - 408

SERVICE Engine oil cooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Engine - Oil cooler and lines

Engine oil cooler - Remove F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine oil filter - Remove (10.304) 1. Remove the mounting bolts (3). 2. Remove the oil filter base (1), oil cooler (2), and all of the gaskets.

NHIL13ENG0686AA

Next operation: Engine oil cooler - Install (10.408)

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Engine - Oil cooler and lines

Engine oil cooler - Install F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Prior operation: Engine oil cooler - Remove (10.408) 1. Place a new gasket (1) on the engine block. 2. Install the oil cooler (2). 3. Place a new gasket (3) on the oil cooler. 4. Install the oil filter base (4). 5. Torque the retaining bolts (5) to 20 - 28 N·m (15 - 21 lb ft). NOTE: Before any assembly operation always verify that the hole and bolt threads have no evidence of wear or dirt.

NHIL13ENG0687AA

Next operation: Engine oil filter - Install (10.304)

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Engine - Oil cooler and lines

Engine oil cooler - Remove F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine oil filter - Remove (10.304) 1. Remove the bolts (5) that secure the oil filter base (4) to the engine block. 2. Remove the oil filter base (4) and the oil cooler (2). NOTE: Be sure to remove all the relevant gaskets and seals (1) and (3).

NHIL13ENG0688AA

Next operation: Engine oil cooler - Install (10.408)

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Engine - Oil cooler and lines

Engine oil cooler - Install F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0688AA

Next operation: Engine oil filter - Install (10.304)

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Index Engine - 10 Oil cooler and lines - 408 Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4GE9484, F4GE9484C*J601, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4GE9684, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4CE9487N, F4CE9487A, F4DE9484, F4CE9684, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CNH Dealer.

47597675 27/09/2013 EN

SERVICE MANUAL Electrical systems F4CE9484 , F4CE9487A , F4CE9487N , F4CE9684 , F4DE9484 , F4DE9684B*J111 , F4DE9684M*J101 , F4DE9684M*J103 , F4DE9684 , F4DE9687 , F4GE9484C*J601 , F4GE9484 , F4GE9684 , F4HE0484G*J102 , F4HE0484G*J109 , F4HE9484C*J102 , F4HE9484C*J103 , F4HE9484 , F4HE9684 , F4HE9687G*J100 , F4HE9687

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Contents Electrical systems - 55

[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

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Electrical systems - 55 Engine control system - 015

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Contents Electrical systems - 55 Engine control system - 015

FUNCTIONAL DATA Engine Control Unit (ECU) Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine wire harness Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

SERVICE Engine Control Unit (ECU) Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine wire harness Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine speed/RPM sensor Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine timing sensors Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Electrical systems - Engine control system

Engine Control Unit (ECU) - Detailed view F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

EDC7 ECU

CRIL04D082G01

(A) - Connector to injectors; (B) - Connector (Provide reference of the vehicle to which the engine is assembled); (C) - Connector to sensors.

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Electrical systems - Engine control system

Engine Control Unit (ECU) - Overview F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

EDC 7 OPERATION Engine preheating element control Pre-post heating is activated when any of the following requirements are met. Water, air, or fuel temperature sensors detect a temperature less than or equal to 5 °C (41 °F).

Phase recognition Signals transmitted by the camshaft and crankshaft sensors determine which cylinder fuel is to be injected at the time of starting.

Injection control On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds.

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

Pilot and main injection advance control On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on the basis of internal mapping.

Idle speed control The control unit processes signals transmitted by the various sensors and adjust the quantity of fuel injected. It also controls the pressure regulator and modulates injection duration of the electro-injectors. Within specific limits, the control unit also monitors battery voltage.

Overheating protection If the water temperature reaches 110 °C (230 °F), the control unit reduces engine performance. When the temperature returns below 100 °C (212 °F), the engine resumes normal operation, (in some applications, the over boosting temperature is the reference temperature).

Maximum engine speed limiting Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine speed surpasses these limits the control unit activates power reduction strategies by controlling the electro-injectors. In some applications the maximum limiting response consists in stopping the engine.

Cut Off Fuel cut off in release phases is managed by the control unit with the following logical interventions: • Deactivation of the electro-injectors. • Reactivation of electro-injectors immediately prior to reaching idle speed. • Control of fuel pressure regulator.

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Electrical systems - Engine control system

Smoke control under acceleration With heavy load demands, in accordance with signals received from the air inlet meter and the engine speed sensor, the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent the emission of smoke from the exhaust.

After Run After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, including the faults log so that they will be available the next time the engine is started.

Control of working speed in normal operating conditions Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions. If the load causes a reduction in power, the control unit increases torque by increasing the amount of fuel injected in order to restore the engine to maximum power.

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

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Electrical systems - Engine control system

Engine wire harness - Electrical schema F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0689FA

(1) Injectors cylinders 1 and 2 (2) Injectors cylinders 3 and 4 (3) Injectors cylinders 5 and 6 (4) Engine RPM sensor (5) Timing sensor

(6) Engine oil pressure/temperature (7) Fuel temperature (8) Coolant temperature (9) Air pressure/temperature (10) Fuel pressure

(11) Pressure regulator (12) Connector C - Sensors (13) Connector A - Injectors

Connector A - Injectors Function

EDC pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Pressure Regulator Pressure Regulator Cylinder 2 injector Cylinder 3 injector Cylinder 1 injector Cylinder 4 injector Cylinder 6 injector Cylinder 5 injector

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Electrical systems - Engine control system

Connector C - Sensors EDC pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

Function Timing sensor Timing sensor Negative for rail temperature and pressure sensor Positive for rail temperature and pressure sensor Signal from rail temperature and pressure sensor Coolant temperature sensor signal from fuel temperature sensor Engine RPM sensor Engine RPM sensor Negative for engine oil pressure and temperature sensor Negative for air temperature and pressure sensor Coolant temperature sensor Signal from engine oil pressure sensor Signal from engine oil temperature Positive for engine oil pressure and temperature sensor Positive for air temperature and pressure sensor Signal from air pressure sensor Negative for fuel temperature sensor Signal from air temperature sensor

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Electrical systems - Engine control system

NHIL13ENG0690AA

Connector A - Injectors Wire color

EDC pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

MN MV VB HR MB VN VG HN HG CN CB CL

Function Injector Injector Injector Injector Earth Injector Injector Injector Injector Injector Injector Injector Injector

Cylinder Cylinder Cylinder Cylinder

2 3 4 2

Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

1 6 5 3 1 4 6 5

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Electrical systems - Engine control system

CONNECTORB

Connector B - Vehicle EDC pin # 1 2 3 4 7 8

Wire # 8150 0087 0000 8885/0159 8150 7777

9 12/13 14/15 16 19 20 27 28 31 32 36 37 39 44 45 46 49 50 52 53 55 62 63 64 72 73 78 81 83

0000 8150 0000 0094 0150 8153 0156 5535 2298 8837 8888 8051 9905 9906 5553 5584 0158 6109 6108 5158 0160 5503 0535 0159 0159 8162 0157 5157

Function Positive driven by battery Negative for switch of fuel filter heater/starter Earth Positive for pre-post heating resistor Positive driven by battery Positive for blink-code button, low oil pressure LED, pre-heating LED, Air conditioner switch (if available), EDC Earth Positive driven by battery Earth Negative for post-heating resistor Negative start/stop push buttons from eng./accelerator pressed Positive from change over switch to key in starting phase (+50) Positive from blink-code button Positive for EDC diagnostic LED K line for diagnostic connector, 30 poles (pin 2) Negative for multi-switch couple-limiter Positive for fuel heating switch Positive for starter Positive from key switch/ L line for diagnosis connector, 30 poles (pin 11) Negative from starter push button from engine Negative from engine stop push button from engine Negative for pre-heating LED in on position Diagnosis connector (pin 28) Negative from accelerator push button pressed CAN Line (if equipped), diagnosis connector (pin 22) CAN Line (if equipped), diagnosis connector (pin 22) Positive for sensor of foot accelerator pedal pos. / Earth multi-switch Negative for clutch sensor Negative for low engine oil pressure LED Negative for EDC diagnosis LED Positive from pressed accelerator push button / multi-switch signal Positive redundant from pressed accelerator push button Positive air conditioner device (if equipped) Negative sensor of foot accelerator pedal pos. / Earth Multi-switch Signal from sensor of foot accelerator pedal pos. / Signal Multi-switch 47597675 27/09/2013

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Electrical systems - Engine control system

EDC pin #

Wire # -

Function Positive for couple multi-switch limiter

CONNECTORC

Connector C - Sensors Wire color C V MN CR HN BL CV GV BZ GN R B R RV LN BH B GR CN NS BG

EDC pin # 5 7 9 10 12 17 18 19 20 21 23 24 25 27 28 29 30 33 34 35 36

Function Earth for pressure regulator Pressure regulating device Feed for engine oil temperature/pressure sensor Feed for air pressure/temperature sensor Feed for rail pressure sensor Earth for fuel temperature sensor Earth for coolant temperature sensor Earth for engine oil temperature sensor Feed for rail pressure sensor Feed for air pressure/temperature sensor Timing system sensor Driving shaft sensor Driving shaft sensor Signal from rail pressure sensor signal from air pressure sensor Signal from air pressure sensor Earth for timing system sensor Signal from engine oil temperature sensor Signal from fuel temperature sensor Signal from engine oil pressure sensor Signal from coolant temperature sensor

Color legend Symbol C A B L G H M

Color Orange Sky Blue White Blue Yellow Gray Brown

Symbol N W S R V Z

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Color Black Light Brown Pink Red Green Purple

Electrical systems - Engine control system

Engine speed/RPM sensor Camshaft - Overview F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0640AA

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

Reference 1 2 3

Signal Signal Shield

EDC pin 10C 9C -

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Electrical systems - Engine control system

Engine speed/RPM sensor Camshaft - Overview F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0640AA

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Electrical systems - Engine control system

Engine timing sensors Crankshaft sensor - Overview F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0641AA

This is an inductive sensor located at the left hand side of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone wheel installed on the crankshaft. The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ~900 Ω.

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Electrical systems - Engine control system

Engine timing sensors Crankshaft sensor - Overview F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0641AA

The crankshaft sensor is an inductive type sensor that is located on the front of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone wheel installed on the crankshaft. The same signal is utilized to control the eventual electronic engine speed indicator placed on the vehicle instrument board. It is connected to the engine control module by pin 25C (signal) and 24C (signal). The third pin is for screening. The resistance value of the sensor is about 900 Ω.

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Electrical systems - Engine control system

Engine timing sensors Crankshaft sensor - Overview F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

NHIL13ENG0641AA

The crankshaft sensor is an induction type sensor and it is placed on the front part of the engine above the crankshaft. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a tone wheel installed on the crankshaft.

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Electrical systems - Engine control system

Engine Control Unit (ECU) - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Fuel supply lines Low pressure - Disconnect (10.210) 1. Disconnect the main wiring harness from the electronic control module (2). 2. Disconnect the low pressure fuel lines that are attached to the control module cooling plate. 3. Remove the three mounting bolts (1) that secure the control module and the cooling plate to the engine block. 4. Remove the control module and cooling plate as one unit.

NHIL13ENG0642AA

Next operation: Engine Control Unit (ECU) - Install (55.015)

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Electrical systems - Engine control system

Engine Control Unit (ECU) - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine Control Unit (ECU) - Remove (55.015) 1. Install the electronic control module (2) and cooling plate on the side of the engine block. 2. Install the retaining bolts (1) and rubber isolators and torque the bolts to 8 - 12 N·m (71 - 106 lb in). NOTE: If the rubber isolators are cracked or excessively deformed, replace them before installation.

NHIL13ENG0642AA

Next operation: Fuel supply lines Low pressure - Connect (10.210)

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Electrical systems - Engine control system

Engine wire harness - Disconnect F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0508AA

(1) Connections for electro-injectors (2) Coolant temperature sensor (3) Fuel pressure sensor (4) Oil pressure/temperature sensor

(5) Driving shaft sensor (6) Electro-injector (7) Air pressure/temperature sensor (8) Timing system sensor

(9) Fuel temperature sensor (10) Pressure regulating gauge (11) EDC 7 UC31

1. Disconnect the engines cable from the connectors (1) to electro-injector (6), air pressure/temperature sensor (7), fuel pressure sensor (3), engine control module (11), high pressure pump sensor (10), timing system sensor (8), coolant temperature sensor (2), driving shaft sensor (5). 2. Remove the engine wire harness from the engine block by removing the holding clamps.

NHIL13ENG0508AA

Next operation: Engine wire harness - Connect (55.015)

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Electrical systems - Engine control system

Engine wire harness - Disconnect F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

HARNESS

(1) Fuel pressure Sensor (2) Coolant temperature sensor (3) Engine oil temperature sensor (4) Crankshaft speed sensor

(5) Electro-injector (6) Air pressure/temperature sensor (7) Timing sensor (8) Fuel temperature sensor

(9) Fuel pressure regulator (10) EDC 7 UC31 (11) Connectors for electro-injectors

1. Disconnect the engine's cable from the connectors wiring harness to Electro-Injectors (11); Air Pressure/Temperature Sensor; (6) Fuel Pressure Sensor (1); Engine Control Module (10); Timing Sensor (7); Coolant Temperature Sensor (2); Crankshaft Speed Sensor (4).

HARNESS

Next operation: Engine wire harness - Connect (55.015)

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Electrical systems - Engine control system

Engine wire harness - Connect F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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

NHIL13ENG0508AA

(1) Connections for electro-injectors (2) Coolant temperature sensor (3) Fuel pressure sensor (4) Oil pressure/temperature sensor

(5) Driving shaft sensor (6) Electro-injector (7) Air pressure/temperature sensor (8) Timing system sensor

(9) Fuel temperature sensor (10) Pressure regulating gauge (11) EDC 7 UC31

2. Connect the engines cable from the connectors (1) to electro-injector (6), air pressure/temperature sensor (7), fuel pressure sensor (3), engine control module (11), high pressure pump sensor (10), timing system sensor (8), coolant temperature sensor (2), driving shaft sensor (5).

NHIL13ENG0508AA

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Electrical systems - Engine control system

Engine speed/RPM sensor - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Install a new O-ring on the speed sensor (3). 2. Install the speed sensor (3) on the front cover (1). 3. Torque the bolt (2) to 6 - 10 N·m (53 - 89 lb in).

NHIL13ENG0644AA

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Electrical systems - Engine control system

Engine timing sensors - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Remove the mounting nut and slide the timing sensor out of the timing gear housing. Next operation: Engine timing sensors - Install (55.015)

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Electrical systems - Engine control system

Engine timing sensors - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Prior operation: Engine timing sensors - Remove (55.015) 1. Install a new O-ring on the timing sensor. 2. Slide the sensor over the mounting stud and install the nut. Tighten to the specified torque.

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Index Electrical systems - 55 Engine control system - 015 Engine Control Unit (ECU) - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine Control Unit (ECU) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine Control Unit (ECU) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine Control Unit (ECU) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine speed/RPM sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine timing sensors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine timing sensors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine timing sensors Crankshaft sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

Engine wire harness - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine wire harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine wire harness - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine wire harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine wire harness - Electrical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Electrical systems - 55 Engine starting system - 201

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Contents Electrical systems - 55 Engine starting system - 201

SERVICE Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine starting system

Engine starter - Remove 1. Disconnect the starter cables from the solenoid and the starter body (2). 2. Remove the three mounting bolts (3) securing the starter (2) to the flywheel housing (1). 3. Remove the starter (2).

NHIL13ENG0645AA

Next operation: Engine starter - Install (55.201)

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Electrical systems - Engine starting system

Engine starter - Install Prior operation: Engine starter - Remove (55.201) 1. Install the starter (2) on the flywheel housing (1) using the three mounting bolts (3). 2. Torque the bolts (3) to 37 - 49 N·m (27 - 36 lb ft). NOTE: Before any assembly operation verify that the hole and bolt threads have no evidence of wear or dirt.

NHIL13ENG0645AA

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Index Electrical systems - 55 Engine starting system - 201 Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Alternator - 301

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Contents Electrical systems - 55 Alternator - 301

FUNCTIONAL DATA Alternator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Alternator

Alternator - Overview

NHIL13ENG0646AA

The alternator is placed on the front right hand side of the engine and is driven by a Poly V-belt. Specifications: • Working voltage: • 12 V • Current delivered: • 90 A @ 6000 RPM • Absorption in stand-by: • Less than or equal to 1 mA • Direction of rotation: • Clockwise

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Electrical systems - Alternator

Alternator - Remove Prior operation: Belt - Remove (10.414) 1. Remove the bolt (1). 2. Hold the alternator (2) and loosen the bolt (3).

NHIL13ENG0647AA

NHIL13ENG0648AA

3. Remove the bolt (2). 4. Remove the alternator (1).

Next operation: Alternator - Install (55.301)

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Electrical systems - Alternator

Alternator - Install Prior operation: Alternator - Remove (55.301) 1. Mount the alternator (1) onto the support. 2. Tighten the bolt (2) without locking it.

NHIL13ENG0648AA

NHIL13ENG0649AA

3. Install the alternator (2) bracket (1) to the engine block and torque the engine block side bolt to 20 - 28 N·m (15 - 21 lb ft). 4. Torque the upper alternator pivot to support bolt to 44 54 N·m (32 - 40 lb ft). 5. Torque the lower alternator bolt (3) securing the alternator (2) to the alternator support to 20 - 28 N·m (15 21 lb ft).

Next operation: Belt - Install (10.414)

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Index Electrical systems - 55 Alternator - 301 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Alternator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Cold start aid - 202

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Contents Electrical systems - 55 Cold start aid - 202

FUNCTIONAL DATA Cold start aid Cold start control Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, 4 Cylinder Common Rail, F4CE9684, F4GE9684, 6 Cylinder Common Rail

Grid heater Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Electrical systems - Cold start aid

Cold start control Temperature sensor - Overview F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, 4 Cylinder Common Rail, F4CE9684, F4GE9684, 6 Cylinder Common Rail

Electrical Cold-start Accelerator (KKSB)

NHIL13ENG0650AA

(1) Hydraulic head electro-magnet - (2) KKSB electro-magnet. The KKSB is located on the fuel injection pump. During engine start-up, the KKSB advances the injection pump timing to reduce white smoke and emissions until the cylinders warm to normal operating temperature. By shifting the start of injection in the advanced direction, the KKSB improves the cold-start characteristics of the emissionized engine. Operation is triggered automatically by means of a temperature sensitive thermostatic switch, which is located in the cylinder head on the engine's left hand side.

NHIL13ENG0651AA

Specifications: • Working tensions: • 12 - 24 V • Electrical Power load: • 2.5 A (induction) • 5.0 A (resistance) • Settings: • 60 - 66 °C (140 - 151 °F) Contact opening upon increasing temperature. • 50 - 56 °C (122 - 133 °F) Contact closure upon decreasing temperature.

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Electrical systems - Cold start aid

Grid heater - Overview F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0652AA

WARNING Explosion hazard! DO NOT use ether starting fluid. Serious engine damage, explosion, death, or serious personal injury could occur. Failure to comply could result in death or serious injury. W0148A

The pre-post heating resistance is located on the intake manifold. The resistance serves to heat the air in pre / post heating operations. The resistance is powered by a contactor. The resistance impedance is approximately 0.5 Ω. The control contactor is connected to the control unit (B) connector. The contactor is tripped with water and/or fuel temperature below 5 °C (41 °F). The contactor impedance is approximately 15 Ω.

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Electrical systems - Cold start aid

Grid heater - Overview F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

NHIL13ENG0653AA

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

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Index Electrical systems - 55 Cold start aid - 202 Cold start control Temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, 4 Cylinder Common Rail, F4CE9684, F4GE9684, 6 Cylinder Common Rail

Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Grid heater - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Electrical systems - 55 Fuel injection system - 010

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Contents Electrical systems - 55 Fuel injection system - 010

FUNCTIONAL DATA Fuel temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel pressure sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Water-In-Fuel sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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Electrical systems - Fuel injection system

Fuel temperature sensor - Overview F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0654FA

(1) Fuel Temperature Sensor

(2) Filter heating resistance

This sensor is identical to the coolant temp sensor. This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel. The fuel temperature sensor is connected to the control unit on pins 35C - 18C. The sensor impedance at 20 °C (68 °F) is approximately 2.50 Ω. Reference 1 2

Description Ground Temperature signal

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EDC pin 35C 18C

Electrical systems - Fuel injection system

Fuel temperature sensor - Overview F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel Temperature Sensor

NHIL13ENG0655FA

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

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Electrical systems - Fuel injection system

Fuel pressure sensor - Overview F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0656AA

Mounted on the end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command. The power supply is 5 Volt. Description

Reference 1 2 3

Ground Signal Power supply

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Electrical systems - Fuel injection system

Water-In-Fuel sensor - Overview F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

NHIL13ENG0657AA

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

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Index Electrical systems - 55 Fuel injection system - 010 Fuel pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Fuel temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Fuel temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Water-In-Fuel sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4CE9484, F4CE9487N, F4CE9487A, F4CE9684

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Electrical systems - 55 Engine intake and exhaust system - 014

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Contents Electrical systems - 55 Engine intake and exhaust system - 014

FUNCTIONAL DATA Intake air pressure and temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

SERVICE Intake air pressure and temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Overview F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0658AA

This component incorporates a temperature sensor and a pressure sensor. Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle. The sensor is connected to the control unit on pins 25C - 36C for temperature and 33C - 34C for pressure. The power supply is 5 volts. Voltage at the sensor output is proportional to the detected pressure or temperature. Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 25C 36C 33C 34C

Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Overview F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0658AA

This component incorporates a temperature sensor and a pressure sensor. Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle. The sensor is connected to the control unit on pins 21C - 29C for temperature and 10C - 28C for pressure. The power supply is 5 volts. Voltage at the sensor output is proportional to the detected pressure or temperature. Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 21C 29C 10C 28C

Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Remove F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Disconnect the wiring harness from the sensor (1). 2. Remove the retaining bolt (2). 3. Remove the sensor (1) and the O-ring seal.

NHIL13ENG0658AA

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Index Electrical systems - 55 Engine intake and exhaust system - 014 Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Intake air pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

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Electrical systems - 55 Engine cooling system - 012

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Contents Electrical systems - 55 Engine cooling system - 012

FUNCTIONAL DATA Engine coolant temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Overview F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0659AA

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine. The same signal is utilized by the control unit to drive an instrument panel gauge, if present. The sensor is connected to the control unit on pins 15C - 26C. The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω. Reference 1 2

Description Ground Temperature signal

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EDC pin 15C 26C

Electrical systems - Engine cooling system

Engine coolant temperature sensor - Overview F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0659AA

This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine. The same signal is utilized by the control unit to drive an instrument panel gauge, if present. The sensor is connected to the control unit on pins 18C - 36C. The impedance of the coolant temperature sensor at 20 °C (68 °F) is approximately 2.50 Ω. Reference 1 2

Description Ground Temperature signal

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ECU pin 18C 36C

Electrical systems - Engine cooling system

Engine coolant temperature sensor - Overview F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

NHIL13ENG0660AA

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

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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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Electrical systems - 55 Engine oil system - 013

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Contents Electrical systems - 55 Engine oil system - 013

FUNCTIONAL DATA Engine oil pressure sensor and switch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

Engine oil pressure and temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

SERVICE Engine oil pressure and temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

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Electrical systems - Engine oil system

Engine oil pressure sensor and switch - Overview F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

NHIL13ENG0661AA

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

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Electrical systems - Engine oil system

Engine oil pressure and temperature sensor - Overview F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

NHIL13ENG0662AA

This component is analogous to the air pressure-temperature sensor. The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position. The sensor measures the engine oil temperature and pressure. The sensor is connected to the control unit on pins 24C - 28C for temperature and 32C- 27C for pressure. The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light). The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit. Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 24C 28C 32C 27C

Electrical systems - Engine oil system

Engine oil pressure and temperature sensor - Overview F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

NHIL13ENG0662AA

This component is analogous to the air pressure-temperature sensor. The engine oil temperature-pressure sensor is installed on the engine oil filter base in a vertical position. The sensor measures the engine oil temperature and pressure. The sensor is connected to the control unit on pins 19C - 33C for temperature and 9C- 35C for pressure. The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light). The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit. Reference 1 2 3 4

Description Ground NTC signal (temperature) +5 V power input Signal (pressure)

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EDC pin 19C 33C 9C 35C

Electrical systems - Engine oil system

Engine oil pressure and temperature sensor - Remove F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

1. Disconnect the wiring harness from the sensor (1). 2. Remove the mounting bolts (2), the sensor (1), and the O-ring seal from the oil filter base.

NHIL13ENG0663AA

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Electrical systems - Engine oil system

Engine oil pressure and temperature sensor - Remove F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Disconnect the electrical connector (1) from the oil temperature pressure sensor (3). 2. Remove the mounting bolts (2) securing the sensor to the oil filter base (4) and remove it from its seat.

NHIL13ENG0664AA

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Electrical systems - Engine oil system

Engine oil pressure and temperature sensor - Install F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

1. Install a new O-ring on the oil temperature/pressure sensor (4). 2. Install the sensor on the oil filter base (1) and torque the mounting bolts (3) to 5 - 7 N·m (44 - 62 lb in). 3. Connect the electrical connection (2) for the sensor.

NHIL13ENG0664AA

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Index Electrical systems - 55 Engine oil system - 013 Engine oil pressure and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F4DE9484, F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4DE9684, F4DE9687, F4HE9684, F4HE9687, F4HE9687G*J100, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 F4HE9484, F4HE0484G*J109, F4HE0484G*J102, F4HE9484C*J102, F4HE9484C*J103, F4HE9684, F4HE9687, F4HE9687G*J100

Engine oil pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F4DE9484, F4DE9684, F4DE9687, F4DE9684M*J101, F4DE9684M*J103, F4DE9684B*J111

Engine oil pressure sensor and switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 F4CE9484, F4GE9484, F4CE9487N, F4CE9487A, F4GE9484C*J601, F4CE9684, F4GE9684

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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

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SPECIAL TOOL INDEX Genuine 380000301 [Rotating Engine Stand] 380000665 [Crankshaft Front Seal Extractor] 380000663 [Crankshaft Rear Gasket Remover] 380001099 [Fuel Injector Extractor] 380000666 [Crankshaft Front Seal Installer] 380000664 [Crankshaft Rear Seal Installer ] 380000670 [Oil Filter Wrench] 380000302 [Cylinder Head Valve Spring Compressor] 380000221 [Pliers For Piston Rings Removal And Installation (65 -110 mm)] 380000667 [Camshaft Bush Assembly And Disassembly Punch] 380000362 [Crankshaft Lifting Hook] 380000216 [Engine Lifting Hook] 380000661 [Brackets Securing Engine To Rotary Stand] 380000669 [Seal Extraction Tool] 380000668 [Handle Interchangeable Driver] 380000364 [Comparator Holder Base For Different Surveys] 380000158 [Electrovalve Connector Nut Torque Wrench] 380000304 [Angle Torque Thightening Screw Tool] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000979 [Puller For Gear Connecting Injection Pump To Engine] 380000665 [Crankshaft Front Seal Extractor] 380000663 [Crankshaft Rear Gasket Remover] 380000671 [Injector Extractor] 380000666 [Crankshaft Front Seal Installer] 380000664 [Crankshaft Rear Seal Installer ] 380000670 [Oil Filter Wrench]

Reference

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Special tools

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47597675 27/09/2013

Genuine 380000302 [Cylinder Head Valve Spring Compressor] 380000221 [Pliers For Piston Rings Removal And Installation (65 -110 mm)] 380000732 [Engine Turning Tool] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000667 [Camshaft Bush Assembly And Disassembly Punch] 380000362 [Crankshaft Lifting Hook] 380000216 [Engine Lifting Hook] 380000994 [Band For Inserting The Piston Into The Cylinder Liner (60--125 mm)] 380002729 [Engine Timing Pin] 380000661 [Brackets Securing Engine To Rotary Stand] 380000669 [Seal Extraction Tool] 380000668 [Handle Interchangeable Driver] 380000364 [Comparator Holder Base For Different Surveys] 380000304 [Angle Torque Thightening Screw Tool] 380001005 [Dial Gauge (0--10 mm)] 380001006 [Diesel Engine Cylinder Compression Tester] 380000140 [Compression Tool For Checking The Protrusion Of Cylinder Liners] 380000301 [Rotating Engine Stand] 380000989 [Adapter Cylinder Compression Tester] 380000661 [Brackets Securing Engine To Rotary Stand] 380000670 [Oil Filter Wrench] 380000661 [Brackets Securing Engine To Rotary Stand] 380000670 [Oil Filter Wrench] 380000661 [Brackets Securing Engine To Rotary Stand] 380000661 [Brackets Securing Engine To Rotary Stand] 380000670 [Oil Filter Wrench]

Reference

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Engine - Compression test

10.1 / 24

Engine - Place on stand

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Engine - Place on stand Engine - Place on stand

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Engine - Place on stand Engine - Place on stand

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Engine - Place on stand

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Engine - Place on stand

10.1 / 28

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Genuine 380000661 [Brackets Securing Engine To Rotary Stand] 380000661 [Brackets Securing Engine To Rotary Stand] 380000216 [Engine Lifting Hook] 380000661 [Brackets Securing Engine To Rotary Stand] 380000670 [Oil Filter Wrench] 380000661 [Brackets Securing Engine To Rotary Stand] 380000661 [Brackets Securing Engine To Rotary Stand] 380000216 [Engine Lifting Hook] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2â&#x20AC;? And 3/4â&#x20AC;? Square Mount] 380000827 [Bore Gauge] 380000645 [Micrometer Set] 17270 [Magnetic Base (For Dial Indicators) ] 380000145 [Camshaft Bushing Remover And Installer] 380001543 [Dial Indicator With Magnetic Base] 380001543 [Dial Indicator With Magnetic Base] 380001543 [Dial Indicator With Magnetic Base] DM370(3/4) [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] DM370(3/4) [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] DM370(3/4) [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)]

Reference

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Engine - Place on stand

10.1 / 28

Engine - Place on stand

10.1 / 29

Engine - Place on stand

10.1 / 29

Engine - Place on stand

10.1 / 30

Engine - Place on stand Engine - Place on stand

10.1 / 30 10.1 / 30

Engine - Place on stand

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Engine - Place on stand

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Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Engine - Service instruction Maintenance Procedures Crankcase - Check

10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1 10.1

Crankcase - Check Camshaft - Measure Camshaft - End play

10.1 / 55 10.3 / 14 10.3 / 17

Camshaft bushings - Replace

10.3 / 25

Camshaft gear - Install

10.3 / 28

Camshaft gear - Install

10.3 / 32

Camshaft gear - Install

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Cylinder head - Install

10.4 / 15

Cylinder head - Install

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Cylinder head - Install

10.4 / 22

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/ / / / / / / / / / / / / / / / /

35 35 35 35 40 41 41 41 46 46 46 46 52 52 52 52 55

Genuine DM370(3/4) [Torque Tightening Angle Gauges (1/2 Inch And 3/4 Inch)] 75291050 [Cylinder Head Valve Spring Compressor] 99305047 [Valve Spring Load Checking Tool] 75291050 [Cylinder Head Valve Spring Compressor] 75291050 [Cylinder Head Valve Spring Compressor] 99305047 [Valve Spring Load Checking Tool] 75291050 [Cylinder Head Valve Spring Compressor] 99305019 [Valve Seat Grinding Kit] 99305019 [Valve Seat Grinding Kit] 99305019 [Valve Seat Grinding Kit] 380000364 [Comparator Holder Base For Different Surveys] 380000228 [Dial Gauge (0 - 5 mm)] 99305019 [Valve Seat Grinding Kit] 99305019 [Valve Seat Grinding Kit] 99305019 [Valve Seat Grinding Kit] 380000364 [Comparator Holder Base For Different Surveys] 380000228 [Dial Gauge (0 - 5 mm)] 380000325 [90 - 175mm Diameter Piston Assembly Band Clamp] 380000324 [Pliers For Assembling And Disassembling Piston Split Rings (110-150 mm)] 380000221 [Pliers For Piston Rings Removal And Installation (65 -110 mm)] 380000228 [Dial Gauge (0 - 5 mm)] 380000364 [Comparator Holder Base For Different Surveys] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000988 [Starter opening plate and Flywheel Rotation Blocker]

Reference

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Cylinder head - Install

10.4 / 26

Valves - Remove

10.4 / 27

Valves Spring - Check

10.4 / 30

Valves - Install

10.4 / 31

Valves - Remove

10.4 / 32

Valves Spring - Check

10.4 / 34

Valves - Install

10.4 / 35

Valve seat - Regrind

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Valve seat - Regrind

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Valve seat - Regrind

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Valve seat - Regrind

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Valve seat - Regrind

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Valve seat - Regrind

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Valve seat - Regrind

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Valve seat - Regrind

10.4 / 40

Valve seat - Regrind

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Valve seat - Regrind

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Connecting rod and piston - Install

10.5 / 8

Piston Ring - Remove

10.5 / 10

Piston Ring - Install

10.5 / 13

Piston - Check

10.5 / 16

Piston - Check

10.5 / 16

Connecting rod bearing - Clearance

10.5 / 18

Connecting rod bearing - Clearance

10.5 / 19

Engine flywheel - Remove

10.6 / 4

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Genuine 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000669 [Seal Extraction Tool] 5-8840-2061-0 [Crankshaft Front Oil Seal Installer] 380000669 [Seal Extraction Tool] 380000664 [Crankshaft Rear Seal Installer ] 99360500 [Crankshaft Lifting Hook] 99360500 [Crankshaft Lifting Hook] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380001717 [Crankshaft Gear Puller] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 380000670 [Oil Filter Wrench] 34591-00100 [Oil Filter Wrench] 380140055 [Fuel Supply / Leakage Test Kit]

Reference

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Engine flywheel - Install

10.6 / 6

Engine flywheel - Install

10.6 / 6

Engine flywheel - Remove

10.6 / 7

Engine flywheel - Install

10.6 / 9

Engine flywheel - Install

10.6 / 9

Engine flywheel - Remove

10.6 / 10

Engine flywheel - Install

10.6 / 11

Engine flywheel - Install

10.6 / 11

Engine flywheel - Install

10.6 / 12

Engine flywheel - Install

10.6 / 12

Engine flywheel Drive plate - Install

10.6 / 14

Crankshaft oil seal Front seal - Remove

10.6 / 15

Crankshaft oil seal Front seal - Install

10.6 / 16

Crankshaft oil seal Rear seal - Remove

10.6 / 17

Crankshaft oil seal Rear seal - Install

10.6 / 18

Crankshaft - Remove

10.6 / 19

Crankshaft - Remove

10.6 / 20

Crankshaft Journal - Clearance

10.6 / 24

Crankshaft gears - Replace

10.6 / 25

Crankshaft damper - Install

10.7 / 6

Fuel supply lines Low pressure - Disconnect Fuel supply lines Low pressure - Disconnect Fuel supply lines Low pressure - Install Fuel supply lines Low pressure - Install Fuel filters - Remove

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Fuel injection system - Test Mechanical fuel injection – Fuel supply/Leakage Test

10.11 / 28

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Genuine 380100056 [Gauge and Hose Assembly] 380100056 [Gauge and Hose Assembly] 380140055 [Fuel Supply / Leakage Test Kit] 380100056 [Gauge and Hose Assembly] 380100057 [Pressure Gauge and Hose Assembly] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380002822 [Engine Turning Tool] 380001543 [Dial Indicator With Magnetic Base] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380002729 [Engine Timing Pin] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001435 [Engine Timing Tool ] 380001435 [Engine Timing Tool ] 380001435 [Engine Timing Tool ] 380000835 [Injection Pump Gear Puller] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001543 [Dial Indicator With Magnetic Base] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001435 [Engine Timing Tool ] 380001435 [Engine Timing Tool ] 380001435 [Engine Timing Tool ] 380000835 [Injection Pump Gear Puller] 380100060 [Tool]

Reference Fuel injection system - Test Mechanical fuel injection – Fuel supply/Leakage Test Fuel injection system - Test Mechanical fuel injection – Fuel supply/Leakage Test Fuel injection system - Test Common rail fuel injection – Fuel supply/Leakage test Fuel injection system - Test Common rail fuel injection – Fuel supply/Leakage test Fuel injection system - Test Common rail fuel injection – Fuel supply/Leakage test Rotary injection pump - Disassemble

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Rotary injection pump - Disassemble

10.11 / 34

Rotary injection pump - Disassemble

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Rotary injection pump - Disassemble

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Rotary injection pump - Disassemble

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Rotary injection pump - Assemble

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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Rotary injection pump - Disassemble

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Rotary injection pump - Disassemble

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Rotary injection pump - Disassemble

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Rotary injection pump - Disassemble

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Rotary injection pump - Assemble

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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Rotary injection pump - Timing adjust

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High pressure pump - Test Pressure Relief Valve Testing

10.11 / 54

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Genuine 380100057 [Pressure Gauge and Hose Assembly] 380001099 [Fuel Injector Extractor] 380001099 [Fuel Injector Extractor] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380140055 [Fuel Supply / Leakage Test Kit] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000670 [Oil Filter Wrench]

Reference

10.11 / 54

Fuel injectors - Remove

10.11 / 59

Fuel injectors - Install

10.11 / 61

Fuel injectors - Install

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Fuel injectors - Test Fuel injector testing

10.11 / 64

Fuel injectors Cross tube - Install

10.11 / 66

Engine oil filter - Remove

10.16 / 10

OEM

Reference

OEM1032 [Dial Bore Gauge ] Crankcase Bore - Check OEM1032 [Dial Bore Gauge ] Camshaft bushings - Measure OEM1032 [Dial Bore Gauge ] Piston pin bushings - Service instruction

Kit 380000229 [Dial Gauge Holder Tool For Rotary Injection Pump Timing]

PAGE

High pressure pump - Test Pressure Relief Valve Testing

Reference Special tools

PAGE 10.1 / 54 10.3 / 24 10.5 / 20

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47597675 27/09/2013

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

47597675 27/09/2013 EN